Modular Housing System and Methods for Using the Same

This application is a continuation of U.S. patent application Ser. No. 16/921,612, filed Jul. 6, 2020, which is a continuation of U.S. patent application Ser. No. 16/043,671, filed Jul. 24, 2018, which claims the benefit of U.S. Provisional Patent Application No. 62/536,825, filed Jul. 25, 2017, each of which is hereby incorporated by reference herein in its entirety.

The disclosed subject matter relates to a modular housing system and methods for using the same.

While populations in urban areas are generally increasing, there is a continued lack of affordable, quality housing, such as multiple unit dwellings. This lack of affordable and quality housing occurred because of a number of reasons. For example, developable land for constructing such multiple unit dwellings is in decreasing supply and, in many instances, owners of such developable land tend to demand high prices for forgoing the future and often unforeseeable development potential. In another example, aside from the fact that approaches for constructing these multiple unit dwellings have generally not evolved, these multiple unit dwellings, which include a number of housing units, are expensive to construct. Moreover, constructing such housing while conforming to local building codes can cause significant delays, thereby further increasing the cost and complexity of a multiple unit housing project.

In continuing with this example, upon constructing such housing, these multiple unit buildings are far too permanent and are difficult to renovate and/or modify based on the current needs of those living in the multiple unit buildings.

Accordingly, it is desirable to provide new modular housing systems and methods for using the same.

A modular housing system and methods for using the same are provided.

In accordance with some embodiments of the disclosed subject matter, a modular housing system is provided, the modular housing system comprising: a plurality of prefabricated system modules that are vertically aligned with each other and joined with a first fastener assembly to form a central system module having a front perimeter portion and a rear perimeter portion; a mechanical, electrical, and plumbing (MEP) module that is connected to the rear perimeter portion of the central system module; an elevator module that is connected to the front perimeter portion of the central system module; and a plurality of prefabricated housing modules that are connected to the central system module, the MEP module, and the elevator module, wherein each of the plurality of prefabricated housing modules is vertically aligned with each other to form a stacked housing unit and joined to the central system module and the elevator module with a second fastener assembly.

In some embodiments, at least one of the MEP module and the elevator module is incorporated into the central system module.

In some embodiments, the MEP module includes an inner perimeter surface and an outer perimeter surface, where the inner perimeter surface of the MEP module is connected to the rear perimeter portion of the central system module and wherein the outer perimeter surface of the MEP module is connected to an egress stair module.

In some embodiments, the MEP module includes a plurality of utilities connectors that are configured to connect one of a plurality of utilities between a utilities source and at least one of the plurality of prefabricated housing modules, the plurality of prefabricated system modules, and the elevator module.

In some embodiments, the central system module has a left perimeter portion and a right perimeter portion, where a first plurality of prefabricated housing modules are connected at the left perimeter portion of the central system module and wherein a second plurality of prefabricated housing modules are connected at the right perimeter portion of the central system module.

In some embodiments, a number of housing modules in the plurality of prefabricated housing modules is the same as a number of prefabricated system modules in the plurality of prefabricated system modules.

In some embodiments, a number of housing modules in the plurality of prefabricated housing modules is different than a number of prefabricated system modules in the plurality of prefabricated system modules.

In some embodiments, each of the plurality of prefabricated housing modules is configured to be removed from the modular housing system and replaced with a replacement prefabricated housing portion.

In some embodiments, each of the plurality of prefabricated system modules is configured to be removed from the modular housing system and replaced with a replacement prefabricated housing module.

In some embodiments, the central system module is configured to be removed from the modular housing system and replaced with a replacement central system module.

In some embodiments, the MEP module is configured to be disconnected from the rear perimeter portion of the central system module and replaced with a replacement MEP module.

In some embodiments, the elevator module is configured to be disconnected from the front perimeter portion of the central system module and replaced with a replacement elevator module.

In some embodiments, an additional prefabricated system module is connected to a top perimeter surface of the central system module and an additional prefabricated housing module is connected to a top perimeter surface of an uppermost prefabricated housing module in the plurality of prefabricated system modules and wherein the additional prefabricated system module is connected to the additional prefabricated housing module.

In some embodiments, an additional MEP module is connected to the MEP module that is connected to the rear perimeter portion of the central system module, and wherein the additional MEP module is also connected to an additional prefabricated system module.

In some embodiments, a first prefabricated system module of the plurality of prefabricated system modules aligns and connects with a second prefabricated system module of the plurality of prefabricated system modules using twistlocks that interlock a receiving portion on the first prefabricated system module with an engagement portion of the second prefabricated system module.

In some embodiments, a first prefabricated housing module of the plurality of prefabricated housing modules aligns and connects with a second prefabricated housing module of the plurality of prefabricated housing modules using twistlocks that interlock a receiving portion on the first prefabricated housing module with an engagement portion of the second prefabricated housing module.

In some embodiments, one of the plurality of prefabricated system modules includes a first hollow structural section, one of the plurality of prefabricated housing modules includes a second hollow structural section, and the elevator module includes a third hollow structural section, where the first hollow structural section is joined to the second hollow structural section and where the second hollow structural section is joined to the third hollow structural section.

In some embodiments, each of the prefabricated housing modules comprises a shell portion, where each of the prefabricated housing modules comprises a plurality of cassettes that are each installed within a prefabricated housing module along the shell portion of the prefabricated housing module.

In some embodiments, each of the plurality of cassettes corresponds with an area within the prefabricated housing module, wherein the area is one of: a bedroom area, a bathroom, a kitchen area, a living room area, and a dining area.

In accordance with various embodiments of the disclosed subject matter, a modular housing system and methods for using the same are provided.

Generally speaking, the modular housing system can include multiple prefabricated housing modules that are connected to a central system module, which can be formed from multiple prefabricated system modules that are connected together. For example, multiple prefabricated housing modules that each have the same or similar dimensions can be vertically aligned and connected to form a stacked housing module, where the multiple prefabricated housing modules in the stacked housing module can be connected to the central system module (which may include a mechanical, electrical, and plumbing (MEP) connection module, an elevator module, an egress stair module, etc.). The central system module is sometimes referred to herein as the “STEM” module.

In some embodiments, the modular housing system can include multiple prefabricated system modules that are vertically aligned with each other and joined with fasteners to form a central system module. For example, as shown in, the central system module can include five prefabricated system modules in which an upper perimeter portion of a lower prefabricated system module is connected with a lower perimeter portion of an adjacent prefabricated system module using a fastener or any other suitable joining mechanism. It should be noted that any suitable number of prefabricated system modules can be connected to form the central system module. It should also be noted that, although the prefabricated system modules shown inare substantially similar in dimension, this is merely illustrative and each of the prefabricated system modules that are connected in a stacked housing unit can have varying dimensions.

As shown in, the modular housing system can begin with a foundationor any suitable site for constructing the modular housing system (e.g., a pier foundation, a raft foundation, or any other suitable type of foundation). As shown in, a first prefabricated system modulecan be positioned on foundation. For example, first prefabricated system modulecan be secured to foundation. As shown in, a second prefabricated system modulecan be vertically aligned and positioned on first prefabricated system module. In a more particular example, an upper perimeter portion of first prefabricated system modulecan be aligned and connected with a lower perimeter portion of second prefabricated system module. Illustrative examples of fasteners or connectors that connect at least two prefabricated system modules are further shown in.

As shown in, a third prefabricated system modulecan be vertically aligned and positioned on second prefabricated system module. In a more particular example, an upper perimeter portion of second prefabricated system modulecan be aligned and connected with a lower perimeter portion of third prefabricated system module.

It should be noted that, in some embodiments, second prefabricated system modulecan be removed and/or replaced with another prefabricated system module. For example, second prefabricated system modulecan be replaced with third prefabricated system module. In a more particular example, second prefabricated system modulecan be disconnected from first prefabricated system moduleand, using a crane, second prefabricated system modulecan be removed and replaced with third prefabricated system module, which may include updated features for use with a prefabricated housing module that is connected to and horizontally adjacent to third prefabricated system module.

In continuing the above-mentioned example, as shown in, a fourth prefabricated system modulecan be vertically aligned and positioned on third prefabricated system module. In a more particular example, an upper perimeter portion of third prefabricated system modulecan be aligned and connected with a lower perimeter portion of fourth prefabricated system module.

As shown in, a fifth prefabricated system modulecan be vertically aligned and positioned on fourth prefabricated system module. In a more particular example, an upper perimeter portion of fourth prefabricated system modulecan be aligned and connected with a lower perimeter portion of fifth prefabricated system module.

In some embodiments, a roof portioncan be connected to an upper perimeter portion of the uppermost prefabricated system module. For example, as also shown in, roof portionis connected to the upper perimeter portion of fifth prefabricated system module. It should be noted that, in some embodiments, roof portioncan be disconnected from fifth prefabricated system moduleto, for example, insert one or more additional prefabricated system modules or remove one or more currently installed system modules. It should be noted that, in some embodiments, roof portioncan be omitted from the central system module.

It should be noted that any suitable system support features can be included in each prefabricated system module. For example, as shown in, a top-down view of one level of the modular housing system shows that central system modulecan include a portion of egress stairs, a walkway, an entryway to an elevator module or another portion of the system module, etc. As also shown in, portions of central system module, such as corner portions, can be connected to MEP module, elevator module, first housing module, and second housing module. These modules can be connected using the connection mechanisms shown in.

Turning to, a side view of the modular housing system shows that multiple system modules (e.g., five prefabricated system modules) have been connected to form central system module. For example, when the system modules are connected in, central system modulecan form an internal staircase that allows one to traverse different levels of the modular housing system, access different system modules, access different housing modules, access a portion of the MEP module, access a roof portion above the uppermost system module, and/or access an elevator module.

It should be noted that, although the embodiments described herein generally describe that the central system module is connected to additional system components, such as a MEP module, an elevator module, and an egress stairway module, this is merely illustrative and one or more of these additional system components can be incorporated into the central system module. For example, central system module or any one of the individual prefabricated system modules can include features, such as an elevator system, a dumbwaiter system for distributing packages, one or more connectors for providing water, hot water (e.g., plumbing risers), electricity (e.g., electrical conduits), sewage, and/or heat, ventilation, and air conditioning (HVAC) (e.g., HVAC ducts), etc. to the system portion and the housing portion connected to the system portion, garbage disposal, Internet connection, etc. In another other example, central system module or any one of the individual prefabricated system modules can include stairways, water heaters, air conditioners, fuel oil systems, water pumps, energy storage units, rain water collection systems, water purification systems, power inverters, solar panels, waste pumps, compost systems, fire protection systems, any other suitable features and/or systems, or any suitable combination thereof.

In some embodiments, the modular housing system can also include a mechanical, electrical, and plumbing (MEP) module. For example, as shown in, a MEP module(e.g., that spans the vertical length of the central system module) can include fittings that engage with corresponding fittings on a rear perimeter portion of the central system module. In a more particular example, MEP modulecan include an inner perimeter surface and an outer perimeter surface, where the inner perimeter surface of MEP modulecan include fittings that engage with corresponding fittings on a rear perimeter portion of the central system module. As shown in, MEP modulecan be positioned to extend between foundationand roof portion.

As shown in, a top-down view of one level of the modular housing system shows that MEP modulecan include an inner region within a shaft for the placement and configuration of multiple mechanical, electrical, and plumbing connectors that can connect a prefabricated housing module to a corresponding source (e.g., a power source, a water source, etc.). As also shown in, each corner portion of MEP modulecan be connected to, for example, central system module, first housing module, second housing module, and/or egress stair module.

As shown in, a side view of the modular housing system shows that MEP modulecan be connected to multiple system modules (e.g., five prefabricated system modules), which have been connected to form central system module. As also shown in, MEP modulecan extend from the lowest system module to the highest system module.

In some embodiments, MEP modulecan include any suitable mechanical support features, such as one or more HVAC ducts for a heating system and/or a cooling system. In some embodiments, MEP modulecan include any suitable electrical support features, such as power supply and distribution components, information and telecommunications system components, control system components, security and access system components, detection and alarm system components, lighting system components, etc. In some embodiments, MEP modulecan include any suitable plumbing support features, such as pipes, valves, risers, plumbing fixtures, tanks, etc. In a more particular example, plumbing support features can include potable water pipes, non-potable water pipes, cold water pipes, hot water pipes, fire protection pipes, rain water collection pipes, refrigeration piping, waste piping, drainage piping, and/or any other suitable type of piping.

It should be noted that MEP modulecan leave minimal peripheral connections, thereby allowing one configuring the modular housing system to connect the plumbing lines, electrical wires, and ducts of MEP moduleto the corresponding sources and to a prefabricating housing module (e.g., providing electricity, plumbing, HVAC, data, and/or control systems to the housing module).

It should also be noted that, in some embodiments, additional MEP modules can be connected to the initial MEP module. For example, upon adding additional prefabricated system modules and/or additional prefabricated housing modules, additional MEP modules can be vertically aligned and connected to the initial MEP module. In a more particular example, HVAC ducts, water risers, and conduit risers in an MEP module can be configured to facilitate future connection with HVAC ducts, water risers, and conduit risers of a systems module or additional MEP module to be connected when needed. For example, HVAC ducts, water risers, and conduit risers can span the vertical length (e.g., from floor to ceiling) of a prefabricated systems module. As another example, HVAC ducts, water risers, and conduit risers can be positioned within a prefabricated systems module with enough clearance to allow for larger HVAC ducts, water risers, and conduit risers of an updated systems module, positioned beneath a prefabricated systems module to be connected vertically (e.g., connected without requiring horizontal ductwork or piping). In some embodiments, conduits can include electrical wiring fitted with male and/or female plugs to facilitate attachment and/or detachment with electrical wiring of an attached prefabricated systems module.

It should also be noted that additional MEP modules can be connected to the initial MEP module in any suitable manner. For example, in some embodiments, an additional MEP module can be connected to the rear perimeter surface of MEP module. The additional MEP module can, for example, include additional HVAC ducts, water risers, and conduit risers needed to support the addition of prefabricated housing modules. In another example, the additional MEP module can, for example, include security and access system components that were not previously included in MEP moduleand/or upgrade security and access system components that are included in MEP module.

It should further be noted that, as mentioned above, MEP modulecan be incorporated as a part of the central system module. For example, alternatively to connecting MEP moduleto a rear surface of the central system module as shown in, a first MEP module in first prefabricated system modulecan include mechanical, electrical, and plumbing connectors and a second MEP module in second prefabricated system modulecan include mechanical, electrical, and plumbing connectors, where, upon connecting first prefabricated system moduleto second prefabricated system moduleusing one or more fasteners, the corresponding mechanical, electrical, and plumbing connectors can be connected.

In some embodiments, the modular housing system can also include an egress stair module. For example, as shown in, an egress stair modulecan be connected to a rear perimeter portion of MEP module. In a more particular example, egress stair modulecan include exterior exit stairways, ramps, and/or platforms that are bolted to the rear perimeter portion of MEP moduleto provide a means of egress from one or more prefabricated housing modules. It should be noted that, in some embodiments, additional portions of egress stair modulecan be added in response to connecting additional prefabricated housing modules.

As shown in, a top-down view of one level of the modular housing system shows that egress stair modulecan include a platform between entries into first housing moduleand adjacent second housing modulethat is connected to stairs to other levels of the modular housing system. As also shown in, portions of egress stair modulecan be connected (e.g., using bolts) to, for example, portions of MEP module, portions of first housing module, and portions of second housing module.

also shows that portions of egress stair modulecan be connected to portions of MEP module. Egress stair modulecan include an external staircase that allows one to traverse different levels of the modular housing system, access different system modules, access different housing modules, and/or access a portion of the MEP module.

shows that egress stair module, when connected to MEP moduleor any other suitable portion of the central system module, can be positioned between stacked housing unitand stacked housing unit. For example, occupants of any of the housing modules in stacked housing unitand stacked housing unitcan access egress stair moduleto traverse different levels of the modular housing system, access different system modules, access different housing modules, and/or access a portion of the MEP module.

It should be noted that, as mentioned above, egress stair modulecan be incorporated as a part of the central system module. For example, alternatively to connecting egress stair moduleto a rear surface of MEP moduleas shown in, a first egress stair module in first prefabricated system modulecan include exterior exit stairways, ramps, and/or platforms and a second egress stair module in second prefabricated system modulecan include exterior exit stairways, ramps, and/or platforms, where, upon connecting first prefabricated system moduleto second prefabricated system moduleusing one or more fasteners, the corresponding exterior exit stairways, ramps, and/or platforms can be connected to allow occupants of the modular housing system to reach a ground level from each level of the modular housing system.