MODULAR BUILDING SYSTEMS, COMPONENTS, AND METHODS
Pre-fabricated components such as beams, beam nodes, floor panels, wall panels, and roof panels are useful for constructing buildings such as houses. In some cases, conservation of materials, ease of construction, and superior structural integrity appear.
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FIELD OF INVENTIONThis invention relates to the construction of buildings from pre-fabricated components.
BACKGROUND OF THE INVENTIONCurrently, most houses in North America are built by hand from raw materials one piece at a time. First, a foundation usually of concrete is framed, poured, and allowed to harden. Then, a wooden frame for the above-ground structure is added by nailing one 2″×4″ stud into place at a time. A roof, exterior wall materials such as bricks and siding, insulation, plumbing, wiring, duct work, and interior drywall surfaces come next. Each piece of wood is measured, cut, and attached on site, as are pieces of many other materials such as weatherproofing, insulation, and the like. This construction by hand requires a relatively enormous amount of skilled manpower employed on the construction site, and leads to a staggering amount of material waste and significant variability in the quality, fit, and finish from one house to the next.
Constructing a house from pre-fabricated components also has been tried. But building by hand remains the norm, because the use of pre-fabricated components raises its own set of difficulties. Transporting and installing bulky components that still require customization by hand have prevented pre-fabrication from replacing building by hand in a broad manner across the house-building industry. In addition, the relatively poor structural integrity and fit and finish of certain pre-fabrication-built houses have hindered wide-spread acceptance by house-buying consumers.
The industry needs an easier way to pre-fabricate components for new houses and buildings, and to assemble those components easily. Those new houses and buildings also need a structural integrity that the public will accept.
SUMMARY OF THE INVENTIONUnexpectedly, Applicants have invented modular building systems, components, and methods that address certain needs of industry. In some embodiments of the present invention, modular building components appear that are smaller than pre-fabricated components tried before. That smaller size facilitates transportation and construction, in some cases. In other cases, certain embodiments provide for the introduction of reinforcements that greatly enhance the structural integrity of the completed building far beyond that exhibited by buildings built by hand and required by conventional building codes. In still other cases, pre-fabrication dramatically reduces material waste, and allows for significant scrap recycling that is not feasible for scrap produced on the construction site of a building built by hand. The types of buildings that can be built in accordance with the present invention are not limited. Houses, garages, sheds, commercial buildings, warehouses, portable or quickly-constructed buildings useful in military and disaster relief efforts, office buildings, and multi-family dwelling structures may be mentioned.
Accordingly, some embodiments of the present invention relate to beams useful in modular construction comprising: one or more vertical support members supporting and separating an upper horizontal support member and a lower horizontal support member; and at least one ledger adapted to support a vertical load.
Other embodiments relate to beam nodes useful in modular construction comprising: a lower horizontal support member supporting at least two vertical support members, wherein the at least two vertical support members define at least two beam coupling elements; and at least one registration element.
Still other embodiments relate to floor panels useful in modular construction comprising: at least one rib supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a floor surface or floor subsurface; and wherein the at least one rib comprises at least one shear-stabilizing coupling element.
Additional embodiments relate to floor panels useful in modular construction comprising: at least one anchor supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a floor surface or floor subsurface; and wherein the at least one anchor comprises at least one shear-stabilizing coupling element. In some embodiments, an anchor comprises a single shear-stabilizing coupling element; in other embodiments, an anchor comprises more than one shear-stabilizing coupling element.
Yet additional embodiments relate to wall panels useful in modular construction comprising: a first main surface; a second main surface; a plurality of edge members that support and separate the first main surface from the second main surface; and at least one shear block receiving port positioned at a first edge of the first main surface; at least one shear block receiving port positioned at a second edge of the first main surface; wherein the first edge and the second edge are positioned on opposing sides of the first main surface.
Still further embodiments relate to corner wall panels useful in modular construction comprising: two main outside surfaces comprising a first main outside surface joining a second main outside surface defining an outside corner; two main inside surfaces comprising a first main inside surface joining a second main inside surface defining an inside corner; a plurality of edge members that support and separate the main outside surfaces from the main inside surfaces; at least one shear block receiving port positioned at an edge of the first main outside surface distal from the outside corner; and at least one shear block receiving port positioned at an edge of the second main outside surface distal from the outside corner.
Additional embodiments relate to roof panels useful in modular construction comprising: at least one rib supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a roof surface or roof subsurface; and wherein the at least one rib comprises at least one shear-stabilizing coupling element.
Additional embodiments relate to roof panels useful in modular construction comprising: at least one anchor supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a roof surface or roof subsurface; and wherein the at least one anchor comprises at least one shear-stabilizing coupling element.
Other embodiments relate to roof beams useful in modular construction comprising: one or more vertical support members supporting and separating an upper support member and a lower support member; and a first registration element and a second registration element adapted to transfer load to structure below.
Still further embodiments relate to buildings comprising at least one beam as described herein; at least one beam node as described herein; at least one floor panel as described herein; at least one wall panel as described herein; at least one corner wall panel as described herein; at least one roof panel as described herein; at least one gable wall panel as described herein; at least one roof beam as described herein; or a combination of any two or more of the foregoing.
Applicants have also invented methods of manufacturing each of the components described herein, the parts that make up those components, and buildings and parts of buildings that contain those components. For example, certain embodiments provide methods of constructing a building, comprising:
(a) installing a plurality of helical piles in ground to establish a subfoundation for the building;
(b) affixing a plurality of beams to the helical piles, wherein the beams comprise one or more vertical support members supporting and separating an upper horizontal support member and a lower horizontal support member; and at least one ledger adapted to support a vertical load, wherein at least some of the beams are coupled to other beams in the plurality of beams, to form a foundation for the building;
(c) affixing a plurality of floor panels to the foundation, wherein the floor panels comprise at least one rib supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a floor surface or subsurface; and wherein the at least one rib comprises at least one shear-stabilizing coupling element, wherein at least some of the floor panels are coupled to adjoining floor panels in the plurality via the at least one shear-stabilizing coupling element, to form a floor of the building;
(d) affixing a plurality of wall panels to the foundation, wherein the wall panels comprise a first main surface; a second main surface; a plurality of edge members that support and separate the first main surface from the second main surface; and at least one shear block receiving port positioned at a first edge of the first main surface; at least one shear block receiving port positioned at a second edge of the first main surface; wherein the first edge and the second edge are positioned on opposing sides of the first main surface; wherein at least some of the wall panels engage registration elements of at least some of the beams of the foundation, and transfer vertical load to at least some of the ledgers of the beams of the foundation;
(e) inserting a plurality of shear blocks into at least some of the shear block receiving ports of adjacent wall panels, thereby stabilizing the wall panels, and thereby forming a wall of the building;
(f) affixing a plurality of roof panels and a plurality of roof beams to the wall, wherein the roof panels comprise at least one rib supporting and separating an upper surface and
a lower surface; wherein the upper surface is adapted to serve as a roof surface or roof subsurface;
wherein the roof beams comprise
one or more vertical support members supporting and separating
an upper support member and
a lower support member; and
a first registration element and a second registration element adapted to transfer load to structure below, wherein the structure below comprises the wall; and
affixing at least one upper surface to at least one upper support member; and wherein the at least one rib comprises at least one shear-stabilizing coupling element; wherein at least some of the roof panels are coupled to adjoining roof panels in the plurality of roof panels via the at least one shear-stabilizing coupling element, to form a roof of the building,
thereby constructing the building.
Yet additional embodiments relate to methods of constructing a floor of a building comprising:
(b) affixing to a subfoundation a plurality of beams, wherein the beams comprise one or more vertical support members supporting and separating an upper horizontal support member and a lower horizontal support member; and at least one ledger adapted to support a vertical load, wherein at least some of the beams are coupled to other beams in the plurality of beams, to form a foundation for the building;
(c) affixing a plurality of floor panels to the foundation, wherein the floor panels comprise at least one rib supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a floor surface or floor subsurface; and wherein the at least one rib comprises at least one shear-stabilizing coupling element, wherein at least some of the floor panels are coupled to adjoining floor panels in the plurality of floor panels via the at least one shear-stabilizing coupling element, to form a floor of the building.
Some embodiments provide methods of constructing a wall of a building, the method comprising:
(d) affixing a plurality of wall panels to a foundation of the building, wherein the wall panels comprise a first main surface; a second main surface; a plurality of edge members that support and separate the first main surface from the second main surface; and at least one shear block receiving port positioned at a first edge of the first main surface; at least one shear block receiving port positioned at a second edge of the first main surface; wherein the first edge and the second edge are positioned on opposing sides of the first main surface; and
(e) inserting a plurality of shear blocks into at least some of the shear block receiving ports of adjacent wall panels, thereby stabilizing the wall panels, and thereby forming a wall of the building.
Other embodiments relate to methods of constructing a roof of a building, comprising:
(f) affixing a plurality of roof panels and a plurality of roof beams to a wall of the building, wherein the roof panels comprise at least one rib supporting and separating an upper surface and
a lower surface; wherein the upper surface is adapted to serve as a roof surface or roof subsurface; and wherein the at least one rib comprises at least one shear-stabilizing coupling element;
wherein the roof beams comprise one or more vertical support members supporting and separating an upper support member and a lower support member; and a first registration element and a second registration element adapted to transfer load to structure below, wherein the structure below comprises the wall;
affixing at least one upper surface to at least one upper support member; wherein at least some of the roof panels are coupled to adjoining roof panels in the plurality via the at least one shear-stabilizing coupling element, to construct the roof of the building.
Certain additional embodiments provide methods of manufacturing a beam useful in modular construction comprising:
constructing a beam comprising one or more vertical support members supporting and separating an upper horizontal support member and a lower horizontal support member; and at least one ledger adapted to support a vertical load, thereby manufacturing the beam.
Still other embodiments relate to methods of manufacturing a floor panel useful in modular construction, comprising:
constructing a floor panel comprising at least one rib supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a floor surface or subsurface; and wherein the at least one rib comprises at least one shear-stabilizing coupling element.
Yet other embodiments provide methods of manufacturing a wall panel useful in modular construction, comprising:
constructing a wall panel comprising a first main surface; a second main surface; a plurality of edge members that support and separate the first main surface from the second main surface; and at least one shear block receiving port positioned at a first edge of the first main surface; at least one shear block receiving port positioned at a second edge of the first main surface; wherein the first edge and the second edge are positioned on opposing sides of the first main surface, thereby manufacturing the wall panel.
Further embodiments relate to methods of manufacturing a roof panel useful in modular construction, comprising:
constructing a roof panel comprising at least one rib supporting and separating an upper surface and a lower surface; wherein the upper surface is adapted to serve as a roof surface or subsurface; and wherein the at least one rib comprises at least one shear-stabilizing coupling element, thereby manufacturing the roof panel.
While the disclosure provides certain specific embodiments, the invention is not limited to those embodiments. A person of ordinary skill will appreciate from the description herein that modifications can be made to the described embodiments and therefore that the specification is broader in scope than the described embodiments. All examples are therefore non-limiting.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. The figures are not necessarily to scale, and some features may be exaggerated to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this disclosure belongs. In the event that there is a plurality of definitions for a term herein, those in this section prevail unless stated otherwise.
Where ever the phrase “for example,” “such as,” “including” and the like are used herein, the phrase “and without limitation” is understood to follow unless explicitly stated otherwise. Similarly “an example,” “exemplary” and the like are understood to be non-limiting.
The term “substantially” allows for deviations from the descriptor that don't negatively impact the intended purpose. Descriptive terms are understood to be modified by the term “substantially” even if the word “substantially” is not explicitly recited.
The term “about” when used in connection with a numerical value refers to the actual given value, and to the approximation to such given value that would reasonably be inferred by one of ordinary skill in the art, including approximations due to the experimental and or measurement conditions for such given value.
The terms “comprising” and “including” and “having” and “involving” (and similarly “comprises”, “includes,” “has,” and “involves”) and the like are used interchangeably and have the same meaning. Specifically, each of the terms is defined consistent with the common United States patent law definition of “comprising” and is therefore interpreted to be an open term meaning “at least the following,” and is also interpreted not to exclude additional features, limitations, aspects, etc. Thus, for example, “a device having components a, b, and c” means that the device includes at least components a, b and c. Similarly, the phrase: “a method involving steps a, b, and c” means that the method includes at least steps a, b, and c.
Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.
Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.
It is an object of the present invention to overcome or ameliorate at least one of the disadvantages of the prior art, or to provide a useful alternative.
The various components of the present invention can comprise any suitable materials. Wood, wood products such as plywood and other engineered wood products such as oriented strand board, plastic, metal, cement, and composite materials such as combinations of any of the foregoing can be suitable in one or more instances. For example, oriented strand board such as those comprising alternating layers of wood particles oriented in alternating perpendicular planes and held together with a suitable amount of polymer or adhesive, can be used in some embodiments. In addition, certain instances of the present invention employ one or more types of insulation. Any suitable insulation can be used. For example, in some cases the insulation is chosen from open cell foams, closed cell foams, fibers, pellets, and combinations thereof. The insulation can be in any suitable form as well, such as, for example, nonwoven fibers, woven fibers, rolls or batts of fiber insulation such as familiar fiber glass insulation, injectable foams, pellets, nuggets, and the like can be used. Individual pieces such as pellets or nuggets can be bound or free, or a combination thereof. Binding pellets of insulation together can be accomplished by any suitable methods. Thermal treatments, adhesives, and combinations thereof may be mentioned. Water-impermeable materials also appear in further embodiments of the present invention. Any suitable water-impermeable material can be used. In some cases, a thin film of polymer such as polyethylene or polyvinyl chloride can be glued to a surface. In other cases, a polymer is sprayed, painted on, polymerized, or otherwise applied to or formed on a surface to impart water impermeability to that surface.
The various components of the present invention can be manufactured according to any suitable method. For example, the various parts of a given component can be cut or formed into their desired shape according to any suitable method. For wood-containing parts, saws, lasers, drills, routers, sanders, and the like can be directed by hand, by computer, or by a combination thereof. Plastic or metal parts can be extruded, cut, molded, milled, or otherwise shaped as desired. In addition, the various parts can be connected to each other according to any suitable means. For example, a piece of oriented strand board can be connected to another piece of oriented strand board with screws, nails, adhesive, or a combination thereof. In some cases, the various parts are engineered to fit together like the pieces of a puzzle. Any suitable technique of wood joinery can be used. Structures such as finger joints, dovetail joints, tongue and groove joints, tongue and fork joints, dowel joints, miter joints of any suitable angle, and the like can be employed.
The various components of the present invention can have any suitable dimensions. For example, in some cases, a wall panel is about 2′ wide by about 6″ thick by about 8′ tall. Without wishing to be bound by theory, it is believed that certain embodiments of the present invention exhibit improved structural integrity over modular components reported before, because of the smaller size of some of the embodiments of the present invention. Before, the apparent goal was to minimize installation effort by making structural insulated panels as large as possible. Those large panels were unwieldy to install, and structural support was sacrificed to reduce weight in some instances. Certain embodiments of the present invention provide handy installation by using smaller-dimensioned components, yet structural integrity is not sacrificed, but rather enhanced, by the dimensions of those certain embodiments. Thus, some cases provide a beam no longer than about 5 feet, no longer than about 6 feet, no longer than about 7 feet, no longer than about 8 feet, longer than about 9 feet, no longer than about 10 feet, no longer than about 15 feet, or no longer than about 20 feet. Other cases provide a wall panel, floor panel, or roof panel no wider than about 1 foot, no wider than about 2 feet, no wider than about 3 feet, no wider than about 4 feet, no wider than about 5 feet, or no wider than about 10 feet.
Various embodiments of the present invention can be used in combination with other embodiments of the present invention. For example, floor beams and beam nodes such as those described herein can be used with floor panels such as those described herein. Or, certain embodiments of the present invention can be used with suitable non-inventive materials and construction techniques. For example, inventive floor beams and beam nodes can be deployed to create a foundation, and then conventional flooring techniques and materials can be applied. In another example, inventive wall panels and ceiling panels can be combined with conventional roof infrastructure such as the ceiling beams (451, 452) seen in
Once the various components are manufactured or installed, any suitable finishing material or materials can be added. For example, once one or more wall panels have been installed, drywall and trim can be added to the interior side of the wall panels, while brick, vinyl, aluminum, wood-cement composite such as HardiPlank™, and combinations thereof can be added to the exterior side of the wall panels. Any suitable utilities can be added, such as plumbing for hot and cold water and wastewater and sewage removal; electrical power cables for illumination, fixtures such as fans and appliances, and electrical outlets; gas lines for heating and cooking, and duct work for air handling as well as heating and cooling appliances. Windows, doors, garage doors, fireplaces, steps, stairs, closets, pantries, attic access doors, and the like can be added and finished as needed. Cabinets, counters, sinks, bathtubs, shower stalls, toilets, and the like can be added in any suitable fashion, such as, for example according to known techniques. One advantage of some embodiments of the present invention is that they are made from wood or engineered wood products: that allows the facile attachment of finishing materials such as drywall, conventional flooring such as, for example hardwood, engineered hardwood, and polymer flooring, according to conventional techniques.
DETAILED DESCRIPTION OF THE DRAWINGSFurther embodiments of the present invention can be described by reference to the accompanying drawings, which are not necessarily to scale. In addition, not every element is labeled, so the figures can be viewed easily. Elements in different figures having the same label are intended to be the same element in each such figure.
The arrow in
Shear blocks such as shear block 22a can be made out of any suitable material, such as wood, engineered wood products, metal, stone, plastic, and composite materials such as wood-cement composites. Moreover, shear blocks such as shear block 22a can be placed in shear block receiving slots such as shear block receiving slot 393a through any suitable means. For example, a shear block comprising a 3″×3″×1½″ block of wood or oriented strand board can be placed in a shear block receiving slot manually, and optionally with the assistance of a mallet or hammer. Friction may suffice to hold a shear block in a shear block receiving slot. Or, some instances allow for the use of adhesive, wood putty, or one or more nails or screws, or combinations thereof, to ensure the shear block remains within the shear block receiving slot. Without wishing to be bound by theory, it is believed that the shear blocks such as shear blocks 22a, 22b, 22c impart superior structural integrity to walls such as the wall comprising wall panels 305, 306.
Wall panel 622 comprises window opening 628 adapted to receive any suitable window frame. The window frame can be custom-built, or pre-fabricated, or a combination thereof. The window frame can be any suitable size, and additional material can be added to secure the window frame in window opening 628. Floor attachment element 363 help secure wall panel 622 to the upper surface 222 of the floor panel 203, via any suitable attachment means. Wall panel 622 comprises edge member 339 that further comprises registration tab 341 and side member extension 351 adapted to transfer load to a ledger of a beam (not shown). Wall panel 622 also comprises a ceiling beam registration slot 386, which in
The vertical arrow in
As stated above, some embodiments of the present invention relate to beams useful in modular construction comprising: one or more vertical support members supporting and separating an upper horizontal support member and a lower horizontal support member; and at least one ledger adapted to support a vertical load. As can be appreciated, “upper,” “lower,” “horizontal,” and “vertical” as used throughout this application are purely relative terms to aid the understanding of the invention, and are not to be construed strictly. In some instances, a beam can be rotated along its main axis by 90°, and its “vertical” support members are now horizontal.
In
Alternatively,
In
Wall panel 307 has a first main surface 317; a second main surface 327; a plurality of edge members 331a, 331b, 337a, 337b that support and separate the first main surface 317 from the second main surface 327, and at least partially enclose and define an interior volume with the first main surface 317 and the second main surface 327; shear block receiving ports 397a, 397b, 397c positioned at a first edge of the first main surface 317; shear block receiving ports 397d, 397e, 397f positioned at a second edge of the first main surface 317; wherein the first edge and the second edge are positioned on opposing sides of the first main surface 317. Wall panel 307 further comprises floor attachment element 367 between first side member 337a and second side member 337b below the lower edge defined by first main surface 317 and second main surface 327. First side member 337a and second side member 337b support and separate the upper edge member 331a from lower edge member 331b. First side member 337a further comprises insulation injection port 398a, registration tab 345a, utility conduit port 387a, and side member extension 352a. Second side member 337b further comprises insulation injection port 398b, registration tab 345b, utility conduit port 387b, and side member extension 352a. Optionally, wall panel 307 comprises insulation, affixed to any surface, within the interior volume, or a combination thereof. Any suitable insulation can be used; in some cases the insulation is chosen from open cell foams, closed cell foams, fibers, pellets, and combinations thereof. In some cases, wall panel 307 comprises a water-impermeable material on the first main surface 317, the second main surface 327, or both. Registration tabs 345a, 345b and side member extensions 352a, 352b are adapted to engage corresponding registration elements such as registration slots of a beam (not shown). Through side member extension 352a, the first side member 337a is adapted to transfer load to one or more ledgers of a beam (not shown). Through side member extension 352b, the second side member 337b is adapted to transfer load to one or more ledgers of a beam (not shown). Wall panel 307 can comprise any suitable material, such as, for example, an engineered wood product such as oriented strand board, among other materials.
Corner wall panel 612 comprises a first upper edge member 722a, a first lower edge member 728a, a first edge member 723a distal from the outside corner 713, and a first corner edge member 723b; and adjacent to the second main outside surface 714b, a second upper edge member 722b, a second lower edge member 728b, a second edge member 723d distal from the outside corner 713, and a second corner edge member 723c.
Roof panel 404, useful in modular construction, comprises at least one rib 442a supporting and separating an upper surface 437a and a lower surface 437b; wherein the upper surface 437a is adapted to serve as a roof surface or roof subsurface; and wherein the at least one rib 442a comprises two shear-stabilizing coupling elements 434c, 434f emerging from opposite sides of roof panel 404, and opening 443. Shear-stabilizing coupling element 434c is proximal to the upper surface 437a; while shear-stabilizing coupling element 434f is proximal to lower service 437b. Two more ribs (not seen) support additional shear-stabilizing coupling elements. One of those ribs comprises shear-stabilizing coupling elements 434b and 434e; the other of those ribs comprises shear-stabilizing coupling elements 434a and 434d. In an alternative embodiment, each of shear-stabilizing coupling elements 434a-434f is attached to an anchor (for a total of six anchors) that supports and separates upper surface 437a and a lower surface 437b. In yet another alternative embodiment, roof panel 404 comprises a combination of one or more ribs and two or more anchors. Roof panel 404 as shown comprises a plurality of edge members 438a and 438b that at least partially enclose and define an interior volume with the upper surface 437a and the lower surface 437b. Roof panel 404 optionally comprises a water-impermeable material such as, for example, on upper surface 437a and/or on lower surface 437b. Upper surface 437a can further comprise any suitable roofing material, such as, for example, tarpaper (which also serves as a water-impermeable material), shingles including asphalt shingles, wooden shingles, slate, tile, photovoltaic “solar panel” shingles, and combinations thereof. Through openings 436c and 436f, rib 442a is adapted to receive and couple to the shear-stabilizing coupling elements of adjacent roof panels (not shown). Similarly, openings 436a, 436b, 436d, and 436e allow coupling to the shear-stabilizing coupling elements of those adjacent roof panels. Edge member 438b shows insulation injection ports 440c, 440d that allow insulation to be injected or blown into the interior volume of roof panel 440. Any suitable insulation can be used. In some cases, that insulation is added after roof panel 404 is installed, so that a roof beam (not shown) can engage roof beam registration elements 441a and 441b on edge members 438a and 438b, respectively, and assist in keeping the insulation within roof panel 404. Similarly, a fascia (not shown—but see fascia 472 in
Six helical piles having a 2-⅞″ tubular shaft manufactured by Goliath Tech were obtained. The helical piles were driven into soil in two rows of three piles each, with 18″ of the 7′ long pile remaining above ground, and each pile being 7′−8″ apart from its neighbor. Each pile was installed with a high torque drill attachment on a Kubota KX057-4 Compact Excavator. Downward pressure on the order of 10.1 Kips (5.05 Tons) up to 11.6 Kips (5.8 Tons) was applied by the excavator during pile insulation to avoid plowing the soil. A 5″×5″ steel plate capped each pile, to which beam nodes similar to three-way beam node 503 and two-way beam node 509 were affixed with structural wood screws through four holes in the plate. Seven beams similar to floor beams 102 and 103 were coupled to the nodes by engaging the beam node coupling elements at each end of a beam, and screws secured the beams to the nodes, such as by securing hole 543a to hole 192a in
To test the shear strength of the eight-panel floor, a ⅜″ heavy chain was passed through the perimeter floor panels end-to-end, and secured to a 6″×6″ steel plate over a 2-ply ¾″ Advantech 24″×8″ board to form a pressure plate. Using
A Dillon Mechanical Dynamometer connected the chain to the Excavator, to apply a tension load simulating a base shear from wind or seismic loading.
The excavator applied a load, and the deflection of each pile was measured at the top of each pile under load. The results appear in Table 2.
After the initial round of incremental load testing, the residual deformation was measured with no load applied. Then, a first cyclic loading of four cycles of 5,000 lbs and release were applied, and residual deformation measured with no load applied. A second cyclic loading of five cycles of 5,000 lbs and release were applied, and residual deformation was measured with no load applied. These residual deformation results appear in Table 3.
The dynamometer has a maximum capacity of 5,000 lbs, but the excavator is rated in excess of 10,000 lbs, perhaps approximately 12,000 lbs. This maximum load was applied five times to seek the weakest components of the test floor. Extreme deflections of the piles were observed, including deflection in excess of 3½″ for pile 1. After five cycles of maximum load and release, each pile returned to its maximum deflection shown in Table 3. No buckling or failure was observed or found in any of the floor beam or floor panel members or connections, nor was any audible cracking or shearing of the glue-joint panel and beam connections noted during the maximum load testing.
After the foregoing tests, the test floor was disassembled and a 5,000 lbs load was applied to pile 5 in the same direction as the previous loads. At 5,000 lbs, pile 5 deflected laterally 1 5/16″.
The International Building Code (2012) recommends a maximum allowable load of one-half of the load causing a 1″ lateral deflection. From the foregoing tests, it is estimated that the lateral allowable design value is 2,000 lbs at 18″ above grade. That far exceeds the expected shear load presented by a 149 mph Category 5 hurricane-force wind having a wind pressure of 29.7 PSF. Distributed over the 28 piles of
A home is constructed on 28 helical piles as shown in
A beam useful in modular construction comprising: one or more vertical support members supporting and separating an upper horizontal support member and a lower horizontal support member; and at least one ledger adapted to support a vertical load.
Embodiment 2The beam of embodiment 1, wherein the upper horizontal support member further comprises at least one registration element.
Embodiment 3The beam of embodiment 2, wherein the at least one registration element is adapted to receive at least one corresponding registration element of a floor panel, wall panel, ceiling panel, or a combination thereof.
Embodiment 4The beam of any one of embodiments 2-3, wherein the beam has a first end and a second end, and the first end comprises a first beam node coupling element.
Embodiment 5The beam of embodiment 4, wherein the second end comprises a second beam node coupling element.
Embodiment 6The beam of any one of embodiments 1-5, wherein the beam comprises an engineered wood product.
Embodiment 7The beam of embodiment 6, wherein the engineered wood product comprises oriented strand board.
Embodiment 8The beam of any one of embodiments 1-7, further comprising insulation.
Embodiment 9The beam of any one of embodiments 2-8, wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least two wall panels.
Embodiment 10The beam of any one of embodiments 2-9, wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least three wall panels.
Embodiment 11The beam of any one of embodiments 2-10, wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least four wall panels.
Embodiment 12The beam of any one of embodiments 1-11, wherein the at least one ledger adapted to support a vertical load is attached to a first vertical face of the one or more vertical support members.
Embodiment 13The beam of any one of embodiments 1-12, wherein the at least one ledger adapted to support a vertical load comprises two ledgers, wherein the first ledger is attached to a first vertical face of the one or more vertical support members, and the second ledger is attached to a second vertical face of the one or more vertical support members.
Embodiment 14A beam node useful in modular construction comprising:
a lower horizontal support member supporting
at least two vertical support members,
wherein the at least two vertical support members define at least two beam coupling elements; and
at least one registration element.
The beam node of embodiment 14, wherein the at least two beam coupling elements comprise a first beam coupling element and a second beam coupling element,
wherein the first beam coupling element is adapted to couple a first beam in line with a second beam coupled to the second beam coupling element.
Embodiment 16The beam node of embodiment 14, wherein the at least two beam coupling elements comprise a first beam coupling element and a second beam coupling element,
wherein the first beam coupling element is adapted to couple a first beam perpendicular to a second beam coupled to the second beam coupling element.
Embodiment 17The beam node of embodiment 14,
wherein the at least two beam coupling elements comprise
a first beam coupling element,
a second beam coupling element, and
a third beam coupling element;
wherein the first beam coupling element is adapted to couple a first beam in line with a second beam coupled to the second beam coupling element, and the third beam coupling element is adapted to couple a third beam perpendicular to the first beam and the second beam.
The beam node of embodiment 14,
wherein the at least two beam coupling elements comprise
a first beam coupling element,
a second beam coupling element,
a third beam coupling element, and
a fourth beam coupling element;
wherein the first beam coupling element is adapted to couple a first beam in line with a second beam coupled to the second beam coupling element,
the third beam coupling element is adapted to couple a third beam perpendicular to the first beam and the second beam, and
the fourth beam coupling element is adapted to couple a fourth beam in line with the third beam and perpendicular to the first beam and the second beam.
The beam node of any one of embodiments 14-18, wherein the at least one registration element comprises two substantially parallel vertical supports separated by a spacer element, thereby defining two registration element receivers between the two substantially parallel vertical supports.
Embodiment 20The beam node of any one of embodiments 14-19, wherein the at least one registration element is adapted to receive at least one corresponding registration element of a floor panel, wall panel, ceiling panel, or a combination thereof.
Embodiment 21The beam node of any one of embodiments 14-20, wherein the at least one registration element is adapted to receive at least one corresponding registration element of at least one wall panel.
B. Floor Panels Embodiment 22A floor panel useful in modular construction comprising:
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a floor surface or floor subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element.
A floor panel useful in modular construction comprising:
at least one anchor supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a floor surface or floor subsurface; and
wherein the at least one anchor comprises at least one shear-stabilizing coupling element.
The floor panel of embodiment 22, further comprising at least one anchor supporting and separating the upper surface and the lower surface, wherein the at least one anchor comprises at least one shear-stabilizing coupling element.
Embodiment 25The floor panel of embodiment 23, further comprising at least one rib supporting and separating the upper surface and the lower surface, wherein the at least one rib comprises at least one shear-stabilizing coupling element.
Embodiment 26The floor panel of any one of embodiments 22-25, further comprising a plurality of edge members that at least partially enclose and define an interior volume with the upper surface and the lower surface.
Embodiment 27The floor panel of any one of embodiments 22-26, further comprising insulation.
Embodiment 28The floor panel of any one of embodiments 26-27, wherein the interior volume comprises insulation.
Embodiment 29The floor panel of any one of embodiments 27-28, wherein the insulation is chosen from open cell foams, closed cell foams, fibers, pellets, and combinations thereof.
Embodiment 30The floor panel of any one of embodiments 22 and 24-29, wherein the at least one rib comprises at least three ribs.
Embodiment 31The floor panel of any one of embodiments 22 and 24-30, wherein the at least one rib comprises at least two shear-stabilizing coupling elements.
Embodiment 32The floor panel of any one of embodiments 22 and 24-31, wherein the at least one rib is adapted to engage at least one shear-stabilizing coupling element from another floor panel.
Embodiment 33The floor panel of any one of embodiments 22 and 24-32, wherein the at least one shear-stabilizing coupling element comprises a first shear-stabilizing coupling element emerging from a first edge of the floor panel, and a second shear-stabilizing coupling element emerging from a second edge of the floor panel,
wherein the first edge and the second edge are positioned on opposing sides of the floor panel.
Embodiment 34The floor panel of embodiment 33,
wherein the first shear-stabilizing coupling element is proximal to the upper surface, and the second shear-stabilizing coupling element is proximal to the lower surface.
Embodiment 35The floor panel of any one of embodiments 23-29, wherein the at least one anchor comprises at least two anchors.
Embodiment 36The floor panel of any one of embodiments 23-29 and 35, wherein the at least one anchor comprises at least six anchors.
Embodiment 37The floor panel of any one of embodiments 23-29 and 35-36, wherein the at least one anchor is adapted to engage at least one shear-stabilizing coupling element from another floor panel.
Embodiment 38The floor panel of any one of embodiments 23-29 and 35-37, comprising a first anchor having a first shear-stabilizing coupling element, and a second anchor having a second shear-stabilizing coupling element;
wherein the first shear-stabilizing coupling element emerges from a first edge of the floor panel, and the second shear-stabilizing coupling element emerges from a second edge of the floor panel,
wherein the first edge and the second edge are positioned on opposing sides of the floor panel.
The floor panel of embodiment 38,
wherein the first shear-stabilizing coupling element is proximal to the upper surface, and the second shear-stabilizing coupling element is proximal to the lower surface.
Embodiment 40The floor panel of any one of embodiments 22-39, wherein at least one of the upper surface and the lower surface comprise a water-impermeable material.
Embodiment 41The floor panel of any one of embodiments 22-40, wherein the floor panel comprises an engineered wood product.
Embodiment 42The floor panel of embodiment 41, wherein the engineered wood product comprises oriented strand board.
Embodiment 43The floor panel of any one of embodiments 26-42, wherein at least one in the plurality of edge members comprise at least one insulation injection port.
Embodiment 44The floor panel of any one of embodiments 22-43, further comprising at least one registration element positioned on at least one edge of the floor panel.
Embodiment 45The floor panel of embodiment 44, wherein the at least one registration element is present in sufficient number to receive the corresponding registration elements of at least two wall panels.
Embodiment 46The floor panel of any one of embodiments 44-45, wherein the at least one registration element is present in sufficient number to receive the corresponding registration elements of at least three wall panels.
Embodiment 47The floor panel of any one of embodiments 44-46, wherein the at least one registration element is present in sufficient number to receive the corresponding registration elements of at least four wall panels.
Embodiment 48The floor panel of any one of embodiments 26-47, wherein at least one in the plurality of edge members is adapted to engage a ledger of a beam.
Embodiment 49The floor panel of any one of embodiments 22-48, wherein the upper surface is adapted to engage an upper horizontal support member of a beam.
C. Wall Panels Embodiment 50A wall panel useful in modular construction comprising:
-
- a first main surface;
- a second main surface;
- a plurality of edge members that support and separate the first main surface from the second main surface; and
- at least one shear block receiving port positioned at a first edge of the first main surface;
- at least one shear block receiving port positioned at a second edge of the first main surface;
- wherein the first edge and the second edge are positioned on opposing sides of the first main surface.
The wall panel of embodiment 50, wherein the plurality of edge members at least partially encloses and defines an interior volume with the first main surface and the second main surface.
Embodiment 52The wall panel of any one of embodiments 50-51, further comprising insulation.
Embodiment 53The wall panel of any one of embodiments 50-52, wherein the interior volume comprises insulation.
Embodiment 54The wall panel of any one of embodiments 52-53, wherein the insulation is chosen from open cell foams, closed cell foams, fibers, pellets, and combinations thereof.
Embodiment 55The wall panel of any one of embodiments 50-54, wherein at least one of the first main surface and the second main surface comprise a water-impermeable material.
Embodiment 56The wall panel of any one of embodiments 50-55, wherein the plurality of edge members comprise
an upper edge member,
a lower edge member,
a first side member proximal to the first edge of the first main surface, and
a second side member proximal to the second edge of the first main surface,
wherein the first side member and the second side member support and separate the upper edge member from the lower edge member.
The wall panel of embodiment 56, wherein at least one of the first side member and the second side member comprise at least one registration element.
Embodiment 58The wall panel of any one of embodiments 56-57, wherein the first side member comprises a first registration element, and the second side member comprises a second registration element.
Embodiment 59The wall panel of embodiment 57, wherein the at least one registration element is adapted to engage a registration element of a beam.
Embodiment 60The wall panel of embodiment 58, wherein the first registration element is adapted to engage a first registration element of a beam, and the second registration element is adapted to engage a second registration element of a beam.
Embodiment 61The wall panel of any one of embodiments 56-60, wherein at least one of the first side member and the second side member is adapted to transfer load to one or more ledgers of a beam.
Embodiment 62The wall panel of any one of embodiments 50-61, wherein the first main surface and the second main surface define a lower edge, and the lower edge comprises at least one floor attachment element.
Embodiment 63The wall panel of any one of embodiments 50-62, wherein at least two in the plurality of edge members each comprise at least one utility conduit port.
Embodiment 64The wall panel of any one of embodiments 50-63, wherein at least one in the plurality of edge members comprises at least one insulation injection port.
Embodiment 65The wall panel of any one of embodiments 50-64, wherein the first main surface and the second main surface define an upper edge, wherein the upper edge comprises at least one registration element.
Embodiment 66The wall panel of any one of embodiments 50-65, wherein the wall panel comprises an engineered wood product.
Embodiment 67The wall panel of embodiment 66, wherein the engineered wood product comprises oriented strand board.
Embodiment 68The wall panel of any one of embodiments 50-67, wherein the first edge of the main surface comprises at least three shear block receiving ports, and the second edge of the main surface comprises at least three shear block receiving ports.
Embodiment 69The wall panel of any one of embodiments 50-68, further comprising a plurality of window edge members that define a window opening in the first main surface and the second main surface.
Embodiment 70The wall panel of embodiment 69, wherein the plurality of window edge members comprises
an upper window edge member,
a lower window edge member,
a first side window member proximal to the first edge of the first main surface, and a second side window member proximal to the second edge of the first main surface,
wherein the first side window member and the second side window member support and separate the upper window edge member from the lower window edge member.
The wall panel of any one of embodiments 69-70, wherein at least some window edge members in the plurality of window edge members comprise window frame registration elements.
Embodiment 72The wall panel of any one of embodiments 70-71, wherein at least one of the first side window member and the second side window member comprise at least one registration element.
Embodiment 73The wall panel of any one of embodiments 70-72, wherein the first side window member comprises a first registration element, and the second side window member comprises a second registration element.
Embodiment 74The wall panel of embodiment 72, wherein the at least one registration element is adapted to engage a registration element of a beam.
Embodiment 75The wall panel of embodiment 73, wherein the first registration element is adapted to engage a first registration element of a beam, and the second registration element is adapted to engage a second registration element of a beam.
Embodiment 76The wall panel of any one of embodiments 70-75, wherein at least one of the first side member and the second side member is adapted to transfer load to one or more ledgers of a beam.
Embodiment 77The wall panel of any one of embodiments 69-76, wherein at least two in the plurality of window edge members each comprise at least one utility conduit port.
Embodiment 78The wall panel of any one of embodiments 50-69, wherein the second main surface comprises at least one utility access port.
Embodiment 79The wall panel of embodiment 78, wherein the second main surface comprises at least three utility access ports.
Embodiment 80The wall panel of any one of embodiments 78-79, wherein the second main surface comprises six utility access ports.
Embodiment 81The wall panel of any one of embodiments 78-80, wherein the at least one utility access port comprises at least one utility access port adapted to function as an electric wall socket port.
Embodiment 82The wall panel of any one of embodiments 78-81, wherein the at least one utility access port comprises at least one utility access port adapted to function as an electric light switch port.
Embodiment 83A corner wall panel useful in modular construction comprising:
two main outside surfaces comprising
-
- a first main outside surface joining
- a second main outside surface defining an outside corner;
two main inside surfaces comprising - a first main inside surface joining
- a second main inside surface defining an inside corner;
a plurality of edge members that support and separate the main outside surfaces from the main inside surfaces;
at least one shear block receiving port positioned at an edge of the first main outside surface distal from the outside corner; and
at least one shear block receiving port positioned at an edge of the second main outside surface distal from the outside corner.
The corner wall panel of embodiment 83, wherein the plurality of edge members at least partially encloses and defines at least one interior volume between the outside main surfaces and the inside main surfaces.
Embodiment 85The corner wall panel of any one of embodiments 83-84, further comprising insulation.
Embodiment 86The corner wall panel of embodiment 84, wherein the at least one interior volume comprises insulation.
Embodiment 87The corner wall panel of any one of embodiments 85-86, wherein the insulation is chosen from open cell foams, closed cell foams, fibers, pellets, and combinations thereof.
Embodiment 88The corner wall panel of any one of embodiments 83-87, wherein the first main outside surface and the second main outside surface comprise a water-impermeable material.
Embodiment 89The corner wall panel of any one of embodiments 83-88, wherein the plurality of edge members comprises adjacent to the first main outside surface,
-
- a first upper edge member,
- a first lower edge member,
- a first edge member distal from the outside corner, and
- a first corner edge member; and
adjacent to the second main outside surface, - a second upper edge member,
- a second lower edge member,
- a second edge member distal from the outside corner, and
- a second corner edge member.
The corner wall panel of embodiment 89, wherein at least one of the first edge member and the first corner edge member comprise at least one registration element.
Embodiment 91The corner wall panel of any one of embodiments 89-90, wherein at least one of the second edge member and the second corner edge member comprise at least one registration element.
Embodiment 92The corner wall panel of embodiment 90, wherein the at least one registration element is adapted to engage a registration element of a beam.
Embodiment 93The corner wall panel of embodiment 91, wherein the at least one registration element is adapted to engage a registration element of a beam.
Embodiment 94The corner wall panel of any one of embodiments 89-93, wherein at least one of the first edge member and first corner edge member is adapted to transfer load to one or more ledgers of a beam.
Embodiment 95The corner wall panel of any one of embodiments 89-94, wherein at least one of the second edge member and second corner edge member is adapted to transfer load to one or more ledgers of a beam.
Embodiment 96The corner wall panel of any one of embodiments 83-95, wherein at least two in the plurality of edge members each comprise at least one utility conduit port.
Embodiment 97The corner wall panel of any one of embodiments 83-96, wherein at least one in the plurality of edge members comprises at least one insulation injection port.
Embodiment 98The corner wall panel of any one of embodiments 83-97, wherein the first main outside surface and first main inside surface define a first upper edge, wherein the first upper edge comprises at least one registration element.
Embodiment 99The corner wall panel of any one of embodiments 83-98, wherein the second main outside surface and the second main inside surface define a second upper edge, wherein the second upper edge comprises at least one registration element.
Embodiment 100The corner wall panel of any one of embodiments 83-99, wherein the corner wall panel comprises an engineered wood product.
Embodiment 101The corner wall panel of embodiment 100, wherein the engineered wood product comprises oriented strand board.
Embodiment 102The corner wall panel of any one of embodiments 83-101, comprising at least three shear block receiving ports positioned at the edge of the first main outside surface distal from the outside corner.
Embodiment 103The corner wall panel of any one of embodiments 83-102, comprising at least three shear block receiving ports positioned at the edge of the second main outside surface distal from the outside corner.
Embodiment 104The corner wall panel of any one of embodiments 83-103, wherein the first main outside surface and the first main inside surface define a first lower edge, and the first lower edge comprises at least one first floor attachment element.
Embodiment 105The corner wall panel of any one of embodiments 83-104, wherein the second main outside surface and the second main inside surface define a second lower edge, and the second lower edge comprises at least one second floor attachment element.
Embodiment 106The wall panel of any one of embodiments 50-82, further comprising a ceiling beam registration element.
D. Roof Panels and Roof Beams Embodiment 107A roof panel useful in modular construction comprising:
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a roof surface or roof subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element.
A roof panel useful in modular construction comprising:
at least one anchor supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a roof surface or roof subsurface; and
wherein the at least one anchor comprises at least one shear-stabilizing coupling element.
The roof panel of embodiment 107, further comprising at least one anchor supporting and separating the upper surface and the lower surface, wherein the at least one anchor comprises at least one shear-stabilizing coupling element.
Embodiment 110The roof panel of embodiment 108, further comprising at least one rib supporting and separating the upper surface and the lower surface, wherein the at least one rib comprises at least one shear-stabilizing coupling element.
Embodiment 111The roof panel of any one of embodiments 107-110, further comprising a plurality of edge members that at least partially enclose and define an interior volume with the upper surface and the lower surface.
Embodiment 112The roof panel of any one of embodiments 107-111 further comprising insulation.
Embodiment 113The roof panel of any one of embodiments 111-112, wherein the interior volume comprises insulation.
Embodiment 114The roof panel of any one of embodiments 112-113, wherein the insulation is chosen from open cell foams, closed cell foams, fibers, pellets, and combinations thereof.
Embodiment 115The roof panel of any one of embodiments 107 and 109-114, wherein the at least one rib comprises at least three ribs.
Embodiment 116The roof panel of any one of embodiments 107 and 109-115, wherein the at least one rib comprises at least two shear-stabilizing coupling elements.
Embodiment 117The roof panel of any one of embodiments 107 and 109-116, wherein the at least one rib is adapted to engage at least one shear-stabilizing coupling element from another roof panel.
Embodiment 118The roof panel of any one of embodiments 107 and 109-117, wherein the at least one shear-stabilizing coupling element comprises
a first shear-stabilizing coupling element emerging from a first edge of the roof panel, and a second shear-stabilizing coupling element emerging from a second edge of the roof panel,
wherein the first edge and the second edge are positioned on opposing sides of the roof panel.
The roof panel of embodiment 118, wherein the first shear-stabilizing coupling element is proximal to the upper surface, and the second shear-stabilizing coupling element is proximal to the lower surface.
Embodiment 120The roof panel of any one of embodiments 108-114, wherein the at least one anchor comprises at least two anchors.
Embodiment 121The roof panel of any one of embodiments 108-114 and 120, wherein the at least one anchor comprises at least six anchors.
Embodiment 122The roof panel of any one of embodiments 108-114 and 120-121, wherein the at least one anchor is adapted to engage at least one shear-stabilizing coupling element from another roof panel.
Embodiment 123The roof panel of any one of embodiments 108-114 and 120-122, comprising a first anchor having a first shear-stabilizing coupling element, and a second anchor having a second shear-stabilizing coupling element;
wherein the first shear-stabilizing coupling element emerges from a first edge of the roof panel, and the second shear-stabilizing coupling element emerges from a second edge of the roof panel,
wherein the first edge and the second edge are positioned on opposing sides of the roof panel.
The roof panel of embodiment 123, wherein the first shear-stabilizing coupling element is proximal to the upper surface, and the second shear-stabilizing coupling element is proximal to the lower surface.
Embodiment 125The roof panel of any one of embodiments 107-124, wherein at least one of the upper surface and the lower surface comprises a water-impermeable material.
Embodiment 126The roof panel of any one of embodiments 107-125, wherein the roof panel comprises an engineered wood product.
Embodiment 127The roof panel of embodiment 126, wherein the engineered wood product comprises oriented strand board.
Embodiment 128The roof panel of any one of embodiments 111-127, wherein at least one in the plurality of edge members comprise at least one insulation injection port.
Embodiment 129The roof panel of any one of embodiments 107-128, wherein the lower surface further comprises at least one registration element adapted to engage at least one gable wall panel.
Embodiment 130The roof panel of any one of embodiments 107-129, further comprising a wall engagement member that comprises a plurality of wall registration elements adapted to engage an upper edge of at least one wall panel.
Embodiment 131A roof beam useful in modular construction comprising:
one or more vertical support members supporting and separating
an upper support member and
a lower support member; and
a first registration element and a second registration element adapted to transfer load to structure below.
The roof beam of embodiment 131, comprising a first end and a second end, wherein the first registration element is proximal to the first end, and the second registration element is proximal to the second end.
Embodiment 133The roof beam of any one of embodiments 131-132, wherein the first registration element comprises a ceiling post registration tab.
Embodiment 134The roof beam of any one of embodiments 131-133, wherein the second registration element comprises a ceiling beam registration slot.
Embodiment 135The roof beam of any one of embodiments 131-134, wherein the upper support member comprises a plurality of roof panel registration elements.
Embodiment 136The roof beam of embodiment 135, wherein the plurality of roof panel registration elements comprises registration slots.
Embodiment 137The roof beam of any one of embodiments 131-136, wherein the lower support member comprises a plurality of registration elements.
Embodiment 138The roof beam of embodiment 137, wherein the plurality of registration elements comprises one or more ceiling beam registration elements, one or more wall registration elements, and combinations thereof.
Embodiment 139The roof beam of any one of embodiments 131-137, wherein the roof beam comprises an engineered wood product.
Embodiment 140The roof beam of embodiment 139, wherein the engineered wood product comprises oriented strand board.
Embodiment 141The roof beam of any one of embodiments 131-140, wherein the roof beam further comprises insulation.
E. Entire Building Embodiment 142A building comprising
at least one beam as claimed in any one of embodiments 1-13;
at least one beam node as claimed in any one of embodiments 14-21;
at least one floor panel as claimed in any one of embodiments 22-49;
at least one wall panel as claimed in any one of embodiments 50-68;
at least one roof panel as claimed in any one of embodiments 107-130;
at least one roof beam as claimed in any one of embodiments 131-141; or
a combination of any two or more of the foregoing.
The building of embodiment 131, further comprising:
at least one wall panel as claimed in any one of embodiments 69-77;
at least one wall panel as claimed in any one of embodiments 78-82;
at least one corner wall panel as claimed in any one of embodiments 83-106;
or a combination of two or more of the foregoing.
F. Methods
Embodiment 144A method of constructing a building, comprising:
(a) installing a plurality of helical piles in ground to establish a subfoundation for the building;
(b) affixing a plurality of beams to the helical piles, wherein the beams comprise one or more vertical support members supporting and separating
an upper horizontal support member and
a lower horizontal support member; and
at least one ledger adapted to support a vertical load,
wherein at least some of the beams are coupled to other beams in the plurality of beams, to form a foundation for the building;
(c) affixing a plurality of floor panels to the foundation, wherein the floor panels comprise
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a floor surface or subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element,
wherein at least some of the floor panels are coupled to adjoining floor panels in the plurality via the at least one shear-stabilizing coupling element, to form a floor of the building;
(d) affixing a plurality of wall panels to the foundation, wherein the wall panels comprise
a first main surface;
a second main surface;
a plurality of edge members that support and separate the first main surface from the second main surface; and
at least one shear block receiving port positioned at a first edge of the first main surface;
at least one shear block receiving port positioned at a second edge of the first main surface;
wherein the first edge and the second edge are positioned on opposing sides of the first main surface;
wherein at least some of the wall panels engage registration elements of at least some of the beams of the foundation, and transfer vertical load to at least some of the ledgers of the beams of the foundation;
(e) inserting a plurality of shear blocks into at least some of the shear block receiving ports of adjacent wall panels, thereby stabilizing the wall panels, and thereby forming a wall of the building;
(f) affixing a plurality of roof panels and a plurality of roof beams to the wall, wherein the roof panels comprise
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a roof surface or roof subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element;
wherein the roof beams comprise
one or more vertical support members supporting and separating
an upper support member and
a lower support member; and
a first registration element and a second registration element adapted to transfer load to structure below, wherein the structure below comprises the wall;
affixing at least one upper surface to at least one upper support member;
wherein at least some of the roof panels are coupled to adjoining roof panels in the plurality of roof panels via the at least one shear-stabilizing coupling element, to form a roof of the building,
thereby constructing the building.
The method of embodiment 144, wherein the plurality of beams comprises at least one beam as claimed in any one of embodiments 1-13;
the plurality of floor panels comprises at least one floor panel as claimed in any one of embodiments 22-49;
the plurality of wall panels comprises at least one wall panel as claimed in any one of embodiments 50-82;
the plurality of roof panels comprises at least one roof panel as claimed in any one of embodiments 107-130;
the plurality of roof beams comprise at least one roof beam as claimed in any one of embodiments 131-141; or
a combination of any two or more of the foregoing.
A method of constructing a floor of a building comprising:
(b) affixing to a subfoundation a plurality of beams, wherein the beams comprise one or more vertical support members supporting and separating
an upper horizontal support member and
a lower horizontal support member; and
at least one ledger adapted to support a vertical load,
wherein at least some of the beams are coupled to other beams in the plurality of beams, to form a foundation for the building;
(c) affixing a plurality of floor panels to the foundation, wherein the floor panels comprise
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a floor surface or floor subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element,
wherein at least some of the floor panels are coupled to adjoining floor panels in the plurality of floor panels via the at least one shear-stabilizing coupling element, to form a floor of the building.
The method of embodiment 146, wherein
the plurality of beams comprises at least one beam as claimed in any one of embodiments 1-13;
the plurality of floor panels comprises at least one floor panel as claimed in any one of embodiments 22-49;
or a combination of any two or more of the foregoing.
A method of constructing a wall of a building, the method comprising:
(d) affixing a plurality of wall panels to a foundation of the building, wherein the wall panels comprise
a first main surface;
a second main surface;
a plurality of edge members that support and separate the first main surface from the second main surface; and
at least one shear block receiving port positioned at a first edge of the first main surface;
at least one shear block receiving port positioned at a second edge of the first main surface;
wherein the first edge and the second edge are positioned on opposing sides of the first main surface; and
(e) inserting a plurality of shear blocks into at least some of the shear block receiving ports of adjacent wall panels, thereby stabilizing the wall panels, and thereby forming a wall of the building.
The method of embodiment 148, wherein the plurality of wall panels comprises at least one wall panel as claimed in any one of embodiments 50-82.
Embodiment 150A method of constructing a roof of a building, comprising:
(f) affixing a plurality of roof panels and a plurality of roof beams to a wall of the building, wherein the roof panels comprise
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a roof surface or roof subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element;
wherein the roof beams comprise
one or more vertical support members supporting and separating
an upper support member and
a lower support member; and
a first registration element and a second registration element adapted to transfer load to structure below, wherein the structure below comprises the wall;
affixing at least one upper surface to at least one upper support member; wherein at least some of the roof panels are coupled to adjoining roof panels in the plurality via the at least one shear-stabilizing coupling element, to construct the roof of the building.
The method of embodiment 150, wherein the plurality of roof panels comprises at least one roof panel as claimed in any one of embodiments 107-130.
Embodiment 152A method of manufacturing a beam useful in modular construction comprising:
constructing a beam comprising
one or more vertical support members supporting and separating
an upper horizontal support member and
a lower horizontal support member; and
at least one ledger adapted to support a vertical load,
thereby manufacturing the beam.
The method of embodiment 152, wherein the beam comprises a beam as claimed in any one of embodiments 1-13.
Embodiment 154A method of manufacturing a floor panel useful in modular construction, comprising:
constructing a floor panel comprising
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a floor surface or subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element.
The method of embodiment 154, wherein the floor panel comprises a floor panel as claimed in any one of embodiments 22-49.
Embodiment 156A method of manufacturing a wall panel useful in modular construction, comprising:
constructing a wall panel comprising
a first main surface;
a second main surface;
a plurality of edge members that support and separate the first main surface from the second main surface; and
at least one shear block receiving port positioned at a first edge of the first main surface;
at least one shear block receiving port positioned at a second edge of the first main surface;
wherein the first edge and the second edge are positioned on opposing sides of the first main surface,
thereby manufacturing the wall panel.
The method of embodiment 156, wherein the wall panel comprises a wall panel as claimed in any one of embodiments 50-82.
Embodiment 158A method of manufacturing a roof panel useful in modular construction, comprising:
constructing a roof panel comprising
at least one rib supporting and separating
an upper surface and
a lower surface;
wherein the upper surface is adapted to serve as a roof surface or subsurface; and
wherein the at least one rib comprises at least one shear-stabilizing coupling element,
thereby manufacturing the roof panel.
The method of embodiment 158, wherein the roof panel comprises a roof panel as claimed in any one of embodiments 107-130.
Embodiment 160A method of manufacturing a roof beam useful in modular construction comprising:
constructing a roof beam comprising
one or more vertical support members supporting and separating
an upper support member and
a lower support member; and
a first registration element and a second registration element adapted to transfer load to structure below.
The method of embodiment 160, wherein the roof beam comprises a roof beam as claimed in any one of embodiments 131-141.
As previously stated, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various forms. It will be appreciated that many modifications and other variations stand within the intended scope of this invention as claimed below. Furthermore, the foregoing description of various embodiments does not necessarily imply exclusion. For example, “some” embodiments may include all or part of “other” and “further” embodiments within the scope of this invention. In addition, “a” does not mean “one and only one;” “a” can mean “one and more than one.”
Claims
1. A beam useful in modular construction comprising:
- one or more vertical support members supporting and separating
- an upper horizontal support member and
- a lower horizontal support member; and
- at least one ledger adapted to support a vertical load.
2. The beam of claim 1, wherein the upper horizontal support member further comprises at least one registration element.
3. The beam of claim 2, wherein the at least one registration element is adapted to receive at least one corresponding registration element of a floor panel, wall panel, ceiling panel, or a combination thereof.
4. The beam of claim 2,
- wherein the beam has a first end and a second end, and the first end comprises a first beam node coupling element.
5. The beam of claim 4, wherein the second end comprises a second beam node coupling element.
6. The beam of claim 1, wherein the beam comprises an engineered wood product.
7. The beam of claim 6, wherein the engineered wood product comprises oriented strand board.
8. The beam of claim 1, further comprising insulation.
9. The beam of claim 2, wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least two wall panels.
10. The beam of claim 2, wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least three wall panels.
11. The beam of claim 2, wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least four wall panels.
12. The beam of claim 1, wherein the at least one ledger adapted to support a vertical load is attached to a first vertical face of the one or more vertical support members.
13. The beam of claim 1, wherein the at least one ledger adapted to support a vertical load comprises two ledgers, wherein the first ledger is attached to a first vertical face of the one or more vertical support members, and the second ledger is attached to a second vertical face of the one or more vertical support members.
14. A method of manufacturing a beam useful in modular construction comprising:
- constructing a beam comprising
- one or more vertical support members supporting and separating
- an upper horizontal support member and
- a lower horizontal support member; and
- at least one ledger adapted to support a vertical load,
- thereby manufacturing the beam.
15. The method of claim 14, wherein constructing the beam comprises:
- joining together two vertical support members;
- affixing the upper horizontal support member to the two vertical support members; affixing the lower horizontal support member to the two vertical support members; and affixing a first ledger to one of the two vertical support members.
16. The method of claim 15, further comprising a second ledger to another of the two vertical support members.
17. The method of claim 15, further comprising:
- before the affixing the upper horizontal support member, creating one or more registration elements in the upper horizontal support member.
18. The method of claim 15, further comprising:
- creating a beam node coupling element in a first end of the beam.
19. The method of claim 15, further comprising:
- creating a beam node coupling element in a second end of the beam.
20. The method of claim 15, wherein the beam comprises an engineered wood product.
Type: Application
Filed: May 26, 2015
Publication Date: Dec 1, 2016
Applicant: Fine and Small Homes LLC (North Charleston, SC)
Inventors: Nicholas C. Godfrey (Charleston, SC), Taylor Thompson (Coeur D'Alene, ID), Brantley M. Green (Conway, SC), William Bradford Boyd, JR. (Charleston, SC)
Application Number: 14/721,275
