MODULAR BUILDING

Description

FIELD OF THE INVENTION

The present invention is in the field of modular building structure construction.

SUMMARY OF THE INVENTION

A modular building has a kitchen bath module, a sidewall module, and a horizontal panel module. A floor assembly can be part of the sidewall module or the horizontal panel module. The kitchen bath module has a kitchen facing a first side and a laundry room, a shower room, and the other room facing a second side away from the first side. The sidewall module includes wall panels, window panels and corner connectors that expand and attach to form a wall system. Some of the wall panels can unfold for faster construction. The horizontal panel module includes roof panels.

The floor assembly fits over a floor frame. The floor frame includes a bedroom area and a living room area connected by a hallway in a U shaped floorplan. The first side faces the living room area the second side faces the bedroom area. The floor assembly is U-shaped and has a floor assembly U-shaped notch. The floor assembly U-shaped notch exposes the bath kitchen footprint. The kitchen bath module is installed to the bath kitchen footprint with the floor assembly mounted around the bath kitchen module.

The sidewall module has a width that is within 10% of the bath kitchen module width. The bath kitchen module further includes a ceiling hollow space. The ceiling hollow space receives a first condenser unit and a second condenser unit.

The first condenser unit faces the bedroom. The second condenser unit faces the kitchen. The first condenser unit receives a first condenser line, and the second condenser unit receives a second condenser line. The second side has a washer dryer, a bath sink, a toilet, and a shower such as by configuring a washer dryer next to a bath sink which is next to a toilet which is next to a shower.

The roof trusses pass across a width of the building. Roof panels are mounted to the roof trusses. The roof panels extend along a width of the building. A water line in the kitchen bath module provides water to a kitchen sink, a washer, a toilet, and a shower. The bath kitchen module fits in a container first section during shipping. The sidewall module fits in a container second section during shipping. The horizontal panel module fits in a container third section during shipping.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing loading of a bath kitchen module into a shipping container.

FIG. 2 is a diagram showing loading of a sidewall module into a shipping container.

FIG. 3 is a diagram showing loading of a horizontal panel module into a shipping container.

FIG. 4 is a diagram showing a floor assembly and floor construction.

FIG. 5 is a diagram showing installation of the bath kitchen module onto the floor frame.

FIG. 6 is an exploded view diagram showing installation of wall panels.

FIG. 7 is a cross-section diagram showing foundation and roof details.

FIG. 8 is an exploded view diagram showing installation of the roof.

FIG. 9 is an isometric view of the building without the roof.

FIG. 10 is a cross-section of the building showing the layout of the building.

The following call out list of elements can be a useful guide in referencing the element numbers of the drawings.

• • 20 Bath Kitchen Module
  • 20 Kitchen Bath Module
  • 21 Sidewall Module
  • 22 Horizontal Panel Module
  • 23 Wall Folding Joints
  • 24 Wall Connection Joints
  • 25 Utility Closet
  • 26 Laundry Room
  • 27 Kitchen
  • 28 Shower Room
  • 29 Toilet Room
  • 30 Shipping Container
  • 31 Container First Section
  • 32 Container Second Section
  • 33 Container Third Section
  • 34 Truck
  • 35 Container Heigh
  • 36 Container Width
  • 37 Container Length
  • 38 Sidewall Module Length
  • 39 Bath Kitchen Module Length
  • 40 Floor
  • 41 Floor Frame
  • 42 Floor Frame Long Exterior Member
  • 43 Floor Frame Periphery
  • 44 First Foldout Floor Section
  • 45 Second Foldout Floor Section
  • 46 Hallway Section
  • 47 Bath Kitchen Foot Print
  • 48 Bedroom Area
  • 49 Living Room Area
  • 50 Wall Panels
  • 50 Wall Panel
  • 51 Corner Connector
  • 52 Window Panel
  • 53 Sliding Door Panel
  • 54 Door Panel
  • 55 Small Window Panel
  • 80 Roof
  • 81 First Roof Panel
  • 82 Second Roof Panel
  • 83 Third Roof Panel
  • 84 Fourth Roof Panel
  • 85 Fifth Roof Panel
  • 86 Sixth Roof Panel
  • 88 Roof Drip Edge
  • 89 Roof Front Parapet
  • 91 First Condenser Unit
  • 92 Second Condenser Unit
  • 93 First Condenser Unit
  • 95 Ceiling Hollow Space
  • 96 Hallway
  • 97 Bathroom Door
  • 98 Bath Kitchen Module Frame
  • 101 Kitchen Sink
  • 102 Range
  • 103 Water Heater
  • 104 Air Conditioner Compressor
  • 105 Shower
  • 106 Toilet
  • 107 Bath Sink
  • 108 Washer Dryer
  • 109 Water Line
  • 111 Dryer
  • 112 Washer
  • 113 Laundry Closet
  • 114 First Air Vent
  • 115 Roof Trass
  • 116 Shade Canopy
  • 117 Porch
  • 118 First Anchor Foundation
  • 119 Steps
  • 119 Second Anchor Foundation
  • 120 Middle Anchor Foundation
  • 121 Wall Insulation
  • 122 Kitchen Bath Module Floor
  • 123 Floor Assembly
  • 124 Kitchen Bath Module Opening
  • 125 Floor Assembly U Shaped Notch
  • 130 Trass Connections
  • 131 First Trass Connection
  • 132 Second Trass Connection
  • 133 Third Trass Connection
  • 134 Fourth Trass Connection
  • 135 Fifth Trass Connection
  • 136 Sixth Trass Connection
  • 137 Seventh Trass Connection
  • 201 First Side
  • 202 Second Side
  • 203 Wall System

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

As seen in FIG. 1, a shipping container 30 has a long hollow container area that can be segmented into a first, second and third section. For example a container first section 31 can retain a bath kitchen module 20. The container second section 32 and a container third section 33 can retain other modules. Thus, an entire building kit can be stowed into a container 30 on a truck 34. The kitchen module 20 has a laundry room 26, a toilet room 29 and a shower room 28 on a first side. The kitchen module 20 has a utility closet 25 facing an exterior part of the building and has a kitchen 27 on a second side facing away from the first side. All of the plumbing and most of the electrical can be concentrated in the bath kitchen module 20 which can be formed as a unit bath kitchen. The bath kitchen module preferably has a frame for hoisting with a crane. The bath kitchen module 20 has a first side 201 with the kitchen facing the first side 201 and the second side 202 includes the laundry room, toilet room and shower room facing another side.

As seen in FIG. 2, the container 30 has a container height 35, a container width 36, and a container length 37. The sidewall module 21 is mounted after the bath kitchen module 20. The sidewall module 21 has a sidewall module length 38 that is similar to the bath kitchen module length 39. The sidewall module 21 may further include wall folding joints 23 and wall connection joints 24. The sidewall module may have wall panels that fold out to form long walls and may have wall connection joints that connect between different wall panels.

As seen in FIG. 3, the horizontal panel module 22 can contain roof panels and trusses that are for supporting the roof. Thus, all three main portions of the building can be shipped a single shipping container 30.

As seen in FIG. 4, the floor 40 starts with a the floor frame 41 which is built first with the floor assembly 123 fitting over it afterwards. The horizontal panel module 22 may also include the floor assembly 123 and the floor frame 41. The floor assembly 123 preferably includes a first foldout floor section 44, a hallway section 46, and a second foldout floor section 45. The floor frame 41 has a floor frame long exterior member 42 that defines a floor frame periphery 43. The floor 40 has a kitchen bath module opening 124 so that the floor assembly U shaped notch 125 goes around the kitchen bath module opening 124. The U-shaped structure created bedroom area 48, a hallway portion, and a living room area 49. The bath kitchen footprint 47 serves as a divider between the bedroom area 48 and the living room area 49.

As seen in FIG. 5, the bath kitchen module 20 has been placed onto the bath kitchen footprint 47, preferably by crane. The plumbing for the bath kitchen module 20 is preinstalled so that the plumbing hookups can be connected on the outside immediately after the bath kitchen module 20 is installed. The bath kitchen module 20 is between the bedroom area 48 and the living room area 49. The bath kitchen module 20 has its own floor and is not part of the floor 40.

As seen in FIG. 6, the individual wall panels 50 can include a corner connector 51 that connects wall panels 50, and a door panel 54. Window panels 52, sliding door panels 53, and small window panels 55 can be modularly attached and configured such as before the item is ordered. The various panels attached together to form a wall system. The wall panels do not have a window. The window panels are the same height as the wall panels and connect to the wall panels. The window panels have preinstalled windows that are installed into a wall.

As seen in FIG. 7, the building anchors include a first anchor foundation 118, a second anchor foundation 119, and a middle anchor foundation 120 which support the bath kitchen module 20. The bath kitchen module 20 has an additional anchor foundation due to its heavier weight. The bath kitchen module 20 has a washer dryer 108, a bath sink 107, a toilet 106 and a shower 105. The washer dryer 108 includes a dryer 111 and a washer 112. The ceiling hollow space 95 is formed at an upper portion of the bath kitchen module 20. A first air vent 114 can be formed between the roof 80 and the rooms of the kitchen bath module 20.

The wall panels 50 have wall insulation 121 and may also have small windows such as in the small window panel 55. The kitchen bath module floor 122 matches the hallway floor height. The roof 80 has a roof drip edge 88 angling away from the shade canopy 116. The roof truss 115 spans between the wall panel 50 and the small window panel 55.

The first air vent 114 supplies air to the bedroom and a second air vent supplies air to the kitchen and living room. The first air vent and the second air vent are preferably formed in the bath kitchen module 20. The shade canopy 116, the porch 117 and the steps 119 of the porch can be installed after the structure is completed.

As seen in FIG. 8, the roof 80 is formed of multiple panels which preferably include a first roof panel 81 mounted inside a roof front parapet 89 and mounted next to a second roof panel 82. The second roof panel 82 is mounted next to the third roof panel 83, which is mounted next to the fourth roof panel 84. The fourth roof panel 84 is mounted next to the fifth roof panel 85 which is mounted next to the sixth roof panel 86. The trusses may include mounting to the wall at a first truss connection 131, a second truss connection 132, a third truss connection 133, a fourth truss connection 144, a fifth truss connection 155, a a six truss connection 166, and a seventh truss connection 137. The truss connections are preferably mounted between the panels such that each truss is supporting a pair of panels.

As seen in FIG. 9, the air-conditioning system can be integrated into the bath kitchen module 20. The air-conditioning system may have a compressor mounted in the utility closet and a first condenser unit 91 fed by a first condenser line 93 that services the bedroom area. A second condenser unit 92 fed by a second condenser line 94 services the kitchen and living room area. The ceiling hollow space 95 is formed as a shelf that can receive the first condenser unit 91 and the second condenser unit 92 along with their respective condenser unit lines. The bath kitchen module frame 98 can have mounting clips or other connectors for tool free installation of the air conditioner condenser units. The air conditioner condenser units are preferably a part of the split air heat pump system which is integrated to the bath kitchen module 20 in the ceiling hollow space 95 of the bath kitchen module 20. The hallway 96 leads to the bathroom door 97 which can be a sliding door such as a pocket door or barn door.

As seen in FIG. 10, the utility closet or utility cabinet can have a water heater 103 and air conditioner compressor 104 pre-mounted with the lines and plumbing preinstalled so that plumbing and electrical work is not required after the bath kitchen module 20 is installed. The water heater 103 can provide hot water for the shower 105, the kitchen sink 101, the toilet 106, the sink 107 and the washer dryer 108. The range 102 can be gas or electric and the water line 109 within the house is minimized such that it can be less than 20 feet long. In this way, the plumbing and electrical work is minimized for the kitchen and bath allowing rapid low-cost construction while maintaining factory quality.

The roof truss can be integrated into the roof panel. The truss connection can be made to the roof panel between the wall and the roof truss of the roof panel. The roof front parapet is assembled together as individual panels and the six individual roof panels plus the side panels can be combined to form a single large roof. The floor assembly can be a part of the sidewall module or a part of the horizontal panel module. Preferably, the floor and wall modules as well as the roof modules are separate modules and are mixed with each other. The wall folding method is an option. End abutments are currently preferred.

A 3D kitchen-bath integrated module improves construction. In the modular building, a kitchen-bath module, also referred to as a kitchen-bath integrated module, may integrate the kitchen and bathroom into a single, independent space. This module is further configured to integrate the primary utility systems for the entire structure, including water, electrical, and air conditioning (HVAC) systems, thereby functioning as the central utility core or “power center” for the building. The kitchen-bath integrated module may comprise a kitchen module, a bathroom module, an air conditioning system, an integrated utility wall for plumbing and electrical lines (pipe wall), and an equipment room. The kitchen module may be disposed on one side of the integrated module, including components such as a sink, a stovetop, and storage cabinets. The bathroom module may be disposed on an opposite side, and can include a laundry room, a toilet room, and a shower room. The plumbing and electrical lines for both the kitchen and bathroom modules are centralized within the intermediate utility wall. Additionally, the kitchen-bath integrated module may feature an equipment room or utility closet facing the exterior of the building. A lower space in this room can be configured to house a hot water pump or water heater supplying the entire building. The top portion may form an equipment platform, suitable for mounting an outdoor air conditioning unit (condenser) or other external equipment.

A 2D panel modules and standardization system improves construction. The modular building further utilizes 2D plate-like or panel modules. These modules are standardized and connect to extended-size expansion modules using a unified bolt connection method, permit flexible and variable assembly configurations and enable rapid on-site installation. The 2D panel modules generally comprise wall system modules and roof system modules. Dimensional module standardization improves construction. The wall system modules preferably include interior and exterior wall modules, window modules, interior door modules, corner connectors, and interior/exterior decorative panels. While maintaining a consistent wall height (e.g., 9 feet), a standard modular width (e.g., 4 feet) is used for the majority of the building's wall panels. To achieve functional diversity, extended-size modules (e.g., 6 feet or 8 feet wide) are also used as expansion modules. These expansion modules, such as window and door modules, preferably have dimensions that are multiples of the standard module width to facilitate easy combination and splicing. The roof system modules can include roof modules, ceiling modules, and roofing panels. The roof modules are preferably long enough to span the width of the building. The width of the roof modules may adopt a 1.5× modulus of the wall module width to adapt to the modular construction. This sizing enhances the overall structural stability and improves wind and seismic resistance. Connection standardization improves wall connection. Wall modules are joined to one another using bolts. At corners, unified corner connectors are used to standardize the junction form of the wall panels so that all wall panels connect to each other only via their side edges. All panels are independent wall panels, and panel-to-panel connections are made exclusively by bolts so that preferable no foldable panels are used in this embodiment. The roof modules are prefabricated to integrate the structural trusses, structural panels, waterproofing materials, and insulation materials. All 2D modules preferably use bolt connections, obviating the need for complex tools, which simplifies the construction difficulty and improves installation efficiency.

The modular building system is designed such that a single shipping container can transport one minimum unit modular building. A minimum unit, such as one comprising one bedroom, one living room, and one bathroom, is optimized so all above-ground building modules and components fit within a standard 40-foot shipping container. The container may be loaded in three sections: a first section for the integrated 3D kitchen-bath module, a second section for all wall modules, and a third section for all roof system modules, floor modules, and any other necessary non-standard components.