|Publication number||US20090223144 A1|
|Application number||US 12/322,380|
|Publication date||Sep 10, 2009|
|Filing date||Feb 2, 2009|
|Priority date||Feb 2, 2008|
|Publication number||12322380, 322380, US 2009/0223144 A1, US 2009/223144 A1, US 20090223144 A1, US 20090223144A1, US 2009223144 A1, US 2009223144A1, US-A1-20090223144, US-A1-2009223144, US2009/0223144A1, US2009/223144A1, US20090223144 A1, US20090223144A1, US2009223144 A1, US2009223144A1|
|Inventors||Charles H. Leahy|
|Original Assignee||Leahy Charles H|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (15), Referenced by (17), Classifications (7)|
|External Links: USPTO, USPTO Assignment, Espacenet|
The present invention claims priority from U.S. provisional patent application 61/063,191 filed Feb 2, 2008, which is incorporated herein by reference in its entirety.
1. Field of the Invention
The present invention relates generally to modular building systems and methods, and more particularly, to modular building systems and methods for containerized shipment thereof.
2. Description of the Prior Art
Modular buildings and components used in making them are known in the art. By way of example, prefabricated housing components, including wall panels are known. However, energy losses most commonly occur in the seam or joint regions of structures, including prefabricated buildings and modular structural components. Additionally, while prefabricated panels and other components are known in the art, they are not packaged or provided for quick and easy assembly to form a predetermined completed structure that also provides for an energy efficient structure that is also stable and reliable, i.e., able to withstand the natural elements including storm conditions.
One example of commercially available modular building components is found at http://aguentium.com/housing.htm.
None of the prior art addresses the longstanding need for stable, energy efficient modular building structures, including kits for installing same, in particular having structurally locked wall panel components that are aligned with a mating double rail track edge system. Thus there remains a need for energy efficient and stable modular building systems and methods for installing them, including providing containerized packaging to facilitate shipment, assembly and installation of the building.
The present invention provides modular building systems and methods for shipment and installation of them.
One aspect of the present invention is to provide systems and methods for a modular building that is self-contained within a standard shipping container, wherein the pre-fabricated panel wall components are easily assembled to form a predetermined structure using a cam-based component connector system that provides for mating, dual-track alignment and locking of the modular panels with each other along their adjoining seams. Another aspect of the present invention is to provide a modular building system for a portable, storable complete building kit wherein the kit is completely optimally provided within a standard shipping container. Still another aspect of the present invention is to provide a modular building system with prefabricated composite wall panels that include conduits provided within the panels. Methods for installation of the modular building system are also considered aspects of the present invention. These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings, as they support the claimed invention.
In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.
The present invention provides systems and methods for a modular building that is self-contained within a standard shipping container, wherein the pre-fabricated panel wall components are easily assembled to form a predetermined structure using a cam-based component connector system. Another aspect of the present invention is to provide a modular building system for a portable, storable complete building kit wherein the kit is completely optimally provided within a standard shipping container. The present invention also provides a modular building system with prefabricated composite wall panels that include conduits provided within the panels; these conduits may optionally be pre-wired. Methods for installation of the modular building system include the steps of providing a prefabricated modular building kit having all components and instructions for assembly optimally disposed within a standard shipping container for portability and storage; removing the kit from the shipping container; assembling the modular housing by arranging and connecting the composite wall panels, which may include conduits for electrical and/or plumbing disposed within the interior section of the composite wall panels, including input/output openings for wiring, etc.
Referring now to the drawings in general, the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in the figures, especially
The structure size is predetermined before packaging, but ranges in size from small to very large buildings, by way of example and not limitation, such as an emergency shelter, a home or a command shelter or office. The size of the panels generally requires only two or three persons to manually maneuver the panels for complete structure erection. The material of both the interior and the exterior siding of the panels is selected based upon the needs of the customer and the environment, but in any case the panels are both insulated and portable. Preferably, the panels are super-insulated and portable to allow the builder to get under roof and into a comfortable space in a very short period of time.
In one embodiment of the present invention, items such as electrical junction boxes, conduit or radiant heating coils are preferably molded inside of the panels, constructed and configured in such a way on site as to add additional value to the structure. Beneficially, the structure is assembled quickly and may be pre-fitted with conduit (as delivered to the site in the self-contained kit, preferably in a shipping container), to allow for quick installation of a fully-equipped building, including electrical functionality. Doors and windows are also preferably delivered with and included in the building kit. Preferably, openings for the windows and doors are pre-framed in the panels in a manner that allows for rapid window and door installation on site, without additional time or materials required for framing and installation. Roof beam pockets are also preferably pre-set in the top of panels to facilitate the placement of rafter or ridge beams to allow for the support of the insulated roof panels.
In a preferred embodiment, the entire system is packed as a complete kit within a cargo container or standard shipping container as illustrated in
Advantageously, the panels of the present invention are the most advanced structurally insulated building panel on the market today. For corner panels they may be provided all flat panels so that they will stack tighter. The present invention provides a modular building system for creating an energy-efficient structure including: a multiplicity of pre-fabricated panel wall components and roof components, each having a face side and a back side and four edges including a pair of spaced-apart parallel tracks that run the length of at least two opposite edges for aligning the edges together to form a seam, wherein the components further include locking components for securedly attaching the components together along the seams.
Also, methods for providing a modular building structure including the steps of: providing a containerized kit wherein the kit is sized and configured to be enclosed by a housing and includes therewithin a modular building system further comprising a predetermined number of modular wall components, a roof system, and at least one door; providing instructions for assembling the modular building system for forming a complete building unit, including aligning the modular wall components along their opposite edges via a double mating spaced apart rail that extends along the length of the wall to provide an energy efficient seam when wall components are joined.
One application for the present invention includes a structure or building for a command or support center after an emergency to be erected on a flat surface. Other applications include but are not limited to medical center, school or residential structures.
In preferred embodiments of the kits for modular buildings, preferably included with the modular panel components for assembling to form a basic structure are the following:
Panels in a pre-configured kit including window panels, door panels, corner panels, beam pocket panels and window(s) pre-set into at least one panel; at least one door frame fitted to allow final site placement quickly and easily; at least one ventilation fan pre-installed in panel; and wherein the panels have at least some finishing on the face side that would be externally or outwardly facing upon assembly and installation for the building structure, by way of example and not limitation the face side finish includes a pre-finished exterior siding such as commercially offered by Hardi Panel or LP SmartSide; a plurality of structural members for supporting roof structure including a modular box beam with joints secured by pins; at least one composite sill plate and secondary base plate with flashing for foundation; tools required for structure assembly including panel cam-locks, sealant foam, foam applicators, etc.; instructions, plans, and figures illustrating assembly in at least one language or even multiple language(s) as required, preferably including figures showing step-wise assembly and installation, as well as an indication or listing of all the parts and components within the kit and how they relate to each other; rigid flashing for the top roof ridge (at the junction of the two different panel slopes), roof lining material, finished roofing material, modular electrical baseboard outlet kit; communications system or equipment (such as by way of example and not limitation, a communication system for satellite-based telecommunication of voice and/or data); scaffolding if wall panels were greater than about 8 ft. in height; Universal Power Supplies & filter (UPS) for sensitive electronic equipment; solar panels (PV or solar-thermal) for attachment or integration with select panels, preferably roof panels; FRP laminated panel interior (like for medical or school application); at least one bathroom module including sink and toilet, and preferably a shower unit.
Additionally, it is preferred to have equipment and/or appliances included with the kit to provide a fully functioning building structure with energy, heat and/or cooling, testing equipment, refrigeration, cleaning equipment, portable beds and/or bedding (in particular in the case of a medical structure application), at least one generator with fuel storage tanks safe for long term storage (LP, LNG, etc.), a potable water supply or container therefor (such as for about 250 gal of water), meals ready to eat (MRE) wherein the quantity depends upon user specification, cooking equipment, such as portable camping-type ovens; matches or other flame source, a ladder, solar oven or solar-powered cooking or heating equipment; water purification system for point-of-use water treatment; water collection system (including but not limited to rain collection), portable battery-powered and/or rechargeable lighting, computers and electronic equipment, etc.
Other optional supplemental items for inclusion in the kit may selectively include the following: basic modular furniture (tables, chairs, filing cabinets, locked storage cabinets, etc.), First Aid Kits; portable transportation for personal use, such as all-terrain vehicles, motorized or manual, or bicycles (mountain bikes); surveillance equipment.
Optional Extras may further include: additional consumable supplies, including but not limited to food, water, medical supplies, batteries, water filters or point-of-use purification equipment; medication or first aid supplies; bedding and clothing; protective gear specific to predetermined location, by way of example and not limitation, gas masks, impermeable gloves, hat, clothing, to protect from contamination or toxic agents; rope, chainsaws, other tools.
Also, supplemental or specific power supply alternatives may be provided, including by way of example and not limitation, a wind power generator, water power generator, solar power generating equipment, etc.
One application of the kits for modular buildings according to the present invention is to provide emergency shelter kits that would be deliverable to a site or location in advance of or following an emergency situation, such as weather catastrophe, illness outbreak, or may also be provided in advance of construction of larger buildings. While the present invention modular buildings formed from the kits and components described herein are suitable for long-term use, they may also be used for temporary buildings or for limited time specific use buildings. As such, the containers housing the kits for modular buildings preferably are rated and/or have a “storage life” where some items like tool batteries, MREs, water, and other items having some predetermined shelf life, would have to be replenished after a predetermined time, by way of example about 5 years. Replenishment kits may optionally be packaged for inclusion within the kit or separately and independently ordered periodically based on the number of containers originally ordered and not yet used.
Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. The above mentioned examples are provided to serve the purpose of clarifying the aspects of the invention and it will be apparent to one skilled in the art that they do not serve to limit the scope of the invention. All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the present invention.
|Cited Patent||Filing date||Publication date||Applicant||Title|
|US3353314 *||Jun 24, 1966||Nov 21, 1967||Bally Case And Cooler Inc||Insulated panel having joined connectors|
|US3392497 *||Oct 21, 1966||Jul 16, 1968||Delron Company Inc||Modular enclosure with clamp joined panels|
|US4020613 *||Jul 2, 1975||May 3, 1977||Reynolds Frank L||Fastener|
|US4223500 *||May 10, 1978||Sep 23, 1980||Clark Howard K||Insulation molded, load bearing, prefabricated panels|
|US4417430 *||Mar 13, 1981||Nov 29, 1983||Standard Keil Hardware Manufacturing Co.||Direct drive positive locking panel fastener|
|US5155960 *||Nov 23, 1990||Oct 20, 1992||Indal Furniture Systems A Division Of Indal Limited||Cam action connector for joining furniture panels|
|US5424118 *||Jan 25, 1994||Jun 13, 1995||Mid-South Industries, Inc.||Interlocking insulative panel construction|
|US6119427 *||Apr 29, 1998||Sep 19, 2000||Louisville Cooler Manufacturing Co.||Apparatus and method of modular panel construction|
|US6564521 *||May 12, 2000||May 20, 2003||Brown Paul A||Structural sandwich panels and method of manufacture of structural sandwich panels|
|US7726088 *||Jul 20, 2007||Jun 1, 2010||Moritz Andre Muehlebach||Flooring system|
|US7793467 *||Feb 2, 2004||Sep 14, 2010||Melton David S||Passively cooled and heated electrical components and power building|
|US20070028547 *||Jan 30, 2004||Feb 8, 2007||Kronotec Ag||Device for connecting building boards, especially floor panels|
|US20070044411 *||Apr 5, 2006||Mar 1, 2007||Meredith Walter D||Panel structures|
|US20080134589 *||Aug 17, 2007||Jun 12, 2008||Alexander Abrams||System for modular building construction|
|US20100064599 *||Dec 20, 2005||Mar 18, 2010||Zhenqiu Yang||Portable Building|
|Citing Patent||Filing date||Publication date||Applicant||Title|
|US7835810||Feb 16, 2007||Nov 16, 2010||Genesistp, Inc.||Tools and methods for designing a structure using prefabricated panels|
|US7894920||Feb 16, 2007||Feb 22, 2011||Genesis TP, Inc.||Information technology process for prefabricated building panel assembly|
|US8364620||Jul 17, 2009||Jan 29, 2013||Boardman Paul B||Method and apparatus for designing, producing, manufacturing and delivering personalized living environments|
|US8439333||May 25, 2010||May 14, 2013||Caldwell Tanks, Inc.||Removable misting array assembly for an abatement system|
|US8554390 *||Nov 16, 2010||Oct 8, 2013||International Business Machines Corporation||Free cooling solution for a containerized data center|
|US8656672||Dec 29, 2010||Feb 25, 2014||James C. Quinn||Systems and methods of revitalizing structures using insulated panels|
|US8973335 *||Feb 3, 2010||Mar 10, 2015||Blue Planet Buildings (Uk) Limited||Modular assembly shelter|
|US9066451 *||Sep 10, 2013||Jun 23, 2015||International Business Machines Corporation||Free cooling solution for a containerized data center|
|US9068372||Aug 14, 2013||Jun 30, 2015||Premium Steel Building Systems, Inc.||Systems and methods for constructing temporary, re-locatable structures|
|US9109354 *||Jul 17, 2013||Aug 18, 2015||University Of Dayton||Rapid assembly of a modular structure|
|US20110065370 *||Sep 13, 2010||Mar 17, 2011||John Reid||Air collector integration with workstation|
|US20110289860 *||Feb 3, 2010||Dec 1, 2011||Blue Planet Buildings (Uk) Limited||Modular assembly shelter|
|US20120123607 *||Nov 16, 2010||May 17, 2012||International Business Machines Corporation||Free cooling solution for a containerized data center|
|US20120246939 *||Apr 2, 2012||Oct 4, 2012||Odom Construction||Integrated Panelization|
|US20140008043 *||Sep 10, 2013||Jan 9, 2014||International Business Machines Corporation||Free cooling solution for a containerized data center|
|US20150020463 *||Jul 17, 2013||Jan 22, 2015||University Of Dayton||Rapid assembly of a modular structure|
|WO2012012688A1 *||Jul 22, 2011||Jan 26, 2012||Trascher Kenneth G||Building system and method|
|U.S. Classification||52/79.1, 52/745.02|
|Cooperative Classification||E04B2001/34389, E04B1/6183, E04B1/34321|