US 12,188,222 B2Granted

Frames and derivative modules based on light weight construction system with standard and transition panels

AssigneeBlue Tomato, LLC

InventorBrian D. Morrow

Life of this patent

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Abstract

Modular building methods and systems using precision machined modular panels. Standard modular panels are used for constructing walls, floor, and roof, with transitions from wall to roof and wall to floor provided by special transition panels. The standard panels include a channel formed configured to receive a flange of a C-channel member. The present method progresses by installation of a foam panel (or stack or row of such panels), followed by installation of a C-channel member, with the flange of such member engaged in the panels, followed by installation of an adjacent row or stack of panels, before installation of the next, adjacent C-channel member. Such alternating placement of panels and frame members eliminates the need for a tape measure, the need for any independent frame for the building, and ensures the walls, floor, and roof are square and plumb, as the precision machined panels ensure these requirements are met.

Claims17

Dependent claims

A building system comprising:

a plurality of modular panels, each modular panel comprising:
a body;
and
one or more channels extending through a length or width of the modular panel, each channel being configured to receive an elongate spline therein, wherein each elongate spline once received in the channel is disposed within the body, so that the elongate spline is restrained once received within the channel;
and
a plurality of elongate splines, wherein the splines are received within the one or more channels of the bodies of the modular panels, the splines being flanges of a C-channel frame member or back-to-back C-channel frame members that form an I-beam that runs vertically along a length of the modular panel;
a wall-to-floor transition panel for use in transitioning from a wall to a floor in a building construction, the wall-to-floor transition panel being configured to be positioned:
between one or a stack of the modular panels forming the wall;
and
one or more of the modular panels that form a floor structure;
wherein the wall-to-floor transition panel comprises (i) a floor leg or a floor connection portion where a floor panel is attachable and (ii) a wall leg where a wall panel is attachable, where the floor leg or floor connection portion is at an angle relative to the wall leg;
and
a wall-to-roof transition panel for use in transitioning from the wall to a roof in the building construction, the wall-to-roof transition panel being configured to be positioned:
between one or a stack of the modular panels forming the wall;
and
one or more of the modular panels that form a roof structure;
wherein the wall-to-roof transition panel comprises (i) a roof leg or a roof connection portion and (ii) a wall leg or a wall connection portion, which are at an angle relative to one another, a vertical length of the wall leg or wall connection portion accommodating an increased height to the wall by including a vertical length that adds to a height of the wall, the angle between the roof leg or roof connection portion and the wall leg or wall connection portion dictating a roof pitch or angle associated with the roof.

14 more elements

A building system comprising:

a modular panel comprising:
a generally rectangular foam body having two major planar faces, a top end, a bottom end, and right and left sides;
and
a channel extending through a length or width of the panel on the right and left sides of the modular panel, the channel in each of the right and left sides being configured to receive a flange of a C-channel member therein, wherein the flange of the C-channel member once received in the channel is disposed within the foam body, without the received flange of the C-channel member being exposed on either of the major planar faces of the body, so that the flange is restrained once received within the channel;
a wall-to-floor transition panel for use in transitioning from a wall to a floor in a building construction, the wall-to-floor transition panel being configured to be positioned:
between one or a stack of the modular panels forming the wall;
and
one or more modular panels that form a floor structure;
wherein the wall-to-floor transition panel comprises (i) a floor leg or a floor connection portion where a floor panel is attachable and (ii) a wall leg where a wall panel is attachable, where the floor leg or floor connection portion is at an angle relative to the wall leg;
and
a wall-to-roof transition panel for use in transitioning from the wall to a roof in the building construction, the wall-to-roof transition panel being configured to be positioned:
between one or a stack of the modular panels forming the wall;
and
one or more modular panels that form a roof structure;
wherein the wall-to-roof transition panel comprises (i) a roof leg or a roof connection portion and (ii) a wall leg or a wall connection portion, which are at an angle relative to one another, a vertical length of the wall leg or wall connection portion accommodating an increased height to the wall by including a vertical length that adds to a height of the wall, the angle between the roof leg or roof connection portion and the wall leg or wall connection portion dictating a roof pitch or angle associated with the roof.

12 more elements

A building system comprising:

a plurality of modular panels, each modular panel comprising:
a body;
and
one or more channels extending through a length or width of the modular panel, each channel being configured to receive an elongate spline therein, wherein each elongate spline once received in the channel is disposed within the body, so that the elongate spline is restrained once received within the channel;
and
a plurality of elongate splines, wherein the splines are received within the one or more channels of the bodies of the modular panels, the splines being flanges of a C-channel frame member or back-to-back C-channel frame members that form an I-beam that runs vertically along a length of the modular panel;
a wall-to-floor transition panel for use in transitioning from a wall to a floor in a building construction, the wall-to-floor transition panel being configured to be positioned:
between one or a stack of the modular panels forming the wall;
and
one or more of the modular panels that form a floor structure;
wherein the wall-to-floor transition panel comprises (i) a floor leg or a floor connection portion where a floor panel is attachable and (ii) a wall leg where a wall panel is attachable, where the floor leg or floor connection portion is at an angle relative to the wall leg;
and
a wall-to-roof transition panel for use in transitioning from the wall to a roof in the building construction, the wall-to-roof transition panel being configured to be positioned:
between one or a stack of the modular panels forming the wall;
and
one or more of the modular panels that form a roof structure;
wherein the wall-to-roof transition panel comprises (i) a roof leg or a roof connection portion and (ii) a wall leg or a wall connection portion, which are at an angle relative to one another, a vertical length of the wall leg or wall connection portion accommodating an increased height to the wall by including a vertical length that adds to a height of the wall;
wherein the building construction is constructed to include back-to-back C-channel members, forming I-beams, (a) between adjacent vertical wall sections of the wall;
(b) between adjacent horizontal floor sections of the floor structure;
or (c) between adjacent roof sections of the roof structure.

17 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/706,463Filed 28 Mar 2022 · continuation in part
Priority: 10 Dec 2018
Published: US 2022/0220728 A114 Jul 2022
Granted: 7 Jan 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification19 codes

E04B 1/6145
By means between frontal surfaces: with recesses in both frontal surfaces co-operating with an additional connecting element
E04B 1/12
Structures consisting primarily of load-supporting, block-shaped, or slab-shaped elements: the elements consisting of other material
E04B 1/24
Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons: the supporting parts consisting of metal
E04B 2/08
Using elements having specially-designed means for stabilising the position: by interlocking of projections or inserts with indentations, e.g. of…

Family

Application62/777,648Us provisional application · filed 10 Dec 2018
Application62/890,818Us provisional application · filed 23 Aug 2019
Application16/709,674Parent of this continuation-in-part · filed 10 Dec 2019
Application16/824,209Parent of this continuation-in-part · filed 19 Mar 2020
Application62/991,889Us provisional application · filed 19 Mar 2020
Application16/942,166Parent of this continuation-in-part · filed 29 Jul 2020
US 10,865,560 B1Parent of this continuation-in-part · filed 15 Dec 2020
Application63/278,042Us provisional application · filed 10 Nov 2021
Application63/278,040Us provisional application · filed 10 Nov 2021
US 2022/0220728 A1Pre-grant publication · published 14 Jul 2022
US 11,286,658 B2Parent of this continuation-in-part
US 11,352,775 B2Parent of this continuation-in-part
US 2020/0354945 A1Published application
US 2021/0040722 A1Published application
US 12,188,222 B2This patent

From the US filing history. Foreign family members aren’t listed.