DOUBLE BOTTOM PLATE

Abstract

Described herein are a system for wall-panel installation, including a first plate designed to be attached directly to concrete slab, and a second plate integrated within a prefabricated wall panel and designed to directly attach to the first plate. Also described are a method for wall-panel installation, including installing the first plate of the system of the disclosure to concrete slab, and installing the prefabricated wall panel of the system of the disclosure by attaching the second plate of the disclosure to the first plate of the disclosure and a modular home or building including the system of the disclosure or constructed using the method of the disclosure.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application relies on the disclosure of and claims priority to and the benefit of the filing date of U.S. Provisional Application No. 63/793,456 filed Apr. 23, 2025, the disclosure of which is hereby incorporated by reference herein in its entirety.

FIELD

The present disclosure is directed to the field of construction, and in particular, modular construction techniques and practices for wall installations.

BACKGROUND

Factory built homes have remained unpopular due to a number of factors including a lack in flexibility or versatility in design options often resulting in unattractive, box-like architectures that are inferior to homes built on site. There is a need for improvement in industrial home construction technology.

SUMMARY

In general, in a first aspect, the disclosure features a system for wall-panel installation, including a first plate designed to be attached directly to concrete slab, and a second plate integrated within a prefabricated wall panel and designed to directly attach to the first plate.

In general, in a second aspect, the disclosure features a method for wall-panel installation, including installing the first plate of the system to concrete slab, and installing the prefabricated wall panel of the system by attaching the second plate to the first plate.

In general, in a third aspect, the disclosure features a modular home or building including the system of the disclosure constructed using the method of the disclosure.

Features of the system, method, and modular home or building can include the following:

The first plate can be directly attached to concrete slab by anchor bolts or hold downs. The anchor bolts or hold can be cast directly into the concrete foundation during pour for attaching the first plate to concrete slab. The first plate can be installed at a construction site. The first plate can be designed to accommodate variations in concrete slab height and irregularities.

The second plate can be manufactured as a component of the prefabricated wall panel offsite from a construction site. The second plate can be directly attached to the first plate by nails.

It should be understood that the systems, methods, and modular homes or buildings are not to be considered limitations on the invention defined by the claims. The featured systems, methods, and modular homes or buildings can be implemented in one or more ways using one or more features depicted in the drawings, described in the detailed description, and set forth in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings illustrate certain aspects and principles of the implementations set forth, and should not be construed as limiting.

FIG. 1 is a diagram showing a front view comparing single plate and double plate panel installations according to one implementation.

FIG. 2 is a diagram showing a rear view comparing single plate and double plate panel installations according to one implementation.

FIGS. 3A and 3B are diagrams showing a detailed side view (FIG. 3A) and plan view (FIG. 3B) and structural detail of a double bottom plate according to one implementation.

FIG. 4 is a diagram of a wall elevation according to one implementation.

FIG. 5 is a diagram of a wall elevation sub-assembly according to one implementation.

FIG. 6 is a diagram of a wall plan according to one implementation.

DETAILED DESCRIPTION

Reference will now be made in detail to various illustrative implementations. It is to be understood that the following discussion of the implementations is not intended to be limiting.

System and Method for Mass Customization and Industrialization of Residential Construction via Productized Components

The disclosure generally relates to a system and method for enabling mass-customizable residential construction by standardizing and productizing subcomponents. The system and method include a digital engine that ingests builder-specific floor plans and decomposes them into standardized construction products, a rules-based generative and computational design system that permits unique configurations of these elements while maintaining structural and code compliance, and a product strategy where both the individual subcomponents and their assembled configurations (e.g., sub-assemblies, assemblies (wall panels), full housing units) are treated as products that can be certified nationally, thereby enabling regulatory approval at both the part and system level.

The result is a scalable framework for manufacturing highly variable home designs using a consistent, factory-built component library.

How it differs from the status quo (with clear differentiators):

The construction industry has historically failed to adopt industrialized methods due to the perceived rigidity of prefabrication and the need for architectural customization. The disclosure addresses that by Micro-Standardization Instead of Macro-Standardization. Existing systems often rely on standardization by large 3D volumetric modules (often as big as 9′×14′×70′). The system of the present disclosure standardizes at the subcomponent level (electrical assembly, plumbing assembly, etc.) enabling greater design flexibility when aggregated into 2D panels.

With respect to plan-ingestion and component translation, architectural floor plans are interpreted through the digital engine that translates architectural intent into manufacturable, repeatable parts.

With respect to rules-based recombination engine, a computational design tool governs how components are assembled and integrated, ensuring structural and regulatory integrity while allowing custom layouts.

Another feature includes certifiable component and assembly framework, where the system supports product certification (e.g., UL, ICC) at both the component and aggregate level, allowing for streamlined permitting and inspection processes across multiple jurisdictions.

Value provided by the systems and methods of the disclosure includes design flexibility with manufacturing efficiency: builders and customers retain architectural freedom while benefitting from cost and speed advantages typical of industrialization. This industrialization enables an automotive-like supply chain: similar to automobile assembly, components (e.g., HVAC modules, plumbing packs, structural frames) can be produced independently and integrated during final assembly. The systems and methods also provide a platform for continuous product optimization: standardization at the component level enables continuous improvement in materials, methods, and tolerances, driving down cost and improving housing quality at scale.

In summary, the systems and methods of the disclosure enable scalable mass customization of residential structures by decomposing architectural designs into standardized, certifiable subcomponents, configurable via a computational design engine. The approach combines digital design interpretation, component-level productization, and rules-based configuration logic to allow for the industrialized manufacture of architecturally diverse, code-compliant homes.

The present inventors have created systems and methods that let people design homes the way they like them—any shape, style, or size—and still build them quickly in a factory. Such systems and methods provide an application or program or software that works by breaking every house design into small, repeatable parts (like Lego bricks) that can be put together in many different ways. The software can take any builder's floor plan and turn it into a set of these building blocks, ready to be made in a factory.

Most factory-built homes today are big boxy shapes because it's easier to build that way. But most people don't want to live in a box—they want a home with a nice roof, cozy porch, or custom touches. That's why factory homes haven't caught on.

The present disclosure addresses this by:

• • Making small, easy-to-build parts that fit together in lots of ways, not just boxes.
  • Using software that understands how a home should look and figures out how to build it from standard parts.
  • Treating each small part (like a piece of a wall or a plumbing unit) as a real product that meets building rules—so cities are more likely to approve it.
    3. Why this matters:
  • People can have the home they want: You don't have to settle for boring designs just to stay on budget.
  • Builders can work faster and cheaper: Like car makers who get parts from different places and put them together on one big line, this lets home builders do the same.
  • We can keep improving the parts: Because the pieces are always the same, we can keep making them better, cheaper, and stronger over time.

In summary, the present inventor has developed an innovation that builds homes like Lego sets: lots of little parts that fit together in many ways. The system helps turn any home design into a set of parts we can make in a factory. That means homes can still be beautiful and personal—but they'll be faster to build, more affordable, and easier to approve across the country.

Executive Summary: Master System Design for Standardized Panel-Based Construction At the core of our innovation is a belief that architectural flexibility is enabled by micro-level standardization, much like LEGO® bricks. The disclosed system breaks down the construction of a house into modular, manufacturable components called panels, which can represent walls, floors, or roofs. This principle applies universally across trades and forms the foundation for nearly every product innovation or patent we pursue.

Key Principles of the System:

1. Panel-Based Modularization:

A home is divided into standardized panels that can be manufactured off-site. While the function of each panel (wall, floor, or roof) varies, the production methodology remains uniform—except for floors, which may require unique handling due to their scale.

2. Trade Sub-Assemblies for Added Value:

Panels become more than structural shells—they serve as carriers for trade-specific sub-assemblies (e.g., electrical, plumbing, HVAC). This builds complexity and value into the panel without complicating the main production line.

3. Standardized Sub-Assembly Design:

Sub-assemblies are value-added component clusters exhibiting high repetition and standardization. They reduce complexity on the main production line by shifting intricate work to batched or mass-produced modules that can be fabricated independently.

4. Indexing for Geometric Integration:

Each sub-assembly is geometrically indexed—either with a self-contained frame or a defined location within the panel frame. This ensures precise placement, rapid field integration, and consistent downstream routing.

5. Aggregation into 3D Assemblies:

Panels are not the endpoint. They can be aggregated into 3D volumetric assemblies (e.g., trusses, pods), providing a scalable pathway from flat-pack components to volumetric or hybrid prefab systems.

Why It Matters:

This system enables scalable mass production of custom homes while preserving architectural flexibility. By anchoring innovation in standardization at the sub-panel level, we unlock a broad design vocabulary across trades and product lines.

Example: Double Bottom Plate System for Offsite Wall Panel Installation

1. The Innovation A dual-bottom-plate system designed for installing offsite-manufactured wall panels onto concrete slab foundations. This invention includes a first, pressure-treated bottom plate secured directly to the foundation slab using traditional anchor bolts or hold-downs, and a second bottom plate integrated into the prefabricated wall panel, connected on-site to the first bottom plate using standard field nailing techniques and an exterior overlap shear panel.
2. How it differs from the status quo (with clear differentiators):

Traditionally, walls are framed directly on a slab with a single bottom plate, allowing framers to manually adjust for variations in slab-levelness by individually sizing studs. In contrast, our dual-plate system separates the tolerance adjustments from the prefabricated panel, enabling precision-manufactured walls to be installed efficiently on imprecise foundations.

Key Differentiators Include:

• • Double Bottom Plate Configuration:

The first (lower) bottom plate of the double bottom plate configuration, which is pressure-treated, accommodates variations in concrete slab height and irregularities (it is also referred to herein as a leveling plate). It is field installed. The second (upper) bottom plate of the double bottom plate remains dimensionally precise, integrated within the prefabricated panel (installed offsite) to ensure structural integrity and accurate panel installation.

• • Simplified Field Attachment Method:

The upper and lower bottom plates are secured together easily in the field by standard nails—both horizontally through exterior shear overlap panels and vertically through direct nailing—ensuring rapid, straightforward assembly without specialized labor or equipment.

• • Selective Application for Efficiency:

This dual-plate system is uniquely necessary only for exterior wall assemblies. Interior walls can continue using standard single bottom plate methods, optimizing overall material usage, reducing complexity, and lowering installation costs.

3. Value provided by the innovation:

• • Scalable Tolerance Accommodation:

Effectively manages inevitable concrete slab inconsistencies, eliminating reliance on highly precise concrete subcontractors and making the system scalable for nationwide use.

• • Accelerated On-Site Installation:

Prefabricated panels can be rapidly and accurately installed using common framing tools, reducing labor costs, installation complexity, and overall project timelines.

• • Compliance With Stringent Building Codes:

Meets structural requirements even in regions with stringent building codes, including areas already requiring 3× bottom plates, thus enhancing the system's universal applicability.

4. Summary:

In essence, this innovation addresses foundational irregularities through a structurally engineered, dual-bottom-plate design, bridging the precision gap between offsite panel manufacturing and onsite slab variability—enabling faster, simpler, and more economical construction methods.

Implementations of the double bottom plate system are shown in the following figures.

FIGS. 1 and 2 are diagrams comparing the conventional single plate versus the double plate panel installation of the disclosure. For each figure, the site scope is shown on the left side and the offsite scope if shown on the right side. The bottom or first plate (leveling plate) of the double plate is attached to the concrete foundation by anchor bolts 10 and the panel or second plate of the double plate is connected to the bottom plate by fasteners such as nails 20 such that the two plates of the double plate are nailed together on site. In contrast, the single plate panel is attached directly to the concrete foundation by anchor bolts 10. Exterior sheathing (overlap) nailed to site bottom plate is called out at 30.

FIG. 3A is a diagram showing a detailed side view of a double bottom plate setup for a wall panel. according to one implementation, showing particular specifications of installation. The configuration of a double sill or second plate built into the panel, attached to the bottom or first plate by nails, which bottom or first plate is anchored into the concrete foundation by anchor bolts is shown. The detailed specification includes, from top to bottom, the following features. Exterior sheathing (wall covering) as specified in the building plans and schedule is called out at 40. A built-in 2-inch by (unspecified depth, typically 4 or 6 inches) upper sill plate 50, is part of the prefabricated wall panel. Sitting between the 2× sill plate, an external nail (Edge Nailing, or EN) 60 secures components. Maximum distance of ½ inch from the edge of the washer to the sheared side of material is called out at 70. Sheathing 80 extends down over the lower sill plate and is nailed to it according to the shear force requirements. A 3-inch thick pressure-treated Douglas Fir (PTDF) 3× leveling plate 90, is installed, leveled and bolted to the foundation before raising the wall. Anchor bolts 100 are placed per shear schedule in the concrete foundation 110, with a maximum 1-inch countersink (recess) into the 3× sill plate. A 16-penny nail (16d) 105 is spaced every 8 inches on center, and passes through the 2× sill plate into the lower plate. Minimum cast-in-place anchor bolts are required at structural walls; the pre-embedded bolts are cast directly into the concrete foundation during pour for securing the sill plate. FIG. 3B is a diagram showing a plan view of the same double bottom plate setup with various typical dimensions shown. The setup includes the 3× leveling plate 111. A 3½ inch notch is called out at 112. Called out at 113, where leveling plate is drilled or notched more than ⅓ the plate width, one bolt is installed each side of notch. Anchor bolts spaced per shear schedule (typically spaced a minimum of 8 inches) are called out at 114. A Simpson BPS5/8-3 plate washer required at all anchor bolts, where a standard cut washer is installed between the anchor bolt and the plate washer, is called out at 115. Such BPS5/8-3 is used at 6 inch wall framing.

FIGS. 4 and 5 are diagrams of a wall elevation according to one implementation. A wall panel is composed of 2× framing and may include value added sub-assemblies. Exterior walls will be sheathed and insulated. A wall panel 120 is shown between the top plate 160 and the bottom plate 165. The position of studs 170 is also shown, as well as mate lines 175A and 175B. The mate line stud 171 is shown at the far right, and at the bottom is a shim leveling plate (bottom or first plate of the double plate) 180 to level against slab. FIG. 5 is a diagram of the same wall elevation with sub-assembly inserted, which shows the location of a cassette or insert 199 indexed horizontally by studs 192 and indexed 191 from the top plate 160, and indexed 193 from the bottom plate 165 by a setting block 195. Sub-assembly (insert 199) is indexed relative to top 160 and bottom 165 plates. The setting block 195 fixes location at set. The leveling plate 180 (bottom or first plate of the double plate) is shown below the wall panel 120. Mounting tabs screw to face of studs 170, which index left/right location. Such wall elevations can be used for construction of a building.

FIG. 6 is a diagram of a wall plan according to one implementation. At the top are two wall panels joined end to end. At the bottom, two panels are shown joined together perpendicularly at a corner. The position of studs is also shown.

The present disclosure has described particular implementations having various features. In light of the disclosure provided above, it will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit of the disclosure. One skilled in the art will recognize that the disclosed features may be used singularly, in any combination, or omitted based on the requirements and specifications of a given application or design. When an implementation refers to “comprising” certain features, it is to be understood that the implementations can alternatively “consist of” or “consist essentially of” any one or more of the features. Other implementations will be apparent to those skilled in the art from consideration of the specification and practice of the disclosure.

It is noted in particular that where a range of values is provided in this specification, each value between the upper and lower limits of that range is also specifically disclosed. The upper and lower limits of these smaller ranges may independently be included or excluded in the range as well. The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. It is intended that the specification and examples be considered as exemplary in nature and that variations that do not depart from the essence of the disclosure fall within the scope of the disclosure. Further, all of the references cited in this disclosure including patents, published applications, and non-patent literature are each individually incorporated by reference herein in their entireties and as such are intended to provide an efficient way of supplementing the enabling disclosure as well as provide background detailing the level of ordinary skill in the art.

Claims

1. A system for wall-panel installation, comprising:

a first plate designed to be attached directly to concrete slab; and

a second plate integrated within a prefabricated wall panel and designed to directly attach to the first plate.

2. The system of claim 1, further comprising anchor bolts or hold-downs, wherein the anchor bolts or hold-downs attach the first plate directly to the concrete slab.

3. The system of claim 1, further comprising nails, wherein the nails directly attach the second plate to the first plate.

4. The system of claim 1, wherein the first plate is designed to accommodate variations in concrete slab height and irregularities.

5. A method for wall-panel installation, comprising:

installing the first plate of the system of claim 1 to concrete slab;

installing the prefabricated wall panel of the system of claim 1 by attaching the second plate to the first plate.

6. The method of claim 5, wherein the first plate is installed by directly attaching the first plate to concrete slab by anchor bolts or hold downs.

7. The method of claim 6, wherein the anchor bolts or hold are cast directly into the concrete foundation during pour for attaching the first plate to concrete slab.

8. The method of claim 6, wherein the first plate is installed at a construction site.

9. The method of claim 5, wherein the prefabricated wall panel is installed by directly attaching the second plate to the first plate by nails.

10. The method of claim 9, wherein the second plate is manufactured as a component of the prefabricated wall panel offsite from a construction site.

11. A modular home or building comprising the system of claim 1.

12. A modular home or building comprising constructed using the method of claim 5.