Abstract:
Disclosed is a modular hurricane proof modular building structure. The structure includes a dual wall system that includes a rugged exterior constructed primarily of concrete and steel and a finished interior, with a thermal break in-between to prevent heat from the concrete and metallic structure from heating the interior surfaces. The thermal break also prevents moisture and water vapor transfer, and therefore, significantly reduces mold growth. The building combines the best of industry desired characteristics in a single modular constructed building, combining hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction.

Description:
CROSS REFERENCE TO RELATED APPLICATION  
       [0001]     This application is a nonprovisional of U.S. Patent Application Ser. No. 60/506,498, filed Sep. 26, 2003, which is incorporated herein by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     This invention relates generally to modular building systems, and more particularly to hurricane proof modular building structures.  
         [0003]     Increasingly, states that are confronted with the possibility of tropical storms and hurricanes have promulgated safety standards in the construction of certain buildings aimed at minimizing damage to those buildings in hurricane-type situations, in effect requiring the buildings to be “hurricane proof” to the extent possible, to for example, withstand extremely high level winds and high velocity projectiles that are associated with such wind levels. In response, the industry has moved towards concrete construction. In the modular building industry, it is a continuing design goal to meet or exceed the state imposed construction parameters for hurricane-resistance, and at the same time maintain a level of portability for the modularly constructed buildings.  
         [0004]     Modularly constructed building structures are advantageous in that they provide shelter from the elements in which a variety of activities can be housed, and are relatively easily transported from one locale to another. Moreover, such structures can typically be assembled in stackable sections, or sections placed side-by-side (i.e., the sections are positioned adjacent each other), right on site after being transported. Modular building structures can be used for production of single and multi-unit or multi-family homes, as well as apartments, condominiums, classrooms, general offices, medical facilities, commercial buildings and the like.  
         [0005]     Further, in the modular building structure industry, there are increasing requirements and market forces aimed at improving the structure resistance to mold and combustion. It has been found that there is a need for a modular building with substantial concrete construction, therefore meeting the hurricane-proof requirements, as well as providing a fire-resistant (or non-combustible) structure with mold-resistant characteristics.  
         [0006]     One construction technique to address the above includes building a wall within a wall. However, such a procedure promotes heat transfer and moisture/vapor transfer that leads to mold growth. A need exists to improve the wall within a wall construction to create thermal barriers and moisture/vapor barriers.  
         [0007]     Many modular building structures are custom designed. However, building structures can also be designed according to standard or pre-fabricated building templates as well. Today&#39;s modular building structures are computer-engineered to meet national building codes. They can be precisely engineered for increased structural durability. High quality can be maintained by inspection during construction process. In one construction example, a modular building structure is delivered to a desired site, after which individual modular structures or “modules” are assembled into an overall modular building structure.  
         [0008]     In general, the metrics of building construction costs break out on a per square foot basis. It is a continuous goal to reduce the construction costs of the modular structures. To this end, it would be desirable to provide a modular building structure that, while meeting all applicable building codes and other standards, is simpler to construct than known modular building structures. For example, a building structure comprising fewer pieces, parts or other components in its construction is desirable. Similarly, material selection for such modular building structures is key, in that the material type and placement can result in a building structure of having a greater useful life and durability.  
         [0009]     It would also be desirable to use stronger and more durable modules or substructures in making the overall modular building structure. This can lead to a decrease in the number of supports or braces in a given area, thereby reducing modular building structure costs on a square foot basis.  
         [0010]     Accordingly, it would be desirable to provide a modular building structure that combines the best of industry desired characteristics in a single modular constructed building, combining hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction.  
       SUMMARY OF THE INVENTION  
       [0011]     This invention relates generally to a hurricane proof modular building structure, and more specifically to a hurricane proof modular building structure that has a combination of hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction.  
         [0012]     In one aspect of the invention, a hurricane proof modular building structure is disclosed. The building structure includes a floor structure for use in a hurricane proof modular building structure. The floor structure includes: a first floor structure portion and a second floor structure portion each comprising: a plurality of metal support structures; a non-composite deck disposed on top of the support structures; and a metal cross-member connected to the metal support structures. The first and second metal cross members are in opposing, spaced apart relationship with respect to each other to define a floor seam that permits separation of the floor structure along the floor seam;  
         [0013]     The building also includes a wall structure comprising: an outer concrete layer; a plurality of metal studs spaced apart from each other and positioned adjacent to, but separated from, the concrete layer, to create metal stud-concrete layer thermal gaps; a first insulation layer located between the plurality of metal studs and adjacent the concrete layer; a second insulation layer positioned adjacent the first insulation layer; and a mold resistant layer located adjacent the second insulation layer. The plurality of thermal gaps and at least one of the first and the second insulation layers create a thermal break. The structure also includes a roof structure, the roof structure comprising: a roof portion having load-bearing perimeter; and an inclined roof comprising opposing slanted portions reaching a central apex such that the apex of the slanted portions does not extend above the load-bearing perimeter. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     Embodiments of the invention are disclosed with reference to the accompanying drawings and are for illustrative purposes only. The invention is not limited in its application to the details of construction or the arrangement of the components illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in other various ways. Like reference numerals are used to indicate like components.  
         [0015]      FIG. 1  is a perspective view of one embodiment of a hurricane proof modular building structure according to one aspect of the present invention;  
         [0016]      FIG. 2  is top view illustrating a floor plan of the hurricane proof modular building structure of  FIG. 1 ;  
         [0017]      FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 1 ;  
         [0018]      FIG. 4  is a cross-sectional view taken along line  4 - 4  of  FIG. 1 ;  
         [0019]      FIG. 5  is an enlarged detailed view of a portion of the hurricane proof modular building structure shown in  FIG. 4 ;  
         [0020]      FIG. 6  is an enlarged detailed view of a portion of the hurricane proof modular building structure taken along line  6 - 6  of  FIG. 2 ; and  
         [0021]      FIG. 7  is a perspective view of a plurality of hurricane proof modular building structures showing their modularity and stackability. 
     
    
     DETAILED DESCRIPTION  
       [0022]      FIG. 1  is a perspective view of one embodiment of a hurricane proof modular building structure  10  according to one aspect of the present invention. By “hurricane proof” it is meant that the structure is built to withstand and be resistant to high winds (e.g., tropical storm level winds up to about 75 mph, hurricane force winds from about 75 mph up to about 150 mph, and the like). The structure is “modular” in that the structure is designed an built with standardized units or dimensions so as to promote ease of assembly and repair. As will be described in greater detail below, each such structure is built from prefabricated and standardized parts and/or component pieces. Various applications are intended and contemplated for the structure shown, and these include: single and multi-unit or multi-family homes, as well as apartments, condominiums, support facilities, general offices, medical facilities, light manufacturing, commercial buildings and the like, although, in a preferred embodiment, the structure can be used for a classroom. In a typical construction, the modular building structure can include such features as door  12  and windows  14 , replicating features found in permanent building structures.  
         [0023]     As shown, the structure  10  is generally rectangular, although other shapes are contemplated and considered within the scope of the present invention. Structure  10  includes a roof structure  16  that typically inclined downwardly from a roof centerline or apex  18  to promote drainage of water off of or away from the roof via, as shown, drainage pipes  20  to a grounded location. The structure shown represents a combination of two half modular sections placed together and connected (as will be shown and described in following) in side-by-side fashion along line  22  after being delivered to the site of use. The structure shown and described herein represents a culmination of a transition or trend in the modular building marketplace towards what is referred to as “concrete construction”. Accordingly, in one embodiment, the structure includes walls  24  that is a poured concrete wall. The walls, notwithstanding the windows, renders the structure substantially bullet-proof.  
         [0024]     The structure  10  is constructed for several design parameters, for example, the floor structure  36  of  FIG. 5  is designed for a 50 PSF live load; roof structure  16  is designed for a 30 PSF live load snow-to-ground load; and the overall structure  10  is designed to withstand an overall wind speed of 150 mph, and a class C wind exposure.  
         [0025]     Advantageously, structure  10  (i.e., both its exterior and in its interior) can be delivered to a site as a substantially complete module (i.e., about 95% finished). This results in a cost reduction for the user, and decreases time to use (e.g., on the order of about a day or two) from the time of delivery of module structure  10  to the site of use.  
         [0026]      FIG. 2  is top view illustrating a floor plan of the hurricane proof modular building structure of  FIG. 1 . Doors  12  are shown in an open position. Centerline  22  delineates the location at which the two half modular sections  26   a - b  are combined to create the overall building structure  10 . One advantage of this structure design is that each of the sections  26   a - b  are easily transported to a specified location. For example, each of the half structures can be brought separately (e.g., via truck) to a job site. In addition, each of the structures  26   a - b  can be used in locations that would otherwise be inaccessible due to the need to previously transport structure as a whole. Walls  24  define structure interior portions  28   a - b.  Because of the high level of structural support provided by walls  24 , portions  28   a - b  are “open-concept” in that other structure support members (e.g., beams, pillars, etc.) are not required. Therefore, a variety of uses can be accomplished within the interior, and the interior is highly adaptable to such uses.  
         [0027]      FIG. 3  is a cross-sectional view taken along line  3 - 3  of  FIG. 1 , showing the building structure  10 , and in particular, illustrating a recessed roof structure  16 , the roof structure supported by walls  24 , connected to a floor structure  40 . Roof structure  16  comprises a raised roof portion  30  defining load-bearing perimeter, and further including an inclined roof  32  comprising two opposing slanted roof portions  34   a - b.  The roof portions are opposingly sloped or pitched so as to reach or define a central apex  35 , which coincides with a roof centerline  18 . The apex of the slanted portions  34   a - b  does not extend above the load-bearing perimeter of the roof portion  30 , thereby permitting or facilitating stacking of at least one additional modular building structure of similar size and shape thereon. Stated another way, the inclined roof first and second opposingly inclined roof structure portions are in spaced apart relationship with respect to each other to define a roof seam that permits separation of the inclined roof along the seam. Since the raised roof portion is preferably substantially level, and since the roof is recessed from the raised roof portion, dual benefits are achieved. Namely, stacking of a plurality of modular structures is facilitated, while simultaneously permitting drainage along the two opposing slanted portions away from the structure itself.  
         [0028]      FIG. 4  is a cross-sectional view taken along line  4 - 4  of  FIG. 1  showing interior portions  28   a - b  of half modular sections  26   a - b.  Although structures  26   a - b  are separate and distinct, they are joined to form a single unit in a cohesive fashion, for example, by common interior finishing of walls  33  and drop ceiling  37 . In this way, interior portions  28   a - b  can be used to create a single interior space.  
         [0029]      FIG. 5  is an enlarged detailed view of a portion of the hurricane proof modular building structure shown in  FIG. 4 . Specifically, a floor structure  36  for use in the hurricane proof modular building structure  10  is shown. The floor structure comprises a first floor structure portion  38  having a plurality of metal support structures  40  (e.g., steel I-beams), one of which is shown, and a non-composite deck  42  disposed on top of the support structures  40 . The first floor structure portion  38  includes a metal cross-member  44  connected to the metal support structures. The floor structure  36  also includes a second floor structure portion  46  having a second plurality of metal support structures  48  (again, one of which is shown) and a second non-composite deck  50  disposed on top of the support structures  48 . The second floor structure portion  46  also includes a second metal cross-member  52  connected to the metal support structures  48 . The first and second metal cross members are in opposing, spaced apart relationship with respect to each other so as to define a floor seam  54  that permits separation of the floor structure along the floor seam or channel. The seam or channel  54  can be bridged using, for example, a lightweight concrete deck. The non-composite deck can comprise, by way example, a 24 gauge galvanized steel. The floor structure can be finished by including a concrete deck  43  over the non-composite deck.  
         [0030]     Advantageously, the inventive floor structure results in a hurricane proof modular building structure that does not comprise a knockout floor section. “Knockout” sections are typically used during the installation of indoor plumbing. “Knockout sections” are sections that are removable prior to such installation (e.g., at the site), and then following installation, the sections are re-poured, for example, with a concrete material.  
         [0031]      FIG. 6  is an enlarged detailed view of a portion of the hurricane proof modular building structure taken along line  6 - 6  of  FIG. 2 . Referring now to  FIGS. 5 and 6 , a wall structure  56  for use in the inventive hurricane proof modular building structure  10  ( FIG. 5 ) is shown in detail. The wall structure comprises an outer concrete layer  58  and a plurality of metal studs  60  spaced apart from each other and positioned adjacent to, but separated from, the concrete layer to create metal stud-concrete layer thermal gaps  62 . The wall structure  56  further includes a first insulation layer  64  located between the plurality of metal studs  60  and adjacent the concrete layer  58 . A second insulation layer  66  is positioned adjacent the first insulation layer  64  and a mold resistant layer  68  is located adjacent the second insulation layer  66 . The plurality of thermal gaps  62  and at least one of the first and the second insulation layers  64 ,  66  are utilized to create a thermal break  70 , and a plurality of thermal breaks are included in the structure. Typically, the concrete layer  58  is of prescribed thickness and density so as to create a moisture-impermeable external vapor barrier. And the vapor barrier and thermal break create substantially mold-resistant conditions within the wall structure. Advantageously, hurricane proof modular building structure comprising a vapor proof wall section. The building structure can include a poured concrete exterior modular wall section having a finished interior wall. It can be said that the hurricane proof modular building structure comprises a wall within a wall, providing both a thermal break and a moisture barrier. In one embodiment, a foam seal insulation system can be used to provide the thermal break, eliminating the need to use mechanical fasteners.  
         [0032]     Advantageously, the wall structure is provided with both a plumbing entry and a plumbing discharge to permit indoor plumbing while also providing for ease of hook up and disconnect to enhance and facilitate mobility of the structures. In such embodiments, it can be said that the plumbing entry and the plumbing discharge do not run through the building structure floor. Because the plumbing entry and discharge can be positioned to run above the floor, and through the exterior wall (as opposed to through the floor), there is no need to utilize a “knock-out” portion of the floor during plumbing installation at the site.  
         [0033]     The present invention provides a wall structure that includes a space defined by the steel studs and the concrete walls, as well as insulation between the steel studs and the interior drywall, in order to create a thermal break. The concrete provides a built-in, external vapor barrier. The combination of the vapor barrier and the thermal break serves to eliminate conditions that allow mold to form, such as mold that results from moisture and temperature change-induced condensation.  
         [0034]     Referring to  FIG. 5 , roof structure  16  is supported by structural steel make beam  72  embedded on a light track  74  and cross beam steel joist  75 , joined by steel angles  76 , which support roofing materials, such as corrugated deck pan  78 . A roofing material  80  (e.g., EPDM) may be applied over the deck pan  78 . Between roofing material  80  and deck pan  78  is a layer (e.g., 2 inches in thickness) of insulation material (e.g., polyiso) to provide additional insulation and heat retention within structure  10 . The advantage of using a steel I-beam, as opposed to, for example, a cast concrete I-beam, provides for a reduced-weight construction, which enhances portability of the structures.  
         [0035]      FIG. 7  is a perspective view of a plurality of hurricane proof modular building structures  10   a - c  showing both their modularity and stackability. The modular building structures shown include a combination of industry-desired characteristics including hurricane force wind resistance, relocateability, modularity, fire and heat resistance, mold resistance and substantial concrete construction. The hurricane proof modular building structure is suitable for human use or habitation. As shown, the structures are formed into a modular building structure arrangement that is two stories high and two structures wide. However, it is contemplated that other arrangements could be of different height or width, as applications vary and conditions so dictate. As referenced previously, the concealed interior slope for drainage, coupled with external load-bearing vertical wall members results in a design that provides for such stackability to create multi-story modular buildings.  
         [0036]     Preferably, in order to eliminate the need for battens to conceal joints and mechanical fasteners, beveled edge drywall panels are used and fasteners are covered with spackle. A specially-designed paint and application system can be used to spray, for example, for colors at once over the walls to provide a suitable finish.  
         [0037]     The present invention combines multiple beneficial features in one composite structure. While the present invention has been described in terms of the preferred embodiment, it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims.