MODULAR CONSTRUCTION STRUCTURES AND ASSOCIATED BUILDINGS AND METHODS

A building includes a base structure with a floor and foundation, defining a cavity between them. The core structure extends vertically from the floor, while an exterior wall is made up of modular wall segments each having the same width and height. Main utilities are located within the core structure, and at least one set of utilities in the modular wall segment is connected to these main utilities through the cavity defined by the base structure.

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Description
CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. Patent Application Serial No. 19/366,217, filed October 22, 2025, which claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Serial No. 63/710,732, filed October 23, 2024, the disclosure of each of which is hereby incorporated herein in its entirety by this reference.

TECHNICAL FIELD

Embodiments of the present disclosure generally relate to modular construction structures. In particular, embodiments of the present disclosure relate to modular construction structures and associated buildings and methods.

BACKGROUND

Buildings, such as houses and commercial buildings, include multiple walls defining the space within the associated structure. Some buildings may be built using modular construction. Modular construction uses prefabricated structures to construct the associated structure. For example, walls, ceilings, roofs, floors, or even complete rooms, may be fabricated in a remote location, such as a factory or construction yard and then transported to the location of the associated building, where the prefabricated structures are assembled to construct the associated building.

Modular construction may increase efficiency of the construction of a building. For example, building the modular structures in a factory or construction yard may facilitate building the structures in a more efficient manner. Furthermore, all the raw materials may be handled at the factory or construction yard, which may reduce the transportation or shipping costs.

BRIEF SUMMARY

Embodiments of the disclosure include a building. The building includes a base structure including a floor and a foundation, the base structure defining a cavity between the floor and the foundation. The building further includes a core structure extending vertically from the floor of the base structure. The building also includes an exterior wall including modular wall segments, the modular wall segments each having a same width and height. The building further includes main utilities positioned within the core structure. The building also includes utilities positioned in at least one modular wall segment of the modular wall segments forming the exterior wall, the utilities in the at least one modular wall segment connected to the main utilities in the core structure through the cavity defined in the base structure.

Another embodiment of the disclosure includes a modular wall structure. The modular wall structure includes a framework. The framework includes studs, spacers positioned between the studs, a termination structure on an end of the framework, and a recess including a bridge and vertical flange defined in the termination structure of the framework.

Other embodiments of the disclosure include a method of constructing a building. The method includes forming a core structure at the building. The method further includes installing main utilities within the core structure. The method also includes forming an exterior modular wall structure in a remote location. The exterior modular wall structure includes a framework, and utilities secured to the framework. The method further includes forming a modular lateral wall structure at the remote location. The lateral wall structure includes a lateral framework and lateral utilities secured to the lateral framework securing the modular wall structure to the modular lateral wall structure at the building. The lateral wall structure extends between the exterior modular wall structure and the core structure. The method also includes connecting the utilities in the exterior modular wall structure to the main utilities through the lateral utilities.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming embodiments of the present disclosure, the advantages of embodiments of the disclosure may be more readily ascertained from the following description of embodiments of the disclosure when read in conjunction with the accompanying drawings in which:

FIGS. 1-6 illustrate perspective views of a structure in various stages of construction in accordance with embodiments of the disclosure;

FIG. 7 illustrates an exploded view of an exterior wall of the structure of FIGS. 1-6 in accordance with embodiments of the disclosure;

FIGS. 8A and 8B illustrate enlarged views of a portion of the exterior wall of FIG. 7 in accordance with embodiments of the disclosure;

FIG. 9 illustrates a perspective view of a modular segment of the exterior wall of FIG. 7 in accordance with embodiments of the disclosure;

FIG. 10 illustrates an enlarged view of the modular segment of the exterior wall illustrated in FIG. 9 in accordance with embodiments of the disclosure;

FIG. 11 illustrates a top-down view of an exterior wall of the structure illustrated in FIGS. 1-6 in accordance with embodiments of the disclosure;

FIG. 12A illustrates a sectional top-down view of a portion of the exterior wall illustrated in FIG. 11 in accordance with embodiments of the disclosure;

FIG. 12B illustrates a perspective view of a portion of the exterior wall illustrated in FIG. 11, with the outer coverings removed showing the framework in accordance with embodiments of the disclosure;

FIG. 13A illustrates a perspective view of a modular exterior wall in accordance with embodiments of the disclosure;

FIG. 13B illustrates an enlarged view of a termination structure of the modular exterior wall of FIG. 13A;

FIG. 13C illustrates an enlarged view of a termination structure of the modular exterior wall of FIG. 13A;

FIG. 13D illustrates an enlarged plan view of the termination structure of the modular exterior wall of FIG. 13A after a subsequent processing step;

FIG. 14 illustrates a perspective view of the exterior wall of FIG. 11 including a lateral wall structure in accordance with embodiments of the disclosure;

FIG. 15A illustrates an enlarged perspective view of the lateral wall structure of FIG. 14 with the outer coverings removed showing the framework in accordance with embodiments of the disclosure;

FIG. 15B illustrates an enlarged perspective view of a portion of the lateral wall structure of FIG. 15A in accordance with embodiments of the disclosure;

FIG. 15C illustrates an enlarged top down view of a portion of the lateral wall structure of FIG. 15A in accordance with embodiments of the disclosure;

FIG. 15D illustrates an enlarged perspective view of a portion of the lateral wall structure of FIG. 15A in accordance with embodiments of the disclosure;

FIGS. 16A and 16B illustrate perspective views of a roof framework in accordance with embodiments of the disclosure; and

FIG. 17 illustrates a floor plan view of a level of the structure of FIGS. 1-6 in accordance with embodiments of the disclosure.

 DETAILED DESCRIPTION

The following description provides specific details, such as material compositions, shapes, and sizes, in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art would understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional techniques employed in the industry.

Drawings presented herein are for illustrative purposes only and are not meant to be actual views of any particular material, component, structure, device, or system. Variations from the shapes depicted in the drawings as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein are not to be construed as being limited to the particular shapes or regions as illustrated, but include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as box-shaped may have rough and/or nonlinear features, and a region illustrated or described as round may include some rough and/or linear features. Moreover, sharp angles that are illustrated may be rounded, and vice versa. Thus, the regions illustrated in the figures are schematic in nature, and their shapes are not intended to illustrate the precise shape of a region and do not limit the scope of the present claims. The drawings are not necessarily to scale. Additionally, elements common between figures may retain the same numerical designation.

As used herein, the term “substantially” in reference to a given parameter means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0 percent met, at least 95.0 percent met, at least 99.0 percent met, at least 99.9 percent met, or even 100.0 percent met.

As used herein, “about” in reference to a numerical value for a particular parameter is inclusive of the numerical value and a degree of variance from the numerical value that one of ordinary skill in the art would understand is within acceptable tolerances for the particular parameter. For example, “about” in reference to a numerical value may include additional numerical values within a range of from 90.0 percent to 110.0 percent of the numerical value, such as within a range of from 95.0 percent to 105.0 percent of the numerical value, within a range of from 97.5 percent to 102.5 percent of the numerical value, within a range of from 99.0 percent to 101.0 percent of the numerical value, within a range of from 99.5 percent to 100.5 percent of the numerical value, or within a range of from 99.9 percent to 100.1 percent of the numerical value.

As used herein, relational terms, such as “below,” “lower,” “bottom,” “above,” “upper,” “top,” and the like, may be used for ease of description to describe one element’s or feature’s relationship to another element(s) or feature(s) as illustrated in the drawings. Unless otherwise specified, the spatially relative terms are intended to encompass different orientations of the materials in addition to the orientation depicted in the figures. For example, if materials in the figures are inverted, elements described as “below” or “under” or “on bottom of” other elements or features would then be oriented “above” or “on top of” the other elements or features. Thus, the term “below” can encompass both an orientation of above and below, depending on the context in which the term is used, which will be evident to one of ordinary skill in the art. The materials may be otherwise oriented (e.g., rotated 90 degrees, inverted, flipped) and the spatially relative descriptors used herein interpreted accordingly.

As used herein, the terms “vertical,” “longitudinal,” “horizontal,” and “lateral” are in reference to a major plane of a structure and are not necessarily defined by earth’s gravitational field. A “horizontal” or “lateral” direction is a direction that is substantially parallel to the major plane of the structure, while a “vertical” or “longitudinal” direction is a direction that is substantially perpendicular to the major plane of the structure. The major plane of the structure is defined by a surface of the structure having a relatively large area compared to other surfaces of the structure. With reference to the drawings, a “horizontal” or “lateral” direction may be perpendicular to an indicated “Z” axis, and may be parallel to an indicated “X” axis and/or parallel to an indicated “Y” axis; and a “vertical” or “longitudinal” direction may be parallel to an indicated “Z” axis, may be perpendicular to an indicated “X” axis, and may be perpendicular to an indicated “Y” axis.

As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

As used herein, the term “and/or” means and includes any and all combinations of one or more of the associated listed items.

Modular construction uses prefabricated structures to construct the associated structure. For example, walls, ceilings, roofs, floors, or even complete rooms, may be fabricated in a remote location, such as a factory or construction yard and then transported to the location of the associated building, where the prefabricated structures are assembled to construct the associated building. Modular construction may increase efficiency of the construction of a building. While modular construction may reduce the costs of construction, modular construction may also reduce the quality of the resulting structure. For example, modular construction may reduce the efficiency of the structure. For example, a modularly constructed structure may have lower insulation factors, such that the structures are less efficient at maintaining an interior temperature. Modular construction may also reduce the customizability of a resulting structure, such that the modularly constructed structures are limited to a small number of designs.

Embodiments of the disclosure are directed to modular construction structures that facilitate greater customization of the resulting completed structure or building. The modular wall structures also provide greater insulation factors than conventionally constructed walls and modular walls. Thus, the modular structures of the disclosure facilitate modular construction of higher quality structures or buildings.

FIGS. 1-6 illustrate sections of a structure 100 at different stages of construction. The structure 100 is constructed through modular structures, such as modular walls or wall segments secured to one another and supporting one another to form the structure 100. The structure 100 is formed over a base 102 configured to support the modular structures and secure the different components of the structure 100 relative to one another.

FIG. 1 illustrates the base 102 of the structure 100. The base 102 includes a foundation 104, such as footings, slab-on-grade, or stem wall foundations, configured to secure the structure 100 to the ground. The base 102 also includes a cavity 106 defined between the foundation 104 and a floor 110 by supports 108 extending up from the foundation 104. The cavity 106 may be configured to facilitate the installation of utilities beneath the floor 110. For example, the cavity 106 may be a crawl space, a utility chase, or a full height basement.

The foundation 104 and the supports 108 may be formed from rigid and strong materials, such as concrete (e.g., poured concrete or insulated concrete forms (ICF)), masonry (e.g., bricks, cinder blocks, etc.), stone, or combinations thereof. The foundation 104 and the supports 108 may define a size and shape of the structure 100. For example, the foundation 104 and the supports 108 may define an outer perimeter of the structure 100. In some embodiments, the base 102 also includes supports 108 running through a central portion of the structure 100 supporting the floor 110 in the central portion of the structure 100 in addition to around the perimeter of the structure 100.

The floor 110 may include a framework of supporting structures (e.g., joists, beams, studs, etc.) extending between the supports 108 to maintain a rigidity of the floor 110. In some embodiments, the supporting structures substantially fill the cavity 106. The framework of supporting structures may define space through which the utilities may run within the cavity 106, such that the floor 110 is supported and the utilities also extend through the cavity 106.

In some embodiments, the base 102 does not include a cavity 106, such that the floor 110 is an upper surface of the foundation 104 (e.g., slab-on-grade construction). The main utilities may enter the structure 100 from beneath the base 102 through openings in the foundation 104. The utilities within the structure 100 may then run outside the base 102.

A core structure 202 may be formed over the floor 110 of the base 102. The core structure 202 may include walls 204 defining an interior region 206. The interior region 206 may be configured to house the main utilities for the structure 100, such as the main gas or oil line (e.g., natural gas line, propane line, heating oil line, etc.), the main water line, water treatment structures (e.g., water heater, water softener, water filters, etc.), the sewer main, the main power connections (e.g., breaker boxes, fuse boxes, etc.), the communication mains (e.g., router connections, switches, phone line connections, fiber connections, etc.), climate control main structures (e.g., furnace, fan, evaporator, humidifier, dehumidifier, etc.).

In some embodiments, the interior region 206 includes partitions or walls separating some of the utilities. For example, the water based utilities, such as the main water line, the water treatment structures and the sewer main may be separated from the electrical mains, such as the main power connections, the communication mains, and the climate control main structures, by partitions or walls.

The core structure 202 may include at least one access point 208, configured to provide access to the utilities, such as for maintenance or repair. In some embodiments, the access point 208 is a door, such as a full size door as illustrated in FIG. 2 or a smaller access door or hatch.

In some embodiments, one or more of the utility connections 210 may be disposed through a wall 204 of the core structure 202. For example, bathroom connections (e.g., toilet connections, sink connections, etc.) may be disposed through a wall 204 of the core structure 202, such that the associated room (e.g., bathroom) shares the wall 204 with the core structure 202.

The core structure 202 may include a separation structure 212 positioned between a first level 214 and a second level 216, such as where the structure 100 is a multilevel structure 100 (e.g., a two-story structure, three-story structure, etc.). The separation structure 212 may form a floor and/or ceiling between the first level 214 and the second level 216 within the interior region 206 of the core structure 202. The separation structure 212 may be configured to facilitate mounting some of the main mechanical structures (e.g., water treatment structures and climate control main structures). For example, some of the main mechanical structures may be mounted to the separation structure 212 on the second level 216 and/or some of the main mechanical structures may be suspended from the separation structure 212 on the first level 214. The separation structure 212 may facilitate a higher concentration or density of the main mechanical structures within the interior region 206 of the core structure 202. A higher concentration or density of the main mechanical structures may increase the usable or livable space outside the core structure 202.

The separation structure 212 may also define openings in the separation structure 212 to facilitate the passage of utilities between the first level 214 and the second level 216. For example, one or more utility chases may be formed in the interior region 206 of the core structure 202. The utility chases may be openings defined through the separation structure 212 where utilities, such as drain or sewer pipes, water lines, electrical, ductwork, etc., pass between the first level 214 and the second level 216. In some embodiments, the chases are walled off from the rest of the interior region 206. In other embodiments, the chases are open within the interior region 206 of the core structure 202.

The main utilities entering the structure 100 from outside the structure 100, such as the water main, sewer main, electrical main, and oil or gas main may pass under the floor 110, such as in the cavity 106 or under the foundation 104 to reach the core structure 202. The main utilities may then pass through the floor 110 into the interior region 206 of the core structure 202 where the main utilities may be connected to the utilities within the structure. Thus, the main utilities may provide a connection between the utilities within the structure and the supply utilities.

Exterior walls 302 may be installed around the core structure 202. The exterior walls 302 may be installed over the supports 108 of the base 102. The exterior walls 302 may be formed from modular segments 304. The modular segments 304 may each be structurally similar. For example, each modular segment 304 may have a same width and height, such that each modular segment 304 may be interchangeable. Thus, the modular segments 304 are modular. The modular segments 304 may be constructed individually off-site and then transported or shipped to the building site.

Some of the modular segments 304 may include doors 306 or windows (not shown). Each of the modular segments 304 includes a framework 308 of studs 310 or other supporting structures. The studs 310 may be uniformly spaced within the framework 308, such that the studs 310 in each modular segment 304 are aligned laterally in the X- and Y-directions and vertically in the Z-direction.

The modular segments 304 are stacked to form the first level 214 and the second level 216. An intermediate header 312 may be positioned between the modular segments 304 of the first level 214 and the modular segments 304 of the second level 216. The intermediate header 312 is configured to facilitate a connection between the modular segments 304 of the first level 214 and the modular segments 304 of the second level 216.

The intermediate header 312 may include multiple utility openings 314 defined in the intermediate header 312. The utility openings 314 may be configured to receive utilities passing through the framework 308 of the exterior walls 302 above or below the intermediate header 312 and direct the utilities into a lateral wall structure 402. In some embodiments, the utilities may be pre-installed in the modular segments 304 of the exterior wall 302 and in the lateral wall structure 402. The utility openings 314 may provide a junction between the pre-installed utilities, where the utilities in the modular segments 304 of the exterior wall 302 may be joined to the utilities in the lateral wall structure 402. In the embodiment illustrated in FIG. 3, two utility openings 314 lie within the lateral footprint of each modular segment 304 of the exterior wall 302. As discussed above, the modular segments 304 may have different configurations. For example, some modular segments 304 may be substantially free of utilities, some modular segments 304 may have electrical utilities and no water utilities or pipes, other modular segments 304 may have water-based utilities and pipes and no electrical utilities, additional modular segments 304 may have each type of utility dispersed throughout the modular segment 304.

In some embodiments, the utilities pass vertically through the intermediate header 312 between the modular segments 304 of the first level 214 and the modular segments 304 of the second level 216 without passing through the utility openings 314. As discussed above, the modular segments 304 may have the utilities pre-installed. Therefore, the modular segments 304 of the first level 214 may be substantially aligned with modular segments 304 in the second level 216, such that the pre-installed utilities in each of the modular segments 304 are substantially aligned. The utilities in the modular segments 304 in the first level 214 may then be joined to the utilities in the modular segments 304 in the second level 216 within the intermediate header 312. For example, the intermediate header 312 may include one or more junction boxes for joining electrical wires or pull boxes for joining conduits in the adjoining modular segments 304 and then pulling wire through the conduits and pull boxes. In another example, the intermediate header 312 may provide a space for joining pipes and/or water lines together. In some embodiments, the intermediate headers 312 include separation structures configured to separate electrical utilities from water based utilities.

A top portion of the exterior walls 302 may include a header 316 forming an upper portion of the structure 100. As described in further detail below, with respect to FIG. 5, the header 316 may be configured to facilitate a connection between the modular segments 304 of the exterior walls 302 and a roof structure.

FIG. 4 illustrates the structure 100 with a lateral wall structure 402 installed between the intermediate header 312 of the exterior wall 302 and the separation structure 212 of the core structure 202. As discussed above, the lateral wall structure 402 may include utilities running through the lateral wall structure 402 to or from the utility openings 314 in the intermediate header 312 of the exterior wall 302. Thus, the lateral wall structure 402 may provide a connection between the utilities in the exterior walls 302 and the main utilities in the core structure 202.

The lateral wall structure 402 may include a framework 404 of supporting structures (e.g., joists, beams, studs, etc.). The framework 404 may separate outer planar structures 406 that form a floor 408 of the second level 216 and a ceiling 410 of the first level 214. The framework 404 may also define a cavity 412 between the outer planar structures 406 (e.g., the floor 408 and the ceiling 410). The cavity 412 may provide a space through which the utilities may pass to connect the utilities in the exterior walls 302 to the utilities in the core structure 202. In some embodiments, the utilities run through the cavity 412 to devices installed in the lateral wall structure 402, such as lights in the ceiling 410, floor outlets in the floor 408, water or drain connections in the floor 408, etc.

FIG. 5 illustrates the structure 100 with a portion of a lateral exterior wall structure 502 installed. Similar to the lateral wall structure 402, the lateral exterior wall structure 502 may include a framework 504 separating outer planar structures 506 of the lateral exterior wall structure 502. The outer planar structures 506 of the lateral exterior wall structure 502 may form a roof 508 of the structure 100 and a ceiling 510 of an upper level of the structure 100. In the embodiment illustrated in FIG. 5, the structure 100 includes a first level 214 and a second level 216, such that the lateral exterior wall structure 502 forms the ceiling 510 of the second level 216. In other embodiments, the structure 100 may include additional levels, such as three levels, four levels, etc., and each level may be separated by lateral wall structures 402, such that the lateral wall structures 402 form the floors 408 and ceilings 410 of the adjacent levels. The final or top level will be bounded by the lateral exterior wall structure 502, such that the lateral exterior wall structure 502 defines the ceiling 510 of the final or top level of the structure 100.

The roof 508 of the structure 100 may include a covering or treatment configured to seal the structure 100. For example, the roof 508 may be covered with an asphalt roofing (e.g., built-up roof (BUR), tar and gravel, etc.), a concrete roof, a membrane roof (e.g., thermoplastic olefin (TPO), ethylene propylene diene monomer (EPDM), polyvinyl chloride (PVC), etc.), or other flat roofing material. The covering or treatment on the roof 508 may be configured to substantially prevent water, such as from precipitation, from entering the structure 100 through the lateral exterior wall structures 502 or through the joints between segments of the lateral exterior wall structure 502. The lateral exterior wall structures 502 may also include one or more drains (not shown) configured to remove water from the roof 508, such as through a drain line in the core structure 202 or through one or more modular segments 304 of the exterior walls 302. In some embodiments, the roof 508 has a pitch, such that the roof 508 slopes toward the exterior walls 302. The pitch or slope of the roof 508 may further facilitate removing water from the roof 508, such as by directing water toward the exterior walls 302, where drains may be located.

In some embodiments, utilities run through a cavity 512 defined between the outer planar structures 506 of the lateral exterior wall structure 502. For example, electrical power to interior lights installed in the ceiling 510 may run through the cavity 512 from either the core structure 202 or adjoining modular segments 304 of the exterior walls 302. Pipes connecting the drains on the roof 508 may also run through the cavity 512 to one or more of the core structure 202 or adjoining modular segments 304 of the exterior walls 302 to connect to drain pipes extending therethrough. In some embodiments, utilities may run through the cavity 512 defined in the lateral exterior wall structure 502 to connect utilities in the modular segments 304 of the exterior walls 302 to utilities in the core structure 202.

FIG. 6 illustrates a view of the completed structure 100. In the embodiment illustrated in FIG. 6, the first level 214 of the structure 100 has a larger lateral footprint than the second level 216. As discussed above, the exterior walls 302 are formed from modular segments 304. Some of the modular segments 304 are covered with wall coverings 602, such as paneling, siding, brick, stone, stucco, plaster, etc., to form a weatherproof outer structure. Other modular segments 304 define openings 604 in the modular segments 304 of the exterior walls 302. The openings 604 may be filled with windows 606, sliding doors 608, lifting doors 610 (e.g., garage doors, roll-up doors, etc.), doors 306 (FIG. 3), etc.

The modular segments 304 of the exterior walls 302 may facilitate customization to the size and/or shape of the exterior walls 302 of the structure 100. Furthermore, the modular segments 304 may facilitate changes to the arrangements of the different openings 604 within an exterior wall 302 of the structure 100. The lateral wall structures 402 and lateral exterior wall structures 502 may facilitate customization to how the utilities are run from the core structure 202 to the modular segments 304 of the exterior walls 302, such that utilities may be positioned in different locations along the exterior walls 302 facilitating further customization of the structure 100.

FIG. 7 illustrates a partially exploded view of an exterior wall 302 of the structure 100. The exterior wall 302 is formed from modular segments 304. Each modular segment 304 has a width 702 and a height 704 that are substantially the same. The modular segments 304 may have different features, such as different configurations (e.g., openings, doors, windows, etc.), different pre-installed utilities, etc. Thus, the modular segments 304 may be configured to be installed in any location along the exterior wall 302. As discussed above, each modular segment 304 includes a framework 308 of studs 310 providing structural support for the modular segment 304.

The modular segments 304 may join together at joints 706. Each of the modular segments 304 may include similar structures on opposing ends of the modular segments 304 to form the joints 706. Terminal structures 708 may be included on ends of the exterior wall 302, such as at corners between two adjoining exterior walls 302 or lateral ends of the exterior wall 302. The terminal structures 708 may include similar structures to form joints 706 between the adjacent modular segments 304 and the terminal structures 708.

In the embodiment illustrated in FIG. 7, the joints 706 are formed by a protrusion 710 extending from an end of one of the modular segments 304 or the terminal structures 708 and a receiving structure 712, such as a complementary groove or recess, in the adjoining modular segment 304 or terminal structure 708. The joints 706 may be substantially the same on all modular segments 304, such that different modular segments 304 may be interchangeably positioned adjacent to other modular segments 304 and/or terminal structures 708.

The base 102 may include junctions 714 configured to facilitate a connection between utilities in the modular segments 304 of the exterior wall 302 and utilities running within the cavity 106 (FIG. 1) defined in the base 102. For example, as discussed above, the modular segments 304 of the exterior wall 302 may include pre-installed utilities, and utilities may run from the core structure 202 (FIG. 2) to the exterior wall 302 within the cavity 106 (FIG. 1) of the base 102. The junctions 714 may be uniformly spaced along the base 102, such that at least one junction 714 is positioned beneath each modular segment 304. Thus, utilities in the modular segments 304 may be connected to utilities in the cavity 106 (FIG. 1) in the junctions 714.

FIGS. 8A and 8B illustrate enlarged views of the joint 706 between the modular segments 304 of the exterior wall 302. The framework 308 of each modular segment 304 may include a termination structure 802 at each end of the modular segment 304. The termination structure 802 may be formed from multiple studs 310 connected together to form a stronger lateral end of the associated modular segment 304. The termination structure 802 may be configured to maintain a shape of the modular segments 304 of the exterior wall 302, such as during transportation.

The termination structures 802 may also be configured to secure adjacent modular segments 304 to each other. For example, the termination structures 802 in adjacent modular segment 304 may combine to define anchor structures 804. The anchor structures 804 may comprise a recess 808 defined in both the termination structures 802 of the adjacent modular segments 304. The recess 808 may be configured to receive an anchor 806 configured to secure the adjacent modular segments 304 both vertically (e.g., in the Z-direction) and laterally (e.g., in the X-direction).

The recess 808 in the termination structure 802 may define a bridge 810 and a vertical flange 812 in each termination structure 802. The bridge 810 may extend laterally (e.g., in the X-direction) between the two adjacent termination structures 802. The bridge 810 in each of the termination structures 802 may be substantially aligned vertically (e.g., in the Z-direction), such that the anchor 806 may extend between the two adjacent termination structures 802 across the joint 706 through the bridges 810 defined in the adjacent termination structures 802.

The vertical flange 812 may have a height in the vertical direction (e.g., Z-direction) that is greater than a height of the bridge 810. In the embodiment illustrated in FIGS. 8A and 8B, the recess 808 defines a horizontal “T” shape in each termination structure 802, such that when the two termination structures 802 are secured together the recesses 808 combine to form a horizontal “I” shape. The “T” shape in each termination structure 802 is formed by the vertical flange 812 extending both vertically above and below the bridge 810. In other embodiments, the vertical flange 812 may only extend vertically above the bridge 810 or vertically below the bridge 810, such that the recesses 808 may each form a horizontal “L” shape. Thus, when joined together the two adjacent termination structures 802 include combined recesses form a horizontal “C” shape.

The termination structures 802 may be formed from multiple studs 310 stacked together. For example, in the embodiments illustrated in FIGS. 8A and 8B, the termination structures 802 are formed from three studs 310 stacked together. The studs 310 include an exterior stud 814 on the side of the termination structure 802 adjacent the joint 706, an interior stud 816 positioned on the side of the termination structure 802 opposite the joint 706 and an intermediate stud 818 positioned between the exterior stud 814 and the interior stud 816. The recess 808 may be formed in the termination structure 802 by removing portions of the exterior stud 814 and the intermediate stud 818. For example, the bridge 810 may be formed by removing a portion of the exterior stud 814 to form a vertical gap in the exterior stud 814 corresponding to the bridge 810. The vertical flange 812 may be formed in the intermediate stud 818 by removing a larger portion of the intermediate stud 818 to form a larger vertical gap in the intermediate stud 818 corresponding to the vertical flange 812.

The anchor 806 may be disposed in the recess 808 between the two adjacent termination structures 802. The anchor 806 may have a complementary shape to the recess 808. For example, the anchor 806 may be an “I”- or “C”-shaped structure including a web 820 corresponding to the bridge 810 and two flanges 822 on opposing sides of the web 820 corresponding to the vertical flanges 812 in the recess 808. The anchor 806 may be configured to secure the adjacent modular segments 304 vertically through the interface between the web 820 and the bridge 810 between the two modular segments 304, and the anchor 806 may be configured to secure the adjacent modular segments 304 laterally through an interface between the flanges 822 and the exterior studs 814 in the vertical flange 812 regions of the recess 808.

FIGS. 9 and 10 illustrate perspective views a modular segment 304 of an exterior wall 302 with some of the wall structures removed to show the internal portions of the exterior wall 302. The exterior wall 302 includes a framework 308 formed from studs 310. The studs 310 may have different sizes in different portions of the exterior wall 302. For example, the studs 310 may be a conventional type of stud used in construction such as wooden studs or metal studs. For example, the wooden studs may be a 2x4, 2x6, a 4x4, etc. Examples of metal studs may include hot rolled steel and cold formed steel, stamped steel, etc. Some studs 310 may be alignment structures 910 formed from material that is thinner than conventional stud material.

The exterior wall 302 may also include one or more assemblies of spacers 902 disposed within a cavity 904 of the exterior wall 302 defined by the framework 308. The exterior wall 302 may include multiple rows 906 and columns 908 of the spacers 902 arranged within the cavity 904 of the exterior wall 302. The spacers 902 in the exterior wall 302 that are in a same row 906 are substantially aligned in the X-direction. The spacers 902 in the exterior wall 302 that are in a same column 908 are substantially aligned in the Z-direction. In some embodiments, the spacers 902 are secured to the studs 310, such as with hardware (e.g., nails, staples, screws, etc.) or through interfacing elements extending from the spacers 902, such as locator pins, clips, clamps, etc. The spacers 902 may be configured to define spaces between the studs 310. For example, the spacers 902 may define lateral spaces between the studs 310 in the X-direction. In some embodiments, the spacers 902 define a lateral space between the studs 310 in a Y-direction, such that there is a gap 928 defined between studs 310 against an outer structure 930 and studs 310 against an inner structure (not shown). In some embodiments, the spacers 902 provide additional support to the studs 310, such as functioning as bridges (e.g., nogging or blocking) between two studs 310 increasing resistance of the adjacent studs 310 to bending.

The studs 310 that are positioned against the inner structure (not shown) may be alignment structures 910. For example, the alignment structures 910 may be configured as a “T”-shaped alignment structure 912. The “T”-shaped alignment structure 912 may be constructed from material that is narrower than conventional studs 310. For example, the “T”-shaped alignment structure 912 may be formed from sheeting materials, such as wood sheet (e.g., plywood, chip board, wood paneling, etc.), drywall, plasterboard, cement sheet, etc. The “T”-shaped alignment structures 912 may include a flange 914 and a web 916.

In some embodiments, a secondary stud 918 may be positioned adjacent the inner structure (not shown). For example, an intermediate support structure 920 may be positioned proximate a lateral middle of the framework 308. The intermediate support structure 920 may be configured to provide additional rigidity or strength to the modular segment 304, such as during transportation or installation. In another example, secondary studs 918 may be used in the terminal structures 708 at the lateral ends of the modular segment 304.

In the embodiment illustrated in FIG. 10, a portion of each of the adjacent spacers 902 in each row 906 is positioned between the studs 310 and the alignment structures 910 or secondary studs 918. Thus, the spacers 902 define a gap 928 between the studs 310 and the alignment structures 910 or the secondary studs 918. The gap 928 may facilitate passing utilities laterally through the exterior wall 302 (e.g., in the X-direction), without reducing a strength of the framework of the exterior wall 302. For example, the utilities may pass laterally through the exterior wall 302 without removing material from any of the studs 310, alignment structures 910, or secondary studs 918.

The gap 928 may also increase a distance between an outer structure 930 of the exterior wall 302 and an inner structure (not shown) of the wall. In other words, the gap 928 may increase a width of the cavity 904 between the outer structure 930 and the inner structure (not shown) of the exterior wall 302. Increasing the distance between the outer structure 930 and the inner structure (not shown) of the exterior wall 302 may increase the insulative properties of the exterior wall 302 by increasing an air gap between the two sides of the exterior wall 302. The increased distance between the outer structure 930 and the inner structure (not shown) of the exterior wall 302 may also create additional space for insulation to be placed in the cavity 904 to further increase the insulative properties of the exterior wall 302. For example, the exterior wall 302 may have an insulative rating in a range from about R-30 to about R-50, such as from about R-40 to about R-42.

As illustrated in FIG. 10, different utilities may be connected to the spacers 902 in different locations. For example, in the embodiment illustrated in FIG. 10, one column 908 of spacers includes water lines 924 connected to the spacers 902, another column 908 of spacers 902 includes pipes 922 connected to the spacers 902, and yet another column 908 of spacers 902 includes wires 926 connected to the spacers 902. In some embodiments, multiple different utilities may be connected to spacers in a same column 908. For example, pipes 922 may be connected to the same column of spacers 902 as the water lines 924. In the embodiment illustrated in FIG. 10, one of the columns 908 includes pipes 922 connected to the spacers 902 in the same column 908 of spacers 902 as the wires 926.

FIG. 9 illustrates the intermediate header 312 over the modular segment 304 of the exterior wall 302. In the embodiment illustrated in FIG. 9, wires 926 pass through one of the utility openings 314 in the intermediate header 312 and pass into a column 908 of the cavity 904 of the exterior wall 302, where the wires 926 are then secured to the spacers 902 in the column 908.

FIG. 11, illustrates a top-down view of a portion of the first level 214 (FIG. 3) of the structure 100. In the embodiment illustrated in FIG. 11, the outer structure 930 and an inner structure 1102 are positioned over the framework 308 (FIGS. 3 and 9) of the exterior walls 302. As discussed above, the exterior walls 302 are formed from modular segments 304 coupled together at joints 706.

In the embodiment illustrated in FIG. 11, two exterior walls 302 are joined together at a corner through a terminal structure 708 with one exterior wall 302 extending in the X-direction and one exterior wall 302 extending in the Y-direction. The wall extending in the X-direction is also illustrated as terminating at a terminal structure 708 on an opposite lateral end from the corner terminal structure 708.

Each modular segment 304 of the exterior walls 302 includes an intermediate header 312. As discussed above, the intermediate headers 312 facilitate a vertical connection between modular segments 304 in the first level 214 (FIG. 3) and modular segments 304 in the second level 216 (FIG. 3). The intermediate headers 312 also include utility openings 314 configured to facilitate passing utilities into the exterior walls 302 through the intermediate headers 312.

As illustrated in FIG. 11, the intermediate headers 312 define a shelf 1104. The shelf 1104 may be configured to support lateral wall structures 402 (FIG. 4) that may be coupled to the exterior walls 302. The shelves 1104 may be positioned such that each lateral wall structure 402 (FIG. 4) is positioned uniformly relative to the modular segments 304 of the exterior walls 302. As discussed above, utilities may pass through the lateral wall structures 402 (FIG. 4) and then enter the exterior walls 302 through the utility openings 314 in the intermediate header 312. Thus, the shelves 1104 may uniformly position the lateral wall structures 402 (FIG. 4) relative to the utility openings 314 to facilitate a connection between the utilities in the lateral wall structure 402 (FIG. 4) and the utilities in the modular segments 304 of the exterior walls 302.

FIG. 12A illustrates an enlarged cross sectional view of the corner portion of the exterior walls 302 of the structure 100 illustrated in FIG. 11. As discussed above, the exterior wall 302 includes multiple spacers 902 aligned in rows 906. The spacers 902 are positioned within the framework 308 of the exterior wall 302. The outer structures 930 and inner structures 1102 secured to the framework 308 form the planes of the walls. For example, the outer structure 930 and/or inner structure 1102 may be formed from sheeting materials, such as wood sheet (e.g., plywood, chip board, wood paneling, etc.), drywall, plasterboard, cement sheet, etc. In some embodiments, the outer structure 930 and the inner structure 1102 are formed from different materials. In other embodiments, the outer structure 930 and the inner structure 1102 may be formed from the same material.

The segments may each include a same number of spacers 902 in a row 906 positioned between two termination structures 802. The termination structures 802 define the ends of the modular segments 304. As discussed above, the termination structure 802 may be formed from multiple studs 310 stacked together to form the termination structure 802. In other embodiments, the termination structure 802 may be formed from a larger structure, such as a larger wooden structure (e.g., having larger dimensions than the studs 310) or a larger metal structure (e.g., having larger dimensions than the studs 310). In another example, the termination structure 802 may be formed from a material having different properties from the studs 310, such as from a stronger material. For example, the termination structures 802 may be formed from a metal material, where the studs 310 are formed from wood. In another example, the termination structure 802 may be formed from a larger wooden structure and the studs 310 may be formed from sheet metal.

The termination structures 802 of adjacent modular segments 304 in the exterior wall 302 may be joined together to form a joint 706, as discussed above. Thus, adjacent modular segments 304 may combine to form an exterior wall 302 that is longer than the individual modular segments 304. In some embodiments, the modular segments 304 are joined together at a terminal structure 708, such that the modular segments 304 extend at an angle relative to one another to form a corner of the associated structure 100.

FIG. 12B illustrates a perspective view of an embodiment of the framework 308 of the corner portion of the exterior walls 302 of the structure 100 illustrated in FIG. 11. For simplicity, the framework 308 is illustrated without any spacers (e.g., spacers 902 (FIG. 9)), utilities (e.g., pipes 922 (FIGS. 9-10), water lines 924 (FIGS. 9-10), or wires 926 (FIGS. 9-10)), and without any wall coverings (e.g., outer structure 930 (FIG. 11) or the inner structure 1102 (FIG. 11)).

As discussed above, the framework 308 is formed from multiple studs 310. In some embodiments, the framework 308 is formed from wood studs 310. In other embodiments, the framework 308 is formed from metal studs 310, such as hot rolled steel and cold formed steel, stamped steel, etc. In the embodiment illustrated in FIG. 12B, the framework 308 is formed from metal studs 310. The framework 308 is formed from an outer framework 1202 and an inner framework 1204. Each of the outer framework 1202 and the inner framework 1204 are formed from the studs 310. As discussed above, in some embodiments, spacers 902 (FIG. 12A) are positioned between the outer framework 1202 and the inner framework 1204. The spacers 902 (FIG. 12A) may be configured to maintain a space between the outer framework 1202 and the inner framework 1204, thereby maintaining a spacing between wall coverings (e.g., wall covering 602 (FIG. 6)) placed over the framework 308. In other embodiments, the outer framework 1202 may be secured directly to the inner framework 1204, such as through hardware (e.g., screws, bolts, clamps, etc.), thermal bonding (e.g., welding, soldering, etc.), or an adhesive, which may secure each of the studs 310 in the outer framework 1202 to the studs 310 in the inner framework 1204.

In the embodiment illustrated in FIG. 12B, the inner framework 1204 has a vertical height that is less than a vertical height of the outer framework 1202. This may facilitate the formation of the shelf 1104. For example, an upper surface of the inner framework 1204 may form the shelf 1104 and the outer framework 1202 may extend vertically to form a header (e.g., the header 316 or the intermediate header 312).

FIG. 12B illustrates a terminal structure 708 forming a corner structure and a termination structure 802 configured to join two modular segments 304. As discussed above, the terminal structures 708 and the termination structures 802 include additional studs 310, which may provide additional structural support and/or rigidity during transportation and assembly.

FIGS. 13A-13D illustrate different views of a termination structure 802 between two modular segments 304 of an exterior wall 302, such as the exterior wall 302 illustrated in FIG. 12B. The exterior wall 302 includes an outer framework 1202 and an inner framework 1204 formed from multiple studs 310. FIG. 13A illustrates a simplified perspective view of the exterior wall 302. FIGS. 13B-13C illustrate enlarged perspective views of the termination structure 802 between two modular segments 304 of the exterior wall 302. FIG. 13D illustrates an enlarged plan view of the termination structure 802 between the two modular segments 304 of the exterior wall 302.

In the embodiment illustrated in FIG. 13A, the inner framework 1204 is laterally offset from the outer framework 1202, such that the termination structure 802 forms a Z-joint 1306. The Z-joint 1306 results in the interface 1308 between the two modular segments 304 of the outer framework 1202 not being laterally aligned with the interface 1310 between the two modular segments 304 of the inner framework 1204. The Z-joint 1306 may be configured to reduce the transfer of heat through the exterior wall 302 at the termination structure 802. For example, imperfections in materials or structures may result in space between the modular segments 304 at the interfaces 1308, 1310. The space may result in greater heat transfer through the interfaces 1308, 1310. The Z-joint 1306 may facilitate reducing this heat transfer at least by interrupting the space between the modular segments 304 with one of the outer framework 1202 or the inner framework 1204. For example, the interface 1308 between the outer frameworks 1202 of the modular segments 304 terminates at a stud 310 of one of the inner frameworks 1204 of the modular segments 304. Similarly, the interface 1310 between the inner frameworks 1204 of the modular segments 304 terminates at a stud 310 of one of the outer frameworks 1202 of the modular segments 304, such that the associated studs 310 form a barrier to the heat transfer through the associated interfaces 1308, 1310.

As illustrated in FIG. 13A, the interface 1310 between the two modular segments 304 of the inner framework 1204 includes a gap 1302 while the interface 1308 between the two modular segments 304 of the outer framework 1202 is substantially flush (e.g., has not gap or a gap that is substantially smaller than the gap 1302 defined in the interface 1310 between the two modular segments 304 of the inner framework 1204. The gap 1302 may be configured to receive an insulative material as discussed in greater detail below with respect to FIG. 13D.

The modular segments 304 may be secured to one another through an anchor structure 1304 across at least one of the interface 1308 between the outer frameworks 1202 of the modular segment 304 and the interface 1310 between the inner frameworks 1204 of the modular segments 304. In the embodiment illustrated in FIG. 13A, the anchor structure 1304 is configured to secure the modular segments 304 across the interface 1310 between the inner frameworks 1204 of the modular segments 304.

FIG. 13B illustrates an enlarged view of the termination structure 802 further illustrating the anchor structure 1304. The anchor structure 1304 may include a fastener 1312, such as a threaded bung, a stud, a bolt, a screw, a cam lock, a latch, etc. In the embodiment illustrated in FIG. 13B, the fastener 1312 includes a threaded bung and a complementary bolt. In the embodiment illustrated in FIG. 13B, the anchor structure 1304 is positioned in the inner frameworks 1204 across the gap 1302 defined by the interface 1310 between the two modular segments 304 in the inner framework 1204.

FIG. 13C illustrates an enlarged view of the Z-joint 1306 between two modular segments 304. As discussed above, the Z-joint 1306 results in the interface 1308 between the outer frameworks 1202 of the modular segments 304 and the interface 1310 between the inner frameworks 1204 of the modular segments 304 not being laterally aligned. The Z-joint 1306 may define an offset 1316 between the interfaces 1308, 1310. The offset 1316 may be in a range from about ½ of a thickness of the studs 310 to about 2 times the thickness of the studs 310.

As discussed above, the interface 1310 between the inner frameworks 1204 of the modular segments 304 define a gap 1302. The gap 1302 has a width 1314 defined at least partially by the interface 1310. The width 1314 may be further defined by the interface 1308 between the outer frameworks 1202 of the modular segments 304. For example, the modular segments 304 may be secured together, such that the outer frameworks 1202 of the modular segments 304 contact one another in the interface 1308 between the outer frameworks 1202. The contact between the outer frameworks 1202 may be maintained through the anchor structure 1304. In embodiments where the anchor structure 1304 is positioned in the inner framework 1204 of the termination structure 802, the anchor structure 1304 may be configured to induce a clamping force between the outer frameworks 1202 of the modular segments 304 at the interface 1308. The inner frameworks 1204 are secured to the respective outer frameworks 1202, such that when the outer frameworks 1202 are clamped together in the interface 1308, the inner frameworks 1204 remained spaced apart in the interface 1310 by the width 1314 defining the gap 1302. The width 1314 may be in a range from about 1/8th of a thickness of the studs 310 to about ½ the thickness of the studs 310.

FIG. 13D illustrates the termination structure 802 after a subsequent process. As discussed above, the gap 1302 may be configured to be filled with an insulative material 1318. In the embodiment illustrated in FIG. 13D, the gap 1302 is filled with the insulative material 1318. The insulative material 1318 may be a spray in insulation, such as spray foam (e.g., open-cell spray polyurethane foam or closed-cell spray polyurethane foam), injection foam, spray-applied cellulose, or spray-applied fiberglass. In other embodiments the insulative material 1318 may include fibrous batt insulation (e.g., fiberglass and/or mineral wool) or rigid foam board insulation. 

In some embodiments, the insulative material 1318 is positioned in gap 1302 during assembly, such that securing the modular segments 304 to one another clamps the insulative material 1318 between the inner frameworks 1204 of the modular segments 304 in the gap 1302. In other embodiments, the insulative material 1318 is disposed in the gap 1302 after the modular segments 304 are secured to one another. The insulative material 1318 may further reduce the heat transfer through the exterior wall 302 by reducing the heat transfer through the interface 1310 between the inner frameworks 1204 of the modular segments 304 of the exterior wall 302.

FIG. 14 illustrates the portion of the first level 214 of the structure 100 illustrated in FIG. 11, with the lateral wall structure 402 installed thereon. As discussed above, the lateral wall structure 402 includes a framework 404 separating outer planar structures 406 that form a floor 408 of an upper level (e.g., the second level 216 (FIG. 3)) and a ceiling 410 of a lower level (e.g., the first level 214).

The framework 404 may be formed from multiple joists 1402 extending laterally (e.g., in the X-direction or the Y-direction). The joists 1402 may be formed from rigid materials, such as wood, metal, or other materials. The joists 1402 may be formed from solid materials, such as studs, or combinations of materials, such as an I-joist or an open-web truss, which may be formed from a single material, such as wood or metal, or combinations of materials, such as a combination of different types of wood or a combination of wood and metal.

In some embodiments, the lateral wall structure 402 is formed to match the specific distances between supporting walls. For example, the joists 1402 may be sized to span a distance between exterior walls 302 or between an exterior wall 302 and an interior wall, such as the core structure 202 (FIG. 4). In some embodiments, the distances between walls (e.g., exterior walls 302, the core structure 202 (FIG. 4), or other interior walls) may be defined by numbers of modular segments 304 (e.g., by multiples of the widths 702 (FIG. 7) of the modular segments 304), such that the different spans between walls are predictable.

In cases where the distances between walls is predictable, the lateral wall structures 402 may be formed in segments 1404, similar to the modular segments 304 of the exterior wall 302. The segments 1404 of the lateral wall structure 402 may each have substantially a same width 1406 (e.g., in the Y-direction) and substantially a same length 1408 (e.g., in the X-direction). In some embodiments, the width 1406 and the length 1408 of the segments 1404 may be the same as the width 702 (FIG. 7) of the modular segments 304 of the exterior wall 302, such that the segments 1404 of the lateral wall structure 402 may be square, having a width 1406 and a length 1408 that are the same. In other embodiments, one of the width 1406 or the length 1408 of the segments 1404 may be greater than the other of the width 1406 or the length 1408 of the segments 1404. For example, the width 1406 of the segments 1404 may be substantially the same as a width 702 (FIG. 7) of the associated modular segments 304 of the exterior walls 302, and the length 1408 may be a multiple of the width 1406, such as about two times the width 1406, such that each segment 1404 spans one modular segment 304 in the Y-direction and spans two modular segments 304 in the X-direction.

As discussed above, the intermediate header 312 includes a shelf 1104. The joists 1402 may rest on the shelf 1104, such that the outer planar structures 406 corresponding to the ceiling 410 are in substantially a same plane as the shelf 1104. The lateral wall structure 402 may include utilities 1410 running in the cavity 412 defined between outer planar structures 406 by the joists 1402. The utilities 1410 may connect utilities on opposing ends of the lateral wall structure 402, such as main utilities within the core structure 202 (FIG. 4) and utilities running in the modular segments 304 of the exterior walls 302.

FIGS. 15A through 15D illustrate enlarged views of portions of embodiments of the framework 404 of the lateral wall structure 402. In the embodiments illustrated in FIGS. 15A through 15D, the outer planar structures 406, utilities 1410, and other associated structures are not illustrated for clarity.

The framework 404 is formed from multiple joists 1402 extending laterally (e.g., in the X-direction). Each of the joists 1402 includes an upper chord structure 1504 and a lower chord structure 1506 that are vertically offset from one-another in a Z-direction. The joists 1402 further include web structures 1508 extending between the upper chord structure 1504 and the lower chord structure 1506. The web structure 1508 join the upper chord structures 1504 to the lower chord structures 1506 forming a truss structure. The web structures 1508 may extend diagonally relative to the associated upper chord structure 1504 and the associated lower chord structure 1506.

The joists 1402 are secured to headers 1502 on opposing lateral ends of the framework 404. The headers 1502 extend horizontally in a direction orthogonal to the direction of the joists 1402 (e.g., in the Y-direction). The headers 1502 each include an upper plate 1510 and a lower plate 1512 that are vertically offset from one-another in the Z-direction. The vertical spacing between the upper plate 1510 and the lower plate 1512 of the headers 1502 may be substantially the same as the vertical spacing between the upper chord structure 1504 and the lower chord structure 1506 of the joists 1402. The headers 1502 may include web structures 1514 extending between the upper plate 1510 and the lower plate 1512 forming a truss structure. Similar to the web structures 1508 of the joists 1402, the web structures 1514 of the headers 1502 may also extend diagonally relative to the associated upper plate 1510 and the associated lower plate 1512.

The upper plates 1510 of the headers 1502 may define multiple pockets 1516. In the embodiment illustrated in FIGS. 15A through 15D, the upper plates 1510 of each of the headers 1502 on opposing lateral ends of the framework 404 define multiple pockets 1516. The pockets 1516 are defined at regular intervals and are substantially aligned with corresponding pockets 1516 in the upper plate 1510 of the neighboring header 1502 in a horizontal direction (e.g., the Y-direction). The pockets 1516 are configured to receive a protrusion 1518 of the upper chord structure 1504 of an associated joist 1402 extending laterally from the joist 1402 in each lateral direction. Thus, the pockets 1516 may be configured to position the joists 1402 relative to one another horizontally along the respective headers 1502.

The headers 1502 and the joists 1402 may each include complementary anchor structures 1520, 1522 extending vertically between the respective upper chord structure 1504 and lower chord structure 1506 or upper plate 1510 and lower plate 1512. In the embodiments illustrated in FIGS. 15A through 15D, the anchor structures 1520 of the header 1502 are positioned vertically below each pocket 1516, such that the anchor structures 1520 extend vertically from the upper plate 1510 to the lower plate 1512 in a region underlying each of the pockets 1516. The anchor structures 1522 of the joists 1402 extend vertically between the upper chord structures 1504 and the lower chord structures 1506 at each of the lateral ends of the joists 1402, such that the anchor structures 1522 form the lateral boundaries of the respective joists 1402. The protrusions 1518 of the upper chord structures 1504 extend laterally beyond the lateral boundaries formed by the anchor structures 1522, such that the anchor structures 1522 may abut against the anchor structures 1520 of the headers 1502 when the framework 404 is assembled.

The anchor structures 1520 of the headers 1502 and the anchor structures 1522 of the joists 1402 may be configured to be secured together joining the joists 1402 to the headers 1502. For example, the anchor structures 1520 may be secured to the respective anchor structures 1522 through hardware (e.g., screws, bolts, clamps, etc.), thermal bonding (e.g., welding, soldering, etc.), or an adhesive. The interface between the pockets 1516 and the associated protrusions 1518 may locate the joists 1402 relative to the headers 1502, such that the anchor structures 1522 of the joists 1402 are substantially aligned with the anchor structures 1520 of the headers 1502 facilitating the connection between the anchor structures 1520 and the anchor structures 1522.

FIGS. 16A and 16B illustrate an embodiment of a roof framework 1600 for inclusion in the structure 100 of FIGS. 1 through 6. The roof framework 1600 is formed from multiple roof trusses 1602 extending laterally (e.g., in the X-direction). Each of the roof trusses 1602 include an upper chord structure 1608 and a lower chord structure 1610 that are vertically offset from one-another in a Z-direction. The roof trusses 1602 further include web structures 1612 extending between the upper chord structure 1608 and the lower chord structure 1610. The web structure 1612 join the upper chord structures 1608 to the lower chord structures 1610 forming a truss structure. The web structures 1612 may extend diagonally relative to the associated upper chord structure 1608 and the associated lower chord structure 1610.

The roof trusses 1602 are secured to a header 1604 on a first lateral end of the roof framework 1600 and to a footer 1606 on an opposing lateral end of the roof framework 1600. The header 1604 and the footer 1606 extend horizontally in a direction orthogonal to the direction of the roof trusses 1602 (e.g., in the Y-direction). The header 1604 may define multiple pockets 1614. In the embodiment illustrated in FIGS. 16A and 16B, the header 1604 defines multiple pockets 1614. The pockets 1614 are defined at regular intervals. The pockets 1614 are configured to receive a protrusion 1616 of the upper chord structure 1608 of an associated roof truss 1602 extending laterally from the roof truss 1602. Thus, the pockets 1614 may be configured to position the roof trusses 1602 relative to one another horizontally along the respective header 1604.

The footer 1606 may define multiple slots 1618. In the embodiment illustrated in FIGS. 16A and 16B, the footer 1606 defines multiple slots 1618. The slots 1618 are defined at regular intervals and are substantially aligned with corresponding pockets 1614 in the header 1604 in a horizontal direction (e.g., the Y-direction). The slots 1618 are configured to receive an anchor structure 1620 of an associated roof truss 1602. Thus, the slots 1618 may be configured to position the roof trusses 1602 relative to one another horizontally along the respective footer 1606. Therefore, the slots 1618 in the footer 1606 may combine with the pockets 1614 in the header 1604 to define the position of the respective roof trusses 1602 within the roof framework 1600.

In the embodiment illustrated in FIGS. 16A and 16B, the upper chord structures 1608 and the lower chord structures 1610 are not parallel. The upper chord structures 1608 are angled downward relative to the lower chord structures 1610, such that a vertical distance between the upper chord structures 1608 and the lower chord structures 1610 decreases as the distance from the header 1604 increases. Thus, the vertical distance between the upper chord structures 1608 and the lower chord structures 1610 is smaller at the footer 1606 than the vertical distance between the upper chord structures 1608 and the lower chord structures 1610 at the header 1604.

The roof trusses 1602 may be configured to be secured to the header 1604 and the footer 1606. For example, the roof trusses 1602 may be secured to the respective header 1604 and the footer 1606 through hardware (e.g., screws, bolts, clamps, etc.), thermal bonding (e.g., welding, soldering, etc.), or an adhesive. The interface between the pockets 1614 and the associated protrusions 1616 and the slots 1618 and the associated anchor structures 1620 may locate the roof trusses 1602 relative to the header 1604 and the footer 1606, facilitating the connection between the roof trusses 1602 and the respective header 1604 and the footer 1606.

In some embodiments, the footer 1606 includes a parapet framework 1622 extending vertically above the slots 1618. The parapet framework 1622 may be configured to form the portion of the header 316 (FIG. 5) that extends above the roof 508 (FIG. 5).

As illustrated in FIG. 16B, the roof framework 1600 is configured to be mounted over an exterior wall 302. The footer 1606 of the roof framework 1600 is configured to be secured to an upper surface of the framework 308 of the exterior wall 302. In some embodiments, the upper surface is a shelf (e.g., shelf 1104 (FIG. 11)). In other embodiments, as illustrated in FIG. 16B, the upper surface of the framework 308 is an uppermost surface of the framework 308, such that no portion of the exterior wall 302 extends above the interface between the framework 308 of the exterior wall 302 and the footer 1606 of the roof framework 1600. In some embodiments, one of the roof trusses 1602 of the roof framework 1600 may be configured to be secured to an upper surface of another wall, such as an interior wall of the structure 100 (FIGS. 1-6). The footer 1606 and/or the roof trusses 1602 of the roof framework 1600 may be secured to the upper surfaces of the exterior wall 302 and/or the interior wall through hardware (e.g., screws, bolts, clamps, etc.), thermal bonding (e.g., welding, soldering, etc.), or an adhesives.

FIG. 17 illustrates a simplified floor plan of a level (e.g., the first level 214 (FIG. 3)) of the structure 100. Exterior walls 302 form a perimeter of the level. The level illustrated in FIG. 17 also includes interior walls 1702 that may combine with the exterior walls 302 to form separate rooms. The exterior walls 302 are formed from modular segments 304 that may include different utilities installed therein. As discussed above, some of the modular segments 304 include doors 306 or windows 606.

The level also includes the core structure 202 positioned proximate a center of the level. As discussed above, the interior region 206 of the core structure 202 houses the main utilities and main mechanical components. In the embodiment illustrated in FIG. 17, the interior region 206 includes the main electrical 1704, the water main 1706, the sewer main 1708, the water heater 1710, the water treatment system 1712, the gas main 1714, the data main 1716, and the climate control device 1718. The main electrical 1704 may be a primary connection point, such as a fuse panel, a breaker panel, a power control panel (e.g., lighting control panel), a meter connection, etc. The water main 1706 may be the main water line from a utility supplier, the main line from a culinary water pump, the main water line from a well connection, etc. The sewer main 1708 may be the main connection to a city sewer system, the main connection to a septic system, etc. The water heater 1710 may be a gas water heater, an electric water heater, a tankless water heater, an instant water heater, a water heater tank, a boiler, etc. The water treatment system 1712 may be one or more of a water filter, a water softener, a water purification system, etc. The gas main 1714 may be a main natural gas line, a main propane line, a heating oil line, etc. The data main 1716 may be a main data connection, a main fiber connection, a main phone connection, a main satellite connection, a splitter, a router, a modem, security system, etc. The climate control device 1718 may include one or more of a furnace, an air conditioning system, an evaporator, a fan, an evaporative cooler, an air filter, a humidifier, a cooling coil, a heating coil, etc. The main connections of other utilities not listed herein may also be included in the interior region 206 of the core structure 202.

The main utilities within the interior region 206 of the core structure 202 are connected to utility fixtures in the exterior walls 302 and/or in the interior walls 1702. As discussed, the utilities may be pre-installed in the modular segments 304. The pre-installed utilities may also include the utility fixtures or connections for the utility fixtures, such as junction boxes, stub outs, etc. The utility fixtures may include plumbing fixtures 1720, such as sinks, toilets, tubs, showers, water faucets (e.g., interior water faucets, exterior water faucets), etc. The plumbing fixtures 1720 may be connected to one or more of the water main 1706, the water heater 1710, the sewer main 1708, or the water treatment system 1712. The utility fixtures may also include electrical fixtures 1722, such as electrical outlets, electrical switches, light fixtures, electric stoves, electric ovens, electric heaters, electric fans, etc. The utility fixtures may further include data fixtures 1724, such as data ports, data switches, etc. As discussed above, the utilities in the modular segments 304 may be connected to the main utilities in the interior region 206 of the core structure 202 through the utilities 1410 (FIG. 14) running through the lateral wall structures 402 (FIGS. 4 and 14) or by utilities running through the cavity 106 (FIG. 1) running under the floor 110 (FIG. 1) of the base 102 (FIG. 1). The utilities in the interior walls 1702 may also be connected to the main utilities in the interior region 206 of the core structure 202 through the utilities running in the lateral wall structures 402 (FIGS. 4 and 14) or under the floor 110 (FIG. 1) of the base 102 (FIG. 1). In other embodiments, the utilities in the interior walls 1702 may be received through the modular segments 304 of the exterior walls 302.

Some of the utility fixtures may be positioned in the lateral wall structures 402, 502 (FIGS. 4, 5, and 14), such as in the ceilings 410, 510 (FIGS. 4, 5, and 14) or floor 408 (FIGS. 4 and 14) of the associated level. For example, electrical fixtures 1722, such as light fixtures, may be suspended from the associated lateral wall structures 402, 502 (FIGS. 4, 5, and 14). In some embodiments, climate control terminals 1726, such as diffusers, registers, supply terminals, return registers, etc., may be installed in the lateral wall structures 402, 502 to supply conditioned air from the climate control device 1718 from the ceilings 410, 510 (FIGS. 4, 5, and 14) or floor 408 (FIGS. 4 and 14) of the associated level. The climate control device 1718 may be connected to the climate control terminals 1726 through ducts 1728 running through the lateral wall structures 402, 502 (FIGS. 4, 5, and 14).

The embodiments of the disclosure may facilitate modular construction of a building while also facilitating customization. Modular construction may reduce the costs of building a structure by mass producing modular segments, which may increase the efficiency of the building process. By mass producing modular segments, the segments may be pieced together in multiple different configurations and may also be interchangeable, such that the arrangements may be changed in different buildings. This may facilitate greater customization. Providing greater customization may facilitate using modular construction to meet the demands of a greater number of users. Thus, embodiments of the disclosure may result in decreased building costs for a greater number of consumers.

The embodiments of the disclosure may also facilitate modularly constructed buildings having greater insulation factors. Conventionally constructed modular buildings generally have low insulation values resulting in lower efficiency with regard to climate control within the structure. Embodiments of the disclosure may facilitate modular construction of buildings having insulation factors that are much greater than conventionally constructed modular buildings. Increasing the insulation factors of a building may reduce the energy consumed by the building, which may further reduce the costs of owning the associated building.

The embodiments of the disclosure described above and illustrated in the accompanying drawing figures do not limit the scope of the invention, since these embodiments are merely examples of embodiments of the invention, which is defined by the appended claims and their legal equivalents. Any equivalent embodiments are intended to be within the scope of this disclosure. Indeed, various modifications of the disclosure, in addition to those shown and described herein, such as alternative useful combinations of the elements described, may become apparent to those skilled in the art from the description. Such modifications and embodiments are also intended to fall within the scope of the appended claims and their legal equivalents.

Claims

1. A modular wall structure comprising:

a framework comprising:
an inner framework formed from inner studs;
an outer framework formed from outer studs secured to the inner framework; and
a termination structure on an end of the framework, wherein the inner studs of the inner framework are not aligned with the outer studs of the outer framework at the termination structure.

2. The modular wall structure of claim 1, wherein the termination structure forms a Z-joint.

3. The modular wall structure of claim 1, wherein the inner studs of the inner framework of the termination structure are offset from the outer studs of the outer framework of the termination structure by at least about ½ of a thickness of the outer studs.

4. The modular wall structure of claim 1, wherein the inner studs of the inner framework of the termination structure are offset form the outer studs of the outer framework of the termination structure by from about ½ of a thickness of the outer studs to about 2 times the thickness of the outer studs.

5. The modular wall structure of claim 1, further comprising an anchor structure positioned in the termination structure on the end of the framework.

6. The modular wall structure of claim 5, wherein the anchor structure is positioned within the inner framework.

7. A modular wall structure comprising:

a first modular wall segment comprising: a first outer wall framework; and a first inner wall framework secured to the first outer wall framework;
a second modular wall segment configured to be secured to the first modular wall segment, the second modular wall segment comprising: a second outer framework; and a second inner wall framework secured to the second outer wall framework, the second inner wall framework positioned and configured to define an inner gap between the second inner wall framework and the first inner wall framework that is greater than a distance between the first outer wall framework and the second outer wall framework when the second modular wall segment is secured to the first modular wall segment.

8. The modular wall structure of claim 7, wherein the second modular wall segment comprises an anchor structure configured to secure the second modular wall segment to the first modular segment.

9. The modular wall structure of claim 8, wherein the anchor structure is positioned in the second inner wall framework.

10. The modular wall structure of claim 8, wherein the anchor structure comprises a threaded bung configured to receive a fastener.

11. The modular wall structure of claim 7, wherein the first inner wall framework, the first outer wall framework, the second inner wall framework, and the second outer wall framework are formed from multiple studs having a substantially uniform width.

12. The modular wall structure of claim 11, wherein the inner gap has a gap width less than the substantially uniform width of any one of the multiple studs.

13. The modular wall structure of claim 11, wherein the inner gap has a gap width that is in a range from about 1/8th of the substantially uniform width of any one of the multiple studs to about ½ the substantially uniform width of any one of the multiple studs.

14. A method of forming a modular wall, the method comprising:

assembling a first modular segment comprising a first outer wall framework and a first inner wall framework secured to the first outer wall framework;
assembling a second modular segment comprising a second outer wall framework and a second inner wall framework secured to the second outer wall framework;
securing the first modular segment to the second modular segment;
defining a gap between the first inner wall framework and the second inner wall framework;
filling the gap with an insulative material.

15. The method of claim 14, wherein securing the first modular segment to the second modular segment comprises clamping the first modular segment to the second modular segment through an anchor structure.

16. The method of claim 15, wherein clamping the first modular segment to the second modular segment through the anchor structure causes the first outer wall framework to contact the second outer wall framework while defining the gap between the first inner wall framework and the second inner wall framework.

17. The method of claim 15, wherein clamping the first modular segment to the second modular segment through the anchor structure comprises securing the first modular segment to the second modular segment through a fastener extending across the gap between the first inner wall framework and the second inner wall framework.

18. The method of claim 14, wherein filling the gap with the insulative material comprises filling the gap with the insulative material before securing the first modular segment to the second modular segment.

19. The method of claim 14, wherein filling the gap with the insulative material comprises filling the gap with the insulative material after securing the first modular segment to the second modular segment.

20. The method of claim 14, wherein filling the gap with the insulative material comprises filling the gap with a spray foam insulative material.

Patent History
Publication number: 20260201693
Type: Application
Filed: Mar 11, 2026
Publication Date: Jul 16, 2026
Inventor: Willem Jacobus de Jager (Park City, UT)
Application Number: 19/563,387
Classifications
International Classification: E04B 2/56 (20060101);