PREFABRICATED MODULAR UNIT

Abstract

A prefabricated modular unit that includes a balcony, a living space, and part of an interior central corridor of a building. Assembly of a plurality of the prefabricated modular units allows the construction of said building. The prefabricated modular units comprise units configured to be installed underground.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application relates to and is a continuation-in-part application claiming priority under 35 U.S.C. § 120 from U.S. patent application Ser. No. 18/416,237, filed Jan. 18, 2024, entitled PREFABRICATED MODULAR UNIT, which is a non-provisional application claiming priority under 35 U.S.C. § 119(e) from U.S. patent application Ser. No. 63/439,756, filed Jan. 18, 2023, entitled PREFABRICATED MODULAR UNIT, the specifications of which are hereby incorporated herein by reference in their entireties.

BACKGROUND

a) Field

The present invention relates broadly to the field of building construction of a multi-level building made of prefabricated modular units for dwelling, hotel and office buildings assembled together.

b) Related Prior Art

At “Montreal Expo 67” World's fair, the architect Moshe Safdie assemblage of prefabricated concrete boxes for the habitat housing caused lots of interest in ways of stacking prefabricated modular units. The following U.S. patents are pertinent to this invention, but are differentiated by conceptual design, methods of construction, size, weight, assembly, erection technique, the inclusion of ventilation, electrical, plumbing, sprinkler network components, etc.

This invention was prompted by the need for affordable housing around the world. Economic recession, long-term interest rates and the recent pandemic have resulted in high material and labour costs for conventional constructions that have made homeownership impossible for many citizens.

This invention relates to multi-story construction employing prefabricated three-dimensional concrete modular units.

Affordable housing can only be achieved through industrialized factory-produced housing. This invention is designed to enable the majority of construction efforts to transpire in a factory, away from the building site. Cost savings through mass production and prefabrication are anticipated due to reduction in the range of materials being used, shortened construction periods and alleviation of delay due to inclement weather and lower site safety issues.

The embodiments of this invention provide advantages over the arrangements taught in the following patents:

• • U.S. Pat. No. 9,556,629 B2 describing Precast concrete module which can be adapted internally to multiple uses; U.S. Pat. No. 4,050,215 A describing Premanufactured modular housing building construction; U.S. Pat. No. 7,673,422 B2 describing Modular buildings; U.S. Pat. No. 4,195,453 A describing a Modular, multi-floor building; U.S. patent application No. 2011/0265395 A1 describing an Earthquake shelter; U.S. Pat. No. 5,893,241 A describing a Precast concrete target house; U.S. Pat. No. 8,950,132 B2 describing Premanufactured structures for constructing buildings; and U.S. patent application No. 2013/0067832 B1 describing Lift-slab construction system and method for constructing multi-story buildings using pre-manufactured structures.

There is therefore a need for improvement in the field that overcomes the shortcomings of the listed references.

SUMMARY

Differences And Advantages

The subject invention differs from U.S. Pat. No. 9,556,629 in that it is designed as an attached structure for similar prefabricated modular units to build multi-story, not an individual single-family residence. The structural system for this invention has an overhanging portion supported by two longitudinal beams, not by a structural slab. The interior dividing wall for this invention has complete finished openings for interior doors, not partial sections of interior dividing wall. This invention includes a cast balcony. The structural system for the roof includes a slab being supported by two longitudinal structural beams, not a pre-stressed concrete slab.

This invention differs from U.S. Pat. No. 4,050,215 in that its structure is complete with all exterior walls, interior walls, balcony, central corridors, two longitudinal structural beams and four structural columns for transmitting vertical loads, not having only two boundary planes for transmitting vertical loads.

This invention differs from U.S. Pat. No. 7,673,422 in that its open box structure is open on top, not on the side. The subject invention embodies a plurality of prefabricated modular units complete with balcony and central corridor; not separate box open on the side for the corridor. This invention has a prefabricated staircase module surrounded by a minimum of three shear walls, not by two modular walls.

The subject invention is differentiated from U.S. Pat. No. 4,195,453 in that its prefabricated modular units are cast with a floor slab supported by two longitudinal structural beams, not sitting on an independent conventional structural slab cast on site.

The subject invention differs from U.S. patent application No. 2011/0265395 in that it is designed as an attached structure of similar prefabricated modular units with seismic resistance to build multi-story, not an individual earthquake shelter.

The subject invention differs from U.S. Pat. No. 5,893,241 in that it is designed as an attached structure of similar prefabricated modular units, not an individual single-family residence.

The subject invention is differentiated from U.S. Pat. No. 8,950,132 in that its prefabricated modular units have a weight-bearing column, not non-load bearing walls. The interior dividing walls are cast in concrete, not made of steel studs and gypsum installed on an independent concrete floor slab cast on site. This invention includes prefabricated modular units complete with a floor slab supported by two longitudinal structural beams, balcony, and central corridor, not a standard structural concrete floor slab cast on site with a standard balcony.

The subject invention differs from U.S. patent application 2013/0067832 in that its prefabricated modular units have weight-bearing walls and columns, not prefabricated modular units being installed in a structural steel framing. This invention includes prefabricated modular units complete with a cast balcony, not a bolted steel balcony.

EMBODIMENTS

In accordance with the preferred embodiment of this invention, an architectural building system is provided which consists of prefabricated modular units cast with two longitudinal structural beams to assemble together for building multi-story buildings for dwellings, hotels and office buildings.

In some aspects, the description herein relates to prefabricated modular units to be assembled together into a multi-story building, a first one and a second one of the prefabricated modular units including: longitudinal structural beams; a horizontal slab spanning between the longitudinal structural beams; structural columns extending vertically between a bottom end about the horizontal slab to a top end; and anchor plates set at the bottom end and at the top end of the structural columns, wherein the anchor plates are configured to secure the prefabricated modular units to each other either with the prefabricated modular units stacked one over another or with the prefabricated modular units laid side-by-side.

In some aspects, the description herein relates to a prefabricated modular units, further including walls extending vertically from the horizontal slab, wherein the structural columns are adjoining the walls.

In some aspects, the description herein relates to a prefabricated modular units, wherein the walls include exterior walls joining at corners and forming together a closed space, and dividing walls extending in the closed space.

In some aspects, the description herein relates to a prefabricated modular units, wherein the structural columns include a corner structural column about at least one of the corners.

In some aspects, the description herein relates to a prefabricated modular units, wherein the structural columns include at least one intermediary structural column distant from the corners.

In some aspects, the description herein relates to a prefabricated modular units, further including a rod coupling the at least one intermediary structural column to one of the longitudinal structural beams.

In some aspects, the description herein relates to a prefabricated modular units, further including a ventilated duct extending at least partially in one of the longitudinal structural beams.

In some aspects, the description herein relates to a prefabricated modular units, wherein the anchor plates include a hole for a securing member to extend across.

In some aspects, the description herein relates to a prefabricated modular units, wherein the prefabricated modular units further include means for securing the anchor plates for securing above-story prefabricated modular units on top of the prefabricated modular units.

In some aspects, the description herein relates to a prefabricated modular units, further including a vertical plumbing shaft and an extruded insulation blanket cast together.

In some aspects, the description herein relates to a prefabricated modular units, wherein the prefabricated modular units are stacked one over another, the prefabricated modular units including a bridge plate configured to be inserted between adjoining ones of the anchor plates of the prefabricated modular units, and a bolt configured to secure the anchor plates adjoining one another to each other.

In some aspects, the description herein relates to a prefabricated modular units, further including a bolt access apparatus configured to provide access to the bolt from aside the longitudinal structural beams.

In some aspects, the description herein relates to a prefabricated modular units, wherein the prefabricated modular units are configured to have a prefabricated roof slab laid thereon, the prefabricated roof slab having a roof drain at a lower position thereof, the roof drain being coupled to plumbing extending downward from the roof drain in a wall of the prefabricated modular units.

In some aspects, the description herein relates to a prefabricated modular units, further including an open top, wherein the open top is configured to be closed by another one of the prefabricated modular units being stacked over.

In some aspects, the description herein relates to a building built with the prefabricated modular units, wherein at least one of the prefabricated modular units is used for an underground level of the building.

In some aspects, the description herein relates to a building built with at least three prefabricated modular units 1, wherein at least one of the prefabricated modular units has a neighboring prefabricated modular unit and a stacked-over prefabricated modular unit, with the at least one of the prefabricated modular units being secured to the neighboring prefabricated modular unit and the stacked-over prefabricated modular unit.

In some aspects, the description herein relates to a building, wherein the anchor plates include a hole for a bolt to extend across.

In some aspects, the description herein relates to a building, wherein at least one of the prefabricated modular units has a prefabricated roof slab secured on top thereof.

In some aspects, the description herein relates to a building, further including a bridge plate configured to be inserted between adjoining ones of the anchor plates, and a bolt configured to secure the anchor plates adjoining one another to each other.

In some aspects, the description herein relates to a building, wherein the prefabricated modular units include at least one of a plumbing pipe and a ventilation duct that is configured to be coupled to the plumbing pipe or the ventilation duct of an adjacent one of the prefabricated modular units.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present disclosure will become apparent from the following detailed description, taken in combination with the appended drawings, in which:

FIG. 1 is a diagrammatic perspective view of the construction of a multi-story building in an incomplete stage according to a system embodying the principles of the present invention employing prefabricated modular units made of reinforced concrete;

FIG. 2 is an isometric view of an exemplary prefabricated modular unit in accordance with an embodiment;

FIG. 3 is a side sectional view of an exemplary portion of the multi-story building of FIG. 1;

FIG. 4 is a front sectional view of an exemplary portion of the multi-story building of FIG. 1;

FIG. 5 is a plan view of the lower level parking of the multi-story building of FIG. 1;

FIG. 6 is a side view of a ground and second level multi-story building prefabricated modular unit with an overhanging portion over the lower level parking, said overhanging portion being structurally supported by two longitudinal cantilever beams, with the prefabricated modular units of other levels having an overhanging portion over the lower prefabricated modular units;

FIG. 7 is a side view of a prefabricated modular unit with two overhanging portions; one over the lower level parking and one over the façade of the building, with the overhanging over the façade and over the lower level parking being supported by cantilever beams;

FIG. 8 is a front sectional view of the structural member being used for attaching the prefabricated modular unit together;

FIG. 9 is a front sectional view of an alternate steel supporting beam;

FIG. 10 illustrates a plan view of a typical floor of a building being built with several prefabricated modular units in accordance with an embodiment;

FIG. 11 is a plan view of an exemplary dwelling built with two prefabricated modular units;

FIG. 12 is a cross-sectional detail view of an exterior wall and of a balcony;

FIG. 13 is a front sectional view of a prefabricated modular unit being partially used for an emergency staircase;

FIG. 14 is a plan view of a prefabricated modular unit being partially used for an emergency staircase;

FIG. 15 is a front sectional view of a prefabricated modular unit being partially used for an elevator shaft;

FIG. 16 is a plan view of a prefabricated modular unit being partially used for an elevator shaft;

FIG. 17 is a front sectional view of a prefabricated roof slab; and

FIG. 18 is a sectional elevation view of the interior portion of an exterior wall;

FIG. 19 is a sectional elevation view of an interior dividing wall;

FIG. 20 is a sectional view of a cast door frame;

FIG. 21 is a plan sectional view of an exterior wall of a prefabricated modular unit;

FIG. 22 is a plan view of a plumbing vertical shaft and a casting technique using extruded insulation;

FIG. 23 is an isometric view of an exemplary prefabricated modular unit showing the height (8) anchor steel plate being used to transport and hoist the prefabricated modular units with standard shipping container trailers and lifting cranes;

FIG. 24 is a partial view of a prefabricated modular unit showing two (2) anchor steel plates welded or screwed to the structural column steel rebars;

FIG. 25 is an elevation cut view of a twist lock stacking pin being made of 2 parts screwed one into another;

FIG. 26 is a top view of a twist lock stacking pin similar to the stacking pins being used in the shipping container industry;

FIG. 27 is a partial view of a prefabricated modular unit showing an anchor steel plate with an oval opening to be used with twist lock stacking pins;

FIG. 28 is a top view of a bridge plate to secure horizontally two prefabricated modular units;

FIG. 29 is a side view of a bridge plate assembly with two (2) twist lock stacking pins;

FIG. 30 is a partial view of two (2) prefabricated modular units being attached horizontally with a bridge plate and two (2) twist lock stacking pins;

FIG. 31 is an isometric view of several levels of prefabricated modular units of an incomplete building in accordance with a second embodiment of the invention;

FIG. 32 is an isometric perspective view of an exemplary prefabricated modular unit according to the second embodiment of the invention;

FIG. 33 is a cross-section view of a prefabricated modular unit according to the second embodiment of the invention;

FIG. 34 is an isometric view of an exemplary underground lower level prefabricated modular unit in accordance with the second embodiment of the invention;

FIG. 35 is a vertical cross-section view of a prefabricated modular unit in accordance with the second embodiment of the invention;

FIG. 36 is a front sectional view of the prefabricated roof slab of a prefabricated modular unit in accordance with the second embodiment of the invention;

FIG. 37 is a plan view of a plumbing vertical shaft of a prefabricated modular unit of the second embodiment of the invention;

FIG. 38 is a partial view of a prefabricated modular unit showing a top anchor steel plate and a lower anchor steel plate in accordance with the second embodiment of the invention;

FIG. 39 is a top view of a bridge plate used to secure two prefabricated modular units to one another in accordance with the second embodiment of the invention; and

FIG. 40 is a side view of a bridge plate assembly with two (2) pins in accordance with the second embodiment of the invention.

It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

DETAILED DESCRIPTION

The realizations will now be described more fully hereinafter with reference to the accompanying figures, in which realizations are illustrated. The foregoing may, however, be embodied in many different forms and should not be construed as limited to the illustrated realizations set forth herein.

As will be realized, the subject matter disclosed and claimed is capable of modifications in various respects, all without departing from the scope of the description. Accordingly, the drawings and the description are to be regarded as illustrative in nature.

With respect to the present description, references to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. Thus, the term “or” should generally be understood to mean “and/or” and so forth.

Recitation of ranges of values and of values herein or on the drawings are not intended to be limiting, referring instead individually to any and all values falling within the range, unless otherwise indicated herein, and each separate value within such a range is incorporated into the specification as if it were individually recited herein. The words “about,” “approximately,” or the like, when accompanying a numerical value, are to be construed as indicating a deviation as would be appreciated by one of ordinary skill in the art to operate satisfactorily for an intended purpose. Ranges of values and/or numeric values are provided herein as examples only, and do not constitute a limitation on the scope of the described realizations. The use of any and all examples, or exemplary language “e.g.,” “such as,” or the like provided herein, is intended merely to better illuminate the exemplary realizations and does not pose a limitation on the scope of the realizations. No language in the specification should be construed as indicating any unclaimed element as essential to the practice of the realizations.

In the following description, it is understood that terms such as “first”, “second”, “top”, “bottom”, “above”, “below”, and the like, are words of convenience and are not to be construed as limiting terms.

The terms “top”, “up”, “upper”, “bottom”, “lower”, “down”, “vertical”, “horizontal”, “interior” and “exterior” and the like are intended to be construed in their normal meaning in relation with the normal installation of the product.

In realizations, there are disclosed prefabricated modular units and assemblies of prefabricated modular units.

It will be noted that throughout the appended drawings, like features are identified by like reference numerals.

Referring now to the drawings, a description is provided of modular units and a building constructed with modular units.

FIG. 1 is an isometric view of several levels of modular units of an incomplete building. Prefabricated modular units, e.g., prefabricated modular units 1, 2, 3, are set in place by means of a crane (not shown) at the building site, over a lower level parking 4 and lower level columns 17, 19. Prefabricated modular units e.g., prefabricated modular units 1, 2, 3, have a floor slab 5 cast to two longitudinal beams 6, 7, an exterior wall 8, interior dividing walls 10 with no ceiling for weight-saving considerations. All prefabricated modular units, e.g., prefabricated modular units 1, 2, 3, are cast with a balcony 22 supported by two longitudinal beams 6 and 7. Prefabricated modular units, e.g., prefabricated modular units 1, 2, 3, include part of a central corridor 11. A prefabricated modular unit, e.g., prefabricated modular unit 2, may exceed the adjacent module 1 to improve the aesthetic of the building or to comply with local bylaws. Corner modular units, e.g., prefabricated modular units 2 and 3, may not include part of a central corridor 11.

FIG. 2 is an isometric perspective view of an exemplary modular unit 1 used in the present invention, which forms a basic structural component of a modular building according to the present invention, and referring to FIG. 1. Each of the embodiments is cast at the factory from concrete as an independent rigid prefabricated modular unit. Each one is basically rectangular in shape, comprising a floor slab 5 cast on two longitudinal beams 6, 7, exterior walls 8, interior dividing walls 10, four structural columns 15, 18, a balcony 22, and a portion of a central corridor 11, but without a ceiling. Several perpendicular beams 54 are attached to the longitudinal beams 6, 7.

FIG. 3 is a side sectional view of an exemplary portion of the multi-story building of FIG. 1 being built over a lower level parking 4 comprising parking spaces 13 and a circulation alley 14. Structural columns 15 of the prefabricated modular units, e.g., prefabricated modular units 20 and 21, sit on top of the foundation wall 16 of the building or on lower level structural columns 17, 19. Structural column 18 of the prefabricated modular units, e.g., prefabricated modular units 20 and 21, sits on top of lower level structural columns 19, 17. It is understood that parking spaces 13 and circulation alley 14 may be located differently from the drawing without departing from the scope of the description. Prefabricated modular units, e.g., prefabricated modular units 20, 21, are cast with a balcony 22. Prefabricated modular units, e.g., prefabricated modular units 20, 21, have an overhanging portion 23 over the circulation alley 14. Prefabricated modular units, e.g., prefabricated modular units 20, 21, are cast with part of central corridors 24, 25, 26, 27.

Prefabricated modular units 52, 53 have an overhanging portion 23 over the lower level prefabricated modular unit(s), e.g., lower level prefabricated modular units 20, 21.

FIG. 4 is a front sectional view of an exemplary portion of the multi-story building of FIG. 1 being built over a lower level parking 4. Prefabricated modular unit 28 is used as a loft. By combining two prefabricated modular units, e.g., prefabricated modular unit 29, the living dwelling becomes a one-bedroom apartment. By combining three prefabricated modular units, e.g., prefabricated modular unit 30, the dwelling becomes a two-bedroom apartment. By combining four prefabricated modular units, e.g., prefabricated modular unit 31, the dwelling becomes a three-bedroom apartment. Prefabricated modular unit 32 is being used as an emergency staircase with cast or steel stairs. Prefabricated modular unit 33 is being used as an elevator shaft.

FIG. 5 is a plan view of the lower level parking 4 of FIG. 1, comprising parking spaces 13, a circulation alley 14, foundation walls 16, structural columns 17 and 19, lower level emergency staircases 34, and a lower level elevator shaft 35. Walls of the emergency staircases 34 and of the elevator shaft 35 are used as shear walls and are made of reinforced concrete to withstand earthquakes.

FIG. 6 is a side view of a ground-level prefabricated modular unit 21 with section 36 of the prefabricated modular unit 21 overhanging parking spaces 13 and circulation alley 14. The prefabricated modular units 53 of other levels have a section 55 of the prefabricated modular unit 53 and central corridor 26 overhanging the lower level modular unit 21. Prefabricated modular units 21 have a floor slab 5 cast with the two longitudinal concrete beams 6, 7 with one shown on the side view. Longitudinal beam 7 extends out of the prefabricated modular unit to support the balcony 22. The balcony 22 is cast at the factory and assembled with railings 37 and an air conditioning condenser 38. To reduce the size of the longitudinal beams 6, 7, rods 39 are attached to the beam 7 and hang from the column 18, with one shown on the side view, to lower the section of the cantilever portion of the longitudinal beams 6, 7. Ventilation duct 42 is being inserted in the beams 6, 7. A ventilation outlet 43 is located at the outside extremity of the beams 6, 7. Perpendicular beams 54 are attached to the longitudinal beams 6, 7.

FIG. 7 is a side view of prefabricated modular units 21, 53 with an overhanging façade 81 of the building, the overhang of the façade 81 being supported by two longitudinal beams 6, 7.

FIG. 8 is a front sectional view of a plurality of prefabricated modular units 1 being joined by a multitude of bridge plates 41. Ventilation duct 42 is shown in the center of concrete beams 6, 7.

FIG. 9 is a front sectional view of a prefabricated modular unit 1 being built with a concrete slab 5 supported by steel beams 44, 45. Fireproofing of the steel beams 44, 45 is realized with a gypsum box 46.

FIG. 10 is a plan view of a typical building built with prefabricated modular units 1, 3. Horizontal interlocking of the individual prefabricated modular units 1, 3 is realized with the structural floor of the central corridor. The interlocking of prefabricated modular units, e.g., prefabricated modular units 1, 3, is realized with a plurality of structural members 47, 48.

FIG. 11 is a plan view of an exemplary one-room dwelling built with two prefabricated modular units, e.g., prefabricated modular units 50, 51.

Prefabricated modular unit 50 contains all mechanical equipment, plumbing fixtures, and electrical distribution systems which service part of the dwelling. The prefabricated modular unit 51 contains a fully furnished kitchen including cabinets, sink, dishwasher, disposal, electric range, ventilation hood, dining and living room, air conditioning 59, condenser 38, balcony 22, railings, insulated exterior wall, and pre-hung doors 57.

The second prefabricated modular unit 50 includes a room, a hallway for internal circulation, a bathroom consisting of a tub, a shower, a toilet, a vanity, a linen closet, a facility comprising an electric clothes dryer, a washing machine, a heat exchanger 56 for venting the bathroom, floor finishing, tiles, and a pre-hung door. Prefabricated modular unit comprises a balcony 22, railing, insulated exterior wall 1, prewired interior dividing wall 10, pre-hung doors 57 and windows 58, hot water tank 49. The prefabricated modular unit exterior wall is completed with insulation, vapor and wind barrier, waterproofing of door, and windows openings.

A third prefabricated modular unit (not shown) is used to build a two-bedroom dwelling and includes a room, a hallway for internal circulation, a bathroom consisting of a tub, a shower, a toilet, a vanity, a linen closet, a fan or heat exchanger 56 for venting the bathroom, floor finishing, tiles, and a pre-hung door. The prefabricated modular unit comprises a balcony 22, railing, insulated exterior wall, prewired interior dividing wall 10, pre-hung doors 57 and windows 58. The prefabricated modular unit exterior wall is completed with insulation, vapor and wind barrier, waterproofing of door, and windows openings.

A fourth prefabricated modular unit (not shown) is used to build a three-bedroom dwelling and includes a room, a hallway for internal circulation, a bathroom consisting of a tub, a shower, a toilet, a vanity, a linen closet, a fan or heat exchanger 56 for venting the bathroom, floor finishing, tiles, and a pre-hung door. The prefabricated modular unit comprises a balcony 22, railing, insulated exterior wall, prewired interior dividing wall 10, pre-hung doors 57, and windows 58. The exterior wall of the prefabricated modular unit is completed with insulation, vapor and wind barrier, waterproofing of door and windows openings.

FIG. 12 is a cross-sectional detailed view of an exterior wall and of a balcony 22. Indoor portion 60 of the exterior wall 8 is pre-wired and cast in concrete. Wind barrier, insulation 61 and vapor barrier are being attached to the indoor portion 60 of the exterior wall 8. The wind barrier, insulation and vapor barrier run through an opening 62 in the slab and in longitudinal concrete beams 6, 7. The opening 62 in the slab is separating the cold outdoor from the heated portion of the dwelling. It acts as a thermal barrier. Exterior finishing consists of wood, metal siding, tiles, or brick that sit on a perpendicular concrete beam 54 spanning from the two longitudinal beams 6, 7. Ventilation outlet 43 at the extremity of the beam is shown with plenum 63, back-draft damper, and duct 42.

FIG. 13 is a front sectional view of a prefabricated modular unit 32 being partially used for an emergency staircase. Access door 64 to the emergency staircase is fire-rated. The perimeter walls 65 of the emergency staircase are used as shear walls made of reinforced concrete. The stairs 66 are made of steel or reinforced concrete. Perpendicular beams 54 span from the longitudinal beams 6, 7.

FIG. 14 is a plan view of a prefabricated modular unit 32 being partially used for an emergency staircase comprising shear walls 65, central corridor walls 67, fire-rated doors 64, and stairs 66. Unused portions 68 of the prefabricated modular unit 32 and balcony 22 are used by an adjacent dwelling.

FIG. 15 is a front sectional view of a prefabricated modular unit 33 being partially used for an elevator shaft 69. The perimeter walls 70 of the elevator shaft 69 are used as shear walls made of reinforced concrete.

FIG. 16 is a plan view of a prefabricated modular unit 33 being partially used for an elevator shaft 69 comprising shear walls 70, central corridor 11. Unused portions 93 of the prefabricated modular unit 33 and balcony 22 are used by an adjacent dwelling.

FIG. 17 is a front sectional view of the prefabricated roof slab 71. Prefabricated roof slab 71 is completed with two longitudinal concrete beams 6, 7, supporting the roof slab 71. The top of roof slab 71 has a two-dimentional slope 72 to guide the rainwater toward the roof drain (not shown). Longitudinal concrete beams are completed with ventilation duct 42 for venting the last floor dwelling unit, the prefabricated roof slab 71 being joined by bridge plates 41.

FIG. 18 is a sectional elevation view of an interior part 60 of an exterior wall. All interior walls and the exterior walls of the prefabricated modular unit are cast at the factory. Door frames 74, latch holes 78, hinges depression 79, and perimeter moldings 73 on one side of the door frame are cast simultaneously with the casting of the wall. Bottom molding 75 on one side of the wall is cast simultaneously with the casting of the wall 60.

Window frames 76, interior finish, and window perimeter molding 77 of the window frame are cast simultaneously with the casting of the interior parts of the perimeter wall 60.

FIG. 19 is a sectional elevation of an internal dividing wall 10. All dividing walls 10 of the prefabricated modular unit are cast at the factory. Door frames 74, latch holes 78, hinges depression 79, and perimeter molding 73 on both sides of the said door frame are cast simultaneously with the casting of the wall. Bottom moldings 75 on each side of the wall are cast simultaneously with the casting of the dividing wall 10.

FIG. 20 is a sectional view of a cast door frame 74, latch holes 78, hinges depression 79, perimeter molding 73, and door stopper 80.

FIG. 21 is an interior sectional view of an exterior wall of a prefabricated modular unit 1. Perpendicular beam 54 spans from the longitudinal beams 6, 7.

FIG. 22 is a plan view of a plumbing vertical shaft 82. Plumbing pipes 9 are placed into an extruded insulation blanket 40. The assembly of the insulation blanket 40 and pipes 9 are inserted into the mold and concrete 85 is poured around the pipe/insulation assembly.

FIG. 23 is an isometric view of an exemplary prefabricated modular unit 1 showing the top anchor steel plate 86 being used to lift the prefabricated modular unit. Lower anchor steel plates 87 are used to transport the prefabricated modular units.

FIG. 24 is a partial view of a prefabricated modular unit 1 showing the top anchor steel plate 86 and the lower anchor steel plate 87 being welded or screwed to the structural columns 18 and steel rebars 88.

FIG. 25 is an elevation cut view of a twist lock stacking pin 83 being made of a top pin 89 and a lower pin 92 comprising a threaded end 94.

FIG. 26 is a top view of a twist lock stacking pin 83. A difference between the twist lock pin 83 and a pin currently used with containers is that the twist lock stacking pin 83 is made of 2 parts instead of being a one-piece cast stacking pin.

FIG. 27 is a partial view of a prefabricated modular unit 1 showing a top anchor steel plate 86 with an oval opening 84 to be used with a twist lock stacking pin 83.

FIG. 28 is a top view of a bridge plate 41 to secure horizontally two (2) prefabricated modular units. Bridge plate 41 has two (2) openings 90, e.g., oval openings, to be used with twist lock stacking pins 83.

FIG. 29 is a side view of a bridge plate 41 assembly with two (2) twist lock stacking pins 83. Locking plate 91 is used to limit the rotation of the bridge plate 41.

FIG. 30 is a partial view of two (2) adjacent prefabricated modular units 1 being attached horizontally with a bridge plate 41, a top anchor steel plate 86 being attached to the bridge plate 41 using two (2) twist lock stacking pins 83 mounted to the top anchor steel plates 86. Depicted on the left is the twist lock pin 83 depicted in an insertion position, and on the right is depicted the twist lock pin 83 being shown in a locking position with an abutting interface 12 preventing the twist lock pin 83 from exiting.

Referring to FIG. 31 to FIG. 40, according to another embodiment, a building is built using prefabricated modular units 101, 102 assembled together to build the underground level and the above-ground levels of the building where some units are stacked one over another, some are laid side by side and some have adjoining units in both configurations.

FIG. 31 is an isometric view of several levels of modular units of an incomplete building. Prefabricated modular units, e.g., prefabricated modular units 101, 102, 103, are set in place by means of a crane (not shown) at the building site over a lower level also made from prefabricated modular units, e.g., units 101, 102, 103. Prefabricated modular units 101, 102, 103 have a floor slab 104 cast to two longitudinal structural beams 105, 106, an exterior wall 107, interior dividing walls 108, and no ceiling for weight-saving considerations. A number of the prefabricated modular units, e.g., units 101, 102, may be cast with a balcony 109 supported by outdoor extensions of the longitudinal structural beams 105, 106. A number of prefabricated modular units, e.g., units 101, 102, may include part of a central corridor 110. A number of prefabricated modular units, e.g., unit 101, may exceed the adjacent module, e.g., unit 102, to improve the aesthetics of the building or to comply with local bylaws. This is achieved by extending the two longitudinal structural beams of the unit that is designed to exceed a neighboring one.

FIG. 32 is an isometric perspective view of an exemplary modular unit 101 used in accordance with an embodiment of the present invention, which forms a structural component of a modular building according to embodiments of the present invention. Each of the embodiments is assembled at the factory, preferably cast from concrete as an independent rigid prefabricated modular unit. Preferably, each one is basically rectangular in shape, comprising a floor slab 104 cast on two longitudinal structural beams 105, 106, exterior walls 107, four structural columns 111 adjoining the exterior walls 107, a balcony 109, and a portion of a central corridor 110, with the exterior walls 107 forming together a closed space. Preferably, the prefabricated modular units comprise no ceiling. Eight anchor plates 112 are used to fasten the modular units to each other.

FIG. 33 is a cross-section view showing the two longitudinal structural beams 105, 106.

FIG. 34 is an isometric view of an exemplary underground lower level prefabricated modular unit 101 showing floor slab 104, longitudinal beam 105, longitudinal beam 106, structural columns 111, and anchor plates 112. The structural columns 111 may be located in corners of the closed space or distant to the corner, providing thereby intermediary structural columns.

FIG. 35 is a vertical cross-section view extending through two vertically stacked modular units as identified through cross-section indications on Fig. #. The cross-section view shows the operative interconnection in-between the units. The bridge plates 116 are installed on the anchor plates 112 of the structural columns 111. The upper modular units are configured to be lowered over the bridge plates 116 of another unit. The anchor plates 112 of the two longitudinal structural beams 105, 106 sit on the bridge plates 116. Bolts 117 are inserted by a bolt access apparatus 118, providing access to the bolt 117 from aside the structural beams, and tightened to secure the units one to another.

FIG. 36 is a front sectional view of the prefabricated roof slab 119. Prefabricated roof slab 119 is completed with two longitudinal structural beams 105, 106, supporting the roof slab 119. The top of roof slab 119 has a two-dimensional slope 172 to guide the rain water toward the roof drain 120 coupled to a pipe of the prefabricated modular unit laid under.

FIG. 37 is a plan view of a plumbing vertical shaft 121. Plumbing pipes 122 are placed into an insulation blanket 123. The assembly of the insulation blanket 123 and pipes 122 are inserted into the mold and concrete 124 is poured around the pipe/insulation assembly.

FIG. 38 is a partial view of a prefabricated modular unit 101 showing the top anchor steel plate 112 and the lower anchor steel plate 125 being welded to the structural columns 111 and steel rebars 126.

FIG. 39 is a top view of a bridge plate 116 used to secure horizontally two (2) prefabricated modular units. Bridge plate 116 has two (2) openings 127 to be used with centering pins 128 and fastening bolts 117.

FIG. 40 is a side view of a bridge plate 141 assembly with two (2) twist lock stacking pins 183.

While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure.

Claims

1. Prefabricated modular units to be assembled together into a multi-story building, a first one and a second one of the prefabricated modular units comprising:

longitudinal structural beams;

a horizontal slab spanning between the longitudinal structural beams;

structural columns extending vertically between a bottom end about the horizontal slab to a top end; and

anchor plates set at the bottom end and at the top end of the structural columns,

wherein the anchor plates are configured to secure the prefabricated modular units to each other either with the prefabricated modular units stacked one over another or with the prefabricated modular units laid side-by-side.

2. The prefabricated modular units of claim 1, further comprising walls extending vertically from the horizontal slab, wherein the structural columns are adjoining the walls.

3. The prefabricated modular units of claim 2, wherein the walls comprise exterior walls joining at corners and forming together a closed space, and dividing walls extending in the closed space.

4. The prefabricated modular units of claim 3, wherein the structural columns comprise a corner structural column about at least one of the corners.

5. The prefabricated modular units of claim 3, wherein the structural columns comprise at least one intermediary structural column distant from the corners.

6. The prefabricated modular units of claim 5, further comprising a rod coupling the at least one intermediary structural column to one of the longitudinal structural beams.

7. The prefabricated modular units of claim 1, further comprising a ventilated duct extending at least partially in one of the longitudinal structural beams.

8. The prefabricated modular units of claim 1, wherein the anchor plates comprise a hole for a securing member to extend across.

9. The prefabricated modular units of claim 1, wherein the prefabricated modular units further comprise means for securing the anchor plates for securing above-story prefabricated modular units on top of the prefabricated modular units.

10. The prefabricated modular units of claim 1, further comprising a vertical plumbing shaft and an extruded insulation blanket cast together.

11. The prefabricated modular units of claim 1, wherein the prefabricated modular units are stacked one over another, the prefabricated modular units comprising a bridge plate configured to be inserted between adjoining ones of the anchor plates of the prefabricated modular units, and a bolt configured to secure the anchor plates adjoining one another to each other.

12. The prefabricated modular units of claim 11, further comprising a bolt access apparatus configured to provide access to the bolt from aside the longitudinal structural beams.

13. The prefabricated modular units of claim 1, wherein the prefabricated modular units are configured to have a prefabricated roof slab laid thereon, the prefabricated roof slab having a roof drain at a lower position thereof, the roof drain being coupled to plumbing extending downward from the roof drain in a wall of the prefabricated modular units.

14. The prefabricated modular units of claim 1, further comprising an open top, wherein the open top is configured to be closed by another one of the prefabricated modular units being stacked over.

15. A building built with the prefabricated modular units of claim 1, wherein at least one of the prefabricated modular units is used for an underground level of the building.

16. A building built with at least three prefabricated modular units according to the prefabricated modular units of claim 1, wherein at least one of the prefabricated modular units has a neighboring prefabricated modular unit and a stacked-over prefabricated modular unit, with the at least one of the prefabricated modular units being secured to the neighboring prefabricated modular unit and the stacked-over prefabricated modular unit.

17. The building of claim 16, wherein the anchor plates comprise a hole for a bolt to extend across.

18. The building of claim 16, wherein at least one of the prefabricated modular units has a prefabricated roof slab secured on top thereof.

19. The building of claim 16, further comprising a bridge plate configured to be inserted between adjoining ones of the anchor plates, and a bolt configured to secure the anchor plates adjoining one another to each other.

20. The building of claim 16, wherein the prefabricated modular units comprise at least one of a plumbing pipe and a ventilation duct that is configured to be coupled to the plumbing pipe or the ventilation duct of an adjacent one of the prefabricated modular units.