WO2019173279A1 - Prefabricated building system - Google Patents

Prefabricated building system Download PDF

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Publication number
WO2019173279A1
WO2019173279A1 PCT/US2019/020668 US2019020668W WO2019173279A1 WO 2019173279 A1 WO2019173279 A1 WO 2019173279A1 US 2019020668 W US2019020668 W US 2019020668W WO 2019173279 A1 WO2019173279 A1 WO 2019173279A1
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WO
WIPO (PCT)
Prior art keywords
floor
engagement member
panel
roof
panels
Prior art date
Application number
PCT/US2019/020668
Other languages
English (en)
French (fr)
Inventor
Fanyu LIN
Harry STENDHAL
Original Assignee
Fluxus Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fluxus Llc filed Critical Fluxus Llc
Priority to CN201980023959.8A priority Critical patent/CN111936710A/zh
Priority to MX2020009264A priority patent/MX2020009264A/es
Priority to BR112020018148-0A priority patent/BR112020018148A2/pt
Priority to EP19763948.7A priority patent/EP3762555A4/en
Priority to CA3092932A priority patent/CA3092932A1/en
Priority to US16/978,376 priority patent/US20210040723A1/en
Publication of WO2019173279A1 publication Critical patent/WO2019173279A1/en

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures 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
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/0023—Building characterised by incorporated canalisations
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/02—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements
    • E04B1/14—Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements the elements being composed of two or more materials
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures 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
    • E04B1/34815—Elements not integrated in a skeleton
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348—Structures 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
    • E04B1/34869—Elements for special technical purposes, e.g. with a sanitary equipment
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B2/00—Walls, e.g. partitions, for buildings; Wall construction with regard to insulation; Connections specially adapted to walls

Definitions

  • the present disclosure is generally directed to a building system, and more particularly to a building system including a plurality of interconnectable prefabricated structural components.
  • Modular and prefabricated construction of building is generally known as a concept. Motivations for adopting modular building technologies range from economic considerations, such as creating economies of scale for individual building components, to environmental concerns, such as sourcing sustainable materials. Other advantages of modular building construction include relatively fast erection of entire buildings and safer assembly practices due to the prefabrication of the building components.
  • the multisided structure includes a floor assembly; a roof assembly; and a side assembly connected to the floor assembly and the roof assembly and extending between the floor assembly and the roof assembly.
  • the floor assembly includes a plurality of the floor panels, each floor panel in direct structural connection with at least one other floor panel.
  • the roof assembly includes a plurality of the roof panels, each roof panel in direct structural connection at least one other roof panel.
  • the side assembly includes a plurality of the wall panels, each wall panel in direct structural connection with at least one floor panel and at least one roof panel.
  • each floor panel includes a floor surface having at least one edge and a floor engagement 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 engagement member extending parallel to the at least one edge of the floor surface.
  • At least one of the wall panels is a fixed wall panel including a fixed wall surface having a bottom edge, a top edge, and a side edge.
  • Each fixed wall panel further 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 edge.
  • the first engagement member of the fixed wall panel is configured to rigidly connect to the floor engagement member of one of the floor panels
  • the second engagement member of the fixed wall panel is configured to rigidly connect to the roof engagement member of one of the roof panels.
  • the floor engagement member of each floor panel includes a channel
  • the first engagement member of each wall panel includes a rail configured to extend into the channel
  • the floor engagement member of each floor panel includes a weather seal configured to engage the first engagement member of each wall panel.
  • the multi-sided structure further includes a service module having a base panel having a 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 sanitary system.
  • each of the floor panels further includes a duct extending below the floor surface. The duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
  • At least one of the floor panels, roof panels, and wall panels includes a first conduit configured to be in alignment with a second conduit of an adjacent one of the floor panels, roof panels, and wall panels.
  • 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 engagement 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 a side edge, 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.
  • 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 engagement member extending parallel to the at least one edge of the floor surface.
  • first engagement member of each fixed wall panel is configured to rigidly connect to the floor engagement member of each floor panel
  • second engagement member of each fixed wall panel is configured to rigidly connect to the roof engagement member of each roof panel
  • 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 rigidly connect to the third engagement member of the second fixed wall panel.
  • the plurality of prefabricated structural components further includes a service module.
  • the service module includes a base panel having a least one edge configured to rigidly connect to another of the plurality of prefabricated structural components, and at least one of a plumbing system, a climate control system, and a sanitary system.
  • the plurality of prefabricated structural components further includes 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 slidably connect to the floor engagement member of each floor panel
  • the second engagement member of the sliding wall panel is configured to slidably connect to the roof engagement member of each roof panel.
  • the plurality of prefabricated structural components further includes at least one foundation pile, each foundation pile configured to be secured in a ground surface and connected to each of the floor panels.
  • each of the floor panels further includes a duct extending below the floor surface.
  • the duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
  • At least one of the plurality of prefabricated structural components includes a first conduit configured to be in alignment with a second conduit of an adjacent one of the plurality of prefabricated structural components.
  • the floor engagement member of each floor panel includes a channel
  • the first engagement member of each fixed wall panel includes a rail configured to extend into the channel
  • the floor engagement member of each floor panel includes a weather seal configured to engage the first engagement member of each fixed wall panel.
  • the plurality of prefabricated structural components consists of fewer than 12 different prefabricated structural components, and complete building is constructable from only the plurality of prefabricated structural components.
  • the plurality of prefabricated structural components consists of fewer than 10 different prefabricated structural components, and a complete building is constructable from only the plurality of prefabricated structural components.
  • At least two of the floor engagement member of each floor panel, the first engagement member of each fixed wall panel, the second engagement member of each fixed wall panel, the third engagement member of each fixed wall panel, and the roof engagement member of each roof panel have a substantially identical profile.
  • the first engagement member, the second engagement member, and the third engagement member of each fixed wall panel have a substantially identical profile.
  • Other aspects of the present disclosure are directed to a method for constructing a building with a plurality of prefabricated structural components. The method includes arranging a plurality of floor panels on a foundation assembly, each floor panel including a floor surface having at least one edge and a floor engagement member extending parallel to the at least one edge of the floor surface.
  • the method further includes arranging a plurality of fixed wall panels substantially perpendicularly to the plurality of floor panels, each fixed wall panel including a fixed wall surface having a bottom edge, a top edge, and a side edge, 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.
  • the method further includes arranging a plurality of roof panels spaced vertically apart from the plurality of floor panels, each roof panel including at least one edge and a roof engagement member extending parallel to the at least one edge of a floor surface of at least one floor panel of the plurality of floor panels.
  • the method further includes connecting the first engagement member of each fixed wall panel to a corresponding floor engagement 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.
  • the method further includes completing the building with only the plurality of prefabricated structural components, wherein the plurality of prefabricated structural components consists of fewer than 12 distinct prefabricated components.
  • a multi-sided structure constructed from a plurality of prefabricated components consisting of fewer than 12 different prefabricated structural components, the multisided structure comprising: a floor assembly; a roof assembly; and a side assembly connected to the floor assembly and the roof assembly and extending between the floor assembly and the roof assembly, wherein the floor assembly comprises a plurality of the floor panels, each floor panel 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 in direct structural connection at least one other roof panel, and wherein the side assembly comprises a plurality of the wall panels, each wall panel in direct structural connection with at least one floor panel and at least one roof panel. [0033] Clause 2.
  • each floor panel comprises: a floor surface having at least one edge; and a floor engagement 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 engagement member extending parallel to the at least one edge of the floor surface.
  • Clause 3 The multi-sided 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 a side edge; 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 multi-sided structure according to any of clauses 1-3, wherein the first engagement member of the fixed wall panel is configured to rigidly connect to the floor engagement member of one of the floor panels, and wherein the second engagement member of the fixed wall panel is configured to rigidly connect to the roof engagement member of one of the roof panels.
  • Clause 7 The multi-sided structure according to any of clauses 1-6, further comprising a service module, the service module comprising: a base panel having a least one edge configured to rigidly connect to at least one of the floor panels; and at least one of a plumbing system, a climate control system, and a sanitary system.
  • each of the floor panels further comprises a duct extending below the floor surface, and wherein the duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
  • a building system comprising a plurality of prefabricated structural components, wherein each of the plurality of prefabricated structural components is connectable with 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 engagement member extending parallel to the at least one edge of the floor surface; (b) at least one fixed wall panel, each fixed wall panel comprising: (i) a fixed wall surface having a bottom edge, a top edge, and a side edge; (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 engagement member extending parallel to the at least one edge of the
  • Clause 12 The building system according to 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 engagement member of the first fixed wall panel is configured to rigidly connect to the third engagement member of the second fixed wall panel.
  • Clause 13 The building system according to any of clauses 10-12, wherein the plurality of prefabricated structural components further comprises a service module, the service module comprising: a base panel having a least one edge configured to rigidly connect to another of the plurality of prefabricated structural components; and at least one of a plumbing system, a climate control system, and a sanitary system.
  • a service module comprising: a base panel having a least one edge configured to rigidly connect to another of the plurality of prefabricated structural components; and at least one of a plumbing system, a climate control system, and a sanitary system.
  • the plurality of prefabricated structural components further comprises a sliding wall panel, the 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 slidably connect to the floor engagement member of each floor panel, and wherein the second engagement member of the sliding wall panel is configured to slidably connect to the roof engagement member of each roof panel.
  • Clause 15 The building system according to any of clauses 10-14, wherein the plurality of prefabricated structural components further comprises at least one foundation pile, each foundation pile configured to be secured in a ground surface and connected to each of the floor panels.
  • each of the floor panels further comprises a duct extending below the floor surface, and wherein the duct of each of the floor panels is configured to be in fluid communication with the duct of each adjacent floor panel.
  • Clause 17 The building system according to any of clauses 10-16, wherein at least one of the plurality of prefabricated structural components comprises a first conduit configured to be in alignment with a second conduit of an adjacent one of the plurality of prefabricated structural components.
  • Clause 20 The building system according to any of clauses 10-19, wherein the plurality of prefabricated structural components consists of fewer than 12 different prefabricated structural components, and wherein a complete building is constructable from only the 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 fewer than 10 different prefabricated structural components, and wherein a complete building is constructable from only the plurality of prefabricated structural components.
  • Clause 22 The building system according to any of clauses 10-21, wherein at least two of the floor engagement member of each floor panel, the first engagement member of each fixed wall panel, the second engagement member of each fixed wall panel, the third engagement member of each fixed wall panel, and the roof engagement member of each roof panel have a substantially identical profile.
  • Clause 23 The building system according to any of clauses 10-22, wherein the first engagement member, the second engagement member, and the third engagement member of each fixed wall panel have a substantially identical profile.
  • Clause 24 A method for constructing a building with a plurality of prefabricated structural components, comprising: arranging a plurality of floor panels on a foundation assembly, each floor panel comprising a floor surface having at least one edge and a floor engagement member extending parallel to the at least one edge of the floor surface; arranging a plurality of fixed wall panels substantially perpendicularly to the plurality of floor panels, each fixed wall panel comprising a fixed wall surface having a bottom edge, a top edge, and a side edge, 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; arranging a plurality of roof panels spaced vertically apart from the plurality of floor panels, each roof panel comprising at least one edge and a roof
  • Clause 25 The method according to clause 24, further comprising completing the building with only the plurality of prefabricated structural components, wherein the plurality of prefabricated structural components consists of fewer than 12 distinct prefabricated components.
  • FIG. 1 is a perspective view of a building according to an aspect of the present disclosure, constructed from a building system according to an aspect of the present disclosure;
  • FIG. 2 is a perspective view of another building according to an aspect of the present disclosure, constructed from the same building system as the building of FIG. 1 ;
  • FIG. 3 is an exploded perspective view of another building according to an aspect of the present disclosure, constructed from the same building system as the building of FIG. 1;
  • 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 according to an aspect of the present disclosure, particularly illustrating a foundation support thereof;
  • FIG. 6 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating a floor panel thereof;
  • FIG. 7 is a partial perspective view of an edge connection member of the floor panel of FIG. 6;
  • FIG. 8 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating a fixed exterior wall panel thereof;
  • FIG. 9 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating a structural cabinet wall component thereof;
  • FIG. 10 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating the structural wall cabinet of FIG. 9;
  • FIG. 11 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating the structural wall cabinet of FIG. 9;
  • FIG. 12 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating the structural wall cabinet of FIG. 9;
  • FIG. 13 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating a sliding exterior wall panel thereof;
  • FIG. 14 is perspective view of the sliding exterior wall panel of FIG. 13;
  • FIG. 15 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating a roof panel thereof;
  • FIG. 16 is a partial perspective view of the roof panel of FIG. 15;
  • FIG. 17 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating a sliding interior wall panel thereof;
  • FIG. 18 is a partial perspective view of a building according to an aspect of the present disclosure, particularly illustrating a sliding cabinet door thereof;
  • FIG. 19 is a perspective view of a service module according to an aspect of the present disclosure.
  • FIG.20 is a cross section view of a junction between a floor panel, a structural cabinet wall component, and a sliding cabinet door according to an aspect of the present disclosure
  • FIG. 21 is a cross section view of a roof panel with piping extending therethrough according to an aspect of the present disclosure
  • FIG. 22 is a cross section view of a seal arrangement between a floor panel and a cabinet wall component according to an aspect of the present disclosure
  • FIG. 23 is a cross section view of a seal arrangement between a roof panel and a cabinet wall component according to an aspect of the present disclosure
  • FIG. 24 is a cross section view of a lighting system according to an aspect of the present disclosure.
  • FIG. 25 is a cross section view of a floor panel with cable extending therethrough according to an aspect of the present disclosure
  • FIG. 26 is a cross section view of a wall panel with cable extending therethrough according to an aspect of the present disclosure
  • FIG. 27 is a schematic top view of a plurality of intercommunicating passageways formed by a building according to an aspect of the present disclosure
  • FIG. 28 is a flowchart of a method of constructing a building according to an aspect of the present disclosure
  • FIG. 29 is a perspective view of a foundation assembly of a building installed
  • FIG. 30 is a perspective view of a service module installed on the foundation assembly of FIG. 29;
  • FIG. 31 is a perspective view of a floor assembly installed on the foundation assembly of FIG. 29;
  • FIG. 32 is a perspective view of an exterior wall assembly partially installed on the floor assembly of FIG. 31;
  • FIG. 33 is a perspective view of the exterior wall assembly of FIG 32 fully installed, along with interior wall panels;
  • FIG. 34 is a perspective view of a roof assembly installed on the exterior wall assembly of FIGS. 32-33.
  • the terms“upper”,“lower”,“right”, “left”, “vertical”, “horizontal”, “top”,“bottom”, “lateral”,“longitudinal”, and derivatives thereof shall relate to the disclosed apparatus as it is oriented in the figures.
  • the apparatus of the present disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary.
  • the specific systems and processes illustrated in the attached drawings and described in the following specification are simply exemplary examples of the apparatus disclosed herein. Hence, specific dimensions and other physical characteristics related to the examples disclosed herein are not to be considered as limiting.
  • the term“associated with”, when used in reference to multiple features or structures, means that the multiple features or structures are in contact with, touching, directly connected to, indirectly connected to, adhered to, or integrally formed with one another.
  • the term“at least one of’ is synonymous with“one or more of’.
  • the phrase“at least one of A, B, and C” means any one of A, B, and C, or any combination of any two or more of A, B, and C.
  • “at least one of A, B, and C” includes one or more of A alone; or one or more B alone; or one or more of C alone; 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.
  • the term“at least two of’ is synonymous with“two or more of’.
  • the phrase“at least two of D, E, and F” means any combination of any two or more of D, E, and F.
  • “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 and one or more of F; or one or more of all of D, E, and F.
  • the terms “direct structural connection”, “directly structurally connected to”, and derivatives thereof define a relationship between two or more components in which the two or more components meet at a junction, and at least one of the components applies a static or dynamic load to the other of the components without the load being first transferred through an intervening structural member.
  • the two or more components may be secured to one another in any suitable manner. For example, a surface of one component may abut a surface of another component. Alternatively or additionally, a key or rail of one component may fit into a groove or channel of another component.
  • Mechanical fasteners such as screws, bolts, pins, rivets, or the like may be used to prevent displacement of the two of more components relative to each other.
  • non-structural members such as seals, alignment shims, or spacers may be provided between the two or more components, such that the two or more components are not in direct physical contact.
  • the term“prefabricate” means to manufacture an assembly or sub- assembly of a structure at a location remote from the location at which the structure is assembled.
  • the term“prefabricated” describes a component manufactured in this manner. For example, a wall segment of a building may be prefabricated from various raw materials at a remote location, and the prefabricated wall segment may then be transported to the assembly site of the building. In this manner, the wall segment need not be constructed from raw materials at the assembly site.
  • prefabricated and“modular” may be used interchangeably herein.
  • prefabricated structural component means an element used in a building that forms at least part of a floor, roof, or wall surface of the building.
  • a prefabricated structural component must be directly structurally connectable with at least one other prefabricated structural component.
  • the term“exterior” is used to describe components component having at least a portion that is suitable for use in an outside environment unprotected from weather and elements. However, it should be understood that components referred to as“exterior” may also be used in interior applications, unless explicitly noted to the contrary.
  • FIGS. 1 and 2 illustrate examples of buildings 1000 constructed from the 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.
  • the 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 one other of the exterior wall assemblies 30 such that the plurality of exterior wall assemblies define a multi-sided structure having an internal volume.
  • the internal volume thus defines the interior space of the building 1000.
  • Non limiting embodiments of the building systems described herein provide for numerous advantages, including significant cost savings and flexibility through the standardization of the components to be manufactured.
  • the floor assembly 10 may be constructed from one or more prefabricated floor panels 110 of the building system of the present disclosure.
  • the roof assembly 20 may be constructed from one or more prefabricated roof panels 210 of the building system of the present disclosure.
  • 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, prefabricated roof panels 210, and prefabricated exterior wall panels 310 of the building system will be described later in greater detail. However, for the purposes of describing the buildings 1000 in general, it is noted that the prefabricated floor panels 110, prefabricated roof panels 210, and prefabricated exterior wall panels 310 are among a plurality of prefabricated structural component types which at least partially make up the building system of the present disclosure.
  • Each of the prefabricated structural components of the building system is connectable with at least one other prefabricated structural component in order to construct the building 1000.
  • each of the floor panels 110 is connected to at least one other floor panel 110, and the floor panels 110 making up the perimeter of the floor assembly 10 are each further connected to at least one of the exterior wall panels 310.
  • each of the roof panels 210 is connected to at least one other roof panel 210, and the roof panels 210 making up the perimeter of the roof assembly 20 are each further connected to at least one of the exterior wall panels 310.
  • Each of the exterior 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 mechanisms for interconnecting the plurality of prefabricated structural components will be described later in greater detail. For clarity, not all of the prefabricated structural components shown in FIGS. 1-2 are identified reference numerals
  • each exterior wall panel 310 may be selected from a variety of component types.
  • each exterior wall panel 310 may be an exterior fixed wall panel 130, a structural cabinet wall component 150, or an exterior sliding wall panel 160.
  • each exterior wall panel 310 regardless of type, may share the same connection mechanism for connecting to the other prefabricated structural components of the building 1000 so that the various types of exterior wall panels 310 may be used interchangeably in constructing the building 1000.
  • the various types of exterior wall panels will be described later in greater detail.
  • some examples of the building 1000 may further include a foundation assembly 140 selected from the building system of the present disclosure.
  • the foundation assembly 140 may be connected to the floor assembly 10 and to a ground surface supporting the building 1000. In addition to supporting the weight of the building, the foundation assembly 140 may elevate the floor assembly 10 above the ground surface and provide ingress and egress points to the building 1000.
  • the foundation assembly 140 may include one or more support columns 142 and one or more stairways or ramps.
  • the building 1000 may be constructed on a poured concrete foundation or other conventional type of foundation, with the foundation assembly 140 being omitted.
  • the prefabricated structural components of the building system may form the entire exterior shell of the building 1000.
  • the building 1000 may be essentially constructed from a finite number of prefabricated structural components selected from the building system of the present disclosure.
  • the building 1000 may be completely constructed from not more than twelve distinct types of prefabricated structural components.
  • the building 1000 defines a rigid, multi- sided structure of interconnected prefabricated structural components which fully enclose an interior volume.
  • the building 1000 may be completely constructed from not more than eleven distinct types of prefabricated structural components.
  • the building 1000 may be completely constructed from not more than ten distinct types of prefabricated structural components.
  • the building 1000 may be completely constructed from not more than nine distinct types of prefabricated structural components.
  • the building 1000 may include, among other prefabricated structural components, one or more interior sliding wall panels 170 and/or one of more service modules 190.
  • Each interior sliding wall panel 170 may be connected with at least one floor panel 110, at least one roof panel 210, and/or at least one exterior wall panel 310.
  • Each service module 190 may generally include at least one of a water supply, water heater, lavatory, shower, and other plumbing fixtures. The service module 190 thus serves as a centralized node for plumbing and other utilities of the building 1000. Greater details of the sliding interior wall panels 170 and the service modules 190 will be described later. For clarity, not all of the prefabricated structural components shown in FIG. 3 are identified reference numerals.
  • FIGS. 1-3 are each single-story buildings, although the present disclosure is not limited to this configuration.
  • FIG. 4 shows a schematic of a building development 4000 including both single story buildings lOOOa and multi-story buildings lOOOb.
  • the multi-story buildings lOOOb may be constructed in much the same way as the single-story buildings lOOOa.
  • the roof assembly 12 of each of the lower stories may also serve as the floor assembly 10 for the story directly above it.
  • prefabricated structural components of the building system may include at least floor panels 110, roof panels 210, exterior wall panels 310, foundation support columns 142, sliding interior wall panels 170, and service modules 190.
  • the buildings 1000 described with reference to FIGS. 1-4 may be constructed by connecting a plurality of the prefabricated structural components with one another in a desired arrangement.
  • the prefabricated structural components may be removably connected to one another to facilitate disassembly and reassembly of the building 1000, allowing the building to be easily relocated or reconfigured.
  • FIG. 5-19 show various partial views of a building 1000 to illustrate the various prefabricated structural components in detail.
  • FIGS. 1 show various partial views of a building 1000 to illustrate the various prefabricated structural components in detail.
  • 5-19 may be fabricated 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. For clarity in FIGS. 5-19, some of the prefabricated structural components and their associated features may not be explicitly identified with reference numerals.
  • the prefabricated foundations of the building system of the present disclosure may include a support column 142 connectable to one or more of the floor panels 110.
  • each support column 142 way be a vertically oriented beam connected at a discrete point, for example a comer, of the corresponding one or more floor panels 110.
  • each support column 142 may be a horizontally oriented beam extending continuously along at least a portion of one or more floor panels 110.
  • each support column 142 may be in direct structural connection with corresponding floor panels 110.
  • each support column 142 may have a head portion 144 which fits into a corresponding foundation groove or recess 1132 in the one or more floor panels 110.
  • each support column 142 may be driven directly into the ground surface or additional foundation members may be provided to secure the support column 142 to the ground surface.
  • a footer 3000 may be provided in the ground surface below the support column 142.
  • Suitable materials for the support columns 142 may be determined by the environmental conditions to which the support will be exposed, as well as the ultimate load supported by the support column 142. Generally, a high-strength, corrosion resistant material such as galvanized steel may be used.
  • the support columns 142 may be omitted in some examples, such as where a building 1000 is constructed on a conventional, preformed foundation.
  • the prefabricated floor panels 110 may include a shell 1110 surrounding an interior core 1120.
  • the shell 1110 may include an exterior panel face 1112, an interior panel face 1114, and edge connection members 1130.
  • the edge connection members 1130 may be substantially C-shaped and extend around the perimeter edge of the shell 1110.
  • the exterior panel face 1112 may extend horizontally across an underside of the shell 1110 between the edge connection members 1130.
  • the interior panel face 1114 may extend horizontally across a top side of the shell 1110 between the edge connection members 1130.
  • the edge connection members 1130 may define or include a plurality of structural features serving as conduits for electrical cable and engagement members for connecting other prefabricated structural components.
  • the foundation groove or recess 1132 may be defined in an underside of the edge connection members 1130 and serve as an engagement member for direct structural connection with one or more support columns 142, as discussed above.
  • One or more floor engagement members 1134 may extend along a top side of the edge connection members 1130 and provide direct structural connection to one or more interior or exterior wall panels.
  • the floor engagement members 1134 may include a plurality of channels extending parallel to the edges of the shell 1110. The plurality of channels may include multiple profiles suitable for connection to different types of walls.
  • one portion of the floor engagement member 1134 may be connectable to an exterior fixed wall panel 130, another portion of the floor engagement member 1134 may be connectable to a cabinet wall component 150, another portion of the floor engagement member 1134 may be connectable to a sliding exterior wall panel 160, and another portion of the floor engagement member 1134 may be connectable to an interior sliding wall panel 170.
  • the floor engagement members 1134 may extend the entire length of each edge of the floor panel 110, such that the floor engagement members 1134 form a continuous structure with the floor engagement members 1134 of adjacent floor panels 110. Covers sitting substantially flush with the interior panel face 1114 may be installed over portions of the floor engagement members 1134 to which no other prefabricated structural components are connected to provide a smooth floor surface.
  • the edge connection members 1130 may further define one or more cable channels 1136, which may extend parallel to the floor engagement members 1134.
  • the cable channels 1136 may be recessed below the interior panel face 1114 and may be used as a conduit for routing electrical, fiber optic, coaxial, Ethernet, and other types of cable to terminals in the floor panel 110, or through the floor panel 110 to adjacent prefabricated structural components. Covers may be installed over the cable channels 1136 substantially flush with the interior panel face 1114 after the various cables are installed in the cable channels 1136. Further details of the cable channels 1136 will be described later with reference to FIGS. 26 and 27.
  • the edge connection members 1130 may further include one or more weather seals for insulating the connection between the floor panel 110 and any adjacent prefabricated structural components.
  • the weather seals may be located adjacent the floor engagement members 1134 and/or the cable channels 1136.
  • the one or more weather seals may extend the entire length of each edge of the floor panel 110, such that the weather seals of adjacent floor panels 110 form a continuous weather seal with one another.
  • the edge connection members 1130 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component.
  • the weather seal engagement surfaces may be located adjacent the floor engagement members 1134 and/or the cable channels 1136.
  • the weather seal engagement surfaces may be included in the floor engagement members 1134 and/or the cable channels 1136.
  • the weather seal engagement surfaces may extend the entire length of each edge of the floor panel 110, such that the weather seal engagement surfaces of adjacent floor panels 110 form a continuous weather seal engagement surface with one another. Further details of the weather seal and weather seal engagement surfaces will be described later with reference to FIGS. 23 and 24
  • One or more ducts 1122 may extend through the core 1120 of the floor panel 110 to facilitate flow of air to the floor panel 110 and to adjacent prefabricated structural components.
  • the edge connection members 1130 and/or the interior panel face 1114 may have an opening in fluid communication with the ducts 1122 such that air can be delivered to and returned from the area above the interior panel face 1114 via the ducts 1122.
  • the one or more ducts may extend the entire length of each edge of the floor panel 110, such that the ducts 1122 of each floor panel 110 form a continuous fluid conduit with the ducts 1122 of adjacent floor panels 110.
  • Materials for the components of the floor panels 110 may be selected to optimize strength, manufacturing cost, environmental sustainability, heat and sound insulation, fire resistance, and other desirable characteristics of residential and/or commercial buildings.
  • the exterior panel face 1112 which functions as a moisture barrier and structural tension member, may be made from a polymer or metal sheet.
  • the interior panel face 1114 which functions as a soft walking and living surface, may be made from easily maintainable vinyl, rubber, or neoprene sheet.
  • the edge connection members 1130 which bear substantially all of the load of the prefabricated structural components connected to the floor panel 110, may be made from a relatively high strength material such as extruded aluminum.
  • the edge connection members 1130 may be connected to the exterior panel face 1112 and the interior panel face 1114 via mechanical fasteners, adhesives, welds, or the like.
  • the core 1120 which functions as a heat insulator, acoustic barrier, and structural compression member, may be made from a foam such as expanded polystyrene (EPS), extruded polystyrene (XPS), or rigid polyurethane. During manufacture of the core 1120, steam may be passed through the ducts 1122 to expand and cure the polystyrene foam forming the core 1120.
  • EPS expanded polystyrene
  • XPS extruded polystyrene
  • rigid polyurethane During manufacture of the core 1120, steam may be passed through the ducts 1122 to expand and cure the polystyrene foam forming the core 1120.
  • the foam of the core 1120 may extend substantially uninterrupted along the exterior panel face 1112 and/or the interior panel face 1114 such that the floor panel 110 has continuous insulation and avoids heat losses through non-insulating framing members. It is to be understood that the various material described herein for use in any component are solely exemplary and not to be construed as limiting.
  • the prefabricated fixed wall panel 130 may include a shell 1310 surrounding an interior core 1320.
  • the shell 1310 may include an exterior panel face 1312, an interior panel face 1314, and edge connection members 1330.
  • the edge connection members 1330 may be substantially C- shaped and extend around the perimeter edge of the shell 1310.
  • the exterior panel face 1312 may extend vertically across an outer side of the shell 1310 between the edge connection members 1330.
  • the interior panel face 1314 may extend vertically across an inner side of the shell 1310 between the edge connection members 1330.
  • the edge connection members 1330 may define a plurality of engagement members for connecting other prefabricated structural components.
  • a portion of the edge connection members 1330 extending parallel to a 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 engagement member 1134 of an adjacent floor panel 110.
  • a portion of the edge connection members 1330 extending parallel to a vertical edge of the fixed wall panel 130 may include or define a second engagement member 1334.
  • the second engagement members 1334 of adjacently arranged fixed wall panels 130 may be configured for direct structural connection with one another.
  • a portion of the edge connection members 1330 extending parallel to a 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 and adjacent roof panel 210 (See FIGS. 15-17).
  • the first, second, and/or third engagement member 1332, 1334, 1336 may include a plurality of channels extending parallel to the edges of the shell 1110.
  • the profiles of the first, second, and/or third engagement member 1332, 1334, 1336 may be substantially identical to one another to reduce the number of component materials necessary to fabricate the fixed wall panel 310. Additionally, the uniformity of the first, second, and/or third engagement member 1332, 1334, and/or 1336 may allow any side of the fixed wall panel 130 to be connected to adjacent floor panel 110 and roof panels 210.
  • the portions of the edge connection members 1330 extending parallel to bottom edge, vertical side edges, and top edge of the fixed wall panel 130 may further define one or more one or more cable channels (not shown) similar to the cable channels 1136 of the floor panel 110.
  • the cable channels of the fixed wall panel 130 may be used for routing electrical or other types of cable to terminal in the fixed wall panel 130, or through the fixed wall panel 130 to adjacent prefabricated structural components.
  • the edge connection members 1330 may further include one or more weather seals for insulating the connection between the fixed wall panel 130 and any adjacent prefabricated structural components.
  • the weather seals may be located adjacent any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels.
  • the one or more weather seals may extend the entire length of an edge of the fixed wall panel 130, such that the weather seals of adjacent fixed wall panels 130 form a continuous weather seal with one another.
  • the edge connection members 1330 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component.
  • the weather seal engagement surfaces may be located adjacent any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels.
  • the weather seal engagement surfaces may be included in any one or more of the engagement members 1332, 1334, 1336 and/or the cable channels.
  • the weather seal engagement surfaces may extend the entire length of an edge of the fixed wall panel 130, such that the weather seal engagement surfaces of adjacent fixed wall panels 130 form a continuous weather seal engagement surface with one another.
  • Material selection for the components of the prefabricated fixed wall panel 130 may be similar to that of the floor panels 110.
  • the exterior panel face 1312 which may function as a moisture barrier, structural tension member, exterior face of the building 1000, and/or impact barrier, may be made from a fiber cement panel or fiber-reinforced plastic (FRP).
  • the interior panel face 1314 which functions as an interior wall surface, may be made from easily maintainable vinyl, rubber, or neoprene sheet.
  • the edge connection members 1330 may be made from a relatively high strength material such as extruded aluminum. The edge connection members 1330 may be connected to the exterior panel face 1312 and the interior panel face 1314 via mechanical fasteners, adhesives, welds, or the like.
  • the core 1320 which functions as a heat insulator, acoustic barrier, and structural compression member, may be made from a foam such as expanded polystyrene (EPS), extruded polystyrene (XPS), or rigid polyurethane.
  • EPS expanded polystyrene
  • XPS extruded polystyrene
  • the foam of the core 1320 may extend substantially uninterrupted along the exterior panel face 1312 and/or the interior panel face 1314 such that the fixed wall panel 130 has continuous insulation and avoids heat losses through non-insulating framing members.
  • the structural cabinet wall component 150 may include a shell 1510 surrounding an interior core 1520. As may be appreciated from FIGS. 10-11, a mid portion of the shell 1510 may be substantially C-shaped and define an internal working area 1550.
  • the shell 1510 may include an exterior panel face 1512, an interior panel face 1514, and edge connection members 1530. As may be appreciated from FIGS. 9, 10, and 12, either end of the internal working area 1550 may be closed off by an end cap 1560 of the shell 1510.
  • the edge connection members 1530 may be substantially C-shaped and extend around the perimeter edge of the shell 1510 including along edges of the end caps 1560.
  • the exterior panel face 1512 may extend between the edge connection members 1530 around an outer side of the shell 1510.
  • the interior panel face 1314 may extend between the edge connection members 1530 around an inner side of the shell 1510 partially enclosing the internal working area 1550.
  • the internal working area 1550 may include integral storage receptacles such as shelving and cabinetry, or the internal working area 1550 may include supports for mounting integral storage receptacles after the cabinet wall component 150 has been assembled with other prefabricated structural components to construct the building 1000.
  • the edge connection members 1530 may define a plurality of engagement members for connecting other prefabricated structural components. A portion of the edge connection members 1530 extending parallel to a bottom edge of the cabinet wall component 150 may include or define a first engagement member 1532 configured for direct structural connection with the floor engagement member 1134 of an adjacent floor panel 110. A portion of the edge connection members 1530 extending parallel to a vertical edge of end caps 1560 of the cabinet wall component 150 may include or define a second engagement member 1534.
  • the second engagement members 1534 of adjacently arranged cabinet wall components 150 may be configured for direct structural connection one another.
  • a portion of the edge connection members 1530 extending parallel to a top edge of the cabinet wall component 150 may include or define a third engagement member 1536 for direct structural connection with a roof engagement member 1232 of and adjacent roof panel 210 (See FIGS. 15-16).
  • the first and third engagement members 1532, 1536 of the cabinet wall component 150 may by 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 engagement member 1134 and the roof engagement member 1232 may then be used for connecting internal sliding cabinet doors 180, as will be described later in connection with FIG. 18.
  • the portions of the edge connection members 1530 extending parallel to bottom edge, vertical side edges, and top edge of the cabinet wall component 150 may further define one or more one or more cable channels (not shown) similar to the cable channels 1136 of the floor panel 110.
  • the cable channels of the cabinet wall component 150 may be used for routing electrical or other types of cable to terminal in the cabinet wall component 150, or through the cabinet wall component 150 to adjacent prefabricated structural components.
  • the edge connection members 1530 may further include one or more weather seals for insulating the connection between the cabinet wall component 150 and any adjacent prefabricated structural components.
  • the weather seals may be located adjacent any one or more of the engagement members 1532, 1534, 1536 and/or the cable channels.
  • the one or more weather seals may extend the entire length of an edge of the cabinet wall component 150, such that the weather seals of adjacent cabinet wall component 150 form a continuous weather seal with one another.
  • the edge connection members 1530 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component.
  • the weather seal engagement surfaces may be located adjacent any one or more of the engagement members 1532, 1534, 1536 and/or the cable channels. In other examples, the weather seal engagement surfaces may be included in any one or more of the engagement members 1532, 1534, 1536 and/or the cable channels. The weather seal engagement surfaces may extend the entire length of an edge of the cabinet wall component 150, such that the weather seal engagement surfaces of adjacent cabinet wall component 150 form a continuous weather seal engagement surface with one another.
  • Material selection for components of the cabinet wall component 150 may be similar to that of like components of the fixed wall panel 130.
  • the sliding exterior wall panel 160 may include at least one subpanel 1610 slidable relative to another subpanel. A portion of each subpanel 1610 extending along a bottom edge of the sliding exterior wall panel 160 may include or define a first engagement member 1632 configured for fixed or slidable connection with the floor engagement member 1134 of an adjacent floor panel 110.
  • the first engagement member 1632 may include one or more wheels, spherical rollers, or the like for rolling along a portion of the floor engagement member 1134 of an adjacent floor panel 110.
  • each subpanel 1610 extending along a top edge of the sliding exterior wall panel 160 may include or define a third engagement member 1636 configured for fixed or slidable connection with a roof engagement member 1232 of an adjacent roof panel 200 (See FIGS. 15-16).
  • the first engagement member 1632 may include one or more wheels, spherical rollers, or the like for rolling along a roof engagement member 1232 of an adjacent roof panel 210.
  • a portion of at least one of the subpanels 1610 extending along a vertical side edge of the sliding exterior wall panel 160 may include or define a second engagement member 1634 for direct structural connection with the second engagement member 1334, 1534 of an adjacent fixed wall panel 130 or cabinet wall component 150.
  • first, second, and third engagement members 1632, 1634, 1636 may further include a seal or sealing surface configured to engage a corresponding seal or sealing surface of an adjacent prefabricated structural component. Additionally one or more of the subpanels 1610 may include a seal or sealing surface configured to engage a corresponding seal or sealing surface of others of the subpanels 1610. In some examples, the seals may be provided on stiles 1620 of the subpanels 1610. [00133] The one or more subpanels 1610 may at least partially overlap and may be slidable relative to one another in a horizontal direction, allowing an opening to be created between the subpanels 1610. In this manner, the exterior sliding wall panel 160 may function as a window or door.
  • the stiles 1620 of the subpanels 1610 may be interlocking to provide a secure and insulated connection between the subpanels 1610.
  • the stiles 1620 may be interlocking in multiple positions allowing the subpanels 1610 to be arranged in horizontal alignment as shown in FIG. 13 or angled relative to one another as shown in FIG. 14.
  • the subpanels 1610 may be made from various materials depending on desired characteristics, such as opacity. Steam cured calcium silicate may be used for opaque subpanels 1610, thermosetting plastics may be used for translucent subpanels 1610, and thermosetting plastic or glass may be used for transparent subpanels 1610. In some examples, different materials may be used for the different subpanels 1610 of a single sliding exterior wall panel 160.
  • the wheels, spherical rollers, or the like may be mechanically secured directly to the subpanels 1610 or, alternatively, secured indirectly to the subpanels 1610 via a mounting frame or the like.
  • the prefabricated roof panels 210 of the building system of the present disclosure may include a shell 1210 surrounding an interior core 1220.
  • the shell 1210 may include an exterior panel face 1212, an interior panel face 1214, and edge connection members 1130.
  • the edge connection members 1230 maybe substantially C-shaped and extend around the perimeter edge of the shell 1210.
  • the exterior panel face 1212 may extend horizontally across a top side of the shell 1210 between the edge connection members 1130.
  • the interior panel face 1214 may extend horizontally across an underside of the shell 1210 between the edge connection members 1230.
  • the edge connection members 1230 may define or include one or more roof engagement members 1232 extending along an underside of the edge connection members 1230 and provide direct structural connection to one or more exterior or interior wall panels.
  • the roof engagement members 1232 may include a plurality of channels extending parallel to the edges of the shell 1210.
  • the plurality of channels may include multiple profiles suitable for connection to different types of walls. For example, one portion of the roof engagement member 1232 may be connectable to an exterior fixed wall panel 130, another portion of the roof engagement member 1232 may be connectable to a cabinet wall component 150, another portion of the roof engagement member 1232 may be connectable to a sliding exterior wall panel 160, and another portion of the roof engagement member 1232 may be connectable to an interior sliding wall panel 170.
  • the roof engagement members 1232 may extend the entire length of each edge of the roof panel 210, such that the roof engagement members 1234 form a continuous structure with the roof engagement members 1232 of adjacent roof panels 210.
  • the profile of the roof engagement members 1232 may be substantially identical to the profile of the floor engagement members 1134 of the floor panels 110 to reduce the number of component materials necessary to fabricate the floor panels 110 and the roof panels 210.
  • identical roof engagement members 1232 and floor engagement members 1134 may allow the exterior and interior wall panel to be connected in multiple orientations between pairs of floor panels 110 and roof panels 210.
  • the edge connection members 1230 may further define one or more cable channels 1236, which may extend parallel to the roof engagement members 1234.
  • the cable channels 1236 may be recessed below the interior panel face 1214 and may be used as a conduit for routing electrical, fiber optic, coaxial, Ethernet, and other types of cable to terminals in the roof panel 210, or through the roof panel 210 to adjacent prefabricated structural components. Covers may be installed over the cable channels 1236 substantially flush with the interior panel face 1214 after the various cables are installed in the cable channels 1236.
  • the edge connection members 1230 may further include one or more weather seals for insulating the connection between the roof panel 210 and any adjacent prefabricated structural components.
  • the weather seals may be located adjacent the roof engagement members 1234 and/or the cable channels 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 one another.
  • the edge connection members 1230 may further include one or more weather seal engagement surfaces for abutting a weather seal provided on an adjacent prefabricated structural component.
  • the weather seal engagement surfaces may be located adjacent the roof engagement members 1234 and/or the cable channels 1236.
  • the weather seal engagement surfaces may be included in the roof engagement members 1234 and/or the cable channels 1236.
  • the weather seal engagement surfaces 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 one another.
  • One or more ducts 1222 may extend through the core 1220 of the roof panel 210 to facilitate flow of air to the roof panel 210 and to adjacent prefabricated structural components.
  • the edge connection members 1230 and/or the interior panel face 1214 may have an opening in fluid communication with the ducts 1222 such air can be delivered to and returned from the area below the interior panel face 1214 via the ducts 1122.
  • the one or more ducts may extend the entire length of each edge of the roof panel 210, such that the ducts 1222 of each roof panel 210 form a continuous fluid conduit with the ducts 1222 of adjacent roof panels 210.
  • Materials for the components of the floor panels 210 may be substantially identical to the materials of like components of the floor panels 210.
  • FIG. 17 another prefabricated structural component of the building system of the present disclosure is a sliding interior wall panel 170.
  • the sliding interior wall panel 170 is substantially structurally identical to the sliding exterior wall panel 160, having first, second, and third engagement members 1732, 1734, 1736 for connecting to adjacent prefabricated structural components.
  • the sliding interior wall panel 170 is connected to adjacent floor panels 110 and roof panels 210 in a manner which divides an interior space defined by the exterior wall panels.
  • the sliding interior wall panel 170 may be movable across multiple floor and roof panels 110, 210 with the building 1000 fully assembled.
  • the sliding interior wall panel 170 may be moved along the aligned floor engagement members 1134 of adjacently arranged floor panels 110, and along the aligned roof engagement members 1232 of adjacently arranged roof panels 210. Movement of the sliding interior wall panel 170 may be facilitated by wheels or spherical rollers similar to the sliding exterior wall panel 160. As such, the sliding interior wall panel 170 may be relocated and reconfigured after the building 1000 is completed in order to alter or repurpose the interior floor plan of the building.
  • FIG. 18 another prefabricated structural component of the building system of the present disclosure is a sliding cabinet door 180.
  • the sliding cabinet door 180 may be arranged directly adjacent a structural cabinet wall component 150 to provide selectable access to the internal working area 1550.
  • the sliding cabinet door 180 may connected to the same floor engagement member 1134 and roof engagement member 1232 as the adjacent structural cabinet wall component 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 subpanels 1810 slidable relative to one another along the floor engagement member 1134 and roof engagement member 1232, similar to the sliding interior wall panel 170.
  • the service module 190 may generally include plumbing and HVAC fixtures to localize all such components in a single area of the building 1000.
  • the 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 shell 1912 and a core (not shown) structurally similar to the shell 1110 and core 1120 of the floor panel 110.
  • the roof portion 1920 may include a shell 1922 and a core (not shown) structurally similar to the shell 1210 and core 1220 of the roof panel 210.
  • the cores of the floor portion 1910 and the roof portion 1920 have ducts 1916, 1926, respectively aligning with the ducts 1122, 1222 of the adjacent floor panels 110 and roof panels 210 (not shown).
  • the service module may include bathroom, kitchen, and/or utility areas.
  • the service module 190 may include a central heating and/or cooling unit 1950, a refrigerator 1952, a laundry washer 1954, a laundry dryer 1956, a dishwasher 1958, a stove 1960, a sink 1962, and a bathroom 1964.
  • Other examples of the service module may include more or less fixtures according to the intended purpose of the building 1000.
  • the service module 190 may be configured for direct structural connection with adjacent prefabricated structural components in a manner similar to that described above in connection with the floor panels 110, roof panels 210, exterior wall panels 310, and sliding interior wall panels 170.
  • the first engagement member 1532 of the structural cabinet wall component 150 is in direct structural connection with a portion of the floor engagement member 1134 of the floor panel 110.
  • the first connection member 1832 of the sliding cabinet door is connected to another portion of floor engagement member 1134 of the floor panel 110.
  • 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 channels, grooves, notches, keys, rails, T-tracks, or like structures interlockable with one another to achieve the direct structural connection between the structural cabinet wall component 150 and the floor panel 110.
  • the other engagement members shown and described with reference to FIGS. 6-20 may include similar interlockable structural features.
  • hollow sections of the prefabricated structural components may be used as passageways for routing piping 500 for carrying fluids such as water or steam throughout the building 1000.
  • FIG. 21 shows piping 500 routed through a duct 1222 of a roof panel 210.
  • FIGS. 22 and 23 sealing arrangements between the prefabricated structural components are shown in greater detail.
  • a weather seal 600 may abut a portion of the engagement members of adjacent prefabricated structural components.
  • FIG. 22 shows a weather seal 600 disposed between the floor engagement member 1134 of a floor panel 110 and the first engagement member 1532 of a structural cabinet wall component 150.
  • FIG. 23 shows a weather seal 600 disposed between the roof engagement member 1232 of a roof panel 210 and the third engagement member 1536 of a structural cabinet wall component 150. Similar arrangements of the weather seals 600 may be utilized between engagement members of the other prefabricated structural components described with reference to FIGS. 5-19.
  • the weather seals 600 may be made from a suitable insulating material such as neoprene.
  • any of the prefabricated structural components may further include lighting systems 550 arranged in the engagement members of the prefabricated structural components.
  • the lighting system 550 may include one or more light-emitting devices, such as LEDs light bulbs, a light strip, and/or the like, extending along the third engagement member 1336 of the fixed wall panel 130.
  • the lighting system 550 may receive power from electrical cable routed into the fixed wall panel 130 as described herein.
  • any of the prefabricated structural components may include cable channels for routing electrical cables 700 throughout the building.
  • Specific types of cable 700 that may be routed through the prefabricated structural components include but are not limit to mains power, telephone, Ethernet, low voltage, fiber optic, and coaxial cable.
  • FIG. 25 shows the cable channel 1136 of a floor panel 110 filled with cable 700.
  • FIG. 26 shows a cable channel 1338 in an exterior fixed wall panel 130 filled with cable 700.
  • the top cross section view illustrates the operative communication between the electrical conduits and air ducts of a building 1000 constructed from a plurality of prefabricated structural components 800 according to an example of the present disclosure.
  • the prefabricated structural components 800 are shown schematically to illustrate that, regardless of which particular prefabricated structural components 800 are used, the universal design of the prefabricated structural components 800 ensures that the electrical conduits and air ducts are always aligned to form an intercommunicating system of passageways.
  • the prefabricated structural components 800 may define a plurality of continuous horizontal passageways 910 extending across multiple prefabricated structural components 800.
  • the comer junctions of the prefabricated structural components 800 may define continuous vertical passageways 920 for supplying air and routing electrical cable 700 between adjacent floors of a multistory building 1000.
  • the passageways 910, 920 may include a plurality of outlet openings 930 for connecting to electrical terminals and/or HVAC registers. In this manner, electrical and ventilation connections may be provided at desired locations throughout the building 1000. Unused openings 930 may be covered with removable plugs to prevent access to predetermined portions of the passageways 910, 920. Plugs may also be used to seal off certain passageways 910, 920 from one another in order to segregate the passageways for dedicated functions.
  • some of the passageways 910, 920 may be used for heating and ventilation, some of the passageways 910, 920 may be used for routing electrical cable 700, some of the passageways may be used for routing piping 500, and some of the passageways 910, 920 may be used for roof water drainage akin to a gutter system.
  • the various uses of the passageways 910, 920 described above is merely illustrative and not to be construed as limiting.
  • FIGS. 28-34 illustrate the method 7000 for constructing a single building 1000.
  • the method 7000 may be used for the simultaneous construction of multiple buildings 1000 forming a development complex.
  • Step 7100 the configuration of the building 1000 is designed.
  • Step 7100 includes choosing a layout of the building 1000 and selecting the types and quantities of prefabricated structural components necessary to achieve that layout. For example, a designer may choose characteristics of the building 1000 such as overall dimensions, floor plans, subdivision of interior spaces, location of building utilities, etc. and choose prefabricated structural components to conform to the chosen characteristics of the building 1000.
  • step 7100 may be performed with the assistance of a computer to provide a virtual simulation of the building 1000 based on inputs of the designer. For example, the designer may input, via an input device of the computer, some or all of the characteristics of the building 1000 listed above.
  • a processor of the computer may receive the inputs and execute program instructions stored in a transitory or non-transitory memory which cause the processor to generate output data, such as the types and quantities of prefabricated structural components necessary to construct the building 1000.
  • the processor may generate and display a virtual model, construction plans, and/or a bill of materials for the building 1000.
  • step 7100 may be further automated with the computer such that the computer, via the program instructions, at least partially chooses or modifies the configuration of the building 1000 to optimize factors such as component costs, environmental impact, energy efficiency, etc.
  • a foundation is installed based on the building design.
  • the foundation may include the foundation assembly 140 described above with reference to FIGS. 1-2.
  • the support columns 142 of the foundation assembly 140 are spaced apart from one another in an arrangement corresponding to the locations of the foundation grooves or recesses 1132 of the one or more floor panels 110 which are installed in steps 7300 and 7400.
  • the foundation assembly 140 of FIGS. 1-2 is omitted and a conventional poured cement foundation is installed.
  • the service modules 190 may be installed as shown in FIG. 30.
  • foundation grooves or recesses in the floor portion 1910 of the service modules 190 may be attached to the support columns 142 installed in step 7200.
  • the foundation grooves or recesses of the floor portion 190 may be specifically designed to engage the heads 144 of the adjacent support columns 142, such that the support columns 142 may substantially dictate the installation locations of the service module 190.
  • the engagement between the heads 144 of the support columns 142 and the floor portion 1910 of the service module 190 may be essentially self-supporting, requiring minimal additional mechanical fasteners to achieve a load-bearing structure. As such, installation of the service module 190 may consume less labor and time than convention methods of construction.
  • Additional benefits of the essentially self- supporting connection between the service module 190 and the support columns 142 include rapid disassembly due to the reduction of additional fasteners required to achieve the connection.
  • the building system of the present disclosure may be particularly well- suited for applications where the building 1000 is intended as a temporarily or relocatable structure.
  • the floor assembly 10 is constructed by attaching the floor panels 110 to the foundation.
  • the foundation grooves or recesses 1132 of the individual floor panels 110 may be attached to the support columns 142 installed in step 7200. Because the foundation grooves or recesses 1132 are specifically designed to engage the heads 144 of the adjacent support columns 142, the support columns 142 may substantially dictate the installation locations of the floor panels 110. As such, no complicated alignment operations are required to construct the floor assembly 10.
  • the engagement between the heads 144 of the support columns 142 and the foundation grooves or recesses 1132 of the floor panels 110 may be essentially self-supporting, requiring minimal additional mechanical fasteners to achieve a load-bearing structure.
  • this feature allows from rapid construction of the building 1000. Further, the engagement between the heads 144 of the support columns 142 and the foundation grooves or recesses 1132 of the floor panels 110 may be easily disassembled due to the reduction of additional fasteners required to achieve the connection.
  • the exterior wall assemblies 30 may be constructed by attaching the exterior wall panels 310 to the floor panels 110. Concurrently with or after construction of the exterior wall assemblies 30, the sliding interior wall panels 170 and sliding cabinet doors 180 may be installed at step 7600.
  • FIG. 32 shows the structural cabinet wall components 150 attached to the floor panels 110. As discussed above with reference to FIGS. 9-12, the first engagement members 1532 of the structural cabinet wall components 150 may be connected to the floor engagement members 1134 of adjacent floor panels 110 such that the structural cabinet wall components 150 are arranged substantially perpendicular to the floor panels 110.
  • the engagement between the first engagement members 1532 of the structural cabinet wall components 150 and the floor engagement members 1134 of the floor panels 110 may be essentially self-supporting, requiring minimal additional mechanical fasteners to achieve a load-bearing structure.
  • the second engagement member 1534 of the structural cabinet wall components 150 may be connected to the corresponding engagement members of adjacent exterior wall panels 310.
  • FIG. 33 shows the installation of the exterior fixed wall panels 130, the sliding exterior wall panels 160, the sliding interior wall panels 170, and the sliding cabinet doors 180.
  • the exterior fixed wall panels 130 may be installed the same manner as the structural cabinet wall components 150, with the first engagement members 1332 attached to the floor engagement members 1134 of adjacent floor panels 110 and the second engagement members 1334 attached to adjacent exterior wall panels 310.
  • the sliding exterior wall panels 160 may likewise be installed in the same manner, with the first engagement members 1632 attached to the floor engagement members 1134 of adjacent floor panels 110 and the second engagement members 1634 attached to adjacent exterior wall panels 310.
  • the sliding interior wall panels 170 may likewise be installed in the same manner, with the first engagement members 1732 attached to the floor engagement members 1134 of adjacent floor panels 110 and the second engagement members 1734 attached to adjacent prefabricated structural components. Finally, the sliding cabinet doors 180 may be installed by attaching the first engagement members 1832 to the floor engagement members 1134 of floor panels 110 adjacent the corresponding structural cabinet wall component 150.
  • the roof assembly 20 may be constructed by attaching the roof panels 210 to the prefabricated structural components already installed.
  • the roof engagement members 1232 of each roof panel 210 may be attached to the corresponding engagement members 1336, 1536, 1636, 1736, 1834 of the exterior fixed wall panels 130, structural cabinet wall components 150, sliding exterior wall panels 160, sliding interior wall panels 170, and sliding cabinet doors 180.
  • the engagement between the roof panels 210 and the adjacent prefabricated structural components may be essentially self-supporting, requiring minimal additional mechanical fasteners to achieve a load-bearing structure.
  • the weather seals 600 may be installed between the engagement members of adjacent prefabricated structural components, as discussed above in connection with FIGS. 22-23.
  • the piping 500 may be routed through the ducts the prefabricated structural components as discussed above in connection with FIG. 21.
  • the lighting 550 may be arranged in the engagement members of the prefabricated structural components as discussed above in connection with FIG. 24.
  • the cable 700 may be routed through the cable channels of the prefabricated structural components as discussed above in connection with FIGS. 25 and 26.
  • Step 7800 may be performed after or concurrently with steps 7300-7700.

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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)
  • Joining Of Building Structures In Genera (AREA)
  • Building Environments (AREA)
  • Conveying And Assembling Of Building Elements In Situ (AREA)
  • Load-Bearing And Curtain Walls (AREA)
PCT/US2019/020668 2018-03-05 2019-03-05 Prefabricated building system WO2019173279A1 (en)

Priority Applications (6)

Application Number Priority Date Filing Date Title
CN201980023959.8A CN111936710A (zh) 2018-03-05 2019-03-05 预制建筑系统
MX2020009264A MX2020009264A (es) 2018-03-05 2019-03-05 Sistema de construcción prefabricado.
BR112020018148-0A BR112020018148A2 (pt) 2018-03-05 2019-03-05 sistema de construção pré-fabricada
EP19763948.7A EP3762555A4 (en) 2018-03-05 2019-03-05 PRE-FABRICATED BUILDING SYSTEM
CA3092932A CA3092932A1 (en) 2018-03-05 2019-03-05 Prefabricated building system
US16/978,376 US20210040723A1 (en) 2018-03-05 2019-03-05 Prefabricated Building System

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201862638451P 2018-03-05 2018-03-05
US62/638,451 2018-03-05

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WO2019173279A1 true WO2019173279A1 (en) 2019-09-12

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PCT/US2019/020668 WO2019173279A1 (en) 2018-03-05 2019-03-05 Prefabricated building system

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US (1) US20210040723A1 (pt)
EP (1) EP3762555A4 (pt)
CN (2) CN113550424A (pt)
BR (1) BR112020018148A2 (pt)
CA (1) CA3092932A1 (pt)
MX (1) MX2020009264A (pt)
WO (1) WO2019173279A1 (pt)

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Also Published As

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EP3762555A1 (en) 2021-01-13
CN113550424A (zh) 2021-10-26
CA3092932A1 (en) 2019-09-12
CN111936710A (zh) 2020-11-13
BR112020018148A2 (pt) 2021-02-02
US20210040723A1 (en) 2021-02-11
EP3762555A4 (en) 2021-11-10
MX2020009264A (es) 2021-02-15

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