US20250172007A1 - Modular prefab delivery system - Google Patents

Abstract

A modular pod for a prefabricated modular building includes a top rectilinear ring of steel beams, a bottom rectilinear ring of steel beams and a plurality of steel columns connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams. A prefabricated module home delivery system includes the modular pod, an infill frame disposed within the modular pod and a protective sheathing disposed around the modular pod.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application claims priority of U.S. Provisional Application No. 63/602,576 filed on Nov. 25, 2023 under 35 U.S.C. § 119(e), the entire contents of all of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTIONField of the Invention
• The present invention generally relates to prefabricated modular building and home construction and more particularly to a modular framing system designed to streamline and safeguard the construction, shipment, and delivery of modular buildings and components.
Description of the Related Art
• Modular homes and other buildings have increased in popularity and use. Modular homes are typically 10% to 20% less expensive than traditionally built homes. Additionally, modular homes can be built up to 60% faster than stick-built homes. Modular homes allow a homeowner to be customized to suit their needs, both in terms of layout/square footage and features. Finally, modular homes can be more energy-efficient than traditionally built houses, and the materials and building process may be more environmentally friendly as well.
• Conventional modular buildings tend to suffer from damage during transportation. For example, during transportation, wood and sheetrock stress cracks are common. Additionally, wood frames can be damaged during transportation and overtime after construction. Finally, conventional modular buildings do not offer sufficient resistance to severe weather, in particular high winds and rain.
• Furthermore, despite the advantages of modular buildings, builders and developers frequently encounter challenges during the transportation of modular or prefabricated structures, regardless of the intended market. Conventional modular frames are often damaged during long-distance shipping over land, air, and sea, with wood frames especially prone to cracking and structural distortion under transport stresses. Additionally, many port facilities, particularly older or limited ones, lack the necessary infrastructure to manage the secure and efficient delivery of large or heavy modular units.
• Beyond shipping issues, traditional modular buildings and homes often lack flexibility for customization. Many structures are proprietary, conforming to specific floor framing, ceiling framing, cladding, foundation, roof framing, and specific modular configurations, which restricts adaptability and limits options for accommodating diverse architectural and functional requirements.
• Furthermore, conventional modular systems are also limited in that they lack design flexibility and lack compatibility with a variety of material options. Structural elements required for shear resistance in wood structures requires significant paneling along long wall runs and limits uninterrupted sections of openings or glass.
• Another challenge with conventional wood framing systems is the requirement for sequential vertical assembly. Floors must be constructed first, followed by walls, and then the ceiling or roof. This step-by-step process is inherently inefficient and significantly extends fabrication time.
• Conventional framing systems reveal significant limitations during craning operations. These systems necessitate lighter loads and smaller module sizes to ensure lifting will not damage the wood structure. Additionally, installing rigging points in wooden substrates presents challenges, as heavier loads risk pulling eyes or hooks out of position. Consequently, strapping often becomes the only viable method for crane lifting, which can compromise the integrity of the wooden structure.
SUMMARY OF THE INVENTION
• In view of the foregoing and other exemplary problems, drawbacks, and disadvantages of the conventional methods and structures, an exemplary feature of the present invention is to provide modular building components with improved protection during delivery/shipment.
• In a first, exemplary, non-limiting aspect of the present invention, a modular pod includes a top rectilinear ring of steel beams, a bottom rectilinear ring of steel beams and a plurality of steel columns connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams.
• In a second, exemplary, non-limiting aspect of the present invention, a prefabricated module home includes a modular pod, the modular pod including a top rectilinear ring of steel beams, a bottom rectilinear ring of steel beams and a plurality of steel columns connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams.
• In a third, exemplary, non-limiting aspect of the present invention, a prefabricated module home delivery system includes a modular pod, an infill frame disposed within the modular pod and a protective sheathing disposed around the modular pod. The modular pod includes a top rectilinear ring of steel beams, a bottom rectilinear ring of steel beams and a plurality of steel columns connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams.
• In accordance with the above, exemplary aspects of the present invention, a method and system are provided in which protection of the modular components is improved during delivery/shipment.
• The present invention uses steel frames for the prefabricated modular pods. Specifically, the present invention uses structural steel, but can also be made from other materials like, for example, aluminum. The steel beams can be provided in several configurations including, but not limited to, hollow steel sections (HSS) tubes, W-section beams, castellated beams, cellular beams, and other structural shapes. The use of steel in the modular pods provides several important benefits. First, the use of a steel frame in the modular pods provides protection for internal components during shipping, whether by land or sea. Second, after the modular pods are assembled to build the home or building, the steel provides improved resistance to severe weather like, for example, hurricanes. Steel also spans further allowing for maximum flexibility for windows and window locations. The steel frame allows for a variety of roof configurations including, for example, wood trusses installed above the steel frame and flat, concrete roofs.
• The modular steel frame of the present addresses the limitations of conventional modular systems by offering a design that not only improves durability and shipment resilience but also provides a flexible framework adaptable to various construction and customization needs, supporting broader applications in modular construction.
• Compared to conventional wood frames, steel has less movement over time. That is, wood will shrink and expand due to moisture content, which is not an issue with steel. Additionally, if steel is protected correctly it is more durable and will last longer than wood. Finally, steel provides stronger connections when placing the pods into position at the building site.
• Conventional modular systems often encounter significant challenges during installation, including issues with alignment and securing connections. The modules in the present invention overcome these challenges by utilizing alignment rods and weldable connections, ensuring a more precise fit. Steel frames further enhance accuracy by delivering consistent and predictable dimensional stability and structural integrity. In contrast, wood frames in conventional systems are prone to variability due to expansion and contraction, resulting in less reliable alignment.
• The present invention exhibits reduced distortion and vibration during shipment, effectively preventing cracking in materials such as sheetrock, tile, and wood. Its rigidity during transport and post-construction also protects secondary framing elements—such as walls, floors, and ceilings—as well as internal components and finishes, ensuring they remain undamaged throughout the process.
• The present invention enables significantly faster construction. Unlike conventional wood framing systems, which require sequential vertical assembly (a process often plagued by inefficiency) the steel frames of this invention provide a strong skeletal frame. Once fabricated, the remaining components can be installed within the structure, allowing simultaneous construction in both vertical and horizontal directions, greatly accelerating the overall process.
• Conventional framing systems require lighter loads and smaller units to make craning feasible. Installing rigging points such as eyes and hooks in wood substrates is particularly challenging, often necessitating lighter loads or strapping as the sole option for crane lifting. In contrast, the steel frames of the present invention offer superior rigidity, supporting longer dimensions even under the gravity load pressure of craning, with significantly reduced risk of deflection or distortion. Steel also accommodates heavier loads, enabling the use of larger, more complete units, and allows for welded rigging points that simplify craning without reliance on strapping. Moreover, when strapping is unavoidable on a project site, steel's enhanced rigidity minimizes the risk of damage caused by strap pressure at the corners of modular units.
• Steel, as used in the frames of the present invention, allows for larger units with longer spans that can extend beyond standard trailer lengths and widths and greater spans between supports when placed on the construction site.
BRIEF DESCRIPTION OF THE DRAWINGS
• The foregoing and other exemplary purposes, aspects and advantages will be better understood from the following detailed description of an exemplary embodiment of the invention with reference to the drawings, in which:
• FIG.1 illustrates amodular home100 according to certain exemplary embodiments of the present invention;
• FIG.2 illustrates an exploded view of themodular home100;
• FIG.3 illustrates the components of amodular pod200 according to certain exemplary embodiments of the present invention;
• FIG.4 illustrates an exploded view of the steel structural frame ofmodular pod200;
• FIGS.5A-5C illustrate various embodiments of the modular pod with floor structure;
• FIGS.6A-6C illustrate various embodiments of the modular pod with ceiling structure;
• FIGS.7A (perspective view) and7B (top view) illustrate the modular pod with room partitions;
• FIG.8A-8C illustrate various embodiments of the modular pod with cladding types;
• FIG.9 illustrates an end view of the steel cage of themodular pod200;
• FIG.10 is an enlarged view of a feature of the steel cage of themodular pod200;
• FIG.11 illustrates several modular pods to be connected together;
• FIG.12 illustrates several modular pods connected together;
• FIG.13A illustrates afoundation structure600 for a modular pod;
• FIG.13B illustrates the modular pods mounted on the foundation;
• FIGS.14A-14C illustrate various the modular pods with various versions of a roof mounted thereon;
• FIG.15 illustrates a prefabricated modular building delivery system according to certain exemplary embodiments of the present invention;
• FIG.16A illustrates an exploded view of asheathing1006;
• FIG.16B illustrates the sheathing1006B on a modular pod;
• FIGS.17A and17B illustrate awaterproof cover1004;
• FIG.18 illustrates aconcrete footing602 of a foundation for the modular pod;
• FIGS.19A and19B illustrate embodiments offoundation base plate603;
• FIGS.20 and21 illustrate various exemplary configurations of modular pods; and
• FIGS.22A and22B illustrate rigging points and alignment rods for craning modular pods into place.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION
• Referring now to the drawings, and more particularly toFIGS.1-22B, there are shown exemplary embodiments of the method and structures according to the present invention.
• FIG.1 illustrates a prefabricatedmodular home100 build using the claimed invention. Thehome100 illustrated inFIG.1 depicts an exemplary beach cottage. The claimed invention, as described herein, however, is not limited to the beach cottage example illustrated inFIG.1. Indeed, the components described in the following description can be assembled in any configuration as desired to create any type, shape or model or home or building. Thebeach cottage home100 illustrated inFIG.1 is provided merely for exemplary purposes and in no way is intended to limit the scope of the present invention.
• FIG.2 illustrates an exploded view of the prefabricatedmodular home100 and its individual components. As is illustrated inFIG.2, the prefabricatedmodular home100 is made up of one or moremodular pods200 according to certain exemplary embodiments of the present invention. In the exemplary embodiment illustrated inFIG.2, the prefabricatedmodular home100 includes three (3)modular pods200. The prefabricated modular home (or building)100 can include one or any number ofmodular pods200. In addition to themodular pods200, thehome100 may include additional exterior components. For example, in the beach cottage illustrated inFIGS.1 and2, the external components includes arear porch300, afront porch400 and aroof500. In accordance with certain exemplary aspects of the invention, themodular pods200 are constructed in advance and then delivered to the location of the home. The external components including, for example, theside porch300, thefront porch400 and theroof500, can be constructed at the location of the home and secured to themodular pods200 onsite.
• Additionally, referring again toFIG.2, the pod may includewalls210,windows212 anddoors214. The floors and ceilings may be infilled with a structural support material such as, for example, wood, steel or concrete. Additionally, thewalls210 may be constructed with a structural support material such as, for example, wood, aluminum, steel or concrete to create open or closed structures withwindows212 anddoors214.
• FIGS.3 and4 illustrates aframe202 of one of themodular pods200 illustrated inFIG.2.FIG.3 illustrates theframe202 assembled whileFIG.4 illustrates the frame in an exploded view. Theframe202 is a steel cage. Theframe202 includes a top rectilinear ring ofsteel beams203, a bottom rectilinear ring ofsteel beams204 and a plurality ofsteel columns205/206 connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams. The plurality of steel columns include at least a plurality ofcorner columns205 disposed at the four corners of the frame. Additionally, depending on the size (e.g., length) of themodular pod200, the plurality of steel columns may also include one or moreintermediate columns206 disposed along the length of theframe202. Theintermediate columns206 provide additional support, both during transportation and upon building. Further, depending on the size of themodular pod200, the frame may includeintermediate steel beams207 for additional structural support.
• Thesteel frame202 illustrated inFIG.3 includes three generally rectilinear, cube-shaped portions, A, B and C. At a minimum, theframe202 will include a single rectilinear cube-shaped portion A. Depending on dimensions of themodular home100, theframe202 of themodular pod200 will include two, three or any number of rectilinear cube-shaped portions to provide sufficient length.
• FIGS.5A-5C illustrate exemplary embodiments of themodular pods200 illustrating various floor framing208 options.FIG.5A illustrates a floor framing208 made of wood trusses,FIG.5B illustrates a floor framing208 made of steel beams, andFIG.5C illustrates a floor framing208 made of a concrete slab. Thefloor framing208 can be pre-installed within themodular pod200 to be shipped with themodular pod200.
• FIGS.6A-6C illustrate exemplary embodiments of themodular pods200 illustratingvarious ceiling209 options.FIG.6A illustrates aceiling209 made of wood trusses,FIG.6B illustrates aceiling209 made of steel beams, andFIG.6C illustrates aceiling209 made of a concrete slab. Theceiling209 can be pre-installed within themodular pod200 to be shipped with themodular pod200.
• FIGS.7A and7B illustrate flexible configurations ofinterior partitions211 created by wood, steel, aluminum, or steel infill framing. Thepartitions211 are configured to provide separate rooms, doorways and hallways. Thepartitions211 can be flexibly designed into any desired configuration or layout. Thepartitions211 can be pre-installed within themodular pod200 to be shipped with themodular pod200.
• FIGS.8A-8C illustrate exemplary embodiments of themodular pods200 illustrating variousexterior cladding213 options.FIG.8A illustrates anexterior cladding213 made of wood or cementitious material installed horizontally, vertically, or in panels,FIG.6B illustrates anexterior cladding213 made of steel baffles for blast-proof construction applications, andFIG.8C illustrates anexterior cladding213 made of glass. Theexterior cladding213 can be pre-installed within themodular pod200 to be shipped with themodular pod200.
• FIG.9 illustrates an end view of thesteel frame202. As is illustrated inFIG.9, eachsteel frame202 includes a C-section steel beam207 disposed along a top and a bottom of theframe202. The C-section steel beam is disposed on a side of thesteel frame202 that will form an intersection between end module pods and interior modular pods. C-section steel beams are used so that when combined with a C-section steel beam of an adjacent pod, the two C-section steel beams will make a combined W-section shape
• Thesteel frame202 may also include a steel I-beam206 disposed along a top and a bottom of theframe202.FIG.10 illustrates an enlarged view of the I-beam206 attached to, for example, the top rectilinear ring of steel beams203. Additionally, as opposed to the above beam configurations, an exemplary embodiment of the invention uses HSS breams for all of the steam beams in theframe202.
• FIG.11 illustrates thesteel frame202 of threemodular pods200 to be connected to one another. The three module pods include a firstexterior pod200A, aninterior pod200B and a secondexterior pod200C. Again, the number ofmodular pods200 to be connected is not limited to the number and/or configuration illustrated inFIG.11. For example, any number of additional interiormodular pods200B could be included between the firstexterior pod200A and the secondexterior pod200C. The firstexterior pod200A and a secondexterior pod200C have I-beams206 on their exterior ends and C-section steel beams207 on their exterior ends. Theinterior pod200B, however, has C-section steel beams207 on both ends so that theinterior pod200B can be connected on each side to another pod.FIG.12 illustrates the firstexterior pod200A, theinterior pod200B and the secondexterior pod200C connected together, forming one series of interior spaces of themodular home100. In accordance with certain exemplary embodiments of the invention, the firstexterior pod200A, theinterior pod200B and the secondexterior pod200C are welded together. The welding technique can be any contemplated or currently used welding technique in the building construction industry. The pods are individually transported to a building site (e.g., location on which thehome100 will be built) and then welded.
• Before thepods200 are welded together, they are mounted onto a foundation, as is illustrated inFIGS.13A and13B. Thepod200 is lifted, for example by a crane, and placed on thefoundation600. Thefoundation600 can be any foundation material and configuration including, for example, a pier, wall, beams, piles, or footings, etc. After thepods200A,200B,200C are secured to the foundation, they are then welded or bolted together.
• FIG.14A illustrates aroof500 secured on top of thepods200A,200B,200C. The roof may be formed in any shape and any material. For example, the roof may be made of wood trusses or wood framing, or may be a flat concrete roof.FIG.14B illustrates anexemplary roof500bin accordance with certain exemplary embodiments of the invention. The roof500B inFIG.14B is a wood truss gable roof.FIG.14C illustrates another exemplary roof500B in accordance with certain exemplary embodiments of the invention. Theroof500cinFIG.14C is a flat wood truss roof.
• As noted, themodular pods200 are prefabricated and then delivered/shipped to a building site.FIG.15 illustrates a prefabricated modulepod delivery system1000. Thesystem1000 includes apod200. Thesystem1000 also includes aframing infill1002. Theframing infill1002 is an frame positioned within the steel frame of thepod200. The infill frame can be constructed with wood, aluminum, or steel. The infill frame forms the elements of the residential or commercial structure (e.g., modular home100) and contains one or more of an exterior wall, interior partition, ceiling, floor, etc. In accordance with certain exemplary embodiments of the invention, theframing infill1002 may include further interior finishes such as, for example, floor finish (e.g., wood, tile, etc.), cabinets, countertops, etc. That is, as discussed above, the flooring208 (FIGS.5A-5C), theceiling209FIGS.6A-6C) and the partitions211 (FIGS.7A and7B) are included in themodular pod200 at this time.
• Additionally, thesystem1000 also includes asheathing1006. Thesheathing1006 is further illustrated inFIGS.16A and16B. Thesheathing1006 includes several portions, as illustrated inFIG.16A, which are secured over themodular pod200. Thesheathing1006 includes atop portion1006a, abottom portion1006d, twoside portions1006band twoend portions1006c. Thesheathing1006 is placed over thepods200 for transport and some or all of the sheathing is removed once thepods200 are delivered to the building site.FIG.16B illustrates thesheathing1006 applied to themodular pod200. Typically, once themodular pods200 are installed at the building site, thetop portion1006aand thebottom portion1006bof the sheathing remain in place while theend portions1006cand theside portions1006bare removed. Thesheathing1006 can be made of wood, cementitious material, plastic, metal, or fiberglass.
• Thesystem1000 also includeswaterproofing1004.FIG.17A illustrates thewaterproofing1004 as it is being applied to themodular module200 andFIG.17B after it is being applied to themodular module200. Thewaterproofing1004 is placed over and around the pods200 (and placed over and around the sheathing1006) for transport and removed once thepods200 are delivered to the building site. The waterproofing can provide additional watertight protection during transit.
• Thesystem1000 also includes thefoundation600, which is constructed at the building site. In the exemplary embodiment illustrated inFIG.15, thefoundation600 includesconcrete footings602 andsteel connectors604 for mounting thepods200 to thefoundation600. This configuration is more clearly illustrated inFIG.17. Thefoundation600 includes abaseplate603 formed on top of eachconcrete footing602. Thebaseplate603 is used to connect thesteel connectors604 to theconcrete footing602.FIGS.18A and18B illustrate two exemplary configurations of thebaseplate603.
• Themodular pods200 can be arranged and stacked in any desired configuration using any desired or necessary number ofmodular pods200.FIG.20 illustrates several exemplary, non-limiting configurations of modular pods assembled horizontally.FIG.21 illustrates several exemplary, non-limiting configurations of modular pods assembled with vertically stackedmodular pods200.
• FIGS.22A and22B further illustrates components for craning and securingmodular pods200. As shown inFIG.22A, themodular pods200 each include one or more weldedeyelets2220 for craning themodular pods200 into place for transit and at the building site. The enlarged view inFIG.22B illustrates components for aligning and securing adjacentmodular pods200. On one side, each modular pod includesalignment holes2202 configured to receive a first end of an aligningrod2206. On an opposite side, the adjacent modular pod includes alignment “mouse-holes”2204 (i.e., curved passages) for receiving another end of the aligningrod2206. Once aligned, the adjacentmodular pods200 are welded together as detailed above. Similar configurations are provided on the tops and bottoms of the modular pods when vertically stacking pods.
• While the invention has been described in terms of several exemplary embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the appended claims.
• Further, it is noted that, Applicant's intent is to encompass equivalents of all claim elements, even if amended later during prosecution.

Claims (5)

What is claimed is:

1. A prefabricated modular building pod, comprising:

a top rectilinear ring of steel beams;

a bottom rectilinear ring of steel beams; and

a plurality of steel columns connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams.

2. The prefabricated modular building pod according toclaim 1, wherein the steel columns are disposed at corners of the pod.

3. The modular pod according toclaim 1, wherein the steel columns are disposed at corners of the pod and at intermediate locations along the pod.

4. A prefabricated module home, comprising:

a modular pod, the modular pod comprising:

a top rectilinear ring of steel beams;

a bottom rectilinear ring of steel beams; and

a plurality of steel columns connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams.

5. A prefabricated module home delivery system, comprising:

a modular pod, the modular pod comprising:

a top rectilinear ring of steel beams;

a bottom rectilinear ring of steel beams; and

a plurality of steel columns connecting the top rectilinear ring of steel beams and the bottom rectilinear ring of steel beams;

an infill frame disposed within the modular pod; and

a protective sheathing disposed over the modular pod.

Images