SYSTEM OF MODULAR CONSTRUCTION AND ASSEMBLED STRUCTURE

Abstract

A system of modular construction including a plurality of pre-manufactured components cooperatively structured for onsite assembly of a building or other structure. A plurality of modules are disposed and structured to at least partially define wall, floor and roof portions of the assembled building, wherein the plurality of modules are interconnected in an intended relation to one another by a connecting web assembly, wherein the connecting web assembly comprises a plurality of different types of component connectors and retaining channels. A water distribution assembly is incorporated within the building such that water is delivered by gravity feed to a plurality of plumbing fixtures and/or outlets and the building also includes an integrated, built-in gutter assembly associated with the plurality of down spouts for the recognized distribution and/or collection of water.

Description

CLAIM OF PRIORITY

The present application is based on and a claim of priority is made under 35 U.S.C. Section 119(e) to a provisional patent application that is currently pending in the U.S. Patent and Trademark Office, namely, that having Ser. No. 61/338,204 and a filing date of Feb. 16, 2010, and which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is directed to a system of modular construction for the onsite assembly of any one of a plurality of different building structures, which may be least partially self-contained. A plurality of pre-manufactured components including a plurality of modules are interconnected by a connecting web assembly comprising a plurality of appropriately structured and disposed component connectors, brackets and/or retaining channels which collectively facilitate the assembly of the building structure.

2. Description of the Related Art

In the construction industry associated with domestic as well as commercial buildings, consumers demand a wide variety of architectural styles, floor plans, etc. dependent on individual desires and/or practical applications for which the buildings are to be used. As conventionally built, various types of “raw materials” and/or components are utilized to construct a building at a given location site, utilizing partially trained as well as skilled craftsmen, such as carpenters, brick masons, plumbers, electricians, etc.

However, due to periods of economic decline over the years, conventional construction techniques and materials have been found to be expensive, labor intensive and time consuming. As a result, the building industry especially, but not exclusively, in recessionary times suffers from significant declines in demand. Attempts to overcome such situations have resulted in modifications in materials with an attendant reduction in cost and/or labor requirements in the assembly of such building materials. Some innovations are considered to at least partially alleviate problems associated with conventional building construction techniques. However, major problems still exist, at least in terms of cost, labor, construction time etc.

Accordingly, more ambitious attempts to overcome problems of the type generally set forth above include the introduction of prefabricated buildings designed for use as either commercial or residential structures. As such, components used in prefabricated buildings are typically manufactured in a factory or other facility where mass production techniques can be employed. After production, such components are shipped to any number of building sites using common commercial carriers. Therefore, while the industries relating to prefabricated structures have enjoyed at least a moderate success, the specific application and/or utilization of such prefabricated buildings has been somewhat limited.

Moreover, a number of disadvantages associated with prefabricated building systems include a limitation or restriction in design, wherein the plurality of prefabricated building components are not universally adaptable for multiple designs, floors plans and/or a variety of practical uses. As a result, consumers interested in prefabricated buildings are often provided with a limited number of options. Also, at least some of the conventional or commercially available prefabricated building systems still require the use of relatively skilled labor due to the complexity or sophistication of the building materials or their assembly into a completed structure. Furthermore, unless prefabricated structures are assembled in accord with relatively demanding specifications, problems associated with their use or occupancy include leaks, the accumulation of condensation, structural deterioration or damage, temperature control, noise insulation and a variety of other situations not normally associated with conventional building construction techniques.

Therefore, there is a need in the building industry for a system of modular construction which includes a plurality of pre-manufactured or pre-formed building components cooperatively structured to facilitate onsite assembly and formation of a variety of different building structures. Moreover, the resulting building structures should overcome known disadvantages and problems relating to wear, maintenance costs, and time of assembly. Also, a preferred and proposed system of modular construction should be capable of producing a building structure which is at least partially self-contained at least regarding energy requirements, water management and/or plumbing, etc. Finally, the overall cost factors associated with materials, highly skilled labor and assembly time should be minimized, regardless if the assembled building is used for domestic or commercial applications.

SUMMARY OF THE INVENTION

The present invention is directed to a system of modular construction for the onsite assembly of any one of a plurality of different structures specifically, but not exclusively, including building structures. As set forth in greater detail hereinafter, the system of the present invention includes a plurality of pre-manufactured components which are to be incorporated within the structure or building to be assembled.

More specifically, the plurality of building components include a plurality of modules cooperatively disposed and structured to define an outer or peripherally disposed wall portion, a floor portion, a roof portion and in at least one or more preferred embodiments and interior partition portion. As such, the plurality of modules comprise a plurality of wall modules, a plurality of floor modules, a plurality of roof modules and a plurality of partition modules. However, it is to be noted that the various, pre-manufactured components of the building or structure to be assembled may include a plurality of other components such as, but not limited to, those associated with a water distribution assembly, a mounting assembly for a solar panel system, a gutter and a down spout assembly, etc.

Further with regard to the roof portion, at least one additional embodiment of the subject invention includes the forming or construction of the plurality of roof modules by a unitary molding procedure. As such, the plurality of roof modules may include a substantially one piece, molded construction, wherein the outer surfaces thereof do not require any decorative facing material. Moreover, this type of unitary, molded construction facilitates the use of the roof portion, specifically including the plurality of roof modules, with or as part of a variety of buildings and/or building systems in addition to the subject modular building system of the present invention.

The assembly of the building or like structure is facilitated through the provision of a connecting web assembly which comprises a plurality of brackets or “component connectors”. Each of the component connectors is cooperatively structured with at least some of the plurality of modules or other components of the building with which they are used, to establish tongue and groove connections between the component connectors of the connecting web assembly and/or between adjacently disposed or otherwise interconnected modules or components. In addition, the connecting web assembly includes a plurality of retaining channels disposed in interconnecting, retaining relation to at least commonly used once of the plurality of modules, such as the plurality of wall modules defining the outer peripheral wall or other portions of the building structure. Therefore, the plurality of component connectors or brackets and the plurality of retaining channels are cooperatively disposed and structured relative to the plurality of modules, and other components of the building structure, to secure the wall portion, floor portion, roof portion, etc. to one another in a manner which facilitates the assembly of the building or like structure.

As will become more apparent hereinafter, the plurality of component connectors, of which the connecting web assembly is comprised, may vary in structure and disposition dependent, at least in part, on the structure and/or disposition of the plurality of building components being connected to one another or otherwise assembled. More specifically, one type of the component connector includes a tongue member integrally or otherwise fixedly secured to a mounting plate. The tongue and mounting plate are disposed in at least a transverse relation to one another but in certain preferred embodiments, in a perpendicular relation to one another. Moreover, the tongue portion of this type component connector includes a free end and a substantially planar configuration which facilitates its insertion into groove or slot formed in one of the building components or modules being assembled. As a result, the insertion of the tongue into the groove of the building component facilitates the establishment of the aforementioned tongue and groove connection. In addition, the mounting plate associated with such a tongue and plate component connector is disposed to be interconnected or engage another building component. As a result, the tongue and plate component connector interconnects two or more building components by the establishment of a tongue and groove connection with one component and a mounting plate connection to a correspondingly disposed other one of the connected building components.

Yet another type of component connector includes a key structure having a substantially planar configuration and oppositely disposed free ends. As such, the key structure is insertable into different grooves of cooperatively disposed building components, such as modules, to be connected to one another. While the preferred embodiment of this key structure type of component connector preferably includes a planar configuration, other configurations may be used for such a key structure. By way of example, different end or side portions thereof may be angularly oriented to one another, such as when the angled key structure connects modules together which have a relative angular disposition or orientation.

As set forth above, the connecting web also includes a plurality of retaining channels. In at least one additional embodiment of the connecting web assembly one or more of the retaining channels includes a tongue structure extending outwardly therefrom. The associated tongue structure is also dimensioned and configured to facilitate the insertion thereof into the correspondingly disposed groove of a module or building component which is to be attached to or interconnected by the aforementioned retaining channel associated with the tongue structure.

Further with regard to the connecting web assembly, the plurality of retaining channels preferably includes a first number of retaining channels. The first number of retaining channels are disposed in retaining, supporting and/or interconnecting relation to a lower end of a plurality of correspondingly disposed wall modules, which define at least a portion of the outer or peripheral wall of the building structure. One or more of these first numbers of retaining channels may include the aforementioned tongue structure, as described above, so as to facilitate the interconnection of the wall portion of the building structure to a foundation portion thereof.

The plurality of retaining channels also includes a second number of such retaining channels which are disposed in interconnecting, retaining relation to the upper end of correspondingly disposed wall channels. As a result, the plurality of wall modules are retained in assembled relation to one another at least partially by the disposition of the first and second number of retaining channels disposed along the lower ends and upper ends respectively.

Additional structural and operative features associated with the connecting web assembly is the provision a supporting flange or “ledger” integrally or fixedly connected to at least some of the lower end retaining channels. The supporting flange extends transversely outward from the corresponding retaining channel(s) towards and into the interior of the building being assembled. As such, the support flange(s) has a sufficient transverse and longitudinal dimension to support and/or be connected to corresponding ends of a plurality of floor modules. As such, the plurality of floor modules are supported in interconnecting relation to one another to define the floor portion of the assembled structure and the flooring on the interior of the building. Accordingly, the opposite ends of correspondingly position ones of the connected floor modules are disposed in supported relation on the support flange associated with the lower end retaining channels.

As set forth above, the building structure of the present invention may also include a roof portion, at least partially defined by a plurality of interconnected roof modules. The roof modules may be secured to one another, as set forth in greater detail hereinafter, utilizing one or more of the different types of component connectors. In addition, one or more of the upper end retaining channels, connected to the upper end of the assembled wall modules, may be disposed in retaining, supporting and/or interconnecting relation to the roof modules defining the roof portion. In addition, the roof portion may include a plurality of roof trusses disposed in underlying but supporting relation to the plurality of connected roof modules. Moreover, roof trusses are disposed in supported and/or interconnected relation to the upper end retaining channels by virtue of a retaining strap or “hurricane strap”. The retaining strap is integrally or fixedly secured to one or more of the upper end retaining channels.

Additional features associated with the roof portion include the formation of the plurality of interconnected roof modules into a plurality of roof sections. As such, at least two of the roof sections may define a sloped roof structure, wherein corresponding inner ends of the two roof sections are interconnected in overlapping relation to one another through the provision of a ridge cap. The ridge cap may also be structured to at least partially define tongue and groove connections with the corresponding sides or ends of the roof sections.

Accordingly, the system of modular construction of the present invention facilitates the building or assembly of any of a plurality of different types and styles of building or other structures at an onsite location. The assembled building may also include additional structural and/or operative features which facilitate it being at least partially self-contained. More specifically, the plurality of interconnected roof modules may include an exterior, exposed mounting structure which facilitates the attachment of solar panels thereto. Also, the assembled building structure may include a water distribution assembly, which facilitates the collection and distribution of water throughout the building structure to the various plumbing fixtures and/or water outlets by means of gravity feed. Also, the water distribution assembly may include “built-in” or integrated gutter structures disposed within the roof portion in a manner which overcomes the disadvantages and problems associated with externally attached gutters. Moreover, the integrated gutter assembly may include a plurality of down spouts which direct the water to a disposal location or collection facility exteriorly of the building, in order to supply water to the water distribution assembly.

These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:

FIG. 1 is a perspective view of one of a possible plurality of buildings or other structures assembled onsite utilizing the system of modular construction of the present invention.

FIG. 2 is a perspective view in partial cutaway disclosing a floor, foundation and stanchion support assembly of the building of the embodiment of FIG. 1, when partially assembled.

FIG. 3 is a perspective view of at least a portion of the embodiment of FIG. 2 in partially assembled condition.

FIG. 4 is the sectional view in partial cutaway of wall, floor and foundation portions of the building of FIG. 1 in at least partially assembled condition.

FIG. 5 is a sectional view in partial cutaway of at least a portion of the embodiment of FIG. 4.

FIG. 6 is a sectional view in partial cutaway of additional details of the embodiment of FIGS. 4 and 5.

FIG. 7 is a sectional view in partial cutaway of an interconnecting junction between two adjacent modules.

FIG. 8 is a sectional view in partial cutaway and in exploded form of a plurality of modules to be interconnected to form a roof portion of the building of FIG. 1.

FIG. 9 is a detailed view in partial section and cutaway of the embodiment of FIG. 8 in assembled form.

FIG. 10 is a sectional view in partial cutaway of the roof and wall portions of the building of the embodiment of FIG. 1 in an at least partially assembled form.

FIG. 11 is a sectional view in partial cutaway of roof sections of a roof portion of the building of the embodiment of FIG. 1, disposed in interconnected relation by a ridge cap.

FIG. 12 is a sectional view in partial cutaway of the connection of at least one of a plurality of partition modules disposed on the interior of the building of the embodiment of FIG. 1.

FIG. 13 is a sectional view in partial cutaway and exploded form of a plurality of partition modules prior to assembly.

FIG. 14 is a sectional view in partial cutaway and exploded form of utility facilities associated with at least one partition module of the type generally represented in FIGS. 12 and 13.

FIG. 15 is a sectional, detailed view in partial cutaway of a water distribution assembly associated with the building of the embodiment of FIG. 1.

FIG. 16 is a sectional view of at least one preferred embodiment of the present invention associated with one or more wall modules incorporating support stanchions and exterior surfaces thereof.

FIG. 17 is a front plan view of the embodiment of FIG. 16.

FIG. 18 is an end view of wall extensions and corresponding roof and wall portions of the building of the embodiment of FIG. 1.

FIG. 19 is a sectional view in partial cutaway of the attachment of wall extensions and structures associated with the roof portion of the building of the embodiment of FIG. 1.

FIG. 20 is a perspective view of an at least partially assembled portion of one embodiment of the building structure of FIG. 1 incorporating structural features of the embodiment of FIG. 19.

FIG. 21 is a perspective view in partial cutaway of yet another embodiment of a piling structure defining at least a portion of a foundation assembly of the type represented in FIG. 1.

FIG. 21A is a front plan view of the embodiment of FIG. 21 including additional structural features for connecting one or more pilings to and in supporting relation with corresponding wall modules.

Like reference numerals refer to like parts throughout the several views of the drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As represented in the accompanying drawings, the present invention is directed to a system of modular construction including a plurality of pre-manufactured components which are cooperatively structured for onsite assembly of a building or other structure generally indicated as 10 in FIG. 1. As emphasized herein, the size, style, floor plan, etc. of the building can vary significantly while still being able to be formed and assembled using the various preferred embodiments of the modular construction system of the present invention.

The aforementioned pre-manufactured components which define the various parts of the building 10 include a plurality of modules cooperatively disposed and structured to define an outer wall portion, generally indicated as 12; a roof portion, generally indicated as 14 and a floor portion, generally indicated as 16, throughout the various accompanying figures. In addition, the building 10 includes a foundation, such as, but not limited to a plurality of pilings 18 disposed in supporting relation to the remainder of the building 10, on a ground or other appropriate supporting surface.

The plurality of modules include a plurality of wall modules 20 disposed in adjacent, interconnecting relation to one another so as to extend about the periphery of building 10 and thereby define the outer wall portion 12. As also represented in FIG. 1, at least some of the wall modules 20 include window and/or door openings, as at 21 and 22, appropriately positioned to provide both visual and physical access to the exterior of the building 10. Moreover, at least one embodiment of the present invention includes the window and door openings 21 and 22 being integrally formed in the wall modules 20 such as by being molded therein during the formation or production of the corresponding wall modules 10. As a result, problems and disadvantages associated with the on-site cutting and/or similar formation of such window and door openings is eliminated.

Similarly, in at least one embodiment, the roof portion 14 comprises a plurality of roof modules 24 also appropriately interconnected to one another in adjacent relation, so as to collectively define the roof portion 14 of the building 10. Moreover, in at least one preferred embodiment of the present invention the building 10 may be structured to have a sloped roof portion 14 comprising at least two roof sections 26 and 28 joined and/or interconnected at their correspondingly disposed upper or inner sides by a ridge cap 30. As will be explained in greater detail hereinafter, the oppositely disposed lower or outer sides of each of the roof sections 26 and 28 are supported on or at least interconnected to the upper ends of the wall portion 12.

Other structural components included within the assembled building structure 10 are generally represented in FIGS. 2, 3 and 20 and comprise a plurality of substantially vertically oriented stanchions 31 formed of a material having performance characteristics sufficient to provide required strength and structural integrity to the assembled building structure 10. In addition, the stanchions 31 are disposed generally about the periphery of the building 10 in spaced relation to one another and are disposed in at least partially interconnecting relation between the lower and upper ends of the wall portion 12 and may also be connected to retaining channels 40.

As also represented in FIGS. 2 and 3, the aforementioned floor portion 16 comprises a plurality of adjacently interconnected floor modules 17 which may vary in size and configuration and which collectively define the floor portion 16 of the building 10. Moreover, as represented in FIG. 6, the outer or exposed surface of the floor module 17 may comprise an integral, molded surface and/or a plurality of separate tiles or other decorative and utilitarian flooring components, as at 19.

Additional features of the assembled building structure 10 include a connecting web assembly comprising a plurality of component connectors or brackets 32 and 32′. Each of the component connectors or brackets 32 and 32′ are appropriately structured to define tongue and groove connection between adjacent and or otherwise interconnected components of the building structure including, but not limited to the various floor modules 17, wall modules 20 and/or roof modules 24. As represented in FIG. 4 one category of component connectors or brackets 32 includes a tongue and plate structure comprising a tongue 34 integrally or otherwise fixedly secured to a mounting plate 34′ in perpendicular or other transverse relation thereto. As such, the tongue 34 of the tongue and plate component connector 32 is dimensioned and configured to be inserted within an appropriately formed groove, as at 35, in any of the building components to which it is to be connected. As a result, a tongue and groove connection, as set forth above, is thereby defined. Cooperatively, the plate 34′ of the tongue and plate component connector is disposed in interconnecting relation to other components of the building 10 as also represented in FIG. 4. Such a connection may be further facilitated a plurality of fasteners 37 extending through the plate and/or other components to which the tongue and groove component connector 32 serves to interconnect.

Yet another structure for attaching pilings 18 to correspondingly disposed wall modules 20 utilizing the retaining channels 40 is represented in FIGS. 21 and 21A. More specifically, this preferred embodiment includes a piling cap 150 secured to the upper end of a corresponding piling 18 and maintained on the upper end thereof by a connector 37, in the manner described with reference to FIG. 4. Moreover, the interconnecting assembly as represented in FIG. 21A includes a connecting plate 134 and a plurality of appropriate connectors 152. Connectors 152 may be in the form of pass through bolts which serve to interconnect the plate 134 to the base portion of the receiving channel 40, as at 40′. These same pass through bolts would pass through appropriate apertures formed in the plate 134 and further pass through correspondingly aligned apertures 154 formed in the expose upper base portion 154′ of the piling cap 150. As such, the connecting, bolts 152 would be secured to the base 40′ of the retaining channel 40, be connected to and/or pass through the plate 134 and also through the apertures 154 in the base 154′ of the piling cap 150 and into the piling 18. As an alternative structure, the connectors 152 could be integrally secured to the exposed base 150′ of the piling cap 150 and protrude outwardly therefrom. Such integrally secured connectors 152 would pass through the plate 134 and be bolted or otherwise fixedly secured to the base 40′ of the retaining channel 40.

As also represented in FIGS. 7 through 9 and 13 the plurality of component connectors may also comprise the aforementioned key structure 32′ preferably including a planar or other appropriate configuration. Opposite ends 32″ of the key structure are substantially free so as to facilitate there insertion into appropriate grooves, as at 33, formed in the various components of the building structure 10 which are to be connected to one another by the key type 32′ component connector. As such, the aforementioned tongue and groove connections are established between adjacent and/or other correspondingly disposed components including, but not limited to, common use modules such as floor modules 17, wall modules 20, roof modules 24, etc.

As also represented in FIGS. 7-9, utilization of the key type component connector 32′ is also part of establishes a connecting junction, generally indicated as 38. The connecting junctions 38 are disposed between adjacently or interconnected modules such as, but not limited to, roof modules 24. The connecting junction 38 is defined not only by the tongue and groove connection established by the key component connector 32′ but also by the inclusion of an adhesive or other type adhering or bonding material 39. The bonding material 39 has sufficient adhesive or bonding characteristics to form a tight leak and/or weather resistant seal between the correspondingly disposed ends or portions of the interconnected modules 24, and in a preferred embodiment at all or most locations such as, but not limited, to a joint, seam, etc. where such a weather resistant seal is of benefit.

In addition, the aforementioned web connecting assembly also comprises a plurality of retaining channels 40 and 42. More specifically, a first number of the retaining channels 40 are disposed in supporting and/or retaining engagement to the lower end of the plurality of wall modules 20 commonly used to define the outer periphery wall portion 12. In cooperation therewith, a second plurality of retaining channels are disposed in retaining and/or supporting relation to the upper end of the commonly used wall modules 20 as represented in FIG. 10.

With initial reference to FIGS. 4 and 6, a first plurality of lower end retaining channels 40 include a generally U-shaped cross sectional configuration dimensioned and configured to receive the lower end 40′ of the wall modules 20. As such, the lower ends 20′ of each of these common use modules 20 may be recessed or otherwise structured such that the outer sides of the lower end retaining channels 40 are disposed in substantially flush relation to both the outer and inner surfaces of the plurality of wall modules 20 which they engage. In the embodiment of FIG. 4, the lower end retaining channels 40 are interconnected to a foundation portion or piling 18 using one or more of the tongue and plate component connectors 32 and interconnecting fasteners 37. In contrast, others of the plurality of lower end retaining channels 40 include an integrally or fixedly formed tongue segment 40′ which is disposed, dimensioned and configured to be inserted within a groove 35 formed in the foundation or piling 18.

As also noted, each or at least some of the lower end retaining channels 40 include a supporting flange or “ledger” 41 integrally or fixedly secured to one side thereof and extending outwardly from the corresponding retaining channel 40 towards the interior of building 10 as clearly demonstrated in both FIGS. 4 and 6. Each of the supporting flanges or ledgers 41 extend along a sufficient length or a corresponding retaining channel 40 to engage and at least partially support corresponding ends 17′ of floor module 17. Therefore, at least the lower end retaining channels 40 serve to interconnect corresponding wall modules 20, floor modules 17 and the foundation portion, such as pilings 18, to one another in a stable and secure manner. Such stability is further enhanced through the inclusion of at least one or more practically a plurality of fasteners 37 which extend through predetermined portions of the lower end retaining channels 40 as well as through the lower ends 20′ of the plurality of wall modules 20 and floor modules 17. The fasteners 37 may vary in size, structure and configuration depending upon their intended use and placement to facilitate a secure and stable interconnection between the plurality of building components included within the assembled building structure 10.

Further with regard to the embodiment of FIG. 6 additional structural features incorporated within the floor portion 16, such as relates to its support and overall construction, include the provision of floor joists 45 disposed in supporting relation to a plurality of floor module 17. More specifically, each of the opposite ends of the one or more joists 45 are secured to a foundation or piling member 18 by means of a joist hanger 45′. In turn, the joist hanger 45′ is mounted on or connected in partially supported relation by corresponding ones of the pilings 18. Recessed or undercut portions 45″ are provided to include a flush, cooperatively configured engagement with the elongated supporting flange or ledger 41 received therein. This further facilitates the support of the plurality of the floor modules 17 on the plurality of joists 45, as also represented in FIG. 6.

With primary reference to FIG. 10, the second plurality of retaining channels are defined by the upper end channels 42 secured in retaining relation to the upper end 20″ of the common use plurality of wall modules 20 defining the outer wall portion 12. In addition, the upper end 20″ of the plurality of wall modules 20 and the upper end retaining channels 42 are disposed in interconnecting, at least partially supporting relation to the plurality of roof modules 24 and a plurality of corresponding roof trusses 48. As set forth above, in the embodiment of the building 10, the roof portion 14 includes at least two roof sections 26 and 28 having an outer or lower end 28′. The lower ends 28′ and/or adjacent portions thereof are at least partially supported, retained or otherwise interconnected to the upper end 20″ of the perimeter wall portion 12 by the plurality of the upper end retaining channels 42. As represented, plurality of retaining structures such as retaining straps or “hurricane” straps 49 are fixedly connected to an appropriate portion of at least some of the retaining channels 42 and are connected to corresponding ones of the roof trusses 48. As such, the outer ends 48′ of the roof trusses 48 are retained by or at least partially supported on the exterior of the corresponding upper end retaining channels 42 and maintained in such supported or retained disposition due to the interconnection of the retaining strap or structure 49.

As also represented in FIG. 10, the exterior or exposed outer surface of the roof portion 14, specifically including the outer surfaces of the roof modules 24, may include one or more exposed surface structures 19′ formed as an integral, molded part of corresponding one of the roof modules 24. Also, the materials from which the roof modules are formed must be approved so as to not contaminate any collected water, passing over and/or along the outer surface structure, as such collected water is to remain potable, as discussed with regard to FIG. 15. In addition, a mounting assembly 50 may be disposed on each or a predetermined number of the roof modules 24. The mounting of assembly 50 includes an appropriate connector 37 and a mounting base 52 which is disposed and structured to facilitate the attachment of a solar panel assembly. As such, the mounted solar panel assembly renders the assembled building 10 at least partially self contained in terms of energy requirements.

Further with regard to the roof portion 14, at least one preferred embodiment of the subject invention includes the forming or construction of the plurality of roof modules 24 by a unitary molding procedure. As such, the plurality of roof modules 24 may include a substantially one piece, molded construction, wherein the outer surfaces thereof do not require any decorative facing material, such as on the exposed portions of the surface structures 19′. Moreover, this type of unitary construction facilitates the use of the roof portion 14, specifically including the plurality of one piece roof modules 24, with a variety of buildings and/or building systems other than the subject modular building system of the present invention.

Yet additional features represented in FIG. 10 include the provision of the integrated or “built-in” gutter assembly generally indicated as 54. The gutter assembly 54 includes a support and/or retaining bracket 55 and an inwardly extending, depending trough 56. As such, rain water may be collected in the integrated or built-in gutters 54, 56 and directed to a collection facility or otherwise away from the building 10 utilizing a plurality of down spouts 57.

With primary reference to FIG. 11, additional structural features relating to the roof portion 14 and the interconnection of correspondingly disposed inner or upper ends of the roof sections 26 and 28 are represented. As set forth above, elongated roof ridge cap 30 includes two outwardly extending connecting flanges 30′ which are inserted within correspondingly disposed and configured elongated grooves 30″. As such, ridge cap 30 accomplishes the aforementioned tongue and groove interconnection with each of the corresponding upper ends of the roof sections 26 and 28. Additional stability is provided by a plurality of connectors 37 passing through portions of the grooved roof modules 24 into a center beam 60 disposed in supporting relation to the crown or apex of the roof portion 14 defined by the connected inner ends of the roof sections 26 and 28.

Yet additional features of the roof portion 14 are represented in FIGS. 18-20 and include the provision of wall extensions 62 covering the gable ends or other exposed areas of the underside of the roof portion 14. More specifically, the wall extensions 62 are connected to and at least partially supported by corresponding ones of the upper end retaining channels 42 as represented in FIG. 19. More specifically, an extension channel segment 64 may be integrally or otherwise fixedly secured to an outer exposed face or portion of the corresponding ones of the upper end channels 42. Such extension channel segments 64 are disposed and dimensioned to receive a lower or other appropriate portion 62′ of the wall extensions 62 therein. An appropriate fastener 37 passes through the extension channel 64 and through the corresponding ends 62′ of the wall extensions 62.

Yet additional features of at least one preferred embodiment of the building structure 10 incorporating the features of the modular construction system of the present invention are represented. More specifically, the interior space or area of the building 10 may be segregated by a plurality of partition modules 70 and 70′ which may vary in size, configuration and location dependent upon the intended floor plan of the interior of the building 10. The plurality of partition modules 70 and 70′ may be interconnected to the outer peripheral wall portion 12 and/or the floor portion 16 utilizing the aforementioned tongue and plate component connector 32 or key structures 32′. As a result, appropriate tongue and groove connections are established between the common use partition modules 70, 70′ or cooperatively disposed and structured modules as at and including partition module 70 and wall modules 20 as represented in FIG. 12. Moreover, one or more of the plurality of partition modules 70 may include utility structures such as wiring or ventilation conduits, etc. generally represented as 74. As a result, the one or more partition modules 70 maybe appropriately structured to include interior recesses or chambers 75 dimensioned and configured to enclose the utility components 74. Cover plates 75′ maybe used to close or cover the chamber 75 and the utility components 74 contained therein. As represented in FIG. 13 the various partition modules 70 and 70′ may have a variety of different configurations so as to enhance the versatility of the modular construction system of the present invention in determining or designing the interior segmented space area and/or floor plan.

FIG. 15 is a schematic representation of a water distribution assembly which may be associated with the building 10 and which, in cooperation with the aforementioned solar panel assembly, facilitates the building 10 being at least partially self-contained and/or self sufficient. More specifically, a water collection tank or other facility 80 is disposed at an elevated location above the fixtures or other upper portions of the building 10. A supply conduit as at 82 may direct water into the collection facility 80 and delivered by a pump or by other means from a predetermined water source. In addition a plurality of distribution conduits 84, which may vary in number and location, are disposed in fluid communication with the water collection facility 80. Moreover, each or at least predetermined ones of the distribution conduits 84 are connected to or otherwise disposed in fluid communication with a plurality of water outlets, plumbing fixtures, etc., schematically represented as 86. As a result, water is supplied to the various plumbing fixtures or water outlets 86 throughout the building 10 from the water collection facility 80 by gravity feed through the distribution conduits 84. The use of gravity feed distribution of collected water provides free flowing water to the outlets 86, as required.

Additional structural details of the wall modules 20 are represented in FIGS. 16 and 17, including internal structuring thereof. Accordingly, in at least one preferred embodiment, one or more of the wall modules 20 include a skin or surface 21 which is intended to be disposed on the interior of the building, as versus the exterior thereof as represented as 21′. More specifically, the exposed, surfaces 21′ and 21 may be formed or at least partially comprised of a fiberglass laminate or plastic material suitable for supplying the required strength, rigidity, physical properties, etc. necessary to meet appropriate building codes and ordinances. In addition, an inner layer of material, such as plywood, is indicated at 90 and is provided to further enhance the rigidity, impact resistance and load carrying abilities of each of the plurality of wall modules 20. Additional strength and load carrying capabilities are provided in the structuring of the wall module 20 through the provision of a plurality of spaced apart inner core supports 31. Interior core supports 31 are disposed in a substantially vertical orientation and laminated or adhered to the plywood or other material 90, as set forth above. In addition, the modules external skins or surfaces 21′ and 21 are structured to form a webbing of support to further enhance the strength of the modules so formed. Additionally, interior cavities that remain after the placement after the aforementioned material 90 may be filled with appropriate foam or other material. This will result in all interior open areas or chambers receive such insulating foam.

Once cured, the foam will not only add to the insulating characteristics of the module 20 but further facilitates the overall rigidity thereof. Finally, in a preferred embodiment the exterior surfaces or skins 21′ and 20 may be finished with appropriate architectural embellishments including, but not limited to, a painted, gel coated finish. Finally, a portion or end of the wall module 20 that is inserted within corresponding ones of the retaining channels 40 is appropriately tapered and secured therein, at least in part, due to an additional adhering or bonding material 39 as discussed with reference to the embodiment of FIGS. 7 and 8.

Accordingly, the system of modular construction of the present invention includes the interconnection of a plurality of pre-manufactured components which are cooperatively structured, as set forth above for onsite assembly. As a result the plurality of building components, including but not limited to, the plurality of modules as well as those components associated with the connecting web assembly facilitate the formation and assembly of any of a plurality of differently designed buildings. Also, it is emphasized that the system of modular construction of the present invention is not necessarily limited to the formation and assembly of a “building” of the type designed for conventional use as represented in FIG. 1. To the contrary, the versatility of the modular construction system of the present invention allows for the formation and assembly of a variety of different structures that may or may not be used as a conventional building having interior areas intended to be occupied by an individual.

Since many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.

Now that the invention has been described,

Claims

1. A system of modular construction including a plurality of pre-manufactured components cooperatively structured for onsite assembly of a building, said system comprising:

a plurality of modules cooperatively disposed and structured to define an outer wall portion, a floor portion and a roof portion of the building,

a connecting web assembly, comprising a plurality of component connectors cooperatively structured with at least some of said plurality of modules to define a plurality of tongue and groove connections,

said connecting web assembly further including a plurality of retaining channels disposed in interconnecting relation to at least common-use ones of said plurality of modules, and

said plurality of component connectors and said plurality of retaining channels cooperatively disposed and structured to secure said wall portion, said floor portion and said roof portion to one another, in a manner at least partially defining an assembled building.

2. A system as recited in claim 1 wherein at least some of said retaining channels include at least one of said component connectors integrally secured thereto.

3. A system as recited in claim 2 wherein said building further includes a foundation; said one component connector being inserted within a foundation portion of the building to define a tongue and groove connection therewith.

4. A system as recited in claim 1 wherein at least one of said retaining channels includes a supporting flange extending outwardly therefrom into supporting relation with at least one of said modules associated with said floor portion of the building.

5. A system as recited in claim 4 wherein said one retaining channel has an elongated configuration of sufficient length to supportingly engage a plurality of said modules associated with said wall portion of the building; said one support flange extending along a sufficient length of said one retaining channel to support a plurality of modules associated with said floor portion.

6. A system as recited in claim 1 wherein a first number of said plurality of retaining channels are disposed in retaining relation to a lower end of a plurality of said modules associated with said wall portion; a second number of said plurality of retaining channels disposed in retaining relation to an upper end of a plurality of said modules associated with said wall portion.

7. A system as recited in claim 6 wherein at least some of said second number of retaining channels are disposed in interconnecting relation to a plurality of modules associated with said roof portion of said building.

8. A system as recited in claim 7 wherein said at least some of said first number of retaining channels include a supporting flange extending outwardly therefrom into supporting relation with a plurality of said modules associated with said floor portion of the building.

9. A system as recited in claim 8 further comprising a plurality of fastener members extending in interconnecting relation with and at least partially through said first number of retaining channels, said lower end of said wall modules and corresponding ones of said floor modules.

10. A system as recited in claim 8 further comprising a plurality of fastener members extending in interconnecting relation with and at least partially through said second number of retaining channels and at least said upper end of said wall modules.

11. A system as recited in claim 6 further comprising a plurality of support stanchions substantially vertically oriented and extending in spaced relation to one another about at least a portion of a periphery of the building, between said first number and said second number of retaining channels.

12. A system as recited in claim 1 wherein at least some of said component connectors include a tongue and a mounting plate fixedly connected in transverse relation to said tongue, said tongue insertable into a correspondingly positioned one of the components of the building to define said tongue and groove connection therewith and said mounting plate disposed in interconnecting relation between said tongue and a correspondingly disposed component of said building.

13. A system as recited in claim 12 wherein said mounting plate and said tongue are integrally connected in perpendicular relation to one another.

14. A system as recited in claim 12 wherein at least some of said component connectors comprise a key structure comprising a substantially planar configuration; said key structure including opposite end portions disposable in inserted relation with adjacently disposed ones of at least some of said plurality of modules and at least partially defining a male-female connecting junction of said adjacent ones of said plurality of modules.

15. A system as recited in claim 14 further comprising a plurality of partition modules disposed in spaced, segregating relation to an interior of said building; said plurality of partition modules connected to one another by said key structure and interconnected to others of said plurality of modules by said tongue and plate component connectors.

16. A system as recited in claim 1 wherein at least some of said component connectors comprise a key structure including a substantially planar configuration; said key structure including free opposite end portions disposable in inserted relation with adjacently disposed ones of at least some of said plurality of modules to define said tongue and groove connection therewith; said tongue and groove connection at least partially defining a connecting junction of said adjacent ones of said plurality of modules.

17. A system as recited in claim 16 wherein said connecting junction further comprises an adhering material disposed in bonding relation between said adjacent ones of said plurality of modules.

18. A system as recited in claim 1 wherein said plurality of modules comprise a plurality of roof modules, adjacent ones of said plurality of roof modules connected together and defining at least two roof sections; a ridge cap disposed and structured in interconnecting relation to corresponding sides of said two roof sections.

19. A system as recited in claim 18 wherein said ridge cap is at least partially inserted in interlocking engagement with each of a plurality of roof modules defining said corresponding sides of each of said two roof sections.

20. A system as recited in claim 19 wherein each of said roof sections includes an outer side disposed in an at least partially supported relation to outer sides of said outer wall portion.

21. A system as recited in claim 20 wherein at least some of said plurality of retaining channels are disposed in retaining engagement with an upper end of said plurality of modules associated with said outer wall portion; said upper end retaining channels disposed in interconnecting relation with said outer sides of each of said roof sections.

22. A system as recited in claim 18 wherein at least some of said plurality of roof modules are structured to facilitate a non-penetrating attachment of a solar panel assembly on exterior, exposed portions thereof.

23. A system as recited in claim 1 further comprising a water distribution assembly incorporated within the building and including a reservoir disposed at an upper portion of the building; said water distribution assembly further including a plurality of distribution conduits disposed in fluid communication between said reservoir and a plurality of water outlets associated with the building.

24. A system as recited in claim 23 wherein said water distribution assembly is disposed and structured to direct water from said reservoir through said plurality of distribution conduits by gravity feed.

25. A system as recited in claim 1 wherein said roof portion of the building further comprises a gutter assembly integrated therein and a plurality of down spouts incorporated within the building in fluid communication with said gutter assembly.

26. A system as recited in claim 1 further comprising a plurality of wall extensions disposed between an upper end of said wall portion and said roof portion; corresponding ones of said retaining channels including at least one extension channel segment disposed in retaining engagement with a corresponding one of said plurality of wall extensions.

27. A system as recited in claim 1 wherein said building further includes a foundation including a plurality of pilings, at least one of said pilings including a piling cap; at least one of said component connectors disposed in interconnecting relation between said piling cap and a corresponding one of said retaining channels; a plurality of connectors disposed in interconnecting engagement with each of said corresponding retaining channel, said one component connector and said piling cap.

28. A system as recited in claim 27 wherein said plurality of connectors are fixedly secured to said piling cap and extend outwardly there from into said interconnecting engagement with said one component connector and said corresponding retaining channel.

29. A system as recited in claim 1 wherein said plurality of modules comprise a plurality of roof modules, adjacent ones of said plurality of roof modules connected together; at least some of said plurality of roof modules formed of a one piece molded construction.