MODULAR PANELIZED BUILDING SYSTEM AND METHOD

Abstract

A modular building frame panel may include first and second frame portions, each including first and second light gauge steel (LGS) vertical load-bearing members in a spaced substantially parallel relationship, top and bottom LGS edge purlins extending between upper and lower ends of the first and second LGS vertical load-bearing members, respectively, and configured to provide shear resistance of the upper and lower ends of the first and second LGS vertical load-bearing members, at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; and, a plurality of cross-frame members extending transversely between the first and second LGS vertical load-bearing members of the first and second frame portions configured for rigidly maintaining the first and second frame portions in a substantially parallel, spaced relationship.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 63/371,363, filed Aug. 12, 2022, the entire contents of which are incorporated herein by reference.

BACKGROUND

Because of the high cost of constructing conventional wood frame buildings of small and medium size and steel and concrete buildings of large size, there have been many attempts to manufacture prefabricated structures. Commonly such structures include some type of wall modules which can be manufactured in a plane and joined together at construction sites. Construction with prefabricated building structures can significantly save on-site building time.

Building panels have various applications, such as exterior and interior walls, partitions, floors, roofs, and foundation systems. There are different forms of building panels, such as structural insulated panels (SIPs) or prefabricated concrete blocks. Existing structural insulated panels generally comprise an insulating layer sandwiched between two layers of structural boards.

SUMMARY

In some aspects, a modular building frame panel includes: a first frame portion, including: a first light gauge steel (LGS) vertical load-bearing member; a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; a second frame portion oriented one hundred and eighty degree (180°) about a vertical axis of the modular building panel relative to the first frame portion, including: a first light gauge steel (LGS) vertical load-bearing member; a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; and a plurality of cross-frame members extending transversely between the first and second LGS vertical load-bearing members of the first and second frame portions configured for rigidly maintaining the first and second frame portions in a substantially parallel, spaced relationship.

In some aspects, a modular building frame system includes: first and second modular building frame panels, each including: a first frame portion, including: a first light gauge steel (LGS) vertical load-bearing member; a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; a second frame portion oriented one hundred and eighty degree (180°) about a vertical axis of the modular building panel relative to the first frame portion, including: a first light gauge steel (LGS) vertical load-bearing member; a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; and a plurality of cross-frame members extending transversely between the first and second LGS vertical load-bearing members of the first and second frame portions configured for rigidly maintaining the first and second frame portions in a substantially parallel, spaced relationship; an intermediate purlin tensile connection assembly configured to secure the first modular building panel to the second modular building panel, including: a first portion of the intermediate purlin tensile connection assembly defined at a first end of the at least one LGS intermediate purlin of the first modular building panel and at a second end of the at least one LGS intermediate purlin of the second modular building panel; and a second portion of the intermediate purlin tensile connection assembly defined at a second end of the at least one LGS intermediate purlin of the first modular building panel and at a first end of the at least one LGS intermediate purlin of the second modular building panel, wherein the first portion of the intermediate purlin tensile connection assembly of the first modular building panel is configured to connect in tension to the second portion of the intermediate purlin tensile connection assembly of the second modular building panel.

In some aspects, a modular building component connection assembly suitable for connecting a horizontal beam structure to first and second modular building panels without the use of fasteners such that vertical loads are transferred from the horizontal beam structure to at least one of first and second vertical load-bearing members of each of the first and second modular building panels includes a knife plate assembly having a main plate with a first main plate portion that is rigidly securable between ends of the first and second modular building panels and a second main plate portion that is securable between first and second beam portions of the horizontal beam structure.

BRIEF DESCRIPTION OF THE DRAWINGS

The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:

FIG. 1 shows a front view of joined modular building panels formed in accordance with an exemplary embodiment of the present disclosure.

FIG. 2 shows an isometric front view of the joined modular building panels of FIG. 1.

FIG. 3 shows a front view of the modular building panel of FIG. 1.

FIG. 4 shows a top view of the modular building panel of FIG. 3.

FIG. 5 shows a side view of the modular building panel of FIG. 3.

FIG. 6A shows an isometric view of a vertical stud member of the modular building panel of FIG. 3 exploded from a nested position with an edge purlin of the modular building panel of FIG. 3.

FIG. 6B shows an isometric view of the vertical stud member and the edge purlin of FIG. 6A nested together.

FIG. 6C shows a side view of a vertical stud member of the modular building panel of FIG. 3.

FIG. 6D shows a top view of the nested vertical stud member and an edge purlin of FIG. 6B.

FIG. 7A shows an interior side of an intermediate purlin of the modular building panel of FIG. 3.

FIG. 7B shows a side view of the intermediate purlin of FIG. 7A.

FIG. 8 shows front views of various sizes and configurations of modular building panels formed in accordance with exemplary embodiments of the present disclosure.

FIG. 9 shows front views of various sizes and configurations of modular building panels for accommodating door and window openings of a building frame formed in accordance with exemplary embodiments of the present disclosure.

FIG. 10A shows a picture of a corner modular building panel formed in accordance with exemplary embodiments of the present disclosure.

FIG. 10B shows a picture of modular building panels formed in accordance with exemplary embodiments of the present disclosure joined at a corner, wherein the panels have insulation panels.

FIG. 11 shows an isometric front view of an exemplary embodiment of a first panel connection assembly for the joined modular building panels of FIG. 1.

FIGS. 12-15 show various components of the first panel connection assembly of FIG. 11.

FIG. 16 shows an isometric view of an exemplary embodiment of a second panel connection assembly for the joined modular building panels of FIG. 1.

FIGS. 17-20 show further aspects of the second panel connection assembly of FIG. 16.

FIG. 21 shows front views of modular building panels formed in accordance with exemplary embodiments of the present disclosure stacked vertically.

FIG. 22 shows front views of various joist header assemblies in use with modular building panels formed in accordance with exemplary embodiments of the present disclosure.

FIG. 23 shows an isometric view of a modular header truss assembly supported by a jack stud modular building panel and a king stud modular building panel formed in accordance with exemplary embodiments of the present disclosure.

FIG. 24 shows a picture of a top view of an exemplary modular header truss assembly.

FIG. 25 shows a picture of an alternative embodiment of a modular header truss assembly.

FIG. 26 shows a picture of a track and stud joist beam structure secured to modular building panels with a modular building component connection assembly formed in accordance with exemplary embodiments of the present disclosure.

FIG. 27 shows a first isometric view of a knife plate assembly for use in joining modular building panels with at least one of a joist, beam, header, truss, other modular building panels, or similar, such as for use with the modular building component connection assembly of FIG. 26.

FIG. 28 shows a second isometric view of the knife plate assembly of FIG. 27.

FIG. 29 shows a front view of the knife plate assembly of FIG. 27.

FIG. 30 shows a side view of the knife plate assembly of FIG. 27.

FIG. 31 shows a top view of the knife plate assembly of FIG. 27.

FIG. 32 shows a picture of a knife plate assembly secured between adjacent beam truss assemblies.

FIG. 33 shows a picture of a lateral bracing assembly of the modular building component connection assembly of FIG. 26.

FIGS. 34-36 show pictures of a first alternative embodiment of a knife plate assembly of a modular building component connection assembly.

FIGS. 37 and 38 show pictures of a single beam truss assembly secured in a frame corner.

FIGS. 39 and 40 show isometric views of a second alternative embodiment of a knife plate assembly of a modular building component connection assembly.

FIGS. 41-43 show isometric views of a third alternative embodiment of a knife plate assembly of a modular building component connection assembly.

FIGS. 44-45 show isometric views of a fourth alternative embodiment of a knife plate assembly of a modular building component connection assembly.

FIG. 46 shows an isometric view of a portion of a building frame formed in accordance with exemplary embodiments of the present disclosure.

FIG. 47 shows an isometric view of a portion of a building frame formed in accordance with exemplary embodiments of the present disclosure.

FIG. 48 shows views of infill panels for use with the building frames formed in accordance with exemplary embodiments of the present disclosure.

FIG. 49 shows an isometric view of a portion of a building frame formed in accordance with exemplary embodiments of the present disclosure.

DETAILED DESCRIPTION

Systems and methods disclosed herein are directed to improved building panels and structural elements for defining a framing structure of a building, such as a house, multi-dwelling unit (e.g., apartment or condominium building), a high-rise structure, etc., as well as methods of assembling the same. Generally, the building panels are configured as modular assemblies available in incremental lengths and/or heights (e.g., increments of one foot (1′)) that can be arranged in a customized manner to define the walls, floors, corners, ceilings, or similar of a framing structure of a building. The modular building panels provide the vertical load support necessary for the framing structure while at the same time being extremely versatile and arrangeable in a customized configuration. For instance, the modular building panels can be turned upside down and inside out, they can be easily connected to other framing components (such as headers, joists, trusses, etc.), they are agnostic to any thickness and insulation fill, they have a flat interior and exterior nominal surface to easily receive any interior or exterior finishings (such as drywall) and provide a structural elements for connection of those finishings, and they require minimal hardware and tooling for connection to each other and other building elements.

The modular building panels can be used in combination with certain modular structural elements configured for customized additional vertical load support in the framing structure. For instance, modular jack and king stud assemblies formed in accordance with exemplary embodiments of the present disclosure can be used in combination with the modular building panels to provide vertical load support for openings in the framing structure (such as windows, doors, garage doors, etc.). In further aspects, primary structural load-bearing elements (truss assemblies) formed in accordance with exemplary embodiments of the present disclosure can be used in combination with the modular building panels and the modular jack and king stud assemblies to support any floor or roof loads above the building panels without the need for additional load bearing top plates.

The systems and methods disclosed herein also include improved connection assemblies that are configured to enable quick, simple, and secure connection of the modular building panels to each other and to the other structural elements, such as the jack/king studs, truss assemblies, etc.

These features as well as other features will become appreciated from the description and illustrations provided herein.

An exemplary modular building panel 100 will now be described with reference to FIGS. 1-7. As noted above, the modular building panels disclosed herein are configured as modular assemblies available in incremental lengths and/or heights (e.g., increments of one foot (1′)) that can be arranged in a customized manner to define the walls, floors, corners, ceilings, or similar of a framing structure of a building. The modular building panels 100 shown in FIGS. 1-7 may be used for a wall construction of standard height (e.g., ten feet). However, it should be appreciated that aspects of the modular building panel 100 may be modified for use in another location of a building, such as beneath a window, above a door, as part of a floor or ceiling, in a corner, etc. (see the exemplary modular building panels shown in FIGS. 8 and 9).

FIGS. 1 and 2 show two interconnected modular building panels 100 defining a building frame section 101. Each modular building panel 100 is an open frame, substantially rectangular structure generally defined by a substantially rectangular first frame portion 102a positioned opposite a substantially rectangular second frame portion 102b. The first frame portion 102a and second frame portion 102b are interconnected by cross-frame members 104 extending transversely across the thickness of the panel. It should be noted that depending on the location of building panel installation, the modular building panel may instead be another suitable overall shape, such as square, triangular, etc.

FIGS. 3-5 depict a single modular building panel 100. As noted above, each modular building panel 100 includes a first frame portion 102a connected to a second frame portion 102b to define a substantially rectangular, open frame structure. The first frame portion 102a and the second frame portion 102b are substantially identical. Accordingly, only the first frame portion 102a will be described in detail.

The first frame portion 102a has a first vertical load-bearing member 106a defining a first vertical elongated side of the substantially rectangular first frame portion 102a. A second vertical load-bearing member 106b defines a second vertical elongated side of the of the first frame portion 102a. The first and second vertical load-bearing members 106a and 106b are in a spaced substantially parallel relationship along a plane of the first frame portion 102a to define a width of the first frame portion 102a. A plurality of horizontal cross-frame members (described below) extend horizontally between the first and second vertical load-bearing members 106a and 106b to secure the first and second vertical load-bearing members 106a and 106b relative to one another and provide lateral bracing support for the first frame portion 102a.

The first and second vertical load-bearing members 106a and 106b are substantially identical, except arranged on the first frame portion 102a in a mirrored configuration. The first and second vertical load-bearing members 106a and 106b may be constructed from a suitable material and have a suitable cross-sectional shape to support the necessary vertical loads. For instance, the first and second vertical load-bearing members 106a and 106b may be made from light-gauge steel (LGS) to define light gauge steel framing members (sometimes called cold-formed steel) or a similar material in a manner well known in the art. For instance, the first and second vertical load-bearing members 106a and 106b may be made from structural quality steel sheets that are formed into shapes either through press-braking blanks sheared from sheets or coils or by roll-forming the steel through a series of dies.

Each of the first and second vertical load-bearing members 106a and 106b may have a size, shape, and configuration that supports vertical loads while minimizing column weight. In the depicted example, the first and second vertical load-bearing members 106a and 106b are an elongated, open frame, rectangular structure.

An exemplary configuration-section of the first vertical load-bearing member 106a is shown in FIGS. 6A-6C. The first vertical load-bearing member 106a has a body 111 that is generally an open rectangular cross-sectional shape, wherein a corner of the rectangular body is left open to define an insertion opening 110. As will become appreciated below, the insertion opening 110 is sized to receive a correspondingly-shaped portion of a cross-frame member of the first frame portion 102a.

The rectangular body 111 includes a first elongated side 103, a second partial elongated side 105 disposed opposite the first elongated side 103 and extending from a first shortened side 107 (which extends between the first elongated side 103 and the second partial elongated side 105) toward the insertion opening 110, and a second partial shortened side 109 extending from the first elongated side 103 toward the insertion opening 110.

A lip or flange 112 extends transversely from the second partial elongated side 105 adjacent the insertion opening 110. The flange 112 may be configured for securing the first vertical load-bearing member 106a to a cross-frame member of the first frame portion 102a with a suitable shear resistance fastener(s), such as through screws, clinch lock fastening, rivets, button punches, autogenous welding, or other mechanical fastening methods appropriate for light-gauge steel construction. It should be appreciated that the first and second vertical load-bearing members 106a and 106b may instead have any other suitable cross-sectional shape.

As noted above, a plurality of horizontal cross-frame members extend horizontally between the first and second vertical load-bearing members 106a and 106b to secure the first and second vertical load-bearing members 106a and 106b relative to one another and provide lateral bracing support. The plurality of horizontal cross-frame members includes top and bottom horizontal bracing members or edge purlins 108a and 108b.

The top edge purlin 108a extends between the top ends of the first and second vertical load-bearing members 106a and 106b to define a top horizontal edge of the first frame portion 102a. The bottom edge purlin 108b extends between the bottom ends of the first and second vertical load-bearing members 106a and 106b to define a bottom horizontal edge of the first frame portion 102a. The top and bottom edge purlins 108a and 108b of the first and second frame portions 102a and 102b act as top and bottom plates for the modular building panel 100, providing primary shear racking resistance for the modular building panel 100. The top and bottom edge purlins 108a and 108b also provide lateral buckling resistance to meet requirements of axially-loaded vertical load-bearing members (columns/studs). Furthermore, as will become appreciated below, the top and bottom edge purlins 108a and 108b are configured for use in securing adjacent panels 100 in a building framing structure.

The top and bottom edge purlins 108a and 108b may have a size, shape, and configuration that supports bracing loads while minimizing panel weight. In the depicted example, the top and bottom edge purlins 108a and 108b are an elongated, open frame, rectangular structure. The top and bottom edge purlins 108a and 108b may be made from light-gauge steel (LGS) as discussed above with respect to the first and second vertical load-bearing members 106a and 106b.

The top and bottom edge purlins 108a and 108b may also be substantially identical in configuration to the first and second vertical load-bearing members 106a and 106b. For instance, each of the edge purlins 108a and 108b may be defined by a body having the cross-sectional shape shown in FIG. 6C. In this manner, a portion of the edge purlins 108a and 108b may be nested within the first and second vertical load-bearing members 106a and vice versa, providing additional structural support to the modular building panel 100 and allowing for ease of installation.

For instance, FIGS. 6A, 6B, and 6D (as well as FIGS. 17 and 18) shows a bottom edge purlin 108b nested with a second vertical load-bearing member 106b. Because the bottom edge purlin 108b is substantially identical in cross-sectional shape to the second vertical load-bearing member 106b, the same part numbers are used for the features of the bottom edge purlin 108b and the features of the second vertical load-bearing member 106b.

To nest the bottom edge purlin 108b with the second vertical load-bearing member 106b, the bottom edge purlin 108b is oriented substantially transversely to the second vertical load-bearing member 106b (or vice versa). Thereafter, a portion of the elongated rectangular body 111 of the bottom edge purlin 108b is engaged with the insertion opening 110 of the second vertical load-bearing member 106b. More specifically, the second partial shortened side 109 of the body 111 of the bottom edge purlin 108b is inserted into the insertion opening 110 of the second vertical load-bearing member 106b such that the second partial shortened side 109 of the bottom edge purlin 108b extends along and may abut the second partial elongated side 105 of the second vertical load-bearing member 106b.

At the same time, a portion of the elongated rectangular body of the second vertical load-bearing member 106b is engaged with the insertion opening 110 of the bottom edge purlin 108b. More specifically, the first elongated side 103 and second partial shortened side 109 are inserted on edge into the insertion opening 110. In this manner, bottom edges of the first elongated side 103 and the second partial shortened side 109 may abut the first elongated side 103 of the bottom edge purlin 108b. When nested, the flange 112 of the bottom edge purlin 108b may be secured to the first elongated side 103 of the second vertical load-bearing member 106b, such as by welding, fasteners, etc.

Although other suitable cross-sectional shapes may instead be used for the edge purlins 108a and 108b, it can be appreciated that by using the same cross-sectional shape as the first and second vertical load-bearing members 106a and 106b, manufacturing and assembly of the first frame portion 102a is optimized. The edge purlins 108a and 108b may be made from light-gauge steel (LGS) as discussed above with respect to the first and second vertical load-bearing members 106a and 106b.

The plurality of horizontal cross-frame members may further include one or more intermediate purlins 113 that extend across the width of the first frame portion 102a between the first and second vertical load-bearing members 106a and 106b in a vertical location between the edge purlins 108a and 108b. The intermediate purlins 113 serve to connect and substantially prevent lateral movement of the spaced apart vertical load bearing members 106a and 106b. For instance, the intermediate purlins 113 also provide lateral buckling resistance to meet requirements of axially-loaded vertical load-bearing members (columns/studs). The intermediate purlins 113 also serve as a mounting structure for finishings, such as dry wall. Furthermore, the intermediate purlins 113 may be configured for use in securing adjacent panels 100 in a building framing structure as well as providing attachment structure for building materials (such as drywall).

Referring to FIGS. 7A and 7B, the intermediate purlins 113 may have a size, shape, and configuration that supports bracing loads while minimizing panel weight. In the depicted example, the intermediate purlins 113 are an elongated, open frame, rectangular structure. Moreover, the intermediate purlins 113 may be made from light-gauge steel (LGS) as discussed above with respect to the first and second vertical load-bearing members 106a and 106b.

The intermediate purlins 113 may have a suitable cross-sectional shape for securing to the first and second vertical load-bearing members 106a and 106b, bracing their lateral movement while minimizing column weight, and providing an attachment surface for finishing materials.

An exemplary cross-section of a horizontal bracing/connecting purlin 113 is shown in FIG. 7B. The horizontal bracing/connecting purlin 113 has a body 114 that is generally an open rectangular cross-sectional shape, having an enclosed elongated side 115 and an open elongated side 117. First and second lips or flanges 116 and 118 extend transversely from short sides 119a and 119b of the rectangular body 114 at corners of the body defined adjacent the open elongated side 117. The flanges 116 and 118 are used for securing the horizontal bracing/connecting purlin 113 to the first and second vertical load-bearing members 106a and 106b, such as through screws, autogenous welding, or other mechanical fastening methods appropriate for light-gauge steel construction. It should be appreciated that the intermediate purlins 113 may instead have any other suitable cross-sectional shape.

The intermediate purlins 113 may be spaced vertically along the height of the first frame portion 102a in predetermined increments. The incremental vertical spacing of the intermediate purlins 113 may depend on the lateral bracing needs for the modular building panel 100, the number of connection points needs between adjacent modular building panels, and/or the connection points needed for finishings and sheathing, such as dry wall. For instance, per standard U.S. construction standards, drywall sheets typically come in sizes of four feet by eight feet or ten feet (4′×8′ or 4′×10′). As such, for U.S. framing systems, the incremental vertical spacing of the intermediate purlins 113 may be two feet (2′) to allow for appropriate fastening of the drywall to the modular building panel 100. In some examples, top and bottom intermediate purlins 113 are spaced one foot (1′) from the top and bottom edge purlins 108a and edge purlins 108b, respectively, with the intermediate purlins 113 spaced two feet from any other connecting purlin 113.

Of note, the enclosed elongated side 115 of the intermediate purlins 113 has a suitable height or a dimension between shortened edges of the body 114 that accommodates fastening of the finishing components, such as drywall. In the embodiments disclosed herein, the enclosed elongated side 115 of the intermediate purlins 113 has a height greater than that offered for typical wood framing systems, wherein the connection points are often defined by abutted studs (typically 2×4 studs placed side by side). As can be appreciated, the joint or seam between abutted studs cannot receive a fastener, so the effective connection area is much smaller compared to the uniform, unbroken enclosed elongated side 115 of the intermediate purlins 113.

A suitable number of intermediate purlins 113 may be used for the first frame portion 102a as needed depending on panel height. For instance, if the modular building panel is configured as a small “filler” panel, such as for beneath a window, the first frame portion 102a may include only one or zero intermediate purlins 113.

As can be appreciated from the foregoing, the substantially rectangular open first frame portion 102a is defined by first and second vertical load-bearing members 106a and 106b that are secured together in a spaced, substantially parallel relationship with a plurality of horizontal cross-frame members (e.g., the edge purlins 108a and 108b and the intermediate purlins 113). The second frame portion 102b is substantially identical to the first frame portion 102a but it is oriented 180 degree (180°) about a vertical axis of the modular building panel 100 relative to the first frame portion 102a.

The first and second frame portions 102a and 102b are connected in a substantially parallel, spaced relationship to define the open frame, modular building panel 100. As noted above, the first frame portion 102a and second frame portion 102b are interconnected by cross-frame members 104 extending transversely across the thickness of the modular building panel 100.

As may best be seen by referring to FIG. 5, the cross-frame members 104 extend transversely across the modular building panel 100 and interconnect the respective first and second vertical load-bearing members 106a and 106b of the first and second frame portions 102a and 102b. For instance, the cross-frame members 104 may be joined to each of the first and second vertical load-bearing members 106a and 106b by passing a fastener transversely through the vertical load-bearing member and securing the fastener within the cross-frame member. For instance, a bolt may be passed through the vertical load-bearing member and threadably secured within a threaded opening of the cross-frame member 104.

The cross-frame members 104 may be any suitable configuration suitable for connecting and rigidly maintaining the first and second frame portions 102a and 102b in a substantially parallel, spaced relationship to define the open frame of the modular building panel 100. In the depicted example, the cross-frame members 104 are tubular members that are made of a suitable material and have a size that maintains rigidity of the modular building panel 100. Furthermore, the cross-frame members 104 may be of hollow tubular construction such that they may be used as an electrical conduit if desired. In that regard, the cross-frame members 104 may be a fiber-reinforced composite material that is thermally insulative, an electrically conduit metal, etc.

Prior art modular building panels rely on fillers (e.g., foam) or sheet goods (e.g., OSB, plywood, gypsum sheathing, etc.) for maintaining panel rigidity. The load-bearing properties of the modular building panel 100 (e.g., shear racking resistance) are not dependent upon other components, such as fillers. Rather, with the first frame portion 102a and second frame portion 102b interconnected by cross-frame members 104, the dimension of the modular building panel 100 remains fixed, and the rigidity of the panel is maintained. In other words, the rigidity of the modular building panel 100 is maintained without the need to add any fillers (e.g., foam) or sheet goods (e.g., OSB, plywood, gypsum sheathing, etc.).

In that regard, the rigidity of the modular building panel 100 is maintained even in the event of a fire. In prior art systems that rely on insulative fill for structural support, the insulative fill will start to burn, melt, or otherwise degrade during a fire. The cross-frame members 104, on the other hand, remain structurally sound during a fire because the integrity of the cross-frame members 104 is not compromised.

In certain cases, the structural load requirements for the modular building panel 100 may be higher than average. In cases of enhanced shear racking resistance needs, diagonal tensile elements (e.g., straps) may be attached to panel frame elements. Foam or other fillers may be added for insulative purposes, as discussed below, however, such fillers are not necessary for panel structural support.

When interconnected by cross-frame members 104, the first and second frame portions 102a and 102b define a panel interior thickness between interior nominal surfaces of the first and second vertical load-bearing members 106a and 106b. The panel interior thickness defines a thermal break between the first and second frame portions 102a and 102b, which reduces or substantially prevents the flow of thermal energy between the inside and outside of a building.

The panel interior thickness is also configured such that the panel is agnostic to an insulative fill, which allows for the application of any suitable known or future insulation technologies as well as locally-sourced materials. In that regard, the panel interior thickness may be configured to support a variety of non-structural insulative fills, depending on thermal, vapor-permeability, acoustical performance requirements, etc. In some examples, the spacing between the first and second frame portions 102a and 102b may be tailored to the insulation needs of the building.

A suitable insulation material or other filler material may be disposed within the open frame structure of the modular building panel 100 by the original equipment manufacturer (OEM) or by another entity, including the framer. In that regard, the modular building panel 100 may be adapted for use with a variety of building types.

FIG. 10B shows joined modular building panels having an exemplary insulation fill configured as composite fill panels F, with horizontal intermediate purlins 113 exposed for finish attachment. The composite fill panels F may consist of expanded polystyrene foam (EPS), but alternative materials may be utilized, depending upon performance requirements, cost and availability of materials, etc. Other types of insulating layers/fill may include extruded polystyrene foam (XPS), polyisocyanurate foam, polyurethane foam, or composite honeycomb (HSC).

After optionally filled with insulation, such as shown in FIG. 10B, the modular building panel 100 may be covered with appropriate interior and exterior coverings (“sheathing”) and finishes. For instance, the modular building panel 100 may be covered with structural boards, such as sheet metal, plywood, cement, magnesium oxide board (MgO), oriented strand board (OSB). The sheathing and any other finishes may be secured to the intermediate purlins 113, such as by simply passing a fastener through both the sheathing/finish and the connecting purlin 113.

As can be appreciated, the interior thickness of the modular building panel 100 may be dictated at least in part by the viability of insulative fill, the thermal break requirements, etc. For instance, the economically optimal insulative thickness of the panel may be based on applicable factors, such as environmental factors (temperature, wind, seismic, etc.), energy cost, and cost of capital. The interior thickness of the modular building panel 100, or spacing between the first and second frame portions 102a and 102b may also be dictated in part by the structural load requirements for the panel. For instance, in some cases, the modular building panel may have a smaller or greater thickness to help distribute vertical loads as needed.

In one embodiment, the thickness for all modular building panels used for framing walls of a building structure (and any features in the walls such as windows, doors, etc.) have the same thickness for ease of assembly and uniformity. For instance, the modular building panel 100 may have a standard overall thickness, or a distance between exterior surfaces of opposing purlins. In one example, the standard overall thickness for the modular building panel 100 of a building is about twelve inches (12″).

Each of the vertical load-bearing members of the modular building panel 100 essentially defines a portion of a braced column or stud 120 of the modular building panel 100. More specifically, when modular building panels 100 are structurally joined side-by-side, as shown in FIGS. 1 and 2, four vertical load-bearing members are grouped together. Specifically, first and second vertical load-bearing members 106a and 106b of the first and second frame portions 102a and 102b of adjacent modular building panels 100 are grouped together. As such, when adjacent modular building panels 100 are connected together side-by-side, the modular building panel 100 essentially defines a ‘4-stud column group’ that can be coordinated with floor and roof loads as needed. Further, the lateral support provided by the cross-frame members 104, the top and bottom edge purlins 108a and 108b, and the intermediate purlins 113 provide bracing support for the stud 120. As such, the modular building panel 100 have an increased load capacity compared to prior art systems that rely on foam fillers for bracing support.

Modular building panels formed in accordance with the present disclosure may be constructed in incremental or standard heights and widths for ease of manufacturing and ease of framing assembly. The width of the modular building panels (as defined between exterior side surfaces of the first and second vertical load-bearing members 106a and 106b) may be of a predefined modular increment, such as modular increments of one foot (1′). For instance, the panel may be available in widths of one foot (1′), two feet (2′), three feet (3′), four feet (4′), etc. In this manner, a wall, floor, ceiling, etc., having an overall dimension that is a multiple of the modular increments may be easily designed and built with the modular building panels. As an example, a twelve foot (12′) wall may be constructed by joining three 4′ panels, four 3′ panels, etc. As shown in FIG. 8, the width of the modular building panels may be in smaller increments, such as increments of 5-12 inches.

The modular building panels may also be constructed in incremental or standard heights (as defined by the height of the first and second frame portions 102a and 102b, or the distance between exterior top and bottom surfaces of the edge purlins 108a and 108b). For instance, the height of a modular building panel may be one a predefined modular increment, such as modular increments of one foot (1′), two feet (2′), three feet (3′), four feet (4′), etc. In one embodiment, a standard wall panel, such as that shown in FIG. 1 may be ten feet (10′) high (floor to ceiling height).

Modular building panels having smaller heights may be used to accommodate window openings or other building features. For instance, as shown in FIGS. 8 and 9, a wall infill panel may have a standard height and width of 4 feet (4′) by four feet (4′). Such a wall infill panel may be used beneath a windowsill or similar. Other wall infill panels may have an appropriate height and width to accommodate a lower ceiling height (e.g., an attic space), larger windows, etc.

In another example, modular building panels may be configured as a corner panel, such as that shown in FIG. 10A for supporting joining of a corner of a building frame, such as that shown in FIG. 10B. Corner panels may have a modular incremental height (e.g., 10 feet (10′)) and width (e.g., twelve inches (12″)) to connect to modular building wall panels at a corner having the same height and width. The thickness of the corner panel may be substantially equal to its width (e.g., twelve inches (12″)) such that the corner panel is essentially square in cross-section for connecting to modular wall panels having the same thickness.

As can be seen in FIG. 10A, the intermediate purlins 113 and top and bottom edge purlins 108a and 108b may wrap horizontally around first and second exterior sides of the corner panel for connecting to the adjacent modular building panels oriented ninety degrees relative to one another. The intermediate purlins 113 and top and bottom edge purlins 108a and 108b may be excluded from the third and fourth interior sides of the corner panel, which abut the ends of the adjacent modular building panels oriented ninety degrees relative to one another. Cross-frame members 104 may extend between the vertical load-bearing members of the corner panel as needed to provide lateral bracing support.

In yet another example, a modular building panel may be configured for use as a jack or king stud in a building frame, such as to support a modular building panel header assembly that spans distances above openings in a wall section. For instance, FIG. 22 shows various configurations of a modular header assembly supported by jack and king stud modular building panels at each end of the modular header assembly. The modular header assembly and jack and king stud modular building panels perform structurally similar to headers, jack studs, and king studs in a traditional stick frame setting; however, the modular header assembly and jack and king stud modular building panels integrate into wall sections formed with modular building panels formed in accordance with the disclosed systems and methods.

As can be seen in FIG. 23, a header assembly configured as a modular header truss assembly 210 rests atop a jack stud modular building panel 214 such that vertical loads of the modular header truss assembly 210 are transferred to the jack stud modular building panel 214. The jack stud modular building panel 214 may be constructed substantially identically to a modular building panel 100 described above, with a width and height as needed to fit beneath the modular header truss assembly 210 in an opening in the building wall section.

A king stud modular building panel 218 is shown positioned adjacent to the modular header truss assembly 210 and jack stud modular building panel 214. The king stud modular building panel 218 may be constructed substantially identically to a modular building panel 100 described above, with a width and height as needed to fit adjacent to the modular header truss assembly 210/jack stud modular building panel 214 and extend along a height of the building wall section.

The modular header truss assembly 210 may also be constructed in a manner similar to a modular building panel 100 described above. For instance, the modular header truss assembly 210 may have a first frame portion 102a positioned opposite a second frame portion 102b and interconnected by cross-frame members 104 (see also FIG. 24). Each frame portion of the modular header truss assembly 210 may include top and bottom edge purlins 108a and 108b, which interconnect first and second vertical load-bearing members 106a and 106b. The top and bottom edge purlins 108a and 108b may extend along the entire length of modular header truss assembly 210, which may be defined by at least first and second sets of adjacent frame portions. Finally, a plurality of vertical and/or diagonal support members 220 extend between the top and bottom edge purlins 108a and 108b to provide structural support for modular header truss assembly 210.

Referring to FIGS. 11-21, exemplary connection assemblies for structurally joining modular building panels 100 side-by-side and/or vertically stacked on top of each other for defining a section of a building frame will now be described. The connection assemblies may be used to structurally join modular building panels 100 before any finishing components (e.g., drywall) are applied to the panels, yet insulation may be added before structurally joining the modular building panels 100. In general, the connection assemblies are configured to structurally join adjacent, side by side, on-edge panels to define a stud 120 therebetween for supporting vertical loads. Further, the connection assemblies are configured to structurally join vertically stacked, on-edge panels in a secure manner, maximizing shear racking resistance. Moreover, the connection assemblies are configured to substantially eliminate any gap between adjacent/stacked, joined panels 100, minimizing thermal inefficiencies. Further, the connection assemblies are concealed within the joined modular building panels 100 (e.g., no parts protrude from the planar nominal surface of the panels), thereby minimizing disruption to application of interior and exterior finishings. As an added benefit, the connection assemblies described herein are low cost, easy to manufacture, and easy to use.

The connection assemblies for structurally joining modular building panels 100 side-by-side may include intermediate purlin tensile connection assemblies 124 and top and bottom edge purlin tensile connection assemblies 126. The intermediate purlin tensile connection assemblies 124 will first be described in detail with respect to FIGS. 9-13.

In general, the intermediate purlin tensile connection assemblies 124 are configured to secure together adjacent modular building panels 100 in a tensile load bearing configuration. The intermediate purlin tensile connection assemblies 124 are defined between some or all of the substantially aligned intermediate purlins 113 of adjacent modular building panels 100. Each intermediate purlin connection assembly 124 includes at least one bolt 128 that passes through first and second intermediate purlin tensile connection washers 132a and 132b mechanically captured within adjacent intermediate purlins 113. The first and second intermediate purlin tensile connection washers 132a and 132b are pulled toward one another by the force of the bolt 128, causing the adjacent intermediate purlins 113 to be pulled together in tension.

FIGS. 10-13 show examples of the first intermediate purlin connection washer 132a both in isolation and received within an intermediate purlin 113. The first and second intermediate purlin tensile connection washers 132a and 132b are identical; and therefore, only the first intermediate purlin connection washer 132a will be described in detail.

The first intermediate purlin connection washer 132a includes a body 136 of sturdy construction for withstanding the necessary tensile loads of the intermediate purlin tensile connection assemblies 124. For instance, the body 136 may be sheet metal that is formed from heavy gauge steel. The body 136 defines a substantially rectangular planar portion 138 and first and second flanged portions 140 and 142 extending transversely from elongated edges of the substantially rectangular planar portion 138. The first and second flanged portions 140 and 142 have a length that is shorter than a length of the elongated edges of the substantially rectangular planar portion 138. Moreover, the first and second flanged portions 140 and 142 are substantially centered along the length of the elongated edges of the substantially rectangular planar portion 138. In this manner, the substantially rectangular planar portion 138 defines first and second tabs 144 and 146 on the shortened ends of the substantially rectangular planar portion 138.

The first and second tabs 144 and 146 are receivable within correspondingly shaped slots defined in the intermediate purlins 113. The slots are arranged such that the substantially rectangular planar portion 138 of the first intermediate purlin connection washer 132a extends between the first and second short sides 119a and 119b of the body 114 of the intermediate purlin 113, substantially transversely to the plane of the enclosed elongated side 115.

In the depicted example best seen by referring to FIGS. 9 and 11-13, the intermediate purlins 113 each include a first slot 150 defined in a portion of the first short side 119a of the body 114 and a second slot 154 defined in a portion of the second short side 119b of the body 114. The first slot 150 extends from the enclosed elongated side 115 of the body 114 of the intermediate purlin 113 towards the first flange 116 of the body. The first slot 150 is generally the same shape and slightly larger in size than the first tab 144 of the first intermediate purlin connection washer 132a such that the first tab 144 is loosely received within the first slot. Similarly, the second slot 154 extends from the enclosed elongated side 115 of the body 114 of the intermediate purlin 113 towards the second flange 118 of the body. The second slot 154 is generally the same shape and slightly larger in size than the second tab 146 of the first intermediate purlin connection washer 132a such that the second tab 146 is loosely received within the second slot. In this manner, the first intermediate purlin connection washer 132a may be inserted into the slots 150 and 154 and loosely retained within the intermediate purlin 113.

The first intermediate purlin connection washer 132a may be inserted into the slots 150 and 154 by first inserting a portion of the first or second tab 144 or 146 into the first or second slot 150 or 154, and then applying a force (such as with a hammer/mallet, robotic means, etc.) to the elongated edge of the substantially rectangular planar portion 138 and/or the first or second flanged portion 140/142 to urge the other of the first or second tab 144 or 146 into the first or second slot 150 or 154. With the first and second tabs 144 and 146 disposed in the first and second slots 150 and 154, the substantially rectangular planar portion 138 of the first intermediate purlin connection washer 132a extends between the first and second short sides 119a and 119b of the body 114 of the intermediate purlin 113, substantially transverse to the plane of the enclosed elongated side 115. The first and second flanged portions 140 may be configured to engage one of an interior surface of the enclosed elongated side 115 and an exterior surface of the corresponding first or second vertical load-bearing member to help brace the first intermediate purlin connection washer 132a in its position within the intermediate purlin 113. The second purlin washer 132b is loosely secured within first and second slots 150 and 154 of an adjacent intermediate purlin 113 in a substantially similar manner.

As noted above, the first intermediate purlin connection washer 132a is arranged such that the substantially rectangular planar portion 138 of the first intermediate purlin connection washer 132a extends between the first and second short sides 119a and 119b of the body 114 of the intermediate purlin 113, substantially transversely to the plane of the enclosed elongated side 115. The second purlin washer 132b is arranged in an intermediate purlin 113 of an adjacent modular building panels 100 in an identical manner. In that regard, the rectangular planar portions 138 of the first and second intermediate purlin tensile connection washers 132a and 132b are in a spaced, substantially parallel relationship relative to one another.

At least one bolt 128 may be passed through corresponding, substantially aligned openings (not labeled) in the rectangular planar portions 138 of the first and second intermediate purlin tensile connection washers 132a and 132b. A nut (optionally secured to the rectangular planar portion 138 of one of the first and second intermediate purlin tensile connection washers 132a and 132b) threadably receives the threaded end of the bolt 128 to form a completed intermediate purlin tensile connection joint. An opening 158 is defined in the enclosed elongated side 115 at each end of the intermediate purlins 113 for accessing the bolt head and nut with a tool (e.g., an L type bent socket wrench). A suitably long bolt may be used to allow for ease of installation.

The opposing forces of the head of the bolt 128 and the nut draw together the rectangular planar portions 138 of the first and second intermediate purlin tensile connection washers 132a and 132b with a tensile force. When the first and second intermediate purlin tensile connection washers 132a and 132b are drawn together, the washers transfer the tensile force to the intermediate purlins 113 of the adjacent modular building panels 100, drawing the panels together. In effect, the intermediate purlin tensile connection assemblies 124 define a load bearing splice, providing a structural load bearing connection and support at the joint of the adjacent intermediate purlins 113.

When adjacent modular building panels 100 are connected side by side, the joined vertical load-bearing members 106a and 106b of each panel together define a load bearing column or stud 120 for the wall section 101 as noted above. Moreover, the tensile force of the intermediate purlin tensile connection assemblies 124 helps brace the columns, effectively reducing the column length such that it can bear more load (per the well-known Euler formula). In that regard, the intermediate purlin tensile connection assemblies 124 define primary shear racking resistance elements for the modular building panels 100.

Further, the intermediate purlin tensile connection assemblies 124 are contained completely within the interior of the intermediate purlins 113. In that regard, no fastening components protrude from the exterior planar surface of the enclosed elongated side 115 of intermediate purlins 113, which would interfere with finishing attachments.

Further bracing and structural connection between adjacent modular building panels 100 can be accomplished with the use of the top and bottom edge purlin tensile connection assemblies 126, which will now be described with reference to FIGS. 14-18. The edge purlin tensile connecting assemblies 126 are configured for structurally joining the top and bottom edge purlins 108a and 108b and the first and second vertical load-bearing members 106a and 106b of adjacent modular building panels 100 in tension.

In general, the edge purlin tensile connecting assembly 126 includes a first edge purlin tensile connection washer assembly 162a configured to be disposed within the top and bottom edge purlins 108a and 108b of a first modular building panel 100. The edge purlin tensile connecting assembly 126 further includes a second edge purlin tensile connection washer assembly 162b identical to the first edge purlin tensile connection washer assembly 162a that is configured to be disposed within the top and bottom edge purlins 108a and 108b of a second, adjacent modular building panel 100 in a mirrored configuration. With the first edge purlin tensile connection washer assembly 162a disposed within top and bottom edge purlins 108a and 108b of a first modular building panel 100 and the second edge purlin tensile connection washer assembly 162b disposed within the top and bottom edge purlins 108a and 108b of a second, adjacent modular building panel 100, the first and second edge purlin tensile connection washer assemblies 162a and 162b may be pulled toward one another in tension to secure together the edge purlins 108a/108b and the first and second vertical load-bearing members 106a/106b of the first and second adjacent modular building panel 100.

Referring to FIGS. 17 and 18, the first and second edge purlin tensile connection washer assemblies 162a and 162b will now be described. The first and second edge purlin tensile connection washer assemblies 162a and 162b are identical; and therefore, only the first edge purlin tensile connection washer assembly 162a will be described in detail. The first edge purlin tensile connection washer assembly 162a includes a first U-shaped washer 166, a top L-shaped planar washer 168, and a bottom L-shaped planar washer 170, all having bodies of sturdy construction for withstanding the necessary tensile loads of the edge purlin tensile connecting assembly 126. For instance, the body may be sheet metal that is formed from heavy gauge steel.

The body of the first U-shaped washer 166 defines a substantially rectangular planar portion 174 and first and second substantially square flanged portions 178 and 182 extending transversely from shortened edges of the substantially rectangular planar portion 174. The substantially rectangular planar portion 174 and first and second substantially square flanged portions 178 and 182 are oriented on edge (e.g., such that the U-shape of the first U-shaped washer 166 is apparent when looking down at the first U-shaped washer 166). Upper and lower tabs 184 and 188 are defined on upper and lower edges of each of the first and second substantially square flanged portions 178 and 182.

The upper and lower tabs 184 and 188 are receivable within correspondingly shaped slots defined in the bodies of the top L-shaped planar washer 168 and the bottom L-shaped planar washer 170, respectively. The top L-shaped planar washer 168 and the bottom L-shaped planar washer 170 are substantially identical in configuration and have substantially planar bodies having an overall L shape with an elongated part 192 and a shortened part 196. The planar bodies of the top L-shaped planar washer 168 and the bottom L-shaped planar washer 170 are substantially perpendicular to the planes of the substantially rectangular planar portion 174 and the substantially square flanged portions 178 and 182 of the first U-shaped washer 166.

The elongated part 192 of the top L-shaped planar washer 168 extends along the length of the first U-shaped washer 166 and includes the slots for receiving the upper tabs 184 of the first U-shaped washer 166. The shortened part 196 of the top L-shaped planar washer 168 extends transversely from a longitudinal axis of the elongated part 192. The bottom L-shaped planar washer 170 is arranged relative to the first U-shaped washer 166 in mirrored configuration to the top L-shaped planar washer 168.

The first edge purlin tensile connection washer assembly 162a further includes a second U-shaped washer 167 that is substantially identical to the first U-shaped washer 166 and oriented in a mirrored configuration to the first U-shaped washer 166. For ease of reference, the same features on the first and second U-shaped washers 166 and 167 are labeled with the same reference numerals. Using identical first and second U-shaped washers 166 and 167 for use in the first and second edge purlin tensile connection washer assemblies 162a and 162b helps increase the ease of manufacturing and assembly of the modular building panel 100.

As noted above, with the first edge purlin tensile connection washer assembly 162a disposed within top and bottom edge purlins 108a and 108b of a first modular building panel 100 and the second edge purlin tensile connection washer assembly 162b disposed within the top and bottom edge purlins 108a and 108b of a second, adjacent modular building panel 100, the first and second edge purlin tensile connection washer assemblies 162a and 162b may be pulled toward one another in tension to secure together the edge purlins 108a/108b and first and second vertical load-bearing members 106a/106b of first and second adjacent modular building panels 100.

FIGS. 15 and 16 show first edge purlin tensile connection washer assemblies 162a disposed within bottom edge purlins 108b/first and second vertical load-bearing members 106a and 106b of a first modular building panel 100. Second edge purlin tensile connection washer assemblies 162b are similarly disposed within bottom edge purlins 108b/first and second vertical load-bearing members 106a and 106b of a second, adjacent modular building panel 100 (see FIG. 14). The first and second edge purlin tensile connection washer assemblies 162a and 162b are arranged in a mirrored configuration for joining the adjacent modular building panel 100 in a tensile connection.

As can be seen, the substantially rectangular planar portion 174 of the first U-shaped washer 166 and the elongated parts 192 of the top and bottom washers 168 and 170 extend along a length of the bottom edge purlin 108b near its open end. More particularly, the elongated part 192 of the bottom L-shaped planar washer 170 extends along and rests upon the interior surface of the first elongated side 103 of the bottom edge purlin 108b. The elongated part 192 of the top L-shaped planar washer 168 extends along and may abut the interior surface of the second partial elongated side 105 of the bottom edge purlin 108b. The substantially rectangular planar portion 174 of the first U-shaped washer 166 extends along and may abut the exterior surface of the first elongated side 103 of the second vertical load-bearing member 106b.

The shortened parts 196 of the top and bottom washers 168 and 170 extend transversely across the width of the bottom edge purlin 108b, i.e., from the first shortened side 107 toward the second partial shortened side 109 of the bottom edge purlin 108b. When the first and second vertical load-bearing members 106a or 106b are received within the bottom edge purlin 108b, an edge of the shortened parts 196 of the top and bottom washers 168 and 170 are configured to engage an exterior surface of the first shortened side 107 of the second vertical load-bearing member 106b.

The substantially rectangular planar portion 174 of the second U-shaped washer 167 extends along an interior surface of the first elongated side 103 of the first vertical load-bearing member 106b (which is nested inside the bottom edge purlin 108b). The first and second substantially square flanged portions 178 and 182 extends along interior surfaces of the first shortened side 107 and second partial shortened side 109, respectively, of the first vertical load-bearing member 106b.

Second edge purlin tensile connection washer assemblies 162b are disposed within bottom edge purlins 108b/first and second vertical load-bearing members 106a and 106b of a second, adjacent modular building panel 100 in an identical, mirrored configuration.

Bolt or other suitable fasteners are passed through openings in the first and second aligned edge purlin tensile connection washer assemblies 162a and 162a of adjacent modular building panel 100 to pull the bottom edge purlins 108b together in tension. An opening 202 in a side face of the bottom edge purlins 108b may provide access to the first edge purlin tensile connection washer assembly 162a for securing the bolt or other fastener.

A bolt may be passed through openings in the first and second substantially square flanged portions 178 and 182 of the first U-shaped washer 166 of each of the first and second edge purlin tensile connection washer assemblies 162a and 162b. A nut may then be secured on the end of the bolt to pull the first U-shaped washer 166 of each of the first and second edge purlin tensile connection washer assemblies 162a and 162b toward each other. The first U-shaped washer 166, through the interface of the upper and lower tabs 184 and 188 and corresponding slots in the top and bottom washers 168 and 170, draws the edges of the shortened parts 196 of the top and bottom washers 168 and 170 into engagement with the exterior surface of the first shortened side 107 of the second vertical load-bearing member 106b. In effect, the bottom edge purlins 108b (and the nested first and second vertical load-bearing members 106a and 106b) are pulled toward one another in tension.

A bolt may also be passed through openings in the first and second substantially square flanged portions 178 and 182 of the second U-shaped washer 167 of each of the first and second edge purlin tensile connection washer assemblies 162a and 162b and openings in the first shortened side 107 of the first and second vertical load-bearing members 106a and 106b. A nut may then be secured on the end of the bolt to pull the second U-shaped washer 167 of each of the first and second edge purlin tensile connection washer assemblies 162a and 162b toward each other. The first substantially square flanged portion 178 exerts a force on the first shortened side 107 of the first and second vertical load-bearing members 106a and 106b of adjacent modular building panels 100 to pull them toward each other in tension.

Fasteners may also be passed through the substantially rectangular planar portion 174 of the first U-shaped washer 166, the first elongated side 103 of the vertical load-bearing member, and the substantially rectangular planar portion 174 of the second U-shaped washer 167 to further secure the bottom edge purlin 108b to the first and second vertical load-bearing members 106a and 106b.

First and second edge purlin tensile connection washer assemblies 162a and 162b may be used to secure the top edge purlins 108a to the first and second vertical load-bearing members 106a and 106b of adjacent modular building panels 100 in a substantially identical manner. By pulling together the top and bottom edge purlins 108a and 108b and the first and second vertical load-bearing members 106a and 106b of adjacent modular building panels 100 in tension, the edge purlin tensile connecting assemblies 126 define primary shear racking resistance elements for the joined modular building panels 100.

The components of the first and second edge purlin tensile connecting assemblies 126 are contained within the interior of the corresponding top and bottom edge purlins 108a and 108b. In other words, no fastening components protrude from the exterior planar surface of the first shortened side 107 of the top and bottom edge purlins 108a and 108b, which would interfere with finishing attachments. In that regard, the exterior planar surface of the first shortened side 107 of the top and bottom edge purlins 108a and 108b may be substantially co-planar with the enclosed elongated side 115 of the intermediate purlins 113 to allow for an overall flat wall panel surface for finishing attachment.

The first and second edge purlin tensile connection washer assemblies 162a and 162b of the edge purlin tensile connecting assembly 126 also facilitate structural stacking of modular building panels 100. For instance, openings defined in the first elongated side 103 and second partial elongated side 105 of the top and bottom edge purlins 108a and 108b of a first modular building panel 100 may be aligned with openings in the elongated parts 192 of each of the top and bottom L-shaped planar washers 168 and 170 for both of the first and second edge purlin tensile connection washer assemblies 162a and 162b.

Similarly, openings defined in the first elongated side 103 and second partial elongated side 105 of the top and bottom edge purlins 108a and 108b of a second modular building panel 100 may be aligned with openings in the elongated parts 192 of each of the top and bottom L-shaped planar washers 168 and 170 for both of the first and second edge purlin tensile connection washer assemblies 162a and 162b. The first and second modular building panels 100 may be stacked such that the openings of each of the first and second edge purlin tensile connection washer assemblies 162a and 162b and the corresponding openings in the top and bottom edge purlins 108a and 108b are aligned. A fastener, such as a bolt with a corresponding nut, may be passed through the aligned openings to pull the first and second panels into tension.

More specifically, a bolt may be passed through the aligned openings in an upper end of a first modular building panel 100 (i.e., the first elongated side 103 and second partial elongated side 105 of the top edge purlin 108a and the openings in the elongated parts 192 of each of the top and bottom L-shaped planar washers 168 and 170 disposed within the top edge purlin 108a). The bolt may also be passed through aligned openings in a lower end of a second, stacked modular building panel 100 (i.e., the first elongated side 103 and second partial elongated side 105 of the bottom edge purlin 108b and the openings in the elongated parts 192 of each of the top and bottom L-shaped planar washers 168 and 170 disposed within the bottom edge purlin 108b).

A nut may then be secured on the end of the bolt to pull the outermost L-shaped planar washers (i.e., the bottom L-shaped planar washers 170 of the first modular building panel 100 and the top L-shaped planar washers 168 of the second, stacked modular building panel 100) toward each other. The first and second substantially square flanged portions 178 and 182 keep the outermost L-shaped planar washers from moving substantially toward each other, allowing the bolt to pull the outermost L-shaped planar washers (and therefore any edge purlin and edge purlin tensile connection washer assembly components therebetween) together in tension. The connections defined between vertically aligned panels can act as primary shear racking resistance elements for the stacked panels.

As shown in FIG. 21, panels may be vertically stacked such that the panels are joined together in a staggered fashion (e.g., a brick layout). In this manner, the tensile connections between first and second stacked modular building panels 100 may be staggered (e.g., not horizontally aligned) throughout the wall section.

FIG. 23 depicts a modular header truss assembly 210 supported by a jack stud modular building panel 214 and king stud modular building panel 218, as briefly described above. The edge purlin tensile connecting assembly 126 may be used to secure the modular header truss assembly 210 to the jack stud modular building panel 214. In particular, the bottom edge purlin 108b of the modular header truss assembly 210 may be connected to a top edge purlin 108a of the jack stud modular building panel 214 with the edge purlin tensile connecting assembly 126, as described above. Further, the top edge purlin 108a of the modular header truss assembly 210 may be connected to the top and bottom edge purlins 108a of the adjacent king stud modular building panel 218 (see FIG. 23) or an adjacent modular building panel 100 (see FIG. 25).

If an intermediate purlin 113 extends across the modular header truss assembly 210, as shown in FIG. 25, intermediate purlin tensile connection assemblies 124 may be used to secure the modular header truss assembly 210 to adjacent king stud modular building panels 218 and/or modular building panels 100 at each end of the modular header truss assembly 210. The modular header truss assembly 210 may also/instead be secured to adjacent king stud modular building panels 218 and/or modular building panels 100 with a knife plate assembly, as described below.

As noted above, the modular building panels can be turned upside down and inside out such that they can be easily connected to other framing components, such as adjacent modular building panels 100. In that regard, the intermediate purlin tensile connection assemblies 124 and the edge purlin tensile connecting assemblies 126 are configured in a female and male orientation on opposite sides of the modular building panels. For instance, an intermediate purlin tensile connection assembly 124 on a first side of the modular building panel 100 will have a bolt, and an intermediate purlin tensile connection assembly 124 on a second, opposite side of the modular building panel 100 will have a nut. Likewise, an edge purlin tensile connecting assembly 126 on a first side of the modular building panel 100 will have a bolt, and an edge purlin tensile connecting assembly 126 on a second, opposite side of the modular building panel 100 will have a nut. Of course, fasteners other than bolts and nuts may be used.

Moreover, the intermediate purlin tensile connection assemblies 124 and the edge purlin tensile connecting assemblies 126 may instead have any other suitable configuration for pulling together in tension and connecting adjacent and/or stacked panels. It can be appreciated, however, that the disclosed intermediate purlin tensile connection assemblies 124 and the edge purlin tensile connecting assemblies 126 have the advantage of being simple and inexpensive to manufacture, easy to assembly (only one tool is needed to tighten the bolts), and they provide a suitable amount of tension at the connection joints without requiring bulky or protruding connection components. Rather, the disclosed intermediate purlin tensile connection assemblies 124 and the edge purlin tensile connecting assemblies 126 provide suitable tensile connections without requiring that any components protrude from the exterior planar surfaces of the intermediate purlins 113 or the top and bottom edge purlins 108a and 108b.

A suitable gasket may be disposed between the adjacent and stacked modular building panels 100 that is compressed when the panels are drawn together in tension by the intermediate purlin tensile connection assemblies 124 and the edge purlin tensile connecting assemblies 126. The gasket substantially eliminates any gap between the adjacent and stacked modular building panels 100, thereby minimizing thermal transmittance within the panel. Although any suitable gasket may be used, in some examples, the gasket is a ¼″ thick strip of polyethylene.

The modular building panels and systems disclosed herein may be used with other building framing components necessary for constructing a building with a light-gauge steel framing system or another suitable type of system. For instance, the modular building panels and systems disclosed herein may be used with joists, trusses, headers, etc., constructed for light-gauge steel framing systems (i.e., track and stud).

Joists, trusses, headers, and the like are load bearing members having beam portions that extend horizontally between frame sections, such as between wall sections. Systems and methods disclosed herein include beam connection assemblies configured to secure track and stud joists, trusses, headers, and the like to vertical elements, such as the modular building panels constructed in accordance with the present disclosure.

In general, the beam connection assemblies are configured as knife plate assemblies rigidly securable between adjacent, connected modular building panels and having features configured to vertically support a track and stud beam structure. Exemplary embodiments of beam connection assemblies will be described with reference to FIGS. 26-45. It should be appreciated that the beam connection assemblies may be adapted for use in structurally connecting any suitable track and stud beam structure to the modular building panels described herein.

A first exemplary modular building component connection assembly 230 suitable for connecting an exemplary track and stud joist beam structure 234 to the modular building panels will first be described with reference to FIGS. 26-33. To start, an overview of the exemplary track and stud joist beam structure 234 will first be provided.

The exemplary track and stud joist beam structure 234 includes substantially identical first and second beam truss assemblies 236 and 238 that are positionable side by side in a substantially mirrored and symmetrical configuration. The first beam truss assembly 236 includes a top horizontal chord 240, a bottom horizontal chord 242 substantially parallel to the top horizontal chord 240, and first and second vertical end tracks 244 and 246 extending vertically between ends of the top and bottom chords 240 and 242. Web elements 248 extend diagonally between the top horizontal chord 240 and the bottom horizontal chord 242. Each of the truss members may be defined by U-track, boxed stud, or any other suitable standard track and stud framing components. The track and stud joist beam structure 234 may instead be any other configuration suitable for use with the modular building component connection assembly 230.

The modular building component connection assembly 230 is shown in detail in FIGS. 27-31. As generally noted above, the modular building component connection assembly 230 is configured as a knife plate assembly that is rigidly securable between adjacent, connected modular building panels 100 and having features configured to vertically support a track and stud beam structure, such as the exemplary track and stud joist beam structure 234.

The modular building component connection assembly 230 includes a main plate 252 that is substantially planar and rectangular in shape having an upper edge 254, a lower edge 256 opposite the upper edge 254, a first side edge 258, and a second side edge 260 opposite the first side edge. The main plate 252 is generally divided into first and second elongated halves, or a first elongated rectangular portion 262 and a second elongated rectangular portion 264.

As noted above, the modular building component connection assembly 230 is rigidly securable between adjacent, connected modular building panels and has features configured to vertically support a track and stud beam structure, such as the exemplary track and stud joist beam structure 234. In general, the modular building component connection assembly 230 includes a plurality of cross-plate features extending from first and second sides of the main plate 252 that are configured to engage portions of adjacent modular building panels 100 and portions of the track and stud joist beam structure 234 for structurally securing the track and stud joist beam structure 234 to joined, adjacent modular building panels 100. The cross-plate features are identical on both sides of the main plate 252; i.e., the modular building component connection assembly 230 is substantially symmetrical about a vertical axis extending along the length of the main plate 252 (see FIGS. 29 and 31).

The cross-plate features configured to engage portions of adjacent modular building panels 100 will first be described. Generally, the modular building component connection assembly 230 includes a plurality of vertical and horizontal cross-plate features configured to engage portions of adjacent modular building panels 100.

The horizontal and vertical cross-plate features configured to engage portions of adjacent modular building panels 100 may be defined by making openings (e.g., slits) in the main plate 252 that receive rectangularly shaped plates of substantially the same height and thickness. Substantially equal elongated parts of each rectangularly shaped plate may protrude through the corresponding slit on each side of the main plate 252. The rectangularly shaped plates may be thereafter welded to the main plate 252 or secured to the main plate in another manner.

In the exemplary embodiment, the modular building component connection assembly 230 includes first, second, third, and fourth vertical cross-plate members 268, 270, 272, and 274 extending from each side of the first elongated rectangular portion 262 along substantially a first vertical plane. The first vertical plane of the first, second, third, and fourth vertical cross-plate members 268, 270, 272, and 274 is substantially parallel to and spaced slightly inwardly from the first side edge 258 of the main plate 252.

The modular building component connection assembly 230 further includes fifth, sixth, seventh, and eighth vertical cross-plate members 276, 278, 280, and 282 extending from each side of the first elongated rectangular portion 262 along substantially a second vertical plane.

The second vertical plane of the fifth, sixth, seventh, and eighth vertical cross-plate members 276, 278, 280, and 282 is substantially parallel to and spaced slightly inwardly from the first vertical plane of the first, second, third, and fourth vertical cross-plate members 268, 270, and 272 (towards the second elongated rectangular portion 264).

The modular building component connection assembly 230 is positionable between adjacent modular building panels 100 such that the first, second, third, and fourth vertical cross-plate members 268, 270, 272, and 274 on each side of the main plate 252 engage and grip against the outer surface of the first elongated side 103 of the first or second vertical load-bearing member 106a or 106b of the first frame portion 102a of adjacent modular building panels 100. At the same time, the sixth, seventh, and eighth vertical cross-plate members 278, 280, and 282 engage and grip against the outer surface of the second partial elongated side 105 of the first or second vertical load-bearing member 106a or 106b of the first frame portion 102a of adjacent modular building panels 100.

The seventh vertical cross-plate members 282 may engage and grip against the outer surface of the second partial elongated side 105 of the first or second vertical load-bearing member 106a or 106b inside or otherwise covered by an intermediate purlin 113. In that regard the seventh vertical cross-plate members 282 may be received within pockets defined in open ends of the intermediate purlins 113 or of each of the adjacent modular building panels 100.

With the first, second, third, and fourth vertical cross-plate members 268, 270, 272, and 274 engaging the outer surface of the first elongated side 103 of the first or second vertical load-bearing member 106a or 106b and the sixth, seventh, and eighth vertical cross-plate members 278, 280, and 282 engaging the outer surface of the second partial elongated side 105 of the corresponding first or second vertical load-bearing member 106a or 106b, the first elongated rectangular portion 262 of the main plate 252 is effectively sandwiched between ends (and particularly, between first shortened sides 107 of the first and second vertical load-bearing members 106a and 106b) of adjacent modular building panels 100. When sandwiched between and gripping onto the adjacent modular building panels 100 in this manner, the modular building component connection assembly 230 can effectively resists moment loads of the track and stud joist beam structure 234 when secured thereto.

Additional support may be provided through engagement of the fourth vertical cross-plate member 276 with portions of the adjacent modular building panels 100. For instance, the fourth vertical cross-plate members 276 may be configured to engage and grip against the flange 112 of the top edge purlins 108a of the first frame portion 102a of adjacent modular building panels 100. The flange 112 of the top edge purlins 108a extends along and is connected to the outer surface of the second partial elongated side 105 of the corresponding first or second vertical load-bearing member 106a or 106b. In that regard, the fourth vertical cross-plate member 276 provides additional resistance of moment loads of the track and stud joist beam structure 234.

As noted above, the modular building component connection assembly 230 includes a plurality of horizontal cross-plate features configured to engage portions of adjacent modular building panels 100 or portions of the track and stud joist beam structure 234. The plurality of horizontal cross-plate features configured to engage portions of adjacent modular building panels 100 will first be described.

First horizontal cross-plate members 284 extend horizontally from an upper edge of each of the fourth vertical cross-plate members 276 toward the second elongated rectangular portion 264. The first horizontal cross-plate members 284 are configured to engage an exterior surface of a second partial elongated side 105 of the top edge purlins 108a of the first frame portion 102a of adjacent modular building panels 100. The first horizontal cross-plate members 284 include an opening for receiving a bolt of the corresponding edge purlin tensile connecting assembly 126. In this manner, a further structural connection is defined between the modular building component connection assembly 230 and the modular building panels 100 to help resist moments of the modular building component connection assembly 230 and/or vertical movements of the modular building component connection assembly 230 relative to the panels.

Second horizontal cross-plate members 286 extends horizontally from lower edges of the seventh vertical cross-plate members 282 toward the second elongated rectangular portion 264. The second horizontal cross-plate members 286 are configured to engage and rest upon an interior surface of a first short side 119a of intermediate purlins 113 of the adjacent modular building panels 100. In this regard, the seventh vertical cross-plate members 282 and the corresponding second horizontal cross-plate members 286 are together configured to be nested inside the pockets defined in open ends of the intermediate purlins 113 or of each of the adjacent modular building panels 100. An opening (not labeled) or other clearance may be defined in the main plate 252 to allow for pass-through of the bolt 128 of the intermediate purlin tensile connection assemblies 124.

Third horizontal cross-plate members 288 may extend horizontally from upper edges of the seventh vertical cross-plate members 282 toward the second elongated rectangular portion 264. The third horizontal cross-plate members 288 are spaced upwardly from the upper edges of the seventh vertical cross-plate members 282.

The vertical cross-plate members 268, 270, 272, 274, 276, 278, 280, and 288 as well as the horizontal cross-plate members 284, 288, and 286 are engaged with the corresponding portions of the first frame portion 102a of a first modular building panel 100 as described above. A second modular building panel 100 may then be joined with the first modular building panel 100 by engaging corresponding portions of the second modular building panel 100 within the vertical and horizontal cross-plate members of the modular building component connection assembly 230 and thereafter securing the adjacent intermediate purlins 113 and top and bottom edge purlins 108a and 108b with the intermediate purlin tensile connection assemblies 124 and edge purlin tensile connecting assembly 126, respectively. When the first and second modular building panels 100 are joined together, the first elongated rectangular portion 262 of the modular building component connection assembly 230 is effectively sandwiched between and rigidly retained within the first and second adjacent modular building panels 100 with the second elongated rectangular portion 264 protruding therefrom.

The protruding second elongated rectangular portion 264 includes cross-plate features configured to engage portions of the track and stud joist beam structure 234 for structurally securing the track and stud joist beam structure 234 to the joined modular building panel 100. In the depicted example, the modular building component connection assembly 230 includes a knife plate seat 292 that extends transversely from the second elongated rectangular portion 264 of the main plate 252. The knife plate seat 292 is configured to engage and support the top horizontal chord 240 and first vertical end track 244 of each of the first and second beam truss assemblies 236 and 238 of the track and stud joist beam structure 234.

The knife plate seat 292 may be configured as an angle iron extending transversely through the second elongated rectangular portion 264 of the main plate 252. In that regard, the knife plate seat 292 includes a horizontal portion 294 that extends toward the second side edge 260 of the main plate 252 from an upper edge of a substantially transverse vertical portion 298. The angle iron may extend through a correspondingly shaped and sized L-shaped opening in the main plate 252 (see FIG. 35) and may be secured thereto by welding or other suitable means.

When the first elongated rectangular portion 262 of the modular building component connection assembly 230 is sandwiched between adjacent modular building panels 100 as described above, the second elongated rectangular portion 264 together with the knife plate seat 292 protrude forwardly of the joined modular building panels 100. The track and stud joist beam structure 234 may be secured on the knife plate seat 292 to structurally secure the track and stud joist beam structure 234 to the modular building panels 100. More particularly, the first beam truss assembly 236 is slid onto or otherwise moved into engagement with substantially a first half of the knife plate seat 292, and the second beam truss assembly 238 is slid onto or otherwise moved into engagement with substantially a second half of the knife plate seat 292, as can be seen in FIG. 32.

Regarding the first beam truss assembly 236, the horizontal portion 294 of the first half of the knife plate seat 292 slides beneath and vertically supports the top horizontal chord 240 of the first beam truss assembly 236. At the same time, the substantially transverse vertical portion 298 of the first half of the knife plate seat 292 slides against the interior of the first vertical end track 244 of the first beam truss assembly 236. The second beam truss assembly 238 is secured to the second half of the knife plate seat 292 in a substantially identical manner.

The top horizontal chord 240 of each of the first and second beam truss assemblies 236 and 238 bear down on the knife plate seat 292, transferring loads to the modular building panels 100. Moreover, the substantially transverse vertical portion 298 of the knife plate seat 292 braces against the interior of the first vertical end track 244 of the first beam truss assembly 236, preventing the first beam truss assembly 236 from sliding forward off the horizontal portion 294.

The first and second beam truss assemblies 236 and 238 are secured to the knife plate seat 292 on either side of the main plate 252. In that regard, the main plate 252 defines a stop for engaging the first and second beam truss assemblies 236 and 238 with the knife plate seat 292. Moreover, as noted above, when the first elongated rectangular portion 262 of the modular building component connection assembly 230 is sandwiched between joined modular building panels 100, the plane of the main plate 252 is substantially centered with the seam or joint between the wall panels. The first and second beam truss assemblies 236 and 238 are thus structurally secured to the joined modular building panels 100 on each side of the modular building panel joint for a substantially even distribution of vertical loads to the joined panels.

The first and second beam truss assemblies 236 and 238 are retained on the knife plate seat 292 through the use of adjacent frame components. In a first aspect, the first and second beam truss assemblies 236 and 238 are substantially prevented from moving along an axis of the beam truss assemblies. More particularly, the top horizontal chord 240 of each beam truss assembly 236 and 238 is wedged between the substantially transverse vertical portion 298 of the knife plate seat 292 and the outer surface of the first elongated side 103 of the first or second vertical load-bearing member 106a or 106b of the first frame portion 102a of the modular building panels 100. In that regard, the first and second beam truss assemblies 236 and 238 are prevented from moving rearward axially off the knife plate seat 292. Further, as noted above, the beam truss assembly is prevented from sliding forward off the horizontal portion 294 by the interface of the substantially transverse vertical portion 298 of the knife plate seat 292 and the first vertical end track 244. As a result, the top horizontal chord 240 is retained between the knife plate seat 292 and the modular building panels 100 to substantially prevent axial movement of the first and second beam truss assemblies 236 and 238.

In a second aspect, the first and second beam truss assemblies 236 and 238 are substantially prevented from moving laterally, e.g., substantially transverse to the axis of the beam truss assemblies. As shown in FIG. 33, a lateral bracing horizontal panel 302 may interface with the top horizontal chord 240 of each of the first and second beam truss assemblies 236 and 238 to substantially prevent lateral movement. FIG. 33 only shows a lateral bracing horizontal panel 302 positioned against and laterally bracing the first beam truss assembly 236, but it can be appreciated that a substantially identical lateral bracing horizontal panel 302 may be used on the opposite side to laterally brace the second beam truss assembly 238. Yet forth, a single lateral bracing horizontal panel 302 may be adapted to laterally brace both first and second beam truss assemblies 236.

As shown in FIG. 33, the lateral bracing horizontal panel 302 includes an elongated frame member 306 that extends from a top surface of the top horizontal chord 240 to a top surface of another horizontal frame element, such as an upper end of a modular building panel 100. An infill frame member 310 is secured to a bottom surface of the elongated frame member 306 and extends along a portion of its length. The infill frame member 310 has a length such that a first end of the infill frame member abuts against a side surface of the top horizontal chord 240 of the first beam truss assembly 236.

At the same time, a second end of the infill frame member 310 abuts against a front surface of the other horizontal frame element, such as the first shortened side 107 of the top edge purlin 108a of a modular building panel 100. In that regard, the infill frame member 310, secured in its position by the elongated frame member 306, substantially prevents lateral movement/buckling of the first beam truss assembly 236. The elongated frame member 306 and infill frame member 310 may be identical in configuration to the intermediate purlins 113 for ease of construction, or any other suitable track and stud configuration.

The lateral bracing horizontal panel 302 may come in standard incremental lengths to accommodate frames of any size using the modular building panels 100 of predefined sizes. In that regard, the lateral bracing horizontal panel 302 may be simply slipped into engagement with the first beam truss assembly 236 and another horizontal frame element, such as a modular building panel 100, without the use of any fasteners.

Moreover, as noted above, when the first beam truss assembly 236 is secured to the joined, adjacent modular building panels 100 using the modular building component connection assembly 230, the top horizontal chord 240 is retained between the knife plate seat 292 and the modular building panels 100 to substantially prevent axial movement of the first and second beam truss assemblies 236 and 238. And of course, the first beam truss assembly 236 cannot move vertically downward when bearing down on the knife plate seat 292.

Further, the modular building component connection assembly 230 effectively resists moment loads of the first beam truss assembly 236 with its vertical and horizontal cross-frame members secured against portions of the joined modular building panels 100. Accordingly, it can be appreciated that the modular building component connection assembly 230 can structurally secure a horizontal frame element, such as the horizontal track and stud joist beam structure 234, to vertical frame elements, such as the vertical modular building panels 100, in a simple, toolless, modular, and secure manner.

Moreover, the modular building component connection assembly 230 can be used to secure horizontal and vertical framing elements of a modular building frame built in accordance with the modular building panels disclosed herein even after insulation is added to the modular panels. As can be appreciated, access to the interior of the adjacent modular building panels 100 is not needed for securing the modular building component connection assembly 230 thereto. Rather, the horizontal and vertical cross-plate features simply engage exposed portions of the adjacent modular building panels 100, such as the exposed faces of the intermediate purlins 113 and the top edge purlin 108a and the open-ended pockets of the purlins. Thus, using the modular building component connection assembly 230 for securing horizontal and vertical framing elements of a modular building frame can substantially reduce the cost and time to assemble the modular panel frame.

FIGS. 34-38 depict an alternative exemplary embodiment of a modular building component connection assembly 330. The modular building component connection assembly 330 is substantially similar to the modular building component connection assembly 230 described above except that the shape of the main plate is different (L-shaped versus rectangular) and the knife plate seat of the modular building component connection assembly 330 is not shown. Moreover, the modular building component connection assembly 330 does not include all the same vertical and horizontal cross-plate members as the modular building component connection assembly 230. As can be appreciated, any suitable combination of vertical and horizontal cross-plate members may be used for mating the modular building component connection assembly with an end of a modular building panel. Therefore, the similar parts of the modular building component connection assembly 330 are not individually labeled for brevity.

FIGS. 34 and 35 show how the modular building component connection assembly 330 is engaged with an end of a modular building panel 100 during assembly. The vertical and horizontal cross-plate members engage exterior surfaces and end pockets of the vertical load-bearing member of the modular building panel 100, as described above with respect to the modular building component connection assembly 230.

FIG. 36 shows a top view of the modular building component connection assembly 330 secured to joined modular building panels 100. As can be seen in FIG. 36, the modular building component connection assembly 330 is sandwiched between adjacent, joined modular building panel 100. Moreover, vertical cross-plate members of the modular building component connection assembly 330 abut against an exterior, rear surface of the vertical load-bearing members 106.

FIGS. 37 and 38 show a track and stud joist beam structure having only a single beam truss assembly secured to vertical frame elements at a corner of the frame. In particular, the modular building component connection assembly 230 and/or 330 may be used to secure a single beam truss assembly to a modular building panel of a standard incremental width (e.g., 4 feet wide and 1 foot deep) joined with a corner modular panel (e.g., one foot wide and 1 foot deep). The main plate of the modular building component connection assembly may be sandwiched between the ends of the standard modular building panel and the corner modular building panel in substantially the same manner as that described above. However, in the instance where a beam truss assembly is secured to vertical frame elements at a corner of the frame, the beam truss assembly is retained laterally on one side of the beam truss assembly by the other modular building panel defining the corner of the frame.

FIGS. 39 and 40 depict yet another alternative exemplary embodiment of a modular building component connection assembly 430 that may be used to structurally secure a beam truss assembly to joined, adjacent modular building panels.

FIGS. 41-43 depict yet another alternative exemplary embodiment of a modular building component connection assembly 530 that is substantially identical to the modular building component connection assembly 430 shown in FIGS. 39 and 40 except that it does not include a knife plate seat or the like. In that regard, the modular building component connection assembly 530 may be used to simply secure adjacent, modular building panels together and provide enhanced shear racking support to the panels.

FIGS. 44 and 45 depict yet another alternative exemplary embodiment of a modular building component connection assembly 630. The modular building component connection assembly 630 is substantially similar to the modular building component connection assembly 230 described above, except that it is configured to structurally securing a roof truss assembly 634 to joined, adjacent modular building panels 100. In that regard, similar parts may be labeled with the same reference numerals except in the '600 series.

Similar to the track and stud joist beam structure 234, the roof truss assembly 634 is defined by a pair of roof trusses 636 and 638 disposed side by side in mirrored configuration. Each of the roof trusses 636 and 638 includes top chords 640, a bottom chord 642, vertical web elements 648, and diagonal web elements 649 extending from an intersection of the bottom chord 642 and the vertical web elements 648 toward a top chord 640. Any other suitable roof truss structure may instead be used.

The modular building component connection assembly 630 may include a main plate 652 that is sandwiched between adjacent modular building panels 100 at its lower end and between vertical web elements 648 of the roof truss assembly 634 at its upper end. Suitable vertical and horizontal cross-plate members may extend from the main plate 652 for engaging with the modular building panels 100 and the vertical web elements 648.

A knife plate seat 692 extends transversely from both sides of the main plate 652 and is configured to engage the roof truss assembly 634 for vertical bracing. The knife plate seat 692 may also be defined by an angle iron, similar to the knife plate seat 292 described above. However, the knife plate seat 692 is inverted (upside down) compared to the knife plate seat 292. In this manner, each roof truss 636 and 638 may be slid into engagement with the knife plate seat 692 such that a horizontal portion of the knife plate seat 692 engages a top surface of the bottom chord 642 and a vertical portion of the knife plate seat 692 engages a side surface of a vertical web element 648, restraining the roof trusses 636 and 638 vertically.

The roof trusses 636 and 638 can be restrained laterally by disposing a lateral bracing horizontal panel adjacent to each roof truss, similar to that described above with respect to the lateral bracing horizontal panel 302 used for the track and stud joist beam structure 234. However, in the case of a roof truss, the lateral bracing horizontal panel is inverted (turned upside down) and installed from underneath the roof trusses. In this manner, an infill frame member of the lateral bracing horizontal panel can abut against a side surface of the bottom chord 642 of each roof truss. Fasteners can be used to secure the lateral bracing horizontal panel to framing components, seeing as gravity does not secure the lateral bracing horizontal panel in its location as is the case with the lateral bracing horizontal panel 302 used for the track and stud joist beam structure 234.

FIG. 46 shows a portion of a building frame constructed using modular building panels and modular building component connection assemblies formed in accordance with the present disclosure. Various different configurations of modular building component connection assembly are used to connect horizontal and vertical components of the building frame. As can be appreciated, the modular building component connection assemblies may be formed to have any configuration of horizontal and vertical cross-plate features and knife plate seats necessary for securing together horizontal and vertical components of the building frame. Moreover, components of the modular building component connection assemblies may be formed from heavy gauge steel (e.g., carbon steel flat plates), although any suitable material may be used.

FIG. 47 shows a lower story of a building frame assembled using modular building panels and associated connection assemblies in accordance with the present disclosure. Of note, a ceiling or sub-floor of the building frame may be defined with infill panels that are made from standard track and stud components, such as U-track members. FIG. 48 depicts exemplary infill panels. FIG. 49 depicts the building frame having roof trusses connected to the wall sections, such as by using the modular building component connection assembly 630 described above.

While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.

References in the specification to “one embodiment,” “an embodiment,” “an illustrative embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

As used herein, the terms “about” and “approximately,” in reference to a number, is used herein to include numbers that fall within a range of 10%, 5%, or 1% in either direction (greater than or less than) the number unless otherwise stated or otherwise evident from the context (except where such number would exceed 100% of a possible value).

Language such as “top”, “bottom”, “upper”, “lower”, “vertical”, “horizontal”, “lateral”, etc., in the present disclosure is meant to provide orientation for the reader with reference to the drawings and is not intended to be the required orientation of the components or to impart orientation limitations into the claims.

In the drawings, some structural or method features may be shown in specific arrangements and/or orderings. However, it should be appreciated that such specific arrangements and/or orderings may not be required. Rather, in some embodiments, such features may be arranged in a different manner and/or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all embodiments and, in some embodiments, it may not be included or may be combined with other features.

The terms used in this specification generally have their ordinary meanings in the art, within the context of the disclosure, and in the specific context where each term is used. Alternative language and synonyms may be used for any one or more of the terms discussed herein, and no special significance should be placed upon whether or not a term is elaborated or discussed herein. In some cases, synonyms for certain terms are provided. A recital of one or more synonyms does not exclude the use of other synonyms. The use of examples anywhere in this specification including examples of any terms discussed herein is illustrative only and is not intended to further limit the scope and meaning of the disclosure or of any example term.

Likewise, the disclosure is not limited to various example embodiments given in this specification. Unless otherwise defined, technical and scientific terms used herein have the meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. In the case of conflict, the present document, including definitions will control.

Note that titles or subtitles may be used in the examples for convenience of a reader, which in no way should limit the scope of the disclosure.

While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the disclosure.

Claims

1. A modular building frame panel, comprising:

a first frame portion, comprising: a first light gauge steel (LGS) vertical load-bearing member; a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins;

a second frame portion oriented one hundred and eighty degree (180°) about a vertical axis of the modular building panel relative to the first frame portion, comprising: a first light gauge steel (LGS) vertical load-bearing member; a second LGS vertical load-bearing member in a spaced substantially parallel relationship with the first LGS vertical load-bearing member; a top LGS edge purlin extending between upper ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the upper ends of the first and second LGS vertical load-bearing members; a bottom LGS edge purlin extending between lower ends of the first and second LGS vertical load-bearing members configured to provide shear resistance of the lower ends of the first and second LGS vertical load-bearing members; at least one LGS intermediate purlin extending transversely between the first and second LGS vertical load-bearing members and located vertically between the top and bottom LGS edge purlins; and

a plurality of cross-frame members extending transversely between the first and second LGS vertical load-bearing members of the first and second frame portions configured for rigidly maintaining the first and second frame portions in a substantially parallel, spaced relationship.

2. The modular building frame panel of claim 1, wherein the first and second LGS vertical load-bearing members, the top LGS edge purlin, and the bottom LGS edge purlin have substantially identical cross-sectional shapes and sizes.

3. The modular building frame panel of claim 2, wherein the cross-sectional shape of the first and second LGS vertical load-bearing members, the top LGS edge purlin, and the bottom LGS edge purlin are an open, substantially rectangular shape having an insertion opening defined on an elongated edge of the substantially rectangular shape.

4. The modular building frame panel of claim 3, wherein the upper and lower ends of the first and second LGS vertical load-bearing members are received within insertion openings of the top and bottom LGS edge purlins, respectively.

5. The modular building frame panel of claim 1, further comprising:

a first portion of an intermediate purlin tensile connection assembly defined at a first end of the at least one LGS intermediate purlin; and

a second portion of an intermediate purlin tensile connection assembly defined at a second end of the at least one LGS intermediate purlin, wherein the first portion of the intermediate purlin tensile connection assembly is configured to connect in tension to a second portion of an intermediate purlin tensile connection assembly of an adjacent modular building panel.

6. The modular building frame panel of claim 5, wherein the first and second portions of the intermediate purlin tensile connection assemblies are disposed on an interior of the at least one LGS intermediate purlin such that no portion of the first and second portions of the intermediate purlin tensile connection assemblies protrude from an exterior plane of the at least one LGS intermediate purlin, the exterior plane of the at least one LGS intermediate purlin substantially co-planar with an exterior plane of the top and bottom LGS edge purlins.

7. The modular building frame panel of claim 6, wherein the first portion of the intermediate purlin tensile connection assembly comprises:

a first intermediate purlin connection washer extending transversely across a width of the at least one LGS intermediate purlin, the first intermediate purlin connection washer received within slots defined in first and second opposing sides of the at least one LGS intermediate purlin; and

a bolt configured to extend transversely through the first intermediate purlin connection washer.

8. The modular building frame panel of claim 7, wherein the second portion of the intermediate purlin tensile connection assembly comprises:

a second intermediate purlin connection washer extending transversely across a width of the at least one LGS intermediate purlin, the second intermediate purlin connection washer received within slots defined in first and second opposing sides of the at least one LGS intermediate purlin, wherein the second intermediate purlin connection washer is configured to receive an end of the bolt; and

a nut configured to be secured on the end of the bolt after passing through second intermediate purlin connection washer.

9. The modular building frame panel of claim 8, further comprising an opening defined in an exterior planar surface of the at least one LGS intermediate purlin providing access to the bolt and nut.

10. The modular building frame panel of claim 1, wherein at least some of the plurality of cross-frame members define electrical conduits for the modular building panel.

11. The modular building frame panel of claim 1, further comprising:

a first portion of an edge purlin tensile connection assembly defined at a first end of the top LGS edge purlin and at a second end of the bottom LGS edge purlin; and

a second portion of an edge purlin tensile connection assembly defined at a second end of the top LGS edge purlin and at a first end of the bottom LGS edge purlin, wherein the first portion of the edge purlin tensile connection assembly is configured to connect in tension to a second portion of an edge purlin tensile connection assembly of an adjacent modular building panel.

12. The modular building frame panel of claim 11, wherein the first and second portions of the edge purlin tensile connection assemblies are disposed on an interior of the top and bottom LGS edge purlins such that no portion of the first and second portions of the edge purlin tensile connection assemblies protrude from an exterior plane of the top and bottom LGS edge purlins, the exterior plane of the top and bottom LGS edge purlins substantially co-planar with an exterior plane of the at least one LGS intermediate purlin.

13. The modular building frame panel of claim 12, wherein the first portion of the edge purlin tensile connection assembly includes a first edge purlin tensile connection washer assembly, and the second portion of the edge purlin tensile connection assembly includes a second edge purlin tensile connection washer assembly substantially identical to the first edge purlin tensile connection washer assembly,

wherein the first edge purlin tensile connection washer assembly is configured to exert a force against a first LGS vertical load-bearing member when it is pulled into tension with a second edge purlin tensile connection washer assembly of an adjacent modular building panel, and

wherein the second edge purlin tensile connection washer assembly is configured to exert a force against a second LGS vertical load-bearing member when it is pulled into tension with a first edge purlin tensile connection washer assembly of an adjacent modular building panel.

14. The modular building frame panel of claim 13, wherein the first edge purlin tensile connection washer assembly comprises:

a first washer having a substantially rectangular planar portion, a first flanged portion extending transversely from a first shortened end of the substantially rectangular planar portion, and a second flanged portion extending transversely from a second shortened end of the substantially rectangular planar portion, wherein upper and lower tabs are defined on each of the first and second flanged portions;

a second, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive upper tabs of each of the first and second flanged portions of the first washer; and

a third, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive lower tabs of each of the first and second flanged portions of the first washer,

wherein the second planar portion of each of the second and third planar washers is configured to exert a force against an LGS vertical load-bearing member when the first washer is pulled into tension with a first washer of a second edge purlin tensile connection washer assembly of an adjacent modular building panel.

15. The modular building frame panel of claim 14, further comprising a bolt configured to extend transversely through the first and second flanged portions of the first washer of the first edge purlin tensile connection washer assembly and a nut configured to be secured on the end of the bolt after passing through the first washer of the second edge purlin tensile connection washer assembly of an adjacent modular building panel.

16. The modular building frame panel of claim 15, further comprising openings defined in an exterior planar surface of each of the top and bottom edge purlins providing access to the bolt and nut.

17. The modular building frame panel of claim 14, wherein the second edge purlin tensile connection washer assembly comprises:

a first washer having a substantially rectangular planar portion, a first flanged portion extending transversely from a first shortened end of the substantially rectangular planar portion, and a second flanged portion extending transversely from a second shortened end of the substantially rectangular planar portion, wherein upper and lower tabs are defined on each of the first and second flanged portions;

a second, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive upper tabs of each of the first and second flanged portions of the first washer; and

a third, planar washer having a first planar portion extending along a length of the substantially rectangular planar portion and a second planar portion that is coplanar with the first planar portion and extends substantially from the first planar portion, wherein the first planar portion includes first and second slots configured to receive lower tabs of each of the first and second flanged portions of the first washer,

wherein the second planar portion of each of the second and third planar washers is configured to exert a force against an LGS vertical load-bearing member when the first washer is pulled into tension with a first washer of a first edge purlin tensile connection washer assembly of an adjacent modular building panel.

18. The modular building frame panel of claim 14, wherein the first edge purlin tensile connection washer assembly includes a fourth washer having a substantially rectangular planar portion, a first flanged portion extending transversely from a first shortened end of the substantially rectangular planar portion, and a second flanged portion extending transversely from a second shortened end of the substantially rectangular planar portion, wherein upper and lower tabs are defined on each of the first and second flanged portions, and wherein the fourth washer is configured to connect in tension to a fourth washer of a second edge purlin tensile connection washer of an adjacent modular building panel.

19. The modular building frame panel of claim 18, further comprising a bolt configured to extend transversely through the first and second flanged portions of the fourth washer of the first edge purlin tensile connection washer assembly and a nut configured to be secured on the end of the bolt after passing through first and second flanged portions of the fourth washer of the second edge purlin tensile connection washer assembly of an adjacent modular building panel.

20. The modular building frame panel of claim 19, wherein the fourth washer of the first edge purlin tensile connection washer assembly is disposed with an end of the first LGS vertical load-bearing member.

21-77. (canceled)