BACKGROUND

Field

[0001] The present disclosure is generally related to modular building structures.

More specifically, the disclosure pertains to modular walls that are made of composite pre formed blocks which interlock.

Description of Related Art

[0002] The residential construction market is nearly a $1T industry. Yet rising costs for materials and labor has made construction requests stagnant with marginal productivity improvements. Although there are pre-fabricated and panel based modular solutions available, there are no (or limited) modular solutions that enable an assembly of a fully functional wall from individual interlocking components.

[0003] A fully functional wall, among other features, is able to support insulation, accommodate electrical, plumbing, and mechanical systems, enable connectivity of interior and exterior facades, and be fire and water resistant (particularly if it serves as an exterior wall). Accordingly, a modular solution that reduces costs and that provides this level of functionality would be beneficial.

SUMMARY

[0004] Disclosed is a modular building system configured to utilize interlocking components to create a fully functional wall(s) that are configured to accommodate a variety of wall systems including, but not limited to, mechanical, plumbing, smart home, and/or electrical systems, as well as interior panel(s) and an exterior panel(s) or facade. As will be become evident by the description, the interlocking components and thus the wall(s) and the includes systems may be assembled on-site by installers.

[0005] More specifically, it is an aspect of this disclosure to provide a modular building system for forming assembled walls. The modular building system includes: a set of interlocking pre-formed blocks, and each of the pre-formed blocks have a profile with both male connectors and female connectors, each of the male connectors and female connectors attachable to one or more corresponding connectors on one or more other pre-formed blocks l via an interference fit connection. Each of the pre-formed blocks has at least one cavity therein. The set of interlocking pre-formed blocks are configured to be assembled and interlocked to form an assembled wall.

[0006] Other features and advantages of the present disclosure will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. 1 shows an interior side of an assembled wall using a modular building system as disclosed herein, in accordance with embodiments.

[0008] FIGS. 2, 3, 4, 5, and 6 show a first (interior) side, a first (interior) angled view, a second (interior) angled view, a first (exterior) side, and a second (exterior) angled view, respectively, of a pre-formed block of the modular building system, in accordance with an embodiment herein.

[0009] FIGS. 7, 8, and 9 show a first (interior) angled view, a first (interior) side, and a second (exterior) side, respectively, of an alternate pre-formed block of the modular building system, in accordance with an embodiment herein.

[0010] FIGS. 10 and 11 illustrate a first (right side) angled view and a second (left side) angled view of two pre-formed blocks that are connected via latching mechanisms. [0011] FIG. 12 is a detailed view of a latched connection of the blocks as shown in

FIGS. 10-11, in accordance with an embodiment.

[0012] FIG. 13 and 14 show a first (interior) angled view of a first (interior) side, and a second (exterior) side, respectively, of an insert (e.g., insulation) which may be used with the pre-formed block, in accordance with an embodiment herein.

[0013] FIG. 15 shows an exploded view of exemplary components (including the pre formed block and the insert) used to form the assembled wall of FIG. 1, in accordance with an embodiment herein.

[0014] FIG. 16 shows an example of structural components used to form a wall frame and designed for receipt of parts of the modular building system, in accordance with an embodiment.

[0015] FIG. 17 shows an angled view of sills of the modular building system that may be placed on the structural components of FIG. 16, in accordance with an embodiment. [0016] FIG. 18 shows placement of exemplary end caps of the modular building system that may be placed on the sills of FIG. 17, in accordance with an embodiment.

[0017] FIG. 19 shows a detailed, cross sectional view of the placement of stanchions with the sills, end caps, and parts of the modular building system, in accordance with an embodiment.

[0018] FIG. 20 shows portions of a wall frame including parts of the modular building system, in accordance with an embodiment.

[0019] FIG. 21 schematically illustrates a building process or method for forming a wall utilizing the parts of the modular building system, in accordance with an embodiment. [0020] FIG. 22 shows an angled view of an interior side of a wall during assembly, including pre-formed blocks within a wall frame, in accordance with an embodiment.

[0021] FIG. 23 shows an exploded view of exemplary parts used to form a wall structure or a wall tile that may be positioned on an interior of a wall or a building, adjacent to the pre-formed blocks placed within the wall frame, in accordance with an embodiment. [0022] FIG. 24 shows an exemplary tongue-and-groove connection for assembling wall structures/tiles of FIG. 23 together along walls, in accordance with an embodiment. [0023] FIG. 25 shows an angled view of exemplary parts for vertically connecting wall structures/tiles, in accordance with an embodiment.

[0024] FIG. 26 shows an exploded view of exemplary parts used to form a wall structure positioned on an exterior of a wall or a building, adjacent to the pre-formed blocks placed within the wall frame, in accordance with an embodiment.

[0025] FIG. 27 shows an example of structural components used to form multiple wall frames for receipt of parts of the modular building system to form a building or a room, in accordance with an embodiment.

[0026] FIG. 28 shows a detailed, exploded view of components used to form the assembled wall, in accordance with an embodiment herein.

[0027] FIGS. 29 and 30 show a first angled view of a first side and a second angled view of a second side, respectively, of a pre-formed block of the modular building system, in accordance with another embodiment herein.

[0028] FIG. 31 shows a side perspective view of one side of the pre-formed block of

FIGS. 29 and 30. DETAILED DESCRIPTION OF EMBODIMENT(S)

[0029] As evident by the drawings and below description, this disclosure relates to a modular building system that includes interlocking components that are easily assembled to construct a high quality building. The entire construction process may be performed on-site at the desired location for the building, and in some cases, by just a couple of installers. In some cases, construction time may be reduced by about 70%, thus cutting costs by about 30%. In an embodiment, the system may be designed to enable installers to efficiently assemble a fully-functional wall on-site in less than thirty minutes using hand tools.

[0030] The system includes modular interlocking components that can quickly be assembled to the required configuration using only hand tools. The wall system may accommodate plumbing, electrical, smart home, and any mechanical elements that are needed for the functionality of the assembled wall. Facades (in the form of panels) may be attached to interior and exterior surfaces to provide a high-quality finish.

[0031] FIG. 1 shows an example of an assembled wall 100 that is formed as a result of the herein disclosed modular building system. Assembled walls may be connected together and used to form a building, in accordance with some embodiments. In other embodiments, the assembled wall may stand alone and/or be positioned for use with one or more other walls to define a space, an area, or a room (e.g., like a cubicle) in a designated area. The wall(s) may be formed from a number of parts, as described in greater detail later.

[0032] In this disclosure, a pre-formed “block” refers to a pre-fabricated component or structure which includes connectors formed in its walls to connect to other blocks. In an embodiment, a set of interlocking, pre-formed blocks are provided with corresponding connectors formed thereon that may be assembled together to form a wall. Accordingly, when using the disclosed modular building system to from a wall, each wall need not be pre assembled, e.g., off-site or before delivery. That is, the blocks or structures may be transported and assembled on-site, e.g., at the location or site that the wall(s), building, etc. are constructed.

[0033] FIGS. 2-6 show different views (front and back; interior and exterior) of a pre formed block 20 in accordance with a non-limiting, exemplary embodiment. As shown in the first side (interior side) view of FIG. 2, each of the interlocking pre-formed blocks 20, in accordance with an embodiment, have a profile with both male and female connectors, 26 and 28, respectively. Each of the male and female connectors 26 and 28 are attachable to one or more corresponding connectors (e.g., female and male connectors, respectively) on one or more other pre-formed blocks 20 via an interference fit connection. In accordance with this disclosure, an interference fit, also known as a press fit or friction fit, is a defined as a form of fastening between mating parts of a pre-formed block with other pre-formed blocks (and, in some embodiment, mating between a pre-formed block and an end cap), which thereby produces a joint which is held together by friction after the parts are pushed (slid) and joined together. In a non-limiting embodiment, the male and female connectors 26 and 28 of each pre-formed block 20 may be provided in the form of dovetail connectors. As will become evident, different connectors 26, 28 and/or combinations of such connectors may be provided along sides of each block 20, thus allowing the block to be connected on all of its sides to another block, end cap, or structure via such connectors 26, 28.

[0034] The pre-formed blocks 20 have a number of vertical and horizontal male and/or female attachment areas 26 and 28, of different shapes and sizes, provided along and/or as part of surrounding walls 32 thereof, and may be connected to other pre-formed blocks 20 by means of friction and geometry (such as dovetail connection or other connections, as noted above). In accordance with an embodiment, each pre-formed block 20 may be provided with a surface in the form of a generally polygonal-shaped structure. The surface of pre-formed block 20 may include a generally rectangular-shaped wall portion 30, generally square-shaped wall portion 30, or other general polygonal shape (e.g., triangular, quadrilateral, pentagon, hexagon, etc.), and is not meant to be limited. For illustrative purposes only, the Figures show the pre-formed block 20 in the form of a generally rectangular-shaped structure. The wall portion 30 has a first (exterior) side (see FIG. 5) and a second (interior) side (see FIG. 2). For example, when used in an assembled wall, the wall portion 30 is positioned substantially vertically or vertically, thus forming a vertical surface (or wall part) of the assembled wall. A first side of the wall portion 30 may face an exterior (of a space, room, or building) when the pre-formed block is placed within a space (e.g., defined by a wall frame), and thus defines an external side of the assembled wall. A second side of the wall portion 30 may face an interior (of a space, room, or building) and defines an interior of each pre-formed block 20. The second side of the wall portion 30 assists in defining an interior cavity 34 of the pre-formed block, in conjunction with side surfaces 32, forming the profile thereof. Specifically, side surfaces 32 (also referred to herein as “extension walls” and/or “side walls”) extend radially from edges of said wall portion 30, i.e., in a generally perpendicular direction to a plane of the wall portion 30 and are connected around the perimeter and at comers thereof, to surround a perimeter of the cavity 34.

[0035] While FIGS. 2 and 5 may be noted as referring to an interior side and an exterior side, respectively, it should be noted that such reference is not limiting and that the positioning of the sides (including cavity 34) may be switched, i.e., cavity 34 may be considered as being provided on a first (exterior) side when assembled as part of an assembled wall. Further, as explained later, the block is not limited to including one cavity. Instead, at least one cavity may be provided in the block 20. In one embodiment, noted later, two cavities may be provided in a block.

[0036] As previously mentioned, in accordance with an embodiment, each pre formed block 20 may be provided in the form of a generally rectangular-shaped structure. Accordingly, each pre-formed block 20 may have at least four sides (and thus four side surfaces 32) and one wall portion 30, in accordance with an embodiment. In accordance with embodiments herein, the side surfaces 32 surround and define a perimeter of the interior cavity 34 of the pre-formed block 20. Accordingly, the side surfaces 32 (along with wall portion 30) define and form the interior cavity 34 (as seen in FIG. 3 and FIG. 4). Each side surface32 extends a length L (see FIG. 6, measured from the wall portion 30 to the plane across the ends of the side wall 32) which thereby defines a depth D (see FIG. 3) of the cavity 34.

[0037] In embodiments, the pre-formed blocks 20 may be a generally square-shaped structure, including similar features.

[0038] In an embodiment, the profiles of each of the interlocking pre-formed blocks

20 include one or more openings therein to receive fasteners therethrough and/or plugs designed to receive a portion of a fastener therein. Such features will become evident via the Figures and further description below.

[0039] It should be noted that while the sides of the block 20 are referenced as being formed with side surfaces or walls 32, such surfaces or walls should not be construed as being limiting to a flat or linear surface in profile. That is, in this disclosure, the side surfaces 32 are defined as including the connectors 26 and 28 formed (e.g., molded) therein or thereon, along with linear portions (e.g., interconnected therebetween). Accordingly, it should be understood that the connectors 26 and 28 may also extend from (in opposite directions) edges of the wall portion 30 in a generally perpendicular direction to a plane along the wall portion 30 and may be placed at different areas, and in different combinations, along the side surfaces 32 (and in different configurations) and/or at the comers thereof. Accordingly, each of the extension walls of the side surfaces 32 may include a combination of the male and/or female connectors 26 and/or 28 formed therein and/or thereon. Alternatively, in an embodiment, side surfaces may be designed to include at least one of either the male connectors 26 or the female connectors 28. As understood herein, male connectors 26 are designed to extend, protrude, project, et al. relatively away from a plane along (or portion of) an extension /side wall 32 and/or cavity 34, whereas female connectors 28 are designed to extend, indent, depress, et al., relatively into (a plane along) or towards extension wall 32 and/or cavity 34.

[0040] This built-in geometry of the interlocking pre-formed blocks 20, when assembled together via such connectors to form a wall, limits and/or substantially prevents movement in certain directions.

[0041] In accordance with an embodiment, a pre-formed block 20 has at least one male connector 26 on one of its side surfaces. In accordance with an embodiment, a pre formed block 20 has at least two male connectors 26 on one of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least three male connectors 26 on one of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least one male connector 26 on each of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least one male connector 26 on two of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least one male connector 26 on three of its side surfaces.

[0042] In accordance with an embodiment, a pre-formed block 20 has at least one female connector 28 on one of its side surfaces. In accordance with an embodiment, a pre formed block 20 has at least two female connectors 28 on one of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least three female connectors 28 on one of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least one female connector 28 on each of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least one female connector 28 on two of its side surfaces. In accordance with an embodiment, a pre-formed block 20 has at least one female connector 28 on three of its side surfaces.

[0043] In an embodiment, a pre-formed block 20 has four sides and includes at least one male connectors 26 on three of its sides, and at least one female connector 28 on a fourth side. In an embodiment, a pre-formed block 20 has four sides and includes at least one male connectors 26 on two of its sides, and at least one female connector 28 on two of its other sides.

[0044] The male and female connectors 26 and 28 may be provided in a number of locations along the wall portion and/or side surfaces of the pre-formed block 20 (including the comers of two adjoining side surfaces). In accordance with one embodiment, male and female connectors 26 and 28 may be positioned at least in a center area or center of each side surface on each pre-formed block 20. For example, as shown in FIG. 2, a male connector 26 may be provided on a first side (the left side in FIG. 2) and in a center of a side surface of the block 20. Similarly, a female connector 28 may be provided on another or second side (the right side in FIG. 2) and in a center of a side surface of the block 20. However, such locations are not limiting. Indeed, as also shown in FIG. 2, comers of the block 20 may include male and female connectors 26 and 28 formed in the surfaces of the block 20. In an embodiment, male and female connectors 26 and 28 may be formed in at least side surfaces 32 and comers of the pre-formed block 20. In another embodiment, male and female connectors 26 and 28 are formed in at least the comers of the block 20. In yet another embodiment, male and female connectors 26 and 28 are formed in at least the side surfaces 32 of the block 20.

[0045] The form of each pre-formed block 20 may be altered or changed according to a location of the block in the building wall, room, space, or ceiling, in accordance with embodiments herein. That is, based on a design of a wall and a space to be filled, dimensions and/or configurations of some of the pre-formed blocks 20 may be manipulated while still including the structure and male/female connectors. For example, in accordance with embodiments, pre-formed blocks 20 may be formed in different sizes, e.g., 6” x 12”, 12” x 12”, 24” x 12”, 24” x 24”, etc. In one non-limiting embodiment, pre-formed blocks 20 may be provided in two different sizes as part of a set or sets, e.g., a set of 12”xl2” full blocks (see, e.g., block 20 in FIG. 2) and a set of 6”xl2” half blocks (see, e.g., block 20A in FIG.

8). FIGS. 7-9 show an angled, interior, and exterior view of a half block 20A that may be used in the set of interconnecting pre-formed blocks, or in a second set of blocks, in accordance with an embodiment. For purposes of clarity and brevity, like elements and components throughout FIGS. 7-9 are labeled with same designations and numbering as discussed with reference to FIGS. 2-6. Thus, although not discussed entirely in detail herein, one of ordinary skill in the art should understand that various features associated with the block 20A of FIGS. 7-9 are similar to those features previously discussed and/or discussed later. In an embodiment, each block 20A has a profile with both male connectors and female connectors, which, in one embodiment, may be in the form of dovetail connectors. Such connectors are attachable to at least one or more corresponding connectors on one or more other pre-formed blocks (20 and/or 20A) via an interference fit connection. Blocks 20 A may also include at least one cavity 34 therein, in accordance with an embodiment. Blocks 20A may be assembled and interlocked to form an assembled wall. Each half block 20A may have connectors attachable to at least corresponding connectors on one or more other pre-formed blocks 20A as part of a second set. In some embodiments, the connectors of the half blocks 20A may be assembled and interconnected with the male connectors and/or the female connectors of the other set (e.g., the full blocks, i.e., blocks 20, as referenced above). Based on a desired wall size, calculations may be used to determine a combination of pre-formed blocks 20 and/or 20A of different sizes to form a set of interlocking pre-formed blocks which are used to form said assembled wall. Accordingly, a combination of different sized blocks - each of which include male and female connectors 26 and 28 - may be connected together to form a wall, in accordance with embodiments herein.

[0046] Although the above example describes six (6) inch increments for dimensions of the pre-formed blocks 20 and 20 A, in cases where a wall size may not be divisible by 6 inches, custom pre-fabricated or pre-formed blocks and/or addition of fillers may be used to achieve the necessary/desired wall size. Further, as previously noted, the shape of the blocks and wall portions 30 are not limited to rectangular and/or square shapes, and thus other polygonal shapes and dimensions, and combinations, may be utilized.

[0047] Another embodiment of an interlocking pre-formed block 20B that may be part of a set of interlocking pre-formed blocks used to form assembled walls is shown in FIGS. 29-31. For purposes of clarity and brevity, like elements and components throughout FIGS. 29-31 are labeled with same designations and numbering as discussed with reference to FIGS. 2-6. Thus, although not discussed entirely in detail herein, one of ordinary skill in the art should understand that various features associated with the block 20B of FIGS. 29-31 are similar to those features previously discussed and/or discussed later. FIG. 29 shows a first side 38A of a pre-formed block 20B and FIG. 30 shows a second side 38B of that block 20B. FIG. 31 shows a side perspective view of one side of the pre-formed block 20B, i.e., viewing from the right side as shown in FIG. 30. Like blocks 20A, each block 20B has a profile with both male connectors and female connectors, which, in one embodiment, may be in the form of dovetail connectors. Such connectors are attachable to at least one or more corresponding connectors on one or more other pre-formed blocks (20, 20A, and/or 20B) via an interference fit connection. Blocks 20A may be assembled and interlocked to form an assembled wall. Each block 20B may have connectors attachable to at least corresponding connectors on one or more other pre-formed blocks 20B as part of a second set. In some embodiments, the connectors of the blocks 20B may be assembled and interconnected with the male connectors and/or the female connectors of the other set (e.g., blocks 20, as referenced above).

[0048] Blocks 20A may also include a first cavity 34A (as provided on and visible from the first side 38A in FIG. 29) and a second cavity 34B (as provided on and visible from the second side 38B in FIG. 30) therein, in accordance with an embodiment. The first cavity 34A may be defined by first side surfaces that are connected to and extending radially from a vertical surface to surround a perimeter of the first cavity 34A. The second cavity 34B is provided on a side opposite the first side and may be defined by second side surfaces that are connected to and extending radially from the vertical surface to surround a perimeter of the second cavity 34B. In accordance with an embodiment, the first and second side surfaces are the same surfaces, e.g., side walls 32 which extend along the sides of the block 20B. In another embodiment, the first and second side surfaces may be separate but joined surfaces, e.g., two side walls 32 which extend from the vertical wall in either direction and along the sides of the block 20B. In accordance with an embodiment, the vertical surface is defined by a vertical wall that is common to both the first cavity 34A and the second cavity 34B. That is, a singular vertical wall may be provided between the cavities 34A and 34B, with a first side of the wall defining part of the first cavity 34A, and a second side of the wall defining part of the second cavity 34B.

[0049] In an embodiment, it is envisioned that two sets of blocks may be provided to a user to form multiple types of assembled walls. For example, in an exemplary embodiment, a set of interlocking pre-formed blocks (e.g., blocks 20) may form a first set, and another set of interlocking pre-formed blocks (e.g., blocks 20B) may form a second set. In one embodiment, the second set of pre-formed blocks 20B are configured to be assembled and interconnected to form an interior assembled wall, whereas the first set of interlocking pre formed blocks 20 form an exterior assembled wall. In some cases, the interior assembled wall may be connected to the exterior assembled wall. For reference, the “exterior” wall need not be a wall that is exposed to environmental elements and/or part of a building. Rather, as an example, an exterior wall may be a wall that defines an outer perimeter of a room (e.g., a bedroom), whereas an interior wall may be a wall that defines a space within that room (e.g., a bathroom or a closet). [0050] In yet another embodiment, a first cavity and a second cavity of an interlocking pre-formed block may be provided adjacent to each other on the same side of a block. That is, in addition to a vertical surface and side surfaces that extend radially from the vertical surface, a dividing surface may be provided between side surfaces which also extends radially from the vertical surfaces and divides the cavity into two cavities provided on either side of the dividing surface.

[0051] The first and second cavities of any of the aforementioned embodiments need not be the same size or dimensions.

[0052] Further possible features of the pre-formed blocks 20, 20 A, 20B are shown in

FIGS. 2-6 (and 7-9) with reference to blocks 20, for simplicity. In addition to the sides including the side surfaces 32 and aforementioned male and female connectors 26 and 28, side surfaces 32 may also have routes 36, grooves, and/or channels formed therein, for placement of pipes, wires, and the like, such as shown in the interior side view of FIGS. 2-3 and exterior view shown in FIG. 5. For example, the routes 36 may be formed by a generally U-shaped cut-out portion provided in side(s) or wall(s) of the block 20. Also, for example, as seen in FIGS. 2-4, internal connectors 22 may be formed generally extending from an interior of the wall portion 30 and into the cavity 34 of the block 20. The internal connectors 22 may be utilized to align with, insert, and/or connect to attachments or accessories (e.g., inserts 24, as described later), for example. Also inside the cavity 34, on the interior (second) side of the wall portion 30 and, e.g., adjacent or near the inside comers, attachment locations 40 (see, e.g., FIGS. 2-3) or integrated connectors may be provided. In an embodiment, the attachment locations 40 or integrated connectors may be provided in the form of an opening to a passageway that extends through the wall portion 30. Accordingly, an opening 44 or slot on the exterior (first) side of the wall portion 30 may also be formed at the other side of the passageway, as shown in FIG. 6. This opening 44 or slot may be an attachment location for an exterior panel connector or plug 104 (also described later). In an embodiment, the first (exterior) side of the wall portions 30 of the pre-formed blocks 20 provides connectivity exterior panels which may be secured via fasteners (e.g., screw-in plugs) situated at the four comers of each pre-formed blocks 20.

[0053] Further, in accordance with an embodiment, the profiles of each of the pre formed blocks 20 include one or more openings therein to receive fasteners therethrough and/or plugs designed to receive a portion of a fastener therein. [0054] Furthermore, one or more locking mechanisms may be provided on the pre formed blocks 20, to releasably secure adjacent blocks to one another. FIGS. 10-11 show detailed views of an example of a snap-fit locking mechanism provided in the form of snap latches 42 and receiving tabs 43. Snap latches 42 may be provided on one side (e.g., right side, when viewed from the interior) of a block 20, whereas receiving tabs 43 may be provided on another (opposite; e.g., left side, when viewed from the interior) side. Generally, as understood by one of skill in the art, each latch 42 has a locking edge which actuated by snapping and locking with tab 43 such that the edge is held by tab 43, an example of which is shown in FIG. 12. In an embodiment, two of the sides (side walls 32) of each block 20 are provided with one or more latches thereon, whereas the other two sides (side walls 32) of the block includes one or more receiving tabs 43. In the non-limiting exemplary embodiment shown in the Figures, two snap latches 42 are provided along two of the walls, and two receiving tabs 43 are provided along the other two walls. The latches 42 may be formed to extend perpendicularly from the wall portion 30, e.g., generally parallel to the side surfaces 32, as shown in FIG. 4, in accordance with an embodiment. The receiving tabs 43 may be provided adjacent to routes 36 that are formed in side walls, as shown in FIG. 3, in accordance with an embodiment.

[0055] In addition to the male and/or female connectors 26 and/or 28 of the pre formed blocks 20 being used for attachment to other pre-formed blocks 20 (and/or blocks 20A), the pre-formed blocks 20 may be attached to a support structure, as described later below with reference to FIGS. 18-21. The support structure may be made of steel, wood or other material using metal screws or alternate means of connection. The pre-formed blocks 20 may attach to the support structure directly and/or using an in-between connector (i.e., end caps 12) which may be connected to the structure, e.g., with screws or alternate means of connections. As described later, in embodiments, the end caps could be attached to each other to create a wall frame, or attached to sills 10 which may be attached to a wall frame. In accordance with an embodiment, the pre-formed blocks 20 are easy to install and simply slide or slot into the wall frame via end caps 12 and/or via the integrated dovetail connection by which individual pre-formed blocks 20 may be securely attached to each other.

[0056] In an embodiment, the pre-formed blocks 20 may be formed of composite material (s) including, but not limited to, polymer(s), fibers and/or nano carbon particles or other materials, that act as a barrier between an exterior and an interior of the wall. A fire- retardant component could be added to the material composition, in accordance with embodiments. The pre-formed blocks 20 may be formed by any number of manufacturing methods, including, but not limited to, molding (e.g., extrusion molding, injection molding), 3D printing, and/or casting. The blocks 20 may be water resistant and may have integral horizontal and vertical design features that limit and/or prevent water from entering the interior of block or the building.

[0057] In an embodiment, the pre-formed blocks 20 may include one or more routes, grooves and/or channels configured to accommodate mechanical, electrical, smart home, and/or plumbing components for the building, so that the pre-formed blocks 20 have opening areas that provide routing paths for pipes, wires, or other components in different locations according to the specific building design. For example, the interior cavity 34 may be configured to accommodate mechanical, electrical, smart home, and/or plumbing components therein and/or therethrough. As will be evident later in this description, the pre-formed blocks 20 may accommodate one or more attachment plates 96 (e.g., see FIG. 15) that connects to the blocks to create at least one attachment point for mechanical, electrical, and plumbing (MEP) components (or smart home components). The plate 96 may be made of metal or other material and may be used for specific placement of outlets, switches, etc. Spacers can be used to determine the depth of the plate 96 to accommodate different components depths. Other attachment components could be added, removed, changed or located differently within the block by use of such attachment plates.

[0058] While the blocks 20 are designed to accommodate a number of attachment components and may be utilized with any number of items in their cavities 34, in some embodiments, one or more cavities 34 of a set of blocks 20 may receive inserts (see FIGS. 13-14) therein. In accordance with an embodiment, insert(s) 24 are designed to reside within designated cavities 34 of each of the pre-formed blocks 20 to provide insulation, guides, and/or attachment areas therein. In one embodiment, at least some of the cavities 34 of the pre-formed blocks 20 include inserts 24 therein when a wall is assembled; that is, not all of the pre-formed blocks 20 require placement of inserts 24 therein to form an assembled wall 100. In an embodiment, at least half of the cavities 34 of the pre-formed blocks 20 include inserts 24 therein when a wall is assembled. In another embodiment, all of the cavities 34 of the pre-formed blocks 20 include inserts 24 therein when a wall is assembled.

[0059] In an embodiment, each of inserts 24 has side surfaces which have a complementary profile to interior surfaces of the cavities 34 of the pre-formed blocks 20. In an embodiment, each of inserts 24 has a corresponding and complementary profile that is receivable into the cavities 34 of the pre-formed blocks 20, such that said inserts 24 may be secured via side surfaces 32. For example, the inserts 24 may be of generally rectangular shape, in accordance with an embodiment and as depicted in the angled views of FIG. 13 and 14. In another embodiment, the inserts 24 may be of a generally square shape. In an embodiment, a profile or perimeter of the inserts 24 may be different than a shape or design of the cavities 34 of the pre-formed blocks 20, while still being designed for receipt and placement and securement therein.

[0060] FIGS. 13-14 show angled views of a first (interior) side (or front), and a second (exterior) side (or back), respectively, of one example embodiment of insert 24. Each insert 24 has a first face 46 (FIG. 13) or front face forming a first (interior or front) side, and a second face 48 (FIG. 14) or back face forming a second (exterior or back) side, respectively, of the insert 24, and edges 50 connecting and extending between the two faces 46, 48, forming a thickness T2 of the insert 24. In an embodiment, the thickness T2 of the insert 24 is substantially equal to the depth D of the cavity 34 of a block 20. In an embodiment, the thickness T2 of the insert 24 is less than the depth D of the cavity 34 of a block 20. As shown in FIG. 13, a number of slots 55 may be formed into the insert 24 with apertures provided on the first face 46. The slots 55 may be configured to receive internal connectors of a pre-formed block 20, thereby assisting in both alignment and connection of the insert in the respective block. The number of slots 55 provided may correspond to the number of internal connectors 22 of the pre-formed block 20. As also shown in FIG. 13, a number of grooves 54 may be formed in (or into) the first face 46, and optionally in the second face 48, extending horizontally, vertically, and diagonally within a body of the insert 24, to guide and accommodate building components (such as wires) therein and provide opening or receiving areas that provide routing paths for pipes, wires, or other components in different locations according to the specific building design. Similarly, a number of channels 52 may be formed in the second face 48, as shown in FIG. 14, and optionally the first face 46, extending horizontally, vertically, and diagonally within a body of the second component, to guide and accommodate building components (e.g., pipes) therein. In some cases, channels 52 and/or grooves 54 may be configured to extend through a portion of the body of the insert, e.g. between edges and/or between faces 46, 48. The channels 52 and grooves 54 may be designed to hold components therein securely, without requiring additional braces, in accordance with an embodiment. In an embodiment, the channels 52 are C-shaped channels for receiving piping, plumbing, or other components therein. For example, the channels 52 may be configured to surround at least half of the component (e.g., pipe 95 of FIG. 15) placed therein.

[0061] In an embodiment, the insert 24 may be designed to accommodate (e.g., in channels 52) pipes of up to 2” in diameter (outside diameter of 2.375”) without adjustments. Accordingly, in one embodiment, the channels 52 may include a radius based on the diameter of the pipes and the material used to form the insert 24. For example, if the insert 50 is made of an expansible or compressible or flexible or resilient material that is configured to accommodate and/or stretch to a certain size, the radius of the insert may be substantially equal to or less than a predetermined diameter of a pipe or component. If larger pipes - such as drainage pipes - are provided for use in the assembled wall and/or building, such pipes may be accommodated by cutting inserts using a cutting tool to accommodate larger diameters.

[0062] In an embodiment, the inserts 24 may be formed of one or more insulation materials, such as foam or other materials having insulated properties, to provide high-quality thermal and acoustic insulation. In an embodiment, a pre-formed block 20 may be insulated by providing insert 24 that resides within the internal cavity 34 and/or which may be added to the internal cavity 34 of the pre-formed block 20, e.g., on site.

[0063] FIG. 15 shows a non-limiting example of aligning and inserting insert 24 into the cavity 34 of a block 20. The first or front face 46 may be aligned relative to the walls of the block 20 and the insert 24 may be pushed into the cavity 34 so as to have its edges 50 at least partially, if not substantially or entirely, surrounded by the side walls 32 and connectors 26, 28, etc. of the block 20.

[0064] The inserts 24 may be formed of open cell foam insulation or closed cell foam insulation, or a combination thereof, in accordance with embodiments. In some embodiments, inserts 24 may be formed of a combination of foam insulation and soundproof insulation materials.

[0065] In yet another embodiment, insulation may be added externally to the block

20, in addition or as an alternative to the insert 24, and/or the pre-formed block itself may have insulation properties.

[0066] Accordingly, when the pre-formed blocks 20 and inserts 24 are assembled together, they form a component that is part of the assembled wall. FIG. 15 shows an exploded view of some of the parts which may be used to form an assembled wall, e.g., pipe(s) 95 may be inserted into channels 52 of insert(s) 24, and an interior panel or interior wall tile 78 and an exterior panel 92 may be attached (e.g., directly to a block / insert or via an attachment plate 96) to the assembly. Further details regarding such panels are described later with reference to FIGS. 23-26.

[0067] To better understand how the assembled wall 100 is formed, reference is now made to an exemplary embodiment described with reference to FIGS. 16-22.

[0068] FIG. 16 shows an example of structural components used to form a structure for securing a wall frame that is designed for receipt of parts of the modular building system, in accordance with an embodiment. A slab 56 may be poured or provided in a case where a building or room may be erected. However, use of a slab is exemplary and not necessary. In an embodiment, a strong wall shear wall 62 is provided at one side of a wall frame with two studs (e.g., 6”x3” in the illustrated example) that form a post 58 on an opposite side thereof. Additional stud(s) may used to form a post 58 on another side of the wall, and beam(s) 60 are secured thereto.

[0069] More specifically, in accordance with an embodiment, the modular building system may include a number of sills 10 in addition to the set of interlocking pre-formed blocks 20. The sills 10 may be designed to be arranged, with a wall frame, to define a space 16 (see FIG. 16) for receipt of the interlocking pre-formed blocks 20, which interconnect to form an assembled wall 100 in said space. For example, based on the wall size of the desired space, an area, or a room / building, a number or set of pre-formed blocks may be determined to fit within the space defined by the frame and sills. As previously noted the set may include one size or a combination of different sized blocks for that space.

[0070] To create the wall frame for assembly of the modular building system, in accordance with embodiments herein, sills 10 are attached to the frame or structure formed by the posts 58 and beams 60, such as shown in FIG. 17, as well as the shear wall 62, which is positioned on a side of the optional slab 56. Specifically, sills 10 may be provided on an inside surface of the posts 58, beams 60, and shear wall 62 to create a frame around the wall structure, for the pre-formed blocks to be attached quickly and efficiently thereto, within space 16. Each sill 10 may include one or more premeasured attachment locations provided thereon, so that the sills 10 may be used as a measuring tape to mark a location for attachment of blocks 20 thereto. For example, in an embodiment, blocks 20 may be attached via fasteners (e.g., inserted through pre-made openings in the walls of the block) to the attachment locations of the sills 10 and thus the wall frame. Each sill 10 may be cut to length, the length being determined according to a width and/or a height of the wall frame, for example. In accordance with anon-limiting embodiment, the sills 10 may be made from a composite material.

[0071] In one embodiment, end caps 12 may be provided as part of the modular building system. The end caps 12 may be connectable to at least one of said premeasured atachment locations of said sills 10, or to each other, and allow for placement and locking of the pre-formed blocks 20, in accordance with an embodiment. Accordingly, the sills 10 may be used as a measuring tape to mark a location for each of the end caps 12 to be atached thereto, in addition or as an alternative to the blocks 20.

[0072] Accordingly, in one embodiment, each end cap 12 may be connected to at least one of said premeasured atachment locations of the sills 10, such as illustrated in FIGS. 18-20. That is, once the wall frame is complete, the end-caps 12 may be designed for installation onto the sills 10. End-caps 12 may be designed to provide the mechanical connectivity for the interlocking pre-formed blocks 20 and determine where the blocks are placed. For example, in an embodiment, each of the end caps 12 has a female receiving portion, e.g., in the form of a channel or groove 70, such as shown in FIGS. 18 and 19. One of the male connectors 26 of a pre-formed block 20 may be configured for insertion into the female receiving portion / groove 70 of the end cap 12. The groove 70 may be flanked by end cap sides 68 which are connected via a plate 72 extending therebetween. One or more channels 76 may be provided on an interior 74 of each end cap side 68. In an embodiment, the end caps 12 are atached to the sills 10 using stanchions 64 (see assembly in FIG. 19) that are secured via fasteners 66 (e.g., screwed using screws or bolts) into the sill 10 and wall frame. In accordance with an embodiment, an opening 76 may be provided in the end cap 12 for insertion of the stanchions 64 and then aligned with holes in the sill 10. The fasteners 66 may provide the necessary atachment and pressure. Tension is determined by the degree to which the screws are tightened. Due to their designed connection points, the end-cap openings 76 may align with the sills 10, allowing for fast and easy assembly. In accordance with a non-limiting embodiment, the end caps 12 may be formed from a composite material. [0073] The end caps 12 may not only determine where the blocks 20 are placed and streamline the wall installation process, but also are designed to connect the pre-formed blocks 20 mechanically to the wall frame and structure.

[0074] Accordingly, in a non-limiting embodiment, to form and install each wall using the disclosed modular building system, first, each sill 10 may be atached to a structure to define the space 16 for receipt of the plurality of interlocking pre-formed blocks, such as depicted in FIGS. 16, 17, and 18. The end caps 12 may be optionally installed on the premeasured attachment locations provided on the number (e.g., four) of sills 10 defining the space 16. As schematically represented in FIG. 21, the pre-formed blocks 20 may be installed in rows to fill the defined space 16. In accordance with one embodiment, the pre-formed blocks 20 are installed by the installing the pre-formed blocks in rows, e.g., installing a first row of the pre-formed blocks 20 along a bottom sill 10 that defines the space 16 by connecting the first row to at least the end caps 12 (if utilized) on and along the bottom sill 10, then installing a second row of the pre-formed blocks 20 to the first row via the male and female connectors 26 and 28, and successively installing rows of the pre-formed blocks 20 until the defined space 16 is filled (shown in FIG. 16, and also FIG. 1) with pre-formed blocks 20. Then, the inserts 24 may be placed or provided within pre-formed blocks 20. In an embodiment, providing the inserts 24 within the pre-formed blocks 20 includes inserting each of the inserts 24 into the cavities 34 of the pre-formed blocks 20. Further, since both the pre formed blocks 20 and the inserts 24 may have one or more routes 36, grooves 54 and/or channels 52 configured to accommodate mechanical, electrical, smart home, and/or plumbing components for the building, and the method of forming the wall may thus include installing mechanical, electrical, smart home, and/or plumbing components into said one or more routes 36, grooves 54, and/or channels 52 of the pre-formed blocks 20 and/or the inserts 24. Such placement may be performed before or after placement of the inserts 24 within the pre formed blocks 20.

[0075] According to one embodiment, installation of the second row and each successive row comprises horizontally shifting placement of each row of pre-formed blocks 20 as compared to the first row. As such, different sized blocks and/or filler blocks may be provided as part of the set of interlocking pre-formed blocks, to fill in any gaps or openings formed by shifting of a row.

[0076] The wall design of the assembled wall 100 may include specification for certain design panel openings to accommodate piping, electrical outlets and switches and other necessary wall accessories. To enhance efficiency and make for fast construction, the pre-formed blocks 20 are designed to accommodate any required add-ons such as insulation pads / inserts 24 and attachment plates for electrical outlets, switches, and more. Besides accommodating the inserts 24 (insulation), the interior side (cavity 34) of the pre-formed blocks 20 accommodate (metal) attachment plates 96 for outlet connections, switches, and other components. As described in greater detail below, the blocks 20 may also have connection points for the Z bars (also known as “French cleats”) to which interior panels and/or exterior panels may be attached.

[0077] The geometry of the blocks themselves may accommodate connectors or channels that are used to attach the interior or exterior panels to the pre-formed blocks 20, in some embodiments.

[0078] To further form each wall, a number of interior panels or interior wall tiles 78 and a number of exterior panels 92 may be provided as part of the modular building system, for attachment to each assembled wall (e.g., attachment to the wall shown in FIG. 1). Each interior wall tile 78 is configured for attachment to a first side (interior side) of one assembled wall and each exterior panel 92 is configured for attachment to a second side (exterior side) of said one assembled wall. As previously mentioned, the use of the term “exterior” is for explanatory purposes only and is not intended to mean or limit only reference to environmental exposure or outside elements such as those of building walls. However, as provided in the exemplary Figures, the panels may be utilized in a such a manner, according to embodiments herein.

[0079] FIG. 23 illustrates one embodiment of an interior panel, in the form of a wall tile 78, formed by a number of layers which are attached to an interior side of the pre-formed blocks 20. In an embodiment, interior panels or tiles 78 may be made from MDF substrate 80 covered with a layer of fire-retardant paint 82 and a sleek, low-maintenance, durable outer acrylic layer 84. The MDF substrate 80 has a tongue and groove connector 86 (shown in FIG. 24) to help with alignment of the panel/tile 78 with another tile, and to create overlapping construction for increased fire resistance. As shown in FIG. 24, the panels / tiles 86 may include tongue-and-groove connections 86 on at least the lateral sides thereof to help align them correctly and connect them securely to one another. An adhesive or glue may be applied to the connections 86 between the panels /tiles 78 and, if necessary, sanded down once dry to disguise any seams and create a unified surface across the entire interior wall.

[0080] The interior panels/tiles 78 may be installed on the wall by means of aluminum Z-shape bars (also called, French cleats) 88 and 90, shown in FIG. 25. One Z bar 90 may be fastened (e.g., screwed) into the integrated connectors 40 (see, e.g., FIG. 3) of the blocks 20 while a second matching Z bar 88 may be fastened (e.g., screwed) into one side of the panel/tile 78. To ensure strength and durability, each panel/tile 78 may be secured with three rows of Z bar pairs, in accordance with an embodiment. In accordance with embodiments, the panels / tiles 78 may be fire rated by using a combination of wood substrate or other substrates, covered with sufficient layers of fire rated paint or other fire- resistant compound, and finished with an acrylic material, laminate or other finishes.

[0081] FIG. 26 illustrates one exemplary embodiment of an exterior panel 92. In an embodiment, the exterior panels 92 may be made of fiber cement or treated wood. As shown in FIG. 26, the panels 92 may be attached to the exterior frame using aluminum Z bars 88, 90 (or, French cleats) and fastened (e.g., screwed) into place at various locations. One Z bar may be fastened (e.g., screwed) through a waterproof panel 98 (e.g., water resistant gypsum sheathing) into the integrated openings 44 on an exterior of the blocks 20 and a second matching Z bar may be either screwed into the panel (for wooden panels) or attached using rivets (for fiber cement panels), for example. Three rows of Z bar pairs may be used to secure one panel 92, in accordance with an embodiment. In addition, an exterior facade 94 is secured by using fasteners (e.g., screws) at a perimeter of each of the panels 92, and connecting them to the structure.

[0082] According to one embodiment, the exterior panels and/or walls may be water proofed using water-resistant or waterproof panels 98 (e.g., gypsum sheets or sheathing) covered by an additional waterproofing membrane or board 102. Waterproof tape may be applied to seams between the water-resistant/waterproof panels 98, following which a layer of liquid waterproofing membrane is applied on the entire surface providing complete water protection with no gaps or leakage points. A fire rated paint layer 101 may be applied between the waterproof panel 98 and the exterior waterproof board 102. Further, as shown in FIG. 26, composite plugs 104 may be provided for alignment with and insertion into the openings 44 on the exterior of the blocks 20.

[0083] Accordingly, when interior panels 78 and exterior panels 92 are provided as part of the disclosed modular system, the method of forming the assembled wall 100 may also include attaching each interior panel to a first side of each interlocked block set that forms the assembled wall, and attaching each exterior panel to a second side of said interlocked block set that forms the assembled wall.

[0084] It should be understood to those skilled in the art based on this disclosure that different wall shapes may be achieved by using different block shapes that are provided with a set of interlocking pre-formed blocks. That is, while most of the pre-formed blocks may be similar to block 20, additional blocks may be provided that may be connected to the blocks 20 to form different parts of a room or area. As an example, one type of wall shape may include a “T” shape connection, i.e., when an interior wall is connected to an outer wall. Accordingly, in an embodiment, one or more “T”-shaped blocks, with surfaces residing in two different planes, may be used to create such a wall shape. Such blocks may include connectors which are attachable to the connectors (26, 28) and/or side surfaces of other blocks in the set.

[0085] This system may additionally support different shapes of walls and ceilings, including, but not limited to, curved walls, angled walls, pitched ceilings, and the like. These shapes may be created by altering a geometry of the pre-formed blocks while still maintaining the basic connectivity approach described above, i.e., male and female connectors that provide an interference fit.

[0086] Ceiling blocks may be used as part of the modular building system, in accordance with an embodiment, and/or the modular building system may be used to form a ceiling. Ceiling blocks may be similar to wall blocks (20, 20A, and/or 20B), and are not used as structural elements or as flooring material for walking. Their purpose is both functional (i.e., accommodation of piping, light fixtures, and other accessories) and decorative, creating a continuous ceiling look and also able to accommodate attachment of design panels. In an embodiment, the modular building system may be used to form a floor of a room, building, space, or area. Similarly to the aforementioned ceiling blocks, they may be in the form of blocks 20, 20 A, and/or 20B, and provide both functional and decorative purposes. In an embodiment, floor blocks may be designed to accommodate attachment of floor panels. [0087] The profile structure (including the male and female connectors) of the pre formed blocks as described throughout this disclosure provides connectivity and strength (limiting and/or substantially preventing movement in certain directions) to an assembled wall.

[0088] As should be understood by one of skill in the art, the structure of the wall frame provides strength and meets gravitational and lateral forces requirements with regards to forming an assembled wall. As shown in the example figures, such may be achieved by a post and beam hollow (or similar) structure configuration. The structure does not have to rely on the walls to provide the required support for the building, room, etc. and adhere to structural building codes. The structure allows for different sizes of open spans or spaces 16. The walls and ceiling may serve as an infill, an insulating barrier and provide support to interior and exterior panels and windows and doors.

[0089] Additionally, the hollow structure can be achieved by having propriety comer elements that meet the gravitational and lateral force requirements from the structure. The blocks may either directly attach to these elements by screws or alternative methods, or be attached via an interim piece described as sill or end caps above, or other alternative methods. [0090] A layer of conductive polymer could be applied to the pre-formed blocks 20 for integration of sensors and integral connectivity to low voltage systems (such as recessed lights and switches). A wire mesh can be integrated into the block to create a magnetic field that can sense movement and turning on and off electrical devices in the building.

[0091] Reference throughout the specification to “one embodiment” or “an embodiment” or the like means that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” et al. in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments. Further, it is intended that embodiments of the disclosed subject matter cover modifications and variations thereof. [0092] Also reference to direction or position such as “interior” and “exterior,”

“front” and “back,” “left” and “right,” etc. are made with reference to the Figures for explanatory purposes only and not intended to limit any description of a particular feature, structure, or characteristic described in connection with an embodiment to such a direction or position.

[0093] While the principles of the disclosure have been made clear in the illustrative embodiments set forth above, it will be apparent to those skilled in the art that various modifications may be made to the structure, arrangement, proportion, elements, materials, and components used in the practice of the disclosure.

[0094] It will thus be seen that the features of this disclosure have been fully and effectively accomplished. It will be realized, however, that the foregoing preferred specific embodiments have been shown and described for the purpose of illustrating the functional and structural principles of this disclosure and are subject to change without departure from such principles. Therefore, this disclosure includes all modifications encompassed within the spirit and scope of the following claims.