Modular structure
A modular building system including methods and kits is provided. The system comprises C-channels anchored to a base. Structural insulated panels are slid into the channels to form walls. Adaptors are provided to provide channels at an angle for the insertion of roof panels. The building system provides for the rapis construction of a building without the need for framing or the use of roof trusses.
The present invention relates to a modular construction system. In particular, the invention relates to modular homes comprising prefabricated elements that can be quickly assembled.
BACKGROUND OF THE INVENTIONThere is an increasing demand for affordable housing that can be constructed quickly. This is particularly true in some areas that have been hit by natural disasters. However, the need high quality homes at an affordable price extends to all areas. Most standard homes are made of brick, stone or wood on a wood frame. Framing a house is time consuming and often requires specialized equipment to, for example, lift heavy roof trusses. A major cause of delay in home construction is coordinating the work of various trades. Particularly in view of several recent natural disasters, there is an increasing demand for homes that can be constructed
To try and overcome some of the costs and time involved in on-site construction, various attempts have been made to prefabricate certain components of the house off-site and to use them to assemble a modular house.
For example, U.S. Pat. No. 6,349,509 discloses a prefabricated wall and roof unit. United States patent application 2007/0051059 describes a structural building system that uses standard material in a configuration that provides for high wind resistance.
There still remains a need for high quality modular homes that are indistinguishable from custom built homes and yet are affordable. Most previous modular homes have few architectural features and tend to be limited in options customized to a particular buyer.
SUMMARY OF THE INVENTIONThe present invention addresses the need for an improved modular construction system by providing an alternative to wood or metal-framed structures.
According to an aspect of the present invention there is provided a modular construction system for housing, retail sites, offices and the like.
The system comprises a series of prefabricated wall and roof panels and a channel and beam system for assembly. The number of walls, the location of pre-cut windows and doors can be varied depending upon the model of home desired. The slope and orientation of the roof can also be varied and the appropriate channels can be provided as part of the building system. This represents an advantage of the present invention over previously known modular construction units, such as container type units that have a pre-set design.
In the present invention, the walls are load bearing and thus there is no need for wood framing. In addition to the advantages of cost saving and ease of construction, the elimination of a wood frame removes the possibility of mold and termites.
The modular system of the present invention comprises wall and roof structural insulated panels (SIP) and channels for receiving those panels. The panels may be from about 2 to 8 inches thick, preferably about 3 to 6 inches.
In a preferred embodiment, the panels are insulated metal panels. More preferably, the panels have a tongue and groove configuration for easy joining.
The shape of the channels depends on the role they play. The channels may include C-channels, L-channels, eave channels, gable channels, etc.
In a preferred embodiment the channels are galvanized steel channels.
C-channels typically form the floor channels, while L-channels are used at corners. In addition to channels, fastening systems such as brackets and adhesives may be used to secure panels in position.
At least one roof beam is also included.
At least two hat section beams are also typically included.
In one aspect of the invention, there is provided a modular building comprising: i) a foundation; ii) a plurality of C channels anchored on said foundation; load bearing panels inserted in said channels; at least one ridge beam; at least one set of hat beams; and connectors for connecting the various components.
In another aspect of the invention, a kit for the construction of a building is provided. The kit comprises prefabricated load bearing panels, a series of C channels for receiving the panels, at least one roof beam, a roof assembly set of adaptors, and instructions for assembly. In a preferred embodiment, the roof assembly set includes an eave channel, an exterior gable channel, a channel for attachment to the exterior walls, a ridge beam and at least one set of hat beams. In another preferred embodiment, the panels are prefabricated insulated panels. The panels are about 2 to 8 inches thick, more preferably about 5 inches thick. The kit typically further includes securing fasteners.
In yet another aspect of the invention, a method of building a modular unit is provided. The method comprises the steps of: i) laying a foundation; ii) anchoring a plurality of C-channels to the foundation; iii) sliding a series of load bearing panels along a C-channel; attaching a number of panels together to form a wall; securing intersecting walls with an L-bracket; installing a ridge saddle at the gable end and along interior walls; inserting a beam into the saddles and installing a hat saddle over the roof assembly.
These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings wherein:
The present invention provides a modular building system that is easy to assemble and avoids the cost and labor of framing and installation of roof trusses. While the description of a home building kit and its assembly is described below for exemplary purposes, it is apparent that the system can also be used to construct offices, stores and other buildings.
The modular building system comprises support channels, exterior and interior walls, structural & non-structural components, adhesives and fasteners. The components are preferably provided as a kit based on a pre-selected design. Alternatively, individual pieces may be selected to adapt to a particular consumers desires or requirements and to form a “custom” kit.
The walls comprise pre-fabricated panels. These panels are typically structural insulated panels that are load bearing when combined up to a length of about 15 to 30 feet or greater. Spans of about 16 to 18 feet are preferred. Each panel is preferably cut to a pre-determined specification including, for example, height, width, and openings for doors and windows. Of course, the panels can always be cut on site, but it is more efficient to provide standard models. The structural insulated panels typically range in thickness from 2 to 8 inches, more preferably from about 3 to 6 inches. A combination of panels having different thicknesses may be used on a single structure.
The support channels are preferably metal, although it is possible that other high strength materials may be used. Galvanized steel and aluminum channels have been demonstrated to be very effective. The channels may have various shapes depending on their location and function. These include C-Channel, L-Channel, Eave Channel, Exterior Gable Channel, Double Channel Section, Interior/Exterior Angle channels.
The modular building system also typically comprises an adhesive, a fastening system, usually bolts, and brackets or plates for securing the elements together. Galvanized steel and aluminum beams are also included.
The following is a description of a method for the assembly of a modular building system of the present invention. C-channels for both exterior and interior walls are affixed to a foundation. The exterior walls are formed by sliding a required number of prefabricated panels into the C-channels. The prefabricated panels typically have a tongue and groove construction to fit them together. Adhesive may also be used to seal the joints. At the corners, L-brackets are used to secure the two walls together. The exterior walls form a continuous perimeter. The interior walls meet up with the exterior walls and are supported by C-channel and L-channels. The panels for the interior walls are slid into the C-channels and affixed to each other. Next, a roof support is installed. This comprises beam that sits on plates in precut openings in the walls. A ridge hanger is installed at the gable ends. Hat hangers are installed over the interior walls. The roof support beams are then fitted into the ridge hangers and hat hangers. A more detailed description of the construction of an exemplary structure, a house, can be found in Example 1 below.
Referring now to the figures, a modular house in accordance with one aspect of the invention is shown.
The steps involved in forming the walls are shown in
As shown in
The above disclosure generally describes the present invention. It is believed that one of ordinary skill in the art can, using the preceding description, make and use the compositions and practice the methods of the present invention. A more complete understanding can be obtained by reference to the following specific examples. These examples are described solely to illustrate preferred embodiments of the present invention and are not intended to limit the scope of the invention. Changes in form and substitution of equivalents are contemplated as circumstances may suggest or render expedient. Other generic configurations will be apparent to one skilled in the art. All journal articles and other documents such as patents or patent applications referred to herein are hereby incorporated by reference.
EXAMPLESAlthough specific terms have been used in these examples, such terms are intended in a descriptive sense and not for purposes of limitation. Methods of construction referred to but not explicitly described in the disclosure and these examples are well known to those skilled in the art.
Example 1 Construction of Modular HousePhase 1 involves the foundation & channel layout. The steps are as follows:
-
- Step 1: Foundation is constructed—concrete slab, basement, wood slab
Step 2: Exterior Perimeter and internal wall c-channels Bolted to foundation.
Phase 2 is the erection of the exterior walls according to the following steps.
-
- Step 1: First panel slides into c-channel into starting position. Starting position is in a corner.
- Step 2: Slide opposing corner piece, along the c-channel, to meet the first panel to create squared corner.
- Step 3: Screw ‘L’ bracket on interior of corner to each panel Step 4: Screw ‘L’ Bracket on exterior of each corner.
- Step 5: Apply adhesive to exposed panel side (tongue & grove).
- Step 6: Slide next exterior wall panel along the c-channel into position-tongue and grove—adhere to previous panel.
- Step 7: repeat step 5 & 6 till the first interior wall c-channel.
- Step 8: Insert interior wall panel into interior c-channel, slide into place flush against the interior side of exterior wall panel.
- Step 9: Screw “L” Brackets on both side of the interior wall panel, for support, to the interior of the exterior wall panel
- Step 10: Apply adhesive to exposed side of Interior wall panel
- Step 11: Slide next panel along the c-channel into position-tongue and grove.
Step 12: Repeat 5 to 11
Phase 3 is the installment of the roof support as follows:
-
- Step 1: Install ridge saddle (exterior gable wall) into precut opening. Bolt into place with specified hardware.
- Step 2: Install Ridge Saddle (interior wall) into pre cut opening on interior walls. Bolt into place with specified hardware.
- Step 3: Install ridge beam (beam#1 main beam) into ridge saddles, this beam runs through the middle of the house.
- Step 4: Install hat Saddle (exterior gable wall) into precut opening. Attach with proper hardware.
- Step 5: Install hat saddle (interior walls) place over top of interior wall.
- Step 6: Install hat beam inot the hat saddle. Attach with proper hardware.
Phase 4 relates to securing the parts of the structure together as follows: - Step 1: Each seam (where panels fit together) is screwed together. Using designated screws and engineered approved distances.
Phase 5 relates to providing utility services as follows: - Step 1: Each panel has wiring conduit prefabricated. All wires are to be installed according to the wiring schematics. Also have cable/internet, phone, central vacuum and alarms installed. All installed prior to installing roof
Phase 6 relates to the Eave Channel Conduit Section. The steps are: - Step 1: Place eave channel on exterior sidewalls (custom design with roof pitch) built in electrical conduit.
- Step 2: Run electrical wires in conduit before fastening eave channel permanently to wall panels.
Phase 7 involves installation of an Exterior Gable Channel. - Step 1: Place exterior gable channel to both gable ends of the house. Attach with proper fasteners.
Step 8 is the installation of roof panels and the ridge cap. The steps are: - Step 1: Slide roof panel into position and using the proper screws and specified bolts, attach the panels to beam support (Beam #1, 2, 3, 4)
- Step 2: Apply adhesive/sealant to grove & tongue section on each roof panel
- Step 3: Install foam insulation where the two roof panels meet at the exterior peak
- Step 4: Place ridge cap into place and fix with the proper fasteners.
Step 9 is the installation of an interior corner angle and interior ceiling/wall connection as follows: - Step 1: Interior corner angles are attached to the interior wall to ceiling connection. These connections are support connections.
Step 10 is directed to installing interior corner angles around window & door openings. - Step 2: Install interior corner angle (L channel), one on the exterior and one on the interior side for window and door attachment.
- Step 3: Place interior corner angles one to each side leaving a space of 1″ (one inch), which eliminates the thermo, break.
-
- 1. Base bottom channel running around the perimeter of the house. The base channel must be flashed. The flashing cavity is to be 1½″ deep and must be insulated to minimum R-19. Flash per detail drawings.
- 2. Eave channel/sidewalls to Roof. This area must be flashed as well, leaving a cavity of at least 1½″ (one and one half inch) and insulated minimum R19.
- 3. The exterior gable channel, this area also must be flashed using the same procedure and insulated to minimum of R-19.
One or more currently preferred embodiments have been described by way of example. It will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as defined in the claims.
Claims
1. A modular building comprising: i) a foundation; ii) a plurality of C channels anchored on said foundation; load bearing panels inserted in said channels; at least one ridge beam; at least one set of hat beams; and connectors for connecting the various components.
2. A building according to claim 1 wherein a plurality of load bearing panels are attached to form a plurality of walls.
3. A building according to claim 2 wherein the walls comprise both exterior and interior walls.
4. A building according to claim 2 wherein the walls comprise prefabricated insulated panels.
5. A building according to claim 2 wherein the panels are connected via a tongue and groove mechanism.
6. A building according to claim 2 wherein intersecting walls are supported at right angles using L brackets.
7. A kit for the construction of a building, said kit comprising prefabricated load bearing panels, a series of C channels for receiving the panels, at least one roof beam, a roof assembly set of adaptors, and instructions for assembly.
8. A kit according to claim 7 wherein the roof assembly set includes an eave channel, an exterior gable channel, a channel for attachment to the exterior walls, a ridge beam and at least one set of hat beams.
9. A kit according to claim 7 wherein the panels are prefabricated insulated panels.
10. A kit according to claim 7 wherein the panels are about 2 to 8 inches thick.
11. A kit according to claim 7 wherein the panels are about 5 inches thick.
12. A kit according to claim 7 wherein the kit further includes securing fasteners.
13. A kit according to claim 12 wherein the fasteners are bolts.
14. A kit according to claim 12 further comprising supporting brackets or plates.
15. A method of building a modular unit, said method comprising: I) laying a foundation; ii) anchoring a plurality of C-channels to the foundation; iii) sliding a series of load bearing panels along a C-channel; attaching a number of panels together to form a wall; securing intersecting walls with an L-bracket; installing a ridge saddle at the gable end and along interior walls; inserting a beam into the saddles and installing a hat saddle over the roof assembly.
16. A method according to claim 15 wherein the panels are attached via a tongue and groove mechanism.
17. A method according to claim 15 wherein the panels are affixed to each other with glue.
18. A method according to claim 15 wherein the wall has a length of about 15 to 30 feet.
19. A method according to claim 15 wherein the wall has a length of up to about 17 feet.
Type: Application
Filed: Nov 13, 2007
Publication Date: May 14, 2009
Inventor: Don A. Hill (Burlington)
Application Number: 11/984,111
International Classification: E04H 1/00 (20060101);