Modular building construction system and method

Abstract

A building construction system of includes a prefinished exterior weather-tight insulating skin (panel), a cavity and structural zone where electrical, mechanical, plumbing, HVAC, data/audio systems can run freely and be modified, and a prefinished interior wall panel which is easily removable allowing access to the cavity and structural zone. The exterior and interior panels are mounted to structural components and create the cavity therebetween.

Claims

1. An interior partition wall structure comprising: a first wall panel having a finished surface; a first vertical support having first and second ends, the first vertical support being securable to a horizontal surface of an associated building; a first partition divider secured to the first vertical support, the first partition divider having a first outer surface on at least one side thereof and at least one rabbet adjacent the first outer surface, the at least one rabbet including a recessed wall panel support surface; wherein a first edge of the first wall panel is mounted to the wall panel support surface such that the finished surface of the first wall panel and the first outer surface of the first partition divider form a portion of a first finished wall surface of the interior partition wall structure; and wherein the first edge of the first wall panel is received in the rabbet to provide a generally flush transition between the first wall panel and the first outer surface of the first partition divider.

2. The interior partition wall structure of claim 1, further comprising a second vertical support having first and second ends, the first vertical support being securable to a horizontal surface of an associated building in spaced relation to the first vertical support; and a second partition divider secured to the second vertical support, the second partition divider having a first outer surface on at least one side thereof and a first rabbet adjacent the first outer surface, the first rabbet including a recessed wall panel support surface; wherein a second edge of the first wall panel is mounted to the wall panel support surface of the second partition divider such that the finished surface of the first wall panel and the first outer surfaces of the first and second partition dividers form a portion of the first finished wall surface of the interior partition wall structure; and wherein the second edge of the first wall panel is received in the rabbet of the second partition divider to provide a generally flush transition between the first wall panel and the first outer surface of the second partition divider.

3. The interior partition wall structure of claim 2, wherein the first and second partition dividers each have a second outer surface opposite the first outer surface, a second rabbet adjacent the second outer surface, the second rabbet including a recessed wall panel support surface; and further comprising a second wall panel having a finished surface, the second wall panel having first and second edges mounted to respective recessed wall panel support surfaces of the first and second partition dividers on an opposite side of the first and second partition dividers than the first wall panel such that the finished surface of the second wall panel and the second outer surfaces of the first and second partition dividers form a portion of a second finished wall surface of the interior partition wall structure.

4. The interior partition wall structure of claim 3, wherein the first and second wall panels are coextensive along respective widths thereof.

5. The interior partition wall structure of claim 2, further comprising a third vertical support between the first and second vertical support.

6. The interior partition wall structure of claim 2, wherein the first vertical support has a thickness of 2.5 inches.

7. The interior partition wall structure of claim 6, wherein the first partition divider has a thickness of 5.5 inches.

8. The interior partition wall structure of claim 7, wherein first and second wall panels have a thickness of less than 1.5 inches, whereby the interior wall structure has a maximum thickness of 5.5 inches.

9. An interior partition wall structure comprising: a first wall panel having a finished surface; a first vertical support having first and second ends, the first vertical support being securable to a horizontal surface of an associated building; a first partition divider secured to the first vertical support, the first partition divider having a first outer surface on at least one side thereof and at least one rabbet adjacent the first outer surface, the at least one rabbet including a recessed wall panel support surface; wherein a first edge of the first wall panel is mounted to the wall panel support surface such that the finished surface of the first wall panel and the first outer surface of the first partition divider form a portion of a first finished wall surface of the interior partition wall structure; a second vertical support having first and second ends, the first vertical support being securable to a horizontal surface of an associated building in spaced relation to the first vertical support; and a second partition divider secured to the second vertical support, the second partition divider having a first outer surface on at least one side thereof and a first rabbet adjacent the first outer surface, the first rabbet including a recessed wall panel support surface; wherein a second edge of the first wall panel is mounted to the wall panel support surface of the second partition divider such that the finished surface of the first wall panel and the first outer surfaces of the first and second partition dividers form a portion of the first finished wall surface of the interior partition wall structure; wherein the first and second partition dividers each have a second outer surface opposite the first outer surface, a second rabbet adjacent the second outer surface, the second rabbet including a recessed wall panel support surface; and further comprising a second wall panel having a finished surface, the second wall panel having first and second edges mounted to respective recessed wall panel support surfaces of the first and second partition dividers on an opposite side of the first and second partition dividers than the first wall panel such that the finished surface of the second wall panel and the second outer surfaces of the first and second partition dividers form a portion of a second finished wall surface of the interior partition wall structure; wherein the first and second wall panels are coextensive along respective widths thereof; and wherein the first edge of the first wall panel includes a rabbet configured to cooperate with the rabbet of the first partition divider.

10. A method of assembling an interior partition wall structure comprising: securing a first vertical support having first and second ends to a horizontal surface of an associated building; securing a first partition divider to the first vertical support, the first partition divider having a first outer surface on at least one side thereof and at least one rabbet adjacent the first outer surface, the at least one rabbet including a recessed wall panel support surface; and securing a first wall panel having a finished surface to the first partition divider by mounting a first edge of the first wall panel to the wall panel support surface such that the finished surface of the first wall panel and the first outer surface of the first partition divider form a portion of a first finished wall surface of the interior partition wall structure; wherein the first edge of the first wall panel is received in the rabbet to provide a generally flush transition between the first wall panel and the first outer surface of the first partition divider.

11. The method of claim 10, further comprising: securing a second vertical support having first and second ends to the horizontal surface of the associated building in spaced relation to the first vertical support; securing a second partition divider to the second vertical support, the second partition divider having a first outer surface on at least one side thereof and a first rabbet adjacent the first outer surface, the first rabbet including a recessed wall panel support surface; mounting a second edge of the first wall panel to the wall panel support surface of the second partition divider such that the finished surface of the first wall panel and the first outer surfaces of the first and second partition dividers form a portion of the first finished wall surface of the interior partition wall structure.

12. The method of claim 11, wherein the first and second partition dividers each have a second outer surface opposite the first outer surface, a second rabbet adjacent the second outer surface, the second rabbet including a recessed wall panel support surface, and further comprising mounting first and second edges of a second wall panel having a finished surface to respective recessed wall panel support surfaces of the first and second partition dividers on an opposite side of the first and second partition dividers than the first wall panel such that the finished surface of the second wall panel and the second outer surfaces of the first and second partition dividers form a portion of a second finished wall surface of the interior partition wall structure.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a front elevation view of an exemplary structure in accordance with the present disclosure;

(2) FIG. 2 is a plan view of a portion of the exemplary structure of FIG. 1;

(3) FIG. 3 is an enlarged portion of the plan view of FIG. 2;

(4) FIG. 4 is an enlarged portion of FIG. 3;

(5) FIG. 5 is an axonometric view of a vertical standard in accordance with the present disclosure;

(6) FIG. 6 is a horizontal cross-sectional view of a portion of an exterior wall in accordance with the present disclosure;

(7) FIG. 7 is a vertical cross-sectional view of a portion of an exterior wall and roof structure in accordance with the present disclosure;

(8) FIG. 8 is a partial cross-sectional view of an exemplary exterior wall panel in accordance with the present disclosure;

(9) FIG. 9 is an elevation view of an interior wall including a window in accordance with the present disclosure;

(10) FIG. 10 is an elevation view of an interior wall including a door in accordance with the present disclosure;

(11) FIG. 11 is a plan view of an exterior wall and exterior door in accordance with the present disclosure;

(12) FIG. 12 is a plan view of an interior partition wall in accordance with the present disclosure;

(13) FIG. 13 is a cross-sectional view of the interior partition wall of FIG. 12,

(14) FIG. 14 is a plan view of an interior wall intersecting another interior wall and having a door and corner in accordance with the present disclosure;

(15) FIG. 15 is a cross-sectional view of an interior wall adjacent a door frame in accordance with the present disclosure; and

(16) FIG. 16 is a cross-sectional view of an interior wall panel in accordance with the present disclosure.

DETAILED DESCRIPTION

(17) The following is a listing of reference characters/numerals used in the description of the exemplary embodiment of the present disclosure: P—Porch Wa—Wall R—Roofing system and/or roof insulating panel 1—Vertical standard (for example, serving as closure over vertical exterior panel joints, may be prefinished cold-formed metal or other suitable material) WP—Wing portion 2—Sealant joint (for example, between vertical standard and edge of pre-applied and prefinished siding material) EP—Exterior panel 3—Exterior panel siding (for example, prefinished composite or wood siding, manufactured and installed as part of an exterior panel EP) 4—Air-and-water barrier (for example, manufactured and installed as part of an exterior panel EP) 5—Structural insulating panel material (for example, manufactured and installed as part of an exterior panel EP) 6—Continuous self-adhered flashing 8—Cavity for mechanical/electrical/plumbing systems 9—Structural post (can include flat interior and exterior faces suitable for fastening, spaced apart based on module, e.g., panel length) 9C—Corner structural post 10—Interior removable panel (can include bottom edge brace; panels of several specific heights) 11—Vertical rabbeted spacer (for example, made of wood or structural composite material, provides end closure for interior panels) 12—Corner panel (can be pre-mitered and glued exterior corner panel with consistent dimension) 13—½ partition divider (for example, can be used as jamb) 14—Window sill below 15—Exterior window casing over butyl tape closure 16—Window Unit 18—Structural beam and rafters 19—Pre-formed holes at structural post for passage of horizontal systems 20—Hi-velocity air-conditioning system or other HVAC 21—Plumbing supply 22—Electrical, data, audio 23—Integrated hot-water heat supply register 24—Screwed, removable connection to structural or intermediate supports 25—Attachment to foundation at post base F—Floor system and structure 27—Rabbet to accept wall panel 28—Pre-assembled head jamb 29—1″ upstand against water infiltration 30—Pressure-equalization chamber 31—Lag screw per structural requirements 32—Metal bracket 33—Screw 34—Panel joint 35—Partition divider on module grid 36—Secondary steel support member 37—2× blocking for partition attachment 38—Grid centerline of regular building module 40—Video panels 41—Door unit 42—Wood or composite reinforced horizontal strut with/without finish 43—Wood or composite shoe mold 45—Pre-mitered wood or composite partition corner 46—Wood or composite top plate 47—2× second top plate 48—Runner for steel studs 49—FDTN: Foundation system 50—Fire stop blocking at floor levels 51—Brick Pier EW—Exterior wall PW—Partition wall RS—Reinforcing strut

(18) At the outset, it should be appreciated that the present exemplary building system includes, among other things, frame components and panel/partition components. The frame components generally include vertical supports (e.g., posts) spaced apart in a generally uniform grid pattern, and horizontal supports (e.g., beams) extending between the posts along grid lines extending therebetween. The panel/partition components, which can include both internal and external panels, are mounted to the posts and/or beams to form walls to both enclose the structure and partition the interior of the enclosed structure into one or more rooms or spaces.

(19) In the exemplary embodiment, each exterior wall is comprised of at least two panels (exterior and interior) mounted on opposite sides of the vertical supports such that an enclosed space bounded by the panels and the vertical supports is created. This enclosed space can be used for electrical and/or mechanical systems such as electrical wiring, plumbing, HVAC ducts and conduits, etc. The panels are removably mounted such that changes to either the panels or the electrical/mechanical or other systems within the wall can readily be made. The exterior panels can include weatherproofing elements and an exterior finished surface such as any of a variety of siding materials. Similarly, the interior panels can include a finished interior surface such as any of a variety of interior wall finishes such as wood, gypsum, plaster, leather, suede etc. Interior walls generally are framed with composite posts at the building module and certain secondary steel support members such as runners at the floor/ceiling or bracing around openings. The wall surface is made up of interior panels forming each side thereof. Further details of the interior and exterior panels will be described below. As will be appreciated, the external and internal panels can have a module length corresponding to the grid spacing.

(20) With reference to FIG. 1, an exemplary structure S is illustrated. As will become apparent throughout the remainder of the description, the structure S is constructed on a grid defined by lines denoted by a letter or number within a circle. In FIG. 1, vertical grid lines A, B, C, D, and E are visible. The physical dimensions of each grid square can be any desired dimension, but typically may be 7′-4″ by 7′-4″ horizontally. Basing the various components of the exemplary system on a common grid allows for the components to be more easily produced and facilitates interchangeability between components.

(21) The structure S of FIG. 1 includes many of the common features of a residential structure including a foundation system FDTN, a porch P, walls Wa and a roof R. A plurality of windows Wi and a door are also present. In general, the exemplary structure S in accordance with the present disclosure outwardly appears to have many of the same visual characteristics as a conventional stick-built residential building.

(22) FIG. 2 is a portion of an exemplary floor plan of the structure S. The grid arrangement of the structure S is evident and identified by the circled numbers and letters at the top and right sides of FIG. 2. Grid line reference numbers/letters appear in many of the drawings where appropriate for ease of reference, but are not further utilized in the following description.

(23) With reference to FIG. 3, which is an enlarged portion of FIG. 2, the exemplary structure S begins with a plurality of structural posts 9 arranged about the grid points (e.g., intersection of grid lines) noted above. The structural posts 9 can be supported in a variety of ways, such as upon a continuous bearing foundation wall through a bolted post-base connection. In some embodiments, the structural posts 9 can be steel or wood posts, but any suitable material can used. The structural posts 9 can be of various sizes and various lengths, depending on the design of the structure. In some arrangements, an individual structural post or post can be omitted, with adjacent structural posts being reinforced, to thereby create larger open spaces than the nominal grid dimensions. As will be appreciated, the structural posts can be configured to accommodate a wide variety of structure S designs.

(24) FIG. 3 illustrates a plan view of a corner portion of the structure S. A pair of corner posts 9C each have a mating beveled edge for arranging the corner posts 9C in abutting configuration about a grid point. Meanwhile, a standard post 9 is spaced along a gridline from the corner posts 9C. Standard post 9 is generally rectangular in cross-section. Of course, the standard posts can have any suitable cross-sectional shape.

(25) Interior panels 10 are mounted to an inside surface of posts 9. To this end, rabbeted spacers 11 are provided. Rabbeted spacers 11 are mounted vertically on posts 9 and/or 9C and provide end closure for the interior panels 10 as will be further described below.

(26) Exterior panels EP are mounted to an outside surface of posts 9 and/or 9C such as with lag screws 31. Each exterior panel EP generally includes a prefinished siding material 3, an air and water barrier 4, and a structural insulating panel 5. A pre-mitered exterior corner panel 12 joins exterior panels on adjacent side of a corner of the structure S. Lateral edges of the exterior panels can include continuous self-adhering flashing 6 for sealing a joint 34 between adjacent exterior panels EP. Joints 34 between adjacent exterior panels EP are further sealed and/or concealed by a vertical standard 1.

(27) With further reference to FIGS. 4 and 5, vertical standard 1, which can be prefinished cold-formed metal or the like, for example, has a general u-shape cross-section with terminal ends of the u-shape being turned outwardly and back along the side of the u-shape cross-section. The outwardly turned edges of the vertical standard for respective longitudinally extending wing portions WP that can flex to accommodate a variation in tolerance between adjacent exterior panels along the height of the structure, and/or variation in tolerance between respective joints of the structure. In addition, wing portions provide a backing for application of a sealant material 2 for sealing the vertical standard to adjacent surfaces of respective external panels EP and serve to stiffen the vertical standard.

(28) Vertical standard 1 generally extends the height of the structure (see FIG. 1) to conceal both the joints between adjacent exterior panels EP and the fasteners 7 and to provide another water-resistant seal to protect the panel joint and the structural panel fasteners concealed by the standard. Each vertical standard 1 can be a single piece, or can be comprised of several pieces. In the illustrated embodiment, a plurality of vertically spaced apart brackets 32 (best seen in FIG. 5) support the vertical standard 1. One or more fasteners 33 secure the vertical standard to each bracket 32.

(29) Turning now to FIGS. 6 and 7, which depict lower and upper portions of the same exterior wall of structure S, further details of the exemplary building system will be described. Beginning with FIG. 6, a floor system 26 which can be an exposed structural decking system with exposed beams (since the building systems can be effectively concealed in the walls they do not need to run across the ceiling), or a conventional floor system including joists and sheathing, etc. extends horizontally and is supported by a foundation system 49, which can be a typical basement or slab foundation. Structure S is supported directly by the foundation system 49.

(30) FIGS. 6 and 7 are vertical cross-sectional views taken through the structure at a position not including posts 9 and/or 9C. Therefore, the manner in which the exterior and interior panels are joined together in the vertical direction is visible. As can be seen, each exterior panel EP has a rabbeted upper and lower surface for mating with a corresponding rabbeted lower or upper surface of an adjacent exterior panel EP. As best seen in FIG. 8, the exterior panels EP are arranged in shiplap fashion such that an upstand 29 is created to prevent water infiltration. In addition, a pressure equalization chamber 30 is created between respective rabbeted portions of mating exterior panels to keep a pressure differential from driving water through the wall. Continuous self-adhering flashing 6 further enhances weatherproofing of the horizontal exterior panel joints.

(31) As best seen in FIGS. 6 and 7, post 9 includes pre-formed holes 19 or other openings for passing electrical, data, or other wiring 22, plumbing 21, etc. between adjacent interior chambers. In addition, it will be appreciated that certain interior panels IC can be replaced by specialized panels that include pre-configured portions of a building system, such as an integrated hot-water heat supply register 23. Other specialized panels can include an integrated continuous power strip; integrated continuous or discrete lighting; integrated video screens; and other similar components.

(32) Turning to the remaining figures, exemplary installations of interior wall panels and other features such as doors and windows are illustrated. It will be appreciated that the various interior features of the structure S are constructed using components that allow for complete non-destructive removability of at least the interior panels 10 from both interior and exterior walls. This includes interior panels 10 adjacent doors, windows, corners etc. In some embodiments, the external panels can also be non-destructively removed by a professional or homeowner for repair and/replacement.

(33) To facilitate such non-destructive removal of the interior panels 10, a variety of interior panel terminal components are provided for use in construction with typical stud-framing components. The terminal components are mountable to posts 9 and/or 9c, as well as to secondary support members composed of steel and wood or of steel or other metal. In general, the terminal components are configured to transition an edge portion of one or more interior panels to either horizontally adjacent interior panels or adjacent structures such as a door jam or window frame. The terminal components can act as both a trim member for concealing end faces of the interior panels, as well as support members for supporting the interior panels. In this regard, the terminal components generally include a rabbet in which an edge portion of the one or more interior panels are configured to be received to provide a generally flush transition between interior panels or adjacent structure.

(34) In the following description, the terminal components include i) vertical rabbeted spacer 11, ii) one-half partition divider 13, iii) partition divider 35, and iv) pre-mitered partition corner 45. Each of these components are configured to provide a clean and non-destructively removable installation of the interior panels to the stud walls and/or posts 9 and/or 9c, as will now be described.

(35) As shown in FIG. 9, which is an elevation view of an exemplary window installation in accordance with the present disclosure, vertical rabbeted spacers 11 extend along vertical gridlines downward from the floor structure 26 at the junction of two adjacent columns of interior panels 10. As will be appreciated, the vertical rabbeted spacers 11 can be wood or any other suitable material, and include two rabbets for receiving respective interior panels on each side thereof. Secondary steel support members 36 are installed for suitable blocking and bracing to form a window opening or frame, to support the exterior panel edges in which window unit 16 can be mounted in conventional fashion.

(36) Similarly, referring now to FIG. 10, door unit 41 is mounted in a door frame bounded by secondary steel support members 36, which themselves are secured between the top and bottom or two sides of the frame structure (e.g. flooring structure, etc.) in a conventional manner. With additional reference to FIG. 11, it will be appreciated that the door unit 41 can be installed at a wide variety of locations by forming a door frame through terminating interior and exterior panels 10 and EP with suitable terminal components at the desired location.

(37) To this end, exterior panel EP is terminated at a suitable location and exterior casing 15 is face-screwed or otherwise secured to the exterior panel adjacent the door opening. Interior panel 10 is similarly terminated and a secondary steel support member 36 is installed for additional blocking adjacent the door frame. A one-half partition divider 13 is installed to capture interior panel edges at the door opening. Further, a secondary steel support member 42 extends across the top of the door opening. Door unit 41 is secured to the exterior panels which attach to the secondary steel support member along with adjacent terminal components. Although only the hinge side of the door unit is illustrated, it will be appreciated that the framing of the latch side of the door unit can be done in a similar manner.

(38) Turning now to FIGS. 12-15, construction of various interior partition wall conditions will be described. FIG. 12 is a plan view illustration of the junction of an exterior wall EW and an interior partition wall PW. As such, exterior wall EW extends horizontally while the partition wall PW extends vertically downward from the exterior wall EW. The exterior wall EW includes the afore-described external wall components such as exterior panels EP and interior panels 10. The interior panels 10 of the exterior wall EW are terminated via respective vertical rabbeted spacers 11. Steel studs and 2× wood blocking are installed in the cavity 8 for reinforcing the wall at the junction. A partition divider 35 is secured to the 2× wood blocking and includes rabbeted edge portions for receiving the interior panels 11 of the partition wall.

(39) FIG. 13 illustrates a vertical cross-sectional view of an exemplary interior partition wall PW. The exemplary partition wall PW includes a runner 48 for secondary steel support members mounted to the floor or other supporting surface. Base molding 43 is secured to the runner 48 with exposed fasteners and allows for some adjustment of the wall to sloping or un-level floors. Each interior panel 10 includes a panel surface with an upward-facing channel leg to slide under the panel above, a downward-facing projection to capture the panels below, and a reinforcing strut RS (see FIG. 16) which strengthens the panel and also provides the back surface capturing the panel below (reinforcing strut RS and downward facing projecting defining a channel or recess in which the upward-facing channel leg of panel below can be received). This allows for a continuous seal between panels needed to slow the progress of fire, contain sound and air drafts between discrete rooms, and other critical functions of typical room walls. A plurality of interior panels 10 are mounted to opposite sides of the steel studs 36 to form the major surfaces of each side of the partition wall PW. As illustrated, some of the steel studs include preformed holes for passing of electrical and/or mechanical systems within the partition wall, such secondary steel support members being identified by reference numeral 36. Wood or composite reinforced horizontal strut 42 is provided at a typical height over any openings in the interior wall IW. The horizontal strut 42 in the illustrated embodiment includes a finished exterior surface. This special reinforcing panel spans horizontally between vertical partition posts to reinforce any secondary steel support members for greater wall heights without an increase in wall thickness (Note: conventional stud walls spanning from floor to ceiling generally need to grow from 2×4 to 2×6 framing if the wall height exceeds nine feet). A top plate 46 is secured to a wood 2×4 plate 47 to thereby join the partition wall PW to the ceiling joist or other structure (e.g., floor structure 26).

(40) FIG. 14 illustrates several other conditions including a junction J of two interior partition walls, an interior door jamb with door unit 41, and an interior wall inside/outside corner construction C. Beginning with the junction of two interior walls J, it will be appreciated that the partition wall PW terminating at the junction is secured to the other partition wall PW via a partition divider 35 that in turn is mounted to 2×4 blocking 37 of the non-terminating partition wall. The non-terminating partition wall is further configured such that the interior panels 10 terminate at suitable locations with either a one-half partition divider 13 or a partition divider 35, which combine with secondary steel support members 36 in a typical fashion as either posts or half-posts adjacent the junction J to properly support the various components.

(41) The door frame D and door unit 41 construction similarly includes placing secondary steel support members 36 at appropriate locations to support the door unit and to attach the termination of the interior panels on respective sides of the partition wall PW such that they properly mate with the door unit 41. Door unit 41 includes both the door frame and the door, and is installable as a unit between.

(42) Corner C is constructed by a pair of half-posts including partition dividers 35 and secondary steel support members 36 disposed at right angles to each other. A pre-mitered corner is installed and secured with exposed screws to a supplemental support member 36 and forms the outside of the corner C. Each partition wall PW is then joined to a respective one of the right angle steel studs 36 via a partition divider 35.

(43) It should be appreciated that construction of many features of the exemplary structure is simplified by having interior/exterior wall joints, interior wall joints, doors and/or corners aligned on grid points such that the interior and/or exterior panel can be used generally without modification.

(44) The exemplary embodiment has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the exemplary embodiment be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.