MODULAR CONSTRUCTION SYSTEM

Description

BACKGROUND OF THE INVENTION

The present invention relates to a modular construction system, and more particularly to a system of freight containers forming living units in a multi-story configuration.

Over time, land use and value can fluctuate based on surrounding environments and local development, as well as other community based economic factors. As a result, a parcel of land that previously was well-suited for one type of residential land use, for example, multi-family housing, apartments, condominiums or townhomes may become better suited for another residential type of land use, for example, single family housing or residential subdivisions, or a different type of land use altogether, such as commercial or industrial development.

As land use evolves, the buildings and other structures supporting one type of land use typically must be demolished and removed, or at the very least highly renovated before new buildings, homes and other structures can be established on a parcel. As a result, acquisition of a parcel for new development may include ancillary costs associated with the conversion to the new use. This can present significant financial challenges to potential developers and can delay or in some cases prevent land use conversion, even though it may be in the best interests of a community, municipality or local economy.

In addition, the cost of constructing housing or living units within communities continues to rise, which in turn leaves many families and working individuals with limited options for housing. Many working families and individuals cannot afford conventional home ownership, which relegates most to renting apartments, studios or other living spaces. Most of these rental based land uses rely on buildings and structures that are permanently built on a parcel. Accordingly, when land use in the surrounding community evolves or changes, as noted above, rather large multi-unit buildings are typically demolished or removed, which can increase associated monetary costs and incur additional administrative burdens.

Accordingly, there remains room for improvement in the field of construction to provide buildings, living spaces and other structures that can be easily erected and deconstructed to provide flexibility in land use.

SUMMARY OF THE INVENTION

A modular construction system is provided including freight containers placed side by side one another so that one or more living units of the system can span from one container to an adjacent container.

In one embodiment, containers can be placed lengthwise alongside one another. A pair of adjacent containers can form one or more U-shaped living units that exploit structural components of the containers.

In another embodiment, the containers can include ends, with adjacent ends defining a living unit connector hallway. The hallway can connect a first portion of a living space provided by one adjacent container and a second portion of the same living space provided by another adjacent container.

In still another embodiment, the first and second portions from adjacent containers can produce the one or more U-shaped living unit. The living unit connector hallway can be formed between an end corner post and an intermediate corner post of each respective adjacent container. The living unit connector hallway can be disposed above the adjacent bottom rails and below the adjacent top rails of the adjacent containers cooperatively forming the U-shaped living unit.

In yet another embodiment, windows, for example large bay windows, can be disposed in the end walls or ends of adjacent containers. The windows can be aligned with the end walls or ends so that a wall of the living unit connector hallway is formed between the windows formed in adjacent containers. The large bay windows can span all the way across or across a majority of the end walls.

In even another embodiment, centers of the adjacent containers can form a common access corridor that extends through two or more adjacent containers. The common access corridor can be cut or breached through multiple adjacent walls of adjacent containers and can include opposing openings on outermost ones of the adjacent containers. The opposing openings can be open to the environment or outfitted with a closure such as a door to provide ingress and egress to the corridor.

In a further embodiment, multiple pairs of U-shaped living units can be disposed on opposite sides of the common corridor. The U-shaped living units can include doorways that open to the common corridor to provide ingress and egress to each respective living unit. The doorways can be confined to either a first portion or a second portion of the living space, or part of the U-shaped living unit.

In still a further embodiment, the containers forming one or more living units can be in a multi-story configuration. For example, multiple paired adjacent containers forming opposing U-shaped living units can be stacked in levels, one upon the other. Because the containers are rated for stacking four, five, six or more on top of one another, a multistory, relatively tall structure can be produced to provide multiple living units on a relatively compact footprint.

In yet a further embodiment, the ground level of the structure of containers can be formed to provide integrated parking under the footprint of the containers. The ground level can include multiple pillars or supports that elevate a first story of vertically stacked adjacent containers to a height of at least eight feet above ground level. This can provide space and allow parking of vehicles under the containers and between or amongst the multiple pillars or supports.

In even a further embodiment, the ground level can include a ground level freight container that is disposed transverse to the living unit containers on the levels above the ground level. The ground level container can be placed on a pier or foundation in the ground. The living unit containers can be placed vertically above the ground level container, which can support a portion of the weight of the containers above. One or more pillars or supports can be placed around and outward from the ground level container to provide additional load support for the living unit containers above.

The current embodiments provide a modular building system well suited for producing efficient living spaces and associated structures, yet able to be erected and deconstructed to quickly and cost effectively shift land use for a parcel on which the system is placed. Where the system includes U-shaped living spaces formed by adjacent freight containers, the floor plan can be spacious and utilize the walls and corner posts of the adjacent containers for support. Where bay windows are provided in the ends of adjacent containers, each living space can have substantial natural lighting. Where the ends of the adjacent containers define living unit connector hallways, and the centers of the adjacent containers form a common access corridor, the structural supports of the freight containers can be well utilized, and structural integrity of those containers maintained for multi-story configurations of the containers and associated living spaces. Where the containers are in a multi-story configuration, a ground level can be reserved for cross traffic and in-envelope parking. This can allow denser construction while meeting parking requirements at costs meeting or surpassing surface parking for a unit of the system.

These and other objects, advantages, and features of the invention will be more fully understood and appreciated by reference to the description of the current embodiment and the drawings.

Before the embodiments of the invention are explained in detail, it is to be understood that the invention is not limited to the details of operation or to the details of construction and the arrangement of the components set forth in the following description or illustrated in the drawings. The invention may be implemented in various other embodiments and of being practiced or being carried out in alternative ways not expressly disclosed herein. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including” and “comprising” and variations thereof is meant to encompass the items listed thereafter and equivalents thereof as well as additional items and equivalents thereof. Further, enumeration may be used in the description of various embodiments. Unless otherwise expressly stated, the use of enumeration should not be construed as limiting the invention to any specific order or number of components. Nor should the use of enumeration be construed as excluding from the scope of the invention any additional steps or components that might be combined with or into the enumerated steps or components.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the modular building system of a current embodiment installed on a parcel of real estate and in a multistory, multi-unit configuration.

FIG. 2 is a front view of the modular building system.

FIG. 3 is a plan view of the modular building system having two pairs of elongate freight containers placed adjacent one another to form U-shaped living units across a common hallway.

FIG. 4 is a perspective view of a first freight container prepared with penetrations to form respective unit connector openings at opposing ends of the first freight container and a common hallway opening in the middle of the first freight container, before the first freight container is installed and set adjacent a second freight container.

FIG. 5 is a perspective view of a second freight container prepared with penetrations to form respective unit connector openings at opposing ends of the second freight container and a common hallway opening in the middle of the second freight container, before the first freight container is installed and set adjacent the second freight container.

FIG. 6 is an alternative embodiment of the modular construction system having a single story and a ground level support freight container with parking spaces under the single story.

DETAILED DESCRIPTION OF THE CURRENT EMBODIMENTS

A current embodiment of the modular building system is shown in FIGS. 1-5 and generally designated 10. The modular building system 10 shown in FIG. 1 includes multiple stories or levels above a ground level parking area 10PA. This form is but one example that can provide a building having multiple units and an in-envelope parking area 10PA under those units as described below. Further, although shown in a multistory configuration, the system 10 can come in a single-story configuration and/or can have multiple additional stories stacked one above another. Because the system 10 utilizes freight containers, the containers themselves can be stacked story upon story, based on the vertical stacking capacity and load capabilities of the freight containers that are used in the modular construction system.

As shown in FIGS. 1 and 2, the modular construction system 10 includes multiple stories 10A, 10B, 10C. Each of these stories can be similar in aesthetics, which can be dictated by the outfitting and construction of individual freight containers used to construct each story and the respective U-shaped units in each story as described below. The individual units in each of the stories and respective parking area can be modified, depending on the application and any particular uses, regulations and or ordinances concerning the building including the modular construction system 10.

Buildings that are formed with the modular construction system can be of a permanent nature with a usable life span the same as or exceeding a conventional building structure. Buildings constructed with the system also can be extended, modified, altered, or converted or reconfigured, depending on the land use or other factors in the area where the modular construction system 10 is installed. Given that the modular construction system is comprised of multiple freight containers that are independently transportable via trailer, rail, or other means, the buildings constructed using the modular construction system 10 can be easily, readily and quickly dismantled and transported or moved to another location or repurposed.

As illustrated in FIGS. 1-6, the modules of the system 10 can be used to construct individual spaces, which optionally can be in the form of U-shaped living units. Of course, the modules in the system 10 can be used for applications other than housing. For example, the system can be designed for use as hotels, hostels, hospitals, assisted living or healthcare homes, educational or institutional facilities, commercial office space, and/or manufacturing, industrial space, storage units, parking units, correctional facilities and the like. Depending on the application, the living units of the system 10 can be separated and divided into a variety of different spaces, such as bedrooms, living rooms, dining rooms, bathrooms, hallways, kitchens, utility spaces, storage spaces, stairwells, balconies, elevators, lift shafts, offices, recreational and/or community areas and the like.

The modular construction system 10 can be outfitted with utilities servicing the units therein. The utilities, such as plumbing, electrical, cable, phone, fiber optic, piping and/or other utility structures can be extended and located under floors, above or in roofs or ceiling spaces, through ducts, voids and internal spaces that are provided, constructed, and/or located inside or exterior to the respective freight containers as described below. The individual freight containers can include appropriate penetrations, holes, apertures, recesses, openings, slots, conduits, access panels, fittings and the like at suitable locations and in suitable configurations, such that utilities can extend from one container to another, one living unit to another, one internal space to another, one story to another and/or in other manners throughout the modular building system 10. Further, the interior space of each freight container can be finished with wood, composite, plastic sheeting, panels and other construction materials suitable for a living space, office space, storage space or other interior space within the freight container 20 depending on the application.

As mentioned above, the primary building components of the modular construction system 10 can be freight containers. The freight containers can be any intermodal freight or shipping container. The dimensions of the buildings constructed with the modular construction system can substantially correspond to the dimensions of the freight containers used to construct the system 10. FIGS. 4 and 5 illustrate a pair of freight containers, including a first container 20 and a second container 30 that can be used to construct a portion of the modular construct system 10. This pair of containers including the first and second containers can form one or more modules 10M1 and 10M2 of the system 10. The modules 10M1 and 10M2 can be repeated multiple times in a single level or story of a building constructed with the system 10. Moreover, these modules can be repeated to form multiple levels or stories of a building. Due to the stack-ability of the freight containers, as mentioned above, multiple modules can be vertically stacked one upon the other in the building in the modular construction system described here.

The freight containers 20 and 30 illustrated and FIGS. 4 and 5 can be of a variety of lengths, widths and heights. Some suitable containers can be provided in lengths of optionally 10 feet (2,991 mm), 20 feet (6,058 mm), 30 feet (9,125 mm), 40 feet (12,192 mm) or 53 feet (17,154 mm). In the current embodiment, each of the first container 20 and the second container 30 can be a 53 foot shipping container. In particular, these containers can have a length of 53 feet, and can include a height of 9′6″ and a width of 8′6″. With this height, these containers can generally fall under the category of high cube containers. In most cases, these 53 feet freight containers can have a capacity or internal volume of approximately 3,884 cubic feet. These containers can be constructed from corrugated steel, posts, beams, castings and other components as described below. Generally, these containers can be substantially air and watertight to keep the elements from penetrating into the internal spaces of the containers before these containers are modified as described herein.

The first freight container 20 will be described in further detail with reference to FIG. 5, and how it is specially outfitted to incorporate into a module 10M1 forming one or more U-shaped units when placed adjacent and combined with the second freight container 30. To begin, the first freight container can include a first longitudinal axis LA1 that extends lengthwise along the length of the container. The container can include a first top rail 21RT and a first bottom rail 21RB located near the bottom or floor 20F of the freight container. The top rail and bottom rail can be substantially parallel along the length of the container and parallel to the longitudinal axis LA1, extending from the first end 21 to the second end 22 of the freight container. The rails can be in the form of tubular or solid supports disposed along the top edge and along the bottom edge on either side of the freight container. Thus, although somewhat out of view, the freight container can also include another top rail 21RT2 and another bottom rail 21RB2 disposed on the opposite side of the axis LA1 from the respective top rail 21RT and bottom rail 21RB.

The top rail 21RT and bottom rail 21RB can extend along the length LL1 of the freight container 20. These rails can connect to a respective first corner post 21CP1 disposed at the first end 21 of the first container. The first corner post can be a solid or tubular elongated member that spans between the first top rail 21RT and the first bottom rail 21RB generally forming the corner of the container 20. The rails also can connect to a respective second corner post 21CP2 disposed at the second end 22 of the first container. This second corner post can be a solid or tubular elongated member that spans between the first top rail 21RT and the first bottom rail 21RB, again generally forming another corner of the container 20.

At the first end 21, the first corner post 21CP1 can be joined with upper 21U and lower 21L cross members that span to an opposing post 21CP1A that is generally parallel to the first corner post 21CP1. Collectively, these corner posts and cross members can form an end frame 21EF. As described below, this end frame 21EF can house, enclose or otherwise form a frame for a bay window 29A which as shown can be in the form of a large bay window. Although not shown, the opposing end 22 also can include another frame, including similar crossmembers and another corner post opposite the second corner post 22CP2. This other end frame also can include a window 29B which can be substantially similar to the window 29A. The bay window 29A can span the entire area or a majority, optionally, greater than 50%, greater than 75%, greater than 90% or perhaps 100%, of the area bounded within the frame, between the posts 21CP1 and 21CP1A, and between cross members 21U and 21L.

The windows 29A and 29B can be disposed at the opposing first end 21 and second end 22 of the freight container 20. These windows can be formed from tempered glass and can be single or double panes to provide insulative properties. As shown, these windows can be in the form of larger bay windows, which can span a substantial portion of the width W1 of the first container and the height H1 of the first container at the end. The windows can optionally span a height that is at least 40%, at least 50%, at least 60%, at least 70%, at least 80% or at least 90% of the height H1 of the container. The windows also can optionally span a width that is at least 40%, at least 50%, at least 60%, at least 70%, at least 80% or at least 90% of the width of the container. With such large windows located at the ends of the container, additional windows typically need not be installed or formed in other portions of the freight container. Accordingly, this can improve, maintain or retain the structural integrity and strength of the walls of the container.

As shown in FIG. 4, the first container 20 can include a roof 20U and a floor 20F. The floor can be a distance V1 above the bottom-most portion of the bottom rail 21RB. The floor thus can form a void 21LV under it, between respective bottom rails 21RB and 21RB2. This void can be used to accommodate utilities to various portions of the interior of the freight container 20. The floor 20F of the freight container can be constructed from corrugated steel, and can include a wood, plastic, metal or other material sheet or panel that is disposed atop the corrugated steel to provide a flat surface inside the freight container. The floor can be covered with a floor covering suitable for a living space, commercial space or other space inside the freight container. The roof 21U can be a corrugated steel roof or can be in the form of a flat panel roof, depending on the application. Optionally, the roof 21U can be substantially flat and does not project above the top rail 21RT. Between the roof 20U and the floor 21L, the freight container can include a first wall 24 that expands from the first end 21 to the second end 22. The first wall 24 can be constructed from corrugated steel. The first wall 24 can span from the top rail 21RT to the bottom rail 21RB. An identical wall can be disposed on the opposite side of the freight container 20.

With further reference to FIG. 5, the freight container 20 can further include a first intermediate post 2111 slightly distal from the first end 21 but located adjacent the first end and spanning between the first top rail 21RT and the first bottom rail 21RB. An identical intermediate post can be disposed on the opposite side on the opposite wall of the container. A second intermediate post 2212 can be distal from the second end likewise can span between the first top rail 21RT and the first bottom rail 21RB. An identical intermediate post can be disposed on the opposite wall of the container. The first intermediate post and second intermediate post can be disposed distal from the respective first end 21 and second end 22, optionally being at least 5 feet, at least 6 feet, or at least 7 feet distal from those ends. These intermediate posts, as well as first and second corner posts, optionally can be outfitted with castings that have one or more connection holes or fasteners join therewith so that one freight container, such as the first freight container 20, can be joined with a second freight container, such as second freight container 30. Moreover, the intermediate posts and corner posts can include these castings or connectors along the top rail and the bottom rail to provide connection directly between the floor or bottom of one container and the top or roof of another container or one wall of one container and another wall of another container. Of course, a variety of different connectors can be used and providing the connection between the first container and the second container to form a module of the modular building modular construction system 10.

The first and second intermediate posts 21PI1 and 2212 can extend along or be a part of the first wall 24. The first intermediate post 21PI1 can be disposed between the first corner post 21CP1 and the second intermediate post 2212. The second intermediate post 2212 can be disposed between the second corner post 22CP2 and the first intermediate post 21PI1. The spatial relationship between the intermediate posts relative to one another and to the corner posts can be exploited to provide passageways, connectors and hallways between the first freight container 20 and the second freight container 30. For example, the first wall 24 of the first container 20 can define a first unit connector first opening 41C1 between the first post 21CP1 and the first intermediate post 21PI1. This opening 41C1 can span between the top rail 21RT and the bottom rail 21RB, extending the full height H1 of the wall 24 between those rails. This opening 41C1 can be formed by penetrating, cutting or otherwise removing a portion of the wall 24 in the location as shown in FIG. 4. The connector first opening 41C1 can include a first edge 41E1 and a second edge 41E2 on opposite sides of the opening. The first edge 41E1 can be disposed adjacent and/or within 6 inches to 12 inches of the first corner post 21CP1. In some cases, the edge 41E1 can be formed by the first corner post 21CP1 itself. The second edge 41E2 can be distal from the first corner post 21CP1 and disposed within 12 inches to 24 inches from the first intermediate post 21PI1. The first edge 41E1 can be closer to the first corner post 21CP1 than the second edge 41E2 is close to the first intermediate post 21PI1. In some cases, a section of the panel or wall can remain between the edge 41E2 and the intermediate post 21PI1. Of course, in other applications, the opening 41C1 can span between the intermediate post 21PI1 and the corner post 21CP1 with all of the wall 24 removed therebetween. With the wall removed in this location, between the respective structural corner post 21CP1 and the intermediate post 2111, this portion of the freight container still maintains its structural integrity yet provides access to the first interior space I1 of the first container 20.

Distal from the first unit connector first opening 41C1, the first wall 24 can define a second unit connector second opening 41C2 between the second post 21CP2 and the second intermediate post 2212. This opening 41C2 can span between the top rail 21RT and the bottom rail 21RB, extending the full height of the wall 24 between those rails. This opening 41C2 likewise can be formed by penetrating, cutting or otherwise removing a portion of the wall 24. The second opening 41C2 can include edges on opposite sides of the opening similar to the first opening 41C1. These edges can have spatial relationships relative to the second corner post 22CP2 and the second intermediate post 2212 similar to that of the edges of the first opening 41C1, so will not be described again here. Optionally, the first and second unit connector second openings can be symmetric about a middle M of the freight container 20 such that living spaces formed by the first interior space I1 and second interior space I2 at the respective ends 21 and 22 of the freight container 20 can be similar or identical in shape, size and/or dimension. Optionally, each of the openings 41C1 and 41C2 can have identical widths. These widths optionally can be about 4 feet to about 6 feet, inclusive, about 5 feet to about 6 feet, inclusive or about 5 feet.

As further shown in FIG. 4, the first wall 24 can define a first common hallway opening 44H1 defined between the first intermediate corner post 2111 and the second intermediate corner post 2212 at the middle M or midway between the first end 21 and the second end 22. This hallway opening 44H1 can span between the top rail 21RT and the lower rail 21RB. In some cases, the opening can span the entire height of the freight container between those rails. This hallway optionally can have a width that can be optionally about 2 feet to about 8 feet, inclusive, about 3 feet to about 7 feet, inclusive, about 4 feet to about 6 feet, inclusive or about 5 feet. This hallway can be placed in the middle M of the freight containers length LL1. It can also be disposed perfectly between the first connector opening 41C1 and the second connector opening 41C2. Further, the hallway can be between the intermediate posts 2111 and 2212. Of course, in other applications, the hallway 44H1 can be offset closer to one end than the other, so that the respective interior spaces I1 and I2 can differ for different sized living spaces in different units.

The second freight container 30 will be described in further detail with reference to FIG. 5. This freight container can be virtually identical but a mirror structure to the first freight container. For example, the second freight container can include a second longitudinal axis LA2 that extends lengthwise along the length of the container. The container can include a second top rail 31RT and a second bottom rail 31RB located near the bottom or floor of the freight container. The top rail and bottom rail can be substantially parallel along the length of the container and parallel to the longitudinal axis LA2, extending from the third end 31 to the fourth end 32 of the freight container 30.

The top rail 31RT and bottom rail 31RB can extend along the length LL2 of the freight container 30. These rails can connect to a respective third corner post 31CP1 disposed at the third end 31 of the second container. The third corner post can span between the second top rail 31RT and the second bottom rail 31RB generally forming the corner of the container 30. The rails also can connect to a respective fourth corner post 31CP2 disposed at the fourth end 32 of the first container. This second corner post can be a solid or tubular elongated member that spans between the second top rail 31RT and the second bottom rail 31RB, again generally forming another corner of the container 30.

Like the first container, the ends of the second container can include respective first 39A and second 39B windows, which can be bay windows as described above, and having the dimensions and areas, heights and widths as described above. The second container 30 also can include a roof and floor similar to those of the first container.

With further reference to FIG. 5, the freight container 30 also can include a third intermediate post 3111 slightly distal from the first end 31 but located adjacent the third end and spanning between the second top rail 31RT and the second bottom rail 31RB. An identical intermediate post can be disposed on the opposite side on the opposite wall of the container. A second intermediate post 3212 can be distal from the fourth end, likewise, can span between the second top rail 31RT and the second bottom rail 31RB. An identical intermediate post can be disposed on the opposite wall of the container. The third intermediate post and fourth intermediate post can be disposed distal from the respective third end 31 and fourth end 32, optionally being at least 5 feet, at least 6 feet, or at least 7 feet distal from those ends.

The third and fourth intermediate posts 31I1 and 3212 can extend along or be a part of the second wall 34. The third intermediate post 3111 can be disposed between the third corner post 31CP1 and the fourth intermediate post 3212. The fourth intermediate post 3212 can be disposed between the fourth corner post 32CP2 and the third intermediate post 31I1.

The second wall 34 of the second container 30 can define a first unit connector first opening 42C1 between the third post 31CP1 and the third intermediate post 3111. This opening 42C1 can span between the top rail 31RT and the bottom rail 31RB, extending the full height H2 of the wall 34 between those rails. This opening 42C1 can be formed by penetrating, cutting or otherwise removing a portion of the wall 34 in the location as shown in FIG. 5. The connector first opening 42C1 can include edges like that of the opening 41C1 described above.

Distal from the first unit connector third opening 42C1, the second wall 34 can define a second unit connector fourth opening 42C2 between the fourth post 31CP2 and the fourth intermediate post 3212. This opening 42C2 can span between the top rail 31RT and the bottom rail 31RB, extending the full height of the wall 34 between those rails. This opening 42C2 likewise can be formed by penetrating, cutting or otherwise removing a portion of the wall 24. The opening 42C2 can include edges on opposite sides of the opening similar to the first opening 41C1. The first unit connector first and second openings can be symmetric about a middle M of the freight container 30 such that living spaces formed by the third interior space I3 and fourth interior space I4 at the respective ends 31 and 32 of the freight container 30 can be similar or identical.

As further shown in FIG. 5, the second wall 34 can define a second common hallway opening 44H2 defined between the third intermediate corner post 31I1 and the fourth intermediate corner post 3212 at the middle M or midway between the ends. This hallway opening 44H2 can span between the top rail and bottom rails like the opening 44H1. Depending on the application, the hallway opening 44H2 can be moved closer to one of the ends, so it can be aligned with the opening 44H1 if that opening is also closer to one of the ends for different sized living spaced or simply different configurations of the building.

The modular construction system 10 as mentioned above can include individual modules, for example module 10M1 and 10M2 on a level as shown in FIG. 3. There, the module 10M1 can comprise the first freight container 20 and the second freight container 30 as described above. These freight containers can be placed immediately adjacent one another as shown in the floor plan of FIG. 3. The first wall 24 and the second wall 34 can be placed adjacent and alongside one another, with the respective longitudinal axis LA1 and LA2 of each of the respective first container 20 and second container 30 aligned and in parallel with one another.

Optionally, the first wall 24 and the second wall 34 can be respectively separated by a first void 24V on a first side 44S1 of the common hallway 44 that is defined through the system 10 on a level as shown in FIG. 3. Likewise, the first wall and the second wall can be respectively separated by a second void 34V on a second side 44S2 of the common hallway 44. The voids can be optionally about 1 foot, about 2 feet or between 1 foot and 2 feet in dimension. Utilities optionally can be installed in the voids and can penetrate openings in the respective walls 24 and 34 of the module 10M1 and the respective freight containers 20 and 30.

When configured in a module 10M1, the first container 20 and the second container 30 can be set and connected with connectors such that the first common hallway opening 44H1 and second common hallway opening 44H2 are aligned with one another. Accordingly, a common hallway 44 can be constructed and can extend through the first common hallway opening 44H1 and the second common hallway opening 44H2. Again, the hallway 44 can separate the first container and second freight container into a first space I1 and a third space I3 of the respective first container 20 and second container 30, as well as into a second space I2 and fourth space I4 on a second side 44S2 of the common hallway 44. The first space I1 of the first container 20 can be connected to and in communication with the third space I3 of the second container. The first space I1 and third space I3 can be connected via the respective first unit connector openings 41C1 and 42C2 and collectively can form a U-shaped first unit L1. This U-shaped first unit can include the first space and the third space on the first side 44S1 of the common hallway 44. The first unit connector first opening 41C1 and first unit connector third opening 42C1 again can be aligned as shown in FIG. 3. A unit connector hallway 41H can extend through the first opening 41C1 and the second opening 42C1. This hallway 41H can be bounded by a first unit connector hallway interior wall 41HW1 that spans generally from the first window 29A to the second window 39A of each of the respective first container 20 and second container 30. This interior wall 41HW1 can span further across or adjacent the first corner post 21CP1 and the third post 31CP1 of the respective freight containers. This interior wall can include one or more panels that also span across the posts, where the panel is secured to the posts or some internal framing structures, like a metal or wood studs or furring strips placed along the interior wall. Opposite this wall can be another first unit connector hallway interior wall 41HW2. This wall can bound at least a portion of the internal void 24V between the first wall 24 and second wall 34 of the respective freight containers. Both walls can be constructed from sheeting, paneling, insulation and/or a combination of materials. Likewise, each of the walls of the U-shaped first unit L1 can be lined with paneling, sheeting, drywall or other finishing materials to provide an aesthetic appearance. The various walls on the interior spaces of the living spaces can be framed with studs or furring strips, of the metal or wood variety. In other cases, the panels or walls can be adhered, glued or otherwise fastened to the walls of the container. The walls also can be insulated and outfitted with the appropriate utilities depending on the application.

Using the structure of the first container 20 and the second container 30, on the opposite side of the hallway 44, a U-shaped second unit L2 can be formed. This U-shaped unit can be a mirror of the U-shaped first unit L1. The second connector opening 41C2 and fourth connector opening 42C2 can be aligned, with one another and a hallway 42H can extend from the second interior space I2 to the fourth interior space I4, thereby forming the U-shaped second unit L2. The interior walls of this hallway can be similar to that of the hallway 41H. Likewise, the windows 29B and 39B can be disposed on opposite sides of the connector hallway 42H. These windows likewise can provide natural illumination to each of the interior spaces I2 and I4 of the U-shaped second unit L2. Due to the size of the windows, a substantial portion of the unit can be illuminated with natural light from these windows. Generally, the first bay window 29A and second bay window 39A can provide natural illumination to the first space I1 and the third space I3 simultaneously. Likewise, the third bay window 29B and the fourth bay window 39B can provide natural illumination to the second space I2 and the fourth space I4 simultaneously. Of course, additional windows can be formed, via penetrations of exterior walls of the first freight container 20 depending on the application.

As shown in FIG. 3, the U-shaped first unit L1 and U-shaped second unit L2 oppose one another across common hallway 44. This common hallway 44 can be bounded by a first hall wall 47 on the first side 44S1 and a second hall wall 48 on the second side 44S2. These hall walls can be separated by the width of the hallway as described above. The first wall can include a first hall wall first portion 47B that bounds the first space I1 inside the first container 20. A first hall wall second portion 47A can bound the third space I3 inside the second freight container 30. As shown, only one of the first hall wall first portion and the first hall wall second portion includes a door 51D that provides a closure for an opening 51 to the first unit L1. This singular door provides singular ingress and egress to the common hallway 44 for the U-shaped first unit L1. The other portion of the first wall does not include a door or other opening to provide access to the other portion of the U-shaped unit L1. Of course, in some applications that second wall portion might include another access door or panel. Similarly, the U-shaped second unit L2 also can include only a singular door 52D that provides singular egress and egress to the U-shaped second unit L2. Optionally, the door 51D and door 52D can be disposed on opposite sides of and face one another across the common hallway 44. In other applications, the respective doors of opposing U-shaped living units can be offset so that they do not face toward one another.

As mentioned above, the modular construction system 10 can include multiple modules. For example, as shown in FIG. 3, the system 10 can include a second module 10M2 that is disposed adjacent the first module 10M1. This second module 10M2 can include a third freight container 60 disposed adjacent a fourth freight container 70. The third freight container 60 and fourth freight container 70 can be substantially parallel to one another, similar to the first and second freight containers. These third 60 and fourth 70 freight containers can respectively form a U-shaped third unit L3 and a U-shaped fourth unit L4. These respective U-shaped units can be comprised of interior spaces that are joined via respective third unit connector hallway 61H and fourth unit connector hallway 71H that are formed and include structure similar to that of the hallways 41H and 42H described in connection with the first and second freight containers and therefore will not be described again here. These units also can include windows at the respective ends of each of the third and fourth freight containers similar to the windows of the first and second freight containers described above, and therefore will not be described again here. The common hallway 44 can extend generally through the middle sections M of the first container, second container, third container and fourth container. The respective U-shaped units can be disposed on opposite sides of this middle section and on opposite sides and across the common hallway 44.

In the system 10 as shown in FIG. 3, where two modules 10M1 and 10M2 are disposed adjacent one another on a single level or story of the system, the common hallway 44 can extend to opposing ends. At these opposing ends, respective balconies 48B1 and 48B2 can be disposed. Optionally, doors 44D1 and 44D2 can open to the respective balconies. The balconies can be outfitted with one or more staircases 48S1 and 48S2 which can provide access to the respective balconies. Of course, in other applications, a lift or elevator shaft can be disposed at an end of the hallway 44 to provide automated and mechanical access to one or more stories of a building having multiple levels of the system 10.

It will be appreciated that in a multistory configuration, there may be additional pairs of freight containers, formed similar to the modules 10M1 and 10M2 on different levels of a multistory building, including the system 10. As shown in FIGS. 1 and 2, for example, the levels 10B and 10C can include additional freight containers forming modules similar to that of the modules 10M1 and 10M2. Those freight containers can be aligned in parallel to the freight containers above and/or below the same.

With further reference to FIGS. 1 and 2, the modular construction system 10 can be configured to form a parking area 10PA under the system 10 and under one or more levels or stories 10A, 10B, 10C including the respective modules 10M1 and 10M2. This parking area can be configured to form a void having a height PH of at least 8 feet such that vehicles can be parked under the system 10. Multiple supports 90A-90E can be strategically and structurally aligned under the respective containers or modules. These supports also can be separated a distance from one another to enable vehicles to be placed and parked there between. These supports can be in the form of pillars, beams, posts or other vertical elongated members, extending from a ground surface up to a support structure and the bottoms of respective freight containers, thereby supporting those freight containers above the parking area. The supports can be further tied structurally to one another with a truss or crossmember system to provide additional strength and stability. The respective supports also can be placed on footings that extend into the ground a distance.

Optionally, as shown in FIG. 1, the vertical supports forming the parking area 10PA can be outfitted with the outermost supports 90E1 and 90E2. These outermost vertical supports on the ground level can be aligned with the intermediate posts IP1 and IP2 respectively of each container disposed above the parking area 10PA. With the supports so aligned, the loads generated by the upper levels 10A, 10B, 10C can be transferred substantially through many of the intermediate posts IP1 and IP2 to the supports 90E1 and 90E2. With this configuration as well, the modules and freight containers of the system 10 can include cantilevered portions CL1 and CL2 which extend outwardly and beyond the outermost supports. This can provide enhanced aesthetics for the building in certain applications. It also can reduce the overall physical footprint of the supports in the parking area 10PA.

An alternative embodiment of a parking or ground level is shown in FIG. 6. There, the ground level can include an optional ground floor freight container 90 which can be of a different size and dimension from the freight containers 20, 30 used to construct the modules 10M1, 10M2 of the system 10 as mentioned above. The ground floor freight container 90 can optionally be a 40 foot shipping container. This container can have the length of 40 feet, a height of 9′6″ and a width of 8 feet with an internal volume of 2660 cubic feet. Of course, other sized freight containers can be used for this ground level container, depending on the application and layout of the parking area and living unit modules above the ground floor. As shown, the ground level container 90 can include a longitudinal axis LAG that can be transverse and optionally perpendicular to the axes LA1 and LA2 of the other containers 20, 30 above the ground level. The container 90 can provide storage at the ground level for units above the container. The container 90 can separate the parking area under the containers and living units above into separated parking areas 110PA1 and 110PA2, which are forward and rearward of the container 90. This can provide some level of protection from or blocking or diversion of wind and the elements on either side of the container. In some applications, the ground level container 90 can provide utility connections or access. For example, the container 90 might house a common set of water heaters, furnaces, air conditioners transformers and the like for the units in the containers above that container. Other uses of the ground level container are contemplated.

Although the different elements and assemblies of the embodiments are described herein as having certain functional characteristics, each element and/or its relation to other elements can be depicted or oriented in a variety of different aesthetic configurations, which support the ornamental and aesthetic aspects of the same. Simply because a system, element or assembly of one or more of elements is described herein as having a function does not mean its orientation, layout or configuration is not purely aesthetic and ornamental in nature.

Directional terms, such as “vertical,” “horizontal,” “top,” “bottom,” “upper,” “lower,” “inner,” “inwardly,” “outer” and “outwardly,” are used to assist in describing the invention based on the orientation of the embodiments shown in the illustrations. The use of directional terms should not be interpreted to limit the invention to any specific orientation(s).

In addition, when a component, part or layer is referred to as being “joined with,” “on,” “engaged with,” “adhered to,” “secured to,” or “coupled to” another component, part or layer, it may be directly joined with, on, engaged with, adhered to, secured to, or coupled to the other component, part or layer, or any number of intervening components, parts or layers may be present. In contrast, when an element is referred to as being “directly joined with,” “directly on,” “directly engaged with,” “directly adhered to,” “directly secured to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between components, layers and parts should be interpreted in a like manner, such as “adjacent” versus “directly adjacent” and similar words. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

The above description is that of current embodiments of the invention. Various alterations and changes can be made without departing from the broader aspects of the invention as defined in the appended claims, which are to be interpreted in accordance with the principles of patent law including the doctrine of equivalents. This disclosure is presented for illustrative purposes and should not be interpreted as an exhaustive description of all embodiments of the invention or to limit the scope of the claims to the specific elements illustrated or described in connection with these embodiments. For example, and without limitation, any individual element(s) of the described invention may be replaced by alternative elements that provide substantially similar functionality or otherwise provide adequate operation. This includes, for example, presently known alternative elements, such as those that might be currently known to one skilled in the art, and alternative elements that may be developed in the future, such as those that one skilled in the art might, upon development, recognize as an alternative. Further, the disclosed embodiments include a plurality of features that are described in concert and that might cooperatively provide a collection of benefits. The present invention is not limited to only those embodiments that include all of these features or that provide all of the stated benefits, except to the extent otherwise expressly set forth in the issued claims. Any reference to claim elements in the singular, for example, using the articles “a,” “an,” “the” or “said,” is not to be construed as limiting the element to the singular. Any reference to claim elements as “at least one of X, Y and Z” is meant to include any one of X, Y or Z individually, any combination of X, Y and Z, for example, X, Y, Z; X, Y; X, Z; Y, Z, and/or any other possible combination together or alone of those elements, noting that the same is open ended and can include other elements.

Reference throughout this specification to “a current embodiment” or “an embodiment” or “alternative embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment herein. Accordingly, the appearance of the phrases “in one embodiment” or “in an embodiment” or “in an alternative embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.