CN111936710A - Prefabricated building system - Google Patents

Prefabricated building system Download PDF

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Publication number
CN111936710A
CN111936710A CN201980023959.8A CN201980023959A CN111936710A CN 111936710 A CN111936710 A CN 111936710A CN 201980023959 A CN201980023959 A CN 201980023959A CN 111936710 A CN111936710 A CN 111936710A
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China
Prior art keywords
floor
panel
roof
edge
wall panel
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Pending
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CN201980023959.8A
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Chinese (zh)
Inventor
林凡榆
哈利·司汤达
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Tempest LLC
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Tempest LLC
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Priority to CN202110899926.9A priority Critical patent/CN113550424A/en
Publication of CN111936710A publication Critical patent/CN111936710A/en
Pending legal-status Critical Current

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    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/0023Building characterised by incorporated canalisations
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815Elements not integrated in a skeleton
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34869Elements for special technical purposes, e.g. with a sanitary equipment
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Epidemiology (AREA)
  • Public Health (AREA)
  • Building Environments (AREA)
  • Joining Of Building Structures In Genera (AREA)
  • Load-Bearing And Curtain Walls (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)

Abstract

A multi-faceted structure constructed from a plurality of prefabricated components consisting of less than 12 different prefabricated structural components, the multi-faceted structure including a floor assembly; a roof assembly; a side assembly connected to and extending between the floor assembly and the roof assembly. The flooring assembly includes a plurality of floor panels, each floor panel being in direct structural connection with at least one other floor panel. The roof assembly includes a plurality of roof panels, each roof panel being connected with at least one other roof panel direct connection structure. The side assembly includes a plurality of wall panels, each wall panel being connected with at least one floor panel and at least one roof panel direct connection structure.

Description

Prefabricated building system
Cross Reference to Related Applications
This application claims the benefit of U.S. provisional patent application No.62/638,451, filed on 3/5/2018, the entire contents of which are incorporated herein by reference.
Technical Field
The present disclosure relates generally to a building system, and more particularly to a building system including a plurality of interconnectable prefabricated structural components.
Background
Modular and prefabricated construction of buildings is commonly referred to as a concept. The motivation for using modular building technology ranges from economic considerations (such as creating economies of scale for individual building components) to environmental issues (such as purchasing sustainable materials). Other advantages of modular building construction include: due to the prefabrication of the building components, the whole building is erected relatively fast, and the assembly practice is safer.
However, current modular and/or prefabricated building systems have several drawbacks that limit the wider use of this technology. First, many prefabricated building systems are not entirely versatile. Second, the components of existing systems are often developed and manufactured in a fragmented manner that is not intended to achieve generality, or the goal of achieving generality. As a result, existing modular and/or building systems lack the ability to be reconfigured or deployed in alternative configurations to meet customer-specific needs. Finally, many existing modular and/or building systems require a wide variety of individual component types, and therefore their use can be cost prohibitive.
Disclosure of Invention
In view of the foregoing, there is a need for a building system that requires a reduced number of prefabricated structural components that can be quickly assembled in various configurations. In addition, there is a need for a method for quickly assembling and disassembling prefabricated buildings.
Aspects of the present disclosure generally relate to multi-faceted structures constructed from a plurality of prefabricated components consisting of less than 12 different prefabricated structural components. The multi-faceted structure includes a floor assembly; a roof assembly; and a side assembly connected to and extending between the floor assembly and the roof assembly. The flooring assembly includes a plurality of floor panels, each floor panel being in direct structural connection with at least one other floor panel. The roof assembly includes a plurality of roof panels, each roof panel being connected with at least one other roof panel direct connection structure. The side assembly includes a plurality of wall panels, each wall panel being connected with at least one floor panel and at least one roof panel direct connection structure.
In some non-limiting examples, each floor panel includes a floor surface having at least one edge and a floor engaging member extending parallel to the at least one edge of the floor surface. Each roof panel includes a roof surface having at least one edge, and a roof engaging member extending parallel to the at least one edge of the floor surface.
In some non-limiting examples, at least one of the shingles is a fixed shingle that includes a fixed wall surface having a bottom edge, a top edge, and side edges. Each fixed wall surface also includes a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edges.
In some non-limiting examples, the first joining member of the fixed wall panel is configured to be rigidly connected to the floor joining member of one of the floor panels, and the second joining member of the fixed wall panel is configured to be rigidly connected to the roof joining member of one of the roof panels.
In some non-limiting examples, the floor engaging member of each floor panel includes a groove, and the first engaging member of each wall panel includes a rail configured to extend into the groove.
In some non-limiting examples, the floor engaging member of each floor panel includes a weather seal configured to engage the first engaging member of each wall panel.
In some non-limiting examples, the multi-faceted structure further includes a service module including a base panel having at least one edge configured to rigidly connect to at least one of the floor panels. The service module further includes at least one of a plumbing system, a climate control system, and a sanitation system.
In some non-limiting examples, each of the floor panels further includes a conduit extending below the floor surface. The conduit of each of the floor panels is configured to be in fluid communication with the conduit of each adjacent floor panel.
In some non-limiting examples, at least one of the floor panel, the roof panel, and the wall panel includes a first conduit configured to align with a second conduit of an adjacent one of the floor panel, the roof panel, and the wall panel.
Other aspects of the present disclosure relate to a building system including a plurality of prefabricated structural components, wherein each of the plurality of prefabricated structural components is connectable with at least another one of the plurality of prefabricated structural components. The plurality of prefabricated structural components includes at least one floor panel, each floor panel including a floor surface having at least one edge, and a floor engaging member extending parallel to the at least one edge of the floor surface. The plurality of prefabricated structural components includes at least one fixed wall panel, each fixed wall panel including a fixed wall surface having a bottom edge, a top edge, and side edges, a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edges. The plurality of prefabricated structural components includes at least one roof panel, each roof panel including a roof surface having at least one edge, and a roof engaging member extending parallel to the at least one edge of the floor surface.
In some non-limiting examples, the first joining member of each fixed wall panel is configured to be rigidly connected to the floor joining member of each floor panel, and the second joining member of each fixed wall panel is configured to be rigidly connected to the roof joining member of each roof panel.
In some non-limiting examples, the at least one fixed wall panel includes a first fixed wall panel and a second fixed wall panel, and the third engagement member of the first fixed wall panel is configured to be rigidly connected to the third engagement member of the second fixed wall panel.
In some non-limiting examples, the plurality of prefabricated structural components further comprises a service module. The service module includes a base panel having at least one edge configured to be rigidly connected to another of the plurality of prefabricated structural components, and at least one of a plumbing system, a climate control system, and a sanitation system.
In some non-limiting examples, the plurality of prefabricated structural components further comprises a sliding wall panel. The sliding wall panel includes a sliding wall surface having a bottom edge and a top edge, a first engagement member extending parallel to the bottom edge, and a second engagement member extending parallel to the top edge. The first engagement member of the sliding wall panel is configured to be slidably connected to the floor engagement member of each floor panel, and the second engagement member of the sliding wall panel is configured to be slidably connected to the roof engagement member of each roof panel.
In some non-limiting examples, the plurality of prefabricated structural components further includes at least one foundation pile, each foundation pile configured to be secured to the ground and connected to each of the floor panels.
In some non-limiting examples, each of the floor panels further includes a conduit extending below the floor surface. The conduit of each of the floor panels is configured to be in fluid communication with the conduit of each adjacent floor panel.
In some non-limiting examples, at least one of the plurality of prefabricated structural components includes a first conduit configured to align with a second conduit of an adjacent one of the plurality of prefabricated structural components.
In some non-limiting examples, the floor engaging member of each floor panel includes a groove, and the first engaging member of each fixed wall panel includes a rail configured to extend into the groove.
In some non-limiting examples, the floor engaging member of each floor panel includes a weather seal configured to engage the first engaging member of each fixed wall panel.
In some non-limiting examples, the plurality of prefabricated structural components consists of less than 12 different prefabricated structural components, and a complete building can only be built from these plurality of prefabricated structural components.
In some non-limiting examples, the plurality of prefabricated structural components consists of less than 10 different prefabricated structural components, and a complete building can only be built from these plurality of prefabricated structural components.
In some non-limiting examples, at least two of the floor engaging members of each floor panel, the first engaging members of each fixed wall panel, the second engaging members of each fixed wall panel, the third engaging members of each fixed wall panel, and the roof engaging members of each roof panel have substantially the same profile.
In some non-limiting examples, the first, second, and third engagement members of each fixed shingle have substantially the same profile.
Other aspects of the present disclosure relate to a method for constructing a building from a plurality of prefabricated structural components. The method includes arranging a plurality of floor panels on a base assembly, each floor panel including a floor surface having at least one edge and a floor engaging member extending parallel to the at least one edge of the floor surface. The method also includes arranging a plurality of fixed wall panels substantially perpendicular to the plurality of floor panels, each fixed wall panel including a fixed wall surface having a bottom edge, a top edge, and side edges, a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edges. The method also includes arranging a plurality of roof panels in vertically spaced apart relation to the plurality of floor panels, each roof panel including at least one edge and a roof engaging member extending parallel to the at least one edge of the floor surface of at least one of the plurality of floor panels. The method also includes connecting the first joining member of each fixed wall panel to a corresponding floor joining member of a floor panel of the plurality of floor panels, and connecting the second joining member of each fixed wall panel to a corresponding roof joining member of a roof panel of the plurality of roof panels.
In some non-limiting examples, the method further comprises completing the building with only a plurality of prefabricated structural components, wherein the plurality of prefabricated structural components consists of less than 12 different prefabricated components.
According to other non-limiting examples, the disclosure of the present application may be characterized by one or more of the following numbered clauses:
clause 1. a multi-faceted structure constructed from a plurality of prefabricated components consisting of less than 12 different prefabricated structural components, the multi-faceted structure comprising: a floor assembly; a roof assembly; and a side assembly connected to and extending between the floor assembly and the roof assembly, wherein the floor assembly comprises a plurality of floor panels, each floor panel being in direct structural connection with at least one other floor panel, wherein the roof assembly comprises a plurality of roof panels, each roof panel being in direct structural connection with at least one other roof panel, and wherein the side assembly comprises a plurality of wall panels, each wall panel being in direct structural connection with at least one floor panel and at least one roof panel.
Clause 2. the polyhedral structure according to clause 1, wherein each floor panel comprises: a floor surface having at least one edge; and a floor engaging member extending parallel to at least one edge of the floor surface; and wherein each roof panel comprises: a roof surface having at least one edge; and a roof engaging member extending parallel to at least one edge of the floor surface.
Clause 3. the polyhedral structure according to clause 1 or 2, wherein at least one of the wall panels is a fixed wall panel comprising: a fixed wall surface having a bottom edge, a top edge, and side edges; a first engagement member extending parallel to the bottom edge; a second engagement member extending parallel to the top edge; and a third engagement member extending parallel to the side edge.
Clause 4. the polyhedral structure according to any one of clauses 1 to 3, wherein the first coupling member of the fixed wall panel is configured to be rigidly connected to the floor coupling member of one of the floor panels, and wherein the second coupling member of the fixed wall panel is configured to be rigidly connected to the roof coupling member of one of the roof panels.
Clause 5. the polyhedral structure according to any of clauses 1-4, wherein the floor engaging members of each floor panel comprise grooves, and wherein the first engaging member of each wall panel comprises rails configured to extend into the grooves.
Clause 6. the multi-faceted structure according to any of clauses 1-5, wherein the floor engaging members of each floor panel include a weather seal configured to engage the first engaging member of each wall panel.
Clause 7. the multifaceted structure of any of clauses 1-6, further comprising a service module comprising: a base panel having at least one edge configured to be rigidly connected to at least one of the floor panels; and at least one of a plumbing system, a climate control system, and a sanitation system.
Clause 8. the polyhedral structure according to any of clauses 1-7, wherein each of the floor panels further comprises a conduit extending below the floor surface, and wherein the conduit of each of the floor panels is configured to be in fluid communication with the conduit of each adjacent floor panel.
Clause 9. the polyhedral structure according to any of clauses 1 to 8, wherein at least one of the floor panel, the roof panel and the wall panel comprises a first conduit configured to align with a second conduit of an adjacent one of the floor panel, the roof panel and the wall panel.
Clause 10. a building system comprising a plurality of prefabricated structural components, wherein each of the plurality of prefabricated structural components is connectable to at least one other of the plurality of prefabricated structural components, the plurality of prefabricated structural components comprising: (a) at least one floor panel, each floor panel comprising: (i) a floor surface having at least one edge; and (ii) a floor engaging member extending parallel to at least one edge of the floor surface; (b) at least one fixed shingle, each fixed shingle including: (i) a fixed wall surface having a bottom edge, a top edge, and side edges; (ii) a first engagement member extending parallel to the bottom edge; (iii) a second engagement member extending parallel to the top edge; and (iv) a third engagement member extending parallel to the side edge; and (c) at least one roof panel, each roof panel comprising: (i) a roof surface having at least one edge; and (ii) a roof engaging member extending parallel to at least one edge of the floor surface.
Clause 11 the building system of clause 10, wherein the first joining member of each fixed wall panel is configured to be rigidly connected to the floor joining member of each floor panel, and wherein the second joining member of each fixed wall panel is configured to be rigidly connected to the roof joining member of each roof panel.
Clause 12 the building system of clause 10 or 11, wherein the at least one fixed wall panel comprises a first fixed wall panel and a second fixed wall panel, and wherein the third joining member of the first fixed wall panel is configured to be rigidly connected to the third joining member of the second fixed wall panel.
The building system of any of clauses 10-12, wherein the plurality of prefabricated structural components further comprises a service module comprising: a base panel having at least one edge configured to be rigidly connected to another of the plurality of prefabricated structural components; and at least one of a plumbing system, a climate control system, and a sanitation system.
Clause 14 the building system according to any one of clauses 10-13, wherein the plurality of prefabricated structural components further comprises a sliding wall panel comprising: a sliding wall surface having a bottom edge and a top edge; a first engagement member extending parallel to the bottom edge; and a second engagement member extending parallel to the top edge, wherein the first engagement member of the sliding wall panel is configured to be slidably connected to the floor engagement member of each floor panel, and wherein the second engagement member of the sliding wall panel is configured to be slidably connected to the roof engagement member of each roof panel.
Clause 15. the building system according to any one of clauses 10-14, wherein the plurality of prefabricated structural components further comprises at least one foundation pile, each foundation pile configured to be fixed to the ground and connected to each of the floor panels.
Clause 16. the building system according to any one of clauses 10-15, wherein each of the floor panels further comprises a conduit extending below the floor surface, and wherein the conduit of each of the floor panels is configured to be in fluid communication with the conduit of each adjacent floor panel.
Clause 17. the building system according to any one of clauses 10-16, wherein at least one of the plurality of prefabricated structural members includes a first conduit configured to align with a second conduit of an adjacent one of the plurality of prefabricated structural members.
The building system of clause 18. the building system of any of clauses 10-17, wherein the floor engaging member of each floor panel comprises a channel, and wherein the first engaging member of each fixed wall panel comprises a rail configured to extend into the channel.
The building system of any of clauses 10-18, wherein the floor engaging member of each floor panel comprises a weather seal configured to engage the first engaging member of each fixed wall panel.
Clause 20. the building system according to any one of clauses 10-19, wherein the plurality of prefabricated structural components consists of less than 12 different prefabricated structural components, and wherein the complete building can only be built from these plurality of prefabricated structural components.
Clause 21. the building system according to any of clauses 10-20, wherein the plurality of prefabricated structural components consists of less than 10 different prefabricated structural components, and wherein the complete building can only be built from these plurality of prefabricated structural components.
The building system of any of clauses 10-21, wherein at least two of the floor engaging members of each floor panel, the first engaging members of each fixed wall panel, the second engaging members of each fixed wall panel, the third engaging members of each fixed wall panel, and the roof engaging members of each roof panel have substantially the same profile.
Clause 23. the building system according to any one of clauses 10-22, wherein the first joining member, the second joining member, and the third joining member of each fixed wall panel have substantially the same profile.
Clause 24. a method for constructing a building from a plurality of prefabricated structural components, comprising: arranging a plurality of floor panels on the base assembly, each floor panel comprising a floor surface having at least one edge and a floor engaging member extending parallel to the at least one edge of the floor surface; arranging a plurality of fixed wall panels substantially perpendicular to the plurality of floor panels, each fixed wall panel comprising a fixed wall surface having a bottom edge, a top edge and side edges, a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edges; arranging a plurality of roof panels in vertically spaced apart relation to the plurality of floor panels, each roof panel including at least one edge and a roof engaging member extending parallel to the at least one edge of the floor surface of at least one of the plurality of floor panels; connecting the first joining member of each fixed wall panel to a corresponding floor joining member of a floor panel of the plurality of floor panels; and connecting the second engagement member of each fixed wall panel to a corresponding roof engagement member of a roof panel of the plurality of roof panels.
Clause 25. the method of clause 24, further comprising completing the building with only a plurality of prefabricated structural components, wherein the plurality of prefabricated structural components consists of less than 12 different prefabricated components.
These and other features and characteristics of the building system, wherein like reference numerals designate corresponding parts in the various figures, are disclosed. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosure. As used in the specification and in the claims, the singular form of "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.
Drawings
FIG. 1 is a perspective view of a building constructed from a building system according to one aspect of the present disclosure, according to one aspect of the present disclosure;
FIG. 2 is a perspective view of another building constructed from the same building system as the building of FIG. 1, according to an aspect of the present disclosure;
FIG. 3 is an exploded perspective view of another building constructed from the same building system as the building of FIG. 1, according to an aspect of the present disclosure;
FIG. 4 is a perspective view of a building development according to an aspect of the present disclosure constructed from the same building system as the building of FIG. 1;
fig. 5 is a partial perspective view of a building, particularly illustrating a foundation support of the building, according to an aspect of the present disclosure.
FIG. 6 is a partial perspective view of a building, particularly illustrating floor panels of the building, according to an aspect of the present disclosure;
FIG. 7 is a partial perspective view of an edge connecting member of the floor panel of FIG. 6;
FIG. 8 is a partial perspective view of a building, particularly illustrating a fixed exterior wall panel of the building, according to an aspect of the present disclosure;
FIG. 9 is a partial perspective view of a building, particularly illustrating structural cabinet wall components of the building, according to an aspect of the present disclosure;
FIG. 10 is a partial perspective view of a building, particularly illustrating the structural wall cabinet of FIG. 9, according to an aspect of the present disclosure;
FIG. 11 is a partial perspective view of a building, particularly illustrating the structural wall cabinet of FIG. 9, according to an aspect of the present disclosure;
FIG. 12 is a partial perspective view of a building, particularly illustrating the structural wall cabinet of FIG. 9, according to an aspect of the present disclosure;
FIG. 13 is a partial perspective view of a building, particularly illustrating a sliding exterior wall panel of the building, according to an aspect of the present disclosure;
FIG. 14 is a perspective view of the sliding outer wall panel of FIG. 13;
FIG. 15 is a partial perspective view of a building, particularly illustrating a roof panel of the building, according to an aspect of the present disclosure;
FIG. 16 is a partial perspective view of the roof panel of FIG. 15;
FIG. 17 is a partial perspective view of a building, particularly illustrating a sliding interior wall panel of the building, according to an aspect of the present disclosure;
FIG. 18 is a partial perspective view of a building, particularly illustrating sliding doors of the building, according to an aspect of the present disclosure;
FIG. 19 is a perspective view of a service module according to an aspect of the present disclosure;
FIG. 20 is a cross-sectional view of the interface between the floor panel, structural cabinet wall components and sliding cabinet door according to one aspect of the present disclosure;
FIG. 21 is a cross-sectional view of a roof panel having a ductwork extending therethrough according to an aspect of the present disclosure;
FIG. 22 is a cross-sectional view of a sealing arrangement between a floor panel and a cabinet wall component according to an aspect of the present disclosure;
FIG. 23 is a cross-sectional view of a sealing arrangement between a roof panel and a cabinet wall component according to an aspect of the present disclosure;
fig. 24 is a cross-sectional view of a lighting system according to an aspect of the present disclosure;
FIG. 25 is a cross-sectional view of a floor panel having cables extending therethrough according to an aspect of the present disclosure;
FIG. 26 is a cross-sectional view of a wall panel having cables extending therethrough according to an aspect of the present disclosure;
FIG. 27 is a schematic top view of a plurality of interconnected channels formed by a building, according to an aspect of the present disclosure;
FIG. 28 is a flow chart of a method of constructing a building according to an aspect of the present disclosure;
FIG. 29 is a perspective view of the base assembly of the installed building;
FIG. 30 is a perspective view of a service module mounted on the base assembly of FIG. 29;
FIG. 31 is a perspective view of the flooring assembly mounted on the base assembly of FIG. 29;
FIG. 32 is a perspective view of the exterior wall assembly partially installed on the floor assembly of FIG. 31;
FIG. 33 is a perspective view of the fully installed exterior wall assembly and interior wall panel of FIG. 32; and
fig. 34 is a perspective view of the roof assembly mounted on the exterior wall assembly of fig. 32-33.
Detailed Description
For purposes of the following description, the terms "upper," "lower," "right," "left," "vertical," "horizontal," "top," "bottom," "lateral," "longitudinal," and derivatives thereof shall relate to the disclosed device as it is oriented in the drawing figures. It is to be understood, however, that the apparatus of the present disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific systems and processes illustrated in the attached drawings, and described in the following specification are simply exemplary examples of the devices disclosed herein. Hence, specific dimensions and other physical characteristics relating to the examples disclosed herein are not to be considered as limiting.
As used herein, the term "associated with" when referring to a plurality of features or structures means that the plurality of features or structures are in contact with, touching, directly connected, indirectly connected, adhered to, or integrally formed with one another.
As used herein, the term "at least one of … …" is synonymous with one or more of "… …". For example, the phrase "A, B and at least one of C" refers to either of A, B and C, or any combination of any two or more of A, B and C. For example, "at least one of A, B and C" includes only one or more of a; or only one or more of B; or only one or more of C; or one or more of a and one or more of B; or one or more of a and one or more of C; or one or more of B and one or more of C; or one or more of all of A, B and C. Similarly, as used herein, the term "at least two of … …" is synonymous with "two or more of … …". For example, the phrase "at least two of D, E and F" refers to any combination of any two or more of D, E and F. For example, "at least two of D, E and F" includes one or more of D and one or more of E; or one or more of D and one or more of F; or one or more of E or one or more of F; or one or more of all of D, E and F.
As used herein, the terms "directly structurally connected," "directly structurally connected," and derivatives thereof, define a relationship between two or more components in which the two or more components meet at a joint and at least one of the components applies a static or dynamic load to another of the components without first transferring the load through an intermediate structural member. Two or more components may be secured to each other in any suitable manner. For example, a surface of one component may abut a surface of another component. Alternatively or additionally, the key or track of one component may fit into a groove or channel of another component. Mechanical fasteners such as screws, bolts, pins, rivets, etc. may be used to prevent two or more components from shifting relative to each other. In other examples, a non-structural member such as a seal, alignment washer, or spacer may be disposed between two or more components such that the two or more components are not in direct physical contact.
As used herein, the term "prefabricated" refers to an assembly or subassembly of a manufactured structure at a location remote from the location at which the structure is assembled. The term "prefabricated" describes a component manufactured in this way. For example, wall sections of a building may be prefabricated at a remote location from various raw materials, and the prefabricated wall sections may then be transported to the assembly site of the building. In this way, there is no need to build a wall section from raw material at the assembly site. The terms "prefabricated" and "modular" are used interchangeably herein.
As used herein, the term "prefabricated structural member" refers to an element used in a building that forms at least a portion of a floor, roof or wall surface of the building. The prefabricated structural component must be directly structurally connectable to at least one other prefabricated structural component.
As used herein, unless expressly stated to the contrary, the terms "perpendicular" and "substantially perpendicular" refer to an angle between two or more components of between 90 ° ± 10 °.
As used herein, the term "exterior" is used to describe a component having at least a portion that is suitable for use in an external environment that is not protected by a weather element. However, it should be understood that components referred to as "external" may also be used in internal applications, unless explicitly stated to the contrary.
Aspects of the present disclosure generally relate to building systems including a plurality of prefabricated structural members, and to buildings constructed from a plurality of prefabricated structural members. Fig. 1 and 2 show an example of a building 1000 constructed from a building system according to the present disclosure. Each of the buildings 1000 may generally include a floor assembly 10, a roof assembly 20, and a plurality of exterior wall assemblies 30. A plurality of wall assemblies may be connected to and extend between the floor assembly 10 and the roof assembly 20. Each of the exterior wall assemblies 30 may also be connected to at least another one of the exterior wall assemblies 30 such that the plurality of exterior wall assemblies define a multi-faceted structure having an interior volume. The interior volume thus defines the interior space of the building 1000. The non-limiting embodiments of the building system described herein provide a number of advantages, including significant cost savings and flexibility through standardization of the components to be manufactured.
The floor assembly 10 may be constructed from one or more of the prefabricated floor panels 110 of the building system of the present disclosure. Similarly, the roof assembly 20 may be constructed from one or more prefabricated roof panels 210 of the building system of the present disclosure. Similarly, each of the exterior wall assemblies 30 may be constructed from one or more prefabricated exterior wall panels 310 of the building system of the present disclosure. The prefabricated floor panels 110, the prefabricated roof panels 210 and the prefabricated exterior wall panels 310 of the building system will be described in more detail later. However, for the purpose of generally describing the building 1000, it should be noted that the prefabricated floor panels 110, the prefabricated roof panels 210 and the prefabricated exterior wall panels 310 are of the variety of prefabricated structural components that at least partially constitute the building system of the present disclosure. Each of the prefabricated structural components of the building system may be connected with at least one other prefabricated structural component in order to construct building 1000. For example, in the building shown in fig. 1 and 2, each of the floor panels 110 is connected to at least one other floor panel 110, and the floor panels 110 constituting the periphery of the floor assembly 10 are also each connected to at least one of the outer wall panels 310. Similarly, each of the roof panels 210 is connected to at least one other roof panel 210, and the roof panels 210 constituting the periphery of the roof assembly 20 are also each connected to at least one of the outer wall panels 310. Each of the outer wall panels 310 is connected to at least one of the floor panels 110 and to at least one of the roof panels 210. The connection mechanism for interconnecting the plurality of prefabricated structural components will be described in more detail later. For the sake of clarity, not all prefabricated structural parts shown in fig. 1 to 2 are identified with reference numerals.
As can be further appreciated from the building 1000 of fig. 1 and 2, the exterior wall panels 310 can be selected from a variety of component types. For example, each outer wall panel 310 may be an outer fixed wall panel 130, a structural cabinet wall component 150, or a sliding outer wall panel 160. However, regardless of the type, each exterior wall panel 310 may share the same connection mechanism for connecting to other prefabricated structural components of the building 1000, such that the various types of exterior wall panels 310 may be used interchangeably in the construction of the building 1000. Various types of exterior wall panels will be described in more detail later.
With continued reference to fig. 1 and 2, some examples of a building 1000 may also include a foundation assembly 140 selected from the building systems of the present disclosure. The foundation assembly 140 may be connected to the floor assembly 10 and to the ground supporting the building 1000. In addition to supporting the weight of the building, the foundation assembly 140 may also elevate the floor assembly 10 above the ground and provide access points to the building 1000. The base assembly 140 may include one or more support posts 142 and one or more stairs or ramps. In other examples, building 1000 may be constructed on a poured concrete foundation or other conventional type of foundation, with foundation assembly 140 omitted.
With continued reference to fig. 1 and 2, the prefabricated structural components of the building system, i.e., the floor panel 110, the roof panel 210, and the exterior wall panel 310, may form the entire exterior shell of the building 1000. Accordingly, the building 1000 may be constructed substantially from a limited number of prefabricated structural components selected from the building systems of the present disclosure. In some examples, building 1000 may be constructed entirely of no more than twelve different types of prefabricated structural components. By fully constructed, it is meant that building 1000 defines a rigid multi-faceted structure of interconnected prefabricated structural components that completely encloses an interior volume. In other examples, building 1000 may be constructed entirely from no more than eleven different types of prefabricated structural components. In other examples, building 1000 may be constructed entirely from no more than ten different types of prefabricated structural components. In other examples, building 1000 may be constructed entirely of no more than nine different types of prefabricated structural components.
Referring now to fig. 3, another example of a building 1000 constructed from the building systems of the present disclosure is shown in a partially exploded view to illustrate the prefabricated structural components of the building systems used in the interior space of the building 1000. That is, building 1000 may include other prefabricated structural components such as one or more sliding interior wall panels 170 and/or one or more service modules 190. Each sliding inner wall panel 170 may be connected to at least one floor panel 110, at least one roof panel 210, and/or at least one outer wall panel 310. Each service module 190 may generally include at least one of a water supply, a water heater, a toilet, a shower, and other plumbing fixture. Thus, service module 190 serves as a centralized node for plumbing and other utilities of building 1000. More details of the sliding interior wall panel 170 and the service module 190 will be described later. For clarity, not all of the prefabricated structural components shown in fig. 3 are identified with reference numerals.
The buildings 1000 shown in fig. 1-3 are all single-storey buildings, but the disclosure is not limited to this configuration. For example, fig. 4 shows a schematic diagram of a building development 4000 including a single-storey building 1000a and a multi-storey building 1000 b. The multi-storey building 1000b may be constructed in much the same way as the single-storey building 1000 a. However, in a multi-storey building 1000b, the roof assembly 12 of each of the lower storeys may also serve as the floor assembly 10 of the storey immediately above it.
Having generally described various examples of buildings 1000, 1000a, 1000b constructed from the building systems of the present disclosure, the individual prefabricated structural components of the building systems will now be described in detail. As described above, the prefabricated structural components of the building system may include at least the floor panel 110, the roof panel 210, the outer wall panel 310, the foundation support columns 142, the sliding inner wall panel 170, and the service module 190. The building 1000 described with reference to fig. 1 to 4 can be built from a plurality of prefabricated structural components by connecting them to each other in a desired arrangement. In some examples, the prefabricated structural components may be removably connected to one another to facilitate disassembly and reassembly of the building 1000, thereby allowing the building to be easily repositioned or reconfigured. Referring now to fig. 5-19, various partial views of a building 1000 are shown to illustrate in detail various prefabricated structural components. Each of the individual prefabricated structural components shown in fig. 5-19 may be manufactured at a location remote from the erection site of the building 1000 to minimize the amount of labor and time required to erect the building 1000. In fig. 5-19, some of the prefabricated structural components and their associated features may not be identified using reference numerals.
Referring first to fig. 5, the prefabricated foundation of the building system of the present disclosure may include support columns 142 that may be connected to one or more of the floor panels 110. In some examples, each support column 142 is a vertically oriented beam connected at a discrete point, e.g., a corner, of the corresponding one or more floor panels 110. In other examples, each support column 142 may be a horizontally oriented beam that extends continuously along at least a portion of one or more floor panels 110. As shown in fig. 5, each support column 142 may be in direct structural connection with a corresponding floor panel 110. For example, each support post 142 may have a head portion 144 that fits into a corresponding base groove or recess 1132 in one or more floor panels 110. Depending on the geology of the underlying ground, each support column 142 may be driven directly into the ground, or additional foundation members may be provided to secure the support columns 142 to the ground. For example, pier foundation 3000 can be provided in the ground below support column 142. Suitable materials for support post 142 may be determined by the environmental conditions to which the support will be exposed and the ultimate load supported by support post 142. Generally, high strength corrosion resistant materials such as galvanized steel may be used. As noted above, in some examples, such as where building 1000 is built on a conventional prefabricated foundation, support columns 142 may be omitted.
Referring now to fig. 6-7, a prefabricated floor panel 110 of the building system of the present disclosure is shown in partial exploded view so that the internal features and contours of the floor panel can be readily understood. The prefabricated floor panel 110 may include a shell 1110 surrounding an inner core 1120. The housing 1110 may include an outer panel 1112, an inner panel 1114, and an edge connector member 1130. The edge connecting member 1130 may be generally C-shaped and extend around the peripheral edge of the shell 1110. The outer panel surface 1112 may extend horizontally on the underside of the housing 1110 between the edge connecting members 1130. Similarly, the inner panel face 1114 may extend horizontally on the top side of the shell 1110 between the edge connection members 1130.
The edge connecting member 1130 may define or include a plurality of structural features for use as conduits for electrical cables and engagement members for connecting other prefabricated structural components. As described above, a base groove or recess 1132 may be defined in the underside of the edge connecting member 1130 and serve as an engagement member for direct structural connection with one or more support posts 142. One or more floor engaging members 1134 may extend along a top side of the edge connecting member 1130 and provide a direct structural connection to one or more interior or exterior wall panels. In some examples, floor engaging member 1134 may include a plurality of grooves extending parallel to the edges of shell 1110. These multiple grooves may include multiple profiles adapted to connect to different types of walls. For example, a portion of the floor engaging member 1134 may be connected to the outer fixed wall panel 130, another portion of the floor engaging member 1134 may be connected to the cabinet wall component 150, another portion of the floor engaging member 1134 may be connected to the sliding outer wall panel 160, and another portion of the floor engaging member 1134 may be connected to the sliding inner wall panel 170.
Floor engaging members 1134 may extend the entire length of each edge of floor panel 110 such that floor engaging members 1134 form a continuous structure with floor engaging members 1134 of adjacent floor panels 110. A cover seated substantially flush with the inner panel face 1114 may be mounted over a portion of the floor engaging member 1134 to which no other prefabricated structural components are attached to provide a smooth floor surface.
The edge connecting member 1130 may also define one or more cable channels 1136 that may extend parallel to the floor engaging member 1134. The cable channels 1136 may be recessed below the inner panel face 1114 and may serve as terminals for routing electrical cables, fiber optic cables, coaxial cables, ethernet cables, and other types of cables into the floor panel 110, or as conduits for routing through the floor panel 110 to adjacent prefabricated structural components. After the various cables are installed in the cable channels 1136, a cover may be installed over the cable channels 1136 so that it is substantially flush with the inner panel face 1114. More details of the cable groove 1136 will be described later with reference to fig. 26 and 27.
In some examples, the edge connecting member 1130 may also include one or more weather seals for isolating the connection between the floor panel 110 and any adjacent prefabricated structural components. The weather seal may be positioned adjacent to the floor engaging member 1134 and/or the cable channel 1136. The one or more weather seals may extend the entire length of each edge of the floor panels 110 such that the weather seals of adjacent floor panels 110 form a continuous weather seal with each other.
In some examples, the edge connecting member 1130 may also include one or more weather seal engaging surfaces for abutting a weather seal disposed on an adjacent prefabricated structural component. In some examples, the weather seal engagement surface may be positioned adjacent to the floor engaging member 1134 and/or the cable groove 1136. In other examples, the weather seal engagement surface may be included in the floor engaging member 1134 and/or the cable channel 1136. The weatherseal engaging surface may extend the entire length of each edge of the floor panel 110 such that the weatherseal engaging surfaces of adjacent floor panels 110 form a continuous weatherseal engaging surface with each other. Further details of the weather seal and the weather seal engagement surface will be described later with reference to fig. 23 and 24.
One or more conduits 1122 may extend through the core 1120 of the floor panel 110 to facilitate air flow to the floor panel 110 and to adjacent prefabricated structural components. The edge connection member 1130 and/or the inner panel face 1114 may have openings in fluid communication with the conduit 1122 such that air may be delivered to and returned from the area above the inner panel face 1114 via the conduit 1122. The one or more conduits may extend the entire length of each edge of the floor panel 110 such that the conduit 1122 of each floor panel 110 forms a continuous fluid conduit with the conduit 1122 of an adjacent floor panel 110.
The materials used for the components of the floor panel 110 can be selected to optimize strength, manufacturing costs, environmental sustainability, thermal and acoustic insulation, fire resistance, and other desirable characteristics of residential and/or commercial buildings. The outer facing panels 1112, which serve as moisture barriers and structural tension members, may be made of polymer or sheet metal. The interior panel face 1114, which serves as a soft walking and living surface, may be made of a vinyl, rubber or neoprene sheet that is easy to maintain. The edge connecting member 1130, which can withstand substantially all loads of the prefabricated structural components connected to the floor panel 110, may be made of a relatively high strength material such as extruded aluminum. The edge connecting member 1130 may be connected to the outer and inner panel faces 1112, 1114 via mechanical fasteners, adhesives, welds, or the like. The core 1120, which serves as an insulator, sound barrier, and structural compression member, may be made of foam such as Expanded Polystyrene (EPS), extruded polystyrene (XPS), or rigid polyurethane. During manufacture of the core 1120, steam may pass through the conduit 1122 to expand and cure the polystyrene foam forming the core 1120. The foam of the core 1120 may extend substantially uninterrupted along the outer panel face 1112 and/or the inner panel face 1114, such that the floor panel 110 has continuous insulation and heat loss through the non-insulated frame members is avoided. It should be understood that the various materials described herein for use in any of the components are merely exemplary and should not be construed as limiting.
Referring now to fig. 8-14, various prefabricated structural components corresponding to the exterior wall panel are shown. Referring first to fig. 8, one type of exterior wall panel 310 is a fixed wall panel 130. The fixed wall panel 130 is shown in a sectional view in fig. 8 so that its internal features and contours can be easily understood. The prefabricated fixed wall panel 130 may include a housing 1310 surrounding an inner core 1320. The housing 1310 may include an outer panel surface 1312, an inner panel surface 1314, and an edge connecting member 1330. The edge connecting member 1330 may be generally C-shaped and extend around a peripheral edge of the housing 1310. The outer panel 1312 may extend vertically on the outside of the housing 1310 between the edge connecting members 1330. Similarly, the inner panel face 1314 may extend vertically on the inside of the housing 1310 between the edge connection members 1330.
Edge connecting member 1330 may define a plurality of engagement members for connecting other prefabricated structural components. A portion of the edge connecting member 1330 extending parallel to the bottom edge of the fixed wall panel 130 may include or define a first engagement member 1332 configured for direct structural connection with the floor engaging member 1134 of an adjacent floor panel 110. A portion of the edge connecting member 1330 extending parallel to the vertical edge of the fixed wall panel 130 may include or define a second engagement member 1334. The second coupling members 1334 of the adjacently disposed fixed wall panels 130 may be configured to be directly structurally connected to each other. A portion of the edge connecting member 1330 extending parallel to the top edge of the fixed wall panel 130 may include or define a third engagement member 1336 for direct structural connection with a roof engagement member 1232 of an adjacent roof panel 210 (see fig. 15-17). In some examples, first engagement member 1332, second engagement member 1334, and/or third engagement member 1336 may include a plurality of grooves extending parallel to an edge of housing 1110. In some examples, the first engagement member 1332, the second engagement member 1334, and/or the third engagement member 1336 may be substantially identical to one another to reduce the amount of component material required to manufacture the fixed wall panel 310. Additionally, the first engagement member 1332, the second engagement member 1334, and/or the third engagement member 1336 may allow either side of the retaining wall panel 130 to be connected to adjacent floor panels 110 and roof panels 210.
In some examples, the portions of the edge connecting member 1330 that extend parallel to the bottom, vertical side, and top edges of the fixed wall panel 130 can also define one or more cable channels (not shown) that are similar to the cable channels 1136 of the floor panel 110. The cable channels of the fixed wall panel 130 may be used to route electrical cables or other types of cables to terminals in the fixed wall panel 130 or through the fixed wall panel 130 to adjacent prefabricated structural components.
In some examples, the edge connecting member 1330 may also include one or more weather seals for isolating the connection between the fixed wall panel 130 and any adjacent prefabricated structural components. The weather seal may be positioned adjacent any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels. One or more weather seals may extend the entire length of the edge of the fixed wall panel 130 such that the weather seals of adjacent fixed wall panels 130 form a continuous weather seal with each other.
In some examples, the edge connecting member 1330 may also include one or more weather seal engaging surfaces for abutting a weather seal disposed on an adjacent prefabricated structural component. In some examples, the weatherseal engagement surface may be positioned adjacent to any one or more of the engagement members 1332, 1334, 1336 and/or the cable groove. In other examples, a weather seal engagement surface may be included in any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels. The weatherseal engaging surface may extend the entire length of the edge of the fixed wall panel 130 such that the weatherseal engaging surfaces of adjacent fixed wall panels 130 form a continuous weatherseal engaging surface with each other.
The material selection of the components of the prefabricated fixed wall panel 130 may be similar to that of the floor panel 110. The exterior panels 1312, which may serve as a moisture barrier, structural tension members, exterior of the building 1000, and/or impact barrier, may be made of fiber cement facing or Fiber Reinforced Plastic (FRP). The interior faceplate 1314 used as an interior wall surface may be made of a sheet of vinyl, rubber, or neoprene that is easy to maintain. The edge connecting member 1330 may be made of a relatively high strength material, such as extruded aluminum. The edge connecting member 1330 may be connected to the outer and inner panel surfaces 1312, 1314 via mechanical fasteners, adhesives, welds, etc. The core 1320, which serves as an insulator, sound barrier, and structural compression member, may be made of foam such as Expanded Polystyrene (EPS), extruded polystyrene (XPS), or rigid polyurethane. The foam of the core 1320 may extend substantially uninterrupted along the outer skin 1312 and/or inner skin 1314 panels so that the fixed wall panel 130 has continuous thermal insulation and heat loss through the non-insulated frame members is avoided.
Referring now to fig. 9-12, another type of exterior wall panel 310 is a structural cabinet wall component 150. The structural cabinet wall component 150 may include a housing 1510 surrounding an interior core 1520. As can be appreciated from fig. 10-11, the middle portion of the housing 1510 may be generally C-shaped and define an inner working area 1550. The housing 1510 may include an outer panel surface 1512, an inner panel surface 1514, and an edge attachment member 1530. As can be appreciated from fig. 9, 10, and 12, either end of the inner working area 1550 may be closed by an end cap 1560 of the housing 1510. The edge connecting member 1530 may be generally C-shaped and extend around the perimeter of the housing 1510, including extending along the edges of the end cap 1560. An outer panel 1512 may extend around the outside of the housing 1510 between the edge connecting members 1530. Similarly, the inner panel face 1314 may extend around the inside of the housing 1510 between the edge connection members 1530, partially enclosing the inner working area 1550.
Interior working area 1550 may include integral storage containers such as shelves and cabinets, or interior working area 1550 may include supports for installing the integral storage containers after cabinet wall components 150 have been assembled with other prefabricated structural components to build building 1000.
The edge connecting member 1530 may define a plurality of engagement members for engaging other prefabricated structural components. A portion of the edge connecting member 1530 that extends parallel to the bottom edge of the cabinet wall component 150 may include or define a first coupling member 1532 configured for direct structural connection with the floor coupling member 1134 of an adjacent floor panel 110. A portion of the edge connecting member 1530 that extends parallel to the vertical edge of the end cap 1560 of the cabinet wall component 150 may include or define a second engagement member 1534. The second engagement members 1534 of adjacently disposed cabinet wall components 150 can be configured for direct structural connection to one another. A portion of the edge connecting member 1530 extending parallel to the top edge of the cabinet wall component 150 may include or define a third engagement member 1536 for direct structural connection with the roof engagement member 1232 of an adjacent roof panel 210 (see fig. 15-16).
In some examples, the first and third engagement members 1532 and 1536 of the cabinet wall component 150 may be configured to engage only a portion of the corresponding floor engagement member 1134 of an adjacent floor panel 110 and the roof engagement member 1232 of an adjacent roof panel 210. The unengaged portions of the corresponding floor engaging members 1134 and roof engaging members 1232 may then be used to connect the interior sliding cabinet doors 180, as will be described later in connection with fig. 18.
In some examples, the portions of the edge connecting member 1530 that extend parallel to the bottom, vertical side, and top edges of the cabinet wall component 150 can also define one or more cable channels (not shown) similar to the cable channels of the floor panel 110. The cable channels of the cabinet wall component 150 may be used to route electrical cables or other types of cables to terminals in the cabinet wall component 150 or through the cabinet wall component 150 to adjacent prefabricated structural components.
In some examples, the edge connecting member 1530 may also include one or more weather seals for isolating the connection between the cabinet wall component 150 and any adjacent prefabricated structural components. The weather seal may be positioned adjacent any one or more of the engagement members 1532, 1534, 1536 and/or the cable grooves. The one or more weather seals may extend the entire length of the edges of the cabinet wall members 150 such that the weather seals of adjacent cabinet wall members 150 form a continuous weather seal with each other.
In some examples, the edge connecting member 1530 may also include one or more weather seal engaging surfaces for abutting a weather seal disposed on an adjacent prefabricated structural component. In some examples, the weatherseal engagement surface may be positioned adjacent to any one or more of the engagement members 1532, 1534, 1536 and/or the cable groove. In other examples, a weather seal engagement surface may be included in any one or more of the engagement members 1532, 1534, 1536 and/or cable channels. The weather seal engaging surface may extend the entire length of the edge of the cabinet wall member 150 such that the weather seal engaging surfaces of adjacent cabinet wall members 150 form a continuous weather seal engaging surface with one another.
The material selection for the components of the cabinet wall component 150 may be similar to the material selection for similar components of the fixed wall panel 130.
Referring now to fig. 13-14, another type of exterior wall panel 310 is a sliding exterior wall panel 160. The sliding outer wall panel 160 may include at least one sub-panel 1610 that is slidable relative to another sub-panel. A portion of each sub-panel 1610 extending along a bottom edge of the sliding outer wall panel 160 can include or define a first engagement member 1632 configured for fixed or sliding connection with the floor engagement member 1134 of an adjacent floor panel 110. In some examples, the first engagement member 1632 can include one or more wheels, spherical rollers, or the like, for rolling along a portion of the floor engaging member 1134 of an adjacent floor panel 110. Similarly, a portion of each sub-panel 1610 extending along the top edge of the sliding outer wall panel 160 can include or define a third engagement member 1636 configured to be fixedly or slidably connected with the roof engagement member 1232 of an adjacent roof panel 200 (see fig. 15-16). In some examples, the first engagement member 1632 may include one or more wheels, spherical rollers, or the like for rolling along the roof engagement members 1232 of adjacent roof panels 210. A portion of at least one of the sub-panels 1610 extending along the vertical side edge of the sliding outer wall panel 160 may include or define a second engagement member 1634 for direct structural connection with a second engagement member 1334, 1534 of an adjacent fixed wall panel 130 or cabinet wall component 150.
One or more of first engagement member 1632, second engagement member 1634, and third engagement member 1636 can also include a seal or sealing surface configured to engage with a corresponding seal or sealing surface of an adjacent prefabricated structural component. Additionally, one or more of the sub-panels 1610 may include a seal or sealing surface configured to engage with a corresponding seal or sealing surface of other ones of the sub-panels 1610. In some examples, a seal may be provided on stiles 1620 of subpanel 1610.
One or more sub-panels 1610 may at least partially overlap and may slide relative to each other in a horizontal direction, allowing an opening to be formed between sub-panels 1610. In this manner, the outer sliding wall panel 160 may be used as a window or a door. Stiles 1620 of subpanels 1610 may interlock to provide a secure and insulated connection between subpanels 1610. In some examples, stiles 1620 may interlock in multiple positions, allowing sub-panels 1610 to be arranged in a horizontally aligned manner as shown in fig. 13, or at an angle relative to each other as shown in fig. 14.
The sub-panel 1610 may be made of various materials depending on desired characteristics such as opacity. Steam cured calcium silicate may be used for opaque sub-panels 1610, thermoset plastic may be used for translucent sub-panels 1610, thermoset plastic or glass may be used for transparent sub-panels 1610. In some examples, different materials may be used for different sub-panels 1610 of a single sliding exterior wall panel 160. Wheels, spherical rollers, etc. may be mechanically secured directly to the sub-panel 1610 or, alternatively, indirectly secured to the sub-panel 1610 via a mounting frame, etc.
Referring now to fig. 15-16, the prefabricated roof panel 210 of the building system of the present disclosure may include a shell 1210 surrounding an inner core 1220. The housing 1210 may include an outer panel 1212, an inner panel 1214, and an edge connecting member 1130. The edge connecting member 1230 may be generally C-shaped and extend around the peripheral edge of the housing 1210. The outer panel surface 1212 may extend horizontally on the top side of the housing 1210 between the edge connecting members 1130. Similarly, the inner panel surface 1214 can extend horizontally on the underside of the housing 1210 between the edge connecting members 1230.
The edge connecting member 1230 may define or include one or more roof engaging members 1232 extending along the underside of the edge connecting member 1230 and providing direct structural connection to one or more of the outer or inner wall panels. In some examples, roof engaging member 1232 may include a plurality of grooves extending parallel to the edges of housing 1210. The plurality of channels may include a plurality of profiles adapted to connect to different types of walls. For example, a portion of the roof engaging members 1232 may be connected to the outer fixed wall panel 130, another portion of the roof engaging members 1232 may be connected to the cabinet wall component 150, another portion of the roof engaging members 1232 may be connected to the sliding outer wall panel 160, and another portion of the roof engaging members 1232 may be connected to the sliding inner wall panel 170.
The roof engaging members 1232 may extend the entire length of each edge of the roof panel 210 such that the roof engaging members 1234 form a continuous structure with the roof engaging members 1232 of adjacent roof panels 210. In some examples, the contour of the roof engaging members 1232 may be substantially the same as the contour of the floor engaging members 1134 of the floor panel 110 to reduce the amount of component material required to manufacture the floor panel 110 and the roof panel 210. Additionally, the same roof engaging members 1232 and floor engaging members 1134 may allow the outer and inner wall panels to be connected in a variety of orientations between pairs of floor panels 110 and roof panels 210.
The rim connecting member 1230 may also define one or more cable channels 1236 that may extend parallel to the roof engaging member 1234. The cable channels 1236 may be recessed below the inner panel face 1214 and may serve as terminals for routing electrical cables, fiber optic cables, coaxial cables, ethernet cables, and other types of cables into the roof panel 210, or as conduits through the roof panel 210 to adjacent prefabricated structural components. After the various cables are installed in the cable trench 1236, a cover can be installed over the cable trench 1236 substantially flush with the inner panel surface 1214.
In some examples, the edge connecting member 1230 may also include one or more weather seals for insulating the connection between the roof panel 210 and any adjacent prefabricated structural components. A weather seal may be positioned adjacent the roof engaging member 1234 and/or the cable channel 1236. The one or more weather seals may extend the entire length of each edge of the roof panel 210 such that the weather seals of adjacent roof panels 210 form a continuous weather seal with each other.
In some examples, the edge connecting member 1230 may also include one or more weather seal engaging surfaces for abutting a weather seal disposed on an adjacent prefabricated structural component. In some examples, the weather seal engagement surface may be positioned adjacent the roof engaging member 1234 and/or the cable channel 1236. In other examples, a weather seal engagement surface may be included 1236 in the roof engaging member 1234 and/or the cable channel. The weather seal engagement surface may extend the entire length of each edge of the roof panel 210 such that the weather seal engagement surfaces of adjacent roof panels 210 form a continuous weather seal engagement surface with each other.
One or more conduits 1222 may extend through the core 1220 of the roof panel 210 to facilitate air flow to the roof panel 210 and to adjacent prefabricated structural components. The edge connecting member 1230 and/or the inner panel face 1214 can have openings in fluid communication with the conduit 1222 such that air can be delivered to and returned from the area below the inner panel face 1214 via the conduit 1122. The one or more conduits may extend the entire length of each edge of the roof panel 210 such that the conduit 1222 of each roof panel 210 forms a continuous fluid conduit with the conduit 1222 of an adjacent roof panel 210.
The materials used for the components of the floor panel 210 may be substantially the same as the materials of similar components of the floor panel 210.
Referring now to fig. 17, another prefabricated structural component of the building system of the present disclosure is a sliding interior wall panel 170. The sliding inner wall panel 170 is substantially identical in structure to the sliding outer wall panel 160, having first 1732, second 1734 and third 1736 engagement members for connection to adjacent prefabricated structural components. The sliding inner wall panel 170 is connected to the adjacent floor panel 110 and roof panel 210 in such a manner as to divide the inner space defined by the outer wall panels. With the building 1000 fully assembled, the sliding interior wall panel 170 can be moved over the plurality of floor and roof panels 110, 210. More specifically, the sliding inner wall panel 170 may move along the aligned floor engaging members 1134 of the adjacently disposed floor panels 110 and along the aligned roof engaging members 1232 of the adjacently disposed roof panels 210. Similar to the sliding outer wall panel 160, the movement of the sliding inner wall panel 170 may be facilitated by wheels or spherical rollers. Thus, after the building 1000 is completed, the sliding interior wall panels 170 may be repositioned and reconfigured to change or reuse the indoor plan view of the building.
Referring now to fig. 18, another prefabricated structural component of the building system of the present disclosure is a sliding cabinet door 180. Sliding cabinet door 180 may be disposed directly adjacent to structural cabinet wall member 150 to provide optional access to interior working area 1550. In particular, the sliding cabinet door 180 may be connected to the same floor engaging members 1134 and roof engaging members 1232 as the adjacent structural cabinet wall components 150. The sliding cabinet door 180 may have a first engagement member 1832 for connecting to the floor engagement member 1134, and a second engagement member 1834 for connecting with the roof engagement member 1232. The sliding cabinet door 180 may include one or more sub-panels 1810 that may slide relative to each other along the floor engaging members 1134 and the roof engaging members 1232 similar to the sliding interior wall panel 170.
Referring now to fig. 19, another prefabricated structural component of the building system of the present disclosure is a service module 190. The service module 190 may generally include plumbing and HVAC fixtures to locate all such components in a single area of the building 1000. Structurally, service module 190 includes a floor portion 1910, a roof portion 1920, and at least one wall portion 1930 extending therebetween. The floor portion 1910 may include a housing 1912 and core (not shown) similar in structure to the housing 1110 and core 1120 of the floor panel 110. Similarly, roof portion 1920 may include a shell 1922 and a core (not shown) similar in structure to shell 1210 and core 1220 of roof panel 210. In particular, the cores of floor portion 1910 and roof portion 1920 have conduits 1916, 1926 that align with conduits 1122, 1222 of adjacent floor panel 110 and roof panel 210 (not shown), respectively. .
The service modules may include bathrooms, kitchens and/or utility areas. In some examples, service modules 190 may include a central heating and/or cooling unit 1950, a refrigerator 1952, a washing machine 1954, a dryer 1956, a dishwasher 1958, a stove 1960, a sink 1962, and a bathroom 1964. Other examples of service modules may include more or fewer fixtures depending on the intended purpose of the building 1000.
The service module 190 may be configured to be directly structurally connected to adjacent prefabricated structural components in a manner similar to that described above in connection with the floor panel 110, roof panel 210, exterior wall panel 310, and sliding interior wall panel 170.
Referring now to fig. 20, an example of the interface between the floor panel 110, structural cabinet wall components 150 and sliding cabinet door 180 is shown in detail. The first coupling member 1532 of the structural cabinet wall component 150 is in direct structural connection with a portion of the floor coupling member 1134 of the floor panel 110. The first coupling member 1832 of the sliding cabinet door is coupled to another portion of the floor engaging member 1134 of the floor panel 110. As can be appreciated from fig. 20, the first engagement member 1532 of the structural cabinet wall component 150 and the floor engagement member 1134 of the floor panel 110 may include one or more grooves, notches, keys, rails, T-shaped rails, or similar structures that may interlock with one another to enable a direct structural connection between the structural cabinet wall component 150 and the floor panel 110. Other engagement members shown and described with reference to fig. 6-20 may include similar interlockable structural features.
Referring now to fig. 21, hollow sections of prefabricated structural components (e.g., conduit 1122 of floor panel 110 and/or conduit 1222 of roof panel 210) may be used as channels for routing piping system 500 for carrying fluids such as water or steam throughout building 1000. In particular, fig. 21 shows the piping system 500 routed through the conduits 1222 of the roof panel 210.
Referring now to fig. 22 and 23, the sealing arrangement between the prefabricated structural components is shown in more detail. As discussed above in connection with fig. 5-19, the weather seal 600 may abut a portion of the joining member of an adjacent prefabricated structural component. Fig. 22 shows the seal 600 disposed between the floor engaging member 1134 of the floor panel 110 and the first engaging member 1532 of the structural cabinet wall component 150. Fig. 23 illustrates a weather seal 600 disposed between a roof engaging member 1232 of the roof panel 210 and a third engaging member 1536 of the structural cabinet wall component 150. A similar arrangement of weather seal 600 may be used between the engagement members of the other prefabricated structural components described with reference to fig. 5-19. The weather seal 600 may be made of a suitable insulating material such as neoprene.
Referring now to fig. 24, any of the prefabricated structural components may further include a lighting system 550 disposed in the joining member of the prefabricated structural component. In some examples, the lighting system 550 may include one or more light emitting devices, such as LED bulbs, light strips, or the like, extending along the third engagement member 1336 of the fixed wall panel 130. As described herein, the lighting system 550 may receive power from electrical cables routed into the fixed wall panel 130.
Referring now to fig. 25 and 26, and again to the description of fig. 5-19, any of the prefabricated structural components may include cable channels for routing electrical cables 700 throughout the building. Specific types of cables 700 that may be routed through the pre-fabricated structural components include, but are not limited to, utility cables, telephone cables, ethernet cables, low voltage cables, fiber optic cables, and coaxial cables. Fig. 25 shows the cable channel 1136 of the floor panel 110 filled with cable 700. Fig. 26 shows the cable channel 1338 in the outer fixed wall panel 130 filled with cable 700.
Referring now to fig. 27, a top cross-sectional view illustrates the effective communication between the electrical ducts and the air ducts of a building 1000 constructed from a plurality of prefabricated structural members 800 according to an example of the present disclosure. The prefabricated structural components 800 are schematically illustrated to illustrate that the general design of the prefabricated structural components 800 ensures that the electrical and air ducts are always aligned to form an interconnected channel system regardless of which particular prefabricated structural component 800 is used. In particular, the prefabricated structural component 800 may define a plurality of continuous horizontal channels 910 extending across a plurality of prefabricated structural components 800. Furthermore, the corner joints of the prefabricated structural components 800 may define continuous vertical channels 920 for supplying air and routing cable 700 between adjacent floors of the multi-storey building 1000. The channels 910, 920 may include a plurality of outlet openings 930 for connection to electrical terminals and/or HVAC registers. In this way, electrical and ventilation connections may be provided at desired locations throughout the building 1000. The unused openings 930 may be covered with removable plugs to prevent access to predetermined portions of the channels 910, 920. Plugs may also be used to separate certain channels 910, 920 from each other in order to isolate the channels for dedicated functions. For example, some of the channels 910, 920 may be used for heating and ventilation, some of the channels 910, 920 may be used for routing the cable 700, some of the channels may be used for routing the ductwork 500, and some of the channels 910, 920 may be used for roof drainage similar to gutter systems. The various uses of the above-described channels 910, 920 are merely exemplary and should not be construed as limiting.
Other aspects of the present disclosure relate to a method for constructing one or more buildings 1000 from a plurality of prefabricated structural components, i.e., the prefabricated structural components discussed above with reference to fig. 1-27. A method 7000 according to some aspects of the present disclosure is illustrated in the flowchart of fig. 28 and the accompanying sequential steps shown in fig. 29-34. For simplicity, fig. 28-34 illustrate a method 7000 for constructing a single building 1000. However, it should be understood that method 7000 can be used to simultaneously build multiple buildings 1000 that form a development complex.
At step 7100, the construction of building 1000 is designed. Step 7100 includes selecting a layout of the building 1000 and selecting the type and number of prefabricated structural components necessary to achieve the layout. For example, a designer may select characteristics of the building 1000, such as overall dimensions, plan views, subdivision of interior spaces, location of building utilities, etc., and select prefabricated structural components to conform to the selected characteristics of the building 1000. In some examples, step 7100 may be performed with the aid of a computer to provide a virtual simulation of building 1000 based on input from the designer. For example, the designer may input some or all of the above listed characteristics of the building 1000 via an input device of the computer. The processor of the computer may receive the input and execute program instructions stored in a temporary or non-temporary memory that cause the processor to generate output data, such as the type and number of prefabricated structural components necessary to construct building 1000. The processor may generate and display a virtual model, construction drawings, and/or bill of materials for the building 1000. In some examples, step 7100 can be further automated by a computer such that the computer, via program instructions, selects or modifies, at least in part, the configuration of building 1000 to optimize factors such as component costs, environmental impact, energy efficiency, and the like.
At step 7200, after building 1000 is designed, a foundation is installed based on the building design. As shown in fig. 29, the base may include the base component 140 described above with reference to fig. 1-2. The support posts 142 of the base assembly 140 are spaced apart from one another in an arrangement corresponding to the location of the base groove or recess 1132 of the one or more floor panels 110 installed in steps 7300 and 7400. As indicated above, in some examples, the foundation assembly 140 of fig. 1-2 is omitted and a conventional poured cement foundation is installed.
At step 7300, the service module 190 may be installed as shown in FIG. 30. In particular, a base groove or recess in the floor portion 1910 of the service module 190 may be attached to the support column 142 installed in step 7200. The base groove or recess of the floor section 190 may be specifically designed to engage the head 144 of an adjacent support column 142 so that the support column 142 may substantially determine the mounting location of the service module 190. The engagement between the head portion 144 of the support post 142 and the floor portion 1910 of the service module 190 may be substantially self-supporting, requiring minimal additional mechanical fasteners to achieve a load bearing structure. Thus, installing the service module 190 may consume less labor and time than conventional construction methods. Additional benefits of a substantially self-supporting connection between service module 190 and support column 142 include quick disassembly due to the reduction of additional fasteners required to effect the connection. Thus, the building system of the present disclosure may be particularly suitable for applications where the building 1000 is intended to be used as a temporary or repositionable structure.
At step 7400, the floor assembly 10 is constructed by attaching the floor panel 110 to a foundation. As shown in fig. 31, the base groove or recess 1132 of a single floor panel 110 may be attached to the support post 142 installed in step 7200. Because the base groove or recess 1132 is specifically designed to engage the head 144 of an adjacent support column 142, the support column 142 can substantially determine the installation location of the floor panel 110. Thus, the floor assembly 10 can be built without the need for complex alignment operations. The engagement between the head 144 of the support post 142 and the base groove or recess 1132 of the floor panel 110 may be substantially self-supporting, requiring minimal additional mechanical fasteners to achieve a load bearing structure. This feature, like service module 190, allows building 1000 to be built quickly. Furthermore, the engagement between the head 144 of the support post 142 and the base groove or recess 1132 of the floor panel 110 may be easily removed due to the reduction of additional fasteners required to effect the connection.
At step 7500, the exterior wall assembly 30 may be built by attaching the exterior wall panel 310 to the floor panel 110. At the same time or after the construction of the exterior wall assembly 30, the sliding interior wall panel 170 and sliding cabinet door 180 may be installed at step 7600. Fig. 32 shows a structural cabinet wall component 150 attached to the floor panel 110. As discussed above with reference to fig. 9-12, the first engagement member 1532 of the structural counter wall component 150 may be connected to the floor engagement member 1134 of an adjacent floor panel 110 such that the structural counter wall component 150 is arranged substantially perpendicular to the floor panel 110. As with other prefabricated structural components, the joint between the first coupling member 1532 of the structural cabinet wall component 150 and the floor coupling member 1134 of the floor panel 110 may be substantially self-supporting, requiring minimal additional mechanical fasteners to achieve a load bearing structure. In a similar manner, the second coupling member 1534 of the structural cabinet wall component 150 may be connected to a corresponding coupling member of an adjacent exterior wall panel 310.
Fig. 33 shows the installation of the external fixed wall panel 130, the sliding outer wall panel 160, the sliding inner wall panel 170 and the sliding cabinet door 180. The external fixed wall panel 130 may be installed in the same manner as the structural cabinet wall component 150, with the first engagement member 1332 attached to the floor engagement member 1134 of the adjacent floor panel 110 and the second engagement member 1334 attached to the adjacent outer wall panel 310. The sliding outer wall panel 160 may be mounted in the same manner as the first engagement member 1632 is attached to the floor engagement member 1134 of the adjacent floor panel 110 and the second engagement member 1634 is attached to the adjacent outer wall panel 310. The sliding interior wall panel 170 may be installed in the same manner as the first joint member 1732 is attached to the floor joint member 1134 of the adjacent floor panel 110 and the second joint member 1734 is attached to the adjacent prefabricated structural component. Finally, the sliding cabinet door 180 may be installed by attaching the first engagement member 1832 to the floor engagement member 1134 of the floor panel 110 adjacent the corresponding structural cabinet wall component 150.
At step 7700, the roof assembly 20 may be built by attaching the roof panel 210 to the already installed prefabricated structural components. As shown in fig. 34, the roof engaging members 1232 of each roof panel 210 may be attached to the corresponding engaging members 1336, 1536, 1636, 1736, 1834 of the external fixed wall panel 130, the structural cabinet wall component 150, the sliding external wall panel 160, the sliding internal wall panel 170 and the sliding cabinet door 180. The joint between the roof panel 210 and the adjacent prefabricated structural components may be substantially self-supporting, requiring minimal additional mechanical fasteners to achieve a load bearing structure.
Throughout steps 7300 through 7700, a weather seal 600 may be installed between the joining members of adjacent prefabricated structural components, as discussed above in connection with fig. 22-23.
In step 7800, the piping system 500 may be routed through a conduit of the prefabricated structural component, as discussed above in connection with fig. 21. The lighting system 550 may be disposed in the joining members of the prefabricated structural components, as discussed above in connection with fig. 24. The cable 700 may be routed through a cable channel of a prefabricated structural component as discussed above in connection with fig. 25 and 26. Step 7800 may be performed after or simultaneously with steps 7300 through 7700.
Although several examples of building systems, buildings, and methods for constructing buildings are illustrated in the drawings and described above in detail, other examples will be apparent to those skilled in the art without departing from the scope and spirit of the present disclosure. For example, it should be understood that aspects of the various examples described above may be combined with aspects of other examples while still falling within the scope of the present disclosure. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The elements of the disclosure described above are defined by the appended claims, and all changes to the disclosed elements that come within the meaning and range of equivalency of the claims are intended to be embraced therein.

Claims (25)

1. A multi-faceted structure constructed from a plurality of prefabricated components, said prefabricated components consisting of less than 12 different prefabricated structural components, said multi-faceted structure comprising:
a floor assembly;
a roof assembly; and
a side assembly connected to and extending between the floor assembly and the roof assembly,
wherein the floor assembly comprises a plurality of the floor panels, each floor panel being in direct structural connection with at least one other floor panel,
wherein the roof assembly comprises a plurality of the roof panels, each roof panel being connected with at least one other roof panel direct connection structure, an
Wherein the side assembly comprises a plurality of said wall panels, each wall panel being connected to at least one floor panel and at least one roof panel direct connection structure.
2. The multi-faceted structure according to claim 1, wherein each floor panel comprises:
a floor surface having at least one edge; and
a floor engaging member extending parallel to the at least one edge of the floor surface; and
wherein each roof panel comprises:
a roof surface having at least one edge; and
a roof engaging member extending parallel to the at least one edge of the floor surface.
3. The multi-faced structure of claim 2, wherein at least one of the wall panels is a fixed wall panel, the fixed wall panel including:
a fixed wall surface having a bottom edge, a top edge, and side edges;
a first engagement member extending parallel to the bottom edge;
a second engagement member extending parallel to the top edge; and
a third engagement member extending parallel to the side edge.
4. The multi-faceted structure according to claim 3, wherein the first joining member of the fixed wall panel is configured to be rigidly connected to the floor joining member of one of the floor panels, and wherein the second joining member of the fixed wall panel is configured to be rigidly connected to the roof joining member of one of the roof panels.
5. The multi-faceted structure according to claim 3, wherein the floor engaging members of each floor panel include a groove, and wherein the first engaging member of each wall panel includes a rail configured to extend into the groove.
6. The multi-faceted structure according to claim 3, wherein the floor engaging members of each floor panel include a weather seal configured to engage the first engaging member of each wall panel.
7. The multi-faceted structure according to claim 1 further comprising a service module, said service module including:
a base panel having at least one edge configured to be rigidly connected to at least one of the floor panels; and
at least one of a plumbing system, a climate control system, and a sanitation system.
8. The multi-faceted structure of claim 1 wherein each of said floor panels further comprises a conduit extending below said floor surface, and wherein said conduit of each of said floor panels is configured to be in fluid communication with said conduit of each adjacent floor panel.
9. The multi-faceted structure of claim 1 wherein at least one of said floor panel, said roof panel, and said wall panel includes a first conduit configured to align with a second conduit of an adjacent one of said floor panel, said roof panel, and said wall panel.
10. A building system comprising a plurality of prefabricated structural components, wherein each of the plurality of prefabricated structural components is connectable with at least another one of the plurality of prefabricated structural components, the plurality of prefabricated structural components comprising:
(a) at least one floor panel, each floor panel comprising:
(i) a floor surface having at least one edge; and
(ii) a floor engaging member extending parallel to the at least one edge of the floor surface;
(b) at least one fixed shingle, each fixed shingle including:
(i) a fixed wall surface having a bottom edge, a top edge, and side edges;
(ii) a first engagement member extending parallel to the bottom edge;
(iii) a second engagement member extending parallel to the top edge; and
(iii) a third engagement member extending parallel to the side edge; and
(c) at least one roof panel, each roof panel comprising:
(i) a roof surface having at least one edge; and
(ii) a roof engaging member extending parallel to the at least one edge of the floor surface.
11. The building system according to claim 10, wherein the first joining member of each fixed wall panel is configured to be rigidly connected to the floor joining member of each floor panel, and wherein the second joining member of each fixed wall panel is configured to be rigidly connected to the roof joining member of each roof panel.
12. The building system according to claim 10, wherein the at least one fixed wall panel comprises a first fixed wall panel and a second fixed wall panel, and wherein the third engagement member of the first fixed wall panel is configured to be rigidly connected to the third engagement member of the second fixed wall panel.
13. The building system of claim 10, wherein the plurality of prefabricated structural components further comprises a service module comprising:
a base panel having at least one edge configured to be rigidly connected to another of the plurality of prefabricated structural components; and
at least one of a plumbing system, a climate control system, and a sanitation system.
14. The building system of claim 10, wherein the plurality of prefabricated structural components further comprises a sliding wall panel comprising:
a sliding wall surface having a bottom edge and a top edge;
a first engagement member extending parallel to the bottom edge; and
a second engagement member extending parallel to the top edge,
wherein the first engagement member of the sliding wall panel is configured to be slidably connected to the floor engagement member of each floor panel, an
Wherein the second engagement member of the sliding wall panel is configured to be slidably connected to the roof engagement member of each roof panel.
15. The building system of claim 10, wherein the plurality of prefabricated structural components further comprises at least one foundation pile, each foundation pile configured to be secured to the ground and connected to each of the floor panels.
16. The building system of claim 10, wherein each of the floor panels further comprises a conduit extending below the floor surface, and wherein the conduit of each of the floor panels is configured to be in fluid communication with the conduit of each adjacent floor panel.
17. The building system according to claim 10, wherein at least one of the plurality of prefabricated structural components comprises a first conduit configured to align with a second conduit of an adjacent one of the plurality of prefabricated structural components.
18. The building system according to claim 10, wherein the floor engaging member of each floor panel comprises a groove, and wherein the first engaging member of each fixed wall panel comprises a rail configured to extend into the groove.
19. The building system according to claim 10, wherein the floor engaging member of each floor panel comprises a weatherseal configured to engage the first engaging member of each fixed wall panel.
20. The building system according to claim 10, wherein the plurality of prefabricated structural components consists of less than 12 different prefabricated structural components, and wherein a complete building can only be built from the plurality of prefabricated structural components.
21. The building system according to claim 20, wherein the plurality of prefabricated structural components consists of less than 10 different prefabricated structural components, and wherein a complete building can only be built from the plurality of prefabricated structural components.
22. The building system according to claim 10, wherein at least two of the floor engaging members of each floor panel, the first engaging members of each fixed wall panel, the second engaging members of each fixed wall panel, the third engaging members of each fixed wall panel, and the roof engaging members of each roof panel have substantially the same profile.
23. The building system according to claim 10, wherein the first, second and third joining members of each fixed wall panel have substantially the same profile.
24. A method for constructing a building from a plurality of prefabricated structural components, comprising:
arranging a plurality of floor panels on a base assembly, each floor panel comprising a floor surface having at least one edge and a floor engaging member extending parallel to the at least one edge of the floor surface;
arranging a plurality of fixed wall panels substantially perpendicular to the plurality of floor panels, each fixed wall panel comprising a fixed wall surface having a bottom edge, a top edge and side edges, a first engagement member extending parallel to the bottom edge, a second engagement member extending parallel to the top edge, and a third engagement member extending parallel to the side edges;
arranging a plurality of roof panels in vertically spaced apart relation to the plurality of floor panels, each roof panel comprising at least one edge and a roof engaging member extending parallel to the at least one edge of the floor surface of at least one of the plurality of floor panels;
connecting the first joining member of each fixed wall panel to a corresponding floor joining member of a floor panel of the plurality of floor panels; and
connecting the second engagement member of each fixed wall panel to a corresponding roof engagement member of a roof panel of the plurality of roof panels.
25. The method of claim 24, further comprising completing the building with only the plurality of prefabricated structural components, wherein the plurality of prefabricated structural components consists of less than 12 distinct prefabricated components.
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EP3762555A4 (en) 2021-11-10
US20210040723A1 (en) 2021-02-11
MX2020009264A (en) 2021-02-15
CN113550424A (en) 2021-10-26

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Application publication date: 20201113