US20200240159A1

US20200240159A1 - Systems and methods for modular housing and modular housing units

Info

Publication number: US20200240159A1
Application number: US16/747,651
Authority: US
Inventors: Ovidiu Grada; Razvan Eugen Dumitru
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-01-24
Filing date: 2020-01-21
Publication date: 2020-07-30
Also published as: CA3068890A1

Abstract

Systems and methods for modular housing and modular housing units are provided. A modular housing system for defining a structure having an adjustable living space, includes: a first housing module for human habitation, the first housing module having at least a section of a side absent; a second housing module for human habitation, the second housing module having at least a section of a side absent; an intermodule connector for connecting the first housing module to the second housing module when the first and second housing modules are positioned such that their respective absent sections are adjacent, thereby defining a continuous space; wherein the adjustable living space of the structure can be adjusted in a plurality of stages, the stages comprising: a first stage wherein the first housing module defines the adjustable living space of the structure; a second stage wherein the first housing module and the second housing module define the adjustable living space of the structure, the first and second housing modules connected via the intermodule connector; and a third stage wherein the first housing module defines the adjustable living space of the structure, the second housing module having been disconnected from the first housing module and removed so that the size of the adjustable living space of the structure is decreased relative to the second stage.

Description

TECHNICAL FIELD

The following relates generally to building construction and design, and more particularly to systems, apparatus, and methods for modular housing having an adjustable living space.

BACKGROUND

The provision of affordable and sustainable housing is a major problem in many places around the world. Without innovative solutions, these problems are expected to increase in the future. Current building techniques are insufficient for addressing these issues.
Traditional on-site housing construction can be a lengthy process, creating prolonged disruptions for homeowners and others. Site-built homes use building materials and workers that are subject to the elements, which can lead to issues with quality control. Modular housing construction provides an attractive alternative to traditional construction. This is particularly true when considering their potential for addressing issues of affordable and sustainable housing. Modular homes can be constructed relatively quickly, particularly by leveraging off-site fabrication of components. However, deficiencies exist that prevent more widespread adoption of modular housing and limit its effectiveness at tackling affordability and sustainability issues. Like traditionally built homes, existing modular housing approaches implement one-way development processes that often don't give homeowners the flexibility needed when it comes to space and cost.
Current housing design approaches do not provide sufficient flexibility for homeowners. Changes in financial or family circumstances can necessitate a change in home size. Upsizing or downsizing a home requires moving, which can be time-consuming, stressful, and expensive. The expense associated with buying a sustainable home or upgrading your existing home to improve sustainability makes it impractical for many given the already high cost of housing.
In particular, existing site-built or modular construction approaches produce homes that cannot be easily modified to adjust the size of the living space. This is especially true when it comes to reducing the size of the living space. Such “one-way construction” adds components to the structure without concern for removing components (e.g. downsizing) or transport to another site. Disassembly causes damage to the structural components of the home. Further, components of modular homes may be linked in such a way that removal causes unwanted damage to the remaining structure (and removed module) or that results in unwanted movement between components (affecting structural stability).
Accordingly, there is a need for improved systems and methods for modular housing that address at least some of the deficiencies of current building design and construction approaches described above.

SUMMARY

A modular housing system is provided herein. The modular housing system defines a structure having an adjustable living space. The modular housing system includes a first housing module for human habitation. The first housing module includes an intermodule aperture traversing at least a section of a side. The modular housing system also includes a second housing module for human habitation. The second housing module includes an intermodule aperture traversing at least a section of a side. The modular housing system includes an intermodule connector for connecting the first housing module to the second housing module when the first and second housing modules are positioned such that their respective intermodule apertures are adjacent, thereby defining a continuous space. The adjustable living space of the structure can be adjusted in a plurality of stages. There is a first stage wherein the first housing module defines the adjustable living space of the structure. There is a second stage wherein the first housing module and the second housing module define the adjustable living space of the structure, the first and second housing modules connected via the intermodule connector. There is a third stage wherein the first housing module defines the adjustable living space of the structure, the second housing module having been disconnected from the first housing module and removed so that the size of the adjustable living space of the structure is decreased relative to the second stage.
The intermodule connector may be configured to restrict vertical movement of the first housing module relative to the second housing module.
The intermodule connector may be configured to restrict horizontal movement of the first housing module relative to the second housing module.
The modular housing system may include a foundation connector for connecting the first housing module to a foundation.
The modular housing system may include a roof module connected to a top surface of the structure.
The modular housing system may include a curtain-ventilated façade applied to an outward-facing surface of the structure.
A connection mechanism for use in a modular housing system having an adjustable living space is provided herein. The modular housing system includes a first container and at least one first container-linkable component. The connection mechanism includes a first connector element attachable to the first container and a second connector element attachable to the first container-linkable component. The first connector element and the second connector element are each adapted to connect to one another in such a way that restricts a movement of the first container relative to the first container-linkable component.
The first container-linkable component may be a foundation.
The first container-linkable component may be a second container.
The first container-linkable component may be a roof module.
The restricted movement may be horizontal movement.
The restricted movement may be vertical movement.
A housing module for use in a modular housing system having an adjustable living space is provided herein. The housing module includes a container for human habitation. The housing module also includes a connection mechanism attachable to the container for connecting the container to a container-linkable component in such a way that restricts a movement of the container relative to the container-linkable component.
The container may be an intermodal container.
The restricted movement may be horizontal movement.
The restricted movement may be vertical movement.
The container-linkable component may be another container.
A method of forming a modular housing structure having an adjustable living space is provided herein. The method includes providing a first housing module for human habitation. The first housing module includes a first container having at least a section of a side absent. The method also includes connecting the first housing module to a second housing module via an intermodule connector. The second housing module includes a second container having at least a section of a side absent. The first and second containers are positioned in such a way that their respective absent sections are adjacent, thereby defining a continuous space. The first housing module is connected to the second housing module in such a way that the second housing module can be disconnected from the first housing module at a later stage to decrease the adjustable living space.
The method may include connecting the first housing module to a foundation.
The intermodule connector may be configured to restrict vertical movement of the first housing module relative to the second housing module.
The intermodule connector may be configured to restrict horizontal movement of the first housing module relative to the second housing module.
Other aspects and features will become apparent, to those ordinarily skilled in the art, upon review of the following description of some exemplary embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings included herewith are for illustrating various examples of articles, methods, and apparatuses of the present specification. In the drawings:

FIG. 1A is a block diagram of a modular housing system in a first stage, according to an embodiment;

FIG. 1B is a block diagram of a modular housing system in a second stage, according to an embodiment;

FIG. 1C is a block diagram of a modular housing system in a third stage, according to an embodiment;

FIG. 2 is a block diagram of a container in untransitioned and transitioned states, according to an embodiment;

FIG. 3 is a block diagram of a connection mechanism for use in a modular housing system, according to an embodiment;

FIG. 4 is a cross-section view of a curtain-ventilated façade for use in a modular housing system, according to an embodiment;

FIG. 5 is a cross-section view of a roof module for use in a modular housing system, according to an embodiment;

FIG. 6A is a top elevation view of a roof module applied to a container as part of a modular housing structure, according to an embodiment;

FIG. 6B is a front elevation view of a roof module applied to a container as part of a modular housing structure, according to an embodiment;

FIG. 6C is a side elevation view of a roof module applied to a container as part of a modular housing structure, according to an embodiment;

FIG. 7 is a cross-section view of a modular housing structure in a first stage, according to an embodiment;

FIG. 8 is a side view of a module-to-roof connector for connecting a housing module and a roof module, according to an embodiment;

FIG. 9 is a side view of a module-to-foundation connector for securing a housing module to a foundation at a build site, according to an embodiment;

FIG. 10 is a side view of an intermodule connector for connecting a first housing module to a second housing module, where the first and second housing modules are positioned horizontally adjacent to one another, according to an embodiment;

FIG. 11 is a cross-section view of a modular housing structure in a second stage, in accordance with an embodiment;

FIG. 12 is a side view of an intermodule connector for connecting a first housing module and a second housing module housing module, where the first and second housing modules are positioned vertically adjacent to one another, according to an embodiment;

FIG. 13 is a side view of an intermodule connector for connecting a first housing module to a second housing module, where the first and second housing modules are positioned horizontally adjacent to one another, according to an embodiment;

FIG. 14 is a cross-section view of a modular housing structure in a first stage, according to an embodiment;

FIG. 15 is a cross-section view of a modular housing structure in a second stage, according to an embodiment;

FIG. 16 is a flow diagram of a method of forming a modular housing structure having an adjustable living space, according to an embodiment;

FIG. 17 is a flow diagram of an assembly procedure for a modular housing system, according to an embodiment; and

FIG. 18 is a perspective view of twist lock connection mechanisms, according to a plurality of embodiments.

DETAILED DESCRIPTION

Various apparatuses or processes will be described below to provide an example of each claimed embodiment. No embodiment described below limits any claimed embodiment and any claimed embodiment may cover processes or apparatuses that differ from those described below. The claimed embodiments are not limited to apparatuses or processes having all of the features of any one apparatus or process described below or to features common to multiple or all of the apparatuses described below.
The present disclosure relates generally to housing construction and design, and more particularly to systems, methods, and connection mechanisms for modular housing.
Generally, systems and methods are provided for defining a modular housing structure having an adjustable living space. The adjustable living space can increase or decrease according to an owner or habitant's needs. The living space of the structure can be adjusted in a plurality of stages by adding or removing housing modules without damaging the living space. A housing module represents the base unit of the adjustable living space. The multi-stage development process can be performed in accordance with a pre-build design. The pre-build design informs the manufacture of structural components including housing modules and their corresponding assembly at the build site, increasing efficiency and modularity. Connection mechanisms are provided for connecting components of the modular housing structure at the build site, including housing modules and other features. On-site linking of structural components via the connection mechanisms increase transportability and modifiability of the modular housing structure (and its components) and promote stability and cohesion of the overall structure through linking components and restricting movement.
Pre-assembled housing modules of various sizes (e.g. 10′×8′, 20′×8′, 30′×8′, or 40′×8′) can be assembled to form either a single level or a multi-level indoor space. Apertures can be established in sides of the housing modules to make the indoor space continuous. In a particular embodiment, an intermodal container provides the frame and structural supports for the housing module.
Referring now to FIGS. 1A to 1C, shown therein is a modular housing system 100 for defining a modular housing structure having an adjustable living space, according to an embodiment. System 100 is implemented according to a pre-build design. The pre-build design identifies the number of development stages, number and layout of housing modules at each stage, additional features of the modular housing structure, and specifications of structural components. The pre-build design can incorporate design preferences of the owner or habitant, including structural and cosmetic preferences. For example, cosmetic preferences may include finishing of inside and outside surfaces of the structure. Components can be manufactured, transported, and assembled in accordance with the pre-build design. To promote efficiency of assembly, components may be assembled prior to transport. Structural components can be designed and manufactured to have an alterable structure such that they can be easily re-configured for a use in a different development stage with minimal work.
In some cases, the pre-build design can be re-visited and modified to accommodate changes to preferences or ownership. New components can be manufactured in accordance with the modified pre-build design and transported as needed. As an example, finishes applied to outward-facing surfaces of the structure can be removed and replaced to change the outward appearance of the structure. Further, the modularity of the system means the pre-build design can be modified to easily incorporate upgrades to the structure. This can be particularly advantageous in making the structure more sustainable, such as in moving towards making the structure a zero-energy building. Modifications to increase sustainability of the structure may include the design, manufacture, and assembly of features such as solar panels, double-glazed windows, insulation to save on energy costs, non-toxic building materials, and the like.
The modular housing structure assembled using the system 100 may have various sizes, layouts, and designs. The modular housing structure may be designed and assembled for residential, commercial, or industrial purposes. Use of the term “housing” or some variation thereof throughout the present disclosure is intended to imply uses and applications beyond simply human residences and extends to commercial and other structures for defining indoor spaces useable by humans; likewise, the term “human habitation” or some variation thereof can be understood to mean suitable for human occupation irrespective of the purpose for which the structure may be used.
Referring specifically to FIG. 1A, shown therein is modular housing system 100 in a first stage 100 a of a multi-stage process for defining a modular housing structure 102 having an adjustable living space, according to an embodiment. At stage 100 a, the adjustable living space includes a first housing module 104. The first housing module 104 is manufactured at a manufacturing site 106. The first housing module 104 may be manufactured in accordance with a pre-build design. As described above, the pre-build design accounts for all stages of development, meaning the first housing module 104 is manufactured, where possible, and includes structure and components that are alterable depending on the then-current stage without the need to return to the manufacturing site 106. The manufacturing site 106 may include multiple manufacturing sites. Once manufactured, the first housing module 104 is transported 108 to a build site 110. The first housing module 104 is transportable from the manufacturing site 106 to the build site 110, such as by rail or truck.
The first housing module 104 includes a container 126 a. The container 126 a provides the structural supports for the housing module 104 and the modular housing structure 102. Accordingly, the container 126 a is made of a material or materials possessing sufficient strength to serve as structural support for the modular housing structure 102 as designed. The container 126 a is of a size and composition that is easily transportable, making the housing module 104 transportable. The container 126 a may be a closed container or an open frame container.
The container 126 a may have different shapes and sizes. The size and shape of the container 126 a may be selected or manufactured to suit the design of the modular housing structure 102. In some embodiments, containers measuring 10′×8′, 20′×8′, 30′×8′, or 40′×8′ may be used. The container 126 a may be cuboid (or box-shaped object) in shape having six rectangular sides. A container side 127 may be inward-facing or outward-facing, determined by whether the side 127 faces into the indoor space or faces outside the structure 102, respectively. The side 127 of the container 126 a may function as a base, a ceiling, or a wall depending on the orientation of the housing module 104 in the structure 102.
In an embodiment, the container 126 a may be a repurposed container modified as required to serve as structural support. In another embodiment, the container 126 a may be manufactured specifically for use in the modular housing structure 102. For example, the container 126 a may be a custom size container (e.g. for a custom size housing module). The custom container may be built from scratch. The custom container may be manufactured by welding together the steel (or other suitable material) frames and connectors to create an open frame container.
In an embodiment, the container 126 a is an intermodal container. The intermodal container may be a closed container or an open frame container. The open frame container may have a partially open frame. The intermodal container may be a large standardized shipping container designed and built for intermodal freight transport. The intermodal container may be used across different modes of transport, including ship, rail, and truck. The intermodal container may have a number of types and standardized sizes. In some cases, the intermodal container is a closed box composed of a durable material, such as steel. The intermodal container may have a length of twenty and forty feet. The intermodal container may have a height of 8 feet 6 inches or 9 feet 6 inches. Using a repurposed intermodal container as container 126 a provides a good source of structural support material and may also save costs and reduce space otherwise required for the storage of unused intermodal containers. Using an intermodal container as the container 126 a may also alleviate environmental concerns associated with unused intermodal containers, such as the negative effects produced by the considerable energy required to melt down intermodal containers.
The container 126 a can be handled, moved, and stacked, and can be packed tightly for transport or storage. The container 126 a is constructed to withstand the stresses of transport 108, to facilitate handling of the container 126 a, and to allow stacking, making the container 126 a suitable for use as structural supports. In variations, the container 126 may be a rectangular, closed box model.
The container 126 a may be made of corrugated weathering steel (e.g. CorTen). The sides 127 of the container 126 a may include corrugating sheet metal. The corrugating sheet metal provides increased rigidity to the container 126 a and increased stacking strength to the container 126 a. Increased rigidity and stacking strength contribute to the stability of the modular housing structure 102 and may facilitate the assembly of multi-level structures. In other embodiments, the container 126 a may be made of or include other materials (e.g. wood). For example, the other material or materials, such as wood, may be used as an alternative to sheet metal when an open frame container is used as the container 126 a.
The container 126 a may include gripping members. The gripping members are configured to engage a lifting device such as a crane or forklift for loading and unloading of the container 126 a from a transport vehicle.
Referring now to FIG. 2, shown therein is a perspective view of a container 200, according to an embodiment. The container 200 is a container (for example, containers 126 a, 126 b, 126 c of FIGS. 1A to 1C) for use in a modular housing system, such as system 100 of FIG. 1.
The container 200 may exist in an untransitioned state 200 a and a transitioned state 200 b. In the transitioned state 200 b, the container 200 can be assembled with another container to form a modular housing structure having multiple housing modules (for example, structure 102 of FIG. 1B or 1C). The container 200 may be manufactured in the untransitioned state 200 a or the transitioned state 200 b. The container 200 may be transformed 216 from the untransitioned state 200 a to the transitioned state 200 b, and vice versa. The state transformation 216 may occur at the build site 110 or the manufacturing site 106, where appropriate. Performing the state transformation 216 at the build site 110 may make onsite assembly more efficient.
In the untransitioned state 200 a, the container 200 includes a stage transition section 206. The stage transition section 206 traverses at least a portion of a side 208 of the container 200. The stage transition section 206 is a section of container side material forming the side 208. In the untransitioned state 200 a, the container 200 is not suitable for use in a modular housing structure having multiple housing modules. This is because in the untransitioned state 200 a the container 200 is a closed structure and cannot form a continuous space with another container. In an embodiment, the stage transition section 206 traverses all or substantially all of the side 208 of the container 210. In other variations, the stage transition section 206 may be smaller. The size and location of the stage transition section 206 on the side 208 may be determined according to the pre-build design.
The stage transition section 206 is removable from the container 200. In some cases, the stage transition section 206 may be reversibly removable such that the stage transition section 206 may be reattached to the container 200 in the same position after removal. The reattached stage transition section 206 may be the original stage transition section 206, or a different stage transition section 206 having substantially similar dimensions. The reversible removability of the stage transition section 206 may allow the side 208 to function as an outward-facing side of the structure after reattachment of the stage transition section 206.
The container 200 may include additional stage transition sections in other sides of the container 200. For example, the container 200 includes a second stage transition section 212 in a second side 214 of the container. The second stage transition section 212 may have similar or different dimensions from that of the stage transition section 206. The second stage transition section 212 may be removed at the same build stage as the stage transition section 206 or at a different build stage. The second stage transition section 212 may be removed at the manufacturing site 106 or at the build site 110.
In the transitioned state 200 b, the container 200 includes an intermodule aperture 210. The intermodule aperture 210 is a void in the container 200 that traverses a section of the side 208. In some cases, the space occupied by the intermodule aperture 210 corresponds to the space occupied by the stage transition section 206 in the untransitioned state 200 a. The intermodule aperture 210 allows the container 200 to define a continuous space with a second container (for example, container 126 b of housing module 138 of FIG. 1B) when an intermodule aperture of the second container is aligned with the intermodule aperture 210. The intermodule aperture 210 may be created by removing the stage transition section 206 from the container 200. In an embodiment, the stage transition section 206 may be removed by cutting a piece of material from the side 208 of the container 200.
The stage transition section 206 may be a window. In some cases, the window may be a floor-to-ceiling window. Use of the window as stage transition section 206 may eliminate or reduce the need for cutting the stage transition section 206 out of the side 208. Eliminating or reducing the need for cutting may reduce waste and mess made in the structure 102 and make the process simpler and cleaner.
The container 200 may have intermodule apertures in multiple sides (for example, sides 208 and 214). A plurality of intermodule apertures 210 may allow the container 200 to be positioned adjacent to multiple other containers in the modular housing structure. The number and position of the intermodule apertures 210 depend on design and how housing modules are to be assembled. Intermodule apertures need not be in the same location on their respective sides of the container 200, or of the same size or kind.
In an embodiment, the intermodule aperture 210 is established by removing the stage transition section 206 from the container 200. Removal of the stage transition section 206 may occur at the manufacturing site 106 or the build site 100.
The side 208 may be a ceiling, a base, or a wall of the container 200. The function of the side depends on the positioning and orientation of the container 200 in the modular housing structure. A “ground floor” container (such as the container 126 b of housing module 138 of FIG. 1C) may have the intermodule aperture 210 in the ceiling to connect with a container positioned above. A “non-ground floor” container (such as the container 126 c of housing module 152 of FIG. 1D) may have the intermodule aperture 210 in the base to facilitate formation of a continuous space with a with a container positioned below. A non-ground floor container that is not a top floor container may have intermodule apertures 210 in the base and ceiling.
The side 208 may be a wall when the container 200 is positioned horizontally adjacent to another container. In some embodiments, the container 200 includes intermodule apertures 210 in multiple walls. Intermodule apertures 210 in multiple walls may facilitate the connection of container 200 with multiple horizontally adjacent containers.
Referring back to FIG. 1A, the system 100 includes at least one connection mechanism 111 for connecting the housing module 104 to another component of the system 100. The connection mechanism 111 is configured to connect specific or general components of the system 100. The connection mechanism 111 restricts movement of the linked components relative to one another. By restricting movement of linked components, the connection mechanism 111 increases structural stability of the modular housing structure 102.
Referring now to FIG. 3, shown therein is a connection mechanism 300 in an unconnected state 300 a, and a connected state 300 b for use in a modular housing system, such as system 100, according to an embodiment. Connection mechanism 300 may be used to connect multiple components of the modular housing structure 102.
The connection mechanism 300 includes a first connector element 302 and a second connector element 304. The first connector element 302 is attachable to a first linkable component 306, such as the first housing module 104. The second connector element 304 is attachable to a second linkable component 308 (for example, the second housing module 138 of FIG. 1B).
The first connector element 302 is engageable with the second connector element 304. Through a linking action 310, the first and second connector elements 302, 304 can be synergistically linked in order to effect an operative connection mechanism 312. The operative connection mechanism 312 connects the first and second linkable components 306, 308 in such a way that a movement relative to each other is restricted.
Advantageously, operative connection mechanism 312 is reversible such that the first connector element 302 and the second connector element 304 can be unlinked through an unlinking action 314. Unlinking action 314 disconnects the first and second linkable components and returns the connection mechanism 300 to the unconnected stage 300 a. The unlinking action 314 may allow reconfiguration of the linkable components 306, 308 in the structure 102. The unlinking action may also facilitate removal of an unlinked component from the structure 102 (and the build site 110).
Referring back to FIG. 1A, in an embodiment, the connection mechanism 111 includes a module-to-foundation connector 120. The module-to-foundation connector 120 connects the first housing module 104 to a foundation 118. The module-to-foundation connector 120 restricts movement between the first housing module 104 and the foundation 118. The module-to-foundation connector 120 includes module-to-foundation connector elements 122 attached to the first housing module 104, and foundation-to-module connector elements 124 attached to the foundation 118. The connector elements 122, 124 may be manufactured at the manufacturing site 106. The module-to-foundation connector elements 122 may be attached to the first housing module 104 at the manufacturing site 106 or the build site 110, where appropriate. In an embodiment, the module-to-foundation connector 120 includes a twist lock (for example, FIG. 9). The twist lock is welded to a plate that rests on the foundation 118. The twist lock inserts into a cavity in the bottom of the first housing module 104. The twist lock can be fitted with a key for unlocking. A further advantage of the module-to-foundation connector 120 is that it may satisfy certain regulatory or financing requirements that the housing structure 102 be secured to a foundation.
In another embodiment, the connection mechanism 111 includes an intermodule connector (for example, intermodule connector 140 of FIG. 1B, or intermodule connector 156 of FIG. 1C). The intermodule connector restricts movement of connected housing modules relative to one another. In some cases, the intermodule connector (for example, intermodule connector 140 of FIG. 1B) restricts horizontal movement of the connected housing modules relative to each other. In other variations, the intermodule connector (for example, intermodule connector 156 of FIG. 1C) restricts vertical and horizontal movement of the connected housing modules relative to each other. The intermodule connector includes module-to-module connector elements 129 attached to the container 126 a of the first housing module 104. The module-to-module connector elements 129 are attached to the container 126 a of the first housing module 104 at the manufacturing site 106. In another embodiment, the module-to-module connector elements 129 may be attached to the container 126 a at the build site 110. Module-to-module connector elements 129 are configured to interface with module-to-module connector elements attached to another housing module (for example, housing module 138 of FIG. 1C) to effect the intermodule connector.
In another embodiment, the connection mechanism 111 includes a module-to-roof connector 130 a. The module-to-roof connector 130 a restricts horizontal and vertical movement of the first housing module 104 relative to a roof module 114 a. The module-to-roof connector 130 a includes a module-to-roof connector element 132 and a roof-to-module connector element 134. The module-to-roof connector element 132 is attached to the container 126 a of the first housing module 104. The roof-to-module connector element 134 is attached to the roof module 114 a. The module-to-roof connector element 132 and the roof-to-module connector element 134 may be attached to the first housing module 104 and the roof module 114 a, respectively, at the manufacturing site 106. In other embodiments, the module-to-roof connector element 132 and/or the roof-to-module connector element 134 may be attached to their respective components at the build site 110. Attaching the module-to-roof connector element 132 and/or the roof-to-module connector element 134 at the manufacturing site 106 may decrease time and complexity of assembly at the build site 110. In an embodiment, the roof-to-module connector 130 a includes a twist lock (for example, FIG. 8). The twist lock includes a portion that inserts into the bottom of the roof module 114 and a portion that inserts into the first housing module 104. The twist lock can be fitted with a key for unlocking.
The connection mechanism 111 is reversible. The reversibility of the connection mechanism 111 facilitates disconnection of linked components with minimal damage to any removed components or to the remaining structure 102. The reversibility of the connection mechanism 111 also increases transportability of the modular housing structure 102. This increased transportability may be advantageous when moving some or all of the structure 102 to another build site. The connection mechanism 111 also increases modularity of the structure 102, particularly in development stages where the adjustable living space is decreased by removing of a housing module. The adjustable living space may be increased by adding an upper module (e.g. module 152 of FIG. 1C). In such a case, the same roof module 114 a may be removed from the housing module 104 and applied to the newly added upper module (e.g. using element 134).
The system 100 includes additional features 112. Additional features 112 include the roof module 114 a and a façade 116 a. The additional features 112 are transported to the build site 110 and applied to the first housing module 104 to make the structure 102 suitable for human habitation. In other embodiments, one or more additional features 112 may be applied to the first housing module 104 at the manufacturing site 106 and transported to the build site 110 to simplify the on-site assembly process. The façade 116 a provides aesthetic appeal of the structure. The façade 116 a may also provide for comfort and energy efficiency of the structure 102. The façade 116 a is applied to the outward facing walls of the first housing module 104. Insulation may be applied to the outside surface of outward-facing walls of the housing module 104. In a particular embodiment, the façade 116 a is a curtain-ventilated façade (for example, FIG. 4).
Additional features 112 may also include insulation and drywall. Insulation may form a layer of the façade 116 a or may be applied elsewhere on the first housing module 104 such as the outside surface of an upper wall. Drywall may be directly applied to inward-facing surfaces such as the walls and ceiling of the first housing module 104. Drainage and soffits may also be added to the outside-facing surfaces of the first housing module 104 at the build site 110.
Advantageously, the modular housing structure 102 requires minimal work inside of the assembled module 104 to complete the indoor space.
Referring now to FIG. 1B, shown therein is a second stage 100 b of a multi-stage development process started in stage 100 a of FIG. 1A using the modular housing system 100, according to an embodiment. Stage 100 b includes the addition of a second housing module 138 to the modular housing structure 102. By connecting the second housing module 138 to the first housing module 104, the adjustable living space of the modular housing structure 102 is increased. The second housing module 138 is connected to the first housing module 104 via an intermodule connector 140.
The second housing module 138 includes a container 126 b and connector elements 128 attachable to the container 126 b. Connector elements 128 include module-to-module connector elements 142, a module-to-roof connector element 132, and module-to-foundation connector elements 122. The connector elements 128 are attached to the container 126 b of the second housing module 138 at the manufacturing site 106. In other embodiments, one or more connector elements 128 may be attached to the container 126 b of the second housing module 138 at the build site 110.
The module-to-module connector elements 142 interface with the module-to-module connector elements 129 on the first housing module 104 to connect the first and second housing modules 104, 138 via the intermodule connector 140. The intermodule connector 140 restricts vertical movement of the first housing module 104 relative to the second housing module 138.
The module-to-roof connector element 132 interfaces with a roof-to-module connector element 134 attached to a roof module 114 b to connect the second housing module 138 to the roof module 114 b via a module-to-roof connector 130 b. The module-to-roof connector 130 b restricts horizontal and vertical movement of the second housing module 138 relative to the roof module 114 b.
The module-to-foundation connector elements 122 interface with foundation-to-module connector elements attached to the foundation 118 to connect the second housing module 138 to the foundation 118 via the foundation connector 120 b. The foundation connector 120 b restricts movement of the second housing module 138 relative to the foundation.
The second housing module 138 is assembled at the manufacturing site 106 in accordance with a pre-build design and transported 108 to the build site 110 for integration into the modular housing structure 102.
At the build site 110, the second housing module 138 is positioned horizontally adjacent to the first housing module 104, according to the pre-build design. Positioning the first and second housing modules 104, 138 horizontally adjacent each other forms a single-level modular housing structure 102. In positioning the second housing module 138, the second housing module 138 may overlap the entire length of the first housing module 104 or may overlap less than the entire the length of the first housing module 104. In some cases, a partial overlap of the first and second housing modules 104, 138 may occur where the first and second housing modules 104, 138 have different dimensions.
To accommodate the addition of the second housing module 138 to the structure 102, the first housing module 104 includes a stage transition section (for example, stage transition section 206 of FIG. 2). The stage transition section is removable from the first housing module. Removal of the stage transition section forms an intermodule aperture (for example, intermodule aperture 210 of FIG. 2) in the first housing module 104. Removal of the stage transition section may be done at the build site 110 to increase efficiency in adjusting the living space of the structure 102.
The second housing module 138 includes a first intermodule aperture (for example, intermodule aperture 210 of FIG. 2) in the container 126 b. The intemodule aperture is in a side functioning as a wall of the container 126 b. When aligned with the intermodule aperture of the first housing module 104, the first intermodule aperture of the second housing module 138 allows the formation of a continuous indoor space defined by the first and second housing modules 104, 138. The second housing module 138 may be manufactured and transported with the first intermodule aperture present in the container 126 b. Manufacturing and transporting the second housing module 138 in this way may simplify assembly at the build site 110, as no material is removed from the second housing module 138 at the build site 110 to establish the first intermodule aperture. In other embodiments, the first intermodule aperture of the second housing module 138 may be formed at the build site 110 in a manner similar to the intermodule aperture of the first housing module 104.
The container 126 b of the second housing module 138 includes a stage transition section (for example, stage transition section 206 of FIG. 2). Location and dimensions of the stage transition section of the second housing module 138 are determined by the pre-build design. The stage transition section is a section of material removable from a ceiling of the container 126 b. The stage transition section may be removed at a later stage of the development process (for example, stage 100 c of FIG. 1C). Removal of the stage transition section from the ceiling of the container 126 b establishes a second intermodule aperture, the second intermodule aperture in the ceiling of the container 126 b. The second intermodule aperture may be aligned with an intermodule aperture in another, vertically adjacent housing module (for example, third housing module 152 of FIG. 1C) to form a continuous space.
Once the second housing module 138 has been positioned at the build site 110, the second housing module 138 is connected to the foundation 118 using the module-to-foundation connector 120 b. The second housing module 138 is connected to the first housing module 104 via the intermodule connector 140. As described above, connecting the first and second housing modules 104, 138 via the intermodule connector 140 restricts movement of the first housing module 104 relative to the second housing module 138. The movement restricted by intermodule connector 140 includes vertical movement. In an embodiment, the intermodule connector 140 includes a bridge fitting with an extension rod (for example, FIG. 10). The extension rod is inserted into the adjacent first and second housing modules 104, 138.
As with the first housing module 104, additional features 112 may be applied to the second housing module 138. The additional features 112 include a façade 116 b that is applied to the container 126 b of the second housing module 138 prior to transport 108. In other embodiments, the façade 116 b (or components thereof) may be applied at the build site 110.
Referring now to FIG. 1C, shown therein is a third stage 100 c of a multi-stage development process using the modular housing system 100, according to an embodiment. Stage 100 c includes the addition of a third housing module 152 to the modular housing structure 102 of stage 100 b. The addition of the third housing module 152 increases the adjustable living space of the modular housing structure 102. The third housing module 152 is positioned vertically adjacent to the second housing module 138 and connected to the second housing module via an intermodule connector 156.
In other embodiments, stage 100 c may be a reduction stage for decreasing the adjustable living space of the modular housing structure 102 relative to stage 100 b. In such a case, the second housing module 138 may be disconnected from the first housing module 104 (by unlinking the intermodule connector 140) and the foundation 118 (by unlinking the module-to-foundation connector 120) and removed from the build site 110. The stage transition section of the first housing module 104 may be reattached to the container 126 a of the first housing module 104 such that the first housing module defines an enclosed space. Additional features 112 that were removed at stage 100 b may be reapplied to the first housing module 104 to finish the structure 102. The additional features 112 that are reapplied may be the same additional features 112 applied in stage 100 a or new additional features 112 providing similar structure and/or function.
The third housing module 152 includes a container 126 c and connector elements 128 attachable to the container 126 c. The connector elements 128 include module-to-module connector elements 142, a module-to-roof connector element 132, and a module-to-module connector element 154. In an embodiment, the connector elements 128 may include module-to-module connector elements that can interface with module-to-module connector elements attached to a vertically or horizontally adjacent fourth housing module as part of a subsequent addition stage.
The third housing module 152 includes an intermodule aperture (for example, intermodule aperture 210 of FIG. 2) in the container 126 c. The intermodule aperture traverses at least a section of a base of the container 126 c. The intermodule aperture may be formed by removing the base of the container 128 c (or a portion thereof). Formation of the intermodule aperture may be done at the manufacturing facility 106 prior to transport 108.
Similar to the first and second housing modules 104, 138, the third housing module 152 may include a stage transition section (for example, stage transition section 210 of FIG. 2). The stage transition section 210 may be removed from the container 126 c of the third housing module 152 at a subsequent stage of development (such as an addition or reconfiguration). Removal of the stage transition section of the third housing module 154 may facilitate the addition of another housing module to the modular housing structure 102 by allowing the formation of a continuous space.
The third housing module 138 includes a façade 116 c. The façade 116 c is applied to the outward-facing surfaces of the container 126 c (for example, side 127 of the container 126 c) of the third housing module 154. The façade 116 c (or parts thereof) may applied to the container 126 c at the manufacturing site 106 in order to simplify on-site assembly.
To facilitate the addition of the third housing module 152 to the modular housing structure 102, the stage transition section of the second housing module 138 is removed to form the second intermodule aperture in the container 126 b. The third housing module 152 is positioned on top of the second housing module 138 so that the second intermodule aperture of the second housing module 138 and the intermodule aperture of the third housing module 152 overlap and define a continuous indoor space.
The third housing module 152 is added to the modular housing structure 102 by connecting the third housing module 152 to the second housing module 138 via an intermodule connector 156. Connection via the intermodule connector 156 is achieved by interfacing the module-to-module connector element 154 attached to the third housing module 152 with the module-to-module connector element 132 attached to the second housing module 138. Depending on the intermodule connector 156, the module-to-module connector element 132 may be the same module-to-module connector element 132 used in the module-to-roof connector 130 b in stage 100 b, or a different module-to-module connector element 132.
The roof module 114 b is disconnected from the second housing module 138. The roof module 114 b may be removed using a small crane. Detaching the roof module 114 b from the second housing module 138 facilitates removal of the second stage transition section from the container 126 b of the second housing module 138. Detaching the roof module 114 b from the second housing module 138 also facilitates connection of the third housing module 152 to the second housing module 138. In an embodiment, the disconnected roof module 114 b may be removed from the build site 110. In another embodiment, the disconnected roof module 114 b may be repurposed as roof module 114 c.
A roof module 114 c is applied to a top surface of the third housing module 152. The roof module 114 c is connected to the third housing module 152 via a module-to-roof connector 130 c. The module-to-roof connector 130 c is effected by interfacing the module-to-roof connector element 132 attached to the third housing module 154 with the roof-to-module connector element 134 attached to the roof module 114 c.
The system 100 may include a stair module. The stair module can be used as part of a multi-level structure, such as structure 102 in the third stage 100 c.
The stair module connects the living space of a lower level housing module with the living space of an upper level housing module. For example, the stair module may connect the living space of the first level structure suitable for human habitation (e.g. housing module 138) with the second level (second floor or third floor) suitable for human habitation. The stair module may include stairs for traveling between floors or levels of the structure 102. The stair module facilitates traveling between floors of a multi-level adjustable housing structure such as structure 102.
The stair module may include a plurality of connected containers. The connected containers house a multi-level stair for traveling between levels. The containers may be connected one on top of another. The containers may be welded together.
In a particular embodiment, the stair module includes two containers welded together one on top of another. Such an embodiment may be used as a two-level stair module to connect the living space of housing modules 138, 152. The lower container of the stair module has its ceiling (or a portion thereof) removed to form an aperture. The upper container has its base (or a portion thereof) removed to form an aperture. The removal of the ceiling and base of the lower and upper containers, respectively, create apertures that function similarly to the intermodule apertures of FIG. 2. The aperture in the lower module and the aperture in the upper module overlap such that the lower module and the upper module form a continuous space. A multi-level stair can be fitted in the aperture between the lower and upper modules. The stair can be used to access the second level of the structure 102 from the first level of the structure, or vice versa.
The stair module includes a plurality of apertures. The apertures of the stair module can be aligned with intermodule apertures of the housing modules to create a continuous space between the housing modules and the stair module. In some cases, the intermodule aperture of the housing module may be formed by removing a window (i.e. the window acts as a stage transition section). The continuous space between the housing module and the stair module allows a habitant to gain access to the stair module from the housing module (and vice versa).
A stair module container may include a stage transition section. The stage transition section functions similarly to a stage transition section of a housing module. The stage transition section can be removed to facilitate addition of another container to the stair module, for example as part of a further development stage (increasing the number of levels of the structure 102). In a particular example, the further development stage includes an addition of a third level to the structure 102. The further development stage includes removal of the ceiling (or a portion thereof) of an upper container of a two-container stair module connecting the first and second levels of the structure 102. An additional stair segment can be added to the existing multi-level stair to facilitate access to the third level of the structure 102 from the second (or first) level of the structure 102, or vice versa.
Advantageously, the stair module may be added to the structure 102 only once the structure 102 becomes multi-level (example at the second development stage 100 b). The stair module can be connected to the first level of the structure 100 via opening 206 in the first level housing module 138.
Generally, the addition of housing modules 138, 152 to the structure 102 may include adjusting one or more of the curtain-ventilated façades 116 a, 116 b, 116 c in order to bring the curtain-ventilated facades flush with one another to create a flush external system for the structure. Adjustment of the curtain-ventilated façade 116 may be performed after application of the roof module or roof modules 114 to the structure 102. Adjustment of the curtain-ventilated façade 116 may include extension or retraction of the curtain-ventilated façade 116 relative to the container of the housing module.
Referring now to FIG. 4, shown therein is a cross-section of a curtain-ventilated façade 400 for use in a modular housing system, according to an embodiment. The curtain-ventilated façade 400 is applied to an outward-facing surface 402 of a ground-level housing module 406. In other embodiments, the curtain-ventilated façade 400 may be applied to a non-ground-level housing module. In some embodiments, the curtain-ventilated façade 400 may be applied to a plurality of outward-facing surfaces. The curtain-ventilated façade 400 provides for aesthetic appeal of an assembled modular housing structure. The curtain-ventilated façade 400 may be adjustable (e.g. extendable, retractable) to provide a flush alignment with an adjacent curtain-ventilated façade. In an embodiment, the curtain-ventilated façade 400 can be used as the façades 116 a, 116 b, or 116 c in the modular housing system 100 described in FIG. 1.
The curtain-ventilated façade 400 includes a substructure 404. The substructure 404 provides an underlying supporting structure upon which further components and layers of the curtain-ventilated façade 400 can be applied. In an embodiment, the substructure 404 includes a metal framework. The substructure 404 is affixed to a container 408 of the housing module 406. The curtain-ventilated façade 400 includes a plurality of fixing points 412 for attaching the substructure 404 to the container 408. The substructure 404 may be attached to the container 408 using bolts, screws, or welding.
The substructure 404 may be adjustable. The substructure can extend (e.g. be pulled out from the container 408) or retract (e.g. be pulled in towards the container 408). Advantageously, the adjustability of the substructure 404 allows the curtain-ventilate façade 400 to be extended or retracted. The curtain-ventilated façade 400 can be extended or retracted so as to be positioned flush with a curtain-ventilated façade of another housing module. Without the adjustability of the curtain-ventilated façade 400, making the curtain-ventilated facades of adjacent housing modules flush may be difficult.
The substructure 404 includes a sill 416 at the base of the substructure 404. The sill 416 may protect and close the curtain-ventilated façade 400. The sill 416 may drain rainwater from the curtain-ventilated façade 400 to the soil.
The curtain-ventilated façade 400 also includes an insulation mortar 420 and an insulation 424. The insulation mortar 420 is applied to the substructure 404 and provides a substrate for the insulation 424. The insulation 424 is applied to the insulation mortar 420. The curtain-ventilated façade 400 also includes a plurality of fasteners 428 for affixing the insulation 424 to the container 408.
The layers of curtain-ventilated façade 400 may be arranged in the order shown in FIG. 4 in order to act as a thermal barrier and air barrier. Using the layered arrangement of the curtain-ventilated façade 400 allow any holes in an outward-facing surface of the container 408 to be sealed to obtain a surface that can act as a vapor barrier.
The curtain-ventilated façade 400 includes a wire lath 432. The wire lath 432 provides a backing material for plaster. Plaster is applied to the wire lath 432 and includes a first coat 436 and a second coat 440. The first and second coats 436, 440 protect the insulation 424 from mechanical damage. The first and second coats 436, 440 act as an air barrier. The curtain-ventilated façade 400 also includes a sheathing 444. The sheathing 444 provides a surface to which a finishing material 448 can be applied. The sheathing 444 may include oriented strandboard, plywood, or the like. The finishing material 448 may be any suitable cladding solution. The finishing material 448 may include tile, stone, wood, composite, or the like. The finishing material 448 provides aesthetic appeal to the curtain-ventilated façade 400. The finishing material 448 contributes to the versatility and adjustability of the curtain-ventilated façade 400. The finishing material 448 provides a cladding solution that can be easily subtracted from or added to (when subtracting or adding a housing module) without damaging or losing materials.
A downspout 452 is positioned on top of the curtain ventilated façade 400 for carrying water from a roof (for example, roof module 500 of FIG. 5) to a drain or to ground level. The downspout 452 is positioned towards an edge 456 of the housing module 406 and runs vertically along the height of the curtain-ventilated façade 400.
The curtain-ventilated façade 400 is reversibly attached to the container 408. The fixing points 412 and fasteners 428 provide for simple attachment and removal of the components of the curtain-ventilated façade 400. The curtain-ventilated façade 400 can be removed from the container 408 without damaging the housing module 406 by unfastening the substructure 404 at the fixing points 412. Disconnecting the substructure 404 in this manner contributes to the modularity of the housing system. In an embodiment, one or more components of the curtain ventilated façade 400 are applied to the housing module 406 at the manufacturing site and transported as such, thereby reducing the need for on-site work.
Reversibly connecting the curtain-ventilated façade 400 to the container 408 simplifies the addition and removal of other housing modules to and from the housing module 406. The reversible connection of the curtain-ventilated façade 400 may be particularly useful when a second housing module is to be connected to the housing module 406. The addition of the second housing module may transform the outward-facing surface 402 of the container 408 to an inward-facing surface, such as where the outward-facing surface 402 of the container 406 is to be positioned adjacent to the second housing module. In such a case, the curtain-ventilated façade 400 can be removed from the outward-facing surface 402 of the container 408. Removal of the curtain-ventilated façade 400 facilitates removal of a stage transition section (for example, stage transition section 206 of FIG. 2) from the outward-facing surface 402 and formation of an intermodule aperture in the container 408. In a similar manner, one or more components of the curtain-ventilated façade 400 may be reapplied to the container 408 in the event that a previously inward-facing surface of the container 408 becomes an outward-facing surface as a result of the removal of the second housing module from the structure.
The curtain-ventilated façade 400 is adjustable. The curtain-ventilated façade 400 can be adjusted (e.g. moved further away from the container, moved closer to the container) in order to bring the curtain-ventilated façade 400 flush (or substantially flush) with a curtain-ventilated façade of an adjacent housing module. The adjustability of the curtain-ventilated façade 400 may advantageously provide a flush external system for an assembled modular housing structure.
The reversible connection of the curtain-ventilated façade 400 may also allow for changes to the design of the curtain-ventilated façade 400 over time, such as to account for different design preferences or needs of the same or different owners.
The curtain-ventilated façade 400 may be reusable. The curtain-ventilated façade 400 may be reused on another housing module of the same structure or as a curtain-ventilated façade for a housing module of another structure. Removal and reapplication of the curtain-ventilated façade 400 may include disassembling the components and reassembling on the new housing module. Reused components of the curtain-ventilated façade 400 may include the metal base (e.g. substructure 404) and exterior components. The components of the curtain-ventilated façade 400 may be disassembled and transported to a manufacturing or storage site. The transported components can be used at a later time for reassembly with the same or other components. Reuse of curtain-ventilated façade 400 components may reduce costs associated with the modular housing system.
Referring now to FIG. 5, shown therein is a cross-section view of a roof module 500 for use in a modular housing system, such as system 100, according to an embodiment. The roof module 500 is applied to a container 502 to make the top of a housing module 504 suitable for human habitation. More particularly, the roof module 500 is connected to an outward-facing surface of a ceiling 505 of container 502 using a module-to-roof connector (for example, module-to-roof connector 130 a of FIG. 1A)
The roof module 500 includes a plurality of layers and components. The roof module 500 may manufactured at manufacturing site 106 of FIG. 1. The roof module 500 includes a modular roof truss system having a wood truss 506. The wood truss 506 provides a structural framework and support for the roof module 500. The wood truss is encased in a sheathing 510. The sheathing may be constructed from oriented strandboard, plywood, or the like. The modular roof truss system includes an insulating material 514 encased within the sheathing 510. The modular roof truss system is secured directly to the container 502 via a module-to-roof connector.
The module-to-roof connector includes a twist lock 518. The twist lock 518 may be positioned at or near an edge 520 of the ceiling 505 of the container 502. The twist lock 518 may be positioned at corners of the container 502. The corners of the container 502 may include standard container holes into which the twist lock 518 can be inserted. The twist lock is configured to restrict horizontal and vertical movement of the housing module 504 relative to the roof module 500. In an embodiment, the twist lock 518 includes a first inserting portion that inserts into the bottom of the roof module 500 and a second inserting portion that inserts into the top of the housing module 504. The twist lock 518 can be fitted with a key for unlocking.
The roof module 500 also includes a membrane 526. The membrane 526 moves water off the roof module 500. The membrane 526 may also prevent leaks in the roof module 500, may reflect sunlight, and may repel unwanted materials such as dirt and dust. In an embodiment, the membrane 526 is a thermoplastic material. In a particular embodiment, the membrane 526 is a polyvinyl chloride (PVC) membrane.
Membrane 526 may promote efficient joining and separation of a plurality of roof modules 500, providing increased modularity. For example, the roof module 500 can be joined to an adjacent roof module by welding a joining strip of membrane connecting the membrane 526 of the roof module 500 to a membrane of the adjacent roof module. This action may form a continuous membrane 526 for the modular housing structure. The roof module 500 can be separated from the adjacent roof module by severing (e.g. cutting or the like) the joining strip of membrane. Once severed, the roof module 500 (or the adjacent roof module) can be removed. Removal of the roof module 500 may facilitate addition of a housing module on top of the housing module 504, or removal of the housing module 504 from the modular housing structure.
The roof module 500 includes a rigid insulation layer 522. The rigid insulation layer 522 is positioned on top of the sheathing 510 of the modular roof truss system. The rigid insulation layer 522 protects the membrane 526 from penetration that may occur if the membrane 526 is in contact with the sheathing 510.
The roof module 500 also includes a plurality of fasteners 530 for securing the rigid insulation layer 522 and membrane 526 to the sheathing 510.
The roof module 500 includes an integrated roof drain 534. The roof drain 534 is configured to carry water from a top surface 550 of the roof module 500 to a drain or to ground-level. The roof drain 534 is joined with a downspout (e.g. downspout 452 of FIG. 4).
The roof module 500 also includes wood planks 536. The wood planks 536 create an attic. The wood planks 536 are positioned along the exterior edges of the roof module 500, particularly along the portion that extends beyond the edge 520 of the container 502. At the edge 520 of the container 502, an edge insulation piece 537 is positioned between the rigid insulation layer 522 and the membrane 526. The edge insulation piece 537 is positioned to provide an easy transition to the membrane 526 from the horizontal roof going up to the attic.
The roof module 500 includes a coping cap 538. The coping cap 538 covers and/or shields the membrane 526. The coping cap 538 prevents water from getting behind the curtain-ventilated façade 400. In an embodiment, the coping cap 538 is a metal coping cap. The coping cap 538 is applied to the upper edges of the roof module 500 near the edge 520 of the container 502.
The roof module 500 also includes finishes 542. The finishes are applied to one or more outward-facing surfaces of the roof module 500. The finishes 542 provide for aesthetic appeal of the roof module 500. The finishes 542 may provide water protection for the roof module 500.
Referring now to FIGS. 6A, 6B, and 6C, shown therein are top, front, and side views, respectively, of the roof module 500 applied to the container 502 as part of a modular housing structure.
Referring now to FIG. 7, shown therein is a side cross-section view of a modular housing structure 700, according to an embodiment. The modular housing structure 700 is suitable for habitation by a human 702. The modular housing structure 700 is a completed structure at a build site having an adjustable living space. Structure 700 is shown in a first stage of a multi-stage development process and comprises a single-floor indoor space. Structure 700 includes a first housing module 704. The first housing module 704 is positioned horizontally adjacent to a second housing module (not shown) and linked via an intermodule connector (for example, intermodule connector 1000 of FIG. 10). The first housing module 704 and the second housing module are collectively referred to as “ground-level housing modules” and generically as “ground-level housing module.” Each of the first and second housing modules includes an intermodule aperture in a wall that is positioned adjacent to the other housing module in order to create a continuous living space 706. All of the features described with reference to the first housing module 704 can be considered applicable to the second housing module as well.
Various modifications made to one or more surfaces 710 a, 710 b, 712 a, 712 b, 714 a, 714 b, 716 a, 716 b of the containers to make the structure 700 suitable for habitation by human 702 will now be described. In each case, functional and cosmetic modifications may be made in accordance with the pre-build design. The first housing module 704 includes a container (such as container 126 of FIG. 1) having a base 710, ceiling 712, and walls 714, 716.
The structure 700 includes base thermal insulation 720. The base thermal insulation 720 is applied to the outside surface 710 b of the container base 710. The structure 700 also includes base thermal/noise insulation. The thermal/noise insulation is applied to the inside surface 710 a of the container base 710. The structure 700 also includes a floor finishing material 724. The floor finishing material 724 provides aesthetics. The floor finishing material 724 is applied on top of the thermal/noise insulation to complete the inside base surface 710 a of the housing module 704.
The structure 700 includes a ceiling vapor barrier. The ceiling vapor barrier may be part of the container ceiling 712. The ceiling vapor barrier prevents diffusion of moisture through the ceiling 712. The ceiling vapor barrier prevents moisture from damaging the insulation of the structure 700. The structure 700 may also include vapor barriers in the base 710 and walls (e.g. walls 714, 716).
The structure 700 also includes ceiling finishes 727 such as drywall, taping, and interior colour. The ceiling finishes 727 may be applied on top of the vapor barrier 726.
The structure 700 includes a roof module 728 applied to the outside surface 712 b of the container ceiling 712. The roof module 728 includes a modular wood truss system 732 providing the structural frame of the roof module 728. The roof module 728 may also have an air space for ventilation. The roof module 728 also includes thermal insulation 756 for energy conservation and maintaining a comfortable indoor climate for the structure 700. Within the roof module 728, the thermal insulation 756 is situated around the modular wood truss system 732.
The roof module 728 includes a PVC roof membrane 758 applied to the top surface of the modular wood truss system 732. The PVC membrane 758 may provide quick and easy waterproofing between adjacent roof modules. Waterproofing may be achieved by hot air welding a strip (e.g. 6″ strip) of PVC membrane along a joining line (the joining line defines where the first roof module is joined with the second roof module). Separating adjacent roof modules may be achieved in a similarly quick and easy manner. The joining strip can be severed (e.g. along the middle) such as by cutting. The roof membranes can be detached from the adjacent roof modules. The attachment and detachment of a roof module in this manner can be done multiple times. Accordingly, the PVC roof membrane 758 (and the joining strip) promotes the modularity of the structure 700.
The structure 700 includes a roof drain 760. The roof drain 760 may be embedded in the roof module 728. The roof drain 760 is connected to a drain pipe 762 that runs from the roof drain 760 through the roof module 728 and vertically down a side of the housing module 704. The drain pipe 762 may be included in the roof module 728 at the manufacturing site to make assembly easier.
The roof module 728 can also include soffit ventilation 762. The soffit ventilation 762 includes a soffit vent 764 embedded in the underside of the roof module 728. Particularly, the soffit vent 764 may be positioned on the underside of an overhang portion of the roof module 728, the overhang portion being a segment of the roof module 728 that extends beyond a side 768 of the housing module 704. The soffit ventilation 762 permits fresh air to be drawn into the roof module 728 via the soffit vent 764. The soffit ventilation 762 also provides ventilation to eliminate moisture.
The structure 700 includes a module-to-roof connector 736 for connecting the roof module 728 to the housing module 704. Particularly, the module-to-roof connector 736 may connect the modular wood truss system 732 to the container ceiling 712 of the first housing module 704.
Referring now to FIG. 8, a zoomed-in side view of the module-to-roof connector 736 is shown. The module-to-roof connector 736 includes a twist lock 740. The twist lock 740 includes a first connection portion 804 for connecting to the bottom of the roof module 728 through the modular wood truss system 732. The first connection portion 804 may be a metal rectangular pipe.
The twist lock 740 includes a second insertion portion 808 for inserting into a cavity 824 in the top of the housing module 704. The twist lock 740 can be fitted with a key for unlocking.
The roof module 728 connects to the housing module 704 (at the corners of the container of the housing module 704 into the cavity 824) by insertion of a fastener 816 (e.g. a screw) into the trusses (of modular wood truss system 732), which are the structural component of the roof module 728. First connection portion 804 and second connection portion 808 connect to the roof module 728.
The first connection portion 804 may run the width of the roof module 728, The first connection portion 804 may ensure weight distribution of the roof module 728 to the structural container. First connection portion 804 may be fixed in place by welding the first connection portion 804 to the twist lock 740. The twist lock 740 is inserted into the cavity 824. The twist lock 740 includes one or more twist lock levers 820. By twisting the lever 820 the twist lock 740 connects the roof module 728 to the housing module 704. The twist lock cavity 824 may be fitted with a twist lock key. The twist lock key prevents unauthorized persons from detached the roof module 728 from the housing module 704.
The module-to-roof connector 736 promotes easy detachment of the roof module 728 from the housing module 704 to allow the addition of an extra housing module (or subtraction of a housing module) and the reuse of the same roof module 728.
Referring again to FIG. 7, the structure 700 includes wall finishes 771. Wall finishes 771 may include drywall, taping, and interior colour. The wall finishes 771 may be applied to the container walls 714, 716 to complete the indoor space and make it suitable for habitation by the human 702.
Thermal insulation is applied to the outside surfaces 714 b, 716 b of the container walls 714, 716. An air barrier is positioned on top of the thermal insulation. Plaster applied to a wire lath (e.g. first and second coats 436, 440 applied to wire lath 452 of FIG. 4) may act as the air barrier.
The structure 700 also includes a curtain-ventilated façade 769 (for example, curtain-ventilated façade 400 of FIG. 4) applied to the outside surfaces 714 b, 716 b of the container walls 714, 716. Specifically, the curtain-ventilated façade 769 may be applied on top of the air barrier. An air space may be left between the air barrier and the curtain-ventilated façade 769. The air space provides space for the curtain-ventilated façade 769 to be adjusted relative to the container wall 714, 716. The adjustability allows the curtain-ventilated façade 769 to be brought flush with a curtain ventilated façade 769 of an adjacent housing module in order to provide a flush external system for the structure 700. The air space also permits evacuation or evaporation of water forming or entering behind the curtain-ventilated façade 769. The air space also forms a space that permits drainage of ventilation of structure 700 with the help of weep holes. In an embodiment, the curtain-ventilated façade 769 is curtain-ventilated façade 400 of FIG. 4.
The structure 700 includes weep holes. In some cases, the weep holes may be gaps in the curtain-ventilated façade 769. The weep holes provide ventilation of the internal wall cavity, which may extend the life of the structure 700 by reducing mildew, dry rot, and damp. The weep holes also provide drainage for water that enters the cavity, which may be caused by such factors as capillary action, condensation, damage, or accidental flooding. The structure 700 also includes a wall air ventilation system that includes an air cavity 772 and a vent. The air cavity 772 is a column that traverses the height of the curtain-ventilated façade on each of the container walls 714, 716. The vent allows air from outside the structure 700 to enter the air cavity 772.
The modular housing structure 700 includes a foundation connector 774 for connecting the first housing module 704 to a foundation 775. Thermal insulation 776 can be applied to an outside surface of the foundation 775 to prevent heat loss.
Referring now to FIG. 9, a zoomed-in side view of the foundation connector 774 is shown. The foundation connector 774 includes a twist lock 777. The twist lock 777 is welded to a plate 922 that rests on the foundation 775. The twist lock 777 includes an insertion portion 901 that inserts into a cavity 902 in the bottom of the first housing module 704. The twist lock 777 may be fitted with a key for unlocking.
The twist lock 777 includes a twist lock lever 904. By twisting the lever 904 the twist lock 777 connects the housing module 704 to the foundation 775. The twist lock cavity 902 may be fitted with a twist lock key. The twist lock key prevents unauthorized persons from detached the housing module 704 from the foundation 775.
The first housing module 704 is connected to the second housing module via an intermodule connector (for example, intermodule connector 1000 of FIG. 10). The intermodule connector restricts horizontal movement of the first housing module 704 relative to the second housing module.
Referring now to FIG. 10, shown therein is a side view of an intermodule connector 1000 for use in modular housing structure 700, according to an embodiment. The intermodule connector 1000 includes a bridge fitting with an extension rod 1002. A first bridge fitting component 1002 is inserted into the container of the first housing module 704 and a second bridge fitting component 1004 is inserted into the container of the second housing module 1008. The extension rod 1006 is inserted through the first and second bridge fitting components 1002, 1004 and fastened using a fastener 1010 to secure the containers.
Referring now to FIG. 11, shown therein is a side cross-section view of a modular housing structure 1100 for human habitation, according to an embodiment. Structure 1100 is established at the build site of FIG. 7 by increasing the adjustable living space of structure 700 via addition of housing modules to the structure 700. The modular housing structure 1100 thus represents a second stage of a multi-stage development process started in FIG. 7. Structure 1100 is a multi-level structure suitable for habitation by a human 1102. The added housing modules include a third housing module 1104 and a fourth housing module (not shown) that together form a second floor of the structure 1100. The third housing module 1104 and the fourth housing module may be referred to collectively as “upper-floor housing modules”, and generically as “upper-floor housing module”. The third housing module 1104 is positioned vertically adjacent to the first housing module 704 and the fourth housing module is positioned vertically adjacent to the second housing module.
Vertically adjacent ground-floor and upper-floor housing modules, such as the first housing module 704 and the third housing module 1104, are linked via an intermodule connector 1108. The intermodule connector 1108 restricts horizontal movement of the first and third housing modules 704, 1104 relative to each other.
Referring now to FIG. 12, a zoomed-in side view of the intermodule connector 1108 for connecting vertically adjacent housing modules is shown, according to an embodiment. The intermodule connector 1108 includes a double twist lock 1112 having two inserting portions. A first inserting portion 1201 of the double twist lock 1112 is insertable into a cavity 1202 in the first housing module 704. The cavity 1202 may be a corner cavity at the bottom of the third housing module 1104. The first insertion portion 1201 twists and locks into the cavity 1202 when activated by a twist lock lever 1203
The double twist lock 1112 also includes a second insertion portion 1204 that is insertable into a cavity 1205 in the third housing module 1104. The second insertion portion 1204 twists and locks into the cavity 1205 when activated by the twist lock lever 1203. The double twist lock 1112 may include a key for unlocking the double twist lock 1112. In other embodiments, the double twist lock 1112 may not have a key. The key may ensure that the connected containers are not detached by unauthorized persons. Detachment may be done by opening the twist lock key, which may be a rod that blocks the twisting of the lever 1203 into the open position (which twists the insertion portion 1201, 1204 open in the cavity 1202, 1205.
Referring back to FIG. 11, the third housing module 1104 and the fourth housing module are positioned horizontally adjacent to one another and linked via an intermodule connector (intermodule connector 1300 shown in FIG. 13). The third housing module 1104 and the fourth housing module each include an intermodule aperture. The intermodule apertures of the third housing module 1104 and the fourth housing module are aligned such that the upper-level housing modules define a continuous living space 1116.
The roof module 728 from the first stage is detached from the first housing module 704 by disconnecting the module-to-roof connector 736 and removed to facilitate addition of the upper level housing modules to the ground-floor housing modules. The detached roof module 728 may be reattached to the top of an upper level housing module (e.g. the third housing module 1104) using the module-to-roof connector 736.
To make the upper-level housing modules suitable for habitation by the human 1102, various modifications to the surfaces of the upper-level housing modules are made. In many cases, these modifications are similar to those made to the ground-level housing modules in the first stage.
The structure 1100 may include thermal insulation applied between the outside surface 712 b of the container ceiling 712 of the first housing module 704 and an outside surface 1120 b of a container base 1120 of the third housing module 1104. The structure 1100 also includes thermal/noise insulation is applied to an inside surface 1120 a of the container base 1120 of the third housing module 1104. A floor finishing may be applied to the container base 1120 on top of the thermal/noise insulation to complete the floor of the third housing module 1104.
The structure 1100 includes a roof module 1128. In an embodiment, the roof module may be the roof module 728 of the structure 700 that has been disconnected and detached from the first housing module 704 and applied to the third housing module 1104. In other embodiments, the roof module 1128 may incorporate components from detached roof module 728. The structure, function, and application of the roof module 1128 is the same as roof module 728 of FIG. 7. The roof module 1128 is connected to the third housing module 1104 via a module-to-roof connector 1132. The module-to-roof connector 1132 may be structurally and functionally similar to or the same as the module-to-roof connector 736 of FIG. 7. The module-to-roof connector 1132 includes a twist lock 1134.
Various features and components of structure 700 described with reference to FIG. 7 may be duplicated or extended, where appropriate, for the upper level housing modules. Such duplication and extension of components and features is intended to make the upper-level housing modules, and thus the structure 1100, suitable for habitation by the human 1102. Those components and features applied to the first housing module 704 in the first stage that may be duplicated or extended for (i.e. applied to) the third housing module 1104 will now be evident to a person of skill in the art. Such components and features include various modifications to the surfaces of the container of the first housing module 704.
Generally, components or features applied to the container walls 714, 716 of the first housing module 704 that are intended to span all or substantially all of the height of the non-roof structure are extended to span the new height of structure 1100 in FIG. 11. Examples of such components or features include the curtain-ventilated façade 769 and the wall air ventilation system 772.
The structure includes a curtain-ventilated façade 1136. The curtain-ventilated façade 1136 is applied to the outward-facing surfaces 1140 b, 1142 b of the container walls 1140, 1142 of the third housing module, and to the outward-facing surfaces 714 b, 716 b of the container wall 714, 716 of the first housing module. The curtain ventilated façade 1136 may include the curtain ventilated façade 769 from FIG. 7 and a new portion of curtain-ventilated façade applied to the upper-level housing modules. In such a case, the curtain-ventilated façade 769 and the new curtain-ventilated façade may be blended or merged to form curtain-ventilated façade 1136. In other embodiments, the curtain-ventilated façade 769 may be removed from the ground level housing modules and replaced with a new curtain-ventilated façade 1136.
The modular housing structure 1100 includes a wall air ventilation system 1144. The wall air ventilation system 1144 spans substantially the height of the connected first and third housing modules 704, 1104 and is structurally and functionally similar to the wall air ventilation system 772 of FIG. 7.
The structure 1100 also includes a drain pipe 1122. The drain pipe 1122 carries water from the roof module 1128 to the ground. The drain pipe is integrated with the roof module 1128 in the same manner as the drain pipe 762 integrates with the roof module 728 in FIG. 7. The drain pipe 1122 traverses a side of the structure 1100 from the roof module 1128 to the bottom of the curtain-ventilated façade 1136.
Referring now to FIG. 13, shown therein is a schematic side view of intermodule connectors 1300 used to connect housing modules in the modular housing structure 1100 of FIG. 11 according to an embodiment. The intermodule connectors include a plurality of bridge fitting and extension rod fasteners 1304 and a plurality of double twist locks 1112. The plurality of bridge fitting and extension rod fasteners 1304 connect the first housing module 704 to the second housing module 1308 and the third housing module 1104 to the fourth housing module 1312, restricting relative vertical movement. The plurality of double twist locks 1112 connect the first housing module 704 to the third housing module 1104 and the second housing module 1308 to the fourth housing module 1312.
Referring now to FIGS. 14 and 15, illustrated therein are embodiments of the modular housing structure described with reference to FIGS. 7 to 13. Specifically, FIG. 14 shows a modular housing structure 1400 in a first stage including a ground level and a basement 1404. FIG. 15 shows a modular housing structure 1500 in a second stage including a ground level, an upper level, and a basement. As can be seen from FIGS. 14 and 15, the modular housing systems of the present disclosure can be easily modified to include a basement level (thus further increasing the adjustable living space) with minimal changes to overall design and components. Particular example methods for use and implementations of the systems will now be described.
Referring now to FIG. 16, shown therein is a flow chart of a method 1600 of forming a modular housing structure, according to an embodiment. The method 1600 may be implemented using the modular housing system 100 described above. Method 1600 can be used to adjust the living space of a modular housing structure (such as the modular housing structure 102 of FIG. 1) in a plurality of stages. Adjusting the living space of the structure may include adding housing modules to the existing structure and/or removing housing modules from the existing structure. Adjusting the living space is done at a build site. Initially, the modular housing structure includes a first housing module. The first housing module may already be connected to a foundation at the build site. In an embodiment, the first housing module has already defined the adjustable living space of the structure in a prior stage (that is, the structure at the build site may be complete and suitable for human habitation).
At 1602, material is removed from the first housing module to allow formation of an intermodule aperture in a side of the first housing module. Removal of material may be directed by the pre-build design. The removed material includes a stage transition section. In some cases, removal of the stage transition section may include cutting a section of material from the side of the housing module to form the intermodule aperture. The removed material may also include a façade (for example, façade 116 of FIG. 1) or a portion thereof. For example, material removal may include detaching a portion of curtain ventilated façade applied to the side that is to have the intermodule aperture. The removed material may include a window. Removal of the window may create an aperture for connecting and adjacent housing module or stair module. The window may be a floor-to-ceiling window. Removed material may be transported from the build site. Removed material may be stored for future use with the structure or repurposed.
At 1604, a second housing module is positioned adjacent to the first housing module at the build site. Positioning of the second housing module is determined by the pre-build design. Depending on the layout of housing modules in the pre-build design, the second housing module may be positioned horizontally or vertically adjacent to the first housing module. A foundation needed can be done on-site for the second housing module.
The second housing module includes a first intermodule aperture. The first aperture is in a first side of the second housing module that is adjacent to the side of the first housing module including the intermodule aperture. Aligning the respective intermodule apertures allows the first and second housing modules to define a continuous space that is greater than that of the first housing module alone. The second housing module may be manufactured and transported including the intermodule aperture. Alternatively, the second housing module may be manufactured and transported to the build site including a first stage transition the removal of which establishes the first intermodule aperture. The first stage transition section may be removed from the second housing module at the manufacturing site or the build site.
At 1606, the second housing module is connected to the foundation using a foundation connector. This step may not be necessary if the second housing module is positioned vertically adjacent to the first housing module at 1604.
At 1608, the second housing module is connected to the first housing module using one or more intermodule connectors. Depending on whether the housing modules are positioned horizontally adjacent or vertically adjacent, different intermodule connectors may be used. Connection of the first and second housing modules restricts their movement relative to one another. Restricting relative movement may increase stability of the structure.
Once connected, additional features such as a roof module and a curtain-ventilated facade may be applied to the outward-facing surfaces of the housing modules, where appropriate.
The next steps of method 1600 demonstrate how the adjustable living space established according to 1602 to 1608 can be further adjusted. Further adjustment of the living space may include an addition stage or reduction stage. The option of increasing or decreasing the adjustable living space through addition or removal of housing modules provides the owner or habitant with flexibility to adjust the living space as his/her needs evolve.
At 1610 to 1614, there is an addition stage. At 1610, material is removed from the second housing module to allow the formation of a second intermodule aperture. Material removal may be done in a manner similar to 1602. The second intermodule aperture is established in a second side of the second housing module.
At 1612, a third housing module that has been transported to the build site is positioned adjacent to the second side of the second housing module. As at 1604, positioning is determined by the pre-build design. In other embodiments, the third housing module may be positioned adjacent to the first housing module. In such cases, the material removal of 1610 can be performed on the first housing module. Depending on the the pre-build design layout, the third housing module may be positioned horizontally or vertically adjacent to the second side of the second housing module. In this particular embodiment of method 1600, the third housing module is positioned vertically adjacent to the second side of the second housing module.
The third housing module includes an intermodule aperture. The aperture is established in a side of the third housing module that is adjacent to the second side of the second housing module. Aligning the intermodule aperture of the third housing module with the second intermodule aperture of the second housing module allows the second and third housing modules to define a continuous space, together with the first housing module, that is greater than that of the first and second housing modules alone. As with the second housing module, the intermodule aperture may be established in the third housing module at the manufacturing site and transported to the build site or, alternatively, at the build site (such as by removal of a stage transition section).
At this point, in embodiments of method 1600 wherein the third housing module is to be used on the ground floor of the structure, the third housing module may be connected to the foundation in a manner similar to the second housing module described at 1606.
At 1614, the third housing module is connected to the second housing module using one or more intermodule connectors (as at 1608). Connecting the third housing module to the second housing module using the intermodule connector restricts their movement relative to one another, contributing to an increased stability of the structure.
Once connected, additional features such as a roof module and a curtain-ventilated facade may be applied to the outside surfaces of the housing modules, where appropriate, to make the structure suitable for human habitation.
At 1616 to 1620, there is a reduction stage. At 1616, the second housing module is disconnected from the first housing module. This is achieved by disengaging the intermodule connector by unlinking connector elements on the respective first and second housing modules. This may include disengaging a twist lock component of the intermodule connector followed by any remaining components. The foundation connector connecting the second housing module to the foundation is also disconnected.
At 1618, the disconnected second housing module is removed from the build site. The second housing module and its attached features can be transported together or separately from the build site and may be stored for future use or repurposed.
At 1620, the intermodule aperture in the first housing module that is used to establish a continuous space with the second housing module is closed. To do this, the stage transition section may be transported to the site from a manufacturing or storage facility and attached to the first housing module. Additional features previously removed from the first housing module to facilitate connection of the second housing module may be added to the first housing module to make it complete and suitable for human habitation. This may include, for example, attaching a curtain-ventilated façade to the side that previously had the aperture. The curtain-ventilated façade may be from the second housing module. Additional features needed to complete the structure may be transported to the build site from a manufacturing or storage site, as appropriate. In some cases, features from the second housing module (e.g. the curtain-ventilated façade) may be reused,
Depending on the orientation of the housing modules in the modular housing structure, addition steps 1602 to 1608 or addition steps 1610 to 1614 may include the addition and connection of a stair module (if the structure is a multi-level structure). Similarly, the reduction stage of steps 1616 to 1620 may include the disconnection and removal of a stair module.
Referring now to FIG. 17, shown therein is a flow chart of an assembly method 1700 for a modular housing system, according to an embodiment. Using assembly method 1700, a modular housing structure can be designed, manufactured, and assembled in a manner that simplifies the home building process. Further, implementing method 1700 establishes a structure that is highly modular, where components can be added or removed easily and efficiently in order to transport or adjust the living space of the structure.
At 1702, a pre-build design is generated. The pre-build design is for a multi-stage modular housing structure development, and may include materials, specifications, dimensions, layout, and the like. In a particular case, the pre-build design includes a 3-in-1 home design accounting for three stages of development in one location. The pre-build design considers factors for all stages of development and design (e.g. foundation dimensions, intermodule apertures).
At 1704, housing modules and additional features are manufactured. This may occur at a designated manufacturing site. The container of the housing module is built to sustain a stage 3 structure (i.e. the structure for the largest adjustable living space of the structure as designed). Fixing points for a curtain-ventilated façade are placed on the container. Insulation is fastened to the container and a protection layer is applied to the insulation. A sealing material is installed on one or more edges or holes of the container. In some cases, the sealing material may be applied to the container selectively. That is, sealing material may be applied to only those edges of the container that will come into contact with another container based on the pre-build design. Selectively applying the sealing material in this manner may save manufacturing time and reduce material costs. The sealing material promotes an air tight fit between containers when fixed together. In a particular embodiment, the sealing material is rubber. Insulation may be applied at the manufacturing site.
In a particular embodiment of assembly method 1700, the following steps 1706 to 1710 are performed at the build site.
At 1706, a main structure is installed. Transported housing modules are connected to the foundation. The foundation may be an existing foundation with or without basement, screw piles, concrete slabs, or the like. Housing modules can be connected to the foundation using a foundation connector. Housing modules can be connected to each other using an intermodule connector. Connection mechanisms used such as foundation connectors and intermodule connectors may include twist locks (including single or double twist locks), twist lock keys, bridge fittings with extension rods, or the like.
At 1708, additional components such as a roof module (e.g. roof module 500 of FIG. 5) and external insulation are installed. The roof module can be connected to a housing module using an intermodule connector. Roof module-to-housing module connector elements (such as twist locks) attachable to the roof module may already be attached to promote efficient assembly. Spaces resulting from adjacent positioning and connection of housing modules and roof modules are filled with insulation to provide a thermal barrier and may be sealed to provide an air barrier. The roof module may be prepared at a designated manufacturing site.
At 1710, remaining elements of the curtain-ventilated façade are applied to outward facing surfaces of the housing modules forming the structure. This can include installation of finished panels on the substructure of the curtain-ventilated façade.
Referring now to FIG. 18, shown therein are multiple views of twist lock connection mechanisms 1800, according to a plurality of embodiments. The twist lock connection mechanisms 1800 include a single twist lock 1802. For example, single twist lock 1802 may be used as twist lock 822 of FIG. 8 or twist lock 777 of FIG. 9. The twist lock connection mechanisms 1800 include a twist lock key 1804. The twist lock key 1804 may be used to lock twist locks 822, 777, or 1112 of FIGS. 8, 9, and 12 respectively. The twist lock connection mechanism 1800 include a double twist lock 1806, The double twist lock 1806 may be used as double twist lock 1112 of FIG. 12.
While the above description provides examples of one or more apparatus, methods, or systems, it will be appreciated that other apparatus, methods, or systems may be within the scope of the claims as interpreted by one of skill in the art.

Claims

1. A modular housing system for defining a structure having an adjustable living space, comprising:

a first housing module for human habitation, the first housing module having an intermodule aperture traversing at least a section of a side;

a second housing module for human habitation, the second housing module having an intermodule aperture traversing at least a section of a side;

an intermodule connector for connecting the first housing module to the second housing module when the first and second housing modules are positioned such that their respective intermodule apertures are adjacent, thereby defining a continuous space;

wherein the adjustable living space of the structure can be adjusted in a plurality of stages, the stages comprising:

a first stage wherein the first housing module defines the adjustable living space of the structure;

a second stage wherein the first housing module and the second housing module define the adjustable living space of the structure, the first and second housing modules connected via the intermodule connector; and

a third stage wherein the first housing module defines the adjustable living space of the structure, the second housing module having been disconnected from the first housing module and removed so that the size of the adjustable living space of the structure is decreased relative to the second stage.

2. The system of claim 1, wherein the intermodule connector is configured to restrict vertical movement of the first housing module relative to the second housing module.

3. The system of claim 1, wherein the intermodule connector is configured to restrict horizontal movement of the first housing module relative to the second housing module.

4. The system of claim 1, further comprising a foundation connector for connecting the first housing module to a foundation.

5. The system of claim 1, further comprising a roof module connected to a top surface of the structure.

6. The system of claim 1, further comprising an adjustable curtain-ventilated façade applied to an outward-facing surface of the structure.

7. The system of claim 1, further comprising a connection mechanism comprising:

a first connector element attachable to the first housing module;

a second connector element attachable to a first housing module-linkable component;

wherein the first connector element and the second connector element are each adapted to connect to one another in such a way that restricts a movement of the first housing module relative to the first housing module-linkable component.

8. The system of claim 7, wherein the first housing module-linkable component is a foundation.

9. The connection mechanism of claim 7, wherein the first housing module-linkable component is a roof module.

10. The system of claim 7, wherein the restricted movement is horizontal movement.

11. The system of claim 7, wherein the restricted movement is vertical movement.

12. A housing module for use in a modular housing system having an adjustable living space, comprising:

a container for human habitation;

a connection mechanism attachable to the container for connecting the container to a container-linkable component in such a way that restricts a movement of the container relative to the container-linkable component.

13. The housing module of claim 12, wherein the container is an intermodal container.

14. The housing module of claim 12, wherein the restricted movement is horizontal movement.

15. The housing module of claim 12, wherein the restricted movement is vertical movement.

16. The housing module of claim 12, wherein the container-linkable component is another container.

17. A method of forming a modular housing structure having an adjustable living space, comprising:

providing a first housing module for human habitation, the first housing module comprising a first container having at least a section of a side absent;

connecting the first housing module to a second housing module via an intermodule connector, the second housing module comprising a second container having at least a section of a side absent;

wherein the first and second containers are positioned in such a way that their respective absent sections are adjacent, thereby defining a continuous space; and

wherein the first housing module is connected to the second housing module in such a way that the second housing module can be disconnected from the first housing module at a later stage to decrease the adjustable living space.

18. The method of claim 17, further comprising connecting the first housing module to a foundation.

19. The method of claim 17, wherein the intermodule connector is configured to restrict vertical movement of the first housing module relative to the second housing module.

20. The method of claim 17, wherein the intermodule connector is configured to restrict horizontal movement of the first housing module relative to the second housing module.