AND METHODS

PRIORITY

[0001] This application is a continuation of and claims priority to U.S. Patent Application No. 17/456,264, filed November 23, 2021 , and claims priority to New Zealand Patent Application No. 783038, filed December 2, 2021 , both of which are incorporated by reference herein.

BACKGROUND

[0002] Conventional building construction typically involves site-specific designs that are constructed entirely or nearly entirely on-site. There is a desire for modular building designs that can be assembled at a remote site and brought to a building site for assembly in various configurations that can be repeated or altered among various sites.

SUMMARY

[0003] Representative embodiments of the present technology include a structural system including one or more modules. A module may include a first upper chord oriented along a length of the module, a first lower chord oriented along the length of the module, a second upper chord positioned opposite the first upper chord, parallel to the first upper chord, a second lower chord positioned opposite the first lower chord, parallel to the first lower chord, and a plurality of rib assemblies positioned between the first upper chord, the first lower chord, the second upper chord, and the second lower chord, the rib assemblies extending along a width of the module perpendicular to the chords. At least one of the chords may include a plurality of chord portions joined together with one or more connector plates. Two of the rib assemblies may include shear keys configured to be received in support structures, such as piers at a final installation site. In some embodiments, each chord portion includes a plurality of arrays of holes. The rib assemblies may include two vertical column beams and two or more horizontal crossbeams connecting the column beams to each other. The shear keys may project downwardly from the vertical column beams.

[0004] Another representative embodiment of the present technology includes a method of making a structure. Making the structure may include making a module of the structure. The method may be at least partially performed at a first location (such as a factory) that is remote from a second location (such as a final outdoor installation location of the structure). The method may include positioning shear keys (attached to the module) into pockets formed in piers (such as concrete piers) at the final installation location. The method may include leveling the module by positioning shims in the pockets under the shear keys or moving the shear keys within the pockets. Empty space in the pockets may be filled with filler material, eliminating a need for bolting the module to the piers.

[0005] Other features and advantages will appear hereinafter. The features described above can be used separately or together, or in various combinations of one or more of them. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In the drawings, wherein the same reference number indicates the same element throughout the several views:

[0007] Figure 1 illustrates a perspective view of a modular structure configured in accordance with embodiments of the present technology.

[0008] Figure 2 illustrates a perspective view of a module configured in accordance with embodiments of the present technology and suitable for use in the modular structure shown in Figure 1 .

[0009] Figure 3 illustrates a side perspective view of a chord portion configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in Figure 2.

[0010] Figure 4 illustrates a chord configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in Figure 2.

[0011] Figure 5a illustrates a rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in Figure 2.

[0012] Figure 5b illustrates another rib assembly configured in accordance with embodiments of the present technology and suitable for implementation in the module shown in Figure 2.

[0013] Figure 6 illustrates positioning a module on a pier at a final installation site, in accordance with embodiments of the present technology. DETAILED DESCRIPTION

[0014] The present technology is directed to modular structures (which may be habitable structures), and associated systems and methods. Various embodiments of the technology will now be described. The following description provides specific details for a thorough understanding and enabling description of these embodiments. One skilled in the art will understand, however, that the invention may be practiced without many of these details. Additionally, some well-known structures or functions may not be shown or described in detail so as to avoid unnecessarily obscuring the relevant description of the various embodiments. Accordingly, embodiments of the present technology may include additional elements or exclude some of the elements described below with reference to Figures 1-6, which illustrate examples of the technology.

[0015] The terminology used in this description is intended to be interpreted in its broadest reasonable manner, even though it is being used in conjunction with a detailed description of certain specific embodiments of the invention. Certain terms may even be emphasized below; however, any terminology intended to be interpreted in any restricted manner will be overtly and specifically defined as such in this detailed description section.

[0016] Where the context permits, singular or plural terms may also include the plural or singular term, respectively. Moreover, unless the word “or” is expressly limited to mean only a single item exclusive from the other items in a list of two or more items, then the use of “or” in such a list is to be interpreted as including (a) any single item in the list, (b) all the items in the list, or (c) any combination of items in the list. Further, unless otherwise specified, terms such as “attached” or “connected” are intended to include integral connections, as well as connections between physically separate components. [0017] As used herein, the term “and/or” when used in the phrase “A and/or B” means “A, or B, or both A and B.” A similar manner of interpretation applies to the term “and/or” when used in a list of more than two terms.

[0018] Figure 1 illustrates a perspective view of a modular structure 100 configured in accordance with embodiments of the present technology. The modular structure 100 may be a habitable structure such as a home or an office, or it may be a structure for storage or other non-habitable purposes. The modular structure 100 may be supported on a plurality of piers 110 or other suitable support structures. In some embodiments, the modular structure 100 can include one or more modules 120. Figure 1 illustrates two modules 120 joined together at an interface 130.

[0019] Each module 120 includes usable or habitable interior space, and when multiple modules 120 are joined, they may form a combined interior space. Supporting the modules 120 on piers 110 enables building the modular structure 100 on uneven terrain while controlling (e.g., minimizing) the impact on the surrounding environment. Supporting the modules 120 on piers 110 may also facilitate using the space beneath the modular structure 100 for storage, additional usable space, or other uses. In coastal areas or other areas prone to flooding, the piers 110 provide elevation above floodwaters. Although Figure 1 shows one example of modules 120 positioned adjacent to each other to form the modular structure 100, in other embodiments, the modules 120 may be positioned or arranged to form other shapes or configurations of modular structures 100 (i.e., any arrangement or quantity of modules 120 abutting or connected to each other).

[0020] Figure 2 illustrates a perspective view of a module 120 configured in accordance with embodiments of the present technology and suitable for use in the modular structure 100 shown in Figure 1. In some embodiments, the module 120 may be rectilinear, with rectilinear components. For example, in some embodiments, the module 120 may include a Vierendeel truss structure. In some embodiments, four piers 110 may support the module 120. In some embodiments, the piers 110 may be positioned approximately 12 feet from ends of the module 120 along the length L of the module 120, and the piers 110 may be positioned approximately 48 feet apart along the length L of the module 120, such that the overall module 120 may be approximately 72 feet long. The piers 110 may be positioned approximately 18 feet apart along the width W of the module 120, such that the overall module 120 may be approximately 18 feet in width. Other embodiments may include other suitable dimensions, other quantities of piers 110, or other support structures.

[0021] The module 120 may include a plurality of chords 200 (such as four chords 200), which may span the length L of the module 120. For example, in some embodiments, the chords 200 may include a first upper chord 202 oriented along the length L of the module, a first lower chord 204 oriented along the length L of the module, a second upper chord 206 positioned opposite the first upper chord 202 and oriented parallel to the first upper chord 202, and a second lower chord 208 positioned opposite the first lower chord 204 and oriented parallel to the first lower chord 204.

[0022] The module 120 may also include a plurality of rib assemblies 210, each of which extends along the width W of the module 120 between the chords 200. The module 120 may further include suitable roof panels 220 and floor panels 230. The roof panels 220 and the floor panels 230 may be supported by the rib assemblies 210 and/or the chords 200. Figure 2 shows two roof panels 220 and two floor panels 230, although more or fewer roof panels 220 and/or floor panels 230 may be included in the module 120. For example, the entirety of the top of the module 120 may include roof panels 220, and the entirety of the bottom of the module 120 may include floor panels 230. The module 120 may also include one or more walls or windows 240, which may also be supported by the rib assemblies 210 and the chords 200.

[0023] One or more of the chords 200 may be formed as a single integral beam or with a plurality of chord portions 250 joined together with one or more connector plates 260. For example, Figure 3 illustrates a side perspective view of a chord portion 250 configured in accordance with embodiments of the present technology and suitable for implementation in the module 120. The chord portion 250 may be an I-beam, a C-beam, a box beam, or another suitable linear extrusion. Figure 4 illustrates a perspective view of a chord 200 configured in accordance with embodiments of the present technology. The chord 200 may include two or more chord portions 250a, 250b joined together with a connector plate 260.

[0024] Referring to Figures 3 and 4, the chord portion 250 may include fastening interfaces in the form of holes 300 that are arranged in arrays 310 (only some of the holes 300 are labeled in Figures 3 and 4 to avoid obscuring the figures). The connector plate 260 includes one or more arrays 310 of holes 300 corresponding to one of the arrays of holes on a first chord portion 250a and one of the arrays of holes on a second chord portion 250b. Suitable fasteners 320, such as bolts, may be installed in corresponding holes 300 to hold the chord portions 250 together with the connector plate 260.

[0025] In some embodiments, the connector plate 260 carries the load from one chord portion 250a to the other chord portion 250b. Although a connector plate 260 is shown and described for connecting the chord portions 250, in some embodiments, a beam with holes similar to the holes 300 in the connector plate 260 may be used to join the chord portions 250. In some embodiments, an overall length L1 of one or more chord portions 250 may be approximately 405 inches, or other suitable dimensions.

[0026] Figure 5a illustrates a bottom perspective view of a rib assembly 500 configured in accordance with embodiments of the present technology and suitable for implementation as one or more of the rib assemblies 210 described above with regard to Figure 2. In some embodiments, the rib assembly 500 is a rectilinear structure that includes two vertical column beams 510 each forming a side of the rib assembly 500, and two or more horizontal crossbeams 520 connecting the column beams 510 to each other, such as one or more upper horizontal crossbeams 520a and one or more lower horizontal crossbeams 520b. In some embodiments, each horizontal crossbeam 520 may be bolted to each column beam 510. In other embodiments, the horizontal crossbeams 520 may be welded to the column beams 510, or they may be attached in other suitable ways. In some embodiments, the rib assembly 500 may include two upper horizontal crossbeams 520a connected with one or more upper tie plates 525, and two lower horizontal crossbeams 520b connected with one or more lower tie plates 527. The upper and lower tie plates 525, 527 enhance the squareness and rigidity of the rib assembly 500.

[0027] In some embodiments, the rib assembly 500 may include one or more shear keys 530 (such as two shear keys 530, or one on each side of the rib assembly 500). The shear keys 530 may be bolted and/or welded into the rib assembly 500. The shear keys 530 project downwardly from the rib assembly 500 and are configured to engage the piers 110 (see Figures 1 and 2), as explained in additional detail below with regard to Figure 6.

[0028] Figure 5b illustrates a rib assembly 540 configured in accordance with embodiments of the present technology and suitable for implementation as one or more of the rib assemblies 210 described above with regard to Figure 2. The rib assembly 540 may be identical to, or generally similar to, the rib assembly 500 described above with regard to Figure 5a, except that it may not include the shear keys 530. Each of the rib assemblies 210, 500, 540 may be attached to the chords 200 or chord portions 250 via suitable fasteners (such as bolts, screws, or other suitable fasteners) or via welding, or via another suitable attachment.

[0029] With additional reference to Figure 2, in some embodiments, a module 120 may be supported on only four piers 110 (or another suitable number of piers 110). A module 120 may include a number of shear keys 530 corresponding to the number of piers 110 (for example, four shear keys 530 for four piers 110). Accordingly, in some embodiments, a module 120 may include two of the rib assemblies 500 with shear keys 530, with the remainder of the rib assemblies 210 being the rib assemblies 540 (without shear keys 530). The rib assemblies 210, 500, 540 may include more or fewer features or may take other forms, in other embodiments.

[0030] With continued reference to Figure 2, the module 120 may further include finishing elements that make it more habitable, such as plumbing, electrical facilities, interior bulkheads or walls to create room spaces, and other finishing elements. In some embodiments, finishing aspects such as flooring, roofing, windows, doors, wiring, plumbing, furnishings, or other aspects may be added to the module 120 in a factory or other site remote from the final installation site. In other embodiments, the module 120 may be moved to a final installation site as a skeletal frame, and finishing aspects may be added at the final installation site. Beams and columns forming the module 120 may be formed with any suitable material, such as steel, aluminum, or another suitable metal material. [0031] Figure 6 illustrates positioning a module 120 on a pier 110 at a final installation site, in accordance with embodiments of the present technology. The piers 110 may be concrete, and therefore may be subject to their own inaccuracies in location. Embodiments of the present technology compensate for the high tolerances associated with the piers 110. For example, in some embodiments, each pier 110 may include a pocket 600 for receiving a shear key 530. In some embodiments, the pocket 600 may be wider than the shear key 530 to facilitate adjustment of the position of the module 120 at the installation site (e.g., by moving the shear keys 530 within the pockets 600).

[0032] In some embodiments, the system may include a shim 610 positioned between the shear key 530 and the bottom 620 of the pocket 600. The shim 610 facilitates leveling and height adjustment to compensate for inaccuracies and/or high tolerances in the pier 110 and/or the pocket 600. Although shims 610 may not be needed if the piers 110 and pockets 600 are positioned with sufficient accuracy, in some embodiments, shims 610 of different sizes may be used in each pier 110. When the module 120 is positioned and leveled at the final installation site, filler material (such as concrete and/or grout material) may be positioned in any empty space surrounding or adjacent to the shear key 530 within the pocket 600. In some embodiments, all the empty space surrounding the shear key 530 within the pocket 600 may be filled with filler material. Accordingly, in some embodiments, anchor bolts are not needed to mount the module 120 to the piers 110.

[0033] A method of making a modular structure in accordance with embodiments of the present technology may include building the chords 200 (such as the chords 202, 204, 206, 208) and the rib assemblies 210, then connecting the elements together, then moving the assembly to a final installation site, and then penetrating/positioning the shear keys 530 into the piers 110. Optionally, the method may include leveling the module 120 using one or more shims 610 and adjusting the position of the module 120 by moving the module 120 relative to the piers 110 (which may include moving the shear keys 530 side to side within the pockets 600).

[0034] Optionally, in some embodiments, other/additional modules 120 may be positioned adjacent to the module 120 on their own piers 110. The modules 120 may be positioned and aligned relative to one another, facilitated by moving the shear keys 530 in the open space of the pocket 600 and/or by positioning one or more shims 610 under the shear keys 530 in the pockets 600. In some embodiments, methods may include filling the open space in the pockets 600 with grout, concrete, or other suitable filler material to lock modules 120 in position. Other finishing work may be performed at any suitable time, such as attachment or installation of components that render the module 120 habitable, including flooring, roofing, electrical, plumbing, and other components. In some embodiments, part of the assembly process may be performed in a factory, including some of finishing work, such as attaching roof or floor panels, electric, plumbing, etc. The modular nature of the assemblies facilitates repeatable and easily duplicated manufacturing and installation of these components.

[0035] Aspects of the embodiments of the present technology provide several advantages. For example, embodiments of the present technology provide known repeatable structures, which enables subsequent finishing trades like mechanical, plumbing, glazing, trim, electrical, etc. to rapidly add their parts with less custom fabrication. In some embodiments, construction of modules 120 configured in accordance with embodiments of the present technology may not involve any welding at the final installation site (all welding may be performed at the prefabrication site/factory).

[0036] From the foregoing, it will be appreciated that specific embodiments of the presently disclosed technology have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the technology. For example, steps of the methods described herein may be performed in different orders or at different times, or concurrently. Accordingly, modules 120 and modular structures 100 configured in accordance with embodiments of the present technology may include other combinations of features disclosed herein.

[0037] Certain aspects of the technology described in the context of particular embodiments may be combined or eliminated in other embodiments. Further, while advantages associated with certain embodiments of the presently disclosed technology have been described in the context of those embodiments, other embodiments may also exhibit such advantages, and not all embodiments need necessarily exhibit such advantages to fall within the scope of the technology. Accordingly, the disclosure and associated technology can encompass other embodiments not expressly shown or described herein.