Systems and methods for manufactured modular construction

Systems, methods, and devices of the various embodiments may enable manufactured modular construction. The various embodiment manufactured modular construction systems, methods, and devices may offer a solution to the housing shortage worldwide that is less than half the cost of the cost of current modular buildings. Various embodiments may include interlocking vertical and horizontal elements. Various embodiments may include a locking system pulling upper horizontal elements of an embodiment modular building toward lower horizontal elements and/or a foundation or a lower floor of the embodiment modular building to thereby lock vertical elements and vertical panels in place between the upper horizontal elements and the lower horizontal elements, foundation, and/or lower floor. In various embodiments, the locking system may include a shock absorber.

SUMMARY

Systems, methods, and devices of the various embodiments may enable manufactured modular construction.

Various embodiments may provide a modular building, comprising: at least one lower horizontal element; at least one vertical element configured to form a hollow central portion; at least one upper horizontal element; and at least one locking system connecting the lower horizontal element, the vertical element, and the upper horizontal element together.

Various embodiments may provide a locking system for a modular building, comprising: a shock absorber; and a locking element connected to the shock absorber, wherein the shock absorber and locking element together connect an upper element of the modular building to a foundation or a lower horizontal element of the modular building and pull the upper element toward the foundation or the lower horizontal element to thereby lock a vertical element and/or a vertical panel in place between the upper element and the foundation or the lower horizontal element. In various embodiments, the upper element may be an upper horizontal element of the modular building.

Various embodiments may provide a method of installing a modular building, comprising: affixing at least one lower horizontal element to a foundation; sliding a vertical element configured to form a hollow central portion over a first raised portion of the lower horizontal element; sliding a vertical panel over a second raised portion of the lower horizontal element and over a raised surface element of the vertical element; sliding an upper horizontal element into the vertical element and the vertical panel; affixing a locking system between the lower horizontal element and the upper horizontal element; and tensioning the locking system to pull the lower horizontal element, the vertical element, and the upper horizontal element together.

Various embodiments may provide a modular building kit, comprising: at least one lower horizontal element; at least one vertical element configured to form a hollow central portion; at least one upper horizontal element; and at least one locking system configured to connect the lower horizontal element, the vertical element, and the upper horizontal element together.

Various embodiments may provide a modular building, comprising: means for affixing at least one lower horizontal element to a foundation; means for sliding a vertical element configured to form a hollow central portion over a first raised portion of the lower horizontal element; means for sliding a vertical panel over a second raised portion of the lower horizontal element and over a raised surface element of the vertical element; means for sliding an upper horizontal element into the vertical element and the vertical panel; means for affixing a locking system between the lower horizontal element and the upper horizontal element; and means for tensioning the locking system to pull the lower horizontal element, the vertical element, and the upper horizontal element together.

DETAILED DESCRIPTION

The various aspects will be described in detail with reference to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. References made to particular examples and implementations are for illustrative purposes, and are not intended to limit the scope of the claims. As used herein terms such as “vertical”, “horizontal”, “upper”, “lower”, “foundation”, “roof”, “wall”, “over”, “under”, etc., are used as typically used in the construction industry to relate to an orientation of a building constructed on level ground, such as the orientation of a building as shown inFIG. 1D.

Affordable housing developers are facing more obstacles to building new projects, even though the need for affordable housing grows stronger every year. In the United States (U.S.), the Federal Low-Income Housing Tax Credit (LIHTC) program is providing less funding than it did in prior years, while the cost of construction is getting more expensive. Specifically, land, labor and material costs continue to rise. As a result, individual development deals that make financial sense are getting harder to find.

In the U.S. market, poor families are having an increasingly difficult time finding an affordable place to live, due to high rents, static incomes and a shortage of housing aid. An estimated 11 million families in the U.S. now pay more than half their income on rent, a number that has grown steadily as the supply of affordable housing shrinks. Similarly, in England, property is unaffordable for one hundred thousand households a year. Almost one hundred thousand households in England are being priced out of the property market each year because of a shortage of affordable homes to rent or buy. Additionally, the government in Germany estimates that there is a need for three hundred and fifty thousand new dwellings per year. The U.S., England, and Germany are merely just three examples, and many more countries worldwide face the same shortage of low income housing.

Commonly, modular buildings are built as a single unit or large component in a factory. These single units and larger components currently used for modular construction are costly to transport to a building site and require large heavy lifting equipment (e.g., a crane, etc.) for installation. The installation of these single units and larger components currently requires a large number of fasteners and is labor intensive. Additionally, current modular buildings are expensive to expand. The cost and labor intensiveness of current modular buildings and their construction techniques has previously prevented modular buildings from being used to address housing shortage worldwide.

Systems, methods, and devices of the various embodiments may enable manufactured modular construction. The various embodiment manufactured modular construction systems, methods, and devices may offer a solution to the housing shortage worldwide that is less than half the cost of the cost of current modular buildings. Additionally, the various embodiment manufactured modular construction systems, methods, and devices may provide labor cost savings in that the various embodiments may enable embodiment modular buildings to be erected in shorter amounts of time than the time required for current modular buildings. Various embodiment manufactured modular construction systems, methods, and devices may provide modular buildings exceeding existing buildings in strength and durability. Various embodiment manufactured modular construction systems, methods, and devices may provide modular buildings having a lower building cost than buildings built using current building technologies. Various embodiment manufactured modular construction systems, methods, and devices may provide modular buildings in which structural elements (e.g., walls, roofs, etc.) are held together without a need for glue or caulk.

Various embodiments may include interlocking vertical and horizontal elements. In various embodiments, the vertical and/or horizontal elements may be extruded, pultruded, cast, or otherwise fabricated elements. In various embodiments, the profiles of the vertical and horizontal elements may interlock together forming vertical and/or horizontal channels for electric, data, plumbing, HVAC (heating, ventilation, and air conditioning), and any other type connections and/or utilities suitable for use in a modular building. In various embodiments, the vertical and/or horizontal elements may be formed from fiber-reinforced plastic (FRP) (also referred to as fiber-reinforced polymer). In various embodiments, the FRP may be colored and/or textured. In various embodiments, the FRP may be a thermal insulator. In various embodiments, panels (e.g., vertical panels, such as door panels, window panels, wall panels, etc. and/or roof panels) may slide into the vertical and/or horizontal elements. In various embodiments, vertical panels (e.g., wall panels, etc.) and/or roof panels may be formed from aluminum composite with a structural foam (e.g., polyethylene foam, etc.). As one example, the aluminum composite may be a layered composite of aluminum sheeting layers adhered to the front and back of a sheet of polyethylene. For example, the vertical panels and/or roof panels may be formed from a foam sandwiched between an aluminum frame. The structural foam may act as an insulator (e.g., an R-38 rated insulator) and a sound absorber. In various embodiments, a roof profile may include an integrated gutter. In various embodiments, the vertical and/or horizontal elements may include raised features that interact with grooves on the panels (e.g., grooves on the vertical panels, such as door panels, window panels, wall panels, etc. and/or grooves on the roof panels) to align the vertical and/or horizontal elements with the adjoining panels as tongue and groove joints. In alternative embodiments, the vertical and/or horizontal elements may include grooves that may interact with raised features on the panels (e.g., grooves on the vertical panels, such as door panels, window panels, wall panels, etc. and/or grooves on the roof panels) to align the vertical and/or horizontal elements with the adjoining panels as tongue and groove joints.

Various embodiments may include a locking system pulling upper horizontal elements of an embodiment modular building toward lower horizontal elements of the embodiment modular building to thereby lock vertical elements and vertical panels in place between the upper horizontal elements and the lower horizontal elements. Various embodiments may include a locking system pulling upper horizontal elements of an embodiment modular building toward the foundation and/or lower floors of the embodiment modular building to thereby lock vertical elements and vertical panels in place between the upper horizontal elements and the foundation and/or lower floors. In various embodiments, the locking system may not require fasteners to connect the vertical elements to the vertical panels of an embodiment modular building. In various embodiments, the locking system may enable an embodiment modular building to be erected or disassembled at a speed faster than the speed at which current modular buildings are assembled/disassembled. In various embodiments, the locking system may include a shock absorber. In various embodiments, the shock absorber may include a rubber block, a hydraulic system, a spring, or any other type shock dampening device. In various embodiments, the locking system may not require glue or caulk to hold the structural elements (e.g., the vertical elements, vertical panels, horizontal elements, roof panels, etc.) of an embodiment modular building together.

Various embodiments may provide modular buildings with multi-floor layouts in various increments. In some embodiments, the increments may be 4.2 foot (ft) (or 1.3 meter (m)) increments. In various embodiments, components of a modular building may be energy efficient. Various embodiments may provide a modular building that may be assembled in two hours or less, such as 1.5 to 2 hours, etc., by unskilled workers without a crane at the building site rather than at a factory. Various embodiments may provide a modular building that may be assembled by two unskilled workers at a rate of 0.5 to 2 minutes (min) per square foot (sqft), such as 1 min per sqft. Various embodiments may provide a modular building that resists fire, water, mold, corrosion, and chemical damage. Various embodiments may provide a modular building that is expandable by adding additional vertical and/or horizontal elements. Various embodiments may provide a modular building that may survive the force of a hurricane. In various embodiments, the heaviest component of the modular building may weigh fifty-five kilograms (kg) (or one hundred and twenty-one pounds (lbs)). Various embodiments may provide a modular building as a kit of components that weight fifty-five kg or less and are assembled at a building site.

Various embodiments may provide a modular building that is a modular housing unit. The modular housing unit may have a foot print of at least 4.1 m×8.1 m (or 13.4 ft×26.5 ft), such as 4.1 to 20 m×8.1 to 30 m, etc. The modular housing unit may provide a living space of at least 30.2 square meters (sq m) (or 325 sqft), such as 325-1000 sqft. The modular housing unit may include a bathroom module having a shower, sink, toilet, and vent. The modular housing unit may include a walk in closet module. The modular housing unit may include a modular kitchen cabinets quick wall connect system. The modular housing unit may include a kitchen sink with faucet. The modular housing unit may include a refrigerator and/or freezer. The modular housing unit may include a stove, such as three or more burner stove. The modular housing unit may include a hot water heater. The modular housing unit may include a split air condition (AC) unit. The modular housing unit may include furniture such as a dining table and chairs, a sofa, a flat screen television mount, a desk and chair(s), etc. The modular housing unit may include a security system.

In some embodiments, a modular building may include a single modular housing unit. In some embodiments, a modular building may include two or more modular housing units. In some embodiments, a modular building unit may be a modular apartment building formed from stacking one or more modular housing unit on another modular housing unit. In such apartment configurations, floor panels may replace the roof panels in all but the upper most modular housing units to thereby provide a floor for each successive stacked modular housing unit. As a specific example, a modular apartment building may include ten modular housing units on a first floor, with ten additional modular housing units on a second floor, and ten additional modular housing units on third floor, thereby creating a three level and thirty unit modular apartment building.

In various embodiments, lower horizontal elements may connect to a foundation, such as a slab foundation, basement foundation, piling foundation, etc. The lower horizontal elements may be connected to the foundation with any type fastener, such as pneumatic driven nails, wedge anchors, screws, adhesives, etc. In various embodiments, the lower horizontal elements may have raised features that interconnect with lower portions (i.e., the portions toward the floor of the modular building when installed) of the vertical panels (such as door panels, window panels, wall panels, etc.). As used herein, “raised features” or “raised elements” may refer to features that extend or protrude out from a surface. As such, the raised features of the lower horizontal elements extend or protrude from a surface of the lower horizontal elements. In various embodiments, an upper portion of the lower horizontal elements (i.e., the portion of the lower horizontal elements that is opposite the foundation side of the lower horizontal elements when installed) may be formed as a tongue structure that inserts into a groove structure of the vertical panels, such as door panels, window panels, wall panels, etc., thereby joining the lower horizontal elements with vertical panels by a tongue and groove type joint. In alternative embodiments, the lower horizontal elements may be formed as the groove structure and the tongue structure may be formed on the vertical panels, such as door panels, window panels, wall panels, etc., thereby joining the lower horizontal elements with vertical panels by a tongue and groove type joint.

In various embodiments, lower horizontal elements may include a raised feature that interconnects with lower portions of the vertical elements (i.e., the portion of the vertical elements toward the floor of the modular building when installed). Vertical elements may be hollow pillars having any suitable horizontal cross sectional shape, such as polygonal (e.g., rectangular, etc.), circular, oval, etc. In various embodiments, an upper portion of the lower horizontal elements (i.e., the portion of the lower horizontal elements that is opposite the foundation side of the lower horizontal elements when installed) may be formed as raised structure (e.g., a tenon structure) that inserts into a center cavity portion (e.g., a mortise structure) of the vertical elements, thereby joining the lower horizontal elements with vertical elements in effect by a mortise and tenon type joint. In various embodiments, the vertical elements may create the height of each level of the modular building. In various embodiments, vertical elements may have different profile shapes depending on the type of joint needed to connect two vertical panels (e.g., door panels, window panels, wall panels, etc.). As examples, some vertical elements may have a profile shape to form a straight wall between two vertical panels (e.g., door panels, window panels, wall panels, etc.), some vertical elements may have a profile shape to form a right angle corner between two vertical panels (e.g., door panels, window panels, wall panels, etc.), some vertical elements may have a profile shape to form a t-shaped corner between three vertical panels (e.g., door panels, window panels, wall panels, etc.), some vertical elements may have a profile shape to form a cross shaped corner between four vertical panels (e.g., door panels, window panels, wall panels, etc.). In various embodiments, the vertical elements may have raised features on their sides that interconnect with side portions (i.e., portions running generally orthogonal to the floor and/or roof when installed) of the vertical panels (such as door panels, window panels, wall panels, etc.). In various embodiments, a side portion of the vertical elements (i.e., the portion of the vertical elements that is generally orthogonal to the floor and/or roof when installed) may be formed as a tongue structure that inserts into a groove structure of the vertical panels, such as door panels, window panels, wall panels, etc., thereby joining the vertical elements with vertical panels by a tongue and groove type joint. In alternative embodiments, a side portion of the vertical elements (i.e., the portion of the vertical elements that is generally orthogonal to the floor and/or roof when installed) may be formed as a groove structure that a tongue structure of the vertical panels, such as door panels, window panels, wall panels, etc., inserts into, thereby joining the vertical elements with vertical panels by a tongue and groove type joint. In various embodiments, at least a portion of a locking system, such as a lock rod, lock cable, shock absorber, and/or any other portion of a locking system, may run through a hollow center portion (or hollow central portion) of the vertical elements. The hollow center portion of a vertical element may run the full vertical length of the vertical element. In various embodiments, no fasteners, glue, or caulk, may be needed to keep the vertical elements in place during assembly of a modular building as the vertical elements may be supported by the raised structure (e.g., a tenon structure) of the horizontal elements that inserts into a center cavity portion (e.g., a mortise structure) of the vertical elements.

In various embodiments, the lower horizontal elements may be configured so as to form slots between the raised features that interconnect with lower portions of the vertical elements (i.e., the portion of the vertical elements toward the floor of the modular building when installed) and the raised features that interconnect with lower portions (i.e., the portions toward the floor of the modular building when installed) of the vertical panels (such as door panels, window panels, wall panels, etc.). The slots formed in the lower horizontal elements may provide a gap between the raised features that aligns with the raised features on the sides of the vertical elements. The slots may enable the vertical elements to slide fully into the horizontal elements.

In various embodiments, a roof truss may be a horizontal element configured similar to the vertical elements. The roof truss may include a hollow center portion that may run the full length of the roof truss. The roof trusses may include raised features on their sides that interconnect with side portions (i.e., portions running generally parallel to the roof when installed) of the roof panels. In various embodiments, a side portion of the roof truss (i.e., the portion of the roof truss that is generally parallel to the roof when installed) may be formed as a tongue structure that inserts into a groove structure of the roof panels, thereby joining roof truss with roof panels by a tongue and groove type joint.

In various embodiments, the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels may be formed from a sandwich of insulating foam (e.g., polyurethane foam, etc.) between aluminum composite sheets. The aluminum composite sheets may be a layered composite sheet of aluminum sheeting layers adhered to the front and back of a sheet of polyethylene. A panel seal may be inserted into the grooves of the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels that join to the vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.) The panel seal may be formed from a compressible material, such a plastic, rubber, or other type material seal, that may act as a weather seal for the joints of the modular building. The panel seal may form a flexible seal between the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels that join to the vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.). The panel seal may be affixed to the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels, such as by glue, nails, friction, physical arrangement of the surface of the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels, and/or any element in any other manner. The presence of the panel seal at the joint connection points may eliminate the need for caulking and/or glue in the modular building. The panel seals may be flexible seals having one or more raised flexible features (e.g., lips, wipers, bubbles, etc.) extending from a main body of the panel seal. The raised flexible features (e.g., lips, wipers, bubbles, etc.) may be compressed toward the main body of the panel seal when the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.) are joined together and the compression of the raised flexible features (e.g., lips, wipers, bubbles, etc.) may form compression interlocks between the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels that join to the vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.). In various embodiments, the raised flexible features (e.g., lips, wipers, bubbles, etc.) may be compressed to lie flat against the main body of the panel seal when the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)) are joined together. Additionally, the raised flexible features (e.g., lips, wipers, bubbles, etc.) may mold to the mating surface of the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)) when the structural elements are joined together. The flexibility of the panel seals may compensate for tolerance variations in the profiles of the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.), especially when such structural elements of the modular building are formed from FRP. As the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.) are joined together, the panel seals may compress (e.g., the raised flexible features (e.g., lips, wipers, bubbles, etc.) may compress toward the main body of the panel seal, and/or the main body of the panel seal may compress) and the compression may provide the required tolerances for the structural elements of the modular building to fit together, as well as may act as a shock absorber between the structural elements. This compression of the panel seals may make the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)) easier to fit together. Additionally, by compensating for tolerance variation in the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)), this compression of the panel seals may prevent modular panels from not fitting together at a build site and needing to be shipped back to a supplier due to not fitting, thereby overcoming the non-fitting problem faced in assembling current modular buildings.

In various embodiments, the grooves of the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels interacting with the raised portions of the vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.) may form vertical and/or horizontal channels for electric, data, plumbing, HVAC (heating, ventilation, and air conditioning), and any other type connections and/or utilities suitable for use in a modular building. Connections to outside utilities may be made by push connections and/or other type connections to the connections and/or utilities running through the modular building. The presence of the vertical and/or horizontal channels may eliminate the need to make holes in the walls of the modular building for connections and/or utilities.

In various embodiments, upper horizontal elements may be the mirror image of the lower horizontal elements. Said another way, the upper horizontal elements may be inverted lower horizontal elements. For example, the upper horizontal elements may have raised features that interconnect with upper portions (i.e., the portions toward the roof of the modular building when installed) of the vertical panels (such as door panels, window panels, wall panels, etc.). In various embodiments, an lower portion of the upper horizontal elements (i.e., the portion of the upper horizontal elements that is toward the foundation side of the upper horizontal elements when installed) may be formed as a tongue structure that inserts into a groove structure of the vertical panels, such as door panels, window panels, wall panels, etc., or vice-versa, thereby joining the upper horizontal elements with vertical panels by a tongue and groove type joint. As another example, the upper horizontal elements may include a raised feature that interconnects with upper portions of the vertical elements (i.e., the portion of the vertical elements toward the roof of the modular building when installed). In various embodiments, a lower portion of the upper horizontal elements (i.e., the portion of the upper horizontal elements that is opposite the roof side of the upper horizontal elements when installed) may be formed as raised structure (e.g., a tenon structure) that inserts into a center cavity portion (e.g., a mortise structure) of the vertical elements, thereby joining the upper horizontal elements with vertical elements in effect by a mortise and tenon type joint. As a further example, the upper horizontal elements may be configured so as to form slots between the raised features that interconnect with upper portions of the vertical elements (i.e., the portion of the vertical elements toward the roof of the modular building when installed) and the raised features that interconnect with upper portions (i.e., the portions toward the roof of the modular building when installed) of the vertical panels (such as door panels, window panels, wall panels, etc.). The slots formed in the upper horizontal elements may provide a gap between the raised features that aligns with the raised features on the sides of the vertical elements. The slots may enable the upper horizontal elements to slide fully into the vertical elements and the vertical panels (such as door panels, window panels, wall panels, etc.). The upper horizontal elements may trap the vertical elements and the vertical panels (such as door panels, window panels, wall panels, etc.) between the upper horizontal elements and the lower horizontal elements.

In various embodiments, a locking system may hold the vertical elements and the vertical panels (such as door panels, window panels, wall panels, etc.) in place between the upper horizontal elements and the lower horizontal elements. In various embodiments, the locking system may include a multitude of rods or cables that pull the upper horizontal elements toward the lower horizontal elements, thereby locking all in-between components (i.e., the vertical elements and the vertical panels (such as door panels, window panels, wall panels, etc.) in place. In this manner, the locking system may eliminate all common fasteners used in the building industry and reduces the time to erect a modular building. Similarly, the locking system may eliminate the need for glue or caulk to be used to hold structural components (e.g., the vertical elements and the vertical panels (such as door panels, window panels, wall panels, etc.), horizontal elements, roof panels, etc.) together. Additionally, the locking system may enable quick disassembly of a building. In various embodiments, a shock absorbing system may be incorporated into the locking system to increase stress resistance during heavy wind loads, explosions, and/or earthquakes. In various embodiments, the shock absorbing system of the locking system may enable the roof to move and snap back during a negative pressure spike. As such, various embodiments may be flexible increasing the modular building's strength under excessive external forces and an embodiment modular building may pass the 8 pounds-per-square-inch (PSI) blast building standard.

In various embodiments, a roof support may be configured to affix to the upper horizontal elements. The roof support may extend horizontally beyond the upper horizontal elements to support the roof. In various embodiments, roof clamps may affix the roof panels and roof trusses to the roof support and thereby to the external vertical walls of the modular building formed by the joined the vertical elements and the vertical panels (such as door panels, window panels, wall panels, etc.). In various embodiments, a weather seal for the roof section may be formed as a gutter forming a channel to collect rain water.

In various embodiments, a floor support may be configured to affix to the upper horizontal elements. In this manner, the floor support may enable the construction of multi-floor modular buildings. The floor support may be a horizontal element configured to support a floor section and/or lower horizontal elements. In various embodiments, a floor section may be similar in construction to a roof as described herein and the floor section may be supported by a protrusion from the floor support. The floor support may extend horizontally beyond the upper horizontal elements to support the floor. The lower horizontal elements of the next floor of the modular building may be affixed to the floor support. The floor support may separate each floor of the modular building and a roof may be affixed to the top floor using a roof support as described herein rather than another floor support.

FIGS. 1A-1Eillustrate aspects of a modular building100according to various embodiments. As one example, the modular building100may be a modular housing unit. The modular building100may be any size. As one example, the modular building100may have a foot print of 4.1 m×8.1 m (or 13.4 ft×26.5 ft). As an example, the modular building100may provide a living space of 30.2 square meters (sq m) (or 325 sqft). With reference toFIGS. 1A-1E,FIG. 1Aillustrates a floor plan of the modular building100. As illustrated inFIG. 1A, the modular building100may include various modules therein, such as a bathroom module, bedroom module115, and living room module116. The bathroom module may include a toilet and sink area103and shower area104. The bedroom module115may include a bed101and desk102. The living room module116may include cabinets107, a refrigerator105, table106, and sofa108. The modular building may include a HVAC unit109, such as a split AC. Exterior walls110may form the outer portions of the modular building100and interior wall111may separate the interior rooms of the modular building100.

FIGS. 1B and 1Cillustrate interior views from the living room module116and bedroom module115, respectively, of the embodiment module building100.FIGS. 1D and 1Eillustrate exterior views of the modular building100. As illustrated inFIGS. 1B-1E, the walls of the modular building100may be formed from a series of panels, such as wall panels123, window panels120, and door panels121, interconnected by vertical elements131. The interconnected panels and vertical elements131may support a roof125of the modular building100.

FIG. 2Ais an exterior view of a multi-floor modular building200according to various embodiments.FIG. 2Bis a close-up view of a portion of the multi-floor modular building200. With reference toFIGS. 1A-2B, in various embodiments, modular building units, such as modular building units similar to modular building100, may be stacked to form the multi-floor modular building200, such as a modular apartment building. For example, three floors201,202, and203of modular building units may be stacked on top of one another to form the multi-floor modular building200. In such multi-floor configurations, floor panels may replace the roof panels in all but the upper most floor203of the modular housing units to thereby provide a floor for each successive stacked modular housing unit. As a specific example, the multi-floor modular building200may include ten modular housing units on a first floor201, with ten additional modular housing units on a second floor202, and ten additional modular housing units on third floor203, thereby creating a three level and thirty unit multi-floor modular building200.

FIG. 3is a cut-away view of a straight wall connection between two wall panels306which correspond to wall panels123inFIGS. 1A-1Eand a vertical element312which corresponds to the vertical element131inFIGS. 1A-1Eaccording to various embodiments. With reference toFIGS. 1A-3, in various embodiments, the vertical element312may be formed from FRP. In various embodiments, the FRP may be colored and/or textured. In various embodiments, the FRP may be a thermal insulator. In various embodiments, the vertical element312may be an extruded and/or pultruded element formed so as to have a hollow central portion329. However other suitable structural materials may be used. In various embodiments, the vertical element312may create the height for each level of a modular building. In various embodiments, vertical elements may have different profile shapes depending on the type of joint needed to connect two vertical panels (e.g., door panels, window panels, wall panels, etc.). As illustrated inFIG. 3, the vertical element312may be a straight wall element configured to form a straight wall connection between two panels, such as two wall panels306(and/or window and/or door panels). In various embodiments, the vertical element312may slide on to a raised portion of the lower horizontal element350that may be affixed to a foundation or floor.

In various embodiments, the wall panels306may be formed from a foam307core sandwiched between an aluminum frame of aluminum composite panels (ACPs)308and an aluminum profile frame310. In various embodiments, the wall panels306may be structural insulated panels (SIPs) formed from a sandwich of ACP or other hard materials and foam. The ACP panels308may be a layered composite of aluminum sheeting layers adhered to the front and back of a sheet of polyethylene. The structural foam307(e.g., polyurethane foam, etc.) may act as an insulator (e.g., an R-38 rated insulator) and a sound absorber. However other suitable structural materials may be used. The aluminum profile frame310may encircle the panel306and support panel seals305. The panel seal305may be a plastic, rubber, or other type material seal that may act as a weather seal for the joints of the modular building. In this manner, glue and/or caulk may not be needed for the joints of the modular building. The ACP panels may extend beyond the foam307core and form a groove structure along the edge of the wall panels306that supports the aluminum profile frame310and panel seals305therein. In some embodiments, the aluminum profile frame310may clamp the panel seals305in place, and the aluminum profile frame310and panel seals305may also form a groove structure within the groove structure along the edge of the wall panels306. The groove structure formed by the aluminum profile frame310and panel seals305along the edge of the wall panels306may slide over a raised portion of the lower horizontal element350that may be affixed to a foundation or floor.

In various embodiments, the vertical element312may have raised features315on sides that interconnect with the panels, such as the two wall panels306(e.g., door panels, window panels, wall panels, etc.). The raised features315may form a tongue structure that inserts into the groove structure formed by the aluminum profile frame310and panel seals305along the edge of the wall panels306, thereby joining the vertical element312with wall panels306by respective tongue and groove type joints. The aluminum profile frame310may be curved metal that holds the panel seal305in place. In various embodiments, the front of the panel seal305may have flexible wipers that contact the raised features315to seal the aluminum profile frame310to the raised features315. When the vertical element312and the wall panel306are joined together, a channel316, such as a vertical channel, may be formed between the vertical element312and the wall panel306. The channel316may provide a passageway for electric, data, plumbing, HVAC (heating, ventilation, and air conditioning), and any other type connections and/or utilities suitable for use in a modular building.

In various embodiments, the vertical element312may be inserted over a shock absorber304affixed to the lower horizontal element350. The shock absorber304may fit within the hollow central portion329. A shock absorber304may be optional, and not all vertical elements may include a shock absorber304. A lock rod302may run through the hollow central portion329of the vertical element312. The lock rod302and/or shock absorber304, may be components of a locking system pulling upper horizontal elements toward the lower horizontal elements and securing the vertical element312and wall panels306in place. The lock rod302(or lock cable, or other locking mechanism) may be tensioned during installation to create force holding the modular building walls together.

FIG. 4Ais a cut-away view of a corner wall connection between two wall panels306and a vertical element412according to various embodiments. With reference toFIGS. 1A-4A, the corner wall connection illustrated inFIG. 4Ais similar to the straight wall connection ofFIG. 3, except that the vertical elements412and312differ. Vertical element412may be similar to vertical element312, except that vertical element412may have a different shape to form a right angle corner between two panels, such as wall panels306. Specifically, the raised features315on sides that interconnect with the panels, such as the two wall panels306, rather than being on opposite sides, may be on ninety-degree offset sides of the vertical element312.

FIG. 4Bis a cut-away view of a corner wall connection between two window panels406(which correspond to window panel120inFIGS. 1A-1E) and a vertical element412. With reference toFIGS. 1A-4B,FIG. 4Billustrates an upper portion of the vertical element412. The corner wall connection ofFIG. 4Bis similar to the corner wall connection ofFIG. 4A, except rather than two wall panels306, two window panels406are connected by the vertical element412. Additionally, the panel seal405inFIG. 4Bis configured in an alternative shape from the panel seal305ofFIGS. 3 and 4A.

The window panels406may include a window pane450affixed to a window frame profile453by a spacer452and lock bar451. In some embodiments, the window frame profile453may be formed from aluminum. In some embodiments, the spacer452may be formed from rubber. The window panels406may include panels454sandwiching the window frame profile453therebetween. Similarly to the wall panels306, the window panels406may include an aluminum profile frame310encircling the window panel406and supporting the panel seals405. The panel seal405may be a plastic, rubber, or other type material seal that may act as a weather seal for the joints of the modular building. The panels454may extend beyond the window frame profile453and form a groove structure along the edge of the window panels406that supports the aluminum profile frame310and panel seals405therein. In some embodiments, the aluminum profile frame310may clamp the panel seals405in place between raised elements315and aluminum profile frame310, and the aluminum profile frame310and panel seals405may also form a groove structure within the groove structure along the edge of the window panels406. The groove structure formed by the aluminum profile frame310and panel seals405along the edge of the window panels406may slide over a raised portion of the lower horizontal element350that may be affixed to a foundation or floor. The raised features315of the vertical element412may interconnect with the panels306,406. The raised features315may form a tongue structure that inserts into the groove structure formed by the aluminum profile frame310and panel seals405along the edge of the panels306,406, thereby joining the vertical element412with panels306,406by respective tongue and groove type joints. When the vertical element412and the panels306,406are joined together, channels316, such vertical channels, may be formed between the vertical element412and the panels306,406as discussed above.

FIG. 5Ais a cut-away view of a t-wall connection between three wall panels and a vertical element according to various embodiments. With reference toFIGS. 1A-5A, the t-wall connection illustrated inFIG. 5Ais similar to the straight wall connection ofFIG. 3and the corner wall connections ofFIGS. 4A and 4B, except that the vertical elements512,312, and412differ. Vertical element512may be similar to vertical elements312,412, except that vertical element512may have a different shape to form a three joint (i.e., t-shaped) corner between three panels, such as wall panels306. Specifically, the raised features315on sides that interconnect with the panels, such as the three wall panels306, offset ninety degrees from one another.

FIG. 5Bis a cut-away view of a t-wall connection between two wall panels306, a window panel406, and a vertical element512. With reference toFIGS. 1A-5B, the t-wall connection illustrated inFIG. 5Ais similar to the t-wall connection inFIG. 5A, except the connection is made with panel seals405rather than panel seals305.

FIGS. 6A and 6Bare cut-away views of a roof portion, vertical element612, and wall panel of an embodiments modular building. With reference toFIGS. 1A-6B, the vertical element612may be any type vertical element, such as a straight wall vertical element312, corner vertical element412, t-wall vertical element512, etc. As illustrated inFIG. 6A, an upper horizontal element610may be inserted in the upper portion of the vertical element612. The lock rod302may pass through the hollow central portion329of the vertical element612and be affixed to the upper horizontal element610, such as by a nut620. The lock rod302may be tensioned to pull the upper horizontal element610down onto the vertical element612and the vertical element612down onto a horizontal element350under the vertical element612. The upper horizontal element610may include panel seals305on a portion of the upper horizontal element610that insert into the hollow central portion329of the vertical element612. Similarly, the upper horizontal element610may insert into the groove portion of the wall panel306formed by the aluminum profile frame310and panel seals305along the edge of the wall panels306. As illustrated inFIG. 6B, the when the wall panel306is joined with the upper horizontal element610, a channel316may be formed therebetween.

A roof support616may be configured to affix to the upper horizontal element610. The roof support616may be a set of elongated bars or hollow frame. The roof support616may extend horizontally beyond the upper horizontal elements610to support a roof panel630. In various embodiments, roof clamps604may affix the roof panels630and roof trusses902(seeFIGS. 9A and 9B) to the roof support616and thereby to the external vertical walls of the modular building formed by the joined vertical elements612and the wall panels306. In various embodiments, the roof panels630may be formed from a foam632core sandwiched between an aluminum frame of aluminum composite panels (ACPs)631and an aluminum profile frame310. In various embodiments, the roof panels630may be structural insulated panels (SIPs) formed from a sandwich of ACP or other hard materials and foam. The ACPs631may be a layered composite of aluminum sheeting layers adhered to the front and back of a sheet of polyethylene. The structural foam632(e.g., polyurethane, etc.) may act as an insulator (e.g., an R-38 rated insulator) and a sound absorber. The aluminum profile frame310may encircle the panel630and support panel seals305. The panel seal305may be a plastic, rubber, or other type material seal that may act as a weather seal for the joints of the modular building. The ACP panels630may extend beyond the foam632core and form a groove structure along the edge of the roof panel630that supports the aluminum profile frame310and panel seals305therein. In some embodiments, the aluminum profile frame310may clamp the panel seals305in place, and the aluminum profile frame310and panel seals305may also form a groove structure within the groove structure along the edge of the roof panel630. The groove structure formed by the aluminum profile frame310and panel seals305along the edge of the roof panel630may be affixed to the roof support616by one or more roof clamps604. In various embodiments, a weather seal for the roof section may be formed as a gutter615forming a channel to collect rain water. The gutter615may insert into a groove of the roof panel630.

In some embodiments, a panel bracket602may affix a portion of a wall panel306to the vertical element612. In some embodiments, a roof support fastener605, such as a bolt, etc., may extend through the roof clamps604, roof support, and upper horizontal elements610to clamp the roof panel630and upper horizontal element610to the panels of the modular building, such as the wall panels306.

FIG. 6Cis a cut-away view of a roof portion and wall panel306of a modular building according to various embodiments. With reference toFIGS. 1A-6C, the roof portion ofFIG. 6Cis similar to the roof portion ofFIGS. 6A and 6B, except a different gutter660shape and different panel seal405shape is shown.

FIG. 7Ais a cut-away view of a lower horizontal element350, vertical element612, and wall panel306connected together. With reference toFIGS. 1A-7A, the vertical element612may be any type vertical element, such as a straight wall vertical element312, corner vertical element412, t-wall vertical element512, etc.FIG. 7Aillustrates one type of shock absorber304suitable for use with the various embodiments. In the shock absorber304may be formed from a rubber block701supported between a top plate702and bottom plate703. In other embodiments, the rubber block701may be replace with a hydraulic system (e.g., a hydraulic cylinder, etc.), spring, or other type shock absorber. The top plate702may be compressed against the rubber block701by a fastener706, such as a bolt, etc., that passes through the top plate702, rubber block701, and bottom plate703. The fastener706may affix the shock absorber304to a lower horizontal element350. The bottom plate703may be compressed against the rubber block701by one or more fasteners705(e.g., one or more bolts, etc.), such as two fasteners705, etc., that passes through the bottom plate703, rubber block701, and top bottom plate702. The one or more fasteners705may connect to a catch plate704that is affixed to the lock rod302. The catch plate704may be affixed to the lock rod302in any manner. For example, the lock rod302may slide into a slot in the catch plate704. The rubber block701may expand and contract between the upper plate702and lower plate703to dampen forces acting on the vertical element612. In various embodiments, the shock absorber304may be incorporated into the locking system to increase stress resistance during heavy wind loads, explosions, and/or earthquakes. In various embodiments, the shock absorber304of the locking system may enable the roof to move and snap back during a negative pressure spike. The tension of the lock rod302and shock absorber304may pull the upper horizontal elements610down toward the lower horizontal elements350to secure the walls of the modular building. As seen inFIG. 7A, the lower horizontal element350may include panel seals305on the rail feature725of the lower horizontal element350contacting the inner surface of the vertical element612when inserted into the hollow central portion329of the vertical element612.

FIG. 7Bis a component diagram of a lower horizontal element350, vertical element512, and wall panel306being slid together. With reference toFIGS. 1A-7B, the lower horizontal element350may include a first raised portion720and a second raised portion721. The first raised portion720and the second raised portion721may both include rail features725. The first raised portion720may be separated from the second raised portion721so as to form a slot722therebetween. The slot722may receive the raised elements315of the vertical element512when slid together. The vertical element512is shown being slid over the shock absorber304. The first raised portion720of the lower horizontal element350may include a panel seal405affixed to the rail elements725, while the second raised portion721may not include a panel seal on the rail elements725.

FIG. 7Cis a cut-away view of a lower horizontal element350and vertical element612connected together with a window panel406. With reference toFIGS. 1-7C, a floor790is also visible inFIG. 7C.

FIG. 8is a view of a roof portion of a modular building. With reference toFIGS. 1A-8, the roof portion is similar to the roof portions shown inFIGS. 6A-6C, except no gutter is shown. The roof support is illustrated clamped to the wall of the building formed by the vertical element612and the wall panel306by the roof clamps604. As illustrated inFIG. 8, the roof clamps604may extend over the panel seal405of the roof panel630and into the groove formed by the aluminum frame profile310.

FIGS. 9A and 9Bare cut-away views of roof portions of a modular building according to various embodiments. With reference toFIGS. 1A-9B,FIG. 9Ashows a roof truss902connected between two roof panels630with one shape of panel seal305whileFIG. 9Bshows the roof truss902connected between two roof panels630with another shape of panel seal405. Roof trusses902may be similar to vertical elements (e.g., vertical elements412,612, etc.) and may connect two roof panels630together. The roof trusses902may include a hollow center portion904.

In various embodiments, the roof trusses902may have raised features903on sides that interconnect with the panels, such as the two roof panels630. The raised features903may form a tongue structure that inserts into the groove structure formed by the aluminum profile frame310and panel seals305,405along the edge of the roof panels630, thereby joining the roof trusses902with roof panels630by respective tongue and groove type joints. When the roof trusses902with roof panels630are joined together, a channel905, such as a horizontal channel, may be formed between the roof trusses902with roof panels630. The channel905may provide a passageway for electric, data, plumbing, HVAC (heating, ventilation, and air conditioning), and any other type connections and/or utilities suitable for use in a modular building.

FIGS. 10A-11are cut away views of embodiment door panels1001. With reference toFIGS. 1A-11, the door panel1001that corresponds to the door panel121inFIGS. 1B-1Eand may include a door1002, door stop1003, a door frame profile1030, aluminum composite panels (ACPs)1008, a foam core1007, and an aluminum profile frame310. The ACPs1008may be a layered composite of aluminum sheeting layers adhered to the front and back of a sheet of polyethylene. In various embodiments, the wall panels door panel1001may be structural insulated panels (SIPs) formed from a sandwich of ACP or other hard materials and foam. The door may be affixed to the door frame profile1030by one or more hinges. The door panel1001may include panels1008sandwiching the door frame profile1030and foam core1007therebetween. Similarly to the wall panels306and the window panels406, the door panels1001may include an aluminum profile frame310encircling the door panel1001and supporting the panel seals305and/or405. The panels1008may extend beyond the door frame profile1030and foam core1007and form a groove structure along the edge of the door panels1001that supports the aluminum profile frame310and panel seals305,405therein. In some embodiments, the aluminum profile frame310may clamp the panel seals305,405in place, and the aluminum profile frame310and panel seals305,405may also form a groove structure within the groove structure along the edge of the door panels1001. The groove structure formed by the aluminum profile frame310and panel seals305,405along the edge of the door panels1001may slide over a raised portion (e.g., a raised portion include the rail features725) of the lower horizontal element350that may be affixed to a foundation or floor. The aluminum profile frame310may rest on the rail features725of the lower horizontal element350and a channel316may be formed between the lower horizontal element350and aluminum profile frame310between the rail features725. The raised features315of the vertical element (e.g., vertical element612,512, etc.) may interconnect with the door panel1001. The raised features315may form a tongue structure that inserts into the groove structure formed by the aluminum profile frame310and panel seals305,405along the edge of the door panel1001, thereby joining the vertical element with the door panel1001by respective tongue and groove type joints. When the vertical element and the panel1001are joined together, channels316, such as vertical channels, may be formed between the vertical element and the panels1001as discussed above. Additionally, when the horizontal element (e.g., upper horizontal element610and/or lower horizontal element350, etc.) are joined together, channels316, such as horizontal channels, may be formed between the horizontal element and the panels1001as discussed above.

FIGS. 12 and 13illustrate cut-away views of the embodiment window panel406. With reference toFIGS. 1A-13, in alternative configurations, the window panel may include additional foam core1302between the panels454. The dimensions of spacer452may also be modified to accommodate thicker or thinner window panels.

FIGS. 14 and 15are cut-away views of a roof panel630according to various embodiments. With reference toFIGS. 1A-15,FIG. 14shows the roof panel630with the aluminum composite panel631removed, whileFIG. 15shows the roof panel630with the aluminum composite panel631installed. InFIG. 14, the aluminum profile frame310encircling the roof panel is visible supporting the panel seal305.

FIGS. 16A-16Cillustrate views of another modular building1600according to various embodiments. With reference toFIGS. 1A-16C, the modular building1600may include more than two rooms and may be larger than the building ofFIGS. 1A-1E.

FIG. 17is a cut-away view of a floor support1703for a modular building according to various embodiments. With reference toFIGS. 1A-17, the floor support1703may be configured to affix to the upper horizontal elements610. In this manner, the floor support1703may enable the construction of multi-floor modular buildings. The floor support1703may include a floor anchor1707, such as a bolt, etc., running through a hollow center portion of the floor support1703and connecting to the upper horizontal portion610of the lower level and the lower horizontal portion350of the upper level. The floor support1703may be a horizontal element configured to support a floor section1702and/or lower horizontal elements350. In various embodiments, a floor section1702may be similar in construction to a roof as described herein, such as formed from a series of panels and trusses. The floor section1702may be supported by a protrusion1704extending inward toward the center of the modular building from the floor support1703. The floor portion1702may be include passages1705therein to provide a passageway for electric, data, plumbing, HVAC (heating, ventilation, and air conditioning), and any other type connections and/or utilities suitable for use in a modular building. The floor support1703may extend horizontally beyond the upper horizontal elements610on which it is affixed to support the floor1702. The lower horizontal elements350of the next floor of the modular building may be affixed to the floor support1703. The floor support1703may separate each floor of the modular building and a roof may be affixed to the top floor using a roof support616as described herein rather than another floor support1703. An upper portion of the floor support1703may be narrower than the lower horizontal elements350to create a lip1706to contact the floor1702.

FIG. 18illustrates different horizontal element configurations1902,1904,1906,1908, and1910according to various embodiments. With reference toFIGS. 1A-18, a horizontal element configuration1902may be a straight element with no slots722. In another configuration1904, the horizontal element may include a slot722between a first raised portion and second raised portion and holes1901passing through the horizontal element to enable connections to other elements, such as a foundation, etc. In another configuration1906, the horizontal element may include a panel seal405on the first raised portion. In another configuration1908, the horizontal element may include a shock absorber304. In another configuration1910, the horizontal element may include a bracket1903at one end. Horizontal elements1902-1910may include rail features725along their lengthwise directions over which a vertical element and/or panel may be slid and/or that may slide into a vertical element and/or panel. A slot between the rail features725may create the channel316between the panels and the horizontal elements1902-1910when joined together.

FIG. 19illustrates lower horizontal elements350arranged into an H-frame2000suitable for installation on a foundation or floor. With reference toFIGS. 1A-19, the lower horizontal elements350may include shock absorbers304. Once the H-frame is affixed to the foundation or floor, the vertical elements and panels discussed herein may be slide onto the lower horizontal elements350to form the walls of a modular building.

FIG. 20illustrates such example panels according to various embodiments. With reference toFIGS. 1A-20,FIG. 20illustrates a roof panel630, a wall panel306, a door panel1001, and a window panel406. The panels slide over the rail features725on the lower horizontal elements350. Similarly, the rail features725of the upper horizontal elements350slide into the panels. In various embodiments, the roof panel630, the wall panel306, the door panel1001, and/or the window panel406may be structural insulated panels (SIPs) formed from a sandwich of ACP or other hard materials and foam.

FIG. 21illustrates a cut-away view a corner portion of a modular building according to various embodiments. With reference toFIGS. 1A-21,FIG. 21illustrates an embodiment modular building in which separate inside walls are affixed inside of the vertical elements and/or vertical panels (e.g., wall panels, door panels, window panels, etc.). The wall panels2101shown inFIG. 21may be similar to the wall panels123and306described herein. The vertical element2102shown inFIG. 21may be similar to the vertical element412described herein. The lower horizontal element2107shown inFIG. 21may be similar to horizontal element350described herein and may further be configured to support the insertion of an inside wall (or inner wall) disposed toward the inside of the modular building affixed to the wall panels2101. The locking system2103may be disposed between the inside wall and the vertical element2102and/or wall panels2101. The locking system2103may connect an upper horizontal element to the lower horizontal element2107. The locking system2103between the inside wall and the vertical element2102and/or wall panels2101may be tensioned to pull the upper horizontal element toward the lower horizontal element to thereby lock vertical elements (e.g., vertical element2102) and vertical panels (e.g., wall panels2101) in place between the upper horizontal elements and the lower horizontal element2107. The locking system2103may include an upper lock bar2106(or lock rod, cable, etc.) coupled to a lower lock bar2105(or lock rod, cable, etc.) by a shock absorber2104. For example, the shock absorber2104may be a metal (e.g., steel, etc.) oval spring, rubber block, hydraulic system, etc. The shock absorber2104may operate similar to shock absorber304as described herein.

In alternative embodiments, the locking systems as described herein may not interact with the lower horizontal elements350. Rather, the locking systems may pull the upper horizontal elements610toward the foundation and/or floor to thereby lock vertical elements and vertical panels in place between the upper horizontal elements and the foundation and/or floor. For example, lock rod302(or lock cable, or other locking mechanism) may connect to a bolt in the foundation on a first level of a modular building and/or lock rod302(or lock cable, or other locking mechanism) may connect to a bolt in a floor of a second or higher level of a modular building. The lock rod302(or lock cable, or other locking mechanism) may be tensioned during installation to create force holding the modular building walls together.

FIG. 22illustrates cut-away side views of two different panel seals305and405. With reference toFIGS. 1A-22, the panel seal305,405may be formed from a compressible material, such a plastic, rubber, or other type material seal, that may act as a weather seal for the joints of the modular building. The panel seal305,405may form a flexible seal between the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels that join to the vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.). The panel seal305,405may be affixed to the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels, such as by glue, nails, friction, physical arrangement of the surface of the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels, and/or any in any other manner. The presence of the panel seal305,405at the joint connection points may eliminate the need for caulking and/or glue in the modular building. The panel seal305,405may be a flexible seal having one or more raised flexible features2201(e.g., lips, wipers, bubbles, etc.) extending from a main body2202of the panel seal305,405. The raised flexible features2201may be compressed toward the main body2202(e.g., in the direction “C”) when the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.) are joined together (e.g., by being inserted in the direction “I”). The compression of the raised flexible features2201may form compression interlocks between the vertical panels (such as door panels, window panels, wall panels, etc.) and/or roof panels that join to the vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.). In various embodiments, the raised flexible features2201may be compressed to lie flat against the main body2202when the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)) are joined together. Additionally, the raised flexible features2201may mold to the mating surface of the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)) when the structural elements are joined together. The flexibility of the panel seal305,405may compensate for tolerance variations in the profiles of the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.), especially when such structural elements of the modular building are formed from FRP. As the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.) are joined together, the panel seal305,405may compress (e.g., the raised flexible features2201may compress toward the main body2202in the direction “C”, and/or the main body2202may compress in the direction “C”) and the compression may provide the required tolerances for the structural elements of the modular building to fit together, as well as may act as a shock absorber between the structural elements. This compression of the panel seal305,405may make the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)) easier to fit together. Additionally, by compensating for tolerance variation in the structural elements of the modular building (e.g., the vertical panels (such as door panels, window panels, wall panels, etc.), roof panels, vertical elements and/or horizontal elements (e.g., lower horizontal elements, upper horizontal elements, roof trusses, etc.)), this compression of the panel seal305,405may prevent modular panels from not fitting together at a build site and needing to be shipped back to a supplier due to not fitting. WhileFIG. 22illustrates two example configurations of the panel seal305,405, other configurations of panel seals, such as other configurations with different shapes of raised features2201and main bodies2202, different numbers of raised features2201, etc., may be substituted for the panel seals305and405described herein.

Various aspects illustrated and described are provided merely as examples to illustrate various features of the claims. However, features shown and described with respect to any given aspect are not necessarily limited to the associated aspect and may be used or combined with other aspects that are shown and described. Further, the claims are not intended to be limited by any one example aspect.