US20240011292A1

US20240011292A1 - Modular building assembly and wall cladding system

Info

Publication number: US20240011292A1
Application number: US18/350,592
Authority: US
Inventors: Ryan Samuel OLSEN
Original assignee: Quantum Assembly Corp
Current assignee: Quantum Assembly Corp
Priority date: 2022-07-11
Filing date: 2023-07-11
Publication date: 2024-01-11

Abstract

A modular building assembly may include one or more chassis blocks coupled together in a predetermined arrangement to form a structural frame of a building. The chassis blocks include a plurality of metal sections forming a rectangular prism. Each chassis block is configured to support wall, floor, and ceiling assemblies that form the sides of the chassis block. The wall assemblies include a frame fastened to a side of the chassis and a plurality of wall panels fastened to the frame. The wall panels are fastened to the frame flush with each other having butt joints adjoining adjacent edges of the wall panels. In some examples, each of the wall panels is prefabricated to a predetermined shape and size and configured to be fastened to the frame at a predetermined position, such that the panels are configured to fit together to form a cohesive wall surface on the frame.

Description

CROSS-REFERENCES

The following applications and materials are incorporated herein, in their entireties, for all purposes: U.S. Provisional Patent Application Ser. No. 63/388,089, filed Jul. 11, 2022.

FIELD

This disclosure relates to systems and methods for building construction. More specifically, the disclosed embodiments relate to modular building assemblies.

INTRODUCTION

Drywall is a common material used in the construction of interior wall and ceiling surfaces. Installation of drywall typically includes cutting the drywall to size on site and the use of tape, mud, and paint to finish the surface of the wall. As a result, the process of installing drywall is labor and time intensive.

SUMMARY

The present disclosure provides systems, apparatuses, and methods relating to building modules and wall cladding systems that have excellent sound insulation and fire resistance while avoiding the use of paperfaced gypsum drywall and related materials.
In some examples, a modular building assembly includes a modular chassis including a plurality of metal beams forming a rectangular prism; and an interior wall cassette installed on the chassis, the wall cassette comprising: a frame nested in a first side of the chassis; and a plurality of non-paperfaced wall panels fastened to the frame; wherein adjacent ones of the wall panels are flush and butt-jointed with each other, such that the plurality of wall panels collectively form a cohesive wall surface without further construction materials.
In some examples, a prefabricated wall cladding system includes a wall frame configured to be nested in a first side of a modular chassis, wherein the wall frame comprises a plurality of metal studs oriented in a first direction, wherein insulation is disposed between adjacent pairs of the metal studs; a plurality of metal channels oriented in a second direction transverse to the first direction, each of the metal channels being secured to one or more of the metal studs; and a plurality of non-paperfaced wall panels fastened to the metal channels, such that the panels are spaced from the metal studs by the metal channels; wherein an air gap exists between each of the panels and the insulation; and wherein adjacent ones of the wall panels are flush and butt-jointed with each other such that the panels fit together to form a cohesive wall surface on the wall frame.
Features, functions, and advantages may be achieved independently in various embodiments of the present disclosure, or may be combined in yet other embodiments, further details of which can be seen with reference to the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an illustrative wall panel in accordance with aspects of the present disclosure.

FIG. 2 is a cross-sectional view of the wall panel corresponding to line 2-2 of FIG. 1 .

FIG. 3 is a perspective view of a structural wall and ceiling frame in accordance with aspects of the present disclosure.

FIG. 4 is a schematic diagram of a wall of the structural frame of FIG. 3 .

FIG. 5 is a schematic diagram of an illustrative wall panel assembly configured to form a wall surface of the wall of FIG. 4 .

FIG. 6 is an isometric view of an illustrative wall and ceiling frame of an interior wall cladding system in accordance with aspects of the present teachings.

FIG. 7 is a schematic diagram of an illustrative wall panel assembly installed on a wall of the frame of FIG. 6 .

FIG. 8 is a schematic diagram of an illustrative wall panel assembly installed on a wall of the frame of FIG. 6 .

FIG. 9 is a schematic diagram of an illustrative ceiling panel assembly installed on the ceiling of the frame of FIG. 6 .

FIG. 10 is a flow chart depicting steps of an illustrative method of manufacturing a wall panel in accordance with aspects of the present teachings.

FIG. 11 is an isometric view of an illustrative modular building assembly in accordance with aspects of the present teachings.

FIG. 12 is an isometric view of a top side corner of an illustrative chassis of the modular building assembly of FIG. 11 .

FIG. 13 is a bottom view of a bottom side corner of the chassis of FIG. 12 .

FIG. 14 is an isometric view of an illustrative chassis with wall, floor, and ceiling assemblies in accordance with aspects of the present teachings.

FIG. 15 is a first exploded view of the wall, floor, and ceiling assemblies of FIG. 14 .

FIG. 16 is a second exploded view of the wall, floor, and ceiling assemblies of FIG. 14 .

FIG. 17 is a schematic diagram depicting a cross section of the wall assembly installed on the chassis of FIG. 14 .

FIG. 18 is a front elevation view of an illustrative wall assembly in accordance with aspects of the present teachings.

FIG. 19 is a cross-sectional view of the wall assembly of FIG. 18 corresponding to line 19-19 of FIG. 18 .

FIG. 20 is a cross-sectional view of the wall assembly of FIG. 18 corresponding to line 20-20 of FIG. 18 .

FIG. 21 is an isometric view of an illustrative floor and ceiling assembly in accordance with aspects of the present disclosure.

FIG. 22 is a cross-sectional view of the floor and ceiling assembly of FIG. 21 .

FIG. 23 is a magnified view of the indicated portion of FIG. 22 .

DETAILED DESCRIPTION

Various aspects and examples of a modular building assembly and wall cladding system are described below and illustrated in the associated drawings. Unless otherwise specified, a modular building assembly and/or wall cladding system in accordance with the present teachings, and/or their various components, may contain at least one of the structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein. Furthermore, unless specifically excluded, the process steps, structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein in connection with the present teachings may be included in other similar devices and methods, including being interchangeable between disclosed embodiments. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples and embodiments described below are illustrative in nature and not all examples and embodiments provide the same advantages or the same degree of advantages.
This Detailed Description includes the following sections, which follow immediately below: (1) Definitions; (2) Overview; (3) Examples, Components, and Alternatives; (4) Advantages, Features, and Benefits; and (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections, each of which is labeled accordingly.

Definitions

The following definitions apply herein, unless otherwise indicated.
“Comprising,” “including,” and “having” (and conjugations thereof) are used interchangeably to mean including but not necessarily limited to, and are open-ended terms not intended to exclude additional, unrecited elements or method steps.
Terms such as “first”, “second”, and “third” are used to distinguish or identify various members of a group, or the like, and are not intended to show serial or numerical limitation.
“AKA” means “also known as,” and may be used to indicate an alternative or corresponding term for a given element or elements.
“Elongate” or “elongated” refers to an object or aperture that has a length greater than its own width, although the width need not be uniform. For example, an elongate slot may be elliptical or stadium-shaped, and an elongate candlestick may have a height greater than its tapering diameter. As a negative example, a circular aperture would not be considered an elongate aperture.
“Coupled” means connected, either permanently or releasably, whether directly or indirectly through intervening components.
“Resilient” describes a material or structure configured to respond to normal operating loads (e.g., when compressed) by deforming elastically and returning to an original shape or position when unloaded.
“Rigid” describes a material or structure configured to be stiff, non-deformable, or substantially lacking in flexibility under normal operating conditions.
“Elastic” describes a material or structure configured to spontaneously resume its former shape after being stretched or expanded.
Directional terms such as “up,” “down,” “vertical,” “horizontal,” and the like should be understood in the context of the particular object in question. For example, an object may be oriented around defined X, Y, and Z axes. In those examples, the X-Y plane will define horizontal, with up being defined as the positive Z direction and down being defined as the negative Z direction.
“Providing,” in the context of a method, may include receiving, obtaining, purchasing, manufacturing, generating, processing, preprocessing, and/or the like, such that the object or material provided is in a state and configuration for other steps to be carried out.
In this disclosure, one or more publications, patents, and/or patent applications may be incorporated by reference. However, such material is only incorporated to the extent that no conflict exists between the incorporated material and the statements and drawings set forth herein. In the event of any such conflict, including any conflict in terminology, the present disclosure is controlling.

Overview

In general, a modular building assembly of the present disclosure includes one or more chassis blocks coupled to each other to form a structural frame of the building. Each chassis block includes metal beams, structural supports, or sections forming a rectangular prism. The chassis blocks may be arranged in any suitable manner to form the structural frame of the building, e.g., arranged adjacent to one another and/or stacked on top of one another. Each chassis block is configured to support wall, floor, and/or ceiling assemblies according to the intended purpose and/or desired layout. The chassis blocks and the wall, floor, and ceiling assemblies are configured to be prefabricated and transported to an installation site where the building is to be assembled.
Modular building assemblies of the present disclosure have a novel wall cladding system. The wall cladding systems may include a novel prefabricated and prefinished wall panel assembly fastened to a structural wall frame. In some examples, the structural wall frame is installed on one of the sides of the chassis block, and the wall panel assembly is fastened to the structural wall frame to form a wall of the chassis block. Similar or substantially identical systems may be utilized in an exterior application. Panels of the wall panel assembly have predetermined sizes and shapes, and can be fastened to the frame at predetermined positions, such that the panels fit together and collectively form a cohesive wall, floor, and/or ceiling surface. For example, adjacent panels may be butt-jointed and flush with each other, such that the panels form a continuous wall surface. Installation of the panels on the frame is a one-step process, including fastening each panel to the frame at the predetermined position (e.g., using screws).
The panels of the wall panel assembly are prefabricated and in some cases prefinished to facilitate an expedited process of installing the panels on the frame. In other words, the panels may be cut to selected sizes and shapes at a location different than the assembly site, such as at a manufacturing facility. In some examples, a face surface finish and/or an edge surface finish is applied to the panels. The panels of the panel assembly arrive at the assembly site having the predetermined size and shape and having a face surface finish and/or an edge surface finish. As a result, installing the panel assembly onto the frame does not include cutting the panels to size at the assembly site, nor does it include the use of tape, mud, spackle, caulk, plaster, or paint to finish the wall, ceiling, or floor surface formed by the panels.
Prefabricating the panels of the panel assembly facilitates precision manufacturing of each panel to a selected shape and size. In some examples, computer numeric control (CNC) equipment is utilized to cut the panel to the predetermined size and shape. The CNC equipment facilitates precise cutting of the panel. The panels are configured to be installed on the frame flush with each other and having butt joints at edges of adjacent panels to form the cohesive wall surface without any gaps. Precise cutting of the panels facilitates the adjacent edges being flush and using butt joints when installed on the frame, to provide excellent aesthetic qualities without needing further construction materials to cover up gaps, imperfections, and fasteners.
Panels of the panel assembly may vary in one or more different dimensions (e.g., length, width, thickness, etc.), and/or have different shapes depending on the intended positioning of the panel on the frame. The panels may have any shape, and/or size suitable for the predetermined positioning of the panel in forming the wall, ceiling, or floor surface. In some examples, the system includes specific types of panels, including wall, floor, ceiling, and/or trim panels. The dimensions and/or shape may be different for each type of panel. In some examples, the trim panels are configured to be installed at transitions between the floor and the wall, between the wall and the ceiling, or near windows or door frames. In some examples, the trim panels are configured to form a chase for the routing of electrical, data, and water lines.
The panels may comprise any suitable material configured to facilitate precision fabrication, and configured to receive a surface finish (e.g., film, paint, edge banding, etc.). In some examples, the panels comprise a non-combustible material. In some examples, the panels comprise magnesium oxide (AKA magnesia). Magnesium oxide (MgO) is non-combustible, resistant to mold and mildew, and is impact resistant. Magnesium oxide panels are configured to be precisely cut to exact dimensions and shapes. Magnesium oxide panels are configured to receive various surface finishes including films, paints, etc.
The panels of the wall panel assembly are prefinished, such that installation of the panel assembly does not require applying paint or any other surface finish to the panels. In some examples, prefinishing the panels includes applying a face surface finish and an edge surface finish to the panels. The face surface finish may include any suitable surface finish configured to be wear resistant and UV stable. In some examples, the face surface finish comprises a film, such as a polyethylene terephthalate (PET) film. PET films are wear resistant and UV stable. PET films provide an aesthetic surface finish and one or more of a variety of different PET films may be utilized, having different colors and/or surface textures. The PET film may be bonded to the panel using a cold bond adhesive, and/or any other suitable method. In some examples, the face surface finish may include paint, ceramic coatings, and/or any other suitable surface finish.
As mentioned above, panels of the present disclosure may further include an edge surface finish. The edge surface finish may comprise any suitable finished edge surface configured to facilitate the flush installation of the panels in a butt-jointed configuration. In some examples, edge banding is fastened to the edges of the panel. The edge banding may comprise acrylonitrile butadiene styrene (ABS) tape and/or any other suitable material. The edge banding may have any suitable thickness configured to provide a durable edge surface finish. In some examples, the edge banding extends around the entire periphery of the panel. The edge banding may be applied to the edge of the panel using automatic edge banding equipment, and/or using any other suitable method.
The structural frame of the wall, ceiling, and floor assemblies may include any suitable structure configured to support the wall, ceiling, and/or floor panel assemblies. In some examples, the structural frame comprises the chassis formed as the rectangular prism, and includes floor, wall, and ceiling cassettes forming the sides of the prism. In some examples, the floor, wall, and ceiling cassettes each comprise metal tracks fastened along opposite edges of a side of the chassis. A plurality of metal studs are slotted in the metal tracks and extend between the metal tracks to form wall, floor, and ceiling frames. The chassis and the wall, ceiling, and floor cassettes may comprise any suitable material configured to facilitate precise fabrication of the chassis, e.g., at tolerances of +/− 1/16″ or less. In some examples, the chassis comprises hollow steel sections (HSS) and the wall, floor, and ceiling cassettes comprise cold formed light gauge steel sections (LGS).
The panels are configured to be installed on the frame, such that adjacent edges of adjacent panels are flush with each other, with butt joints between the adjacent edges of the adjacent panels. The butt joints joining the adjacent edges of the adjacent panels are configured to be exposed. In other words, upon completion of assembly, the butt joints are configured to remain uncovered by tape, mud, paint, and/or any other substrate or covering. Instead, the panels are configured to fit tightly together to form a cohesive wall surface.
In some examples, the panels are configured to fit together such that any gaps between the flush adjacent edges of adjacent panels do not exceed 1/32″. Having the adjacent edges of the adjacent panels fit together tightly, such that the gaps between the adjacent edges of the panels are 1/32″ or less facilitates the panels collectively forming the cohesive wall surface while having exposed joints. Precise fabrication of the panels results in the ability to leave the inter-panel joints exposed without creating unsightly gaps or seams, facilitating an expedited installation process without using mud, tape, and/or paint. In some examples, the exposed butt joints are configured to provide flexion between the panels. In some examples, the frame may be transported with the panels installed. Flexion provided by the unconstrained butt joints facilitates transporting the frame without damaging the panels.
Installation of the panels on the frame is a one-step process wherein the wall, floor, ceiling, and trim panels are fastened to the frame using screws, adhesive, and/or any other suitable fasteners. In some examples, the panels are fastened to the metal studs of the wall, ceiling, and/or floor cassettes. In some examples, a metal hat channel is fastened to an interior side of the metal studs and the panels are fastened to the metal hat channel. In such examples, the metal hat channel may comprise an aluminum or steel channel having a trapezoidal cross section and a pair of flanges extending laterally from each end of the upper side of the trapezoidal channel. Each flange is fastened to the interior side of the metal studs and the panels are fastened to the bottom side of the trapezoidal channel.
A method of manufacturing the wall, floor, and ceiling panels in accordance with the present teachings may include applying a face surface finish to the panel, cutting the panel to a predetermined size and shape, predrilling the panel, and applying an edge surface finish to the panel.
Applying the face surface finish to the panel may include bonding a film, such as a PET film to the faces of the panel. The film may be bonded to the panel utilizing a cold bond adhesive, a polyurethane (PUR) hot melt adhesive, and/or any other suitable adhesive configured to create a delamination-resistant bond between the panel and the film. The film may be bonded to the panel using any suitable method configured to facilitate the delamination-resistant bond between the panel and the film and configured to bond the film to the panel at high speed. The film may have a variety of different colors, and/or textures. In some examples, applying the face surface finish includes applying paint, and/or a ceramic coating to the face of the panel.
The panel (including the face surface finish) is cut to a selected size and shape dependent on the predetermined position of the panel in the panel assembly. The panel may be cut utilizing any suitable method configured to precisely cut the panel to the correct shape and size. In some examples, the panel is cut to size using CNC equipment. The CNC equipment facilitates the precise cutting of the panel to the proper shape and size. In some examples, the panel is predrilled (e.g., using the CNC equipment) to speed up onsite assembly and facilitate even spacing of the fasteners (e.g., screws and/or bolts) utilized to fasten the panel to the frame.
An edge surface finish is applied to the edges of the panel to facilitate the flush, butt jointed installation of the panel with other panels of the panel assembly. The edge surface finish may comprise any suitable edge surface finish configured to facilitate the flush, butt jointed installation of the panels. In some examples, the edge surface finish comprises edge banding applied to each edge of the panel. The edge banding may be applied using an automatic edge banding machine, and/or any other suitable method. In some examples, the wall panels are unfinished with respect to their surfaces and/or edges. For example, a building module having uncoated MgO wall panels would be within the scope of the present disclosure.

Examples, Components, and Alternatives

The following sections describe selected aspects of illustrative building modules and wall cladding systems as well as related systems and/or methods. The examples in these sections are intended for illustration and should not be interpreted as limiting the scope of the present disclosure. Each section may include one or more distinct embodiments or examples, and/or contextual or related information, function, and/or structure.

A. Illustrative Wall Panel

As shown in FIGS. 1 and 2 , this section describes an illustrative interior wall, floor, and/or ceiling panel 100. Panel 100 is an example of the prefabricated and prefinished wall panels, described above.
Panel 100 is configured to be fastened to a structural frame of a building to form a portion of an interior wall, and/or ceiling panel assembly. Panel 100 and the other panels forming the interior wall, floor, and/or ceiling panel assemblies are configured to fit together, such that the panels collectively form a cohesive wall, floor, and/or ceiling surface on the frame. Panel 100 is prefabricated to a variable but preselected size and shape based on the expected positioning of panel 100 in the wall, floor, or ceiling assembly. As shown in FIG. 1 , panel 100 is an illustrative panel having a square shape with an equal length 101 and width 103. However, panel 100 may have any suitable shape and/or size dependent on the intended positioning of panel 100 on the wall, floor, or ceiling. Panel 100 may have any suitable thickness configured to provide a durable wall surface. Installation of panel 100 is a one step process including fastening the panel to a portion of a structural frame of the wall or ceiling without the use of tape, mud, or paint.
As shown in FIG. 2 , prefinished panel 100 includes a panel core 102, a finished face surface 104, and a finished edge surface 106. Panel core 102 may comprise any suitable material configured to facilitate precise cutting of the panel to predetermined dimensions, and configured to receive a face surface finish and an edge surface finish.
In some examples, panel core 102 comprises Magnesium oxide. Magnesium oxide is suitable for receiving paint, film, or other alternative finishes. Magnesium oxide may be cut to various shapes and sizes, and is non-combustible as well as mold and mildew resistant.
Panel core 102 may have any suitable shape and/or size depending on the intended positioning of panel 100 in the wall, floor, and/or ceiling assembly. For example, the panel core of a floor panel may have different thickness and/or shape than the panel core of a wall panel. In some examples, panel core 102 comprises magnesium oxide having a 12 mm thickness.
Finished face surface 104 is configured to increase the durability, wear resistance, and/or UV stability of panel core 102. Finished face surface 104 may comprise any suitable surfacing, such as a film, paint, or ceramic coating. In some examples, finished face surface 104 includes a PET film. PET films provide a durable, wear resistant, and UV stable surface finish. The PET film may be bonded to panel core 102 using any suitable method to create a delamination-resistant bond between panel core 102 and the film. The film may be bonded to the panel using a cold bond adhesive, Polyurethane (PUR) hot melt adhesive, and/or any other suitable adhesive configured to create the delamination-resistant bond between panel core 102 and the film. A variety of different PET films having a variety of different colors, and/or surface textures may be utilized to finish the face surface of panel 100.
Finished edge surface 106 is configured to provide a durable edge surface of panel 100 and facilitate butt-jointed installation of the panel with the other panels of the wall or ceiling panel assembly. Finished edge surface 106 may comprise any suitable edge surface finish configured to facilitate butt joining of the panels of the wall or ceiling assembly. For example, finished edge surface 106 may comprise edge banding (e.g., ABS tape). The edge banding may be bonded to the panel using a cold bond adhesive, Polyurethane (PUR) hot melt adhesive, and/or any other suitable adhesive configured to create a delamination-resistant bond between panel core 102 and the edge banding material. Edge banding may be applied to the panel 100 using an automated edge banding machine, and/or any other suitable method.
Panel 100 further includes preformed (e.g., predrilled) holes 108. Holes 108 facilitate quick assembly and proper (e.g., even) spacing of the fasteners (e.g., screws, bolts, etc.) used to fasten panel 100 to the frame of the building. As shown in FIG. 1 , panel 100 includes two rows of predrilled holes proximate a top and bottom edge of the panel. However, panel 100 may have any suitable arrangement and number of predrilled holes depending on the size and shape of the panel. In some examples, holes 108 are drilled into the panel utilizing CNC equipment.

B. Illustrative Frame and Wall Panel Assembly

As shown in FIGS. 3-5 , this section describes an illustrative frame 200 and an illustrative wall panel assembly 202. Frame 200 is an example of the frames described above. Wall panel assembly 202 is an example of an assembly of the wall panels described above, e.g., including wall panel 100.
Frame 200 includes a pair of chassis 204A, 204B disposed adjacent one another. Chassis 204A, 204B are substantially identical, and include metal sections forming a rectangular prism. Chassis 204A, 204B provide the primary structure of the frame and are configured to support prefabricated and prefinished wall and ceiling panel assemblies. Chassis 204A, 204B may have any suitable size and shape. Precise fabrication of chassis 204A, 204B may be performed at tolerances of +/− 1/16″ or less.
Precise fabrication of the chassis ensures the prefabricated panels of the panel assembly fit together on the frame to form a cohesive wall, ceiling, and/or floor surface on the frame. In some examples, chassis 204A, 204B have a smaller footprint (e.g., 10′ wide×20′ long by 11′ 6″ tall) as compared to typical building modules (12′-16′ wide and 40′-60′ long). The relatively small footprint facilitates the precision fabrication of the chassis to ensure the wall panels of the prefabricated wall panel assembly 202 fit together properly on the frame. Chassis 204A, 204B may comprise any suitable material configured to facilitate precise fabrication of the chassis and configured to support wall panel assembly 202. In some examples, chassis 204A, 204B comprises hollow steel sections (HSS). In some examples, chassis 204A, 204B are fastened to each other utilizing fasteners (bolts, screws, etc.), and/or any other suitable method.
As shown in FIG. 3 , frame 200 further includes wall and ceiling cassettes 206A-B, and 208A-B respectively) forming the sides of chassis 204A, 204B and forming wall and ceiling frames configured to support the attachment of wall and ceiling panels. Wall cassettes 206A, 206B each include metal track 210A-B, 211A-B fastened to a top edge and bottom edge of a respective side of chassis 204A, 204B. Wall cassettes further include a plurality of metal studs 212, 213 extending vertically from the bottom edge to the top edge of the chassis and slotted in the metal track. Similarly, ceiling cassettes 208A-B include metal track 214 fastened to opposite edges of a side of the chassis and include a plurality of ceiling joists 216 extending horizontally across the top side of the chassis and slotted in metal track 214. A floor 218A-B of each chassis may include a floor cassette similar to the wall and ceiling cassettes, described above.
The wall and ceiling cassettes may comprise any suitable material configured to facilitate precise fabrication of the cassette at tolerances of +/− 1/16″ or less, and configured to receive fasteners to attach the panel assemblies to the cassette. In some examples, the wall and ceiling cassettes comprise light gauge steel (LGS). In some examples, the panels of the wall panel assembly are fastened directly to the metal studs and ceiling joists of the wall and ceiling cassettes. In some examples, wall and ceiling cassettes (206A-B, and 208A-B respectively) further include one or more metal hat channels fastened to an interior side of the cassettes, and the panels of the wall panel assembly are fastened to the metal hat channel(s). In such examples, the metal hat channel may comprise a trapezoidal-shaped aluminum or steel channel having a pair of flanges extending from each end of the upper side of the trapezoidal channel. Each flange is fastened to the interior side of the metal studs and the panels are fastened to the bottom side of the trapezoidal channel.
FIG. 4 depicts a single side wall 209 of frame 200. As described above the frame includes two chassis 204A, 204B disposed adjacent each other and a respective wall cassette 206A, 206B filling the side of each chassis. Each wall cassette includes metal track 210B, 211B fastened to the top edge of chassis 204A-B and metal track 210A, 210B fastened to the bottom edge of chassis 204A-B respectively. A plurality of metal studs 212, 213 extend vertically from the bottom edge to the top edge of the chassis and each end of the metal studs is slotted in the metal track. The metal track may be fastened to the chassis utilizing screws, bolts, adhesive, or any other suitable method. In some examples, the metal studs are fastened to the metal track and/or the chassis itself utilizing screws, bolts, adhesive, and/or any other suitable method. Wall 209 further includes a door frame 222 formed in wall cassette 206A. Door frame 222 is bordered on each side by a pair of metal studs. Metal track 223 extends horizontally across the top of the door frame and metal studs 224A-B extend from metal track 223 to metal track 210B.
FIG. 5 depicts illustrative wall panel assembly 202 fastened to side wall 209 of frame 200. Wall panel assembly 202 includes a plurality of prefabricated and prefinished wall panels 224, a top edge trim panel 226, and a bottom edge trim panel 228. Wall panels 224, and trim panels 226 and 228 are sized and shaped and coupled to the frame at predetermined positions, such that the panels fit together and collectively form a cohesive wall surface 227.
Wall panels 224 are fastened to the frame flush with each other having butt joints 225 joining adjacent edges of adjacent panels. In some examples, each of the panels includes a finished edge surface (e.g., edge banding) configured to facilitate the butt joining of the panels. As shown in FIG. 5 , butt joints 225 joining the adjacent edges of adjacent panels are exposed. In other words, butt joints 225 are not covered by tape, mud, or paint. In some examples, gaps between the adjacent edges of adjacent panels are less than 1/32″. Having gaps between panels of 1/32″ or less facilitates the panels forming cohesive wall surface 227 and having exposed butt joints 225.
Trim panels 226 and 228 extend along the bottom edge and top edge of wall 209 to provide an aesthetic transition between the wall and floor surfaces, and the wall and ceiling surfaces. In some examples, trim panels 226 and 228 are installed having overlap joints 329A-B with the adjacent wall panels 224, such that the trim panels overlap an interior side of the adjacent wall panels. This configuration creates a space behind the trim panels which can be used as a chase for the routing of electrical, data, and/or water lines.
As shown in FIG. 5 , wall panels 224 have different shapes, and/or dimensions dependent on the positioning of the panel in wall surface 227. Each panel may have any suitable shape and/or size, such that collectively the panels of panel assembly 202 fit together to form cohesive wall surface 227. The panels are precisely cut to the specific size and shape, such that the panels fit together on frame 200 and any gap between adjacent edges of adjacent panels does not exceed 1/32″. Having gaps between panels of 1/32″ or less facilitates the panels forming cohesive wall surface 227 and having exposed butt joints 225.
In some examples, panels 224 are cut to the predetermined size and shape of the panel using CNC equipment. Utilizing CNC equipment to precisely cut the panels to the predetermined size and shape facilitates the flush, butt jointed installation of the panels on the frame and ensures that any gap between adjacent edges of adjacent panels does not exceed 1/32″. In some examples, the CNC equipment is utilized to predrill the panels to ensure even spacing of the fasteners used to fasten the panels to the metal studs of the frame. In some examples, the spacing of metal studs 212A-B corresponds to the positioning of the panels and the predrilled holes of the panels. Some of panels 224 include precut openings 229A-C for outlets or light switches.
Wall panels 224 may be fastened to the metal studs using screws, bolts, adhesive, and/or any other suitable method. In some examples, one or more metal hat channels and/or Z-shaped channels are fastened to an interior side of metal studs 212A-B and extend horizontally in rows from a left to right side of the wall. In such examples, wall panels 224 may be fastened to the metal hat channel and/or Z-shaped channels.
In some examples, panels 224 are removably fastened to metal studs 212A-B and/or the hat-shaped or Z-shaped channel, such that the panels are configured to be removed from the frame without damaging the frame or the panels. In some examples, the heads of the screws and/or bolts utilized to fasten the wall panels to the frame are exposed on a face surface of the wall panel, such that the fasteners may be accessed and removed. Removably fastening the panels to the frame facilitates removing and replacing damaged panels and accessing the interior of the wall. In some examples, the panels removable to access mechanical, electrical, and/or plumbing systems disposed in the wall. For example, trim panels 226 and 228 may be removable to access the data, electrical, and/or water lines disposed in the chase behind the trim panels. Alternatively, or additionally, the wall panels 224 may be removed to access mechanical, electrical, and/or plumbing components disposed in the wall assembly.

C. Illustrative Frame and Wall Panel Assembly

As shown in FIGS. 6-9 , this section describes an illustrative frame 300, illustrative wall panel assemblies 302A-B and an illustrative ceiling panel assembly 304. Frame 300 is an example of frame 200, described above. Wall panel assemblies 302A-B and ceiling panel assembly 304 are examples of panel assembly 202, described above.
FIG. 6 depicts frame 300 including wall frame 306A, wall frame 306B, and ceiling frame 308. Wall frame 306A may comprise any suitable structure configured to support wall panel assembly 302A. In some examples, wall frame 306A comprises a wall cassette including metal track 310A and 310B extending horizontally at top and bottom edges of the wall. A plurality of metal studs 312 are slotted in metal track 310A, 310B and extend from the bottom edge to the top edge of the wall. Wall frame 306B includes a similar arrangement to wall frame 306A including metal track 311A-B and metal studs 313. Ceiling frame 308 also includes a similar arrangement including metal joists 314 extending between metal track 316A and metal track 316B and slotted in the metal track at each end. In some examples, wall frames 306A, 306B and ceiling frame 308 are fastened to each other using screws, bolts, adhesive, or using any other suitable method.
Frame 300 including wall frames 306A-B and ceiling frame 308 is prefabricated to predetermined dimensions to facilitate the use of the frame with the prefabricated wall and ceiling panel assemblies. Frame 300 including the wall frames 306A-B and ceiling frame 308 may comprise any suitable material configured to support wall panel assemblies 302A-B and ceiling panel assembly 304. In some examples, frame 300 is fabricated at tolerances of +/− 1/16″. In some examples, the metal studs and metal track of wall frames 306A-B and ceiling frame 308 comprise light gauge steel (LGS). In some examples, wall frames 306A-B, and ceiling frame 308 are configured to infill respective sides of a chassis formed as a rectangular prism, as described above.
FIG. 7 depicts wall panel assembly 302A including a plurality of prefabricated and prefinished wall panels 318A-C and trim panels 319A-B fastened to wall frame 306A. Wall panels 318A-C and trim panels 319A-B are prefabricated to predetermined dimensions, such that the panels fit together to collectively form a cohesive wall surface 321 of wall frame 306A. FIG. 7 depicts one possible arrangement of panels forming a cohesive wall surface of wall frame 304A, but there are many other possible configurations of panels that could be used to create the cohesive wall surface of wall 304A.
As shown in FIG. 7 , wall panels 318A-C have a height 330A-C respectively and a width 331. Wall panels 318A-C may have any suitable dimensions, such that collectively the panels form cohesive wall surface 321 on wall frame 306A. For example, as shown in FIG. 7 , heights 330A and 330C of wall panels 318A and 318C are the same, but height 330B of wall panel 318B is larger than the heights 330A and 330C.
Wall panels 318A-C are installed flush with each other having butt joints 323A-B joining the adjacent edges of the panels. In some examples, the edge of each wall panel includes a finished edge surface (e.g., edge banding) configured to facilitate the butt joint joining of the panels. The gaps between adjacent edges of wall panels 318A-C do not exceed 1/32″. As shown in FIG. 7 , the butt joints 323A-B are exposed and not covered by tape or mud. Having the gaps between adjacent edges of the wall panels less than 1/32″ facilitates the panels collectively forming cohesive wall surface 321 without requiring taping, and/or mudding to cover the butt joints.
Trim panels 319A-B extend along the bottom edge and top edge of wall 306A to provide an aesthetic transition between the wall and floor surfaces, and the wall and ceiling surfaces. In some examples, trim panels 319A and 319B are installed having overlap joints with wall panels 318A and 318C respectively, such that the panels overlap an interior side of wall panels 318A and 318C. This configuration creates a space behind the trim panels which can be used as a chase for the routing of electrical, data, and water lines.
The wall panels and trim panels may be fastened to the metal studs, and/or metal track of wall frame 306A using screws, bolts, and/or any other suitable fastener. As shown in FIG. 8 , the fasteners are exposed. In some examples, wall panels 318A-C and trim panels 319A-B are removably fastened to the frame to facilitate replacement or repairment of a damaged panel. For example, the panels may be fastened to the metal studs of the wall frame using screws, and the panels are removable from the frame by unscrewing the panel from the metal studs.
FIG. 8 depicts wall panel assembly 302B fastened to wall frame 306B. Wall panel assembly 302B is similar to wall panel assembly 302A including a plurality of wall panels 320A-H and trim panels 322A, 322B fastened to wall frame 304B. Wall panels 320A-H and trim panels 322A-B collectively form a cohesive wall surface 325 of wall 306B. FIG. 8 depicts one possible configuration of wall panels, but there are many other possible configurations of wall panels to create the wall surface.
Wall panels 320A-H and trim panels 322A-B are prefabricated and prefinished, such that installation of the panels onto wall frame 306B includes only fastening the panels to the frame using screws, bolts, and/or any other suitable fastener. Wall panels 320A-H are installed, such that adjacent edges of the panels are flush and have butt joints between the panels. The gap between adjacent edges of the wall panels is less than 1/32″. Having gaps between adjacent wall panels less than 1/32″ facilitates wall panel assembly 302B forming a cohesive wall surface with exposed butt joints and exposed fasteners. Tape, mud, and/or paint is not used to cover the butt joints, and/or fasteners.
FIG. 9 depicts a ceiling panel assembly 324 fastened to ceiling frame 308. Ceiling frame includes a panel 326 fastened to a plurality of ceiling joists 328 using bolts, screws, and/or any other suitable fastener. Panel 326 forms a ceiling surface 327 of ceiling frame 308. FIG. 11 depicts one possible arrangement including only a single panel 326. In some examples, ceiling panel assembly 324 includes a plurality of ceiling panels installed flush with each other having butt joints between the flush edges of the panels. Thus, the ceiling panel assemblies can be installed in the same manner as the wall panel assemblies described above to form a cohesive ceiling surface.
In some examples, the panels of the wall panel assemblies 302A-B and/or ceiling panel assemblies 324 are configured to be removable from the respective frames without damaging the panels. The panels being removable facilitates replacing damaged panels. Additionally, the panels being removable facilitates easy access to mechanical, electrical, and plumbing systems disposed in the wall, floor, and/or ceiling assembly. For example, components of mechanical, electrical, and plumbing systems can be concealed within the wall, floor and/or ceiling assembly by the panels, but easily accessed by removing the panels from the frame. In other words, the components of the mechanical, electrical, and plumbing systems can be concealed without needing to be accessible by a junction box and/or an accessible patch panel as is the case if utilizing drywall. Instead, the mechanical, electrical, and plumbing systems may be accessed by removal of one or more of the panels from the frame.

D. Illustrative Method

This section describes steps of an illustrative method 400 for manufacturing an illustrative wall panel; see FIG. 10 . Aspects of the panels and frames described above may be utilized in the method steps described below. Where appropriate, reference may be made to components and systems that may be used in carrying out each step. These references are for illustration, and are not intended to limit the possible ways of carrying out any particular step of the method.
FIG. 10 is a flowchart illustrating steps performed in an illustrative method, and may not recite the complete process or all steps of the method. Although various steps of method 400 are described below and depicted in FIG. 10 , the steps need not necessarily all be performed, and in some cases may be performed simultaneously or in a different order than the order shown.
Step 401 of method 400 includes applying a face surface finish to each face of the wall, ceiling, floor, or trim panel. The face surface finish may be any suitable surface finish configured to provide wear resistance and UV stability. In some examples, the face surface finish comprises a film-based surface finish, such as a PET film. In some examples, the face surface finish comprises paint, or a ceramic coating.
The film may be bonded to the panel using any suitable method configured to facilitate a delamination resistant bond between the panel and the film. For example, the film may be bonded to the panel using a cold bond adhesive, Polyurethane (PUR) hot melt adhesive, and/or any other suitable adhesive configured to create the delamination-resistant bond between panel and the film. In some examples, the film is applied to the panel using a high-speed lamination machine.
Step 402 of method 400 includes cutting the panel to a predetermined size and shape. In some examples, the predetermined size and shape of the panel is determined based on the intended positioning of the panel in forming the cohesive wall surface with other panels of a wall, ceiling, or floor panel assembly. The panel may be cut to the predetermined size and shape using any suitable method configured to precisely cut the panel to the exact size and shape. In some examples, the panel is cut to the predetermined size and shape using computer numerical control (CNC) equipment. Utilizing CNC equipment facilitates precise and consistent cutting of the panels to the predetermined size and shape.
Step 403 of method 400 includes predrilling the film bonded wall panel. Predrilling the panel ensures that the fasteners used to fasten the panel to the frame are properly spaced apart and facilitates correctly aligning the panel onto the frame. Any suitable number and arrangement of holes may be predrilled into the panel dependent on the size of the panel and the intended positioning of the panel on the frame. In some examples, the panel includes several rows of evenly spaced predrilled holes and the spacing of the holes is configured to correspond to the distance between the studs of the frame to which the panel is configured to be attached to. The predrilled holes may be drilled using the CNC equipment utilized to cut the panel to size.
Step 404 of method 400 includes applying an edge surface finish to the panel. The edge surface finish is configured to facilitate the flush, butt jointed installation of the panel onto a frame with other panels of a wall panel assembly. In some examples, the edge surface finish comprises edge banding. In some examples, the edge banding is applied to the edge of the panel around an entire periphery of the panel. In some examples, the edge banding comprises acrylonitrile butadiene styrene (ABS) tape and/or any other suitable material.

E. Modular Building Assembly

As shown in FIGS. 11-13 , this section describes a modular building assembly 500. Modular building assembly 500 may be utilized to form any suitable building, e.g., an apartment building, school, medical center, retirement community, etc. Modular building assembly 500 includes examples of frames 200 and 300, described above.
As shown in FIG. 11 , modular building assembly 500 includes a plurality of chassis blocks 502 coupled to each other to form building assembly 500. Each chassis block 502 includes metal sections forming a rectangular prism. Each chassis block 502 may comprise any suitable material configured to facilitate precise fabrication of the chassis block and configured to support wall, floor, and ceiling assemblies, described herein. For example, each chassis block 502 may comprise hollow steel sections (HSS). Chassis block 502 may have any suitable dimensions, e.g., 20′ length, 10′ wide, 11.5′ tall. In some examples, each chassis block 502 is prefabricated and configured to be transported to the installation site. In some examples, chassis block 502 has dimensions corresponding to standard shipping containers and/or is compatible with standard shipping container handling equipment to facilitate ease of transport of chassis block 502 to the installation site.
As shown in FIGS. 12 and 13 , each chassis block 502 may include features to facilitate coupling the chassis blocks to each other to form modular building assembly 500. In some examples, each chassis block 502 includes a respective post or pin 504 disposed at each corner of a top side 506 of the chassis block. Post 504 extends vertically upwards from the corner of chassis block 502. As shown in FIG. 13 , each chassis block 502 may include an aperture 508 disposed on each corner of a bottom side 510 of chassis block 502. When a chassis block 502 is stacked on top of another chassis block as shown in FIG. 11 , aperture 508 receives post 504 to align the two chassis blocks and to couple the two chassis blocks together. Additionally, or alternatively, the chassis blocks 502 may be fastened together using screws, bolts, and/or any other suitable fasteners. In some examples, each corner of top side 506 of chassis block 502 has the aperture and each corner of bottom side 510 includes the pin or post.
In some examples, as shown in FIG. 11 , building assembly 500 is disposed on a foundation 503 that includes a plurality of concrete pylons or piers 501 either serving as the foundation or extending upward from foundation 503. Piers 501 are spaced to align with the respective corners of a bottom side of chassis blocks 502 and may have one or more components configured to couple to the bottom side of chassis block 502. For example, each pier 501 may include a post that is compatible with aperture 508 disposed on each corner of the bottom side of chassis block 502. Chassis blocks 502 may be coupled to piers 501 by the posts extending into apertures 508 in the bottom of the chassis block 502.
In some examples, the post 504 and aperture 508 coupling mechanism facilitates non-permanently connecting the plurality of chassis 502 together and/or non-permanently connecting chassis 502 to foundation 501. Non-permanently connecting the chassis together facilitates reconfiguring building assembly 500. Chassis 502 may be disconnected from each other and reconnected to each other in a different configuration, without damaging the structural integrity of the chassis. Additional chassis 502 may be added on to the assembly as desired and/or one or more chassis 502 may be removed. In some examples, chassis 502 being non-permanently connected to foundation 501 facilitates relocating building assembly 500 to a new location without damaging the structural frame of the building formed by the plurality of chassis 502.
In some examples, as shown in FIG. 13 , each corner of bottom side 510 of chassis block 502 includes a shipping container coupling piece 512. Shipping container coupling piece 512 is compatible with (e.g., may be substantially identical to) the shipping container corner fittings disposed on the corners of standard shipping containers. Shipping container coupling piece 512 is configured to facilitate positioning, loading, and securing chassis block 502 using the same machinery as standard shipping containers. This eases the process of transporting chassis blocks 502 from the place of manufacture to the installation site.
Chassis blocks 502 are configured to be prefabricated and transported to the installation site to be assembled to form any suitable building. FIG. 11 depicts one example arrangement of chassis blocks 502, however chassis blocks may be arranged in any suitable manner dependent on the intended design and layout of the building. In some examples, chassis blocks of different sizes and shapes may be utilized and included in modular building assembly 500. Chassis blocks 502 form a structural frame of the building and are configured to support wall assemblies, ceiling assemblies, and floor assemblies, described herein.

F. Illustrative Chassis for Modular Building Assembly

As shown in FIGS. 14-17 , this section describes an illustrative chassis 602 for a modular building assembly, such as modular building assembly 500, described above. Chassis 602 is an example of chassis block 502, described above.
As shown in FIGS. 14-17 , chassis 602 includes metal sections forming a rectangular prism configured to support a wall assembly 604, a floor assembly 606, and a ceiling assembly 608. Chassis 602 may comprise any suitable material configured to facilitate precise fabrication of the chassis and configured to support the wall, floor, and ceiling assemblies. For example, chassis 602 may comprise hollow steel sections (HSS). Chassis 602 may have any suitable dimensions, e.g., 20′ length, 10′ wide, 11.5′ tall. In some examples, chassis 602 has dimensions corresponding to a standard (e.g., 20-foot) shipping container and/or is compatible with standard shipping container handling equipment to facilitate ease of transport of chassis 602 to the installation site.
As shown in FIG. 16 , floor assembly 606 includes a pair of floor cassettes 610A, 610B configured to support a floor panel assembly 612. Floor cassettes 610A, 610B are substantially identical and each include a plurality of metal studs 614A, 614B, respectively. Floor cassettes 610A, 610B are configured to be coupled to a bottom side 616 of chassis 602. In some examples, as shown in FIGS. 15 and 16 , a bottom crossbar 618 bisects bottom side 616 of chassis 602. Floor cassettes are sized and shaped to fit within bottom side 616 of chassis 602 on opposing sides of bottom crossbar 618. Floor cassettes 610A, 610B may be fastened to bottom side 616 of chassis 602 in any suitable manner, e.g., using bolts, screws, adhesive, etc. Floor cassettes 610A, 610B may comprise any suitable material configured to be fastened to chassis 602 and configured to support floor panel assembly 612. For example, floor cassettes 610A, 610B may comprise light gauge steel (LGS).
Floor cassettes 610A, 610B and bottom side 616 of chassis 602 are configured to support floor panel assembly 612. Floor panel assembly 612 comprises a plurality of floor panels 620 fastened to metal studs 614A, 614B of the floor cassettes and/or to portions of chassis 602, such as bottom cross bar 618. Floor panels 620 may be fastened to metal studs 614A, 614B and chassis 602 using bolts, screws, and/or any other suitable fastener. In some examples, a Z-shaped channel and/or hat-shaped channel is fastened to an interior side of floor cassettes 610A, 610B, such that the Z-shaped or hat-shaped channel extends perpendicular to metal studs 614A, 614B across the floor cassettes. In such examples, floor panel assembly 612 is fastened to the Z-shaped or hat-shaped channel.
Floor panels 610 are arranged to collectively form a floor surface 622. Floor surface 622 extends substantially across an entirety of bottom side 616 of chassis 602. FIGS. 14-16 depict one possible arrangement and number of floor panels 620. However, any suitable number and size of floor panels 620 may be utilized to form floor surface 622. Floor panels 620 are installed flush with each other having butt joints between the flush edges of the panels. This ensures that floor surface 622 is effectively sealed to prevent dirt, debris, liquids, etc. from passing through floor surface 622.
Ceiling assembly 608 is substantially similar to floor assembly 606 having a pair of ceiling cassettes 624A and 624B configured to support a ceiling panel assembly 626. Ceiling cassettes 624A, 624B are substantially identical to each other, and each include a plurality of ceiling joists 628A, 628B, respectively. In some examples, as shown in FIGS. 14-16 , ceiling cassettes 624A, 624B each comprise a plurality of strips of Z-shaped channel 630A, 630B. Z-shaped channel 630A, 630B is fastened to an interior side of ceiling cassettes 624A, 624B, such that Z-shaped channel 630A, 630B extends across the ceiling cassettes perpendicular to ceiling joists 628A, 628B. Z-shaped channel 630A, 630B may be fastened to cassettes using screws, bolts, and/or any other suitable fasteners. Ceiling cassettes 624A, 624B may comprise any suitable material configured to be fastened to chassis 602 and configured to support ceiling panel assembly 626. For example, ceiling cassettes 624A, 624B may comprise light gauge steel (LGS).
Ceiling cassettes 624A, 624B are configured to be fastened to a top side 632 of chassis 602. In some examples, a top-side crossbar 634 bisects top side 632 of chassis 602. Ceiling cassettes 624A, 624B are sized and shaped to fit within top side 632 of chassis 602 on opposing sides of top-side crossbar 634. Ceiling cassettes 624A, 624B may be fastened to top side 632 of chassis 602 in any suitable manner, e.g., using bolts, screws, adhesive, etc.
Ceiling cassettes 624A, 624B and top side 632 of chassis 602 are configured to support ceiling panel assembly 626. Ceiling panel assembly 626 comprises a plurality of ceiling panels 636 fastened to Z-shaped channel 630A, 630B of the ceiling cassettes and portions of chassis 602. Ceiling panels 636 may be fastened to Z-shaped channel 630A, 630B and chassis 602 using bolts, screws, and/or any other suitable fastener.
Ceiling panels 636 collectively form a ceiling surface 638. Ceiling surface 638 extends substantially across an entirety of top side 632 of chassis 602. FIGS. 14-16 depict one possible arrangement and number of ceiling panels 636. However, any suitable number of ceiling panels 636 and size of ceiling panels 636 may be utilized to form ceiling surface 638. In some examples, ceiling panels 636 are installed flush with each other having butt joints between the flush edges of the panels. This ensures that ceiling surface 638 is effectively sealed to prevent dirt, debris, liquids, etc. from passing through ceiling surface 638.
In some examples, floor assembly 606, and/or ceiling assembly 608 includes insulation material inserted between metal studs 614A, 614B or ceiling joists 628A, 628B of the floor and ceiling cassettes. The insulation material may comprise mineral wool, fiberglass, and/or any other suitable material configured to mitigate heat and sound transfer through the floor and ceiling assemblies.
Wall assembly 604 is installed on a first lateral side 640 of chassis 602. In some examples, a respective wall assembly substantially similar to wall assembly 604 is installed on each lateral side of chassis 602. Wall assembly 604 includes an interior wall assembly 642 and an exterior wall assembly 644. Interior wall assembly 642 is configured to face towards an interior of chassis 602 and exterior wall assembly is 644 is configured to face away from chassis 602. Interior wall assembly 642 is fastened to exterior wall assembly 644 in any suitable manner, e.g., screws, bolts, etc.
FIG. 16 depicts an exploded view of wall assembly 604. FIG. 17 depicts a schematic diagram of a vertical cross section of wall assembly 604 inserted into lateral side wall 640 of chassis 602. As shown in FIGS. 16 and 17 , interior wall assembly 642 includes a wall cassette 646 configured to support an interior wall panel assembly 647. Wall cassette 646 includes a plurality of metal studs 648 extending vertically from a top to a bottom of wall cassette 646 and a plurality of Z-shaped channel segments 650 extending horizontally across wall cassette 646. Z-shaped channel segments 650 are fastened to an interior side of wall cassette 646. Wall assembly 604 includes insulation material 652 configured to be inserted between metal studs 648 of wall cassette 646. Wall cassette 646 is sized and shaped to fit inside the metal sections forming first lateral side 640 of chassis 602. Wall cassette 646 including metal studs 648 and Z-shaped channel 650 may comprise any suitable material configured to support interior wall panel assembly 647 (e.g., light gauge steel).
Wall cassette 646 and the metal sections forming first lateral side 640 of chassis 602 are configured to support interior wall panel assembly 647. Interior wall panel assembly 647 includes a plurality of wall panels 654. Wall panels 654 are fastened to Z-shaped channel 650 of wall cassette 646 and/or the metal sections forming first lateral side 640 of chassis 602 utilizing screws, bolts, and/or any other suitable fastener.
Wall panels 654 collectively form a lateral wall surface 656 of chassis 602. Lateral wall surface 656 extends substantially across an entirety of first lateral side 640 of chassis 602. FIGS. 14-16 depict one possible arrangement and number of wall panels 656. However, any suitable number of wall panels 654 and size of wall panels 654 may be utilized to form lateral wall surface 656. Wall panels 654 are installed flush with each other having butt joints between the flush edges of the panels. This ensures that lateral wall surface 656 is effectively sealed to prevent dirt, debris, liquids, etc. from passing through lateral wall surface 656. Wall panels 654 may comprise any suitable material configured to form sealed wall surface 656 (e.g., magnesium oxide).
Wall assembly 604 includes exterior wall assembly 644 fastened to interior wall assembly 642 and disposed on an exterior side of the metal sections forming first lateral side 640 of chassis 602. Exterior wall assembly 644 is configured to seal an exterior side of chassis 502 from an external environment surrounding chassis 602. As shown in FIGS. 15-17 , the components of exterior wall assembly 644 have a vertical length greater than the vertical length of the components of interior wall assembly 642, such that exterior wall assembly 644 is configured to be disposed on an exterior side of the metal sections forming first lateral side 640 of chassis 602.
Exterior wall assembly 644 includes an exterior sheathing 658 and an exterior cladding 660. Exterior sheathing 658 is fastened to wall cassette 646 and an exterior side of the metal sections forming first lateral side 640 of chassis 602 utilizing screws, bolts, and/or any other suitable fasteners. Exterior cladding 660 is fastened to an exterior side of exterior sheathing 658. In some examples, rainscreen gap framing 662 is fastened to the exterior side of exterior sheathing 658 and exterior cladding 660 is fastened to rainscreen gap framing 662. Rainscreen gap framing 662 is configured to separate exterior cladding 660 from exterior sheathing 658, such that an air gap 664 is formed between exterior sheathing 658 and exterior rainscreen panel assembly 660. Air gap 664 facilitates the circulation of air between exterior cladding 660 and exterior sheathing 658 to increase evaporation of liquid on the exterior surface of exterior sheathing 658. Additionally, air gap 664 provides a space for water to drain between exterior sheathing 658 and exterior cladding 660.
Exterior sheathing 658 is configured to provide insulation and prevent wind and water from penetrating the sheathing and reaching the components of interior wall assembly 642. Exterior sheathing 658 may comprise any suitable material configured to provide insulation and create a weather resistant barrier (WRB). For example, exterior sheathing 658 may comprise a structural insulated sheathing (SIS), such as a Rok-on sheathing.

G. Illustrative Frame and Wall Assembly

As shown in FIGS. 18-20 , this section describes an illustrative section of a wall assembly 700. Illustrative wall assembly 700 is an example of wall assembly 604, described above. Wall assembly 700 is configured to provide an insulated, weather resistant, and fire-resistant wall assembly for a chassis of a modular building assembly, such as chassis 602, described above. For example, wall assembly 700 may be configured to form a lateral side wall of chassis 602, described above.
FIG. 18 depicts an isometric view of wall assembly 700. FIG. 19 depicts a cross section of wall assembly 700 corresponding to line 19-19 in FIG. 18 . FIG. 20 depicts a cross section of wall assembly 700 corresponding to line 20-20 in FIG. 18 .
As shown in FIG. 19 , wall assembly 700 includes an interior wall assembly 702 and an exterior wall assembly 704 fastened to sections of a chassis 701A and 701B. Sections of chassis 701A, 701B may comprise vertical metal sections forming a side wall of a chassis, such as chassis 602, described above. Sections of chassis 701A, 701B comprise hollow steel sections (HSS). Interior wall assembly 702 is configured to face towards the interior of the chassis (e.g., chassis 602) on which wall assembly 700 is installed. Exterior wall assembly 704 is configured to face towards an external environment outside of the chassis.
Interior wall assembly 702 includes an interior frame 706 fastened to sections of chassis 701A, 701B. Interior frame 706 is configured to support interior wall panel assembly 708. Interior frame 706 includes metal studs 710 extending vertically from a top to a bottom of wall assembly 700. In some examples, interior frame 706 includes metal track extending horizontally across a top edge of the frame and metal track extending horizontally across the bottom edge of the interior frame. In such examples, top and bottom ends of metal studs 710 fit within the metal track disposed at the top edge and bottom edge of interior frame 706. Z-shaped channel 714 is fastened to an interior side of metal studs 710 and extends horizontally across interior frame 706. Metal studs 710, the metal track, and Z-shaped channel 714 of interior frame 706 may each comprise any suitable material configured to support interior wall panel assembly 708. For example, metal studs 710, the metal track, and/or Z-shaped channel 714 may comprise light gauge steel (LGS).
Interior frame 706 is infilled with insulation material 716 configured to mitigate heat and sound transfer through wall assembly 700. Insulation material 716 may comprise mineral wool, fiberglass, and/or any other suitable material configured to mitigate heat and sound transfer through wall assembly 700. In some examples, as shown in FIG. 19 , insulation material 716 is disposed between sections of chassis 701A, 701B.
Interior wall panel assembly 708 includes examples of prefinished wall panel 100 and wall panel assemblies 202, 302A-B, and 648, described above. Interior wall panel assembly 708 is fastened to interior frame 706 to form an interior wall surface 720 of wall assembly 700. Interior wall panel assembly 708 comprises a plurality of wall panels 718 forming interior wall surface 720. Wall panels 718 are installed flush with each other having butt joints between the flush edges of the panels. This ensures that interior wall surface 720 is effectively sealed to prevent dirt, debris, liquids, etc. from passing through interior wall surface 720. Wall panels 718 are configured, such that the butt joints are exposed and do not require tape or mud to seal the joints. In some examples, wall panels 718 comprise magnesium oxide.
In some examples, wall panels 718 are removably fastened to the frame, such that wall panels 718 are removable from the frame without damaging the panels. The panels being removable facilitates easy replacement of individual damaged panels without needing to replace the entire wall panel assembly. Additionally, the panels being removable facilitates easy access to mechanical, electrical, and plumbing systems disposed in wall assembly 700. For example, components of mechanical, electrical, and plumbing systems can be concealed within the wall, floor and/or ceiling assembly by wall panels 718, but easily accessed by removing the panels from the frame. Wall panels 718 are each fastened to Z-shaped channel 714 of interior frame 706 using screws 721. Screws 721 are exposed on an internal side of wall panels 718. As shown in FIG. 20 , Z-shaped channel 714 provides an air gap 722 between wall panels 718 and metal studs 710A, 710B and insulation material 716. In some examples, air gap 722 is configured to facilitate improved fire resistance properties of wall assembly 700. In some examples, a protective magnesium oxide panel 723 is fastened to an interior side of chassis sections 701A, 701B. Protective magnesium oxide panel 723 is configured to improve the fire resistance properties of wall assembly 700.
Wall assembly 700 includes exterior wall assembly 704 configured to face towards an exterior environment, when wall assembly 700 is installed on the chassis. Exterior wall assembly 704 is configured to block wind and rain from reaching the components of interior wall assembly 702. Exterior wall assembly 704 includes an exterior sheathing 724, rainscreen gap framing 725, and exterior cladding 726 collectively forming a rainscreen wall system.
Exterior sheathing 724 is fastened to metal studs 710A, 710B on an exterior side 727 of interior frame 706 using one or more screws 728. Exterior sheathing 724 is configured to provide insulation and prevent wind and water from penetrating the sheathing and reaching interior wall assembly 702. Exterior sheathing 724 may comprise any suitable material configured to provide insulation and create a weather resistant barrier 730 (WRB). In some examples, exterior sheathing 724 comprises a structural insulated sheathing (SIS).
Rainscreen gap framing 725 is fastened to an exterior side of exterior sheathing 724 using screws and/or any other suitable fastener. Exterior cladding 726 is fastened to rainscreen gap framing 725 using screws 732. Rainscreen gap framing 725 may comprise any suitable material configured to support exterior cladding 726. For example, rainscreen gap framing 725 may comprise extruded aluminum. As shown in FIGS. 19 and 20 , rainscreen gap framing 725 is configured to space exterior cladding 726 from exterior sheathing 724 to form an air gap 734 between the exterior sheathing and the exterior cladding. Air gap 734 facilitates the circulation of air between exterior cladding 726 and exterior sheathing 724 to increase evaporation of liquid on weather resistant barrier 730. Additionally, air gap 734 provides a space for water to drain between exterior sheathing 724 and exterior cladding 726.
Exterior cladding 726 may comprise any suitable wall cladding configured to provide a water and air resistant barrier. In some examples, exterior cladding 726 comprises a plurality of exterior cladding panels 736 configured to be installed flush with each other having butt joints between the flush edges of the panels. In some examples, the butt joints between the flush edges of the panels are exposed. In some examples, exterior cladding 726 is configured to have exposed screws 732 fastening exterior cladding 726 to rainscreen gap framing 725.
Collectively, interior wall assembly 702 and exterior wall assembly 704 form an insulated, weather resistant, and fire-resistant wall assembly 700 for a chassis of a modular building assembly, such as chassis 602, described above. Wall assembly 700 is configured to be installed on a lateral side of the chassis to form a lateral wall of the chassis. In some examples, wall assembly 700 is prefabricated at a manufacturing site and configured to be transported to an installation site to be installed on the chassis of the modular building assembly. Installing wall assembly 700 on the chassis does not require the use of drywall, mud, tape, and/or paint. Instead, installing wall assembly 700 requires only arranging the interior and exterior wall assemblies relative to the chassis and fastening the components together, as described above. In this manner, wall assembly 700 is configured to reduce installation time in comparison to standard methods of forming a wall that involve onsite installation of drywall.

H. Illustrative Ceiling and Floor Assembly

As shown in FIGS. 21-23 , this section describes illustrative ceiling assemblies 800A, 800B and illustrative floor assemblies 802A, 802B. Ceiling assemblies 800A, 800B are each an example of ceiling assembly 608, described above. Floor assemblies 802A, 802B are each an example of floor assembly 606, described above.
As described with reference to FIG. 11 , chassis of the present disclosure are configured to be arranged adjacent to one another and stacked on top of one another to form the structural frame of any suitable building. FIGS. 21-23 depict a respective top side 804A, 804B of a first pair of chassis 806A, 806B disposed adjacent one another and a respective bottom side 808A, 808B of a second pair of chassis 810A, 810B disposed adjacent one another. Second pair of chassis 810A, 810B are stacked on top of first pair of chassis 806A, 806B. In FIGS. 21-23 only the respective top or bottom sides of the chassis are shown. However, respective top sides 804A, 804B of first pair of chassis 806A, 806B may each comprise the top side of a chassis, such as chassis 602 formed as a rectangular prism. Similarly, respective bottom sides 808A, 808B of second pair of chassis 810A, 810B may each comprise the bottom side of a chassis, such as chassis 602, described above. First pair of chassis 806A, 806B and second pair of chassis 810A, 810 comprise hollow steel sections (HSS).
Ceiling assemblies 800A, 800B each include a respective ceiling cassette 812A, 812B configured to support one or more panels of a ceiling panel assembly 814. Ceiling cassettes 812A, 812B are substantially identical to each other, and each include a plurality of ceiling joists 816A, 816B respectively. Ceiling cassettes 812A each comprise a plurality of Z-shaped channel segments 818A, 818B. Z-shaped channel segments 818A, 818B are fastened to an interior side of ceiling cassettes 812A, 812B such that Z-shaped channel segments 818A, 818B extend across the ceiling cassettes perpendicular to ceiling joists 816A, 816B. Z-shaped channel segments 818A, 818B may be fastened to cassettes using screws, bolts, and/or any other suitable fasteners. Ceiling cassettes 812A, 812B may comprise any suitable material configured to be fastened to respective top sides 804A, 804B of chassis 806A, 806B and configured to support the one or more panels of ceiling panel assembly 814. For example, ceiling cassettes 812A, 812B may comprise light gauge steel (LGS).
Ceiling cassettes 812A, 812B are configured to be fastened to respective top sides 804A, 804B of chassis 806A, 806B and are sized and shaped to fit within the top sides of the chassis. Ceiling cassettes 812A, 812B may be fastened to chassis 806A, 806B in any suitable manner, e.g., using bolts, screws, adhesive, etc.
Ceiling cassettes 812A, 812B and top sides 804A, 804B of chassis 806A, 806B are configured to support ceiling panel assembly 814. Ceiling panel assembly 814 includes a plurality of ceiling panels 820 fastened to cassettes 812A, 812B. As shown in FIG. 21 , ceiling panels 820 of ceiling panel assembly 814 are fastened to Z-shaped channel 818A, 818B of ceiling cassettes 812A, 812 B using screws 822. Ceiling panel assembly may include any suitable ceiling panels 820 configured to form a sealed ceiling surface 824. In some examples, ceiling panels 820 are installed flush with each other having butt joints between the flush edges of the panels.
As shown in FIGS. 22 and 23 , ceiling cassettes 812A, 812B are infilled with insulation material 826 disposed between ceiling joists 816A, 816B. Insulation material 826 is configured to mitigate heat and sound transfer through ceiling assemblies 800A, 800B. Insulation material 826 may comprise mineral wool, fiberglass, and/or any other suitable material configured to mitigate heat and sound transfer through the ceiling assembly. In some examples, as shown in FIG. 23 , insulation material 838 (e.g., mineral wool, Rockwool, etc.) and a first sealing member 840 is positioned in the space between chassis 806A and chassis 806B. First sealing member 840 may comprise any suitable component configured to seal off the space between chassis 806A and 806B to prevent debris and/or moisture from entering the space between the chassis. Insulation material 838 is configured to mitigate heat and sound transfer through ceiling assemblies 800A, 800B.
Floor assemblies 802A, 802B each include a pair of floor cassettes 828A, 828B. Floor cassettes 828A, 828B are substantially similar to ceiling cassettes 812A, 812B each having a plurality of floor studs 830A, 830B. Floor studs 830A, 830B of floor cassettes 828A, 828B may comprise any suitable material configured to support a floor panel assembly and/or a subfloor assembly 832. For example, floor studs 830A, 830B may comprise light gauge steel (LGS). Floor cassettes 828A, 828B are sized and shaped to fit within respective bottom sides 808A, 808B of chassis 810A, 810B.
Floor cassettes 828A, 828B are infilled with insulation material 844 configured to mitigate heat and sound transfer through floor assemblies 802A, 802B. Insulation material 844 may comprise mineral wool, fiberglass, and/or any other suitable material configured to mitigate heat and sound transfer through the ceiling assembly. In some examples, as shown in FIG. 23 , insulation material 844 (e.g., mineral wool, Rockwool, etc.) and a second sealing member 846 are positioned in the space between chassis 810A and chassis 810B. Second sealing member 846 may comprise any suitable component configured to seal off the space between chassis 810A and 810B to prevent debris and/or moisture from entering the space between the chassis. Insulation material 844 is configured to mitigate heat and sound transfer through floor assemblies 802A, 802B.
In some examples, subfloor assembly 832 is fastened to floor studs 830A, 830B of floor cassettes 828A, 828B. Subfloor assembly 832 may comprise a plurality of concrete subfloor panels 834 fastened to floor studs 830A, 830B of floor cassettes. Concrete subfloor panels 834 may be fastened to floor studs 830A, 830B using screws, bolts, and/or any other suitable fasteners. In some examples, concrete subfloor panels 834 provide a surface 850 for tile, stone, or wood flooring to be installed on top of.
As shown in FIGS. 21-23 , chassis 810A is stacked on top of chassis 806A and chassis 810B is stacked on top of chassis 806B. In this example, floor assemblies 802A, 802B may comprise the floor assemblies for the second floor in a building and ceiling assemblies 800A, 800B comprise the ceiling of the first floor in the building. Chassis 806A includes a respective post 852 extending vertically upwards from each corner of top side 804A of chassis 806A. The bottom side of chassis 810A has a respective aperture 854 disposed on each corner of the chassis that is configured to receive a corresponding one of posts 852. Posts 852 and apertures 854 are configured to couple chassis 806A to chassis 810B and ensure proper alignment of the chassis. Similarly, chassis 806B includes posts 856 and chassis 810B includes apertures 858 configured to receive posts 856 to couple chassis 806B to chassis 810B.
In some examples, as shown in FIGS. 22 and 23 , connection plates 860 are disposed between each of the chassis. Each of posts 852 and posts 856 may extend through an aperture in a respective connection plate 860, such that connection plate 860 is sandwiched between chassis 806A, 806B and chassis 810A, 810B. Bolts 862 are utilized to fasten chassis 806A to chassis 810A and chassis 806B to chassis 810B. Bolts 862 extend through connection plates 860. Bolts 862 are configured to securely fasten the respective chassis to each other. Connection plates 860 may comprise any suitable material configured to receive bolts 862. For example, connection plates 860 may comprise steel.

I. Selected Embodiments and Claim Concepts

This section describes additional aspects and features of the modular building assembly and interior wall cladding system, presented without limitation as a series of paragraphs, some or all of which may be alphanumerically designated for clarity and efficiency. Each of these paragraphs can be combined with one or more other paragraphs, and/or with disclosure from elsewhere in this application, including any attached Appendices and materials listed in the Cross-References, in any suitable manner. Some of the paragraphs below may expressly refer to and further limit other paragraphs, providing without limitation examples of some of the suitable combinations.

- A0. An interior wall cladding system comprising:
  - a plurality of wall panels configured to be fastened to a wall frame;
  - wherein each of the panels is prefabricated to a predetermined shape and size and configured to be fastened to the frame at a predetermined position, such that the panels are configured to fit together to form a cohesive wall surface on the wall frame.
- A1. The system of paragraph A0, wherein each of the panels is prefinished having a finished face surface and a finished edge surface.
- A2. The system of any other numbered paragraph, wherein the finished face surface comprises a Polyethylene terephthalate (PET) film bonded to a face of the panel.
- A3. The system of any one of paragraphs A1 through A2, wherein the finished edge surface comprises edge banding fastened to the edges of the panel.
- B0. A method for manufacturing an interior wall panel, the method comprising:
  - applying a face surface finish to a wall panel;
  - cutting the wall panel to a predetermined size and shape;
  - predrilling the wall panel; and
  - applying an edge surface finish to the wall panel.
- B1. The method of paragraph C0, wherein applying the face surface finish comprises bonding a polyethylene terephthalate (PET) film to a face of the wall panel.
- B2. The method of any one of paragraphs C0 to C1, wherein the panel is cut to the predetermined size and shape utilizing computer numeric control (CNC) equipment.
- B3. The method of any of paragraphs C0 to C2, wherein predrilling the wall panel includes utilizing computer numeric control (CNC) equipment.
- B4. The method of any one of paragraphs C0 to C3, wherein applying the edge surface finish to the wall panel includes applying an edge banding to an edge of the wall panel.
- B5. The method of paragraph C4, wherein applying the edge banding includes utilizing an automatic edge banding machine.
- C0. A modular building assembly comprising:
- a chassis comprising a plurality of metal sections forming a rectangular prism; and
- a wall panel assembly installed on a first side of the chassis, the wall panel assembly comprising:
  - a frame infilling the first side of the chassis; and
  - a plurality of wall panels fastened to the frame;
- wherein the wall panels are fastened to the frame flush with each other having butt joints adjoining adjacent edges of the wall panels, such that the plurality of wall panels collectively form a cohesive wall surface.
- C1. The building assembly of paragraph C0, wherein the frame includes a plurality of metal studs extending vertically from a top edge to a bottom edge of the first side of the chassis.
- C2. The building assembly of paragraph C1, wherein the frame includes one or more Z-shaped channel segments fastened to the plurality of metal studs and extending horizontally across the frame.
- C3. The building assembly of paragraph C2, wherein the plurality of wall panels are fastened to the one or more Z-shaped channel segments of the frame.
- C4. The building assembly of any one of paragraphs C0-C3, wherein each of the wall panels is prefabricated to a predetermined shape and size and configured to be fastened to the frame at a predetermined position, such that the panels are configured to fit together to form the cohesive wall surface on the wall frame.
- C5. The building assembly of any one of paragraphs C0-C4, wherein each of the wall panels is fastened to the frame using exposed fasteners.
- C6. The building assembly of any one of paragraphs C0-C5, further comprising an exterior wall assembly fastened to the wall panel assembly.
- C7. The building assembly of paragraph C6, wherein the exterior wall assembly comprises:
- an exterior sheathing fastened to an exterior side of the frame;
- an exterior cladding assembly fastened to the exterior sheathing by gap framing configured to provide an air gap between the exterior sheathing and the exterior cladding.
- C8. The building assembly of paragraph C7, wherein the exterior sheathing forms a weather resistant barrier configured to provide insulation and prevent wind and water from penetrating the sheathing.
- C9. The building assembly of any one of paragraphs C0-C8, wherein each of the wall panels comprises magnesium oxide.
- C10. The building assembly of any one of paragraphs C0-C9, further comprising a ceiling panel assembly installed on a top side of the chassis and a floor panel assembly installed on a bottom side of the chassis.
- C11. The building assembly of paragraph C10, further comprising a second chassis coupled to the first chassis.
- C11.1 The building assembly of paragraph C11, wherein the second chassis is non-permanently coupled to the first chassis by a post of the first chassis extending into an aperture in the second chassis.
- C12. The building assembly of paragraph C0, wherein the plurality of wall panels are removably fastened to the frame.
- D0. An interior wall cladding system comprising:
  - a wall frame configured to be nested in a first side of a six-sided modular chassis; and
  - a plurality of non-paperfaced wall panels fastened to the wall frame, such that adjacent ones of the wall panels are flush and butt-jointed with each other;
  - wherein each of the wall panels is prefabricated to a predetermined shape and size and configured to be fastened to the frame at a predetermined position, such that the panels fit together to form a cohesive wall surface on the wall frame.
- D1. The system of paragraph DO, wherein each of the panels is prefinished having a finished face surface and a finished edge surface.
- D2. The system of paragraph D1, wherein the finished face surface comprises a polyethylene terephthalate (PET) film bonded to a face of the panel.
- D3. The system of paragraph D1, wherein the finished edge surface comprises edge banding fastened to the edges of the panel.
- D4. The system of any one of paragraphs DO-D3, wherein each of the panels comprises magnesium oxide.
- D5. The system of any one of paragraphs DO-D4, further comprising an exterior wall assembly fastened to an exterior side of the wall frame.
- D6. The system of any one of paragraphs DO-D5, wherein the interior wall cladding system is configured to be installed on a side of a chassis to form a side wall of the chassis.
- E0. A method of assembling a modular building assembly, the method comprising:
- installing a wall cassette on a first lateral side of a six-sided modular chassis, wherein installing the wall cassette comprises:
  - fastening a wall frame to a first lateral side of the modular chassis, such that the wall frame is nested in the first lateral side of the modular chassis;
  - fastening a plurality of non-paperfaced wall panels to the wall frame in a predetermined arrangement, such that adjacent ones of the wall panels are flush and butt-jointed with each other, and the wall panels collectively form a continuous wall surface.
- E1. The method of paragraph E0, further comprising:
- installing a respective wall cassette on each lateral side of the modular chassis.
- E2. The method of paragraph E0 or E1, further comprising:
- installing a ceiling cassette on a top side of the modular chassis.
- E2.1. The method of paragraph E2, wherein installing the ceiling cassette comprises:
  - fastening a ceiling frame to the top side of the modular chassis, such that the ceiling frame is nested in the top side of the chassis; and
  - fastening a plurality of ceiling panels to the ceiling frame, such that adjacent ones of the ceiling panels are flush and butt-jointed with each other.
- E3. The method of any one of paragraphs E0-E2.1, further comprising:
- installing a floor cassette in bottom side of the modular chassis, wherein the floor cassette includes a plurality of concrete subfloor panels fastened to a floor frame.
- E3.1 The method of paragraph E3, wherein installing the floor cassette comprises:
  - fastening a floor frame to the bottom side of the modular chassis, such that the floor frame is nested in the bottom side of the chassis; and
  - fastening a plurality of subfloor panels to the floor frame, such that adjacent ones of the floor panels are flush and butt-jointed with each other.
- E4. The method of any one of paragraphs E0-E3.1, further comprising:
- prior to installing the wall cassette on the first lateral side of the modular chassis, transporting the wall cassette and the modular chassis to an installation site.
- E5. The method of any one of paragraphs E0-E3.1, further comprising:
- after installing the wall cassette on the first lateral side of the modular chassis, transporting the modular chassis to an installation site.
- E6. The method of any one of paragraphs E0-E5, further comprising:
- coupling a bottom side of the modular chassis to a foundation.
- E7. The method of any one of paragraphs E0-E6, further comprising:
- coupling the modular chassis to a second modular chassis.
- E7.1 The method of paragraph E7, wherein coupling the modular chassis to the second modular chassis comprises coupling the top side of the modular chassis to a bottom side of the second modular chassis.
- E8. The method of any one of paragraphs E0-E7.1, further comprising:
- manufacturing each of the non-paperfaced wall panels according to any one of paragraphs B0-B5.
- F0. A prefabricated wall cladding system comprising:
- a wall frame configured to be nested in a first side of a modular chassis, wherein the wall frame comprises a plurality of metal studs oriented in a first direction, wherein insulation is disposed between adjacent pairs of the metal studs;
- a plurality of metal channels oriented in a second direction transverse to the first direction, each of the metal channels being secured to one or more of the metal studs; and
- a plurality of non-paperfaced wall panels fastened to the metal channels, such that the panels are spaced from the metal studs by the metal channels;
- wherein an air gap exists between each of the panels and the insulation; and
- wherein adjacent ones of the wall panels are flush and butt-jointed with each other such that the panels fit together to form a cohesive wall surface on the wall frame.
- F1. The system of paragraph F0, wherein each of the wall panels is prefinished having a finished face surface and a finished edge surface.
- F2. The system of paragraph F0 or F1, wherein each of the metal channels comprises a Z-shaped metal channel.
- F3. The system of paragraph F0 or F1, wherein each of the metal channels comprises a hat-shaped or trapezoidal metal channel.
- F4. The system of any one of paragraphs F0-F3, wherein each of the wall panels comprises magnesium oxide.
- F5. The system of any one of paragraphs F0-F4, further comprising an exterior wall assembly fastened to an exterior side of the wall frame.
- F6. The system of any one of paragraphs F0-F5, wherein the wall frame is nested in the first side of the modular chassis.

Advantages, Features, and Benefits

The different embodiments and examples of the modular building assembly and interior wall cladding system described herein provide several advantages over known solutions for modular building systems. For example, illustrative embodiments and examples described herein include an easy to install wall assembly for a modular chassis that is configured to facilitate excellent sound insulation and fire resistance while avoiding the use of paperfaced gypsum drywall and related materials (e.g., tape, mud, paint, etc.). The wall assembly includes prefabricated and prefinished components (e.g., wall panels, wall frame, insulation material, etc.) that facilitate an expedited installation process of the wall assembly on the modular chassis. The components of the wall assembly are configured to be arranged in a specific manner (e.g., with an air gap between the panels and the wall frame, with insulation material infilling the wall frame, etc.) to facilitate excellent heat insulation, sound insulation, and fire resistance of the assembly. Accordingly, embodiments of the present disclosure may have equivalent or superior performance with respect to these features as compared to a similar structure built using drywall and traditional techniques.
Additionally, and among other benefits, illustrative embodiments and examples described herein include metal channel(s) (e.g., Z-shaped channel, hat-shaped channel, etc.) to separate the wall panels from metal studs of the frame and provide an air gap between insulation of the wall frame and the wall panels. The air gap facilitates improved fire resistance and sound insulation of the wall assembly. Additionally, the metal channel may reduce the weight of the wall assembly, provide some flexing capabilities of the panels with respect to the underlying studs, and/or reduce the number and size of potential transmission pathways for heat and/or sound. In contrast, traditional methods create ungapped structures with several solid structures in direct contact with each other, increasing the transmission of sound and heat.
Additionally, and among other benefits, illustrative embodiments and examples described herein include a prefabricated modular building assembly that is configured to facilitate ease of transport, e.g., from a manufacturing site to an installation site. For example, a modular chassis of the building assembly may have one or more components that are compatible with standard shipping container handling equipment. Wall panels may be installed on the frame with unconstrained butt joints between adjacent panels that allow for minor flexion and/or translation of the panels to facilitate transporting the frame without damaging the panels. In comparison, boards of a standard drywall assembly are typically fixed together by tape and mud, such that damage is more likely unless they are transported in an unfinished state. Additionally, and among other benefits, illustrative embodiments and examples described herein allow a prefabricated and (in some cases) prefinished wall assembly including a frame and a plurality of panels configured to be fastened to the frame. The frame and the plurality of panels are precision fabricated to predetermined dimensions, such that the plurality of panels fit together when installed on the frame to collectively form a cohesive wall, ceiling, or floor surface. In contrast, standard stud-and-drywall construction must be finished after onsite construction, because a wall exposing the paperfaced surface of the drywall and the dried mud used to patch and tape the seams is inadequate for use as a finished wall.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow for the panels of the wall, ceiling, and/or floor assemblies to be removable from the frame without damaging the panels. This facilitates replacing damaged panels. Additionally, the removable panels provide easy access to mechanical, electrical, and plumbing systems disposed in the underlying wall assembly. For example, components of mechanical, electrical, and plumbing systems can be concealed within the wall assembly, but easily accessed by removing one or more of the wall panels. In this manner, the entire wall assembly can function as a junction box or mechanical closet. In other words, the components of the mechanical, electrical, and plumbing systems can be concealed without needing to be accessible by a junction box and/or an accessible patch panel as is the case if utilizing drywall. Instead, the mechanical, electrical, and plumbing systems may be accessed by straightforward removal of one or more of the panels from the frame. In addition, the removable wall panels described herein facilitate all structural connections between the modular chassis, between the modular chassis and a foundation of the building, etc. being accessible from an interior of the chassis by removing the panels of the assembly.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow non-permanently connecting the modular chassis together to form the structural frame of the building, e.g., utilizing reusable fasteners and connection mechanisms. This non-permanent connection of the modular chassis to each other facilitates reconfiguring the layout of the building by disconnecting any given modular chassis from the others and reconnecting the chassis together in different configuration. Additionally, in some examples, the modular chassis being non-permanently connected to each other and to the foundation (or foundation-equivalent) facilitates relocating the building to a new geographic location. In some examples, the non-permanent connection of the chassis and the removability of the wall, floor, and ceiling assemblies from the chassis without damaging the assemblies facilitates ease of reconfiguration and/or relocation of the entire building assembly, without damaging or destroying any of the components of the assembly in the process.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow for a fire rated wall, floor, and/or ceiling assembly without utilizing drywall, tape, mud, concealed fasteners, etc. In some examples, the wall, floor, and ceiling assemblies are configured to provide a minimum of one hour of fire protection. In some examples, floor and ceiling assemblies described herein have been tested at Western Fire Center and passed a 1-hour fire-resistance test. In some examples, floor and ceiling assemblies described herein were found to provide fire protection for 1 hour and 24 minutes during a 1-hour test. In some examples, wall, floor, and/or ceiling assemblies described herein may provide fire protection for two hours or more.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow for an acoustic rated wall, floor, and/or ceiling assembly without utilizing drywall, tape, mud, concealed fasteners, etc. In some examples, the floor and ceiling assemblies described herein have been tested by Intertek labs and shown to have a Sound Transmission Class (STC) rating of 64 (STC 64) without a finished flooring surface and an impact insulation rating (IIC) of 59 without a finished floor surface.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow a wall panel assembly including a plurality of prefabricated and prefinished panels configured to facilitate a one-step installation process of installing the panels onto the frame. Because the panels are prefinished and prefabricated, installation of the panels does not include cutting the panels to size on site or the use of tape, mud, or paint.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow a plurality of chassis blocks configured to be arranged in any suitable manner to form a structural frame of a building, e.g., arranged adjacent one another and/or stacked on top of one another in a predetermined arrangement. The chassis blocks are configured to support the wall, floor, and ceiling panel assemblies. In some examples, chassis blocks with wall, floor, and ceiling assemblies described herein form a “universal building block” that may be combined with other chassis blocks supporting wall, floor, and ceiling assemblies in a modular fashion to become any suitable type of building structure. By changing the components of the universal building blocks and the arrangement of the universal building blocks relative to each other, many different types and styles of buildings may be formed. Additionally, buildings formed by the universal building blocks are easy to modify by adding more universal building blocks and/or removing universal building blocks from the building. This can be done without damaging any of the components (e.g., the chassis, the wall, floor, and ceiling panel assemblies) of the universal building block.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow for a wide variety of different surface finishes for the wall panels of the wall assemblies according to a user's preferences. In some examples, wall panels may be painted and/or may have a film-based finish.
Additionally, and among other benefits, illustrative embodiments and examples described herein allow the chassis blocks and the wall, floor, and ceiling assemblies to be prefabricated. This facilitates ease of assembly and an expedited assembly process.

CONCLUSION

The disclosure set forth above may encompass multiple distinct examples with independent utility. Although each of these has been disclosed in its preferred form(s), the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense, because numerous variations are possible. To the extent that section headings are used within this disclosure, such headings are for organizational purposes only. The subject matter of the disclosure includes all novel and nonobvious combinations and subcombinations of the various elements, features, functions, and/or properties disclosed herein. The following claims particularly point out certain combinations and subcombinations regarded as novel and nonobvious. Other combinations and subcombinations of features, functions, elements, and/or properties may be claimed in applications claiming priority from this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.

Claims

1. A modular building assembly comprising:

a modular chassis including a plurality of metal beams forming a rectangular prism; and

an interior wall cassette installed on the chassis, the wall cassette comprising:

a frame nested in a first side of the chassis; and

a plurality of non-paperfaced wall panels fastened to the frame;

wherein adjacent ones of the wall panels are flush and butt-jointed with each other, such that the plurality of wall panels collectively form a cohesive wall surface without further construction materials.

2. The building assembly of claim 1, wherein the frame includes a plurality of metal studs extending vertically from a top edge to a bottom edge of the first side of the chassis.

3. The building assembly of claim 2, wherein the frame includes one or more Z-shaped channel segments fastened to the plurality of metal studs and extending horizontally across the frame.

4. The building assembly of claim 3, wherein the plurality of wall panels are fastened to the one or more Z-shaped channel segments of the frame.

5. The building assembly of claim 1, wherein each of the wall panels is prefabricated to a predetermined shape and size and configured to be fastened to the frame at a predetermined position, such that the plurality of wall panels are configured to fit together to form the cohesive wall surface on the wall of the frame.

6. The building assembly of claim 1, wherein each of the wall panels is fastened to the frame using exposed fasteners.

7. The building assembly of claim 1, further comprising an exterior wall assembly fastened to the interior wall cassette.

8. The building assembly of claim 7, wherein the exterior wall assembly comprises:

an exterior sheathing fastened to an exterior side of the frame; and

an exterior cladding assembly fastened to the exterior sheathing;

wherein framing of the exterior wall assembly includes an air gap between the exterior sheathing and the exterior cladding.

9. The building assembly of claim 8, wherein the exterior sheathing forms a weather resistant barrier configured to provide insulation and prevent wind and water from penetrating the exterior sheathing.

10. The building assembly of claim 1, wherein each of the wall panels comprises magnesium oxide.

11. The building assembly of claim 1, further comprising a ceiling panel assembly installed on a top side of the chassis and a floor panel assembly installed on a bottom side of the chassis.

12. (canceled)

13. The building assembly of claim 1, further comprising a second modular chassis coupled to the first modular chassis.

14. The building assembly of claim 1, wherein the frame comprises:

a plurality of metal studs oriented in a first direction, wherein insulation is disposed between adjacent pairs of the metal studs; and

a plurality of metal channels oriented in a second direction transverse to the first direction, each of the metal channels being secured to one or more of the metal studs;

wherein the plurality of non-paperfaced wall panels are fastened to the metal channels, such that the non-paperfaced wall panels are spaced from the metal studs by the metal channels; and

wherein an air gap exists between each of the panels and the insulation.

15. The building assembly of claim 1, wherein each of the wall panels is prefinished having a finished face surface and a finished edge surface.

16. The building assembly of claim 14, wherein each of the metal channels comprises a Z-shaped metal channel.

17. The building assembly of claim 14, wherein each of the metal channels comprises a hat-shaped metal channel.

18. The building assembly of claim 1, wherein each of the wall panels comprises magnesium oxide.

19-20. (canceled)