Methods and systems for modular buildings

This application is a continuation of U.S. patent application Ser. No. 18/511,572, filed Nov. 16, 2023, which is a continuation of U.S. patent application Ser. No. 17/033,101, filed Sep. 25, 2020, which is a continuation-in-part of U.S. patent application Ser. No. 15/592,388, filed May 11, 2017, which is a continuation-in-part of U.S. patent application Ser. No. 12/322,380, filed Feb. 2, 2009, which claims the benefit of U.S. Provisional Application No. 61/063,191 filed Feb. 2, 2008, each of which is incorporated herein by reference in its entirety.

The present invention relates generally to modular building systems and methods, and more particularly, to modular building panels configured to be integrated with stud frame construction.

Modular buildings and components used in making them are known in the art. By way of example, prefabricated housing components, including wall, floor and roof panels are known. However, energy losses most commonly occur in the seams, framing or joint regions of structures, including prefabricated buildings and modular structural components. Additionally, while prefabricated panels and other components are known in the art, they are not packaged or provided for quick and easy assembly to form a predetermined completed structure that also provides for an almost continuously insulated and energy efficient structure that is also stable and reliable, i.e., able to withstand the natural elements including storm conditions or man-made elements like hostile fire or blasts.

Prior art patent documents include the following:

U.S. Pat. No. 3,662,507 for Preformed building wall construction by inventor Espeland, filed Mar. 11, 1970 and issued May 16, 1972, is directed to a building wall construction having preformed panels preferably of plastic material for use particularly as basement walls and also as room walls above the basement level. The panels are keyed to each other and to supporting structures and secured by a suitable bonding agent. There are special panel sections with preformed window units and also preformed support areas for heavy beams. There is a selection of preformed corners to accommodate varying situations. The panels include preset bolts for the base plates and in one embodiment are provided on their exterior side with preformed brick ledges to support brick facing.

U.S. Pat. No. 6,564,521 for Structural sandwich panels and method of manufacture of structural sandwich panels by inventor Brown, et. Al, filed May 12, 2000 and issued May 20, 2003, is directed to rigid structural members, profiles, joints, and forms added to structural sandwich panels to provide higher strength, integral joining joint, and single facing sheet manufacturing. Facing sheets, rigid structural members, latch side and pin side cam-locks, fabricated wire truss assembly, and rigid structural headers and an integrated top plate are positioned into containment form assembly in the proper position. Facing sheets are placed in position in the containment form assembly forming a structural sandwich panel assembly. A foam resin core material is injected into the structural sandwich panel assembly and allowed to cure. The resultant structural sandwich panel includes rigid structural members and elongated recesses which also form a joint for joining abutting structural sandwich panels together and cam-locks used to secure adjoining panels together. Comer and angle panels have a comer rigid structural assembly.

U.S. Pat. No. 8,327,593 for Insulated wall filed by inventor Laprise filed Mar. 10, 2011 and issued Dec. 11, 2012, is directed to a section of the wall having a plurality of interspaced structural members mounted between an upper frame member and a lower frame member, and insulating material generally filling the space between the structural members and upper and lower frame members.

U.S. Pat. No. 5,424,118 for Interlocking insulative panel construction filed by inventor Mclaughlin on Jan. 25, 1994 and issued Jun. 13, 1995, is directed to refrigeration units such as walk-in coolers and freezers, particularly interlocking insulative panels used in construction of such units. The individual insulative panels are characterized by a densified urethane perimeter and a core of low density insulating urethane abutting the perimeter and held in place by a thin outer skin. The densified urethane perimeters of the panels have a tongue-in-groove configuration, as well as a cam locking means, securing abutting panels together.

U.S. Pat. No. 8,973,337 for Modular sheet metal building kit filed by inventor Hires et. Al., filed Aug. 6, 2013 and issued Mar. 10, 2015, is directed to a modular construction kit for erecting a building. The kit comprises a plurality of base track sections, a plurality of roof receiving tracks, and a plurality of wall panels. The base track is a U-shaped channel that extends around the base of the building and maintains the lower edges of the wall panels in a linear alignment. Wall panels include male, female, and hybrid (male/female) varieties, each variety having a different tongue and groove configuration on laterally opposing ends of the panel. Each wall panel has an outer skin and an inner skin separated by two divider walls and a structural bridge, which provide structural support across two axes. The roof receiving track is affixed to the upper edges of the wall panels to provide a supporting shelf for a roof structure. Thus, the invention is an easy to assemble kit for rapidly erecting buildings.

U.S. Pat. No. 8,002,490 for Corner piece for valance interface in cases and containers filed by inventor Hamlen, filed Nov. 29, 2007 and issued Aug. 23, 2011, is directed to a unitary, bent corner piece for a valance frame having an extending tongue at each end shaped to interfit the hollow cross-section of an adjacent, extruded, valance frame member. Complementary corner pieces so formed provide part of a valance interface between the lid and body of a container, ensuring sealing continuity around corners fitted with such corner pieces. Each corner piece is provided with a mating valance surface for presentation to the valance interface to provide an intimate engagement with the mating valance surface of the complementary, opposed corner piece. Gaskets fitted within the corner pieces may form part of the interface. Tongues formed a at the respective ends of a corner piece are provided with a groove to accommodate the inclusion of a gasket into the interior core of the longitudinal frame members. Corner pieces may also be formed with two or more cavities beneath the valance surface, such cavities being defined by bridging walls extending from an inside surface of the corner piece to an outside surface of the corner piece. The outside surface of a corner piece may be provided with one or more perforated fastener openings, penetrating the outside wall of the corner piece, for attaching sidewalls of a container to the corner piece.

U.S. Pat. No. 4,163,349 for Insulated building panels was filed by inventor Smith, was filed May 26, 1977 and issued Aug. 7, 1979 is directed to an insulated building panel including a core and overlapping skins, the interior skin at the panel's bottom covering a panel foot plate and the exterior skin at the panel's bottom covering the foot plate and extending beyond to form an erection stop. End panels have relieved core areas for receiving bearing members associated with a wall splice bearing post, and double parallel spaced header beams have offset splice areas within a several panel wall section. Two end panels include improved end structure for forming an improved corner at the panel's intersection. Methods are provided for making and erecting a multiple panel wall section.

U.S. Pat. No. 4,192,113 for Corner assembly for wall panels filed by inventor Martin, filed Mar. 23, 1978 and issued Mar. 11, 1980, is directed to a covering and sealing assembly for concealing and sealing the gap between a pair of edge adjoining wall panels which are disposed at an angle to each other, such as at a corner. The assembly includes an exterior trim piece, a supporting member for the exterior trim piece, fastening means to tighten the supporting and clamping members together to squeeze the edges of the panels at the corner and to thus provide a structural tie therebetween, and an interior trim piece which snaps over the free vertical edges of the clamping member and hides the fastening means and the clamping member. The structural tie between the two corner panels is effected by the squeezing action of the legs of the supporting member and of the clamping member upon the faces of the adjoining wall panels at the points of contact between the faces and the supporting and clamping members.

U.S. Patent Pub. No. 2010/0095629 for Insulating thin-brick, thin-stone, and thin-block siding system filed by inventor Taylor, filed Oct. 20, 2009, and published Apr. 22, 2010, is directed to surface facing materials structured for facing indoor and outdoor surfaces, consisting of facing sections having interdigitating connectors on opposing first and second surfaces so as to securely connect a long connecting-side of a section to a long connecting-side of an adjacent section and/or interdigitating connectors on each end so as to securely connect each section end to an end of an adjacent section, so as to provide light weight, moisture resistant, sound and heat insulating facing. One style of the facing section comprises a single row of thin-bricks positioned short end to short end securely adhered to an elongate, lightweight, insulating backing-panel having interdigitating connectors sized so as to accept a single row of bricks so as to result in a thin-bricked panel. In one preferred embodiment, from 2 to 10 thin-bricks are adhered end to end to a backing-panel forming an elongated row of thin-bricks on a backing panel.

The present invention provides modular building systems with integrated electronic technologies. One aspect of the present invention is to provide modular building panels with embedded electrical supply components and embedded electronic devices. Another aspect of the present invention is to provide a modular building constructed with modular building panels; the building controlled by a central computer system in communication with the embedded electronic devices in the panels. These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings, as they support the claimed invention.

In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.

None of the prior art addresses the longstanding need for stable, energy efficient modular building structures, including kits for installing same, in particular having an almost continuously insulated and structurally locked wall, floor and roof panel components that are aligned with a mating edge system with the potential for embedding additional technologies inside of the panels. Thus there remains a need for energy efficient and stable modular building systems and methods for installing them, including providing containerized packaging to facilitate shipment, assembly and installation of the building offering improved value for the consumer through integrated technologies

The present invention provides systems and methods for a modular building that is self-contained within a standard shipping container, wherein the pre-fabricated panel wall components are easily assembled to form a predetermined structure using a cam-based component connector system. Another aspect of the present invention is to provide a modular building system for a portable, storable complete building kit wherein the kit is completely optimally provided within a standard shipping container or other pre-specified configuration or delivery mechanism. The present invention also provides a modular building system with prefabricated composite wall panels that include conduits provided within the panels; alternatively, these conduits may be pre-wired. As shown in, each panel is separately a structural element to be used in construction. While framing lumber, structural sheathing and insulation are traditionally sold separately, a structural insulated panel combines the capability of all three materials yet with a significantly reduced amount of framing lumber and therefore much less energy loss through thermal bridging of the building envelope. And while normal structural insulated panels are sold as part of a kit to be assembled as a set, ASSP can be sold separately as money becomes available. The panels are thus assembled in any number of alternative configurations and moved around as desired by the owner, allowing them to create an almost infinite number of designs from a very limited number of panel types.

In another embodiment, the continuously insulated panels are angled in shape or forming a t-wall or other multi-segment single panel to aid in both strength and structure assembly such that they tessellate. Other regular and irregular shapes that tessellate are provided for in the present invention.

Methods for installation of the modular building system include the steps of providing a prefabricated modular building kit having all components and instructions for assembly optimally disposed within a standard shipping container for portability and storage; removing the kit from the shipping container; assembling the modular housing by arranging and connecting the composite wall panels, which include conduits for electrical and/or plumbing disposed within the interior section of the composite wall panels, including input/output openings for wiring, and complimentary technologies like lighting, cameras, sensors, etc.

The structure size is predetermined before packaging or panels erected as changing conditions require, but ranges in size from small to very large buildings, by way of example and not limitation, such as an emergency shelter, a home or a command shelter or office or simply as an item of convenience for a consumer. The size of the panels generally requires only two or three persons to manually maneuver the panels for complete structure erection. The material of both the interior and the exterior siding of the panels is selected based upon the needs of the customer and the environment, but in any case the panels are both insulated and portable. Preferably, the panels are super-insulated and portable to allow the builder to get under roof and into a comfortable space in a very short period of time.

In another embodiment, a structural insulated panel has a finished exterior that provides a drainage plane over which other siding is applied.

Referring now to the drawings in general, the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. As best seen in the figures, especially, an illustration of a container for housing a modular building kit is shown; in, modular building materials are shown including interlocking pre-engineered and pre-insulated panels that are constructed and configured to be quickly attached together by properly aligning their respective edges to form the walls, roof, or floor of a structure.

shows a perspective view of a containerfor housing the modular building system according to one embodiment of the present invention.illustrates a perspective view of stacked contents of the kit for modular building structures as one example (since not all will require the same materials) of the present invention, configured to fit within the container shown in; the contents of this illustration include furniture, panel splines, bedding & food prep supplies, windows & doors, exterior flashing material, kitchen core module, tools & fasteners, bath core module, power generator, environmental equipment, plumbing & electrical equipment, additional supplies, wall panels, gable end panels, roof panels, and roof panel support beams.shows a loaded containerofwith the components of.illustrates a side view of a knock-down building packaged using the corner panels to hold and protect the flat panels.illustrates a perspective view of a partially assembled modular building structure, including door component, wall panel edges,, wall panel face side, and back side, wall panel (generally referenced), joined edges or seam, roof panel.shows a perspective view of a completed modular building from the partially completed illustration ofincluding a window unit.illustrate several related views; ina top view of two edges of modular wall panels having mating double railingfor alignment and locking mechanism;illustrates an end perspective view illustrating the parallel spaced apart double track or railing system;illustrates a side view and cut-away of joined panel edges with the interlocking cam-based locking mechanism (cam, locking arm, seam).illustrates a top view of a corner wall panel modular component with a continuously insulated seamless cornerwith insulationa face sideand back sideof the wall panel, and double rail mating alignment components,.illustrates several perspective views of the modular building components in various stages of installation.

Doors and windows are also preferably delivered with and included in the building kit. Preferably, openings for the windows and doors are pre-framed in the panels in a manner that allows for rapid window and door installation on site, without additional time or materials required for framing and installation. Doors and windows may also be pre-installed within individual panels at the factory prior to packing into the container. Roof beam pockets are also preferably pre-set in the top of panels to facilitate the placement of rafter or ridge beams to allow for the support of the insulated roof panels.

In an alternative embodiment, the panels are locked together with a magnetic locking system, generally described in. Magnets or electro-magnets on the opposing peripheries of a panel are further inter-connected via a rod or cable to each other contained within a single panel. In this manner the magnetic locking system connects an entire structure with structural reinforcement. The magnets may be permanent magnets or electro-magnets, which are rendered non-functional by either turning off the electric current for the electro-magnet or by sliding segments of a magnet orthogonally to the direction of the magnetic field to facilitate assembly or disassembly or electromagnets, which are activated once they are in place. Alternatively, the electromagnets are deactivated during normal conditions, and are activated or even increased in strength compared to normal operation during events that stress the structure, such as during earthquakes, hurricanes, tornados, floods, explosions, and the like.

Another magnetic locking system, used to anchor the structure to a floor or footing or to a truss or other structural member of a roof is shown in. Not only is this magnetic locking system used to attach one panel to another panel, but it is also used to attach a panel to a non-panel structural member, or to attach two or more non-panel structural members to each other.

A header panel is a load bearing member that goes over a large opening like a window or a door. Standard industry practice is to have this member be a continuous framing member such as laminated veneer lumber (LVL) or similar and having very high strength but low insulation value. Prior Artshows a standard wall section detail at a framed opening, which allows thermal bridging (energy loss) where the framing member bisects the wall. The present invention is an insulated box beam offering a continuous end-to-end insulated core and still offering very high structural strength.-C show this energy efficient method of mounting a window or door section.shows a wall section detail at a framed opening where a continuous framing member has been replaced with a much more energy efficient configuration while still providing structure for window or door mounting.illustrates both a top and bottom chord (typically framing lumber) of the header or footer and its adjoining panel skins along with additional framing lumber at the ends of the header or footer to allow attachment to adjacent panel.shows that there is minimal thermal bridging from one side of the panel to the other while still retaining significant structural strength by virtue of the interior foam insulation.

Thus, the header or footer panel is provided that eliminates much of the thermal bridging normally associated with the framing of the opening for a window or door type panel.

In another embodiment of the present invention, the present invention includes electrical supply components. The electrical supply components include electrical junction boxes, conduit and/or radiant heating coils, wherein the electrical supply components are preferably molded inside of the panels. Beneficially, the structure is assembled quickly and is pre-fitted with conduit (as delivered to the site in the self-contained kit, preferably in a shipping container), to allow for quick installation of a fully-equipped building, including electrical functionality (). The panels include a standardized box which is hot pluggable by consumers to facilitate changing out the modular device contained in the box. For example, the modular device is a standard electrical socket, or a networking interface, or a USB charger, or a sensor array. These modules also preferably include a locking mechanism, so that they can't be easily removed from the wall. This is useful in public buildings.

In another embodiment, the panels are pre-wired to include embedded technology modules, wherein the embedded technology modules include embedded data+power access points. In a preferred embodiment, these access points are mounted flush with the panel surface, and opened, for example by popping out, to provide a connection interface.

The present invention provides for pre-installation of devices in the panels. Thus, the panels arrive at the construction site with devices such as microphones or wireless transceivers already installed or easily inserted because receiving hardware is already installed within the panel.

Pluggable, embedded technology modules as provided for by the present invention are also used in structures that are not entirely built with the modular panels. The pluggable, embedded technology modules are configured for network connectivity. For example, in a building wherein only the ceiling is built with panels or not at all built with panels, a data/power access box in a panel in the ceiling is used for a pluggable light or a camera. In another example, in a building without panels these new technologies could be installed in sockets or receivers of the same or similar form factor, like a common 4″×4″×2″ electrical box normally used for wall power outlets or light switches.

The system provides for mounting LED lighting within the panels. For example, on the upper part of the wall, LEDs are mounted to provide illumination. The longevity of LEDs means that they rarely need to be changed. With ambient light sensors, they are also used to produce a constant amount of light making the space more pleasant.

As shown inand, the panels are embedded with power technology, electronics, software, sensors, and network connectivity that enable them to collect and exchange data and control the structure and its accessories. Multiple technologies are utilized, ranging from wireless communication to the Internet and from embedded systems to micro-electromechanical systems (MEMS). Thus, the panels merge embedded systems, wireless sensor networks, control systems, and home and building automation into the structure. Electronics are embedded in panels at factory or on the job-site.is a semi-transparent, perspective view of a panel with a 4-way chase. The 4-way chase allows circuits to be run from horizontally and vertically.

The panels also include an AC/DC converter or inverter. For example, a Texas Instruments-port device (), which takes in AC power and then pass out DC power for lighting and other building management functions. The TI port box looks like a standard wired AC device, but it outputs a DC supply at an Intermediate Bus Voltage (IBV). IBV is preferred to be below 48V for safety reasons. In an embodiment, the output is floating.

Additionally or alternatively, the panel includes an AC/DC inverter, such that a DC electrical supply can be plugged into the system via one of the panels to power the system.

IR or light based communication devices are also used in the present invention. For example, these are used to turn off appliances, such as a TV or stereo, if no one is in the room. Likewise, ultrasonic communication is used in some embodiments.

In another embodiment, a power lines networking system is included. The system preferably has a security that is unique to the building.

The communication lines for the communication system are pre-installed or pulled through the same conduit (chase) as the power lines or having dedicated communications chases to prevent signal degradation through conflicting electrical fields.

Preferably, the embedded technology modules are modular network electronics, such as: wireless access point (router); wireless signal repeater; antennae; access control technology such as remote-controlled magnetic locking device for doors; and the like.shows a panel with embedded wireless or data technology for standard residential installation. The panels include and/or are pre-configured to accommodate various networking technologies, including: RFID and near-field communication; bidirectional optical technology; optical tags and quick response codes; Bluetooth low energy; Low energy wireless IP networks, such as embedded radio in system-on-a-chip designs, lower power WiFi, and sub-GHz radio in an ISM band; ZigBee; Z-Wave; LTE-Advanced; WiFi-Direct and the like. These devices are connected wirelessly or via wires run through the chase. Any number of chases are provided in a panel, either independent or connected.illustrate a panel with a 4-way chase. In one embodiment, Smart RFID tags help ensure adjacent panels are supposed to be connected together.

Wireless relays are also be mounted to the access points to create or extend a communication network. The communication network created by the assembled panels are wired, wireless or combinations thereof. In a preferred embodiment, the panels contain wireless relays that provide a wireless mesh network.

In another embodiment, the embedded technology modules include sensor and recorder technologies. Preferably the sensor technologies are modular and either embedded during manufacturing or on the job-site. Information from either side of the panel or the interior of the panel is captured. By way of example and not limitation, sensors include: temperature sensors, humidity sensors, video, smoke/fire sensors, image capture (still image for comparison), air quality, radiofrequency (RF), gas (CO2, CO, etc.), sound sensors (microphone), volatile organic carbons (VOC) sensors, ion mobility spectrometry (IMS), accelerometers, and motion sensors. Accelerometers can be used to determine if a panel is vibrating abnormally, and therefore indicate that the cam-locks might be failing. The sensors generate panel events, which are recorded in a database in the central computer system.

Recorders are also mounted with the sensors at the data access points (). By way of example and not limitation, video recorders are mounted with the video cameras.

Another type of panel provides an external video camera and at least one monitor mounted on, or embedded in, the interior side of the panel, thus providing inhabitants with a view of the exterior (). The “one-sided-window” is preferably a web-enabled camera and monitor embedded in a panel for energy saving, security and/or entertainment purposes. In an example embodiment, a small aperture high quality camera is mounted to penetrate the exterior of the panel skin and is connected to a video monitor viewable from the interior side of the panel, thus serving as both an inconspicuous surveillance device and as a “one sided window” offering a view of the outside. This system provides significantly higher insulation value than a standard window, thereby saving energy. Additionally, in another embodiment the monitor windows are mounted in the reverse direction beside a door, thereby providing external visitors with a view of the approaching occupant. These same panels are provided as skylights; enabling the user to control the amount of lighting throughout the day. The monitor windows are also used for teaching: when a particular topic is discussed, the windows change from a view of the exterior to the topic of discussion. The present invention also provides for a panel with a camera with a monitor mount. Thus, the panel with camera are shipped separately from the monitor.

Alternatively, a web-connected monitor allows a user to experience different vistas by connecting to remote cameras all over the world. For example, a viewer “wakes up in the Caribbean” by having a view from a Caribbean island transmitting in the morning. In conjunction with an exterior motion detector, the system switches to the exterior view when motion is detected; otherwise, the monitor displays a predetermined view.

Alternatively, a structure erected in Afghanistan could have camera/monitor panels allowing someone in Nevada to “remote monitor” the outside of the structure while the occupants slept in the interior or while they were not there at all. This is much like remote flying of an aerial drone.

Automatic door unlocking is also provided for, such that emergency response personnel can unlock the building quickly in case of medical emergency. The audio sensors with cameras and RF doppler are programmed to determine if an occupant has collapsed or is not moving when they are expected to, or gives an alert. Once the central computer system determines that there is an emergency situation, it alerts the appropriate emergency services. For example, in case of a fire, the fire department will be notified by the central computer system. If the building is occupied while on fire, the fire department and the EMS will be notified. The central computer system also unlocks the doors, windows and other access points, or alternatively enables the emergency unlock system, which allows the emergency services to unlock the doors, windows and other access points. When the emergency services arrive, they trigger a pre-determined electronic signal, such as an RFID or EMS band radio, which signals the doors and windows to unlock. In this manner, the access points cannot be unlocked by these emergency signals when there is no emergency.

In a preferred embodiment, as shown in, the solar panels are integrated with the building panels such that the exterior surface of each solar panel is ideally flush with the exterior surface of the building panel. A structural insulating panel is modified to receive a solar collector that produces either solar thermal or electrical energy for power or water or air heating.

Standard practice for the mounting of a solar collector panel is to mount it on top of the wall or roof panel as an entirely separate assembly. Large air cavities or gaps often exist between a solar thermal collector and the roof, for example, and this creates very large losses of thermal energy. By mounting a solar collector contained within an insulating wall or roof panel the efficiency of the thermal collector is increased while at the same time moving connections (plumbing or electrical) to the interior, where they are better protected.

Furthermore, in another embodiment the panels include concentrating photovoltaic systems comprising high efficiency multi-junction solar cells that use optics to concentrate sunlight.