Patent application title:

MODULAR CONSTRUCTION SYSTEM COMPRISING INTERCHANGEABLE PREMANUFACTURED COMPONENTS

Publication number:

US20260110168A1

Publication date:
Application number:

19/196,700

Filed date:

2025-05-01

Smart Summary: A modular construction system uses ready-made parts that can be easily swapped to build a structure. It features columns that rise from the ground, cross beams that connect to these columns, and rafters that link to the beams, creating arches. The rafters have notches in the center for added support. Panels can be attached to the arches to create walls, doors, windows, and roofs. This system allows for quick assembly on-site, saving time and money, and can support various roof designs and sizes. 🚀 TL;DR

Abstract:

A modular construction system having premanufactured, interchangeable parts to construct a structure is disclosed. The system includes columns extending from the ground, cross beams connected to the columns, and rafters connected to the cross beams. The columns, the cross beams and the rafters form arches of the structure. The system includes notched rafters at the center, providing structural support to the rafters. The system includes premanufactured panels that are configured to interchangeably connect to the arches to construct walls, doors, windows, roofs or combinations thereof of the structure. The system facilitates quick on-site installation of the arches and panels and reduces the time and cost required to construct the structure. The interchangeable parts can withstand the load and enable the construction of the structure with single or multi-level roof designs of varied sizes.

Inventors:

Applicant:

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Classification:

E04B1/185 »  CPC main

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs; Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons Connections not covered by and , e.g. connections between structural parts of different material

E04B1/18 IPC

Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part Application of a U.S. application Ser. No. 18/831,292, filed Oct. 17, 2024; all of which is incorporated herein in its entirety and referenced thereto.

BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to construction methods. More specifically, the present invention relates to a modular construction system utilizing pre-manufactured, interchangeable parts, including arches and panels, for framing roofs, supporting walls, and integrating structural elements such as doors and windows.

Description of the Prior Art

It is known that traditional construction methods require extensive on-site labor and assembly of parts that are time consuming. The traditional construction methods may result in inconsistent quality and result in structural integrity issues. In order to overcome the issues with traditional construction methods, modular construction systems are used.

An example of a construction system 5 is shown in FIG. 1, in accordance with prior art. Traditional construction system 5 includes a roof 7 placed on top of wall panels 6. Wall panels 6 typically have fixed geometry and are not customizable. Several other modular construction systems have been disclosed in the prior art. One such example is disclosed in a United States Publication No. 20090272051, entitled “Prefabricated temporary building system consisting of interchangeable panels and a plurality of connectors used to construct walls, roofs, and floors without the need of fasteners, or tools or heavy construction equipment” (“the '051 Publication”). The '051 Publication discloses a system for constructing temporary prefabricated structures for the motion picture, television and stage play industries. The invention uses interchangeable panels with an array of connecting elements for constructing walls, roofs and floors. Because of this nature of interchangeability, flexibility in the use of our panels affords last minute changes in set design to accommodate desirable camera or actor movements. The materials used are substantially strong enough to withstand transportation, use in adverse weather conditions, and storage for reuse, and are recyclable when life expectancy is reached. The system does not require site preparation prior to assembling structures. Buildings can be erected on virtually any surface and over existing vegetation without destruction. More particularly, the components used to erect the structure are easy to assemble and disassemble and do not require the use of any fasteners or tools or heavy construction equipment.

Another example is disclosed in a U.S. Pat. No. 8,869,492 , entitled “Structural building panels with interlocking seams” (“the '492 Patent”). The '492 Patent discloses a modular building having pre-fabricated panel wall components are easily assembled to form a predetermined, energy efficient structure that provides for mating alignment and securement of the modular panels with each other along their adjoining seams.

Another example is disclosed in an Australian Publication No. 2014201972, entitled “Prefabricated modules” (“the '972 Publication”). The '972 Publication discloses a module of prefabricated part comprising a plurality of arch panels having interengageable forms to allow ready engagement substantially into a self-supporting arch; and a plurality of floor panels extending at least between the opposing lower ends of the arch. The floor panels extend over a predetermined width and the plurality of arch panels extend substantially between the predetermined width in a self-supporting arch formation whereby a building section is created having a floor and a roof.

Although the above-discussed disclosures are useful, they still present problems and incomplete solutions. For example, the existing prefabricated temporary building systems require significant customization on-site, negating many of the benefits of prefabrication. Further, existing prefabricated temporary building systems struggle to effectively integrate large openings and specialized features without compromising structural stability.

Therefore, there is a need in the art to provide a modular construction system that utilizes pre-manufactured, interchangeable parts, including arches and panels, for framing roofs, supporting walls, and integrating structural elements such as doors and windows.

DEFINITION OF TERMS

The following term definitions are intended to provide clarity in the description of the invention that follows.

Arch—A structural member consisting of columns and a roof assembly that is used to help support the load bearing walls and roof of a building.

Panel—A structural wall section that can be used to accommodate doors, windows, floor joists, entryways, roof assemblies, notched rafter(s) etc. within an Arch and Panel wall.

End Cap—A wall that connects the first and/or last columns in an Arch and Panel wall. Placed at the ends of the structure, the walls may be constructed using traditional framing, panels, or a combination of both.

Roof Assembly—A roof truss that is embedded within an Arch and Panel wall. The truss must fit securely and held in place using both vertical and horizontal connecting points.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a modular construction system that utilizes pre-manufactured or prefabricated, interchangeable parts.

It is another object of the present invention to provide a modular construction system that reduces the time and cost of on-site construction.

It is another object of the present invention to provide a system having panels that integrate channels for installing wiring and plumbing.

In order to achieve one or more of the stated objects, the present invention presents a modular construction system having premanufactured, interchangeable parts to construct a structure. The system includes columns extending from the ground, cross beams connected to the columns, and rafters connected to the cross beams. The columns, the cross beams, and the rafters form arches of the structure. The system includes notched rafters at the center providing structural support to the rafters. The system includes pre-manufactured panels that are configured to interchangeably connect to the arches to construct walls, doors, windows, roofs or combinations thereof of the structure.

In one aspect, the panels are configured to have the same length as the columns. The panels include extending panels, a window section, a header, sections, a connection section, a closed plate or a combination thereof. The connection section helps to connect the panels to one of the cross beams, the columns, and the rafters. Each of the extending panels, the window section, the header, and the sections vary in size and height to accommodate different structural designs.

In one advantageous feature of the present invention, the system utilizes premanufactured, interchangeable parts (arches and panels) to frame the roof and supporting walls of a building or other structure. The arches and panels are kept in inventory until needed. The premanufactured parts can be more easily and quickly assembled on-site compared to conventional framing. The structure constructed using the premanufactured parts is stronger and more wind resistant than conventional framing.

In another advantageous feature of the present invention, the system facilitates quick on-site installation, and reduces the time and cost required to construct the structure. The interchangeable parts can withstand the load and enable the construction of the structures with single or multi-level roof designs of varied sizes.

In another advantageous feature of the present invention, the system simplifies the construction of the structure while offering stability. The system provides premanufactured parts that offer quick on-site installation, and eliminates the need for cutting or modifications of any of the parts.

The features and advantages of the invention here will become more apparent in light of the following detailed description of selected embodiments, as illustrated in the accompanying FIGURES. As will be realized, the invention disclosed is capable of modifications in various respects, all without departing from the scope of the invention. Accordingly, the drawings and the description are to be regarded as illustrative in nature.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a construction system, in accordance with prior art.

FIG. 2A and FIG. 2B illustrate a modular construction system having arches and panels, in accordance with exemplary embodiments of the present invention.

FIG. 3A and FIG. 3B illustrate structures constructed using components or parts of the system, in accordance with one embodiment of the present invention.

FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10A, FIG. 10B, FIG. 11, and FIG. 12 illustrate various configurations of panels, in accordance with one embodiment of the present invention.

FIG. 13 illustrates a cross beam having connection points, in accordance with one embodiment of the present invention.

FIG. 14 illustrates a column connected to rafters via the cross beam, in accordance with one embodiment of the present invention.

FIG. 15, FIG. 16, FIG. 17, and FIG. 18 illustrate constructional features of the cross beams, in accordance with one embodiment of the present invention.

FIG. 19, FIG. 20 and FIG. 21 illustrate a structure layout, a floor plan and a structure constructed, respectively, in accordance with one embodiment of the present invention.

FIG. 22 and FIG. 23 illustrate a structure layout, and a structure constructed, respectively, in accordance with one embodiment of the present invention.

FIG. 24, FIG. 25 and FIG. 26 illustrate a structure layout, a virtual model, and a structure constructed, respectively, in accordance with one embodiment of the present invention.

FIG. 27, FIG. 28 and FIG. 29 illustrate a structure layout, a virtual model, and a structure constructed, respectively, in accordance with one embodiment of the present invention.

FIG. 30 and FIG. 31 illustrate a virtual model, and a large structure constructed, respectively, in accordance with one embodiment of the present invention.

FIG. 32 illustrates a structure having a staircase constructed using the parts of the system, in accordance with one embodiment of the present invention.

FIG. 33 illustrates various arch shapes constructed over columns of varied length, in accordance with one embodiment of the present invention.

FIG. 34 illustrates columns and panels that can be designed for constructing a structure, in accordance with various embodiments of the present invention.

FIG. 35 illustrates the use of roof assemblies inserted into a series of panels.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description set forth below in connection with the appended drawings is intended as a description of exemplary embodiments in which the presently disclosed invention may be practiced. The term “exemplary” used throughout this description means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other embodiments. The detailed description includes specific details for providing a thorough understanding of the presently disclosed modular construction system. However, it will be apparent to those skilled in the art that the presently disclosed invention may be practiced without these specific details. In some instances, well-known structures and devices are shown in functional or conceptual diagram form in order to avoid obscuring the concepts of the presently disclosed modular construction system.

In the present specification, an embodiment showing a singular component should not be considered limiting. Rather, the invention preferably encompasses other embodiments including a plurality of the same component, and vice-versa, unless explicitly stated otherwise herein. Moreover, the applicant does not intend for any term in the specification to be ascribed an uncommon or special meaning unless explicitly set forth as such. Further, the present invention encompasses present and future known equivalents to the known components referred to herein by way of illustration.

Although the present invention provides a description of a modular construction system, it is to be further understood that numerous changes may arise in the details of the embodiments of the modular construction system. It is contemplated that all such changes and additional embodiments are within the spirit and true scope of this disclosure.

The following detailed description is merely exemplary in nature and is not intended to limit the described embodiments or the application and uses of the described embodiments. All of the implementations described below are exemplary implementations provided to enable persons skilled in the art to make or use the embodiments of the disclosure and are not intended to limit the scope of the disclosure.

Various features and embodiments of a modular construction system are explained in conjunction with the description of FIGUREs (FIGS.) 2A-34.

FIG. 2A shows a modular construction system 10, in accordance with one exemplary embodiment of the present invention. For ease of reference, modular construction system 10 is referred as system 10 hereinafter. System 10 includes premanufactured interchangeable parts such as arches and panels to construct a building or other structure. The arches are used to frame roofs and supporting walls. In other words, the arches are used to construct support walls/frames that, in turn, helps to mount an arch/roof of a structure. The panels are used to integrate structural elements such as doors and windows to the arches. In other words, the panels are used to construct interior structural elements such as walls, windows, doors, interiors of the structure, etc. The arches and panels are made of wood, hard plastic, metal or any other suitable material. The arches and panels are designed to withstand the weight of the structure and resist extreme weather conditions.

System 10 includes columns 12. Columns 12 are positioned in a vertical configuration and provide required support for the structure. Columns 12 extend from the ground and act as base frames for supporting the building. System 10 includes blocks 14 for connecting cross beams 16. As can be seen from FIG. 2A and FIG. 2B, blocks 14 and/or cross beams 16 can be connected to columns 12 using connectors 18. Connectors 18 may include nuts and washers. Further, system 10 includes rafters 20 configured to form an arch at the top. System 10 further includes a cross member 22 positioned at the top of rafters 20. Rafters 20 position at the ends of system 20 i.e., above columns 12. System 10 further includes notched rafters 24 positioned at the center, connecting columns 12 and cross member 22. Notched rafters 24 provide structural support to the roof and distribute the load. Optionally, notched rafters 24 connect to panels P. System 20 includes an end rafter 26. End rafter 26 positions adjacent to rafters 20. In the present embodiment, columns 12, blocks 14, cross beams 16, connectors 18, rafters 20, cross member 22, notched rafters 24 and end rafter 24 become components of arches that are selectively used to construct a roof/arch, while panels P are interchangeably used for walls, windows, doors, interiors of the structure, etc.

In the present invention, the components of system 10 are designed to be premanufactured to ensure consistent quality and precise dimensions. These premanufactured interchangeable parts allow quick on-site installation and significantly reduces the time and cost required to construct the structure. Further, the interchangeable parts allow for customization of the design as per need. Furthermore, the interchangeable parts offer flexibility in load-bearing capacities, enabling system 10 to construct different building types such as a single-floor building with roof, a multi-story building with a roof, a bunkhouse, large house, a multi-family house, etc. depending on the need.

FIG. 2B shows system 10, in accordance with another embodiment of the present invention. System 10 features a pocket 15 formed within column 12. FIG. 2A and FIG. 2B differ from the prior art in FIG. 1, in that rafters 20 in FIGS. 2A and 2B are recessed into pockets 15 of columns 12 to secure a roof assembly within columns 12 (walls). Furthermore, notched rafters 24 depicted in FIG. 2A and FIG. 2B are not present in prior art FIG. 1. A person skilled in the art understands that FIG. 2A and FIG. 2B are provided to illustrate exemplary implementations of modular construction system 10. Any possible modifications, including additions or deletions of the components described herein, fall within the scope of the present invention.

FIG. 3A shows an exemplary structure 100 constructed using components or parts of system 10 explained above. It should be understood that structure 100 is shown to present construction of arches using the components of system 10. Structure 100 includes columns 12 extending from both sides. Structure 100 includes cross beam 16 connecting both columns 12. Further, rafters 20 extend at an angle forming a roof with support from notched rafter 24. Further, FIG. 3B shows another exemplary structure 200 constructed using components of system 10. Here, structure 200 includes three columns 12 extending upwards from the ground. One of three columns 12 is shorter in length enabling construction of a small space/room adjacent to a larger room. Structure 200 includes cross beams 16 connecting columns 12 at varied heights depending on the need. In the present example, structure 200 has two roofs, each positioned at a varied height. Each roof has rafters 20 extending at an angle forming a roof. In some scenarios, notched rafter 24 is used for supporting the rafters 20. The above embodiments are presented to illustrate the possibility of constructing single and multi-level roof designs/arches using components of system 10.

Now referring to FIG. 4, FIG. 5, FIG. 6, FIG. 7, FIG. 8, FIG. 9, FIG. 10A, FIG. 10B, FIG. 11, and FIG. 12, panels P used to construct walls, doors or windows for the structure are explained. It should be understood that panels P may come in different shapes or sizes depending on the need. In one example, panels P include, but not limited to, a first panel A, a second panel B, a third panel C, a fourth panel D, a fifth panel E, a sixth panel F, a seventh panel G, an eighth panel H, and a ninth panel I.

Each of first panel A, second panel B, third panel C, fourth panel D, fifth panel E, sixth panel F, seventh panel G, eighth panel H, and ninth panel I may be constructed from pieces of lumber and may be assembled using fasteners, adhesive, or any other known connecting mechanisms.

FIG. 4 shows first panel A, in accordance with one exemplary embodiment of the present invention. First panel A includes extending panels 302 separated by a midsection 304. In one example, midsection 304 may include an empty space or a solid panel created between adjoining extending panels 302. Further, first panel A may include a connecting section 306 configured to connect first panel A to other panels or parts (e.g., notched rafters 24) of system 10 during the construction of the structure.

FIG. 5 shows second panel B, in accordance with one exemplary embodiment of the present invention. Second panel B includes first sections 308 separated by a midsection 310. Second panel B may include a window section 312 configured to receive window panels. Here, window section 312 is positioned at an appropriate length and allows placing window panels as part of a section of a wall of the structure. Second panel B may include a header 314 positioned above window section 312. Second panel B may include second sections 316 positioned above header 314. Second sections 316 may feature a connecting section 318 configured to connect second panel B to other panels or parts of system 10 during the construction of the structure.

FIG. 6 shows third panel C, in accordance with one exemplary embodiment of the present invention. Third panel C includes first sections 320, a midsection 322, a window section 324, a header 326, second sections 328, and a connecting section 330. Third panel C appears the same as second panel B, but differs in the shape of sections and their lengths/heights (e.g., shorter and wider window section 324 than window section 312). FIG. 7 shows fourth panel D, in accordance with one exemplary embodiment of the present invention. Fourth panel D includes first sections 332, a midsection 334, a window section 336, a header 338, second sections 340, and a connecting section 342. Fourth panel D appears the same as second panel B, but differs in the shape of sections and their lengths/heights (e.g., longer window section 336 and longer second sections 340).

FIG. 8 shows fifth panel E, in accordance with one exemplary embodiment of the present invention. Fifth panel E includes extending panels 344 separated by a midsection 346. Further, fifth panel E may include a closed plate 348 at the top. Fifth panel E differs from first panel A in that fifth panel E has closed plate 348 at the top instead of connecting section 306 in first panel A. FIG. 9 shows sixth panel F, in accordance with one exemplary embodiment of the present invention. Sixth panel F includes first sections 350, a midsection 352, a window section 354, a header 356, second sections 358, and a closed plate 360. Sixth panel F differs from second panel B in that sixth panel F has closed plate 360 at the top instead of connecting section 318 in second panel B.

FIG. 10A and FIG. 10B show a front view and a top view, respectively of seventh panel G. Seventh panel G includes a base 362 presenting a floor 364 and a joist 366. Floor 364 and joist 366 allow the addition of flooring elements to the structure. FIG. 11 shows exemplary eighth panel H. Eighth panel H includes a base 368, first sections 370 separated by a connecting section 372. FIG. 12 shows exemplary ninth panel I. Ninth panel I includes a base 374, first sections 376 separated by a connecting section 378. Ninth panel I is the same as eighth panel H, but differs in height/length of first sections 376.

From the above, a person skilled in the art understands that the variety of panels P offers flexible configurations for constructing walls, doors, and windows of the structure. In some implementations, columns 12 and/or panels P may be configured to integrate channels to install wiring and plumbing. This helps to reduce on-site labor and minimize waste. The varied panels P enable creation of unique building facades and interior layouts.

FIG. 13 shows a top view of cross beam 16 having top connection points 380 and side connection points 381 to connect to columns 12 or panels P. FIG. 14 shows column 12 connected to rafters 20 via cross beam 16. Here, rafters 20 connect to column 12 and cross beam 16 via top connection points 380. Side connection points 381 might be used to connect panel P e.g., second panel B. Further, bottom connection points 382 may be used to connect second panel B to column 12, and foundation connection points 383 may be used to connect second panel B to a foundation i.e., the ground. The multiple connection points allow for the connection of various structural elements such as column 12, cross beam 16, rafters 20, panels P, etc. In one example, panels P and arches (i.e., columns 12, blocks 14, cross beams 16, connectors 18, rafters 20, cross member 22, notched rafters 24) are assembled above and below a window area using the connection points.

FIG. 15 through FIG. 18 show constructional features of cross beams, in accordance with various exemplary embodiments of the present invention. FIG. 15 shows a cross beam 400 having two layers 402 of lumber of 2×6 inches sandwiched between two outer layers 404 of plywood of ¾ inches. FIG. 16 shows a cross beam 410 having two layers 412 of lumber of 2×8 inches sandwiched between two outer layers 414 of plywood of ¾ inches. FIG. 17 shows a cross beam 420 having a single layer 422 of lumber of 1¾×9½ inches Laminated Veneer Lumber (LVL) sandwiched between two outer layers 424 of plywood of ⅝ inches. FIG. 18 shows a cross beam 430 of 3×9½ inches Laminated Veneer Lumber (LVL). The type and thickness of the cross beams may be selected based on the structural loads and design requirements.

Now referring to FIG. 19, FIG. 20 and FIG. 21, construction of a structure e.g., a bunkhouse using system 10 is explained. At first, an architect (not shown) creates a structure layout 500 (FIG. 19) and draws a floor plan 502 (FIG. 20). Here, structure layout 500 includes a list of premanufactured arches and panels that can be selected from a software library. After selection, arches and panels are connected to construct a structure 510, as shown FIG. 21. In some implementations, structure 510 includes end caps 512 at the bottom similar to conventional framing. It should be understood that ends of the structure or “end caps” are framed using conventional methods. Further, at the sides, a channel 514 is provided adjacent to column 12 to allow a space for a chimney hose (not shown) to be placed. Optionally, the channel is provided to draw/route wires or pipes required for wiring and plumbing. Panels P or columns 12 are configured to integrate other features of the structure such as chimney hoses, pipes and minimize the need for on-site modifications.

FIG. 22 shows an exemplary structure layout 600 for constructing a structure 602 using arches and panels. Structure 602 features first panel A, panels P, cross beams 16, rafters 20, and an end cap Q constructed using traditional framing methods, as shown in FIG. 23. It should be understood that structure 602 is presented merely to illustrate how arches and panels P can be interchangeably used for constructing a building or structure.

Now referring to FIG. 24, FIG. 25 and FIG. 26, a large structure/house constructed using system 10 is shown, in accordance with one exemplary embodiment of the present invention. First, an architect (not shown) creates a structure layout 700 (FIG. 24). Here, structure layout 700 includes a list of premanufactured arches and panels P that can be selected from a software library to create a virtual model 702, as shown in FIG. 25. After creating the virtual model 702, arches and panels P are interchangeably connected to construct a structure 704, as shown FIG. 26. Structure 704 may include an end cap 706 at the bottom similar to conventional framing. In some implementations, structure 704 includes panels P arranged in a customized manner based on the size of structure 704 and the number of windows or doors needed. Multiple panels are arranged in such a manner that the stacked panels have the same length as the columns, as can be seen in FIG. 26, for example. This ensures multiple panels form the entire interior wall length and match the height of the columns of the structure. The use of a virtual model 702 allows for visualization of structure design before starting construction. When needed, the arches and panels P are arranged in different manners based on size and functional requirements. The prefabrication of components and the use of virtual models helps to reduce errors during construction and saves cost.

In one implementation, structure 704 is constructed in a way such that all arch and panel walls begin and end with an arch. The length of all arch and panel walls might be divisible by four feet plus nine inches i.e., 36 feet 9 inches, for example. An exemplary formula for computing the length of an arch and panel wall is as follows:

WL = CW + ( NP × ( PW + CW ) )

    • WL—Length of arch and panel wall
    • CW—Column width
    • NP—Number of panels
    • PW—Panel width

A connecting section (306, 318, 330, 342, 372, 378 in previous FIGURES) can also be modified to receive a notched rafter (24 in FIGS. 3A and 3B) or roof assembly of up to 4 inches in width or greater. To compute the width of the roof assembly and/or the width of the connecting section in the current example, the formula WRA=CW−3 would be used, where WRA is the width of the roof assembly.

The height of the column must be equal to the height of the panels. For structures with two or more stories, the height of the column must be equal to the height of all panels plus floor joists, if possible. For sliding doors, prefabricated doors greater than 36 inches wide, large picture windows and most fireplaces must be located in end caps 706 to allow for adequate space.

Now referring to FIG. 27, FIG. 28 and FIG. 29, a large structure/house constructed using system 10 is shown, in accordance with one exemplary embodiment of the present invention. At first, an architect (not shown) creates a structure layout 800 (FIG. 27). Here, structure layout 800 includes a list of premanufactured arches and panels that can be selected from a software library to create a virtual model 802, as shown in FIG. 28. After creating the virtual model 802, arches and panels are connected to construct a structure 804, as shown FIG. 29.

Now referring to FIG. 30 and FIG. 31, a large structure/house constructed using system 10 is shown, in accordance with one exemplary embodiment of the present invention. First, an architect (not shown) creates a layout 900 (FIG. 30) showcasing arch and panel alignment. After creating layout 900, arches and panels are connected to construct a structure 902, as shown FIG. 31.

FIG. 32 shows a structure 1000 having a staircase 1002, in accordance with one exemplary embodiment of the present invention. Columns 12 are positioned at the sides and center, and panels P are connected based on need. Here, wooden staircase 1002 might be firmly supported by the center column 12. Structure 1000 presents a unique way in which the roof assembly is recessed into wall/columns 12, allowing for both vertical AND horizontal connections for the roof. In traditional framing, only a vertical connection can be made, usually with ties that are used to connect the roof to the walls. The horizontal connection provides much greater support during very high wind. FIG. 33 illustrates various arches 1100 constructed over columns of varied length, in accordance with various embodiments of the present invention. FIG. 34 illustrates a system 1100 having various columns 12 and panels P that can be designed for constructing a structure, in accordance with various embodiments of the present invention.

FIG. 35 illustrates the use of roof assemblies inserted into a series of panels P.

The presently disclosed modular construction system provides several advantages over the prior art. The system utilizes premanufactured, interchangeable parts (arches and panels) to frame the roof and supporting walls of a building or other structure. The premanufactured parts reduce material waste and minimizes the need for skilled labor to assemble the parts, which may lead to substantial cost savings. Further, the premanufactured parts can be used to construct structures of various shapes and sizes without requiring specialized materials or techniques. The interchangeable parts can be customized at the construction site depending on the need.

A person skilled in the art appreciates that the modular construction system can come in a variety of shapes and sizes depending on the need and comfort of the user. Further, many changes in the design and placement of components may take place without deviating from the scope of the presently disclosed modular construction system.

In the above description, numerous specific details are set forth such as examples of some embodiments, specific components, devices, methods, in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to a person of ordinary skill in the art that these specific details need not be employed, and should not be construed to limit the scope of the invention.

In the development of any actual implementation, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system-related and business-related constraints. Such a development effort might be complex and time-consuming, but may nevertheless be a routine undertaking of design, fabrication, and manufacture for those of ordinary skill. Hence as various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

The foregoing description of embodiments is provided to enable any person skilled in the art to make and use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the novel principles and invention disclosed herein may be applied to other embodiments without the use of the innovative faculty. It is contemplated that additional embodiments are within the spirit and true scope of the disclosed invention.

Claims

What is claimed is:

1. A modular construction system, comprising:

a plurality of columns positioned in a vertical configuration;

a plurality of cross beams connected to said columns;

a plurality of rafters connected to said cross beams, wherein said columns, said cross beams and said rafters form arches of a structure; and

a plurality of premanufactured panels, wherein said panels are configured to interchangeably connect to said arches to construct walls, doors, windows, roof or combinations thereof of said structure.

2. The system of claim 1, wherein a panel of said panels or a column of said columns comprises channels to install wiring and plumbing.

3. The system of claim 1, further comprises connection points configured to facilitate connection between said cross beams, said columns, said rafters, and said panels.

4. The system of claim 1, wherein said columns, said cross beams, and said rafters are arranged to begin and end with a shape of an arch.

5. The system of claim 1, wherein said panels are configured to have same length as said columns.

6. The system of claim 1, wherein said panels comprise extending panels, a window section, a header, sections, a connection section, a closed plate or a combination thereof.

7. The system of claim 6, wherein each of said extending panels, said window section, said header, and said sections vary in size and height.

8. The system of claim 6, wherein said connection section facilitates connecting said panels to one of said cross beams, said columns, and said rafters.

9. The system of claim 1, further comprises notched rafters configured to provide center support to said rafters.

10. A modular construction system, comprising:

a plurality of columns positioned in a vertical configuration;

a plurality of cross beams connected to said columns;

a plurality of rafters connected to said cross beams;

notched rafters configured to provide center support to said rafters, wherein said columns, said cross beams, said rafters and said notched rafters form arches of a structure;

a plurality of premanufactured panels; and

connection points facilitating connection between said cross beams, said columns, said rafters, and said panels,

wherein said panels are configured to interchangeably connect to said arches to construct walls, doors, windows, roof or combinations thereof of said structure.

11. The system of claim 10, wherein a panel of said panels or a column of said columns comprises channels to install wiring and plumbing.

12. The system of claim 10, wherein said columns, said cross beams, and said rafters are arranged to begin and end with a shape of an arch.

13. The system of claim 10, wherein said panels are configured to have same length as said columns.

14. The system of claim 10, wherein said panels comprise extending panels, a window section, a header, sections, a connection section, a closed plate or a combination thereof.

15. The system of claim 14, wherein each of said extending panels, said window section, said header, and said sections vary in size and height.

16. The system of claim 13, wherein said connection section facilitates connecting said panels to one of said cross beams, said columns, and said rafters.

17. A method of providing a modular construction system, said method comprising the steps of:

providing a plurality of columns positioned in a vertical configuration;

providing a plurality of cross beams connected to said columns;

providing a plurality of rafters connected to said cross beams, said columns, said cross beams and said rafters forming arches of a structure;

providing a plurality of premanufactured panels; and

interchangeably connecting said panels to said arches to construct walls, doors, windows, roof or combinations thereof of said structure.

18. The method of claim 17, further comprising providing said panels to have same length as said columns.

19. The method of claim 17, further comprising providing extending panels, a window section, a header, sections, a connection section, a closed plate or a combination thereof at each panel of said panels.

20. The method of claim 17, further comprising providing connection points facilitating connection between said cross beams, said columns, said rafters, and said panels.