Modular Reattachable Structure System and Method

This application is a Continuation of and claims priority to U.S. patent application Ser. No. 18/482,489, filed Oct. 6, 2023 and entitled “MODULAR REATTACHABLE STRUCTURE SYSTEM AND METHOD, the application which is a Continuation of and claims priority to U.S. patent application Ser. No. 18/135,820, filed Apr. 18, 2023, and entitled “MODULAR REATTACHABLE STRUCTURE SYSTEM AND METHOD,” now granted as U.S. Pat. No. 11,939,766, the application which is a Continuation of and claims priority to U.S. patent application Ser. No. 17/887,323, filed Aug. 12, 2022, and entitled “MODULAR REATTACHABLE STRUCTURE SYSTEM AND METHOD,” now granted as U.S. Pat. No. 11,674,308, the disclosures of each which are incorporated by reference in their entireties.

Building and maintaining a building or home can be an extremely expensive and time-consuming task. Even further, the current construction methods are extremely wasteful and not sustainable. Current construction methods also do not allow for structures to be easily rebuilt or reconfigured. In many instances, it is not cost effective to build structures that are temporary or easily damaged due to extreme weather. In particular, in certain climates, there are different issues that can cause havoc. Many cost-effective building strategies have failed for a number of reasons.

It is with these issues in mind, among others, that various aspects of the disclosure were conceived.

The present disclosure is directed to a modular reattachable structure system and method. The system may include one or more interior walls that may together form an internal space or room. The one or more interior walls may each be attached to one another using at least one attachment device. In addition, each interior wall may be attached to a respective exterior wall that may form an exterior of a structure. Each interior wall may be attached to the exterior wall using a magnetic device. In one example, each interior wall may have a first wall plate that may connect and magnetically attach to a second wall plate that may be incorporated into the exterior wall. The modular reattachable structure system may be used for a single-story structure or may be used to build a multi-story structure.

There may be a cavity or space between each interior wall and each exterior wall that may house objects such as lateral or horizontal plumbing, lateral or horizontal electrical, cabling and/or wiring, and other objects. In addition, in another example, the one or more interior walls may be attached to a respective exterior wall of the structure, and this may serve as the exterior wall. Each interior wall may be detached from the exterior wall to allow for easy access to the objects in the cavity or space between each interior wall and each exterior wall. As a result, the one or more interior walls may create an interior space or room and the exterior walls may protect the interior space or room, together creating a structure. The structure is easily reconfigurable as each interior wall may be detached from the associated exterior wall that may be a shipping container. This may allow for cost effective construction of a permanent structure as well as cost effective construction of a temporary structure. In addition, the structure allows for reconstruction and reconfiguration.

In one example, the system may include a ground rod attachment device comprising at least one upper part connected to a base sill plate of an exterior wall that may comprise (1) a plate having dimensions comprising one of (a) six inches, by six inches, by one inch thick and (b) twelve inches, by six inches, by one inch thick that is attached to a first rod that is tee welded to a concrete stem wall and (2) two cross bars that are set perpendicular to one another and welded to the first rod, and at least one lower part attached to a respective upper part and comprising a second rod to be driven into the ground.

In one example, a system may include at least one interior wall having a first interior facing side and a second side opposite the interior facing side, at least one exterior wall having a first interior facing side and a second exterior facing side, at least one first attachment device for each interior wall, and at least one second attachment device for each exterior wall, each first attachment device connecting to a respective second attachment device to temporarily attach a respective interior wall to a respective exterior wall and create a cavity between the second side of the interior wall and the first interior facing side of the exterior wall.

In another example, a method may include attaching at least one interior wall to one another to create an internal space between the at least one interior wall, attaching a first attachment device incorporated into an exterior face of each interior wall to a second attachment device, the second attachment device incorporated into an interior face of an exterior wall to create a cavity between the exterior face of the interior wall and the interior face of the exterior wall, detaching a particular interior wall from the exterior wall in response to a force applied to the particular interior wall, and replacing the particular interior wall with a new interior wall.

In another example, a system may include at least one wall having a first interior facing side and a second exterior side opposite the interior facing side, at least one first attachment device for each wall, a shipping container, at least one second attachment device for each wall, each first attachment device connecting to a respective second attachment device to temporarily attach a respective interior wall to the shipping container and create a cavity between the second exterior side and an interior wall of the shipping container, and a ground rod attachment device comprising at least one upper part connected to the shipping container comprising (1) a plate having dimensions comprising one of (a) six inches, by six inches, by one inch thick and (b) twelve inches, by six inches, by one inch thick that is attached to a first rod that is tee welded to a concrete stem wall and (2) two cross bars that are set perpendicular to one another and welded to the first rod, and at least one lower part attached to a respective upper part and comprising a second rod to be driven into the ground.

These and other aspects, features, and benefits of the present disclosure will become apparent from the following detailed written description of the preferred embodiments and aspects taken in conjunction with the following drawings, although variations and modifications thereto may be effected without departing from the spirit and scope of the novel concepts of the disclosure.

The present disclosure is more fully described below with reference to the accompanying figures. The following description is exemplary in that several embodiments are described (e.g., by use of the terms “preferably,” “for example,” or “in one embodiment”); however, such should not be viewed as limiting or as setting forth the only embodiments of the present disclosure, as the disclosure encompasses other embodiments not specifically recited in this description, including alternatives, modifications, and equivalents within the spirit and scope of the invention. Further, the use of the terms “invention,” “present invention,” “embodiment,” and similar terms throughout the description are used broadly and not intended to mean that the invention requires, or is limited to, any particular aspect being described or that such description is the only manner in which the invention may be made or used. Additionally, the invention may be described in the context of specific applications; however, the invention may be used in a variety of applications not specifically described.

The embodiment(s) described, and references in the specification to “one embodiment”, “an embodiment”, “an example embodiment”, etc., indicate that the embodiment(s) described may include a particular feature, structure, or characteristic. Such phrases are not necessarily referring to the same embodiment. When a particular feature, structure, or characteristic is described in connection with an embodiment, persons skilled in the art may effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

In the several figures, like reference numerals may be used for like elements having like functions even in different drawings. The embodiments described, and their detailed construction and elements, are merely provided to assist in a comprehensive understanding of the invention. Thus, it is apparent that the present invention can be carried out in a variety of ways, and does not require any of the specific features described herein. Also, well-known functions or constructions are not described in detail since they would obscure the invention with unnecessary detail. Any signal arrows in the drawings/figures should be considered only as exemplary, and not limiting, unless otherwise specifically noted. Further, the description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. Purely as a non-limiting example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a”, “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be noted that, in some alternative implementations, the functions and/or acts noted may occur out of the order as represented in at least one of the several figures. Purely as a non-limiting example, two figures shown in succession may in fact be executed substantially concurrently or may sometimes be executed in the reverse order, depending upon the functionality and/or acts described or depicted.

Conditional language, such as, among others, “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements and/or steps. Thus, such conditional language is not generally intended to imply that features, elements and/or steps are in any way required for one or more embodiments or that one or more embodiments necessarily include logic for deciding, with or without user input or prompting, whether these features, elements and/or steps are included or are to be performed in any particular embodiment.

A modular reattachable structure system includes at least one interior wall having a first interior facing side and a second side opposite the interior facing side, at least one exterior wall having a first interior facing side and a second exterior facing side, at least one first attachment device for each interior wall, and at least one second attachment device for each exterior wall, each first attachment device connecting to a respective second attachment device to temporarily attach a respective interior wall to a respective exterior wall and create a cavity between the second exterior facing side of the interior wall and the first interior facing side of the exterior wall.

There may be a cavity or space between each interior wall and each exterior wall that may house objects such as plumbing, electricity, cabling, and other objects. In addition, in another example, the one or more interior walls may be attached to a respective exterior wall of a shipping container and this may serve as the exterior wall. Each interior wall may be detached from the external wall to allow for easy access to the objects in the cavity or space between each interior wall and each exterior wall. As a result, the one or more interior walls may create an internal space or room and the exterior walls may protect the internal space or room, together creating a structure. The structure is easily reconfigurable as each internal wall may be detached from the associated exterior wall. This may allow for cost effective construction of a permanent structure as well as cost effective construction of a temporary structure. In addition, the structure allows for reconstruction and reconfiguration.

The present disclosure has many purposes which include the ability to build and install a modular reattachable structure system and method for building and installing interior wall systems that can be remodeled easily. The interior wall system may include one or more interior walls that may together form an internal space or room. In addition, each interior wall may be attached to a respective exterior wall that may form an exterior of a structure. Each interior wall may be attached to the exterior wall using an attachment device.

In one example, the system may include a ground rod attachment device comprising at least one upper part comprising (1) a plate having various dimensions, one example being (a) six inches, by six inches, by one inch thick that is attached to a first rod that runs vertically down and may or may not run through the foundation and may or may not include cross bars that are set perpendicular to the rod and that may or may not be welded to the rod to increase stability, and connects to at least one lower part that is attached to a respective upper part and at least a second rod that runs down and may or may run down through and past the footer and run down a minimum of six to eight feet into the earth. An electronic switch may or may not be connected to the ground rod where the switch regulates the electricity passing through the ground rod. The switch controls the excess power to the ground rod by diverting the electricity into the earth or passing it through to electrical storage or the existing power grid.

Additionally, the system may include an exterior wall sill plate ground rod attachment device comprising at least one upper part connected to additional rods that can be driven into the ground. The exterior wall sill plate ground rod attachment device may include (1) a plate having dimensions comprising one of (a) six inches, by six inches, by one inch thick and (b) twelve inches, by six inches, by one inch thick that is attached to a first rod that is tee welded to a concrete stem wall and (2) two cross bars that are set perpendicular to one another and welded to the first rod, and at least one lower part attached to a respective upper part and comprising a second rod to be driven into the ground. In other examples, the ground rod attachment device may be attached to a stem wall, pier, and/or slab.

Building and maintaining a building or home can be fun and exciting. To make it more affordable and more efficient, disclosed herein is a system and method to enhance single and multi-story residential and commercial construction methods in a manner that allows current labor supply chains, material supply chains and licensure laws and processes to continue operating as they do today. Through new systems and methods structures can be more easily built, maintained and updated. The systems and methods are effective to build structures that are permanent or temporary, that can withstand high wind loads, flooding, snow loads, earthquakes, and lightning, while creating a cost effective space for residential, commercial or agricultural uses, including commercial retail use.

It is desirable to create durable buildings that can be built in cost conscious ways that allow for low maintenance and that can be temporary or permanent structures. Even further, it is desirable to create highly efficient, durable, low maintenance, cost conscious homes that can be temporary or permanent structures. Additionally, it is desirable to have buildings that can easily be reconfigured with one or more reattachable interior and/or exterior walls.

Traditional drywall and wood stud construction can be replaced with the modular reattachable system that provides a new way to wire and plumb a building. Plumbing lines can be run below the electrical lines in the design, such that condensation does not drip from the water lines and affect any of the wires or systems in the building. The modular design also allows for electrical and plumbing systems to be installed and updated easily.

In one example, the interior walls of a room or space can be magnetized or fixed together using an attachment device such as an alligator style clip. The interior walls can attach, detach, and reattach to each other. Additionally, the interior walls can allow externally adapted items such as light emitting diode (LED) lights, LED screens, shelving units and other items found in residential, commercial and agricultural buildings to be attached to a structural exterior or interior wall.

The dimensions of the exterior and interior structural walls may vary. Structural insulated panels (SIPs) are one example of how to construct an interior wall and/or exterior wall. SIP panels can be cut to a specific custom dimension. As an example, a SIP panel may include two pieces of plywood, steel, or fiberboard. Typically, two pieces of material form around an interior foam insulated core and they can either stand alone as a structural exterior wall, or they can be attached with screws to either an existing wood or metal stud wall, or inside of a shipping container.

In one example, the modular reattachable system can be used with or incorporated into a shipping container to create a building. Shipping containers can be made of Corten steel, a highly corrosion resistant metal, with a medium to low weld-ability factor.

The upper part may include either a (6″ wide×6″ wide×1″ thick) or (16″ wide×6″ wide×1″ thick) metal sill plate attachment that is tee welded to a 3 foot (3 ft) long 1″ diameter steel rod that is to be held in place inside of a concrete stem wall. The upper part may have two (2), 1 inch (1″) diameter thick×1 inch (1″) long cross bars, that are welded to the rod, one at 1 foot (1 ft) from the top of the rod, and the other at 2 feet (2 ft) from the top of the rod. These steel cross rods can be perpendicular to each other when viewing them from the top of the ground rod attachment device, looking down, making a + sign.

The lower part(s) may include one (1) straight 14 foot (14 ft)×1 inch (1″) diameter rod that can be driven at least 10 feet (10 ft) into the ground. It can be cut, and it can be connected to a second (2) lower part through the use of a connector if the foundation is greater than 16 feet (16 ft) tall. Multiple lower parts can be connected through the use of the connector, and may not be connected to the horizontal carbon based rebar used by the system. The lower part(s) can replace the existence of vertical rebar in certain locations in the engineering design of the building, while traditional carbon based rebar can still be used in other locations. The base lower part may be driven at least ten feet into the ground before any concrete is poured for the concrete pad or concrete footer. The top of the lower parts can be connected to the upper part through the connector before the concrete is poured into either an insulating concrete form (ICF), concrete masonry unit, or cement block stem wall design or slab.

By selecting a highly corrosion resistant ground rod material, the electrical current can spread out all electrical activity both inside and outside of the building, down through the ground rods, to disperse electricity from the building's power source and any sources of electricity inside or outside of the building, or in the case of lightning strikes or stray electrical activity, down into the earth or into a relay.

The National Electrical Grounding Research Project (NEGRP) by the National Bureau of Standards found that ground rods with 10 mils of copper will likely perform well for 40 years or more in most soil types. Copper degrades in salty environments however, and is very malleable, which can make it difficult to drive into the ground in rocky environments.

As an example, the grounding rod can be made of a martensitic stainless steel, and becomes a ground rod with a layer of oxide to help prevent corrosion in unique environments high in salts. Due to the outside oxide layer, stainless steel is very strong and unlikely to bend or break when installed even in soil with rocks. Martensitic steel is chromium, which usually accounts for 11.5-18% of its composition. Other common components include up to 1.2% carbon, and nickel.

SIP Panels may also be attached directly to foundation concrete block or ICF concrete wall types. As an example, the modular reattachable system could be used on any floor of a building and could be used to create one or more different types of rooms or internal spaces such as basements, bedrooms, living areas, kitchens, bathrooms, mud rooms, retail spaces, warehouses, artist studios, medical clinics, etc.

The modular reattachable system may also be used along with other types of exterior walls such as traditional 2×4 and 2×6 walls, and the magnetic blocks or alligator clamps can be attached directly to the interior of wood or metal studs, or even over drywall that is already attached to the studs through the use of a stud finder.

The modular reattachable system can meet building codes as they may be associated with one or more interior partition walls. The structural exterior walls may have both the structural engineering support for the building as well as the appropriate vapor, fireproofing, and insulation requirements for the building.

Additionally, the modular reattachable system may work in conjunction with interior load bearing and non-load bearing walls. The hardware associated with the modular reattachable system can provide an aperture, space, pocket, chamber, or passage between an exterior wall and an interior wall. In one example, this space or gap between the interior wall and the exterior wall may allow for installation of electrical wiring, plumbing lines, and outlets, among others.

In current construction methods, electrical wiring and plumbing is generally fish eyed through holes cut into the exterior structural walls' studs or metal beams, and runs through or against the insulation of the wall, whether the insulation be foam, rolled in fiberglass, or blown in insulation. This can cause the insulation to deteriorate through condensation from the plumbing lines. It also enables electrical wires to potentially create a fire hazard. However, the modular reattachable system provides a separation of the insulation and the electrical and plumbing lines and reduces the risk of fire and extends the life of the building materials.

As an example, strategic placement and attachment of the interior and exterior structural wall allows for a gap of space that is created between the exterior structural wall, and an interior wall. This can create a cavity of variable depth that will allow various electrical outlet boxes, and plumbing attachment fixtures to be installed or located inside of the gap. The outlets and fixtures can be fixed to the exterior structural wall, so that the boxes and fixtures protrude out to match the depth of the blocks. All electrical boxes in the house could be uniform in depth, 1.25″ inches (1.25 in) in depth, as an example.

As an example, interior walls can be detached and reattached to exterior walls easily. By detaching the interior wall, electricians, plumbers, and others can work in an open space to install and maintain new systems, and update or perform maintenance on existing systems. This can assist an owner of the building to address updates of technologies that are constantly evolving, without undergoing expensive home remodeling projects that require the destruction and reconstruction of walls. By removing the interior wall, and updating the electrical wiring and plumbing, the same interior wall, or an entirely new interior wall can be reinstalled, effectively updating the remodeling process in a matter of days, rather than weeks or months. For those who like to simply just update the look and feel of their home, it can allow a do-it-yourselfer (DIY) to entirely rearrange their home. As an example, one can shut down the electricity and plumbing in their home and can remove one or more internal walls. They can move walls around or replace internal walls and update their home in a matter of hours.

Licensed electricians and plumbers will not need to be retrained to understand how to use the modular reattachable structure system. Interior designers can continue to design layouts for homes, and choose color palettes and material choices to build new interior walls. As noted herein, the modular reattachable structure system may utilize magnetic devices and attachment devices to attach and detach the one or more walls. Drywall can still be used as an interior wall finish material, along with just about any other material of choice. The material choice can be associated with the depth of the electrical and plumbing outlets.

If the interior wall is to support cabinets, or cement board and tile, as in the case of a kitchen wall, or a bathroom shower, the wall may utilize a conventional building method in some areas of the building, to prevent insurance claims, injuries, or water damage.

A moisture barrier can be attached to the inside of all exterior walls to prevent condensation from the plumbing lines from penetrating and deteriorating the exterior walls or insulation in the exterior walls. Electrical lines can be hung above and out of the way of any water lines and the plumbing lines can be hung as low as possible along the exterior walls to prevent condensation from the water lines from dripping onto any of the electrical lines causing a short in the electrical system. Plumbing lines can be attached to the exterior wall through the use of plastic or metal fasteners. Plumbing lines can be run along the base of the wall in most cases, with a tee occurring where the line is to run vertically to reach a shower handle valve. These vertical plumbing lines can be run between the vertical and horizontal spaces between the wall attachments, and in the case of a shower handle valve, the plumbing lines for the bathroom may not need to cross paths with the electrical lines, as there should not be electrical lines running behind a shower.

As an example, a small pull style handle or a different type of handle can be attached to the interior wall panels on the side facing the inside of the room, so the panel can easily be detached from the exterior wall and the hardware attached to the exterior wall that was holding it in place.

In one example, the modular reattachable structure system may work and fit inside of a 40 foot×8 foot×9.5 foot high shipping container. This may allow all floors, ceilings and walls to be constructed in a manner that passes international building codes. However, the modular reattachable system can work and fit in any building, created from any building materials. In one example, an electric generator can be attached to an electrical line in the building, so that it can be wired into either a new construction or existing construction building. In another example, an electric generator can emit wireless electrical current and all electrical devices inside or outside of the building can be powered wirelessly. By measuring wall sizes and ordering the appropriate hardware and new interior walls, the generator can be connected through wires or provide wireless energy electrifying current state of the art electrical devices and equipment. This can allow the generator to be installed in older homes that have outdated electrical systems as well as in new construction homes and buildings. By running the electricity deep into the ground, the potential for ground electricity to build up harming livestock, pets and people is reduced.

If traditional carbon based rebar is not used for grounding rods, there are other options. The National Electrical Grounding Research Project (NEGRP) by the National Bureau of Standards found that rods with 10 mils of copper will likely perform well for 40 years or more in most soil types. Copper degrades in salty environments however, and is very malleable, which makes it difficult to drive into the ground in rocky environments.

In one example, the modular reattachable structure system may include a grounding rod be used that is made of a martensitic stainless steel. The grounding rod can have an outside layer of oxide to help prevent corrosion in unique environments high in salts. Due to the outside oxide layer, stainless steel is very strong and unlikely to bend or break when installed even in soil with rocks. Martensitic steel is chromium, which usually accounts for 11.5-18% of its composition. Other common components include up to 1.2% carbon, and nickel. This style of ground rod can survive for 40 years in any type of soil having almost any pH level.

By combining the use of magnetic pocket blocks and alligator clips to create new pockets between new interior walls and exterior structural walls, newer electrical and plumbing systems can easily be installed and maintained. As new buildings become entirely powered more frequently by electricity, the concept of a ground rod system that is dispersed throughout the buildings foundation is a unique way to accommodate the electrical power used in the construction methods of the future.

is a block diagram of a modular reattachable structure systemaccording to an example of the instant disclosure. As shown in, the modular reattachable structure systemmay include one or more interior or internal wallshaving a first interior faceand a second exterior face. The modular reattachable structure systemmay include one or more external or exterior walls. The exterior wallmay have a first interior face and a second exterior face similar to the first interior wall.

The second exterior faceof the interior wallmay have a first attachment point or deviceand the exterior wallmay have a second attachment point or devicethat attaches to the first attachment point or device. The first attachment point or deviceand the second attachment point or devicemay each be a magnetic device or another type of attachment device. Additionally, there may be one or more electrical outlet boxes or plumbing leads.

In one example, the interior facemay be an interior finished wall that may include drywall, fiberglass, wood, light emitting diode (LED) touchscreens, preprinted digital art, and other objects. The interior support wall or second facemay be constructed of plastic, steel, plywood, and/or fiberglass and may have one or more openings or spaces for electrical and plumbing to protrude from the exterior wallinto the second face. The first attachment point or deviceand the second attachment point or devicemay be structural connection hardware. The first attachment point or devicemay be a first magnetic object that may be attached or screwed to the second faceand the second attachment point or devicemay be a second magnetic object that may be attached or screwed to the exterior wall. Each of the first magnetic object and the second magnetic object may have one or more high strength magnets that may connect and attach to one another through their polarity.

In another example, an interior wallmay attach to another internal wall. In one example, the exterior faceof one interior wall may attach to another exterior face of the other internal wall. In other words, the first attachment point or deviceis not limited to attaching or being magnetically attracted to the second attachment point or device. The first attachment point or devicecan attach or be magnetically attracted to another first attachment point or device.