Modular Building System

Abstract

A modular building system in which individual cuboid modules are assembled at a manufacturing facility, optimized for transportation, and transported to a building site by conventional delivery systems. On site, the modules may be modularly assembled into multi-modular buildings. Buildings may be assembled by attaching together a plurality of the structurally self-supporting modules. The modules may be attached horizontally adjacent or vertically adjacent one another using a variety of specialized, interchangeable adaptors. The modules may also be offset horizontally, vertically or perpendicularly to one another.

1 . A structurally self-supporting cuboid module comprising:
 a cuboid framework of vertical corner columns interconnected by horizontal beams defining a bottom floor frame, a top ceiling frame, and four side wall frames;   a floor disposed in the floor frame;   a ceiling disposed in the ceiling frame; and   receiving means at each end of each column for receiving one of a plurality of adaptors.   
     
     
         2 . The module of  claim 1 , wherein the cuboid framework is 8 feet wide, 40 feet long, and 9.5 feet high. 
     
     
         3 . The module of  claim 1 , wherein the floor is manufactured of steel. 
     
     
         4 . The module of  claim 3 , wherein the steel floor further comprises a concrete layer on its upper surface. 
     
     
         5 . The module of  claim 1 , wherein the floor is manufactured of pre-stressed, pre-cast concrete. 
     
     
         6 . The module of  claim 1 , further comprising at least one intermediate column extending between the ceiling frame and the floor frame between adjacent corner columns. 
     
     
         7 . The module of  claim 1 , further comprising a wall disposed in each of the one or more wall frames. 
     
     
         8 . The module of  claim 7 , wherein each wall comprises a plurality of spaced studs and drywall attached to the inner side of the studs and panels attached to the outer side of the studs. 
     
     
         9 . The module of  claim 8 , wherein each wall further comprises at least one window. 
     
     
         10 . The module of  claim 8 , wherein each wall further comprises at least one door. 
     
     
         11 . The module of  claim 8 , further comprising a building envelope connected to the outer side of at least one wall. 
     
     
         12 . The module of  claim 8 , further comprising a roof assembly connected outer side of the ceiling frame. 
     
     
         13 . The module of  claim 8 , further comprising one or more components of an electrical distribution system disposed within the framework, the electrical components selected from the group of electrical components consisting of electrical breaker panels, light fixtures, switches, dimmers, plugs, fans, appliances, air handlers, heat pump components, furnaces, electric baseboards, electric fireplaces, thermostats and controls. 
     
     
         14 . The module of  claim 8 , further comprising one or more components of a plumbing system disposed within the framework, the plumbing components selected from the group of plumbing components consisting of toilets, sinks, waste disposal units, hot water tanks, washers, dryers, hot and cold water distribution conduits, faucets, baths and showers. 
     
     
         15 . The module of  claim 8 , further comprising heating, ventilation and air conditioning units and air distribution ducting disposed within the framework. 
     
     
         16 . The module of  claim 8 , further comprising one or more finishing elements, the finishing elements selected from the group of finishing elements consisting of paint, wallpaper, carpeting, flooring, baseboards. 
     
     
         17 . The module of  claim 8 , further comprising one or more finishing elements selected from the group of finishing elements comprising cabinetry, tiling, countertops, trim, and appliances. 
     
     
         18 . The module of  claim 8 , further comprising a fire-rated drywall membrane installed along the inner and outer surfaces of the framework. 
     
     
         19 . The module of  claim 8 , wherein all elements are non-combustible. 
     
     
         20 . A structurally self-supporting cuboid module comprising:
 a cuboid framework 8 feet wide, 40 feet long, and 9.5 feet high of vertical corner columns interconnected by horizontal beams defining a bottom floor frame, a top ceiling frame, and four side wall frames;   receiving means at each end of each column for receiving one of a plurality of adaptors.   a floor disposed in the floor frame;   a ceiling disposed in the ceiling frame;   a wall disposed in each of the one or more wall frames, each wall having a plurality of spaced studs and drywall attached to the inner side of the studs and panels attached to the outer side of the studs;   at least one window in at least one wall;   at least one door in at least one wall;   a building envelope connected to the outer side of at least one wall;   a roof assembly connected to the outer side of the ceiling frame;   one or more components of an electrical distribution system disposed within the framework, the electrical components selected from the group of electrical components consisting of electrical breaker panels, light fixtures, switches, dimmers, plugs, fans, appliances, air handlers, heat pump components, furnaces, electric baseboards, electric fireplaces, thermostats and controls;   one or more components of a plumbing system disposed within the framework, the plumbing components selected from the group of plumbing components consisting of toilets, sinks, waste disposal units, hot water tanks, washers, dryers, hot and cold water distribution conduits, faucets, baths and showers;   heating, ventilation and air conditioning units and air distribution ducting disposed within the framework;   one or more finishing elements, the finishing elements selected from the group of finishing elements consisting of paint, wallpaper, carpeting, flooring, baseboards, cabinetry, tiling, countertops, trim, and appliances; and   a fire-rated drywall membrane installed along the inner and outer surfaces of the framework.   
     
     
         21 . A modular building system comprising
 a plurality of the structurally self-supporting cuboid modules of  claim 1 ; and   a plurality of adaptors, each adaptor attachable to one end of a column of a module for interconnection of each module to at least one horizontally adjacent or vertically adjacent other module, roof assembly, balcony, foundation or corridor, each adaptor selected from the group of adaptors comprising transportation adaptors, foundation adaptors, corner adaptors, lateral spacing adaptors, roof adaptors, balcony adaptors, corridor adaptors, H-clips, mid-component adaptors, and flush corner adaptors.   
     
     
         22 . The modular building system of  claim 21 , further comprising an online planning software tool for designing, modelling and pricing a building. 
     
     
         23 . The modular building system of  claim 21 , wherein each module has the same dimensions. 
     
     
         24 . The modular building system of  claim 21  wherein a plurality of modules of differing length are interconnected. 
     
     
         25 . The modular building system of  claim 21 , further comprising a foundation having a plurality of foundation anchors for receiving foundation adaptors connected to the lowermost columns. 
     
     
         26 . The modular building system of  claim 21 , wherein corner adaptors and lateral spacing adaptors are used to connect horizontally adjacent modules a desired horizontal distance apart. 
     
     
         27 . The modular building system of  claim 21 , wherein corner adaptors and spacers are used to connect vertically adjacent modules a desired vertical distance apart. 
     
     
         28 . The modular building system of  claim 21 , further comprising roof assemblies attached to the uppermost columns using roof adaptors. 
     
     
         29 . The modular building system of  claim 21 , further comprising one or more balconies attached between vertically adjacent modules using balcony adaptors. 
     
     
         30 . The modular building system of  claim 21 , further comprising one or more corridors attached between horizontally adjacent modules using corridor adaptors. 
     
     
         31 . The modular building system of  claim 31 , further comprising seismic bracing disposed within at least one corridor or floor structure of one or more modules. 
     
     
         32 . The modular building system of  claim 21 , further comprising a plurality of conduits disposed within one or more beams for interconnection of electrical or mechanical components between adjacent modules. 
     
     
         33 . The modular building system of  claim 21 , wherein a system of colour coding is used to distinguish among the plurality of functionally distinct adaptors. 
     
     
         34 . The modular building system of  claim 21 , further comprising sheathing attached between adjacent modules. 
     
     
         35 . The modular building system of  claim 21 , further comprising application of insulation and building envelope to the exterior of the building. 
     
     
         36 . The modular building of  claim 21 , further comprising interlocking, insulated wall panels attached to the exterior walls of the outer modules of the building, the wall panels having a flashing having a foam insulation therein, the foam compressible between vertically adjacent modules to form a water resistant and airtight connection between modules. 
     
     
         37 . The modular building system of  claim 21 , further comprising a foam or rubber strip along one or more of the outer sides of the columns, the strip compressible between horizontally adjacent modules to form a water resistant and airtight connection between modules. 
     
     
         38 . The modular building system of  claim 21 , wherein a first modular building may be assembled, then disassembled and reassembled into a second modular building of the same or different design at the same or different building site. 
     
     
         39 . A method of constructing a building, comprising the following steps:
 assembling a plurality of the structurally self-supporting cuboid modules of  claim 1  at a manufacturing facility;   transporting the modules to a construction site;   assembling the modules into a building on a foundation using a plurality of specialized adaptors for interconnection of modules, each adaptor attachable to one end of a column of a module for interconnection of each module to at least one horizontally adjacent or vertically adjacent other module, roof assembly, balcony, foundation or corridor, each adaptor selected from the group of adaptors comprising transportation adaptors, foundation adaptors, corner adaptors, lateral spacing adaptors, roof adaptors, balcony adaptors, corridor adaptors, H-clips, mid-component adaptors, and flush corner adaptors;   interconnecting components of electrical, plumbing, heating, ventilation and other systems between adjacent modules;   applying sheathing to brace adjacent modules;   applying waterproof membranes to the exterior walls of the building;   applying insulation to the exterior walls of the building;   installing flashing on the top of each module, the flashing having a compressible gasket tape for sealing the space between vertically adjacent modules; and   installing compressible strips along columns between horizontally adjacent modules.   
     
     
         40 . The method of  claim 39 , further comprising insertion of transportation adaptors for use during transportation of the modules to a building site.