MODULAR HOUSING FRAMEWORK SYSTEM AND METHOD

A modular housing system includes a plurality of hollow steel section beam members of multiple standard lengths. Each hollow steel section beam member is designed to be coupled to at least one other hollow steel section beam member wherein the hollow steel beam members and are designed to form a rectangular frame assembly. The system includes at least four hub members designed to connect rectangular frame assemblies horizontally and vertically. Hub members couple multiple rectangular frame assemblies horizontally and solid tension rod members couple multiple rectangular frame assemblies vertically. Siding and roofing members may be preinstalled within a factory environment.

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Description
FIELD OF THE INVENTION

The inventive concept relates generally to a modular housing framework system and assembly method.

BACKGROUND

Potential homeowners may find buying a traditional home made using traditional construction techniques to be difficult. Even when potential buyers can receive the financing to buy the home, they face high taxes, upfront costs, and mortgage payments that may leave them living paycheck to paycheck. Rising prices may keep potential homeowners from being able to find homes they can afford.

Traditional housing construction techniques have many drawbacks. The most prevalent construction material, wood, is expensive. Materials must often be measured and prepared on site. Construction can take longer than non-traditional construction approaches, and traditional housing units may have unique design plans or design plans used a few times, limiting the opportunity to mass produce sections. Further, traditional housing construction techniques often require skilled workers specialized in building housing structures to codes, particularly when the parts assembled arrive on sites as only the fundamental basics of construction such as stacks of two-by-fours, plywood, nails, and ducts. Workers may require years of apprenticeship, and many specialists may be called upon to handle the sum of tasks required to complete a dwelling.

Other system, such as prefabricated housing and volumetric systems, may allow units to be constructed and moved to final assembly locations, but such transport may be difficult compared to panelized systems and shipping components in unassembled or less assembled states. Therefore, there is a need in the market for an easily transported and improved construction framework for housing that can produce structurally sound housing faster and with less specialized workers than traditional housing construction methods.

SUMMARY OF THE INVENTION

Disclosed is a modular housing system and method wherein the system includes a plurality of hollow steel section beam members having multiple different lengths and multiple members of each length. Each hollow steel section beam member is designed to be coupled to at least one other hollow steel section beam member wherein the hollow steel beam members are each of perpendicular to at least one other hollow steel beam member to which it is coupled and parallel to at least one other hollow steel beam member. The plurality of hollow steel beam members is designed to form a rectangular frame assembly. The system includes at least four hub members designed to connect rectangular frame assemblies horizontally and vertically.

The hub members can be of three varieties. Some may have singular couplers. Some may have double couplers. Some may have quadruple couplers. The couplers are at least one or more of disposed on a hub first side and disposed on a hub second side. Each coupler on the hub second side is axially aligned with a coupler on the hub first side wherein axially aligned. Hollow steel beam members may be correspondingly coupled to each side.

The at least four hub members each have a planar base. The planar base has a width and a length and at least one tapered protrusion member extending orthogonally outward from the planar base. Each of the at least one tapered protrusion members is designed to extend at least partially within an end of a hollow steel section beam member, coupling the given hollow steel beam member to the given coupler. A cylindrical hole member is disposed through an axial center portion of each protrusion member and orthogonal to the planar base of its hub member.

The system includes a plurality of solid tension rod members. The solid tension rod members are designed to be at least partially disposed through the at least one cylindrical hole member of at least one protrusion member. Each solid tension rod member is linearly coupling at least one coupler and at least one hollow steel section beam member along a central axis defined by the given solid tension rod member. The solid tension rod members are designed to extend from an uppermost end to a lowermost end of at least one rectangular frame, linearly coupling vertically aligned coupler hollow steel beam members of the coupled rectangular frame assemblies.

In some embodiments of the modular housing system, two or more frames are coupled at least one or more of vertically and horizontally and are interiorly navigable by at least one or more of a doorway, a horizontal opening, a stairway, and an elevator to leave interiorly accessible to a user at least two rectangular frame assemblies.

In some embodiments of the modular housing system, a preinstalled roof member is coupled to the upper hollow steel section beam members and top joist members of given rectangular frame assemblies. Preinstalled means installed away from a final assembly, typically in a factory.

In some embodiments of the modular housing system, a parapet roof member is coupled to the top rectangular frame assemblies of at least one rectangular frame assembly.

In some embodiments of the modular housing system, the rectangular frame assembly includes a plurality of horizontally disposed joist members and a plurality of vertically disposed wall stud members.

In some embodiments of the modular housing system, panel members are coupled to the rectangular frame assemblies to create exterior wall members, the exterior wall members wrapped in magnesium oxide board sheathing.

In some embodiments of the modular housing system, the protrusion member of each hub assembly protrudes at least three inches from the planar base.

In some embodiments of the modular housing system, at least one or more of a hollow steel beam member, a joist member, and a wall stud member is disposed at a non-vertical and non-horizontal angle to other hollow steel beam members, joist members, and wall stud members and are designed to create at least one triangular frame portion of the rectangular frame assembly.

The modular housing system and corresponding methods now will be described more fully hereinafter with reference to the accompanying drawings, which are intended to be read in conjunction with both this summary, the detailed description and any preferred and/or particular embodiments specifically discussed or otherwise disclosed. Inventive concepts may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete, and will fully convey the full scope of the inventive concepts to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates a side view of a representative hollow steel section beam member;

FIG. 1B illustrates representative hollow steel section beam members having different sizes;

FIG. 1C illustrates a top view of the representative hollow steel section beam member;

FIG. 2 illustrates a representative construction of a rectangular frame assembly;

FIG. 3A illustrates a side view of a hub member with a single coupler on one side;

FIG. 3B illustrates a perspective view of a hub member with a single coupler on one side;

FIG. 3C illustrates a top view of a hub member with a single coupler on one side;

FIG. 3D illustrates a side view of a hub member with a single coupler on each of two sides;

FIG. 3E illustrates a perspective view of a hub member with two couplers on one side;

FIG. 3F illustrates a top view of a hub member with two couplers on one side;

FIG. 3G illustrates a side view of a hub member with two couplers on each of two sides;

FIG. 3H illustrates a perspective view of a hub member with four couplers on one side;

FIG. 3I illustrates a top view of a hub member with four couplers;

FIG. 3J illustrates a side view of a hub member with four couplers on one side;

FIG. 3K illustrates a side view of a hub member with four couplers on each of two sides;

FIGS. 4A-4I illustrate as sequence of assembling a single rectangular frame;

FIGS. 5A-5J illustrate a sequence of assembling rectangular frame assemblies together;

FIG. 6 illustrates inserting a solid tension rod member axially through a hub member and a hollow steel section beam member;

FIG. 7A illustrates a side view of four connected rectangular frame assemblies;

FIG. 7B illustrates a side view of four connected rectangular frame assemblies illustrating further stairway assemblies;

FIG. 7C illustrates a side view of four connected rectangular frame assemblies illustrating an elevator assembly;

FIG. 8 illustrates a rectangular frame assembly with a representative diagonal hollow steal beam member;

FIGS. 9A-9C illustrate a representative method for constructing a modular housing system;

FIGS. 10A-10C illustrate a representative method for constructing a modular housing system;

FIG. 11 illustrates an associated interlocking waterproof assembly;

FIG. 12 illustrates coupling hollow steal section beam members with a hub member.

 DETAILED DESCRIPTION OF THE INVENTION

Following are more detailed descriptions of various related concepts related to, and embodiments of, methods and apparatus according to the present disclosure. It should be appreciated that various aspects of the subject matter above and discussed in greater detail below may be implemented in any of numerous ways, as the subject matter is not limited to any particular manner of implementation. Examples of specific implementations and applications are provided primarily for illustrative purposes.

The inventive concept is a modular structural system designed to maximize the assembly of building components and systems in a factory environment. The inventive concept is designed to minimize on-site installation of roofing, glazing, window and door installation, waterproofing and structural steel welding. In addition, the interlocking of modules, a module being a complete housing unit, is accomplished in the vertical direction via post-tensioning rods and horizontally with custom fabricated steel corner plate hub members. Waterproofing of these modules is achieved through the custom fabrication of an interlocking components. Collectively, the inventive concept is designed to reduce on-site labor and costs while maximizing the number of factory-installed building components used in proportion to those installed on an installation site.

Benefits of the system and associated method include, but are not limited to, a factory installed roof that reduces the need for a roofing trade with workers on-site and includes integral gutters and MEP vents that can be installed in the factory. Roofing has waterproofing of horizontal to vertical components is also designed to happen in a factory, including a parapet to unitized facade connection, a gutter to roof connection, and a parapet-to-parapet connection done on an installation site with parapet cap. Resulting benefits include eliminate time required to do roof installations on module installation sites and eliminating a need to stop other on-site work impacted by roofing, equipment, smell of petroleum-based tar results, increasing speed of construction overall.

Disclosed, therefore, is a representative modular housing system including a plurality of hollow steel section beam members 100 having multiple different lengths and multiple members of each length. Each hollow steel section beam member 100 is designed to be coupled to at least one other hollow steel section beam member 100 wherein hollow steel beam members 100 are each of perpendicular to at least one other hollow steel beam member 100 to which they are coupled and parallel to at least one other hollow steel beam member 100.

As illustrated in FIG. 2, the plurality of hollow steel beam members 100 is designed to form rectangular frame assembly 200, further illustrated in 4A-4J. The system includes at least four hub members 300 designed to connect rectangular frame assemblies 200 horizontally and vertically.

FIGS. 3A-3K illustrate varied hub members 300A, 300B, 300C with couplers 310 that can be of three varieties. 300A has singular couplers 310. 300B has double couplers 310. 300C has quadruple couplers 310. Couplers 310 are at least one or more of disposed on hub first side 301 and disposed on hub second side 302. Each coupler 310 on hub second side 302 is axially aligned with a coupler 310 on hub first side 301. Hollow steel beam members 100 may be correspondingly coupled to each side hub member side 301, 302.

FIGS. 3A-3K illustrate the at least four hub members 300A, 300B, 300C each having planar bases 350. Planar bases 350 have a width and a length and at least one tapered protrusion member 375 extending orthogonally outward from planar base 350. Each of the at least one tapered protrusion members 375 is designed to extend at least partially within an end of hollow steel section beam members 101A, 101B, coupling given hollow steel beam members 100 to given couplers 310. Cylindrical hole members 380 are disposed through axial center portions 385 of protrusion member 375 and orthogonal to the given planar base 350 of the axial center portions 385 of their hub members 300A, 300B, 300C, further illustrated in FIG. 6. In some embodiments of the modular housing system, protrusion members 375 of each hub assembly 300A, 300B, 300C protrudes at least three inches from planar base 350.

FIGS. 4A-4J illustrate a sequence of assembling a single rectangular frame assembly 200 into assemblies of rectangular frame assemblies 200. The system includes a plurality of solid tension rod members 400. Solid tension rod members 400 are designed to be at least partially disposed through at least one cylindrical hole member 380 of at least one protrusion member 375. Each solid tension rod member 400 is linearly coupling at least one coupler 310 and at least one hollow steel section beam member 100 along central axis 382 defined by given solid tension rod members 400, central axes 382 linearly aligned with axial center portions 385. Solid tension rod members 400 are designed to extend from an uppermost end of at least one rectangular frame assembly 210 to a lowermost end of at least one rectangular frame assembly 290, linearly coupling vertically aligned couplers 310 and hollow steel beam members 100 of coupled rectangular frame assemblies 200.

FIGS. 4A to 4J further illustrate that in some embodiments of the modular housing system, rectangular frame assemblies 200 include a plurality of horizontally disposed upper joist members 441, a plurality of horizontally disposed lower joist members 449, and a plurality of vertically disposed wall stud members 460.

FIGS. 5A-5J illustrate that in some embodiments of the modular housing system, two or more frames 200 are coupled, as illustrated in FIG. 7A-7B, at least one or more of vertically and horizontally and are interiorly navigable by at least one or more of doorway 710, horizontal opening 720, stairway 730, and an elevator 740, to leave at least two rectangular frame assemblies 200 interiorly accessible to a user.

FIG. 4G illustrates that in some embodiments of the modular housing system, preinstalled roof member 430 is coupled to upper hollow steel section beam members 110 and top joist members of given rectangular frame assemblies 200. Preinstalled means installed away from a final assembly, typically in a factory.

As illustrated in FIG. 4I, in some embodiments of the modular housing system, parapet roof member 440 is coupled atop at least one rectangular frame assembly 200. In some embodiments of the modular housing system, panel members are coupled to rectangular frame assemblies 200 to create exterior wall members 470, exterior wall members 470 wrapped in magnesium oxide board sheathing 475.

FIG. 8 illustrates that in some embodiments of the modular housing system, at least one or more of hollow steel beam members 100, joist members 441, 442, and wall stud members 460 are disposed at a diagonal (non-vertical and non-horizontal) angle to other hollow steel beam members 100, joist members 441, 442, and wall stud members 460 and are designed to create at least one triangular frame portion of rectangular frame assembly 200. Illustrated is a representative diagonal hollow steel beam member 800.

FIGS. 9A-9C illustrates a representative method for constructing the modular housing system having step 900, coupling the plurality of hollow steel section beam members 100 having multiple different lengths and multiple members of each length, each hollow steel section beam member 100 coupled to at least one other hollow steel section beam member 100 wherein hollow steel beam members 100 are each of perpendicular to at least one other hollow steel beam member 100 to which it is coupled and parallel to at least one other hollow steel beam member 100, the plurality of hollow steel beam members 100 forming rectangular frame assemblies 200. The modular housing system includes step 905, coupling at least one rectangular frame assembly 200 with at least one second rectangular frame assembly 200, rectangular frame assembly 200 coupled with hub members 300A, 300B, 300C on each abutting corner, each hub member retaining at least one vertically aligned and adjacent hollow steel section beam member 100 vertically and horizontally. Tapered protrusion members 375 extend at least partially within the end of hollow steel section beam members 101A, 101B coupling given hollow steel beam members 100 to the given coupler 310.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system includes step 910, vertically inserting at least one solid tension rod member 400 through corresponding cylindrical hole members 380 disposed through axial center portion 385 of each protrusion member 375 and orthogonal to planar base 350 of given hub members 300A, 300B, 300C, disposing solid tension rod members 400 further through corresponding coupled hollow steel section beam members 100, securing, therefore, corresponding vertically aligned couplers 310 and hollow steel section beam members 100 along central axes 382 defined by given solid tension rod members 400, solid tension rod members 400 extending from uppermost ends of at least one rectangular frame assembly 210 to lowermost ends of at least one rectangular frame assembly 290.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system includes step 915, coupling at least two rectangular frame assemblies 200, creating and aligning at least one or more rectangular frame assemblies 200 vertically and horizontally with at least one or more of doorway 710, horizontal opening 720, stairway 730, and elevator 740, interiorly connecting two or more rectangular frame assemblies 200 for navigation by users.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system may further include step 920, preinstalling roof member 430 by coupling roof member 430 to upper steel section beam members 100 and top joist members 441 of given rectangular frame assemblies 200.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system may further include step 925, coupling parapet roof member 440 to top hollow steel section beam members 100 and top joist members 441 of at least one rectangular frame assembly 200.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system may further include step 930, installing the plurality of horizontally disposed joist members 441, 442 and the plurality of vertically disposed wall studs, coupling joist members 441, 442 and wall stud members 460 to hollow steel section beam members 100.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system may further include step 935, coupling panel members to rectangular frame assemblies 200 to create exterior wall members 470 and wrapping exterior wall members 470 with magnesium oxide board sheathing 475.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system may further include step 940, inserting at least one protrusion member 375 of at least one hub member planar base 350 at least three inches into given corresponding hollow steel section beam members 100.

FIGS. 9A-9C further illustrate the representative method for constructing the modular housing system may further include step 945, designing construction plans from at least one or more of standard and custom plans and providing from the plans the guide, sequence, and schedule for assembly.

FIGS. 10A-10C illustrate another representative method for constructing a modular housing system, the method including step 1000, coupling within a factory the plurality of hollow steel section beam members 100 having multiple different lengths and multiple members of each length, each hollow steel section beam member 100 coupled to at least one other hollow steel section beam member 100 wherein hollow steel beam members 100 are each perpendicular to at least one other hollow steel beam member 100 to which it is coupled and parallel to at least one other hollow steel beam member 100, the plurality of hollow steel beam members 100 forming rectangular frame assemblies 200.

FIGS. 10A-10C further illustrate another representative method for constructing a modular housing system including step 1005, the method installing within the factory the plurality of horizontally disposed joist members 441, 442 and the plurality of vertically disposed wall studs 460, coupling joist members 441, 442 and wall studs 460 to hollow steel section beam members 100. The method for constructing the modular housing system including step 1010, installing within the factory the roof members 430 by coupling roof members 430 to upper steel section beam members 100 and top joist members 441, 442 of given rectangular frame assemblies 200. The method for constructing the modular housing system further includes step 1015, coupling within the factory exterior wall members to rectangular frame assemblies 200 wrapping the exterior wall members 470 with magnesium oxide board sheathing 475.

FIGS. 10A-10C further illustrate this representative method for constructing a modular housing system, including step 1020, coupling on the installation sight at least one rectangular frame assembly 200 with at least one second rectangular frame assembly 200, rectangular frame assemblies 200 coupled with hub members 300A, 300B, 300C on each abutting corner, each hub member retaining at least one vertically aligned and adjacent hollow steel section beam members 100 vertically and horizontally, constructing at least one rectangular frame assembly 200 at least one or more of horizontally and vertically, tapered protrusion members 375 extending at least partially within the end of hollow steel section beam members 101A, 101B coupling given hollow steel beam members 100 to given couplers 310.

FIGS. 10A-10C further illustrate this representative method for constructing a modular housing system, including step 1025, vertically inserting on the installation site at least one solid tension rod member 400 through corresponding cylindrical hole members 380 disposed through axial center portions 385 of each protrusion member 375 and orthogonal to planar bases 350 of given hub members 300A, 300B, 300C, disposing solid tension rod members 400 further through corresponding coupled hollow steel section beam members 100, securing, therefore, corresponding vertically aligned couplers 310 and hollow steel section beam members 100 along central axes 382 defined by given solid tension rod members 400, solid tension rod members 400 extending from uppermost end of at least one rectangular frame assembly 210 to lowermost end of at least one rectangular frame assembly 290.

FIGS. 10A-10C further illustrate this representative method for constructing a modular housing system, including step 1030, coupling on the installation site at least two rectangular frame assemblies 200, creating and aligning at least one or more rectangular frame assemblies 200 vertically and horizontally with at least one or more of doorway 710, horizontal opening 720, stairway 730, and elevator 740, interiorly connecting two or more rectangular frame assemblies 200 for navigation by users.

FIGS. 10A-10C further illustrate this representative method may include the step 1035, inserting on the installation site at least one protrusion member 375 of at least one hub member planar base 350 at least three inches into given corresponding hollow steel section beam members 100.

FIGS. 10A-10C further illustrate this representative method may include the step 1040, designing construction plans from at least one or more of standard and custom plans and providing from the plans the guide, sequence, and schedule for assembly.

FIG. 11 illustrates that the inventive concept may include a unitized facade that can eliminate scaffolding, exterior wall caulked joints, on-site work related to window and facade installation and includes on-site installed interlocking waterproof “chicken head” assembly 1100.

FIG. 12 illustrates a representative coupling of hollow steal section beam members 100 with hub member 300B.

The following patents are incorporated by reference in their entireties: U.S. Pat. Nos. 5,092,099A, 6,892,504B1, 9,121,168B2, US20090307994A1, US20140298745A1, US20160160515A1, US20200332513A1, JP2019052534A, and WO201268800A1.

While inventive concepts have been described above in terms of specific embodiments, it is to be understood that the inventive concepts are not limited to these disclosed embodiments. Upon reading the teachings of this disclosure, many modifications and other embodiments of the inventive concepts will come to mind of those skilled in the art to which these inventive concepts pertain, and which are intended to be and are covered by both this disclosure and the appended claims. It is indeed intended that the scope of the inventive concepts should be determined by proper interpretation and construction of the appended claims and their legal equivalents, as understood by those of skill in the art relying upon the disclosure in this specification and the attached drawings.

The assembly sequence of the inventive concept includes such elements as:

    • 1. Heavy Gauge Steel Bottom Rail Steel Beams to create floor frame
    • 2. Steel Columns
    • 3. Top Rail Beams
    • 4. Light gauge metal floor joists
    • 5. Light gauge metal ceiling/roof joists
    • 6. Light gauge metal wall studs with framed openings for doors, windows, etc.
    • 7. Floor, Ceiling/Roof & Exterior sheathing
    • 8. Rough Electrical—testing of all wiring
    • 9. Install Electric Panels and subpanels
    • 10. Rough Plumbing—pressure test of all piping
    • 11. Install PEX Manifolds
    • 12. Rough Mechanical—pressure test/charge of freon line test
    • 13. Windows & Window Frames
    • 14. Fixed Glazing
    • 15. Doors & thresholds
    • 16. Insulation, caulking, waterproofing
    • 17. Roofing
    • 18. Exterior Finishes—building wrap/rainscreen/Unitized facade
    • 19. Wall & ceiling panels
    • 20. Millwork/cabinets
    • 21. Finish Flooring
    • 22. Finish Electrical
    • 23. Finish Plumbing
    • 24. Finish Mechanical & charge freon/condensing units
    • 25. Finish paint, stain, accessories
    • 26. Door hardware & locks—final install & keyed lock testing
    • 27. Module Wrap for transport

Terms accorded to the inventive concept, which may be synonymous with one or more if the industry terms, include:

    • 100 hollow steel section beam member
    • 101 end of a hollow steel section beam member
    • 200 rectangular frame assembly
    • 210 uppermost end of rectangular frame assembly
    • 290 lowermost end of rectangular frame assembly
    • 300A hub member with single coupler
    • 300B hub member with double coupler
    • 300C hub member with quadruple coupler
    • 310 coupler
    • 350 hub member planar base
    • 375 tapered protrusion member
    • 380 cylindrical hole member
    • 385 central axis of hub member
    • 400 solid tension rod member
    • 430 preinstalled roof member
    • 440 parapet roof member
    • 441 horizontally disposed upper joist member
    • 449 horizontally disposed upper joist member
    • 460 vertically disposed wall stud
    • 470 exterior wall members
    • 475 magnesium oxide board sheathing
    • 710 horizontal opening
    • 720 doorway
    • 730 stairway
    • 800 diagonal hollow steel beam member

Claims

1. A modular housing system comprising:

a plurality of hollow steel section beam members having multiple different lengths and multiple members of each length;
each hollow steel section beam member adapted to be coupled to at least one other hollow steel section beam member wherein the hollow steel beam members are each of perpendicular to at least one other hollow steel beam member to which it is coupled and parallel to at least one other hollow steel beam member, the plurality of hollow steel beam members adapted to form a rectangular frame;
at least four hub members adapted to connect rectangular frame assemblies horizontally and vertically;
the hub members having at least one or more singular, double, and quadruple couplers, the couplers at least one or more of disposed on a hub first side and disposed on a hub second side, each coupler on the hub second side axially aligned with a coupler on the hub first side wherein axially aligned, hollow steel beam members may be correspondingly coupled to each side;
the at least four hub members each having a planar base, the planar base having a width and a length and at least one tapered protrusion member extending orthogonally outward from the planar base, each of the at least one tapered protrusion member adapted to extend at least partially within an end of a hollow steel section beam member, coupling the given hollow steel beam member to the given coupler;
a cylindrical hole member disposed through an axial center portion of each protrusion member and orthogonal to the planar base of its hub member;
a plurality of solid tension rod members, the solid tension rod members adapted to be at least partially disposed through at least one cylindrical hole member of at least one protrusion member, each solid tension rod member linearly coupling at least one coupler and at least one hollow steel section beam member along a central axis defined by the given solid tension rod member, the solid tension rod member adapted to extend from an uppermost end to a lowermost end of at least one rectangular frame, linearly coupling vertically aligned coupler hollow steel beam members of the coupled rectangular frame assemblies.

2. The modular housing system of claim 1 wherein two or more frames are coupled at least one or more of vertically and horizontally, interiorly navigable by at least one or more of a doorway, a horizontal opening, a stairway, and an elevator to leave interiorly accessible to a user at least two rectangular frame assemblies.

3. The modular housing system of claim 2 wherein a preinstalled roof member is coupled to the upper hollow steel section beam members and top joist members of given rectangular frame assemblies.

4. The modular housing system of claim 2 wherein a parapet roof member is coupled to the top rectangular frame assemblies of at least one rectangular frame assembly.

5. The modular housing system of claim 1 wherein the rectangular frame assembly includes a plurality of horizontally disposed joist members and a plurality of vertically disposed wall stud members.

6. The modular housing system of claim 1 wherein comprising panel members are coupled to the rectangular frame assemblies to create exterior wall members, the exterior wall members wrapped in magnesium oxide board sheathing.

7. The modular housing system of claim 1 wherein the protrusion member of each hub assembly protrudes at least three inches from the planar base.

8. The modular housing system of claim 1 wherein at least one or more of a hollow steel beam member, a joist member, and a wall stud member is disposed at a non-vertical and non-horizontal angle to other hollow steel beam members, joist members, and wall stud members and are adapted to create at least one triangular frame portion of the rectangular frame assembly.

9. A method for constructing a modular housing system, the method comprising:

coupling a plurality of hollow steel section beam members having multiple different lengths and multiple members of each length, each hollow steel section beam member coupled to at least one other hollow steel section beam member wherein the hollow steel beam members are each of perpendicular to at least one other hollow steel beam member to which it is coupled and parallel to at least one other hollow steel beam member, the plurality of hollow steel beam members forming a rectangular frame;
coupling at least one rectangular frame assembly with at least one second rectangular frame, the rectangular frame assemblies coupled with hub members on each abutting corner, each hub member retaining at least one vertically aligned and adjacent hollow steel section beam members vertically and horizontally, constructing at least one rectangular frame assembly at least one or more of horizontally and vertically, tapered protrusion members extending at least partially within an end of a hollow steel section beam member, coupling the given hollow steel beam member to the given coupler; and
vertically inserting at least one solid tension rod member through corresponding cylindrical hole members disposed through an axial center portion of each protrusion member and orthogonal to the planar base of the given hub members, disposing the solid tension rod member further through corresponding coupled hollow steel section beam members, securing, therefore, corresponding vertically aligned couplers and hollow steel section beam members along a central axis defined by the given solid tension rod members, solid tension rod members extending from an uppermost end to a lowermost end of at least one rectangular frame assembly.

10. The method for constructing a modular housing system of claim 9, the method including coupling at least two rectangular frame assemblies, creating and aligning at least one or more rectangular frame assemblies vertically and horizontally with at least one or more of a doorway, a horizontal opening, a stairway, and an elevator, interiorly connecting two or more frames for navigation by users.

11. The method for constructing a modular housing system of claim 9, the method including preinstalling a roof member by coupling the roof member to upper steel section beam members and top joist members of the given rectangular frame assemblies.

12. The method for constructing a modular housing system of claim 9, the method including coupling a parapet roof member to top hollow steel section beam members and top joist members of at least one rectangular frame assembly.

13. The method for constructing a modular housing system of claim 9, the method including installing a plurality of horizontally disposed joist members and a plurality of vertically disposed wall studs, coupling the joist members and wall studs to hollow steel section beam members.

14. The method for constructing a modular housing system of claim 9, the method including coupling exterior wall members to the rectangular frame assemblies to create exterior wall members and wrapping the exterior wall members with magnesium oxide board sheathing.

15. The method for constructing a modular housing system of claim 9, the method including inserting the at least one protrusion member of the at least one hub member planar base at least three inches into given corresponding hollow steel section beam members.

16. The method for constructing a modular housing system of claim 9, the method including designing construction plans from at least one or more of standard and custom plans and providing from the plans a guide, sequence, and schedule for assembly.

17. A method for constructing a modular housing system, the method comprising:

coupling within a factory a plurality of hollow steel section beam members having multiple different lengths and multiple members of each length, each hollow steel section beam member coupled to at least one other hollow steel section beam member wherein the hollow steel beam members are each of perpendicular to at least one other hollow steel beam member to which it is coupled and parallel to at least one other hollow steel beam member, the plurality of hollow steel beam members forming a rectangular frame;
installing within the factory a plurality of horizontally disposed joist members and a plurality of vertically disposed wall studs, coupling the joist members and wall studs to hollow steel section beam members;
installing within the factory a roof member by coupling the roof member to upper steel section beam members and top joist members of the given rectangular frame assemblies;
coupling within the factory exterior wall members to the rectangular frame assemblies to create exterior wall members and wrapping the exterior wall members with magnesium oxide board sheathing;
coupling on an installation site at least one rectangular frame assembly with at least one second rectangular frame, the rectangular frame assemblies coupled with hub members on each abutting corner, each hub member retaining at least one vertically aligned and adjacent hollow steel section beam members vertically and horizontally, constructing at least one rectangular frame assembly at least one or more of horizontally and vertically, tapered protrusion members extending at least partially within an end of a hollow steel section beam member, coupling the given hollow steel beam member to the given coupler; and
vertically inserting on an installation site at least one solid tension rod member through corresponding cylindrical hole members disposed through an axial center portion of each protrusion member and orthogonal to the planar base of the given hub members, disposing the solid tension rod member further through corresponding coupled hollow steel section beam members, securing, therefore, corresponding vertically aligned couplers and hollow steel section beam members along a central axis defined by the given solid tension rod members, the solid tension rod members extending from an uppermost end to a lowermost end of at least one rectangular frame assembly.

18. The method for constructing a modular housing system of claim 17, the method including coupling on the installation site at least two rectangular frame assemblies, creating and aligning at least one or more rectangular frame assemblies vertically and horizontally with at least one or more of a doorway, a horizontal opening, a stairway, and an elevator, interiorly connecting two or more frames for navigation by users.

19. The method for constructing a modular housing system of claim 17, the method including inserting on the installation site the at least one protrusion member of the at least one hub member planar base at least three inches into given corresponding hollow steel section beam members.

20. The method for constructing a modular housing system of claim 17, the method including designing construction plans from at least one or more of standard and custom plans and providing from the plans a guide, sequence, and schedule for assembly.

Patent History
Publication number: 20240191496
Type: Application
Filed: Dec 8, 2022
Publication Date: Jun 13, 2024
Inventors: THOMAS TIMMONS (MEDFORD, OR), PETER DEMARIA (AUSTIN, TX), ANDREW TYLER HENRY-THOMPSON (AUSTIN, TX), ERIC CORBETT (THOUSAND OAKS, CA)
Application Number: 18/077,659
Classifications
International Classification: E04B 1/348 (20060101);