Modular building construction system

Patent metadata

Field	Value
Publication number	US-9670669-B2
Application number	US-201314009728-A
Country	US
Kind code	B2
Filing date	Jun 6, 2013
Priority date	Jun 11, 2012
Publication date	Jun 6, 2017
Grant date	Jun 6, 2017

Abstract

Implementations of the present invention relate to systems, methods, and apparatus for constructing a building. More specifically, the present disclosure provides an interlocking wall system that can allow a builder to accurately position, orient, and/or secure various structural wall modules. Additionally, this disclosure provides systems and methods for securing one or more cladding layers to the building's envelope. Furthermore, implementations of the present disclosure can allow for quick and modifiable installation of utility and communication lines within the building.

First claim

We claim:

1. An interlocking modular wall system for constructing at least a portion of a building, the interlocking modular wall system comprising:
a first structural wall module including a first interlock positioned at an offset from one or more of a vertical centerline or a horizontal centerline of the first structural wall module, wherein:
a first cladding portion attached to a first side of the first structural wall module comprises an external surface of a building, wherein the first cladding portion is attached to the first side of the first structural wall via a double-sided interconnector having first and second directly opposing connecting features, the first directly opposing connecting feature connecting to an interior surface of the building and the second directly opposing connecting feature connecting to an interior surface of the first cladding portion, and
a second cladding portion attached to a second side of the first structural wall module comprises an internal surface of the building; and
a second structural wall module including a second interlock positioned at an offset from one or more of a vertical centerline or a horizontal centerline of the second structural wall module, wherein:
the first interlock is connectable with the second interlock;
when connected together, the first and second interlocks orient and position the first structural wall module relative to the second structural wall module in a specified position;
the first and second interlocks are positioned at different offset distances from a top and bottom of the structural wall modules, such that alternate orientations of the first and second structural wall modules are prevented;
a third cladding portion attached to a first side of the second structural wall module comprises another external surface of the building, and
a fourth cladding portion attached to a second side of the second structural wall module comprises another internal surface of the building.

2. The interlocking modular wall system as recited in claim 1 , wherein:
one or more of the first structural wall module and the second structural wall module includes one or more openings sized and configured for a door or a window; and
when connected together, the first and second interlocks orient and position the one or more openings at predetermined positions and orientations.

3. The interlocking modular wall system as recited in claim 1 , further comprising:
a third structural wall module including a third interlock positioned at an offset from one or more of a vertical centerline or a horizontal centerline of the third structural wall module, wherein the first structural wall module includes a fourth interlock positioned at an offset from one or more of the vertical centerline or the horizontal centerline of the first structural wall module, the fourth interlock being connectable with the third interlock and having a different offset from one or more of the vertical centerline or the horizontal centerline than the first interlock.

4. The interlocking modular wall system as recited in claim 1 , wherein the first interlock is a female interlock and the second interlock is a male interlock sized and configured to at least partially enter the female interlock.

5. The interlocking modular wall system as recited in claim 4 , wherein the male interlock and the female interlock have corresponding snap-fit connections.

6. The interlocking modular wall system as recited in claim 1 , wherein the first interlock is a female interlock and the second interlock is a female interlock, and the interlocking wall system includes a dowel sized and configured to fit within the first and second interlocks.

7. The interlocking modular wall system as recited in claim 1 , wherein one or more of the first and second structural wall modules comprise a SIP configured wall module.

8. An interlocking modular wall system for constructing a building, the interlocking modular wall system comprising:
a first structural wall module including one or more first interlocking features and one or more first wall-side connectors, wherein:
a first side of the first structural wall module comprises an exterior surface of the building to which a first cladding is attachable, wherein the first cladding is attached to the first side of the first structural wall via a double-sided interconnector having first and second directly opposing connecting features, the first directly opposing connecting feature connecting to an interior surface of the building and the second directly opposing connecting feature connecting to an interior surface of the first cladding, and
a second side of the first structural wall module comprises an interior surface of the building to which a second cladding is attachable; a second structural wall module including one or more second interlocking features and one or more second wall-side connectors, the one or more second interlocking features being connectable to the one or more first interlocking features, the first and second interlocking features being configured to orient and position the first structural wall module relative to the second structural wall module in a specified position, the first and second interlocking features being positioned at different offset distances from a top and bottom of the structural wall modules, such that alternate orientations of the first and second structural wall modules are prevented, wherein the first structural wall module is separate from the second structural wall module; and
one or more cladding layers including cladding-side connectors secured thereto or integrated therewith, wherein:
the cladding-side connectors are connectable to one or more of the one or more first wall-side connectors and the one or more second wall side connectors.

9. The interlocking modular wall system as recited in claim 8 , wherein a first cladding layer of the one or more cladding layers is connected to an exterior side of one or more of the first structural wall module and the second structural wall module.

10. The interlocking modular wall system as recited in claim 8 , wherein the cladding-side connectors and the one or more first and second wall-side connectors form a space between the cladding layer and the first and second structural wall modules.

11. The interlocking modular wall system as recited in claim 10 , further comprising one or more utility lines or communication lines located in the space between the cladding layer and one or more of the first and second structural wall modules.

12. An interlocking modular wall system for constructing at least a portion of a building, the interlocking modular wall system comprising:
a first structural wall module including a first interlock positioned at an offset from one or more of a vertical centerline or a horizontal centerline of the first structural wall module, wherein:
a first cladding portion attached to a first side of the first structural wall module comprises an external surface of a building, wherein the first cladding portion is attached to the first side of the first structural wall via a double-sided interconnector having first and second directly opposing connecting features, the first directly opposing connecting feature connecting to an interior surface of the building and the second directly opposing connecting feature connecting to an interior surface of the first cladding portion, and
a second cladding portion attached to a second side of the first structural wall module comprises an internal surface of the building;

a second structural wall module including a second interlock positioned at an offset from one or more of a vertical centerline

Assignees

• Dirtt Environmental Solutions

Inventors

• Gosling Geoff
• Smed Mogens

Classifications

• E04B1/14 Primary

  the elements being composed of two or more materials (of reinforced concrete E04B1/04) · CPC title

• E04C2/46

  specially adapted for making walls (E04C2/52, E04C2/54 take precedence; structure of slab-shaped elements E04B1/02; walls of elements of relatively thin form E04B2/72) · CPC title

• E04B2/721 Primary

  connections specially adapted therefor · CPC title

• E04B1/40

  Fixed Constructions · mapped topic

• E04C2/288

  composed of insulating material and concrete, stone or stone-like material · CPC title