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Modular Building System

  • US 20160040443A1
  • Filed: 04/06/2015
  • Published: 02/11/2016
  • Est. Priority Date: 07/29/2013
  • Status: Abandoned Application
First Claim
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1. A method of constructing a building, comprising the following steps:

  • assembling a plurality of structurally self-supporting pre-finished cuboid modules at a manufacturing facility, each module comprising;

    a cuboid framework 8 feet wide, 40 feet long, and 9.5 feet high of vertical corner columns interconnected by horizontal beams defining a bottom floor frame, a top ceiling frame, and four side wall frames;

    receiving means at each end of each column for receiving one of a plurality of adaptors,a floor disposed in the floor frame;

    a ceiling disposed in the ceiling frame;

    a wall disposed in each of the one or more wall frames, each wall having a plurality of spaced studs and dry wall attached to the inner side of the studs and panels attached to the outer side of the studs;

    at least one window in at least one wall;

    at least one door in at least one wall;

    a building envelope connected to the outer side of at least one wall;

    a roof assembly connected to the outer side of the ceiling frame;

    all intra-modular components of an electrical distribution system disposed within the framework, the electrical components consisting of electrical breaker panels, light fixtures, switches, dimmers, plugs, fans, appliances, air handlers, heat pump components, furnaces, electric baseboards, electric fireplaces, thermostats and controls;

    all intra-modular components of a plumbing system disposed within the framework, the plumbing components consisting of toilets, sinks, waste disposal units, hot water tanks, washers, dryers, hot and cold water distribution conduits, faucets, baths and showers;

    heating, ventilation and air conditioning units and air distribution ducting disposed within the framework;

    all finishing elements, the finishing elements consisting of paint, wallpaper, carpeting, flooring, baseboards, cabinetry, tiling, countertops, trim, and appliances;

    fire-rated drywall installed along the inner and outer surfaces of the framework; and

    a plurality of adaptors, each adaptor attachable to one end of a column of a module for interconnection of each module to at least one horizontally adjacent or vertically adjacent other module, roof assembly, balcony, foundation or corridor, each adaptor selected from the group of adaptors comprising transportation adaptors, foundation adaptors, corner adaptors, lateral spacing adaptors, roof adaptors, balcony adaptors, corridor adaptors, H-clips, mid-component adaptors, and flush corner adaptors;

    inserting transportation adaptors for use during transportation of the modules to the building site;

    transporting the modules to a construction site;

    assembling the modules Into a building on a foundation using a plurality of specialized adaptors for interconnection of modules, each adaptor attachable to one end of a column of a module for interconnection of each module to at least one horizontally adjacent or vertically adjacent other module, roof assembly, balcony, foundation or corridor, each, adaptor selected from the group of adaptors comprising transportation adaptors, foundation adaptors, corner adaptors, lateral spacing adaptors, roof adaptors, balcony adaptors, corridor adaptors, H-clips, mid-component adaptors, and flush corner adaptors;

    interconnecting components of electrical, plumbing, heating, ventilation and other systems between adjacent modules;

    applying sheathing to brace adjacent modules;

    applying waterproof membranes to the exterior walls of the building;

    applying insulation to the exterior walls of the building;

    installing flashing on the top of each module, the flashing having a compressible gasket tape for sealing the space between vertically adjacent modules; and

    installing compressible strips along columns between horizontally adjacent modules;

    wherein intra-modular assembly of all components is completed prior to transportation of the modules to the construction site.

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