WO2009152476A1

WO2009152476A1 - Module with moment frame and composite panels for a bulding structure

Info

Publication number: WO2009152476A1
Application number: PCT/US2009/047280
Authority: WO
Inventors: Scott D. Cathcart; Chris Ransel
Original assignee: Veristeel, Inc.
Priority date: 2008-06-13
Filing date: 2009-06-12
Publication date: 2009-12-17
Also published as: US20090307994A1; TW201002918A

Abstract

A module for building structure includes a moment frame, a set of four top corner pieces, and a set of two or more composite panels. The moment frame is comprised of beams and columns jointed to form a top, a bottom and four sides. Each top corner piece is located at a corner of the top of the moment frame. The set of two or more composite panels is attached to the bottom of the moment frame to provide a sub-floor of the building structure. A first composite panel, of the set, is adapted to transfer a load to a second abutting composite panel of the set, in response to a deflection of the moment frame. Each composite panel is comprised of a core element encased in a metal frame, which includes two face sheets, two end cap pieces, and two side pieces.

Description

MODULE WITH MOMENT FRAME AND COMPOSITE PANELS FOR A BUILDING

STRUCTURE

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to U.S. Application Serial No. 12/483,157, filed June 11, 2009, and U.S. Provisional Application Serial No. 61/131,957, filed June 13, 2008, which are incorporated herein by reference in their entirety for all purposes.

BACKGROUND

1. Field

[0002] This application relates generally to modular building construction and, more specifically, to using a modular building moment frame to construct rapidly deployable structures that can be used to house or shelter people.

2. Description of the Related Art

[0003] Known methods of building construction can be used to provide homes, schools, medical facilities and other essential structures. While traditional construction methods can be applied to a wide range of applications, traditional methods may require significant lead time, raw materials, and skilled labor resources.

[0004] For example, portions of a building structure may require custom fabrication that must be performed at the building site. This presents at least three constraints on a traditional construction project. First, it may be necessary to deliver large amounts of raw materials to the building site. The raw materials must be stored, protected from the elements and secured from theft. Second, a skilled labor force may be required to fabricate each element of the building structure using the raw materials provided. Foundations, walls, floors, ceilings and roofs may be fabricated by hand and integrated into the building piece by piece. Third, traditional methods may require a substantial lead time between the perceived need for a building and the completion of a working facility. Traditional projects typically require time to design, draft, and procure materials before fabrication can begin. Planning and executing even a small construction project may require months of advanced planning. Large scale projects may require years. [0005] The time constraints due to traditional methods may be unacceptable for projects that require an accelerated build schedule. Traditional methods may also be unsuitable for projects with limited access to raw materials or skilled labor. For example, exigent circumstances, such as military troop deployment, natural disaster relief, or population displacement, present immediate needs in areas that may be far removed from traditional construction resources.

[0006] In many cases, modular construction may overcome limitations of traditional construction techniques. By prefabricating portions of the structure off-site, lead time can be reduced, and fewer raw materials may be required on-site for the final construction. Prefabricated modules can be manufactured ahead of time, stored, and then shipped to the final location once a facility is needed. Modules can also be configured on-site into a wide range of facilities and custom tailored to the needs of the occupant. Additionally, modules designed to facilitate on-site assembly may reduce the need for large numbers of skilled construction workers.

[0007] What is needed is a modularized structural building system that can be customized and manufactured in scalable quantities, and deployed world wide.

SUMMARY

[0008] A module for building structure includes a moment frame, a set of four top corner pieces, and a set of two or more composite panels. The moment frame is comprised of beams and columns jointed to form a top, a bottom and four sides. Each top corner piece, of the set of four top corner pieces, is located at each corner of the top of the moment frame. Each top corner piece has a coupler element to interface with a lifting mechanism that lifts the module. The set of two or more composite panels is attached to the bottom of the moment frame to provide a sub- floor of the building structure. A first composite panel, of the set, is adapted to transfer a load to a second abutting composite panel of the set, in response to a deflection of the moment frame. Each composite panel is comprised of a metal frame having two face sheets, two end cap pieces, and two side pieces. The two face sheets are substantially parallel to each other, the two end cap pieces are substantially perpendicular to the face sheets, and the two side pieces are substantially perpendicular to both the face sheets and the end cap pieces. Each composite panel is further comprised of a core element encased within the metal frame, and bonded to the two metal face sheets. DESCRIPTION OF THE FIGURES

[0009] FIG. IA illustrates an exemplary embodiment of a building structure composed of multiple moment modules.

[0010] FIG. IB illustrates an alternate embodiment of a building structure composed of multiple moment modules.

[0011] FIG. 1C illustrates a sectional cut-away view of a building structure, including a gable roof structure.

[0012] FIG. 2 illustrates a moment module.

[0013] FIG. 3 illustrates an interlocking panel joint.

[0014] FIG. 4 illustrates a moment frame.

[0015] FIGs. 5 A to 5B illustrate 8x20 foot and 8x40 foot moment modules.

[0016] FIG. 6 illustrates a range of moment module sizes.

[0017] FIG. 7 illustrates a moment module with composite panels installed in both the bottom and top of the moment frame.

[0018] FIG. 8 illustrates a type T moment module.

[0019] FIG. 9 illustrates a type-U moment module.

[0020] FIG. 10 illustrates a moment module with a single-pitch roof.

[0021] FIG. 11 illustrates a moment module with a double-pitch roof.

[0022] FIG. 12 illustrates a drainage system for a moment module.

[0023] FIG. 13 illustrates a moment module with side walls.

[0024] FIGs. 14A to 14H illustrate components of a composite panel assembly.

[0025] FIGs. 15A to 15H illustrate components of an alternative embodiment of a composite panel assembly.

[0026] FIG. 16 illustrates the profile of an interlocking joint piece. [0027] FIGs. 17 A to 17C illustrate one embodiment of a face sheet.

[0028] FIGs. 18A to 18C illustrate an alternate embodiment of a face sheet.

[0029] FIGs. 19A to 19C illustrate one embodiment of an end cap.

[0030] FIGs. 2OA to 2OC illustrate an alternative embodiment of an end cap.

[0031] FIG. 21 illustrates an example of a flat pattern of an end cap.

[0032] FIG. 22 illustrates an example of mounting a composite panel using a ledger configuration.

[0033] FIG. 23 illustrates an example of mounting a composite panel directly to a beam member.

[0034] FIGs. 24A and 24B illustrate an elevation view and detail view of a lower frame corner.

[0035] FIGs. 25 A and 25B illustrate an elevation view and detail view of an upper frame corner.

[0036] FIGs. 26 A and 26B illustrate an elevation view and detail view of an alternative upper frame corner.

[0037] FIGs. 27 A and 27B illustrate a corner interface of four moment modules in a building structure.

[0038] FIGs. 28A to 28F illustrate moment modules assembled into a building structure.

[0039] FIG. 29 illustrates a three by three moment module structure.

[0040] FIGs. 30A to 30C illustrate alternative configurations of a building structure using moment modules.

[0041] The figures depict one embodiment of the present invention for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein can be employed without departing from the principles of the invention described herein. DETAILED DESCRIPTION

[0042] Modularized steel moment frames can be used to construct scalable building structures for immediate deployment anywhere in the world. The following embodiments describe how different variations of a rapidly deployable and stackable moment module (referred to simply as "moment module" hereafter) can be fabricated, shipped and assembled on-site to help create a variety of building facilities.

[0043] FIGs. IA to 1C depict moment modules assembled together to form examples of a building structure. In FIG. IA, a 3 story building structure is formed using 3 stacks of 12 moment modules for a total of 36 moment modules. As discussed in greater detail below, a moment module 100 can be adapted in a variety of ways to form a completed building facility 110. As shown in FIG. IA, a moment module 100 can include stairs, external walls, windows and other traditional building features. FIG. IB depicts another example of a building structure 120 featuring a fully enclosed, internal stairway.

[0044] FIG. 1C depicts multi-story building 110 in a cut-away view. As discussed in greater detail below, the moment module 100 allows for an open span, which allows for a floor plan that is free from internal columns or load-bearing walls.

[0045] A completed building 110 may also include a gable roof structure 140. The gable roof structure 140 may be constructed using composite panels or more traditional wooden truss construction and roofing materials. The roof structure may also be constructed of a hybrid of composite panels and traditional building materials. For additional descriptions of composite panels being used to provide a roof structure, see U.S. Patent No. 6,588,171, which is incorporated herein by reference in its entirety for all purposes. In alternative embodiments described herein, the roof structure may also be integrated into individual moment modules that make up the top floor in a building.

1. Moment Module

[0046] As mentioned above, the moment modules can be used as the fundamental structural elements in a variety of building construction configurations. Creating a building structure using moment modules, as described herein, allows for a majority of the fabrication to be performed off-site. The completed or partially completed moment modules can then be shipped to the location of the building, and assembled into place. As depicted in FIGs. 2 to 13, moment modules can be constructed in a variety of configurations to provide features that are suited to a particular application.

[0047] FIG. 2 is a perspective view of moment module 100, including a moment frame 210 and a set of two or more composite panels 220, which forms the floor or sub-floor of moment module 100. In one alternative embodiment, a single composite panel may be used to form the floor or sub-floor. In another alternative embodiment, the floor or sub-floor is constructed using materials that are not composite panels.

[0048] The moment frame 210 includes eight beams 212 and four columns 214, which are joined to form a top, bottom, and four sides. The four sides of the moment module 100 can be left open because the columns 214 of the moment frame 210 can provide sufficient structural integrity without requiring the use of load-bearing panels/walls.

[0049] In FIG. 2, two or more composite panels are attached to the bottom of moment frame 100. Each composite panel 220 may be attached using ledger frame elements and threaded fasteners as described in more detail below. Once installed, the two or more composite panels become a structural member of the moment module 100. For example, in some embodiments, the moment module 100, including two or more composite panels, is able to distribute floor loads up to or in excess of 240 kg/m² (approximately 50 lbs/ft²).

[0050] In some embodiments, the composite panels are able to distribute bending or twisting loads exerted on the moment module. Because the composite panels are physically integrated into the moment frame 210, the composite panels are able to resist a deflection or deformation in the moment frame. For example, each composite panel 220 (of the set of composite panels) is able to resist a moment load, particularly if the moment load is perpendicular to a face sheet of the composite panel. (See section 3 below for a description of composite panel components.). By attaching the composite panel 220 to a beam 212 in the moment frame 210, the composite panel 220 is able to impede a deflection of the beam by resisting the moment load created by the beam deflection. This is particularly true for deflections that result in a moment that is perpendicular to the face sheet of the composite panel.

[0051] Thus, each individual composite panel 220 is able to provide additional rigidity or structural support to the moment frame 210. In addition, each composite panel 220 is able to distribute loads to other, abutting composite panels. For example, FIG. 3 depicts an exemplary embodiment of an interlocking panel joint between abutting composite panels 220. [0052] In some embodiments, the composite panels 220 may include interlocking joint pieces along two sides of composite panel 220. Preferably formed from steel sheet, the interlocking joint pieces can be used to locate and support the composite panels 220 when they are installed in moment frame 210. FIG. 3 depicts an exemplary side detail of two composite panels 220 joined together using interlocking joint pieces 234. In some embodiments, the interlocking joint pieces 234 may form the side piece of the composite panel 220. For a detailed description of the composite panel construction, see section 3, below.

[0053] Exemplary embodiments of the interlocking joint pieces 234 have a protrusion shape 236 and a channel shape 238. Both shapes are formed into the metal sheet and extend the length of the interlocking joint piece. When assembled in the moment frame, the protrusion shape 236 of the interlocking joint piece can be inserted into the channel shape 238 of another interlock joint piece, to form an interlocking panel joint between two abutting composite panels.

[0054] The interlocking panel joint resists relative movement of the composite panels in at least the direction perpendicular to the joint. For example, if the panels are horizontal as shown in FIG. 3, the joint resists relative movement in the vertical direction. By resisting vertical motion, the joint is able to withstand sheer loads between the composite panels. For example, if the composite panels are used to create the floor of the moment module, the joint can support vertical sheer loads created by the weight of objects in contact with the floor of the moment module.

[0055] In a preferred embodiment, the protrusion shape 236 of the interlocking joint piece is deeper than the channel shape 238 of a mating interlocking joint piece so that there is a gap between the face sheets of the two abutting composite panels. Depending on the strength of the material forming the protrusion shape 236, a compression load may be transferred from one composite panel to another, abutting composite panel. For example, a compression load, substantially parallel to the face sheet of the composite panel and perpendicular to the panel joint may be transferred from one composite panel to a second, abutting composite panel.

[0056] In some embodiments, the panel joint may also resist torsional or twisting loads between two composite panels. This may also increase the rigidity of the moment module when a set of two or more composite panels are installed in the moment frame. For example, if the moment frame is subjected to a torsional or twisting load, the beams in the moment frame may deflect or distort. As discussed above, this deflection may be resisted by each composite panel that is mounted to a deflecting frame member due to the rigidity or stiffness of each individual composite panel.

[0057] Additionally, the moment frame deflection may be resisted due to the panel joint between abutting pairs of composite panels. As the moment frame is distorted, a first composite panel may tend to shift with respect to a second, abutting composite panel. The panel joint, however, resists this shifting by resisting relative movement of the two composite panels in a direction that is perpendicular or transverse to the panel joint. By resisting this transverse motion, the two abutting panels are able to distribute a transverse load created by the frame distortion. Additionally, the panel joint may resist a movement of the composite panels in a direction that is substantially parallel to the face sheet of the composite panels and perpendicular to the panel joint. By resisting motion in this direction, the two abutting panels are able to distribute a compression load created by the frame distortion. Thus, depending on the deflection of the moment frame, the panel joint may transfer a compression load, a transverse load, or a combination of the two loads from a first composite panel to a second, abutting composite panel.

[0058] In some embodiments, the panel joint connects a set of composite panels such that the combined and joined panels exhibit properties similar to a single continuous panel. As described above, the panel joint may resist motion of the composite panels in a direction parallel to the face sheet of the composite panel, and in a direction transverse or at an angle to the face sheet of the composite panel.

[0059] The amount of rigidity or support created by the set of composite panels may also be reduced. Depending on the clearance between the mating faces in the joint, the panels may also be allowed to shift with respect to each other to comply with a certain amount of deformation or planar twist in the moment module frame.

[0060] Note that FIG. 3 depicts the composite panels 220 horizontally mounted in a moment frame. However, various embodiments may use the composite panels 220 with interlocking panel joints in other configurations or in conjunction with other elements of the structure, such as composite panels used in a wall, ceiling or roof panel structure.

[0061] FIG. 4 depicts a perspective view of the moment frame 210 of the moment module 100 without composite panels. Four metal columns 214 are used to form the four sides of the moment frame. Eight metal beams 212 are used to form the top and bottom of the moment frame. The metal beams and columns can be made of any structural grade steel or aluminum and may either be welded or connected using metal fasteners (e.g., bolts or rivets). Alternatively, the beams and columns could include different cross sections or could be formed from metal sheet.

[0062] In some embodiments, the metal columns 214 may be made from a closed cross- section rectangular tube with a 150mm x 150mm x 9mm cross-section. In some embodiments, the metal beams 212 may be made from a 200mm x 90mm x 9mm cross-section steel channel.

[0063] The moment frame includes four top corner elements attached to each corner of the top of the moment frame. In some embodiments, the moment frame may also include four bottom corner pieces attached to each corner of the bottom of the moment frame. FIG. 4 depicts an embodiment including four top corner pieces 216 attached to the top of the moment frame and four bottom corner pieces 218 attached to the bottom of the moment frame. FIGs. 24-26 depict specific examples of corner piece integration in more detail.

[0064] Each top corner piece includes a coupler element to interface with a lifting mechanism that lifts the module. For example, each top corner piece may include three external faces, with a slotted hole on each face. The slotted holes project inward to a hollow core of the top corner piece. In some embodiments, the top corner pieces may be designed in accordance with standard ISO freight container upper corner castings.

[0065] In some embodiments, the top corner pieces 216 can be used to lift or load the moment module during transportation. For example, if the top corner pieces 216 are ISO corner castings, the module may be lifted using existing crane and hoist equipment designed to move and transport traditional cargo shipping containers.

[0066] Each bottom corner piece includes a coupler element to interface with a securing mechanism that secures the module. For example, each bottom corner piece may include three external faces, with a slotted hole on each face. The slotted holes project inward to a hollow core of the bottom corner piece. In some embodiments, the bottom corner pieces may be designed in accordance with standard ISO freight container lower corner castings.

[0067] In some embodiments, the bottom corner pieces 218 can be used to secure the moment module to a deck or shipping platform. For example, if the bottom corner pieces 218 are ISO corner castings, the moment module may be secured to the bed of a truck or deck of a boat designed to interface with traditional cargo shipping containers. Additionally, if the corner pieces (top or bottom) are ISO corner castings, the moment module may also be stacked on top of or underneath a traditional cargo shipping container. Similarly, the corner pieces (top or bottom) may also be used to physically tie the moment module to another moment module.

[0068] FIGs. 5 A and 5B depict examples of two different sizes for the moment module as moment modules 520 and 540, respectively. FIG. 5A depicts the moment module 520 as being approximately 9 feet, 6 inches tall by 8 feet wide by 20 feet long. The moment module 520 has approximately the dimensional footprint of a standard 8x20 cargo container. FIG. 5B depicts the moment module 540 as being approximately 9 feet, 6 inches tall by 8 feet wide by 40 feet long. The moment module 540 has approximately the dimensional footprint of a standard 8x40 cargo container. FIG. 6 depicts an end view and elevation view of a moment module with a range of sizes. While this range includes the preferred embodiments described in FIGs. 5A and 5B, the size of a moment module may include embodiments outside of the range of values shown in FIG. 6. In a preferred embodiment, the interior dimension of the moment module provides a minimum 8 foot ceiling clearance. To provide for increased ceiling height, moment modules can be made to an external height of 11 feet, 6 inches.

[0069] Because the moment modules 520 and 540 have approximately the same footprint as standard cargo containers, they can be handled, transported, and/or relocated using existing transportation and handling equipment available throughout the world. As described above, if a module conforms to ISO specifications, the moment module can be transported using trucks, hoists, and ships that are used to transport standard cargo containers. The moment modules can also be handled at building sites and assembled using handling equipment adapted to interface with standard cargo containers. In this way, moment modules can be rapidly deployed throughout the world using existing transportation infrastructure. It should be noted, however, that moment modules can have various sizes and various shapes.

2. Moment Module, Configurations

[0070] A moment frame, composite panels and other structural elements may be integrated to create various configurations of the moment module. For example, one or more composite panels can be used to construct the moment module floor, the moment module ceiling, the moment module roof, and/or the moment module walls. For a more detailed description of a composite panel, see sections 3 below.

[0071] In the moment module 710 depicted in FIG. 7, a top set and a bottom set of two or more composite panels 220 are attached to the bottom and top of the moment frame 210 to form a sub-floor and a ceiling, respectively, of a building structure. Note, however, that the set of composite panels attached to the bottom of the frame may differ from the composite panels attached to the top of the frame.

[0072] As described earlier, a moment module may include only the first set of two or more composite panels attached to the bottom of the moment frame to provide a sub-floor of a portion of a building structure. Alternatively, a moment module may include only the second set of two or more composite panels that can be attached to the top of the moment frame to provide a ceiling of a portion of a building structure. In some embodiments, a single composite panel can be used to provide either the sub-floor or ceiling of a building structure. In another alternative embodiment, the moment module does not include any composite panels.

[0073] FIGs. 8 and 9 depict two types of moment modules. One moment module is referred to herein as a type-T moment module 810, while the other is referred to as a type-U moment module 910. As depicted in FIG. 8, the type-T moment module 810 has composite panels attached to the top of the moment module with the top of the panels approximately flush with the top of the top beams of the moment frame of the moment module. The type-T moment module 810 can be used for a single story building or as the top floor of a multi-story building. As depicted in FIG. 9, the type-U moment module 910 has composite panels attached to the top of the moment module with a space between the top of the panels and the top of the top beams of the moment frame of the moment module. The type-U moment module 910 can be used as the lower unit in multi-story buildings. In some embodiments, the spacing can be used for wires, plumbing, duct- work, etc.

[0074] FIGs. 10 and 11 depict moment modules with a single and double-pitch roof, respectfully. The slope of the pitched roof allows water to drain off the building structure. FIG. 10 depicts moment module 1010 with a single -pitch roof. In one exemplary embodiment, the pitch of the roof may be approximately a 10mm to 20mm drop per meter length (1/8" to 1/4" drop per foot length). However, the pitch of the roof is typically a result of the space available in the top of the moment frame. FIG. 11 depicts an embodiment of a moment module 1110 using a double-pitch roof with the highest point in the center of the moment module. Pitched roof elements may be made using composite panels, metal sheet or wood.

[0075] In one embodiment, the roof may be made from stamped corrugated steel sheet and then covered with a polyisocyanurate (PIR) extruded foam board. The PIR board may then be covered with an ethylene propylene diene (EPDM) M-class synthetic rubber. Other embodiments may include alternative materials for insulating and waterproofing roofs. In some embodiments, support for the pitched roof may be provided by ledger elements (described below) or cross beam support (not shown). Pitched-roof moment modules 1010 and 1110 may be used for a single story building or as the top floor of a multi-story building.

[0076] In an alternate embodiment, the roof may be constructed using stamped corrugated steel sheet. The steel sheet may be welded along the seams to provide a waterproof barrier. The steel sheet may be installed to provide a pitch, as described above. In alternate embodiments, the steel sheet may be preformed or installed to form a convex shape. This allows water or other fluids to drain from the top of the moment module.

[0077] FIG. 12 depicts one embodiment of a roof drainage system. As shown in FIG. 12, a channel member 1112 may be used to support one end of the pitched roof. Alternatively, the pitched roof may be supported by ledger or other frame elements. The portion of the frame above the roof is left open to allow water to flow without obstruction. In some embodiments, a beam member 1114 may be used above the open portion of the frame to increase the strength of the top of the moment frame. In alternative embodiments, the beam of the frame may have holes or slots that also allow for fluids to drain from the top of the moment module.

[0078] FIG. 13 depicts a walled moment module 1310. In some embodiments, the walls 1320 of the moment module 1310 may include a set of one or more composite panels. Similar to the panels used floor of the moment module 100 in FIG. 2, the wall panels may include interlocking panel joint elements. See also FIG. 3 for an example of an interlocking panel joint. In alternative embodiments, the side panels may be made from metal sheet. For example, a single metal sheet or several metal sheets may be attached to portions of the moment frame beam. Alternatively, side walls may also be constructed from traditional wall materials, including metal studs, sheet rock and insulation.

[0079] In some embodiments, a rubberized sheet may be included in the side wall installation to provide a water-tight barrier. In some embodiments, the side walls are installed only for shipping and are removed before the moment module is assembled into a building structure. In other embodiments, the panels are installed as permanent structural components of the frame.

3. Moment Module, Composite Panel Construction

[0080] As described above, moment modules may use various forms of a composite panel to provide the floor, ceiling, walls or roofing of a building structure. FIGs. 14A to 14H depict various views of an exemplary composite panel 220. FIGs. 15A to 15H depict an alternate composite panel 250 that provides an end cap 262 with a flanged portion for mounting.

[0081] As shown in FIG. 14F, the composite panel 220 includes a frame 230, a core element 222 and two face sheets 224. The core element 222 is encased in an outer skin. In particular, the core element 222 is bonded to each of the two face sheets 224. In one preferred embodiment, the core element 222 is made of foam. For example, the core element 222 can be an extruded polystyrene foam, such as an extruded polystyrene Type VI foam plastic board with a nominal density of 29 kg/m³ (2.0 lb/f³). It should be noted, however, that the core element 222 can be made from various materials, including, without limitation, cellular honeycomb cores of various materials such as aramid fiber and resin impregnated paper, foam cores such as polyurethane or polystyrene (both EPS and XPS).

[0082] The core element 222 can be bonded to the two face sheets 224 using an adhesive, such as a Type II, Class 2, adhesive. For example, the core element 222 can be bonded to the two face sheets 224 using a polyurethane adhesive. It should be noted, however, that various types of adhesives may be used.

[0083] In one exemplary embodiment, the adhesive is applied to the face sheets 224, such as by spraying the adhesive onto the face sheets. The face sheets 224 with the adhesive applied are then pressed against the core element 222. This assembly can be heated under pressure to cure the adhesive. Temperature and curing conditions may vary according to the adhesive used. It should be noted that the composite panel can be fabricated using various fabrication processes to bond the face sheets 224 to the core element 222.

[0084] In one embodiment, the frame 230 includes two end cap pieces 232 and two interlocking joint pieces 234. As described above, the interlocking joint pieces 234 may be formed from a metal sheet to provide a protrusion shape 236 and a channel shape 238. See FIG. 16 for an exemplary embodiment of the profile of an interlocking piece 234. This embodiment of an interlocking joint piece 234 may also be referred to as a side piece.

[0085] Additionally, two metal flanges may be formed into the interlocking joint piece 234 so that the flanges can be inserted into a hem fold on the face sheets 224. This particular embodiment allows the interlocking joint pieces 234 to be physically connected to the face sheets 224 without the use of fasteners or welds. However, in some embodiments, the interlocking joint pieces 234 may also be spot welded to the face sheets 224. The end cap pieces 232 may then be installed by attaching the flanges of the end cap pieces 232 to the interlocking joint pieces 234, using threaded fasteners.

[0086] When fully assembled, the two face sheets 224 are substantially parallel to each other. Additionally, the two end cap pieces 232 are substantially perpendicular to the face sheets 224, and the two interlocking joint pieces 234 are substantially perpendicular to both the face sheets 224 and the end cap pieces 232. The frame 230 and face sheets 224, together, form the outer skin of the composite panel. In some embodiments, the frame and face sheets are made of galvanized steel.

[0087] FIGs. 17 A to 17C depict the face sheet 224 used as both the top and bottom face sheets in the embodiment of the outer skin depicted in FIGs. 14A to 14H. FIGs. 19A to 19C depict the end cap 232 used as the front and back edge pieces in the embodiment of the outer skin depicted in FIGs. 14A to 14H. As depicted in FIG. 14E, in the present embodiment, the end of the metal frame is flush.

[0088] FIGs. 15A to 15H depict various views of another exemplary composite panel 250. The present exemplary composite panel 250 differs from the exemplary composite panel depicted in FIGs. 14A to 14H in that the end caps 262 are Z-shaped to have a portion that extends outward from the edge of the frame (see FIGs. 15E and 15H). The portion of the end cap that extends outward can be used to support or hang the panel when mounted in a moment module. FIGs. 2OA to 2OC depict the z-shaped end caps 262 in more detail. Note, as depicted in FIGs. 21A and 21B, the end caps of the two exemplary composite panels can be formed from the same blank 2100.

[0089] The top face sheet 266 of the present exemplary composite panel 250 may also differ from the top face sheet of the exemplary composite panel 220 depicted in FIGs. 14A to 14H. The top face sheet of an alternative embodiment of a composite panel is depicted in more detail in FIGs. 18A to l8C.

[0090] For additional description of composite panels, see U.S. Patent No. 6,588,171, which is incorporated by reference in its entirety for all purposes.

4. Frame and Panel Integration

[0091] As described above, composite panels may be installed in a moment module using a variety of configurations. In some embodiments, composite panels 220 are supported in the moment module frame 210 through the use of ledgers 270. With reference to FIG. 22, the beams 212 of the moment frame can include ledgers 270 used to support the composite panels 220. The ledger 270 depicted in FIG. 22 is an angle iron extrusion that is welded to the beam 212 of the moment frame. Alternatively, a ledger may be formed from any material that provides a shelf for mounting a composite panel 220. For example, the ledger may be formed from sheet metal or integrated into the beam extrusion profile. As depicted in FIG. 22, the composite panel 220 can be attached to the ledgers 270 using threaded fasteners 272. For example, the threaded fastener may be a self-drilling, self-tapping threaded screw fastener. With reference to FIG. 23, a beam 212 without a ledger is depicted. In the embodiment illustrated in FIG. 23, the composite panel 220 is attached to the top of the beam using a threaded fastener 272.

[0092] It should be noted, however, that the composite panel can be attached to the moment frame using various means. For example, some embodiments of the composite panel may include an outwardly extended flange formed from the end cap piece of the composite panel frame. See FIGs. 15A to 15H, for examples of a z-shaped end cap 262. In some embodiments, the flange of the end cap can be secured to the moment frame using metal fasteners.

[0093] FIGs. 24 to 26 depict exemplary embodiments of the use of ledgers in a moment frame. FIGs. 24A and 24B depict a detail and elevation view of a ledger element used to support a composite panel installed in the floor of the moment frame. In one embodiment, the ledger is welded to the frame elements as shown in FIG. 24 A.

[0094] In FIGs. 25 and 26, a hollow structural section (HSS) is used to form the ledger element. FIGs. 25 A and 25B depict an embodiment of a type-T moment module 810 using ledger elements in the top of the moment frame. FIGs. 26A and 26B depict an embodiment of a type-U moment module 910 using ledger elements in the top of the moment frame.

6. Modular Building Structures

[0095] A complete building structure can be designed and built using variations of the moment module embodiments described above. Building moment modules may be fabricated off- site in accordance with the final building specifications and then shipped to the construction site for assembly. Alternatively, the moment modules may be customized once they arrive at the building site or after they have been integrated into the building structure.

[0096] FIGs. 27A and 27B depict a detail view of four moment modules joined at their respective corners. FIG. 27A depicts a corner connection at the corner of the frame of four moment modules without composite panels. In some embodiments, the top and bottom corner elements 216, 218 may be used to support the main weight of the moment module frame. In some embodiments, the top and bottom corner elements are upper and lower ISO corner castings, respectively. In other embodiments, the weight of the moment module frame may be distributed along frame members. Moment modules may be joined by welding the portions of the frame that are adjacent to other moment module frame members. For example, a weld may be placed on each of the meeting edges of the four corner elements 216, 218. In alternative embodiments, a connecting plate or other connecting hardware may be used to join the corners of the frame. For example, in some embodiments, an ISO attachment bridge clamp can be used to tie the moment modules together.

[0097] FIG. 27B depicts a corner connection with the composite panels of the moment modules installed. As can be seen in FIG. 27B, a space is left between the composite panel of a lower moment module, which would form the ceiling of the lower moment module, and the composite panel of an upper moment module, which would form the floor of the upper moment module. As discussed earlier, this space can be used to run wires, plumbing, duct-work, etc.

[0098] FIGs. 28A to 28F depict structural elements of an exemplary 12 moment module building. FIG. 28A depicts a building without external walls or facing material. FIG. 28B depicts a building without ceiling or roof elements. FIGs. 28C and 28D depict moment modules assembled together to form three separate building floors with an open span (i.e., no internal supporting columns).

[0099] FIG. 28E depicts an embodiment of a single building level 2800 using 12 moment modules 100. FIG. 28E illustrates how moment modules 100 can be used with different wall configurations to provide an enclosed space. For example, exterior walls 2810 can be used to provide a barrier between the interior of the building floor and outside weather or environmental elements. The exterior walls 2810 may include windows, doors, or other traditional design features. The external walls 2810 may also incorporate a protective facing material, such as vinyl siding, stucco or brick. Alternatively, the external walls 2810 may be wood, metal or composite and provide for the mounting of protective facing materials or facade. The building level 2800 may also incorporate internal walls 2820 used to partition off space in the level or create separate rooms. Note that it is not necessary for these exterior walls 2810 or interior walls 2820 to provide structural or load-bearing support to the building level 2800. For example, several of the moment modules 100 have an open span and do not require additional vertical support from walls or partitions. [0100] FIG 28F depicts an alternative embodiment of a building floor 2850 including individual rooms 2860 and connecting hallway 2870. Because the interior walls are not needed for structural support, the interior space of a building floor can be reconfigured or adapted to provide for a flexible floor design layout.

[0101] The building structures, illustrated in FIGs. 28 A to 28F, are merely exemplary embodiments that illustrate the use of a modular moment frame as a structural element in a building structure. Alternative embodiments may arrange moment modules in different configurations or incorporate moment modules with other known construction elements.

[0102] FIG. 29 depicts moment modules 2920, 2930, and 2940 as structural elements in a multi-story building 2910. In this configuration, lower moment modules 2920 support the weight of upper moment modules 2930 and 2940. Because the lower moment modules 2920 support a larger load, the lower moment modules 2920 may be constructed using different materials or components than the upper moment modules 2930 and 2940. For example, the vertical column or horizontal beam members of the lower moment modules may be larger and, therefore, able to support the additional weight.

[0103] FIGs. 30A to 30C depict various examples of a moment module 100 used in different sized building structures. As discussed above, the components used in each of the moment modules may vary depending on the loading conditions of the overall building structure. For example, moment modules located on the lower levels or on the outside of the structure may be designed to provide increased load-carrying capabilities.

[0104] FIGs. 30A to 30C further illustrate how the top panels of a lower moment module can be left open to create a higher ceiling height for a particular story. Alternatively, the panels of the bottom of an upper moment module can be left open to create additional ceiling height.

Claims

CLAIMSI claim:

1. A module for a building structure comprising: a moment frame comprised of beams and columns joined to form a top, a bottom and four sides; a set of four top corner pieces, each top corner piece located at a corner of the top of the moment frame, each top corner piece having a coupler element to interface with a lifting mechanism that lifts the module; and a set of two or more composite panels attached to the bottom of the moment frame to provide a sub-floor of the building structure, wherein a first composite panel of the set is adapted to transfer a load to a second abutting composite panel of the set, in response to a deflection of the moment frame, wherein each composite panel comprises: a metal frame having two face sheets, two end cap pieces and two side pieces, wherein the two face sheets are substantially parallel, the two end cap pieces are substantially perpendicular to the face sheets, and the two side pieces are substantially perpendicular to both the face sheets and the end cap pieces; and a core element encased within the metal frame, wherein the core element is bonded to the two metal face sheets.

2. The module of claim 1, wherein each side piece is a metal sheet formed to create an interlocking joint piece, wherein the interlocking joint piece includes a channel shape and a protrusion shape extending the length of the interlocking joint piece.

3. The module of claim 2, wherein the channel shape of an interlocking joint piece of the first composite panel interconnects with protrusion shape of the interlocking joint piece of the second composite panel.

4. The module of claim 3, wherein the interlocking joint piece is adapted to provide vertical support for a second composite panel abutting the first composite panel.

5. The module of claim 3, wherein the interlocking joint piece of the first composite panel is further adapted to transfer a compression load to the second composite panel abutting the first composite panel.

6. The module of claim 3, wherein the composite panels are adapted to support a compression load in response to the module being subjected to a moment load.

7. The module of claim 1, wherein the metal frame is made of steel, and wherein the core element is made of foam.

8. The module of claim 1, further comprising, a second set of two or more composite panels,

wherein the second set of two or more composite panels is attached to the top of the moment frame to provide a ceiling of the building structure.

9. The module of claim 8, wherein the second set of composite panels that provide the sub-floor comprises different materials than the set of composite panels that provide the ceiling.

10. The module of claim 1, further comprising, ledgers attached to at least two beams in the frame,

wherein the set of two or more composite panels is attached to the ledgers.

11. The module of claim 1 , wherein the set of two or more composite panels provide the sub-floor of a first module and the same composite panels provide a ceiling of a second module, wherein the second module is mounted below the first module.

12. The module of claim 1, wherein each of the set of four top corner pieces having a coupler element comprises: three external faces and three slotted holes, each slotted hole extending inward from each of the three external faces.

13. The module of claim 1, wherein each of the four top corner pieces is comprised of an ISO corner casting.

14. The module of claim 1, further comprising, a set of four bottom corner pieces, each bottom corner piece located at a corner of the bottom of the moment frame, each bottom corner piece having a coupler element to interface with a securing mechanism that secures the module.

15. The module of claim 14, wherein each of the set of four bottom corner pieces having a coupler element comprises: three external faces and three slotted holes, each slotted hole extending inward from each of the three external faces.

16. The module of claim 14, wherein each of the four bottom corner pieces is comprised of an ISO corner casting.

17. The module of claim 1, wherein the bottom of the moment frame has approximately the footprint of a standard 8x20 cargo container.

18. The module of claim 1, wherein the bottom of the moment frame has approximately the footprint of a standard 8x40 cargo container.

19. The module of claim 1, wherein the bottom of the moment frame has an outside width of approximately 8 feet and an outside length of about 20 feet.

20. The module of claim 1, wherein the bottom of the moment frame has an outside width of approximately 8 feet and an outside length of about 40 feet.

21. The module of claim 1, wherein the beams are comprised of a steel channel with a cross-section ranging between 150mm to 250mm in height and between 60mm and 120mm in width.

22. The module of claim 1, wherein the columns are comprised of a steel rectangular tube with a cross-section ranging between 120mm to 180mm in height and width.

23. The module of claim 1, further comprising, a roof panel section, wherein the roof panel section includes one or more corrugated steel sheet pieces, each sheet piece welded along the edge to create a water resistant seam.

24. The module of claim 23, wherein the roof panel section is formed into a convex shape to direct water to the edges of the module.

25. The module of claim 1, further comprising, a pitched-roof section, wherein the pitched roof includes at least one flat panel piece and at least one weather resistant sheet attached to the top of the flat panel piece.

26. The module of claim 25, wherein the flat panel piece is a composite panel.

27. The module of claim 25, wherein the pitched-roof section includes a single pitch of 1/8 inch rise per foot of length.

28. The module of claim 25, wherein the pitched-roof section includes a double- pitch section of 1/4 inch rise per foot of length, and wherein the top of the double-pitch section is in a center of the module.

29. The module of claim 1, wherein another set of two or more composite panels form a side wall of the module.

30. The module of claim 29, wherein a first composite panel of the set forming the side wall interconnects with an abutting second composite panel of the set forming the side wall.

31. A modular system for constructing a building structure, comprising: two or more modules joined together to form a portion of the building structure, each module comprising: a moment frame comprised of beams and columns joined to form a top, a bottom, and four sides; a set of four top corner pieces, each corner piece located at a corner of the top of the moment frame, each corner piece having a coupler element to interface with a lifting mechanism that lifts the module; and a set of two or more composite panels attached to the bottom of the moment frame to provide a sub-floor of the building structure, wherein each composite panel comprises: a metal frame having two face sheets, two end cap pieces and two side pieces, wherein the two face sheets are substantially parallel, the two end cap pieces are substantially perpendicular to the face sheets, and the two side pieces are substantially perpendicular to both the face sheets and the end cap pieces; and a core element encased within the metal frame, wherein the core element is bonded to the two metal face sheets.

32. The modular system of claim 31, wherein the two or more modules are joined side-by- side to one another to form a portion of one story of the building structure.

33. The modular system of claim 31, wherein the sets of two or more composite panels of the two or more modules are attached to the bottoms of the two or more modules, and wherein adjacent sides of side -by- side modules are left open to create a clear span for the building structure.

34. The modular system of claim 31, wherein the two or more modules are joined one on top of another to form multiple stories of the building structure.

35. The module system of claim 34, wherein the two or more modules comprise:

a first type of modules, wherein the first type of modules forms an upper most story of the building structure, wherein the sets of two or more composite panels of the first type of modules are attached to the top of the moment frame with top metal face sheets of the sets of the two or more composite panels being substantially flush with tops of the beams that form the top of the first type of modules.

36. A module for a building structure comprising: a moment frame comprised of beams and columns joined to form a top, a bottom and four sides; a set of four top corner pieces, each top corner piece located at a corner of the top of the moment frame, each top corner piece having a coupler element to interface with a lifting mechanism that lifts the module; and a set of four bottom corner pieces, each bottom corner piece located at a corner of the bottom of the moment frame, each bottom corner piece having a coupler element to interface with a securing mechanism that secures the module.