Patent Publication Number: US-2023160196-A1

Title: Modular habitable structures, and associated systems and methods

Description:
BACKGROUND 
     Conventional building construction typically involves site-specific designs that are constructed entirely or nearly entirely on-site. There is a desire for modular building designs that can be assembled at a remote site and brought to a building site for assembly in various configurations that can be repeated or altered among various sites. 
     SUMMARY 
     Representative embodiments of the present technology include a structural system including one or more modules. A module may include a first upper chord oriented along a length of the module, a first lower chord oriented along the length of the module, a second upper chord positioned opposite the first upper chord, parallel to the first upper chord, a second lower chord positioned opposite the first lower chord, parallel to the first lower chord, and a plurality of rib assemblies positioned between the first upper chord, the first lower chord, the second upper chord, and the second lower chord, the rib assemblies extending along a width of the module perpendicular to the chords. At least one of the chords may include a plurality of chord portions joined together with one or more connector plates. Two of the rib assemblies may include shear keys configured to be received in support structures, such as piers at a final installation site. In some embodiments, each chord portion includes a plurality of arrays of holes. The rib assemblies may include two vertical column beams and two or more horizontal crossbeams connecting the column beams to each other. The shear keys may project downwardly from the vertical column beams. 
     Another representative embodiment of the present technology includes a method of making a structure. Making the structure may include making a module of the structure. The method may be at least partially performed at a first location (such as a factory) that is remote from a second location (such as a final outdoor installation location of the structure). The method may include positioning shear keys (attached to the module) into pockets formed in piers (such as concrete piers) at the final installation location. The method may include leveling the module by positioning shims in the pockets under the shear keys or moving the shear keys within the pockets. Empty space in the pockets may be filled with filler material, eliminating a need for bolting the module to the piers. 
     Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings, wherein the same reference number indicates the same element throughout the several views: 
         FIG.  1    illustrates a perspective view of a modular structure configured in accordance with embodiments of the present technology. 
         FIG.  2    illustrates a perspective view of a module configured in accordance with embodiments of the present technology and suitable for use in the modular structure shown in  FIG.  1   . 
         FIG.  3    illustrates a side perspective view of a chord portion configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in  FIG.  2   . 
         FIG.  4    illustrates a chord configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in  FIG.  2   . 
         FIG.  5   a    illustrates a rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in  FIG.  2   . 
         FIG.  5   b    illustrates another rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in  FIG.  2   . 
         FIG.  6    illustrates positioning a module on a pier at a final installation site, in accordance with embodiments of the present technology. 
     
    
    
     DETAILED DESCRIPTION 
     The present technology is directed to modular structures (which may be habitable structures), and associated systems and methods. Various embodiments of the technology will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments. Accordingly, embodiments of the present technology may include additional elements or exclude some of the elements described below with reference to  FIGS.  1 - 6   , which illustrate examples of the technology. 
     The terminology used in this description is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section. 
     Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all the items in the list, or (c) any combination of items in the list. Further, unless otherwise specified, terms such as “attached” or “connected” are intended to include integral connections, as well as connections between physically separate components. 
     As used herein, the term “and/or” when used in the phrase “A and/or B” means “A, or B, or both A and B.” A similar manner of interpretation applies to the term “and/or” when used in a list of more than two terms. 
       FIG.  1    illustrates a perspective view of a modular structure  100  configured in accordance with embodiments of the present technology. The modular structure  100  may be a habitable structure such as a home or an office, or it may be a structure for storage or other non-habitable purposes. The modular structure  100  may be supported on a plurality of piers  110  or other suitable support structures. In some embodiments, the modular structure  100  can include one or more modules  120 .  FIG.  1    illustrates two modules  120  joined together at an interface  130 . 
     Each module  120  includes usable or habitable interior space, and when multiple modules  120  are joined, they may form a combined interior space. Supporting the modules  120  on piers  110  enables building the modular structure  100  on uneven terrain while controlling (e.g., minimizing) the impact on the surrounding environment. Supporting the modules  120  on piers  110  may also facilitate using the space beneath the modular structure  100  for storage, additional usable space, or other uses. In coastal areas or other areas prone to flooding, the piers  110  provide elevation above floodwaters. Although  FIG.  1    shows one example of modules  120  positioned adjacent to each other to form the modular structure  100 , in other embodiments, the modules  120  may be positioned or arranged to form other shapes or configurations of modular structures  100  (i.e., any arrangement or quantity of modules  120  abutting or connected to each other). 
       FIG.  2    illustrates a perspective view of a module  120  configured in accordance with embodiments of the present technology and suitable for use in the modular structure  100  shown in  FIG.  1   . In some embodiments, the module  120  may be rectilinear, with rectilinear components. For example, in some embodiments, the module  120  may include a Vierendeel truss structure. In some embodiments, four piers  110  may support the module  120 . In some embodiments, the piers  110  may be positioned approximately 12 feet from ends of the module  120  along the length L of the module  120 , and the piers  110  may be positioned approximately 48 feet apart along the length L of the module  120 , such that the overall module  120  may be approximately 72 feet long. The piers  110  may be positioned approximately 18 feet apart along the width W of the module  120 , such that the overall module  120  may be approximately 18 feet in width. Other embodiments may include other suitable dimensions, other quantities of piers  110 , or other support structures. 
     The module  120  may include a plurality of chords  200  (such as four chords  200 ), which may span the length L of the module  120 . For example, in some embodiments, the chords  200  may include a first upper chord  202  oriented along the length L of the module, a first lower chord  204  oriented along the length L of the module, a second upper chord  206  positioned opposite the first upper chord  202  and oriented parallel to the first upper chord  202 , and a second lower chord  208  positioned opposite the first lower chord  204  and oriented parallel to the first lower chord  204 . 
     The module  120  may also include a plurality of rib assemblies  210 , each of which extends along the width W of the module  120  between the chords  200 . The module  120  may further include suitable roof panels  220  and floor panels  230 . The roof panels  220  and the floor panels  230  may be supported by the rib assemblies  210  and/or the chords  200 .  FIG.  2    shows two roof panels  220  and two floor panels  230 , although more or fewer roof panels  220  and/or floor panels  230  may be included in the module  120 . For example, the entirety of the top of the module  120  may include roof panels  220 , and the entirety of the bottom of the module  120  may include floor panels  230 . The module  120  may also include one or more walls or windows  240 , which may also be supported by the rib assemblies  210  and the chords  200 . 
     One or more of the chords  200  may be formed as a single integral beam or with a plurality of chord portions  250  joined together with one or more connector plates  260 . For example,  FIG.  3    illustrates a side perspective view of a chord portion  250  configured in accordance with embodiments of the present technology and suitable for implementation in the module  120 . The chord portion  250  may be an I-beam, a C-beam, a box beam, or another suitable linear extrusion.  FIG.  4    illustrates a perspective view of a chord  200  configured in accordance with embodiments of the present technology. The chord  200  may include two or more chord portions  250   a ,  250   b  joined together with a connector plate  260 . 
     Referring to  FIGS.  3  and  4   , the chord portion  250  may include fastening interfaces in the form of holes  300  that are arranged in arrays  310  (only some of the holes  300  are labeled in  FIGS.  3  and  4    to avoid obscuring the figures). The connector plate  260  includes one or more arrays  310  of holes  300  corresponding to one of the arrays of holes on a first chord portion  250   a  and one of the arrays of holes on a second chord portion  250   b . Suitable fasteners  320 , such as bolts, may be installed in corresponding holes  300  to hold the chord portions  250  together with the connector plate  260 . 
     In some embodiments, the connector plate  260  carries the load from one chord portion  250   a  to the other chord portion  250   b . Although a connector plate  260  is shown and described for connecting the chord portions  250 , in some embodiments, a beam with holes similar to the holes  300  in the connector plate  260  may be used to join the chord portions  250 . In some embodiments, an overall length L 1  of one or more chord portions  250  may be approximately  405  inches, or other suitable dimensions. 
       FIG.  5   a    illustrates a bottom perspective view of a rib assembly  500  configured in accordance with embodiments of the present technology and suitable for implementation as one or more of the rib assemblies  210  described above with regard to  FIG.  2   . In some embodiments, the rib assembly  500  is a rectilinear structure that includes two vertical column beams  510  each forming a side of the rib assembly  500 , and two or more horizontal crossbeams  520  connecting the column beams  510  to each other, such as one or more upper horizontal crossbeams  520   a  and one or more lower horizontal crossbeams  520   b . In some embodiments, each horizontal crossbeam  520  may be bolted to each column beam  510 . In other embodiments, the horizontal crossbeams  520  may be welded to the column beams  510 , or they may be attached in other suitable ways. In some embodiments, the rib assembly  500  may include two upper horizontal crossbeams  520   a  connected with one or more upper tie plates  525 , and two lower horizontal crossbeams  520   b  connected with one or more lower tie plates  527 . The upper and lower tie plates  525 ,  527  enhance the squareness and rigidity of the rib assembly  500 . 
     In some embodiments, the rib assembly  500  may include one or more shear keys  530  (such as two shear keys  530 , or one on each side of the rib assembly  500 ). The shear keys  530  may be bolted and/or welded into the rib assembly  500 . The shear keys  530  project downwardly from the rib assembly  500  and are configured to engage the piers  110  (see  FIGS.  1  and  2   ), as explained in additional detail below with regard to  FIG.  6   . 
       FIG.  5   b    illustrates a rib assembly  540  configured in accordance with embodiments of the present technology and suitable for implementation as one or more of the rib assemblies  210  described above with regard to  FIG.  2   . The rib assembly  540  may be identical to, or generally similar to, the rib assembly  500  described above with regard to  FIG.  5   a   , except that it may not include the shear keys  530 . Each of the rib assemblies  210 ,  500 ,  540  may be attached to the chords  200  or chord portions  250  via suitable fasteners (such as bolts, screws, or other suitable fasteners) or via welding, or via another suitable attachment. 
     With additional reference to  FIG.  2   , in some embodiments, a module  120  may be supported on only four piers  110  (or another suitable number of piers  110 ). A module  120  may include a number of shear keys  530  corresponding to the number of piers  110  (for example, four shear keys  530  for four piers  110 ). Accordingly, in some embodiments, a module  120  may include two of the rib assemblies  500  with shear keys  530 , with the remainder of the rib assemblies  210  being the rib assemblies  540  (without shear keys  530 ). The rib assemblies  210 ,  500 ,  540  may include more or fewer features or may take other forms, in other embodiments. 
     With continued reference to  FIG.  2   , the module  120  may further include finishing elements that make it more habitable, such as plumbing, electrical facilities, interior bulkheads or walls to create room spaces, and other finishing elements. In some embodiments, finishing aspects such as flooring, roofing, windows, doors, wiring, plumbing, furnishings, or other aspects may be added to the module  120  in a factory or other site remote from the final installation site. In other embodiments, the module  120  may be moved to a final installation site as a skeletal frame, and finishing aspects may be added at the final installation site. Beams and columns forming the module  120  may be formed with any suitable material, such as steel, aluminum, or another suitable metal material. 
       FIG.  6    illustrates positioning a module  120  on a pier  110  at a final installation site, in accordance with embodiments of the present technology. The piers  110  may be concrete, and therefore may be subject to their own inaccuracies in location. Embodiments of the present technology compensate for the high tolerances associated with the piers  110 . For example, in some embodiments, each pier  110  may include a pocket  600  for receiving a shear key  530 . In some embodiments, the pocket  600  may be wider than the shear key  530  to facilitate adjustment of the position of the module  120  at the installation site (e.g., by moving the shear keys  530  within the pockets  600 ). 
     In some embodiments, the system may include a shim  610  positioned between the shear key  530  and the bottom  620  of the pocket  600 . The shim  610  facilitates leveling and height adjustment to compensate for inaccuracies and/or high tolerances in the pier  110  and/or the pocket  600 . Although shims  610  may not be needed if the piers  110  and pockets  600  are positioned with sufficient accuracy, in some embodiments, shims  610  of different sizes may be used in each pier  110 . When the module  120  is positioned and leveled at the final installation site, filler material (such as concrete and/or grout material) may be positioned in any empty space surrounding or adjacent to the shear key  530  within the pocket  600 . In some embodiments, all the empty space surrounding the shear key  530  within the pocket  600  may be filled with filler material. Accordingly, in some embodiments, anchor bolts are not needed to mount the module  120  to the piers  110 . 
     A method of making a modular structure in accordance with embodiments of the present technology may include building the chords  200  (such as the chords  202 ,  204 ,  206 ,  208 ) and the rib assemblies  210 , then connecting the elements together, then moving the assembly to a final installation site, and then penetrating/positioning the shear keys  530  into the piers  110 . Optionally, the method may include leveling the module  120  using one or more shims  610  and adjusting the position of the module  120  by moving the module  120  relative to the piers  110  (which may include moving the shear keys  530  side to side within the pockets  600 ). 
     Optionally, in some embodiments, other/additional modules  120  may be positioned adjacent to the module  120  on their own piers  110 . The modules  120  may be positioned and aligned relative to one another, facilitated by moving the shear keys  530  in the open space of the pocket  600  and/or by positioning one or more shims  610  under the shear keys  530  in the pockets  600 . In some embodiments, methods may include filling the open space in the pockets  600  with grout, concrete, or other suitable filler material to lock modules  120  in position. Other finishing work may be performed at any suitable time, such as attachment or installation of components that render the module  120  habitable, including flooring, roofing, electrical, plumbing, and other components. In some embodiments, part of the assembly process may be performed in a factory, including some of finishing work, such as attaching roof or floor panels, electric, plumbing, etc. The modular nature of the assemblies facilitates repeatable and easily duplicated manufacturing and installation of these components. 
     Aspects of the embodiments of the present technology provide several advantages. For example, embodiments of the present technology provide known repeatable structures, which enables subsequent finishing trades like mechanical, plumbing, glazing, trim, electrical, etc. to rapidly add their parts with less custom fabrication. In some embodiments, construction of modules  120  configured in accordance with embodiments of the present technology may not involve any welding at the final installation site (all welding may be performed at the prefabrication site/factory). 
     From the foregoing, it will be appreciated that specific embodiments of the presently disclosed technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the technology. For example, steps of the methods described herein may be performed in different orders or at different times, or concurrently. Accordingly, modules  120  and modular structures  100  configured in accordance with embodiments of the present technology may include other combinations of features disclosed herein. 
     Certain aspects of the technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Further, while advantages associated with certain embodiments of the presently disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.