Abstract:
Prefabricated, steel framed, rectangular building modules are joined in groups to form multi-unit residences, or commercial or institutional buildings. The modules are disposed in rectangular groups abutting one another so as to form a central rectangular core bounded by the units. Utilities are connected to each module through the core. Multiple story buildings are formed by similar groups having cores aligned vertically. Alternating stories are rotated relative to one another about the central core axis to produce cantilevered structures.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is the U.S. national phase of PCT/US2008/078952 filed Oct. 6, 2008, which claims priority of U.S. Provisional Patent Application Ser. No. 60/977,435 filed Oct. 4, 2007, which is incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to building modules having rigid frames formed of beams and covered with wall panels and to structures suitable for use as residential, commercial or institutional buildings formed with such modules. 
     BACKGROUND OF THE INVENTION 
     Rectangular building modules have previously been used to construct multi-unit buildings for use as residences and in commercial and industrial centers. By way of example, my U.S. Pat. No. 3,461,633 titled “Prefabricated Building Structure” discloses a modular prefabricated building structure formed with a rigid frame of tubular beams suitable for use as a residence, commercial or industrial building, either by itself, or in combination with similar related modules. 
     Prefabricated building modules have gained increasing marketplace acceptance since the time of my original patents, due to the economies of mass production and the general ability to perform operations in a factory setting which would be impossible or uneconomical at the construction site. There clearly exists a need for similar modules incorporating improved materials and construction techniques and for multi-unit structures incorporating these modules. 
     SUMMARY OF THE INVENTION 
     The present invention is accordingly directed toward a rigid framed rectangular module suitable for a wide variety of applications and to an innovative method of stacking these modules to form multifamily housing units, industrial, institutional and retail structures and the like. 
     Additionally, I have developed novel stacking arrangements particularly suitable for use of the prefabricated modules. These stacking arrangements achieve compact structures with the appearance of custom designed buildings which masks their factory origin. A wide variety of multi-modal structures may be formed using the present invention. 
     A preferred stacking arrangement broadly involves joining four rectangular modules with their central axes arranged in alternating orthogonal directions. One rectangular corner of each of the modules is devoted to a common utility core area shared by all four of the modules. Stories above the first story are designed in a complementary manner so that the units do not stack one above the other, but the patterns of the modules at each level are varied. In a two level stack, modules in the second level cantilever over the modules of the first level, and modules in the first level project beyond the upper modules so that portions of their roof are exposed in the completed structure. The result is an irregular yet harmonious appearance which lends itself to forming clusters of the modules which produce a heterogeneous appearance. The modules are also well adapted to be arrayed in clusters on inclined surfaces to produce varying appearance and sight lines. They may also be combined with multistory modules to produce a unique community appearance. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other aspects, advantages and applications of the present invention will be made apparent by the following detailed description of the accompanying drawings. The description makes reference to the accompanying drawings in which: 
         FIG. 1  is an isometric drawing of a preferred embodiment of a module useful with the present invention; 
         FIG. 2  is an isometric section of the module of  FIG. 1  in its completed form with floor, roof, wall panels, windows and foundation pads; 
         FIG. 3  is a plan view of a structure incorporating four of the modules joined together to form a unitary structure incorporating a central utility core formed by all four of the modules; 
         FIG. 4  is an isometric view of a two story structure incorporating two levels, each like the level of  FIG. 4 , but varied in layout to provide cantilevered sections; 
         FIG. 5  is a perspective view of a completed structure formed in accordance with  FIG. 5 ; 
         FIG. 6  is a perspective view of a two story module like  FIGS. 5 and 6  with finishing details; 
         FIG. 7  is a site study of a cluster of modular structures arrayed on a site plan; 
         FIG. 8  is a site study variation like  FIG. 7 ; 
         FIG. 9  is an illustration of a variety of site variations, including a central high-rise tower in one of the variations; and 
         FIG. 10  is an elevation view of a structure formed by a plurality of two level modules arranged along a sloping site. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIGS. 1 and 2  illustrate a basic form of the rectangular, rigid frame, module forming the preferred embodiment of the present invention.  FIG. 1  illustrates the module in frame form and  FIG. 2  in finished form with floor, roof, and wall panels, windows and foundation pads. The modules are formed of a welded steel frame. In a preferred embodiment the outer framing members  10  are formed of C channels. In other embodiments they could be tubular members. The vertical members  12 , which join the framing members  10 , are preferably formed of steel 2×4 tubular sections; and the cross framing members  14  may be junior beams. The corner 2×4 framing members may extend downwardly to provide legs  14 . 
     Joists  16  extend across the width of the module to support floor and ceiling panels. The joints are preferably welded. 
     The second floor module is substantially similar except that there are no legs  14  and a number of lifting hooks  18 , preferably four in number, are attached to the top framing members to allow the second floor structures to be lifted by cranes on top of the first floor structures. 
       FIG. 2  shows a typical manner in which the first floor structure may be covered by insulated panel  20  and aluminum glass panels or door walls  21  and in which foundation pads  22  may be attached to the bottom of legs  14 . 
     The modules may of course differ in size and proportions from those illustrated in  FIGS. 1-2 , but are preferably steel framed and rectangular in configuration. 
       FIG. 3  illustrates how modules may be joined together to form four residences.  FIG. 3  constitutes a plan view of an aggregate of eight modules which form four residential units. Four of the modules  30   a ,  32   a ,  34   a  and  36   a  are rectangular in form and relatively long. Each of these units is paired with a shorter module,  30   b ,  32   b ,  34   b  and  36   b . Thus the two contiguous modules  30   a  and  30   b  form one dwelling unit, the modules  32   a  and  32   b  a second dwelling unit, the modules  34   a  and  34   b  a third dwelling unit, and the modules  36   a  and  36   b  the fourth dwelling unit. Each pair of modules forming one dwelling unit have appropriate interior walls and doors (not shown) so as to create a single dwelling unit. 
     The units are arrayed in rectangular configuration, with the major axes of the units  30   a  and  30   b  parallel to the major axes of the units  34   a  and  34   b , and with the major axes of the units  32   a  and  32   b  parallel to the major axes of the units  36   a  and  36   b . The resulting structure is rectangular with an unoccupied central core  38 , which is formed by one quadrant of each of the four modules  30   a ,  32   a ,  34   a  and  36   a  and acts as a utility core. The four dwelling modules share the central utilities provided through the core  38 . 
     Broadly the modules are arrayed so that each module has a section of a vertical wall bordering and defining the central rectangular core area  38  and each module has sections of its vertical walls abutting sections of vertical walls of at least two other modules. 
     The units are particularly useful to form emergency housing after a natural disaster such as a hurricane, fire, etc. Bringing all of the utilities  38  for the four units (or additional units which may be supported on the four units, as will be subsequently disclosed) great economies of connection time are achieved. 
     Two or more sets of modules, of the type generally indicated in  FIG. 3 , may be stacked one on top of the other in the manner illustrated in  FIG. 4 . The plans for each level are rotated by 90 degrees with respect to one another so that the modules are not arrayed directly on top of one another, but sections of the top modules cantilever beyond the lower modules and sections of the top of the lower modules are exposed. The central utility core extends through both levels of modules. In this arrangement the modules are double wide and have a distinct aesthetic appearance. 
     A wide variety of multistory combinations of the modules may be created in which the levels of modules are not stacked directly above and below each other, but an upper level projects beyond the support provided by the lower level, in a cantilevering manner. This construction is possible because of the strength of the metal beams used to form the modules. The beams are preferably of steel but could be aluminum in some cases. 
     The vertically staggered result of this non-uniform stacking arrangement provides an aesthetically pleasing appearance to the structures, which may be varied from structure to structure, so as to avoid a uniform appearance. The arrangement also provides excellent sound insulation and exterior ventilation conditions when compared to structures in which multiple levels of modules are directly stacked upon one another. 
       FIG. 5  illustrates the two level modular array of  FIG. 4  in a finished form, illustrating a variety of finishes that may give a distinctive appearance to the module group. 
     The modules may be finished in a variety of manners such as the one shown in  FIG. 6 . Groups of modules of the types illustrated in  FIGS. 4 and 5  may be arrayed over a site in a non-regular manner, as illustrated in  FIG. 7 , to provide an aesthetically varied community of modules.  FIGS. 8 and 9  illustrate a variety of site arrangements which may vary depending upon the topography of the land. High-rise towers, as illustrated in the upper left-hand corner of  FIG. 10 , may be interposed among the modules to further vary the aesthetics of the arrangement. The high-rise could be formed by a plurality of stacked modules of the type shown in  FIGS. 1-2 . 
       FIG. 10  illustrates an elevation view of the plurality of the modules arrayed along a sloped terrain. 
     It is clear that the basic modules, while uniform, may be joined together in a variety of aesthetically pleasing combinations to provide communities which give the appearance of custom design despite the factory manufactured nature of the individual modules.