US20190032327A1

US20190032327A1 - Permanent building structure with reusable modular building units

Info

Publication number: US20190032327A1
Application number: US16/049,791
Authority: US
Inventors: Brent Musson
Original assignee: Individual
Current assignee: Individual
Priority date: 2017-07-31
Filing date: 2018-07-30
Publication date: 2019-01-31

Abstract

Systems and methods are disclosed. The method includes inserting, from outside of a building structure, a first reusable modular building unit (RMBU) onto a floor of the building structure. The first RMBU including a room. The method also includes after inserting the first RMBU, placing the first RMBU on the floor. The method includes after placing the first RMBU on the floor, removably coupling the first RMBU to the building structure. The building structure includes a permanent interface connecting the building structure to the ground. The building structure also includes the floor. The building structure includes a support to support the floor. The building structure also includes an access point configured to house and support a service.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 62/539,307, filed Jul. 31, 2017 and titled “Reusable, Modular, Building System,” which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates to building structures capable of receiving building units, and more particularly, reusable modular building units.

SUMMARY OF THE DISCLOSURE

In various embodiments, a building structure receiving building units is disclosed.
In accordance with embodiments of the present disclosure, a method includes a number of operations. One such operation is to insert, from outside of a building structure, a first reusable modular building unit (RMBU) onto a floor of the building structure. The first RMBU includes a room. Another such operation is after inserting the first RMBU, to place the first RMBU on the floor. Yet another such operation is after placing the first RMBU on the floor, to removably couple the first RMBU to the building structure. The building structure includes a permanent interface connecting the building structure to the ground. The building structure also includes the floor. The building structure further includes a support to support the floor. The building structure also includes an access point configured to house and support a service.
In embodiments, another operation is to construct the building structure prior to inserting the first RMBU. Constructing the building structure includes inserting the permanent interface into the ground. The permanent interface includes a foundation or a plurality of posts and footings.
In embodiments, the first RMBU includes a utility. Removably coupling the first RMBU to the building structure includes coupling the utility to the service. Removably coupling the first RMBU to the building structure also includes coupling a floor joist of the first RMBU to the floor of the building structure.
In embodiments, inserting the first RMBU onto the floor of the building structure includes lifting and placing the first RMBU onto the floor.
In embodiments, placing the first RMBU onto the floor of the building structure, includes using at least a winch on the floor to pull the first RMBU into a position on the floor.
In embodiments, placing the first RMBU onto the floor of the building structure includes deploying a roller assembly of the first RMBU to roll the first RMBU onto a position on the floor.
In embodiments, the first RMBU includes a removable panel. The removable panel including a door, a camera, a window, a double door, or a mailbox slot.
In embodiments, the removable panel is configured to house and support services.
In embodiments, another operation is to insert from outside of the building structure, a second RMBU onto a second floor of the building structure. The second RMBU including a room. The second RMBU includes a removable panel. The removable panel of the second RMBU is different from the removable panel of the first RMBU and includes a door, a camera, a window, a double door, or a mailbox slot.
In embodiments, another such operation is to install one or more caps on an exterior of the building structure. Installation of one more caps gives the first RMBU and the second RMBU an integrated appearance from an exterior of the building structure.
In embodiments, another operation is to insert from outside of the building structure, a second RMBU onto the floor of the building structure. The second RMBU includes a room. Another such operation is to place the second RMBU adjacent the first RMBU on the floor. Yet another such operation is after placing the second RMBU, to secure the second RMBU to the building structure, wherein the combination of the first and second RMBUs forms a functional living or office space.
In accordance with additional aspects of the present disclosure, a system is disclosed. The system includes a building structure. The building structure includes a permanent interface connecting the building structure to the ground. The building structure also includes a floor. The building structure includes a support to support the floor. The building structure also includes an access point configured to house and support a service. The system also includes a first reusable modular building unit (RMBU) configured to be inserted, from outside of the building structure, onto the floor of the building structure. The first RMBU is placed onto the floor after it is inserted into the building structure. The first RMBU is removably coupled to the building structure The first RMBU includes a room.
In embodiments, the building structure further includes a crane configured to lift and place the first RMBU onto the floor.
In embodiments, the first RMBU includes an adjustable rolling mechanism to allow the first RMBU to roll into a position on a surface.
In embodiments, the adjustable rolling mechanism can be adjusted to engage or disengage the rolling mechanism with the surface.
In embodiments, the permanent interface is a foundation.
In accordance with additional aspects of the present disclosure, a method is disclosed including a number of operations. One such operation is to decouple a first reusable modular building unit (RMBU) from a first building structure. The first RMBU includes a room. Another such operation is after decoupling the first RMBU, to move the first RMBU from the floor to an outside edge of the floor to remove the first RMBU from building structure. Yet another such operation is after moving the first RMBU to the outside edge of the floor, to remove the first RMBU from the building structure. The first building structure includes a permanent interface connecting the building structure to the ground. The first building structure also includes a floor. The first building structure includes a support to support the floor. The first building structure also includes an access point configured to house and support a service.
In embodiments, another such operation is after removing the first RMBU, to transport the first RMBU to a second permanent building structure. The second building structure includes a floor. Another operation is after transporting the first RMBU to the second building structure, to insert, from outside of the second building structure, a first RMBU onto the floor of the second building structure. Yet another such operation is after inserting the first RMBU, to place the first RMBU on the floor of the second building structure. Another operation is after placing the first RMBU on the floor of the second building structure, to removably couple the first RMBU to the second building structure.
In embodiments, the operation is to insert, from outside of the first building structure, a second RMBU onto the floor of the first building structure. The second RMBU including a room. Another such operation is after inserting the second RMBU, to place the second RMBU on the floor. Yet another such operation is after placing the second RMBU on the floor, to removably couple the second RMBU to the first building structure
In embodiments, the first RMBU has at least one of a different size, shape, and configuration from the second RMBU.
Other features and aspects of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the features in accordance with embodiments of the invention. The summary is not intended to limit the scope of the invention, which is defined solely by the claims attached hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The various embodiments are described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict typical or example embodiments. These drawings are provided to facilitate the reader's understanding of the invention and shall not be considered limiting of the breadth, scope, or applicability of the invention. It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.

FIG. 1A illustrates an example building structure, including RMBUs, that may be assembled in accordance with implementations of the disclosure.

FIG. 1B illustrates an example of a permanent slab foundation that provides an interface between a building and the earth, in accordance with implementations of the disclosure.

FIG. 1C illustrates an example of a permanent interface to the earth using posts and footings, in accordance with implementations of the disclosure.

FIG. 2 is an operational flow diagram illustrating an example method for manufacturing a building structure, in accordance with implementations of the disclosure.

FIG. 3 illustrates front, rear, and side views of an exterior of an example RMBU, in accordance with implementations of the disclosure.

FIG. 4 illustrates an example interior layout of an RMBU, in accordance with implementations of the disclosure.

FIG. 5 illustrates several examples of a removable panel that may be implemented in a wall of an RMBU configured to face an interior of a building structure, in accordance with implementations.

FIG. 6 is an operational flow diagram illustrating an example method for manufacturing a RMBU, in accordance with implementations of the disclosure.

FIG. 7 illustrates a skate-trailer assembly, including a skate and trailer, onto which a base of an RMBU may be set during assembly, in accordance with implementations of the disclosure.

FIG. 8 illustrates an example method to install an RMBU into a building structure, in accordance with implementations of the disclosure.

FIG. 9 illustrates one example roller assembly that may be incorporated into an RMBU for this purpose, in accordance with implementations of the disclosure.

FIG. 10 illustrates one example implementation of securing an RMBU to a floor of a concrete building structure using a wedge bolt, in accordance with implementations of the disclosure.

FIG. 11 illustrates one example implementation of securing an RMBU to a floor of a steel building structure using a bolt-washer-nut assembly, in accordance with implementations of the disclosure.

FIG. 12 illustrates an example connection of plumbing services between a building structure and an RMBU, in accordance with implementations of the disclosure

FIG. 13 illustrates an exterior view of building structure after RMBUs have been installed, in accordance with implementations of the disclosure

FIG. 14 illustrates a cross sectional side view of a building structure after an RMBU has been installed, in accordance with implementations of the disclosure.

FIG. 15 is an operational flow diagram illustrating an example method for installing an RMBU into a building structure, in accordance with implementations of the disclosure.

FIG. 16 illustrates an example method to remove a RMBU from a building structure, in accordance with implementations of the disclosure.

FIG. 17 is an operational flow diagram illustrating an example method for removing an RMBU from a building structure, in accordance with implementations of the disclosure.

The figures are not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be understood that the embodiments and invention can be practiced with modification and alteration, and that the invention be limited only by the claims and the equivalents thereof.

DETAILED DESCRIPTION

As used herein to refer to the installation of an RMBU into a building structure, the terms “removably coupling” or “removably coupled” are intended to refer to coupling the RMBU to the building structure in such a manner that the RMBU may be uncoupled from the building structure at a future date without structurally impacting the building structure or the RMBU. For example, RMBU utility services, including plumbing, electrical, natural gas, cable TV/internet, etc. may be connected to services of the building structure during the installation process in such a manner that the RMBU may be disconnected at a future date to allow removal of the RMBU. As another example, an RMBU may be secured to the floor of the building in such a manner that the securing mechanism may be removed without structurally impacting the building structure or RMBU.
One of the most salient problems is “the housing crisis.” Related to this are the rising cost of home ownership, a shortage in the number of available housing units, and a growing homeless count. The housing crisis also includes the tendency of new housing to be mostly built in the market-rate and luxury housing sectors, while few developments focus on affordable, low-income, and workforce housing sectors. The housing crisis is so severe in major cities, such as Los Angeles and San Francisco, that illegal units have become common and prohibitions are generally treated as unenforceable by code enforcement officials.
One common barrier to solving housing crisis issues is that the cost of producing housing is greater than the market value of finished inventory in the categories with the most acute shortages: affordable, low-income, and workforce; so, developers concentrate on market-rate and luxury housing, which is a much more profitable, but a much smaller market. As an example, buildings today are fairly rigid permanent structures. Improvements within these buildings must be torn down and reconstructed if fewer partitions, or a different design, is desired. The improvements cannot be reconfigured or transported to different locations. In other situations, temporary structures, such as trailers, are placed onto a site and remain as stand-alone structures. There is no system that provides a flexible building that allows improvements to be easily inserted and removed. While various incentives, ranging from tax breaks to direct subsidization, are utilized, the scope of the problem is far too great to be mitigated with publicly-funded incentives.
The cost of producing housing is greater than the market value for at least several reasons. 1) The cost of land is high in areas with high demand. 2) The entitlements process is slow and expensive, and the larger the project, the more prohibitive the process. 3) Unlike other manufacturing environments, construction has not exploited the greater efficiencies of manufacturing best practices. The third of these three reasons presents the greatest opportunity for correction and subsequent exploitation.
Implementations of the disclosure are directed to addressing these and other problems that arise when manufacturing and providing housing. To this end, systems and methods are described for implementing a building structure with removable and reusable modular building units (RMBUs). In particular, techniques described herein may be applied with building structures having permanent foundations.
As further described herein, the RMBUs may be configured to be removable from the building structure and replaced with another RMBU without compromising the integrity of the building structure or the RMBU upon installation or removal. This may provide several advantages. First, the removability of the RMBUs allows a RMBU to be purchased at a lower cost than the cost of constructing a new building structure with permanent units in a more traditional manner. Second, the efficiencies of manufacturing may be applied to building construction by using factory-built, modular construction. Instead of building on-site, components of the building (i.e., the RMBUs) may be manufactured in a controlled factory environment, transported, and assembled on-site. Further, the use of RMBUs as described herein make it possible, over time, to adapt, customize, and/or update the housing provided by a building structure with a permanent interface to the earth (e.g., a permanent foundation). By virtue of being able to update the housing provided by a permanent building structure by replacing existing reusable modular building structures, the longevity of building structures having permanent interfaces to the earth may be extended over time. These and other advantages that may be realized by implementing building structures with RMBUs are further described below.
FIG. 1A illustrates an example building structure 100, include RMBUs, that may be assembled in accordance with implementations of the disclosure. Although FIG. 1A illustrates a particular example of a building structure that may be used in implementations, it should be appreciated that other building structures may be used, such as a single loaded building structure providing access points to a set of RMBUs on one side of the building structure.
As illustrated, the building structure 100 may include a permanent foundation 150, access point 10, a frame 12, and one or more floors supported by one or more supports 14. In alternative embodiments, the building structure does not include an access point 10. The building structure may be constructed using concrete, a steel frame, wood, and/or using other construction materials.
In various implementations, the building structure 100 may be a permanent building structure including a permanent foundation 150. Foundation 150 may be a shallow foundation such as a spread footing or a slab-on-grade foundation. Alternatively, foundation 150 may be a deep foundation such as a foundation based on piles driven or drilled deep into the ground in the earth.
FIG. 1B illustrates one example of a permanent slab foundation 150-1 that provides an interface between a building and the earth, in accordance with the disclosure. In particular, FIG. 1B illustrates a permanent building 100-1 seated on a slab foundation 150-1 including a slab 151, foundation walls 152, and footings 153. This example foundation design serves as an interface between the building 100-1 and the Earth 170, and provides a strong, stable, level platform on which the building sits.
In other implementations, permanent building structure 100 may not have a permanent foundation but some other permanent interface between the building structure and the earth. For example, building structure 100 may be engineered with footings and posts that provide a permanent interface to the earth. FIG. 1C illustrates one such example of a permanent interface 170 to the earth 195 using posts and footings, in accordance with implementations of the disclosure. As illustrated, permanent interface 170 includes posts 180 and 190. Post 180 is anchored to a pier 181 and footing 182 (e.g., using a concrete anchor). Post 190 is anchored to a footing 192 with no pier (e.g., using a concrete anchor). The pier 181 and footing 182, or simply footing 192, may provide a strong, stable, and level platform on which each post sits. The posts 180 and 190, along with the piers and footings, may provide a permanent interface between the building (e.g., a building implemented as a raised podium supported by the posts) and earth 195. Although two posts are illustrated in this example, it should be appreciated that any number of posts having piers and footings, or simply footings, may be utilized.
Referring again to FIG. 1A, access point 10 may provide access between RMBUs 18 and support services. Access point 10 may also provide one or more structures to travel between floors, such as elevators, escalators, stairs, etc. Access point 10 may also provide one or more structures to travel on the same floor, such as hallways. Access point 10 may also be configured to support the building structure and floors.
In some implementations, structures to travel between floors may be provided external to the building structure. In such implementations, access point 10 may be excluded from the building structure, or it may be implemented in combination with the structures external to the building. Access point 10 may be substantially rectangular, circular, and/or other shapes.
In particular implementations, access point 10 may be a core, of a core and shell building structure. The core may include a central area of a building housing the elevator and stairwells, electrical equipment, restrooms, and other facilities, whereas the shell may include the remaining building structure. In such implementations, the core and shell together comprise the essential minimum structure that composes the building. For example, a core and shell may include exterior weatherproofing, but not partition walls between floors to separate different occupants or spaces. In embodiments, access point 10 does not include any tenant improvements or a weatherproofed exterior.
The support services provided to the building structure 100 may include, water, natural gas, electricity, sewage, and/or other utilities. These support services may provide utilities for individual RMBUs 18. In some embodiments, the utilities may be connected to the services, such that it is building code compliant. In embodiments, utilities and services may run through supports 14 to connect to RMBUs 18. In some embodiments, utilities may run through a utility closet, walls between RMBUs, hallways, etc.
Frame 12 may include one or more floors. The one or more floors may be supported by supports 14. As illustrated, supports 14 may be on the corners of the floors, but it should be appreciated that supports 14 may be placed in other locations. In embodiments, supports 14 may be placed in between RMBUs 18. In some embodiments, supports 14 may be substantially circular, rectangular, and/or other shapes. Supports 14 may be solid, hollow, and/or partially hollow. Supports 14 may be made of metal, wood, and/or other materials. In some embodiments, frame 12 may be a shell of a core and shell building structure.
The one or more floors may be configured to receive one or more RMBUs 18, such that the space conforms to the size required for installing a RMBU 18. In some implementations, a RMBU 18 does not provide any type of structural support to a floor above it.
In other implementations, an RMBU 18 may provide structural support to a floor above it having one or more installed RMBUs. In such implementations, RMBUs may be installed in an ascending manner, starting with the lower floor and finishing at the upper floor. During removal of RMBUs, the RMBUs may be removed in a descending manner, starting with the upper floor and finishing at the lower floor.
As further described below, the RMBUs may individually include a room, a utility which interfaces with the services, and one or more walls. A first wall may face towards the inside of the building structure. The first wall may include interchangeable panels. A second wall may face toward the outside of the building structure.
In some implementations, building structure 100 may also include one or more areas that are not designed to receive one or more RMBUs, but are otherwise designed as part of the floorspace of the building when the building is constructed (e.g., prior to inserting any RMBUs). Such areas may be referred to as permanent building units, and they may provide structural support for the building structure 100. For example, the one or more areas may include a walled area such as a permanent room, a courtyard area, etc.
FIG. 2 is an operational flow diagram illustrating an example method for manufacturing a building structure (e.g., building structure 100), in accordance with implementations of the disclosure. At operation 202, a building site may be graded and trenched. Grading may include measuring an angle of the existing ground, and removing or adding material to the ground to get to a desired second angle. For example, after grading, the building site may have an angle of between 0 and 10 degrees from the horizon. Material such as dirt, may be added or removed in the building site and compacted, such that the building site has a desirable angle (e.g., about 0 degrees.)
At operation 204, services may be run into the building site. These services may then be run to individual RMBUs after they are installed into the building structure (e.g., after performing method 200).
At decision 206, it is determined whether a slab foundation type or podium foundation type will be used. While slab and podium foundations are illustrated in this example, it should be recognized that other foundation types or permanent interfaces to the earth may be used. If a slab foundation type is selected, at operation 208, the foundation may be formed by pouring a slab directly onto the graded and trenched ground. In embodiments, a slab may be poured into a matrix of rebar. If a podium foundation type is selected, at operation 210, a podium may be constructed by pouring concrete over an array of shorter walls or supports.
At operation 212, a first portion of an access point may be constructed. The first portion of the access point may be the first floor of the access point. It may not have a top to cover the access point as the access point may be hollow. In some embodiments, operation 212 may be skipped (i.e., the access point may not be constructed at all).
At decision 214, it is determined whether the floors are constructed by making an elevated slab or a joist. While two techniques for floor construction are illustrated in the example of FIG. 2, it should be recognized that other floor construction techniques may be used. If an elevated slab floor type is selected, at operation 216, the first floor may be constructed by pouring concrete to make an elevated slab. If a joist floor type is selected, at operation 218, the first floor may be constructed using a joist system in combination with lightweight concrete, a wood subfloor, a framed steel structure, and/or other materials. Joists may be used to support a floor and other loads over an open area.
At operation 220, operations 214-218 may be repeated until a desired number of floors are constructed. The floors may be constructed in ascending order, starting with the first floor, and terminating with the top floor. In some implementations, only one floor may be desired, and operation 220 may be omitted.
FIG. 3 illustrates front, rear, and side views of an exterior of an example RMBU 300, in accordance with implementations of the disclosure. As illustrated from the exterior views, the RMBU may include a living space 301, a subfloor 302, and a utility space 303. In this example, a side of the building structure facing the exterior of the building structure (front view) may have windows 304, and a side of the building structure facing the interior of the building structure (interior view) may have an entry door 305. However, it should be appreciated that other configurations of windows 304 and entry door 305 may be utilized. For example, an entry door 305 may be positioned along a side of the RMBU 300, a window may be positioned along a side or rear of the RMBU 300, a window may not be positioned along a front of the RMBU 300 facing the exterior of the building, etc.
Utility space 303 may include a space for utilities of an individual RMBU to run through to connect to services from the building structure (e.g., building structure 100). Subfloor 302 may extend across the length of RMBU 300.
In implementations, a RMBU may be implemented as a standalone unit (e.g., a complete apartment unit), or as a subunit (e.g., one or more rooms of a living or office unit). In implementations where a RMBU is implemented as a subunit, multiple RMBUs may be combined during installation into a building structure (e.g., building structure 100) to form a functional space. For example, an apartment unit may be made of two RMBUs, while an office space may be made of three RMBUs.
In some implementations, an RMBU may be implemented as a living unit, such as a one bedroom apartment. The one bedroom apartment may have a living room, a dining room, a kitchen, a dining room, a bathroom, and a bedroom. FIG. 4 illustrates one such example interior layout of an RMBU, in accordance with implementations. The bedroom and bathroom may face the outside of the building. The living room may face the inside of the building structure. In some embodiments, the living room may open up into the inside of the building which may be a communal hallway. The living unit may be a two bedroom, three bedroom, and/or another living unit. For example, an apartment unit may be made of two RMBUs, while an office space may be made of three RMBUs.
In some implementations, an RMBU may be implemented as an office space, hotel, restaurant, retail space, art gallery, and/or other functional space. In embodiments, the RMBU may vary in sizes that correspond, in part, to the available building structure. For example, four one bedroom RMBUs may span across one side of the building structure, which may be two retail spaces, or three retail spaces. In other words, while the heights of the various RMBUs may be fixed, the widths and lengths may be adapted to accommodate the various functional spaces of the building structure. In some embodiments, the heights of the various RMBUs may be adjusted based on the building structure, custom requests, and/or other factors. In embodiments, one or more RMBUs may be combined to form a functional space.
Referring again to FIG. 3, as illustrated by the rear view, the side/wall of the RMBU 300 facing the interior of the building structure may include a removable panel 306, including entry door 305. The removable panel 306 may be replaced by another removable panel to customize the entrance (e.g., change appearance or type of entry door, add mail/package slots, etc.) to the RMBU. FIG. 5 illustrates several examples of a removable panel that may be used instead of removable panel 306, in accordance with implementations.
As illustrated in FIG. 5, the removable panel may include a simple single door 305, a double door 304, a door 305 with a mail slot 306 adjacent to the door 305, a door 305 with a package delivery slot 307 adjacent to the door 305, a door 305 with a security camera and/or pad 308, a windowed door 309, a glass door 310, a glass assembly 311 with a door, and/or other door assemblies. While eight examples of removable panels are illustrated, it should be appreciated that other types of door assemblies may be used based on different customizations. For example, there may be pet doors, Dutch doors, and/or other doors. By virtue of using a removable panel design, an RMBU may be adapted over time to suit a present occupant or a new occupant that moves into the RMBU. For example, an RMBU may be repurposed from living space to office space by, among other things, swapping a panel 306 including a 305 with a panel including a glass assembly 311.
In implementation where the panel does not include a glass assembly 311, bolts that are accessible from the door jam may extend through the panel, to the wall of the RMBU. These bolts may be tightened or loosened from the door jam to remove or insert the panel. In the case of a glass assembly 311, connections may be around the edges of the panel, to the RMBU, to allow for insertion or removable of the panel.
FIG. 6 is an operational flow diagram illustrating an example method 600 for manufacturing a RMBU, in accordance with implementations of the disclosure. At operation 602, a base of a RMBU is set onto a skate-trailer assembly. The base may include the starting framework for forming the RMBU. The skate portion of the assembly may be configured to interface with a building structure, as illustrated in FIG. 8, which will be described in greater detail below. The trailer portion of the assembly may interface with various vehicles. For example, FIG. 7 illustrates a skate-trailer assembly 710, including a skate 711 and trailer 712, onto which a base of an RMBU may be set, in accordance with implementations.
As illustrated in the example of FIG. 7, a forklift 720 may move the skate-trailer assembly 710 holding the RMBU within a factory, while a truck 730 may move the skate-trailer assembly 710 to a building work site. The skate-trailer assembly may include strap notches 740 to facilitate lifting of the skate with a crane as illustrated by FIG. 8. Strap notches 740 may allow straps to be inserted or removed while the skate is on the trailer with the skate fully seated flush on the trailer. In other implementations, the skate may include loops to attach chains, straps, ropes, etc., or some other mechanism may be used to facilitate lifting of the skate with a crane. By virtue of setting a base of an RMBU onto a skate-trailer assembly, time may be saved during the RMBU assembly and transportation process. Additionally, injuries may be avoided (e.g., due to loading the RMBU after assembly).
At decision 604, it is determined whether to use a steel frame or wood frame for framing the RMBU. While steel frame and wood frame options are illustrated in this example, it should be recognized that other types of frames such as cross-laminated timber, concrete blocks, etc., may be used. Additionally, in some implementations, a combination of the aforementioned framing materials may be used. If it is determined to use a steel frame, at operation 606, the RMBU is framed using a steel such as light gauge steel. If it is determined to use a wood frame, at operation 608, the RMBU is framed using a wood frame.
At operation 610, exterior sheathing is installed. Exterior sheathing may include the material surrounding the RMBU frame, which may provide a surface to apply other materials onto. Exterior sheathing may be structural or non-structural. Structural sheathing may provide support to the RMBU and may include plywood, oriented strand board (OSB), wafer board, exterior gypsum board, cement board, and/or other materials. Non-structural sheathing may not provide strength to a wall, but may increase the insulation provided by the walls and may include plastic, foam, cellulose fiber, extruded polystyrene, polyisocyanurate, and/or other materials.
At decision 612, it is determined whether to use copper plumbing or crosslinked polyethylene (PEX) plumbing. While copper and PEX plumbing options are illustrated in this example, it should be recognized that other types of plumbing may be used. Additionally, in some implementations, a combination of copper and PEX plumbing may be used. If it is determined to use copper plumbing, at operation 614, copper plumbing is installed. If it is determined to use PEX plumbing, at operation 616, PEX plumbing is installed.
At operation 618 rough installations are finished. Rough installations may include electrical, heating, ventilation, and air conditioning (HVAC), and glazing. The various installations may utilize space underneath a RMBU, within the walls, overhead, and/or in other spaces. Any other necessary services may also be installed.
At operation 620, insulation is installed. At operation 622, the RMBU is finished. Finishing the RMBU may include installing a wall covering to cover the interior structure of the walls, such as drywall, paneling, tile, and/or other materials. The wall covering may be primed and painted. Finishing may also include installing a floor covering, such as wood, tile, carpet, concrete, and/or other materials. Hardware may also be installed, such as cabinets, molding, and/or other components. In embodiments, appliances and fixtures may be installed, such as ovens, refrigerators, fans, and/or other appliances and fixtures.
At operation 624, the finished RMBU is transported to the building structure site (e.g., building structure 100 to be installed, or to a factory or another destination for storage) via a vehicle (e.g., truck 730). As noted above, method 600 may all be accomplished on the skate trailer (e.g., starting with placement of the base of the RMBU on the skate trailer), and the same skate trailer may be transported to the building site for installation of the RMBU. This may save time by using the same platform to build the RMBU, as well as reduce injuries.
FIG. 8 illustrates an example method to install an RMBU 810 into a building structure 820, in accordance with implementations of the disclosure. In this example, an RMBU 810 is inserted into the building structure 820 using a crane 821, a winch cable 822, and skate 823. The crane 821 may be integrated into the building structure 820 or be an external crane system. For example, in building structures having an access point (e.g., access point 10 of structure 100), the crane may be installed into the access point of the building structure to help install RMBUs into the building structure and/or remove RMBUs from the building structure. The crane may be integrated or embedded within the access point, and it may include a removable crane head that is attached for installation and removal, and may be removed when not in use.
During installation, crane 821 may pick up the skate 823, including RMBU 810 disposed on skate 823, from a skate-trailer assembly (e.g., assembly 710). The skate 823 may be configured to interface with a floor 825 of the building structure 820 at interface 824. The configuration of the interface 824 may be structural, such that the shape of the skate 823 and the shape of the floor 825 are complementary, or the configuration may be magnetic such that an edge of the skate 823 facing the floor 825 and the edge of the floor 825 facing the skate 823 both include a magnet attracted to the other, thereby creating a secure connection. It should be appreciated that other interfaces may be used to secure a connection between the skate and the building structure.
After the skate interfaces with the floor, a winch (not shown) may interface with a side of the RMBU facing the building structure (e.g., by means of a winch cable 822) to pull or otherwise guide the RMBU 800 into position on floor 825. As RMBU 800 is guided (e.g., pulled) into place on floor 825, the RMBU may itself deploy an assembly to facilitate its motion.
FIG. 9 illustrates one example roller assembly 900 that may be incorporated into an RMBU for this purpose, in accordance with implementations of the disclosure. As illustrated, the roller assembly 900 may include a roller 910 on a hinge 920 that can be deployed via an adjustment screw 930. As the adjustment screw 930 is fully tightened, it may cause the hinged portion of the roller assembly 900 to pivot downward, thereby deploying the roller 910 (e.g., from the bottom of the RMBU) and allowing the RMBU to move. As the adjustment screw is loosened, it may cause the hinged portion of the roller assembly 900 to pivot upward (e.g., into the bottom of the RMBU), thereby retracting the roller 910, and substantially preventing further movement of the RMBU. By virtue of using a roller assembly, the RMBU may be moved into place without additional equipment, such as, for example, a forklift. It should be appreciated that although roller assembly 900 illustrates a single roller, roller assembly 900 may include any number of rollers (e.g., 2, 4, 5, 6, 8, 10, etc.) that may be deployed to guide the RMBU into place. In some implementations, multiple roller assemblies 900 may be utilized.
Referring back to FIG. 8, when the assembly of the RMBU (e.g. roller assembly 900) is deployed to facilitate motion, the winch may use winch cable 822 to pull the RMBU 810 onto the floor 825 of the building structure 820. After the RMBU 810 is pulled into a final position, the system configured to allow the RMBU to move (e.g., roller assembly 900) may be retracted to prevent further unwanted movement. In the final position, the RMBU may be secured to the building structure.
While the foregoing examples illustrate some ways in which an RMBU may be pulled or moved into place on a floor of a building structure, it should be appreciated that a variety of different mechanism may be used to pull or otherwise move into place the RMBU on the floor. For example, rollers, bearings, pulleys, slides, or any combination of these or other mechanical devices or parts may be utilized.
FIG. 10 illustrates one example implementation of securing an RMBU to a floor of a concrete building structure using a wedge bolt 1010, in accordance with implementations of the disclosure. Wedge bolt 1010 may be a bolt configured to attach into a base material like concrete of floor 1020. To install a wedge bolt, a hole may be drilled through a floor joist 1030 (e.g., metal joist) and into the concrete, the wedge bolt may be inserted into the hole, and the nut tightened. As illustrated, one or more floor joists 1030 may separate the subfloor 1040 of the RMBU from the corresponding floor on which the RMBU is installed. Although a single wedge bolt 1010 is illustrated in this example as being secured through a floor joist 1030, it should be appreciated that any number of wedge bolts 1010 may be used to secure the RMBU to the floor (e.g., each wedge bolt being secured through a corresponding floor joist) of the concrete building structure.
FIG. 11 illustrates one example implementation of securing an RMBU to a floor of a steel building structure using a bolt-washer-nut assembly 1110, in accordance with implementations of the disclosure. In this implementation, the use of the bolt-washer-nut assembly 1110 may be appropriate because of the open spaces provided by a steel-framed building structure. In this example building structure, the floors may include a set of floor joists covered by plywood (CDX), oriented strand board (OSB), dimensional lumber, or a thin layer of lightweight concrete usually poured over corrugated galvanized steel.
While the foregoing examples illustrate some ways in which an RMBU may be secured to a floor of a building after it has been put in place, it should be appreciated that a variety of different mechanisms may be used to secure the RMBU to the floor of the building structure. For example, an RMBU may be secured using bolts, cleats, clamps, brackets, other mechanical devices, or any combination thereof.
FIG. 12 illustrates an example connection of plumbing services between a building structure and an RMBU, in accordance with implementations of the disclosure. As illustrated, plumbing services may be run in the utility space (e.g., utility space 303 under the living space 301) of an RMBU, and then down through a support (e.g., support 14 or 1304). In implementations, other services (e.g., electrical, gas, etc.) may be ran in the utility space, in the subfloor, in walls of the RMBU, utility closets, the walls of supports, the walls of the access point, and/or in other spaces and/or structures. In implementations, utilities may run horizontally through walls before connecting to the building structure. In implementations utilities may run vertically from floor to floor of the building structure through utility closets. For example, the utility closets may be in units on multiple floors, all positioned one above the other, such that utilities may pass from one utility closet to the next, vertically, from the top floor to the ground.
FIG. 13 illustrates an exterior view of building structure after RMBUs 1300 have been installed, in accordance with implementations of the disclosure. The exterior view illustrates RMBUs 1300 installed in a building structure with multiple floors 1302. Supports 1304 may be placed between RMBUs, as described above. In this example, the rectangles delineated with diagonal lines are areas that are not covered by caps. The areas that are shown (where RMBUs meet each other, meet a support 1304, or the distance between the living space 301 and the floor 1302) may be covered by caps. The areas delineated with diagonal lines may be gaps or holes in the caps.
FIG. 14 illustrates a cross sectional side view of a building structure after an RMBU 1400 has been installed, in accordance with implementations of the disclosure. As illustrated, caps 1404 may be installed to provide weatherproofing to the building structure and/or to provide a uniform/aesthetic experience even though RMBUs may come from different sources. Caps 1404 may be made of different materials, so the installation may be substantially different. For instance, a cap may have a stucco finish, wood/vinyl/aluminum/cement siding, aluminum composite paneling, etc. Caps 1404 may help prevent deterioration from elements entering the space between the RMBU and the floors 1402 of the building structure, entering the RMBU, and/or entering other spaces. In some embodiments, the caps may help prevent the RMBU from moving.
FIG. 15 is an operational flow diagram illustrating an example method 1500 for installing an RMBU into a building structure, in accordance with implementations of the disclosure. Prior to installation of the RMBU into the building structure, the building structure may be need to be constructed. As such, at operation 1512, the building structure may need to be constructed or otherwise finished to prepare it for installation of an RMBU. For example, operation 1512 may be performed as described above with reference to method 200 of FIG. 2. Additionally, prior to installation of the RMBU, the RMBU itself will need to be obtained. In implementations, a decision may be made as to whether a newly manufactured RMBU is obtained or whether an RMBU is obtained from a donor building structure. If a newly manufactured RMBU is to be used for the installation, at operation 1506 the RMBU may be manufactured (e.g., if it has not been manufactured already). For example, operation 1506 may be performed as described above with reference to method 600 of FIG. 6. If an RMBU from a donor building structure is to be used for the installation, at operation 1510, an RMBU may be removed from a donor building structure (e.g., if it has not been removed already). For example, operation 1510 may be performed as further described below with reference to method 1700 of FIG. 17.
At operation 1514, the RMBU, whether it is coming from the factory or a donor building structure, may be transported to the target building structure via a vehicle.
At decision 1516, it is determined whether to use a crane integrated into the building structure or an external crane to lift the RMBU into place (e.g., a floor where it is to be installed). The RMBU may be lifted into place by lifting a skate carrying the RMBU from a skate-trailer assembly. If a crane integrated into the building structure is to be used, at operation 1518, a crane head may be installed to the integrated crane prior to lifting the RMBU. The crane head may then pick up the skate carrying RMBU. Otherwise, if an external crane is to be used, at operation 1520, an external crane may be positioned to pick up the skate and RMBU.
At operation 1522, the crane may move the RMBU to an insertion position at the outer edge of the building structure. For example, the crane may be used to position a skate carrying the RMBU such that it interfaces with the building structure, as described above with reference to FIG. 8.
At operation 1524, after being moved to an insertion position, the RMBU may be inserted into the building structure into a final position. In implementations, the RMBU may be pulled into position via various mechanisms, such as a winch, manually, using a motor, using a forklift, and/or using other mechanisms. In particular implementations, the RMBU may be pulled into position using a winch and roller assembly as described above with reference to FIGS. 8-9.
At operation 1526, once the RMBU reaches a final position, it may be secured to the building structure. A variety of different securing mechanisms may be used, which may depend on the construction of the building. Examples of securing mechanisms that may be used are further described above with reference to FIGS. 10-11.
At operation 1528, a removeable panel may be installed to the RMBU. Examples of removeable panels that may be installed are described above with reference to FIGS. 3 and 5. Alternatively, in other implementations, the RMBU may come pre-installed with a removeable panel.
At operation 1530, operations 1522-1528 may be repeated until a desired number of RMBUs are installed into the building structure.
At operation 1532, caps may be installed to provide an integrated and uniform appearance to the building structure. For example, caps may be installed as discussed above with reference to FIG. 14.
At operation 1534, services from the building structure may be connected to the utilities of the RMBUs. For example, plumbing services may be installed as discussed above with reference to FIG. 12.
At operation 1536, landscaping may be completed. At operation 1538, the remaining building areas that are non-modular may be finished as well.
At operation 1540, occupants may be able to occupy the finished RMBUs.
FIG. 16 illustrates an example method to remove a RMBU from a building structure, in accordance with implementations of the disclosure. FIG. 16 may be substantially the reverse of the process described in FIG. 8. For example, an RMBU 1630 may be unsecured from the building structure (e.g., by removing one or more wedge bolts holding it in place and disconnecting the RMBU from utilities). Thereafter, a roller assembly of the RMBU (or other assembly of the RMBU that allows it to be move) may be deployed.
A crane 1605, whether integrated to the building structure or an external crane, may be coupled to a skate 1615. The skate 1615 may be configured to interface with the building structure at an interface point 1616. The skate 1615 may include a winch 1610 to couple to the side of the RMBU 1630 to extract the RMBU from the building structure. The winch 1610 may pull the RMBU 1630 via winch cable 1611 onto the skate 1615. Once, the RMBU is positioned on the skate, the roller assembly (or other assembly allowing movement) may be retracted so that the RMBU does not move once it is on the skate. Thereafter, the skate with the mounted RMBU may be lowered onto a trailer to be moved to another building structure or elsewhere (e.g., a storage location).
FIG. 17 is an operational flow diagram illustrating an example method 1700 for removing an RMBU from a building structure, in accordance with implementations of the disclosure. At decision 1702, it is determined whether to use a crane integrated into the building structure or a crane external to the building structure to remove an RMBU. If a crane integrated into the building structure is to be used, at operation 1704, a crane head is installed. If a crane external to the building structure is used, at operation 1706, the crane is positioned.
At operation 1708, caps of the building structure may be removed, at least where a corresponding RMBU is to be removed. At operation 1710, a removable panel may be removed from the RMBU. Alternatively, the removable panel may remain coupled to the RMBU. For example, it may remain coupled to the RMBU, and the RMBU may be inserted into another building structure.
At operation 1712, the utilities of the RMBU may be disconnected from the services of the building structure. At operation 1714, the RMBU may be unsecured from the building structure. In implementations, this may include removing a wedge bolt for a concrete frame or a bolt assembly for a steel framed building structure.
At operation 1716, the RMBU may be removed from the building structure. For example, the crane may be coupled to a skate that interfaces with the building structure, as described above in more detail above. The RMBU may be removed from the building structure via a mechanism, as described above. As illustrated in FIG. 16, the mechanism may be a winch attached to the skate. The skate and RMBU may be removed via the crane to a trailer coupled to a vehicle.
At operation 1718, the skate-trailer assembly with the RMBU may be transported away from the building site. In some implementations, the RMBU may be used in another building structure.
At operation 1720, operations 1708 to 1716 may be repeated until a desired number of RMBUs are removed from the building structure. In some implementations, less than all RMBUs may be removed. The removed RMBUs may or may not be replaced by other RMBUs.
Implementations of the building structure with RMBUs described herein may introduce various benefits to the housing industry.
Market-rate real estate developers may make development decisions based primarily on a 10 year financial proforma. The proforma calculates development costs and project revenues, discounting them back to year zero. The proforma is based on a 10 year timeline because that is when parties often want to liquidate accumulated value for distribution to vested parties. When a project is projected to yield an acceptable return on investment (ROI), the developer will likely proceed; otherwise, the developer will not proceed. Many prospective projects are rejected before they ever begin because of low ROIs.
The RMBUs may allow the market-rate developer to sell the RMBUs after 10 years and retain the land. This provides several interrelated benefits. If, for example, the old RMBUs are sold at 50% of new RMBUs prices, the developer would enjoy a 50% subsidy on new RMBUs, and be paying down a loan on 10 year old land values, as well as being 10 years into the amortization schedule, which means the developer is paying more principal and less interest than a new loan on new land. In addition, the branding and community capital that have been built over the 10 years are retained. With stronger financial proformas, market-rate developers may be able to proceed with more projects, make more money, and contribute to housing stock.
Downstream developers (workforce, affordable, and low-income housing) can seldom afford to build without subsidies because, in part, the cost of development is often too high to justify investment (i.e., the ROI is negative or approaching zero). The availability of 10 year old RMBUs at 50% of the cost of new construction may make building downstream multifamily housing types more profitable. In some examples, refreshing downstream developments with new or used RMBUs may be financially reasonable when maintenance costs become unmanageable.
Currently, workforce housing is typically market-rate housing that has depreciated downstream, over time. In other words, workforce housing is a function of the age of a development, not a function of proximity to employment, which can lead to transportation planning problems. For example, after the time bond measures pass, environmental impact reports are filed, entitlements are approved, land is acquired, and infrastructure is built, the workforce housing may have depreciated to low-income housing or slums, and the new workforce housing may be what used to be the oldest market-rate housing in another location.
The reusability and mobility of RMBUs may help stabilize housing types and locations. Market-rate housing may remain market-rate because the market-rate housing can be refreshed every 10 years. Downstream housing types enjoy a supply of used modules.
Renters may also benefit because housing stock should increase through use of RMBUs. More available housing should translate to more affordable housing. Market-rate developers may be able to proceed with more projects, and downstream developers may enjoy lower development costs by building with used RMBUs. Fewer dwelling units may be demolished because older units can simply be sold to make room for the new. Environmentalists may also appreciate the emphasis on reusing RMBUs instead of sending existing building materials and structures to the landfill.
While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not of limitation. Likewise, the various diagrams may depict an example architectural or other configuration for the invention, which is done to aid in understanding the features and functionality that can be included in the invention. The invention is not restricted to the illustrated example architectures or configurations, but the desired features can be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations can be implemented to implement the desired features of the present invention. Also, a multitude of different constituent module names other than those depicted herein can be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context so dictates.
Although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.
Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future. The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent.

Claims

What is claimed is:

1. A method, comprising:

inserting, from outside of a building structure, a first reusable modular building unit (RMBU) onto a floor of the building structure, the first RMBU comprising a room;

after inserting the first RMBU, placing the first RMBU on the floor; and

after placing the first RMBU on the floor, removably coupling the first RMBU to the building structure, wherein the building structure comprises:

a permanent interface connecting the building structure to the ground;

the floor;

a support to support the floor; and

an access point configured to house and support a service.

2. The method of claim 1, further comprising: constructing the building structure prior to inserting the first RMBU, wherein constructing the building structure comprises inserting the permanent interface into the ground, wherein the permanent interface comprises a foundation or a plurality of posts and footings.

3. The method of claim 2, wherein the first RMBU comprises a utility, wherein removably coupling the first RMBU to the building structure comprises:

coupling the utility to the service; and

coupling a floor joist of the first RMBU to the floor of the building structure.

4. The method of claim 1, wherein inserting the first RMBU onto the floor of the building structure, comprises: lifting and placing the first RMBU onto the floor.

5. The method of claim 4, wherein placing the first RMBU onto the floor of the building structure, comprises: using at least a winch on the floor to pull the first RMBU into a position on the floor.

6. The method of claim 4, wherein placing the first RMBU onto the floor of the building structure, comprises: deploying a roller assembly of the first RMBU to roll the first RMBU onto a position on the floor.

7. The method of claim 1, wherein the first RMBU comprises a removable panel, the removable panel comprising a door, a camera, a window, a double door, or a mailbox slot.

8. The method of claim 7, wherein the removable panel is configured to house and support services.

9. The method of claim 2, further comprising: inserting from outside of the building structure, a second RMBU onto a second floor of the building structure, the second RMBU comprising a room, wherein the second RMBU comprises a removable panel, wherein the removable panel of the second RMBU is different from the removable panel of the first RMBU and comprises a door, a camera, a window, a double door, or a mailbox slot.

10. The method of claim 8, further comprising: installing one or more caps on an exterior of the building structure, wherein installation one more caps gives the first RMBU and the second RMBU an integrated appearance from an exterior of the building structure.

11. The method of claim 2, further comprising:

inserting from outside of the building structure, a second RMBU onto the floor of the building structure, wherein the second RMBU comprises a room;

placing the second RMBU adjacent the first RMBU on the floor; and

after placing the second RMBU, securing the second RMBU to the building structure, wherein the combination of the first and second RMBUs forms a functional living or office space.

12. A system, comprising:

a building structure, the building structure comprising:

a permanent interface connecting the building structure to the ground;

a floor;

a support to support the floor; and

an access point configured to house and support a service; and

a first reusable modular building unit (RMBU) configured to be inserted, from outside of the building structure, onto the floor of the building structure, wherein the first RMBU is placed onto the floor after it is inserted into the building structure, and the first RMBU is removably coupled to the building structure, wherein the first RMBU comprises a room.

13. The system of claim 12, wherein the building structure further comprises a crane configured to lift and place the first RMBU onto the floor.

14. The system of claim 12, wherein the first RMBU has an adjustable rolling mechanism to allow the first RMBU to roll into a position on a surface.

15. The system of claim 14, wherein the adjustable rolling mechanism can be adjusted to engage or disengage the rolling mechanism with the surface.

16. The system of claim 12, wherein the permanent interface is a foundation.

17. A method, comprising:

decoupling a first reusable modular building unit (RMBU) from a first building structure, wherein the first RMBU comprises a room;

after decoupling the first RMBU, moving the first RMBU from the floor to an outside edge of the floor to remove the first RMBU from building structure; and

after moving the first RMBU to the outside edge of the floor, removing the first RMBU from the building structure, wherein the first building structure comprises:

a permanent interface connecting the building structure to the ground;

a floor;

a support to support the floor; and

an access point configured to house and support a service.

18. The method of claim 17, further comprising:

after removing the first RMBU, transporting the first RMBU to a second permanent building structure, wherein the second building structure comprises a floor;

after transporting the first RMBU to the second building structure, inserting, from outside of the second building structure, a first RMBU onto the floor of the second building structure;

after inserting the first RMBU, placing the first RMBU on the floor of the second building structure; and

after placing the first RMBU on the floor of the second building structure, removably coupling the first RMBU to the second building structure.

19. The method of claim 17, further comprising:

inserting, from outside of the first building structure, a second RMBU onto the floor of the first building structure, the second RMBU comprising a room;

after inserting the second RMBU, placing the second RMBU on the floor; and

after placing the second RMBU on the floor, removably coupling the second RMBU to the first building structure.

20. The method of claim 19, wherein the first RMBU has at least one of a different size, shape, or configuration from the second RMBU.