Patent Publication Number: US-8539732-B2

Title: Structural building panels with seamless corners

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present invention is related to co-pending U.S. non-provisional patent application Ser. No. 12/322,380 filed Feb. 2, 2009, which is incorporated herein by reference in its entirety. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to modular building systems and methods, and more particularly, to modular building systems and methods for making them and for installing them to form a building structure. 
     2. Description of the Prior Art 
     Modular buildings and components used in making them are known in the art. By way of example, prefabricated housing components, including wall panels are known. However, after windows and doors energy losses most commonly occur in the seam or joint regions of structures, including prefabricated buildings and modular structural components. Additionally, while prefabricated panels and other components are known in the art, they are not structured or configured for quick and easy assembly to form a predetermined completed structure that also provides for an energy efficient structure that is also stable and reliable, i.e., able to withstand the natural elements including storm conditions. Sheer forces produced by large wind events (i.e. hurricanes, etc.) or seismic (earthquake) events can quickly render traditional building corners ineffective at maintaining the structural integrity of the building. There further exists a need for energy efficient structures that prevent heat and/or cooling losses through the seam or joint region of the structure, which, after windows and doors, is the most common area of energy loss in modular building structures. 
     One example of commercially available modular building components is found at http://aquentium.com/housing.htm. 
     Examples of relevant art includes the following US Patent documents: 
     U.S. Pat. No. 6,564,521 issued May 20, 2003 to Brown et al. for Structural sandwich panels and method of manufacture of structural sandwich panels, which teaches rigid structural members, profiles, joints, and forms added to structural sandwich panels to provide higher strength, integral joining joint and single facing sheet manufacturing. The joints provide for mating alignment via vertically oriented rigid members and corresponding elongated recesses. However, these members are provided for alignment and require the securement of joined abutting structural sandwich panels together with cam-locks.
 
U.S. Pat. No. 5,344,700 for Structural panels and joint connector arrangement therefore, describing a tongue-in-groove joint combined with a rod-like connecting mechanism.
 
U.S. Pat. No. 5,373,678 for Structural panel system also uses tongue-in-groove joints.
 
U.S. Pat. No. 5,950,389 for Splines for joining panels and U.S. Pat. No. 5,628,158 for Structural insulated panels joined by insulated metal faced splines, which provide for metal splines that are glued into slots in adjacent panels.
 
U.S. Pat. No. 5,842,314 for Metal reinforcement of gypsum, concrete or cement structural insulated panels and U.S. Pat. No. 5,349,796 for Building panel &amp; method, which teach improvements for reinforcement and strengthening structural panels using metal strips, and shear rail structures that function like I-beams to strengthen the panel, respectively.
 
U.S. Pat. No. 5,519,971 for Building panel, manufacturing method and panel assembly system, and U.S. Pat. No. 5,373,678 for Structural panel system describe the use of a header to interconnect adjacent panels; notably, the header is not mentioned in connection with an increased load-bearing capacity for the panels.
 
     None of the prior art addresses the longstanding need for stable, energy efficient modular building structures, including kits for installing same, in particular having structurally locked wall panel components that are aligned with a mating multiple rail track edge system. Thus there remains a need for energy efficient and stable modular building systems and methods for manufacturing and for installing them to form a building structure having energy efficient seams that provide for simultaneous alignment and friction-based securement of the panels at the joints. 
     SUMMARY OF THE INVENTION 
     The present invention provides modular building systems and methods for manufacturing and installing them. 
     One aspect of the present invention is to provide systems for a modular building having structural prefabricated wall panel components that are juxtapositioned, aligned and interconnected along their edges to form joints or seams, wherein the wall components are assembled and locked in place to form an energy efficient and stable modular building including energy efficient seams that provide for simultaneous alignment and securement of the panels at the joints, and further including energy efficient corner modular components that provide for seamless, insulated corners. 
     Another aspect of the present invention is to provide methods for manufacturing energy efficient and stable modular building systems having energy efficient seams or joints including energy efficient corners that are seamless and that provide for simultaneous alignment and friction-based securement of the panels at the joints. 
     Another aspect of the present invention is to provide methods for installing energy efficient and stable modular building systems having energy efficient seams or joints including energy efficient corners that are seamless and that provide for simultaneous alignment and friction-based securement of the panels at the joints. 
     Another aspect of the present invention is to provide a modular panel that is either insulative or non-insulative, but that still provides energy efficient corners that are seamless and that provide for structural integrity and strength. 
     Still another aspect of the present invention is to provide a modular building system with prefabricated composite wall panels that include conduits in the panel body with conduit input/output openings along predetermined edge areas of the panel body, and energy efficient seams or joints that provide for simultaneous alignment and friction-based securement of the panels at the joints. Methods for manufacturing and installation of the modular building systems are also considered aspects of the present invention. These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings, as they support the claimed invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1-14  illustrate various views related to the present invention. 
         FIG. 1  illustrates a perspective view of a partially assembled modular building structure. 
         FIG. 2  shows a perspective view of a completed modular building from the partially completed illustration of  FIG. 1 . 
         FIG. 3  illustrates several related views; in  FIG. 3A  a top view of two edges of modular wall panels having mating double railing for alignment and locking mechanism;  FIG. 3B  illustrates an end perspective view illustrating the parallel spaced apart double track or railing system;  FIG. 3C  illustrates a side view and cut-away of joined panel edges with the interlocking cam-based locking mechanism. While the interlocking cam mechanism is desirable for providing additional securement at the joints between two panels, it is not a requirement for some level of stability. 
         FIG. 4  illustrates a top view of a corner wall panel modular component with seamless corner and two wall component segments integrally connected therewith and extending outwardly therefrom. 
         FIG. 5A  illustrates a top view of a corner wall panel modular component with seamless corner and two wall component segments extending outwardly therefrom. 
         FIG. 5B  illustrates a “T” cross-section a top view of a corner wall panel modular component with seamless corner and three wall component segments extending outwardly therefrom. 
         FIG. 5C  illustrates a “+” cross-section a top view of a corner wall panel modular component with seamless corner and four wall component segments extending outwardly therefrom. 
         FIG. 6  illustrates several perspective views of the modular building components including  FIG. 6A  showing a basic flat wall panel component;  FIG. 6B  showing a 90 degree corner panel component;  FIG. 6C  showing a 135 degree angle corner panel or transition panel;  FIG. 6D  showing a window opening in a wall panel component;  FIG. 6E  showing a door opening in a wall panel component. 
         FIG. 7  illustrates an exploded view of various component panels. 
         FIG. 8  illustrates various component roof panels. 
         FIG. 9  illustrates a cut-away partial side view of a wall panel installation according to one aspect of the present invention. 
         FIG. 10A  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention;  FIG. 10B  illustrates a partial perspective view of a section of  FIG. 10A ;  FIG. 10C  shows a cut-away side view of a section of  FIG. 10A . 
         FIG. 11  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention. 
         FIG. 12  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention, including two stages of corner panel installation. 
         FIG. 13  illustrates a cut-away partial perspective view of a wall panel installation of two components constructed and configured for connection following the step illustrated in  FIG. 12B . 
         FIG. 14  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention, including a unitary and integral single component seamless corner panel and wall panel components connected thereto. 
     
    
    
     DETAILED DESCRIPTION 
     In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms. 
     The present invention provides systems and methods for a modular building that is self-contained within a standard shipping container, wherein the pre-fabricated panel wall components are easily assembled to form a predetermined structure further including energy efficient corner modular components that provide for seamless, insulated corners. The present invention also provides a modular building system with prefabricated composite wall panels that include conduits provided within the panels; these conduits may optionally be pre-wired. Methods for installation of the modular building system include the steps of providing prefabricated modular building components, including modular panel components having edges with interconnecting interfaces for aligning, connecting, and securing panel components together at their edges and forming an energy efficient seam thereby, and further including energy efficient corner modular components that provide for seamless, insulated corners; assembling the modular housing by arranging and connecting the composite wall panels, which may include conduits for electrical and/or plumbing disposed within the interior section of the composite wall panels, including input/output openings for wiring, etc. 
     Referring now to the drawings in general, the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. In the figures, the modular building materials are shown including interlocking pre-engineered and pre-insulated panels that are constructed and configured to be quickly attached together by juxtapositioning, aligning, interconnecting, and securedly connecting two panel components along their respective edges to form the walls, roof, and/or floor of a structure, and further including connecting energy efficient corner modular components that provide for seamless, insulated corners, wherein the corner modular components are connected to other non-corner modular components, i.e., wall panel components, at corresponding edges as for described herein for aligning, connecting or joining, and securing the basic wall panel components. 
     Preferably, the corner panel component is constructed and configured to form at least one corner; however, multiple corners may be provided by a single corner panel component, including by way of example and not limitation, a “T” cross-section or a “+” cross-section, when viewed from the top. In preferred embodiments, the corner element is established within a single, integral and seamless modular panel having at least two wall panel body members extending outwardly therefrom for providing wall panel component intersections at edges from those at least two wall panel body extending outwardly from the corner element to form the corner panel component. By way of example, as illustrated in  FIG. 5B , a “T” cross-section provides for two corners and three wall panel component intersections extending outwardly from the seamless corner edge; as illustrated in  FIG. 5C , a “+” cross-section provides for four corners and four wall panel components extending outwardly from the corner element, each wall panel having one edge at a spaced apart distance from the corner element, wherein at those edges, other wall components may be connected thereto for forming a seam and extending the length of the wall region formed by the connection of multiple wall panel components. 
     As illustrated in  FIG. 5A , the corner modular components include a corner element positioned between and formed by two body sections having edges spaced apart at least about one foot from the corner element. Preferably, the corner element forms an angle of between about 45 and about 135 degrees, more preferably about 90 degrees. However, other angles are optionally provided, depending upon the desired building configuration. 
     More preferably, the corner panels as set forth hereinabove are provided as a unitary, integral single molded panel component, including the corner(s). Also, by providing one or more extended segments from at least one corner in a unitary, integral single molded panel component, it correspondingly provides for a multiplicity of panel configurations with corner(s). 
     Referring now to the drawings overall,  FIG. 1  illustrates a perspective view of a partially assembled modular building structure  1180 , including door component  28 , wall panel edges  20 ,  22 , wall panel face side  16 , and back side  18 , wall panel (generally referenced  14 ), joined edges or seam  24 , roof panel  26 .  FIG. 2  shows a perspective view of a completed modular building from the partially completed illustration of  FIG. 1  including a window unit  30 .  FIG. 3  illustrates several related views; in  FIG. 3A  a top view of two edges of modular wall panels having mating double railing  32  for alignment and locking mechanism  34 ;  FIG. 3B  illustrates an end perspective view illustrating the parallel spaced apart double track or railing system  33 ;  FIG. 3C  illustrates a side view and cut-away of joined panel edges with the interlocking cam-based locking mechanism (cam  36 , locking arm  38 , seam  40 ).  FIG. 4  illustrates a top view of a corner wall panel modular component with seamless corner  42  with insulation  19  a face side  16  and back side  18  of the wall panel, and double rail mating alignment components  32 ,  33 . 
       FIG. 5A  illustrates a top view of a corner wall panel modular component with seamless corner and two wall component segments extending outwardly therefrom.  FIG. 5B  illustrates a “T” cross-section a top view of a corner wall panel modular component with seamless corner and three wall component segments extending outwardly therefrom.  FIG. 5C  illustrates a “+” cross-section a top view of a corner wall panel modular component with seamless corner and four wall component segments extending outwardly therefrom. By way of more detailed description,  FIG. 5A  illustrates a top view of a corner wall panel modular component with seamless corner  42  with insulation  19  a face side  16  and back side  18  of the wall panel, and double rail mating alignment components  32 ,  33 . Similarly,  FIG. 5B  illustrates a “T” cross-section and  FIG. 5C  illustrates a “+” cross-section a top view, respectively, of a corner wall panel modular component with seamless corner and four wall component segments extending outwardly therefrom. 
       FIG. 6  illustrates several perspective views of the modular building components including  FIG. 6A  showing a basic flat wall panel component;  FIG. 6B  showing a 90 degree corner panel component;  FIG. 6C  showing a 135 degree angle corner panel or transition panel;  FIG. 6D  showing a window opening in a wall panel component;  FIG. 6E  showing a door opening in a wall panel component.  FIG. 7  illustrates an exploded view of various component panels.  FIG. 8  illustrates various component roof panels.  FIG. 9  illustrates a cut-away partial side view of a wall panel installation according to one aspect of the present invention.  FIG. 10A  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention;  FIG. 10B  illustrates a partial perspective view of a section of  FIG. 10A ;  FIG. 10C  shows a cut-away side view of a section of  FIG. 10A .  FIG. 11  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention. 
       FIG. 12  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention, including two stages of corner panel installation.  FIG. 13  illustrates a cut-away partial perspective view of a wall panel installation of two components constructed and configured for connection following the step illustrated in  FIG. 12B .  FIG. 14  illustrates a cut-away partial perspective view of a wall panel installation according to one aspect of the present invention, including a unitary and integral single component seamless corner panel and wall panel components connected thereto. 
     The present invention provides for systems and methods for a modular building having structural prefabricated wall panel components that are juxtapositioned, aligned and interconnected along their edges to form joints or seams, wherein the wall components are assembled and locked in place to form an energy efficient and stable modular building including energy efficient seams that provide for simultaneous alignment and friction-based securement of the panels at the joints; wherein the alignment and interconnection of the panels is provided by at least two mating vertically oriented rail systems that are connected to and protrude from and extend along the length of an edge of the wall panel body and wherein two wall panels are connectable by aligning the mating edges of the two panels and then interconnecting the rail systems, thereby providing the alignment and securement of the panels at those edges or seams formed at the joined edges of two panels. In one embodiment, the at least two vertically oriented rails systems include spaced apart rails that matingly correspond to receptive cavities in the mating panel edge, so that when the two panels are aligned, connected and joined at these edges, the rail system provides for mating securement of the panels. Preferably, the corresponding edges include one edge with protruding rails and the opposite edge having cavities sized, shaped and configured for receiving the protruding rail system counterparts. In another embodiment, the rails on one edge are alternatingly spaced apart with the protruding rail having a mating receiving cavity disposed therebetween. In another embodiment, the rails are spaced apart with no cavity disposed therebetween, such that the seam is formed not by abutting wall panel bodies wherein the seam or joint exists at the direct connection of the panel edges, but that the seam is formed by interleaved protruding rails that form an aligned, friction-based securement of the joined wall panel bodies. In this way, the rails form interleaved laminae whose surface area of overlapping laminae create a seam. The seam thickness may be equivalent to the wall panel body thickness, or it may be less than the thickness of the wall panel body; if the latter, then additional insulation, covering material, or tape is provided to ensure seam thickness consistency with the wall panel body. 
     In one embodiment, the rail system is continuous. Alternatively, instead of or combined with at least one continuous protruding rail on an edge, the system includes discrete protruding tabs that are spaced apart along the length of the edge, and wherein corresponding cavities for receiving those protruding tabs are provided. 
     Preferably, the modular building system with prefabricated composite wall panels of the present invention may be constructed and configured to include conduits in the panel body with conduit input/output openings along predetermined edge areas of the panel body, and energy efficient seams or joints that provide for simultaneous alignment and friction-based securement of the panels at the joints. 
     Thus the present invention provides for energy efficient and stable modular building systems having energy efficient seams or joints that provide for simultaneous alignment and friction-based securement of the panels at the joints, without requiring any additional securement mechanism at the joints for ensuring stability of the connected panels at those joints or seams. 
     The structure size for a building kit may be predetermined before packaging, but ranges in size from small to very large buildings, by way of example and not limitation, such as an emergency shelter, a home or a command shelter or office. The size of the panels generally requires only two or three persons to manually maneuver the panels for complete structure erection. The material of both the interior and the exterior siding of the panels is selected based upon the needs of the customer and the environment, but in any case the panels are both insulated and portable. Preferably, the panels are super-insulated and portable to allow the builder to get under roof and into a comfortable space in a very short period of time. 
     In one embodiment of the present invention, items such as electrical junction boxes, conduit or radiant heating coils are preferably molded inside of the panels, constructed and configured in such a way on site as to add additional value to the structure. Beneficially, the structure is assembled quickly and may be pre-fitted with conduit (as delivered to the site in the self-contained kit, preferably in a shipping container), to allow for quick installation of a fully-equipped building, including electrical functionality. Doors and windows are also preferably delivered with and included predetermined wall panel components or attachable thereto. Preferably, openings for the windows and doors are pre-framed in the panels in a manner that allows for rapid window and door installation on site, without additional time or materials required for framing and installation. Roof beam pockets are also preferably pre-set in the top of panels to facilitate the placement of rafter or ridge beams to allow for the support of the insulated roof panels. 
     Advantageously, the panels of the present invention are the most advanced structurally insulated building panel to date. The present invention provides a modular building system for creating an energy-efficient structure including: a multiplicity of pre-fabricated panel wall components and roof components, each having a face side and a back side and four edges including at least two spaced-apart parallel tracks that run the length of at least two opposite edges for aligning the edges together to form a seam, wherein the components do not require additional locking components for securedly attaching the components together along the seams, since the rail systems that align and secure the joining at the seams of two panel components provide for friction-based securement and wall panel stability, while still providing energy efficient seams. 
     Also, methods for providing a modular building structure including the steps of: 
     providing a modular building system further comprising a predetermined number of modular wall components, a roof system, and at least one door; 
     providing instructions for assembling the modular building system for forming a complete building unit, including aligning the modular panel components along their opposite edges via at least two mating rail systems of the two panel components. The rail systems may be selected from alternating rails that are spaced apart and extend vertically along the edge and that correspondingly mate with spaced apart cavities in the second panel component; at least one rail and tabs system protruding from one edge and mating with corresponding cavities in the other edge of the adjoining panel component; alternating protruding rail and cavity in each edge that mates with corresponding cavity and rail in the adjoining panel component; interleavable laminae that alternatingly extend from the wall component body plane at the edge and extend along the length of the edge that provide for alignment and friction-based securement of the panel components when connected; or combinations thereof, to provide an energy efficient seam when wall components are joined. 
     One application for the present invention includes a structure or building for a command or support center after an emergency to be erected on a flat surface. Other applications include but are not limited to medical center, school or residential structures. In preferred embodiments of the modular buildings, the modular panel components for assembling to form a basic structure include modular pre-fabricated panel wall components and/or roof components, each having a face side and a back side and four edges including spaced-apart parallel interleavable laminae that run the length of at least two opposite edges for aligning the edges together to form a seam by interleaving the laminae, wherein the laminae provide for friction-based locking of the components without requiring additional locking components for securedly attaching the components together along the seams. 
     Prefabricated panel components may be provided in a pre-configured kit including window panels, door panels, corner panels, beam pocket panels and window(s) that may be pre-set into at least one panel component, in particular a wall panel; at least one door frame fitted to allow final site placement quickly and easily; at least one ventilation fan pre-installed in panel; and wherein the panels have at least some finishing on the face side that would be externally or outwardly facing upon assembly and installation for the building structure, by way of example and not limitation the face side finish includes a pre-finished exterior siding such as commercially offered by Hardi Panel or LP SmartSide; bullet resistant layer(s); a plurality of structural members for supporting roof structure including a modular box beam with joints secured by pins; at least one composite sill plate and secondary base plate with flashing for foundation; tools required for structure assembly including panel cam-locks, sealant foam, foam applicators, etc.; instructions, plans, and figures illustrating assembly in at least one language or even multiple language(s) as required, preferably including figures showing step-wise assembly and installation, as well as an indication or listing of all the parts and components within the kit and how they relate to each other; rigid flashing for the top roof ridge (at the junction of the two different panel slopes), roof lining material, finished roofing material, modular electrical baseboard outlet kit; communications system or equipment (such as by way of example and not limitation, a communication system for satellite-based telecommunication of voice and/or data); scaffolding if wall panels were greater than about 8 ft. in height; Universal Power Supplies &amp; filter (UPS) for sensitive electronic equipment; solar panels (PV or solar-thermal) for attachment or integration with select panels, preferably roof panels; FRP laminated panel interior (like for medical or school application); at least one bathroom module including sink and toilet, and preferably a shower unit. 
     Also, supplemental or specific power supply alternatives may be provided, including by way of example and not limitation, a wind power generator, water power generator, solar power equipment, which may be connectable to or embedded with the panel components in predetermined configurations, etc. 
     One application of the modular buildings according to the present invention is to provide emergency shelters that would be deliverable to a site or location in advance of or following an emergency situation, such as weather catastrophe, illness outbreak, or may also be provided in advance of construction of larger buildings. While the present invention modular buildings formed from the components described herein are suitable for long-term use, they may also be used for temporary buildings or for limited time specific use buildings. 
     Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description. By way of example and not limitation, the present invention provides a modular panel that is either insulative or non-insulative, but that still provides energy efficient corners that are seamless and that provide for structural integrity and strength. In a “sandwich” panel, a core material is positioned between two spaced apart siding materials as illustrated hereinabove, the panel functions as a structural element, similar to an I-beam, wherein the interior core material is the web and the siding materials are like the flanges of an I-beam; thus, it is the materials acting together that provide significant structural strength to the panel. In applications of tropical climate, insulation may not be as important a factor as low-cost construction, so insulative materials could be eliminated and replaced with non-insulative materials or less insulative materials, while still providing structural integrity and strength but preventing moisture or insects. 
     The above mentioned examples are provided to serve the purpose of clarifying the aspects of the invention and it will be apparent to one skilled in the art that they do not serve to limit the scope of the invention. All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the present invention.