Wooden modular structures

Abstract

This invention provides wooden modules that facilitate the connection of multiple modular assemblies for constructing buildings. [Solution] A wooden module 12-17 for use in constructing a building, including a wooden ceiling assembly 13, wherein a plurality of wooden side wall assemblies 15 are configured for attachment to the opposite side of the wooden ceiling assembly 13. A wooden floor assembly 17 is configured for attachment to the wooden side wall assemblies. The wooden side wall assemblies extend to the top of the wooden ceiling assembly and to the bottom of the wooden floor assembly so that the wooden ceiling assembly and wooden floor assembly come into contact with the inner surfaces of the wooden side wall assemblies when they are attached to the wooden side wall assemblies.

Description

Technical Field

[0001] The present disclosure is generally directed to modular building construction, and more particularly to wooden module assemblies for use in modular building construction. The module assembly comprises a system configured to rapidly construct a building framework at a construction site or a work site. In particular, the modular assembly facilitates connecting a plurality of modular assemblies to construct a building.

Summary of the Invention

[0002] In one aspect, a wooden module connectable to one or more additional wooden modules for constructing a building generally comprises a wooden ceiling assembly. A plurality of wooden sidewall assemblies are configured for attachment to the opposite side of the wooden ceiling assembly. A wooden floor assembly is configured for attachment to the wooden sidewall assemblies. When the wooden ceiling assembly and the wooden floor assembly are attached to the wooden sidewall assemblies, the wooden sidewall assemblies extend to the top of the wooden ceiling assembly and to the bottom of the wooden floor assembly such that the wooden ceiling assembly and the wooden floor assembly contact the inner surfaces of the wooden sidewall assemblies.

[0003] In another aspect, a wall assembly for use in a module for constructing a building generally comprises a top plate assembly including a top plate and a header mounted directly to the bottom of the top plate. A bottom plate assembly comprises a bottom plate and a header mounted directly to the top of the bottom plate. A plurality of studs extend between the top plate assembly and the bottom plate assembly. The plurality of studs comprises a first stud extending between the top and bottom plate assemblies and at least one second stud extending between the top and bottom plate assemblies. The first stud has a length that is each longer than the length of at least one second stud.

[0004] In yet another embodiment, a ceiling assembly for use in a module for constructing a building generally comprises a first ceiling plate and a second ceiling plate extending along the length of the ceiling assembly. Multiple ceiling joists extend between the first and second ceiling plates. Each ceiling joist comprises a truss assembly including multiple truss members. Support blocks are attached to at least one of the truss members. The support blocks have support surfaces for supporting MEP (mechanical, electrical, and plumbing) components that extend through the ceiling joists.

[0005] In yet another embodiment, a wooden module assembly generally comprises a first wooden module including a first wooden ceiling assembly, a plurality of first wooden side wall assemblies configured for attachment to the opposite side of the first wooden ceiling assembly, and a first wooden floor assembly configured for attachment to the first wooden wall assemblies. A second wooden module includes a second wooden ceiling assembly, a plurality of second wooden side wall assemblies configured for attachment to the opposite side of the second wooden ceiling assembly, and a second wooden floor assembly configured for attachment to the second wooden wall assemblies. The first wooden module is attached to the second wooden module by the first and second wooden side wall assemblies.

[0006] Other features of the present invention will become apparent from the following description. [Brief explanation of the drawing]

[0007] [Figure 1] This is a perspective view of the module assembly of this disclosure.

[0008] [Figure 2A] This is a schematic perspective view of the modular assembly.

[0009] [Figure 2B] This is a schematic perspective view of a modular assembly with the ceiling assembly removed to show the internal structure.

[0010] [Figure 3]A fragmentary perspective view of the module assembly of FIG. 1 with the end wall assembly removed.

[0011] [Figure 4] A fragmentary perspective view of the floor assembly and side wall assembly of the first module of the module assembly of FIG. 1.

[0012] [Figure 5] A view of the assembly of the first module stacked on top of each other for transportation.

[0013] [Figure 6] An enlarged fragmentary perspective view of the side wall assembly of the first module.

[0014] [Figure 7] A view of a fragmentary part of the side wall assembly of the first module.

[0015] [Figure 8] An enlarged fragmentary right side view of the first module.

[0016] [Figure 9] An end view of the first module showing the end wall assembly with the ceiling assembly removed.

[0017] [Figure 10] An enlarged fragmentary end view of the first module.

[0018] [Figure 11] An end view of the first module with the floor assembly and end wall assembly removed.

[0019] [Figure 12A] A fragmentary left perspective view of the first module of FIG. 9.

[0020] [Figure 12B] A fragmentary left side view of the first module.

[0021] [Figure 12C] It is an enlarged fragmentary left side view of the first module.

[0022] [Figure 13A] It is an enlarged fragmentary left side view of the first module.

[0023] [Figure 13B] It is an enlarged fragmentary left perspective view of the first module.

[0024] [Figure 14A] It is a fragmentary end view of the first module with the floor assembly removed.

[0025] [Figure 14B] It is an enlarged fragmentary end view of the first module of FIG. 14A.

[0026] [Figure 15] It is a right perspective view of the side wall assembly and the floor assembly of the second module of the module assembly.

[0027] [Figure 16] It is an enlarged fragmentary right side view of the second module of FIG. 15.

[0028] [Figure 17] It is an end view of the second module with the ceiling assembly removed.

[0029] [Figure 18] It is an enlarged fragmentary end view of the second module of FIG. 17.

[0030] [Figure 19] It is a perspective view of the ceiling assembly of the second module.

[0031] [Figure 20]This is an enlarged, fragmentary perspective view of the ceiling assembly of the second module.

[0032] [Figure 21] This is an enlarged, fragmentary perspective view of the ceiling assembly of the second module, showing the MEP components installed within the ceiling assembly.

[0033] [Figure 22] This is a right-hand perspective view of the second module with the ceiling assembly removed.

[0034] [Figure 23A] This is a fragmentary view of the right side of the second module in Figure 22.

[0035] [Figure 23B] This is an enlarged, fragmented view of the second module of Figure 23A.

[0036] [Figure 24] This is a right-hand perspective view of the second module with the floor assembly removed.

[0037] [Figure 25A] This is a fragmentary right-hand perspective view of the side wall assembly and ceiling assembly of the second module.

[0038] [Figure 25B] This is a fragmentary left perspective view of the side wall assembly and ceiling assembly of the second module.

[0039] [Figure 26] This is a perspective view of the second module with the floor assembly removed.

[0040] [Figure 27] This is a left perspective view of the second module, which has the floor assembly of the third module attached to the second module.

[0041] [Figure 28A]Figure 27 is an enlarged, fragmented perspective view of the module.

[0042] [Figure 28B] Figure 27 is an enlarged, fragmented perspective view of the module.

[0043] [Figure 29] This is a left perspective view of the second and third modules.

[0044] [Figure 30A] These are end views of the second and third modules.

[0045] [Figure 30B] Figure 30A is an enlarged, fragmented perspective view of the module.

[0046] [Figure 31A] This is an enlarged, fragmentary perspective view showing the connection between the first and second modules.

[0047] [Figure 31B] This is an enlarged, fragmentary side view showing the connection between the first and second modules in the module's bottom plate assembly.

[0048] [Figure 31C] This is an enlarged, fragmentary side view showing the connection between the first and second modules in the top plate assembly of the module.

[0049] [Figure 32] This is an exploded view of a pair of modular assemblies that can be attached to each other.

[0050] [Figure 33] This is an enlarged, fragmentary perspective view of a modular assembly showing drainage pipes installed within a wall assembly.

[0051] The corresponding reference numerals indicate the corresponding parts through several figures in the drawing. [Modes for carrying out the invention]

[0052] Referring to Figures 1 and 2, the modular assemblies of this disclosure are generally represented by 11. A modular assembly 11 may comprise modular components of a building frame, such that the building frame may consist of at least a number of interconnected modular assemblies. Each modular assembly 11 may comprise a number of modules 12, 14, 16 that can be attached to one another to form a modular assembly. Each module 12, 14, 16, or modular assembly 11 used in the construction of a building frame may be referred to as a “skeleton,” “frame,” “wooden cage,” or “cage.” For example, a number of assembled modular assemblies 11 may be arranged end-to-end, in parallel, and / or stacked on top of one another to form a building frame. In the illustrated embodiment, each module 12, 14, 16 of the modular assembly 11 comprises a wooden module, such that the entire structural framework of the module is formed from wood. For example, the modular assembly 11 may be formed from processed wood (structural composite wood). However, modules 12, 14, and 16 may be formed at least partially or entirely from another material, such as steel, without departing from the scope of the disclosure. In one embodiment, the assembly 11 comprises a first “dry” module 12, a second “wet” module 14, and a third “corridor” module 16. For example, the first module 12 may comprise a framework for a bedroom, the second module 14 may comprise a framework for a bathroom, and the third module 16 may comprise a framework for a corridor. Thus, the first, second, and third modules 12, 14, and 16 may be assembled to form the framework for a single hotel or apartment room within a building. It will be understood that other types of rooms may be constructed using the modular assembly 11 without departing from the scope of the disclosure.

[0053] Referring to Figures 1, 3, and 4, the first module 12 comprises a pair of side wall assemblies 15, a ceiling assembly 13 that can be attached to the top of the side wall assemblies, a floor assembly 17 that can be attached to the bottom of the side wall assemblies, and end wall assemblies 19 that can be attached to the ends of the side wall assemblies, floor assemblies, and ceiling assemblies. The side wall assemblies 15, and to a lesser extent the end wall assemblies 19, are configured to support the floor assembly 17 and ceiling assembly 13 so that the floor assembly and ceiling assembly may be suspended from the sides of the side wall assemblies. Therefore, the first module 12 may be appropriately constructed by attaching the wall assemblies 15 and 19 separately to the floor assembly 17, and then attaching the ceiling assembly to the wall assemblies. In this regard, the floor assembly 17 and ceiling assembly 13 may be "suspended" from the wall assemblies 15 and 19 so that the weight of the floor and ceiling assembly is supported by the wall assemblies. Other mounting sequences for assemblies 13, 15, 17, and 19 are also conceivable without departing from the scope of this disclosure. In one embodiment, the first module 12 incorporates balloon framing in the construction of the module. Thus, the bottom of the side wall assembly 15 extends below, or at least to the bottom of, the floor assembly 17. The side wall assemblies 15, 19 form deep beams, each of which may support the load of module 12 when lifted. The wall assemblies 15, 19 are strong enough to prevent substantial downward deflection or bending when module 12 is lifted by the side wall assemblies. Therefore, it is not necessary to lift by supporting the floor assembly 17 from below. Since the wall assemblies 15, 19 may withstand the weight of the floor assembly 17, module 12 may be lifted from above for stacking positioning in a modular building structure. This differs from other construction framings in which the floor provides supports for the walls, and therefore the floor extends below the walls. As a result, module 12 may be handled by directly engaging with the side wall assembly 15 when the module is moved during the construction of the building (e.g., being lifted). Furthermore, balloon framing isolates the floor assemblies of adjacent modules 12, 14, and 16, thereby isolating vibrations (i.e., noise) in each floor assembly, preventing vibrations from being transmitted from one module to the next.This also allows for the incorporation of insulation within the floor assembly. Further other advantages to the modular configuration are anticipated.

[0054] Referring to Figure 5, assemblies 13, 15, 17, and 19 may be stacked on top of each other by a single trailer to transport the unassembled modules to a construction site or work site (e.g., an assembly plant). In one embodiment, modules 12, 14, and 16 are constructed, and other components are attached to the modules to create a finished volumetric module for installation at the construction site. For example, a substantially finished room including drywall, paint / wall finish, plumbing, electrical work, and even furniture may be installed and shipped to the construction site. As used herein, “module” or “wooden module” may refer to modules 12, 14, and 16, or a more entirely or fully finished construction unit including additional components added to the module cage to partially or entirely finish the interior.

[0055] Referring to Figures 4 and 6 to 8, each side wall assembly 15 comprises a top plate assembly or beam assembly 21, a bottom plate assembly or beam assembly 23, a plurality of vertical members or studs 25A, 25B extending between the top and bottom plate assemblies, and a corner post 25C extending between the top and bottom plate assemblies at one end of the side wall assembly. In one embodiment, the main faces of the studs 25A, 25B extend perpendicular to the length of the side wall assembly 15, and the main face of the corner post 25C extends parallel to the length of the side wall assembly. The top and bottom plate assemblies 21, 23 extend parallel to each other, and the studs 25A, 25B and the corner post 25C extend parallel to each other. The first stud 25A constitutes the majority of the stud and is spaced inward from the longitudinal ends of the top and bottom plate assemblies 21, 23. The first stud 25A extends into the top and bottom plate assemblies 21 and 23 such that the first stud passes through the bottom of the top plate assembly and extends below the top of the bottom plate assembly. The second stud 25B defines one end of the side wall assembly 15, while the corner post 25C defines the opposite end. The second stud 25B is positioned entirely between the top and bottom plate assemblies 21 and 23 such that the second stud extends from the top surface of the bottom plate assembly to the bottom surface of the top plate assembly. As will be described in more detail below, this configuration facilitates the attachment of the first module 12 to the second module 14 at the second stud end of the wall assembly 15. Corner post 25C is similar to the first stud 25A in that the corner post extends into the top and bottom plate assemblies 21 and 23, so that the corner post passes through the bottom of the top plate assembly and extends below the top of the bottom plate assembly.

[0056] Panels 26 made of plywood or oriented strand board may be attached to studs 25A to 25C (see Figure 6). Securing the panels 26 to studs 25A to 25C and other components of the wall assembly 15 further increases the rigidity of the wall assembly, allowing it to support greater loads. In one embodiment, at least one sub-panel 26A of the panel 26 is attached to the wall assembly 15 only temporarily. Therefore, the sub-panel 26A may be removed after the module 12 has been constructed to access the interior of the wall assembly 15. The removal may be performed without damaging the wall assembly. The remainder of the panel 26 still provides substantial rigidity for the wall assembly 15.

[0057] The lengths of the top and bottom plate assemblies 21 and 23 may define the length of the first module 12. The horizontal spacing between the studs 25A and 25B may vary. These dimensions are illustrative only, and it should be understood that the components of the side wall assembly 15 may have other dimensions and spacings depending on the desired size and shape of the module 12. In the illustrated embodiment, each of the top and bottom plate assemblies 21 and 23, the studs 25A and 25B, and the corner posts 25C are constructed from a rectangular wooden member. However, the plate assemblies 21 and 23 and the studs 25A, 25B, and 25C may have other configurations without departing from the scope of the present disclosure.

[0058] Referring to Figures 4 and 6 through 8, the bottom plate assembly 23 may comprise a first bottom plate 27 defining the bottom of the side wall assembly 15, a header 29 positioned at the top of the bottom plate, and a plurality of spaced-apart second bottom plates 31 positioned at the header. In the illustrated embodiment, a single first bottom plate 27 and header 29 extend along the entire length of the side wall assembly 15. The continuous extension of the bottom plate 27 and header 29 provides increased structural rigidity to the side wall assembly 15 at the bottom of the side wall assembly. A second stud 25B rests on the top of the second bottom plate 31, positioned at the end of the bottom plate assembly 23. A first stud 25A extends past the second bottom plate 31 and rests on the top of the first bottom plate 27, so that the second bottom plate is spaced apart by the first stud. In particular, the first stud 25A includes a notch 32 at its bottom edge to allow the bottom edge of the first stud to extend past the header 29 to the first bottom plate 27, and to allow the header 29 to extend continuously across the side wall assembly 15. The notch 32 allows the first stud 25A to engage with the main face of the header 29. Multiple fasteners (e.g., three screws) may be driven into the header by penetrating the portion of the first stud 25A that overlaps the main face of the header 29. The spaced-out relationship of the fastener connections of the portion of the first stud 25A that overlaps the main face of the header 29 provides a moment couple that strongly resists stud racking and can support lateral loads. The structure also allows the modular assembly 11 to transmit lateral loads in a building structure composed of multiple modular assemblies. Furthermore, the resistance to racking facilitates the transport of the side wall assembly 15 without causing damage to the side wall assembly due to lateral forces.

[0059] Configuring the first stud 25A and header 29 in the manner described above also allows additional piping components to be included within the area occupied by the wall assembly 15. For example, a side wall assembly 15 with a depth / thickness of 3 inches (7.6 cm) is configured to allow piping to change direction from the side wall to the floor 17 by passing piping through the header 29 without compromising the overall structural stability of the module 12. The width or thickness of the first and second bottom plates 27, 31 and the first stud 25A is greater than the width / thickness of the header 29 so that the bottom plate assembly 23 defines a number of bottom recesses 33 spaced apart along the length of the side wall assembly 15. Fasteners 36 (Figures 31A and 31B) extending through the first and second bottom plates 27, 28 attach the support header 29 to the first and second bottom plates. In one embodiment, the fasteners 36 are 3-inch (7.6 cm) threaded. Other suitable fasteners may be used.

[0060] Referring to Figure 33, it may be understood that a mechanical-electrical-pipe (MEP) component 164 in the form of a drainpipe is shown within the wall assembly 15. The drainpipe 164 extends downward from the top of the wall assembly 15 to a recess 130. To enter the recess, the second bottom plate 31 is cut to allow the drainpipe 164 to pass through the recess without going beyond the outer casing of the wall assembly 15. In the recess 130, the drainpipe 164 changes direction from vertical to horizontal. The recess 130 provides space for doing so without going outside the outer casing of the wall assembly 15. After changing direction, the drainpipe 164 extends generally horizontally (although some variation from horizontal is maintained to facilitate gravity flow). An opening is formed within the header 29, allowing the drainpipe 164 to extend through the header into the floor 17. Preferably, the opening is formed before the installation of the drainpipe 164 so that cutting is not required when the drainpipe 164 is installed. Additional supports 166 (broadly defined as "support blocks") (Figure 1) may be provided for the purpose of supporting MEP components or internal fixtures such as sinks or cabinets. Supports 166 not only provide mechanical support for articles but also establish the proper position of articles (e.g., fixtures) within module 14. Supports 166 may also be equipped with markings to indicate where mounting will take place, as well as to indicate where mounting will be made, so that appropriate fixtures or other articles can be mounted. As a result, little to no measurement is required when fixtures are mounted on supports 166.

[0061] Referring to Figures 4 and 7, the top plate assembly 21 may comprise a first top plate 37 defining the top of the side wall assembly 15, a second top plate 38 positioned at the bottom of the first top plate, a header 39 positioned at the bottom of the second top plate, and a plurality of third top plates 41 positioned at the bottom of the header. In the illustrated embodiment, a single first and second top plate 37, 38 and a single header 39 extend along the entire length of the side wall assembly 15. The continuous extension of the first and second top plates 37, 38 and the header 39 provides increased structural rigidity to the side wall assembly 15 at the top of the side wall assembly. The second stud 25B terminates at the bottom of the third top plate 41 positioned at one end of the top plate assembly 21. The first stud 25A extends past the third top plate 41 and terminates at the bottom of the second top plate 38, so that the third top plate is spaced apart by the first stud. In particular, the first stud 25A is configured such that the top edge of the first stud extends past the header 39 to the third top plate 41, and allows the header 39 to extend continuously across the side wall assembly 15, and includes a notch 32 at the top edge. The notch 32 allows the first stud 25A to engage with the main face of the header 39. Multiple fasteners (e.g., three screws) may be driven into the header by penetrating the portion of the first stud 25A that overlaps the main face of the header 39. The spaced-apart relationship of the fastener connections of the portion of the first stud 25A that overlaps the main face of the header 39 provides a moment couple that strongly resists stud racking. The structures of the top plate assembly 21 and the bottom plate assembly 23 also allow each module to support and transmit lateral loads applied to the modules when the modules 12 are assembled together to form a building.

[0062] Configuring the first stud 25A and header 39 in the manner described above also allows additional piping components to be included within the area occupied by the sidewall assembly 15. For example, a sidewall assembly 15 with a depth / thickness of 3 inches (7.6 cm) is configured to allow piping to change direction from the sidewall to the ceiling 13 by passing piping through the header 39 without compromising the overall structural stability of the module 12. The width or thickness of the second and third top plates 38, 41 is greater than the width / thickness of the header 39 so that the top plate assembly 21 defines a plurality of top recesses 43 spaced apart along the length of the sidewall assembly 15. Fasteners 44 (Figure 31C) extending through the first, second, and third top plates 37, 38, 41 may attach the header 39 to the first, second, and third top plates. In one embodiment, the fasteners 44 are equipped with 5-inch (12.7 cm) threads. Other suitable fasteners may be used.

[0063] Referring to Figures 9 and 10, the end wall assembly 19 comprises a top plate 45, a bottom plate 47, a plurality of vertical members or studs 49 extending between the top and bottom plates, and noggins 51 extending between the studs. The top and bottom plates 45, 47 extend parallel to each other, the studs 49 extend parallel to each other, and the noggins 51 extend parallel to each other. The studs 49 are arranged overall between the top and bottom plates 45, 47 such that the studs extend from the top surface of the bottom plate to the bottom surface of the top plate. At least one header 53 may extend between a pair of studs 49 along the length of the end wall assembly 19 and, together with a sill 55 positioned below the header and extending between the same two studs, define an opening (i.e., a window opening) in the end wall assembly. The support block 57 may be provided on the bottom surface of the top plate 45 and / or the top surface of the bottom plate 47. The end wall assembly 19 may have other configurations without departing from the scope of the present disclosure.

[0064] The lengths of the top and bottom plates 45, 47 may define the width of the first module 12A. The horizontal spacing between the studs 49 may vary. These dimensions are illustrative only, and it should be understood that the components of the end wall assembly 19 may have other dimensions and spacings depending on the desired size and shape of the module 12. In the illustrated embodiment, each of the top and bottom plates 45, 47, the studs 49, the noggin 51, the sill 55, and the support block 57 is constructed from a rectangular wooden member. A lintel 53 is provided above the door opening in the end wall assembly 19. However, the components of the end wall assembly may have other configurations without departing from the scope of the present disclosure.

[0065] Referring to Figure 11, the ceiling assembly 13 comprises a plurality of parallel ceiling joists 61 extending across the width of the ceiling assembly 13 and spaced apart along the length of the ceiling assembly, a pair of ceiling plates 62 positioned on the opposite side of the ceiling assembly and extending along the length of the ceiling assembly, and a plurality of ceiling panels 63 covering the joists and plates. In the illustrated embodiment, the joists 61 and plates 62 comprise rectangular wooden members. However, the joists 61 and plates 62 may have other configurations without departing from the scope of the present disclosure. The joists 61 are attached to the inner surfaces of the ceiling plates 62 so as to connect the joists to each other, thereby forming the ceiling assembly 13.

[0066] The horizontal spacing between the joists 61 along the length of the ceiling assembly 13 may vary. These ranges are illustrative only, and it should be understood that the components of the ceiling assembly 13 may have other dimensions and spacings depending on the desired size and shape of the module 12. The joists 61 preferably extend in a direction perpendicular to the axis over which the wall assembly 15 extends.

[0067] Referring to Figure 4, the floor assembly 17 comprises a plurality of parallel floor joists 71 spaced apart along the length of the floor assembly, a pair of floor plates 72 (only one shown) located on the opposite side of the floor assembly and extending along the length of the floor assembly, and a plurality of floor panels 73 covering the joists and floor plates. The floor assembly 17 is configured similarly to the ceiling assembly 13. In particular, the floor joists 71 extend across the width of the floor assembly 17. However, in the illustrated embodiment, the joists 71 comprise a rectangular truss assembly including a plurality of truss members. The joists 71 may have other configurations without departing from the scope of the present disclosure. The joists 71 are attached to the inner surfaces of the floor plates 72 so as to connect the joists to each other, thereby forming the floor assembly 17.

[0068] The horizontal spacing between the joists 71 may vary. These ranges are illustrative only, and it should be understood that the components of the floor assembly 17 may have other dimensions and spacings depending on the desired size and shape of the module 12. The joists 71 preferably extend in a direction perpendicular to the axis over which the wall assembly 15 extends. The floor joists 71 may still have other configurations without departing from the scope of this disclosure.

[0069] Referring to Figure 8, the floor assembly 17 is attached to the side wall assembly 15 along the side of the floor assembly by fasteners 75. In the illustrated embodiment, the fasteners 75 are threaded (e.g., 3-inch (7.6 cm) threads). Other suitable fasteners may be used. The fasteners 75 attach the bottom plate assembly 23 of the side wall assembly 15 to the floor plate 72 of the floor assembly 17. In particular, the fasteners 75 penetrate the header 29 of the side wall assembly 15 and are inserted into the floor plate 72 of the floor assembly 17. The fasteners 75 are positioned between the floor joists 71 so that they do not extend through the floor joists 71. In the illustrated embodiment, each header section between the first studs 25A includes a plurality of fasteners 75 spaced vertically along the header. For example, each header section includes a single row of fasteners with a spacing of 3 inches (7.6 cm) between each adjacent fastener. However, the fasteners 75 may be positioned on the header 29 in other ways without departing from the scope of this disclosure. Furthermore, other means of attaching the floor assembly 17 to the side wall assembly 15 may be used without departing from the scope of this disclosure.

[0070] Referring to Figures 10 and 12A to 12C, the end wall assembly 19 is attached to the side wall assembly 15 along the side of the end wall assembly by fasteners 77 and to the floor assembly at the end of the floor assembly 19 by fasteners 79. In the illustrated embodiment, the fasteners 77 are threaded (e.g., 5-inch (12.7 cm) threads). The fasteners 77 attach the corner posts 25C of the side wall assembly 15 to the end studs 49 of the end wall assembly 19. In particular, the fasteners 77 penetrate the corner posts 25C of the side wall assembly 15 and are inserted into the end studs 49 of the end wall assembly 19. In the illustrated embodiment, the fasteners 77 are arranged in horizontally spaced pairs, with each pair spaced vertically along the height of the side wall assembly 15. For example, each adjacent pair of fasteners is spaced about 12 inches (30.5 cm) apart. However, the fastener 77 may be positioned on the corner post 25C in other ways without departing from the scope of this disclosure. Furthermore, other means for attaching the end wall assembly 19 to the side wall assembly 15 may be used without departing from the scope of this disclosure.

[0071] Referring to Figure 10, the fastener 79 comprises a screw (for example, a 3-inch (7.6 cm) screw). Other suitable fasteners may be used. The fastener 79 attaches the bottom portion of the end wall assembly 19 to the floor joists 71 of the floor assembly 17. In particular, the fastener 79 is inserted into the floor joists 71 of the floor assembly 17 by passing through the support block 57 on the bottom plate 47 of the end wall assembly 19. In the illustrated embodiment, each support block 57 includes a pair of fasteners 79 spaced horizontally across the support block. For example, each pair of fasteners may have a spacing of 8 inches (20.3 cm) between the fasteners 79. However, the fasteners 79 may be positioned on the support block 57 in other ways without departing from the scope of the disclosure. Furthermore, other means of attaching the floor assembly 17 to the end wall assembly 19 may be utilized without departing from the scope of the disclosure. The floor panel 73 may be attached to the floor joists 71 by fasteners (not shown). In one embodiment, the fastener comprises a 10d nail.

[0072] Referring to Figures 11, 13A, and 13B, the ceiling assembly 13 is attached to the side wall assembly 15 along the side of the ceiling assembly by fasteners 75. In the illustrated embodiment, the fasteners 75 comprise screws (e.g., 3-inch (7.6 cm) screws) or other suitable fasteners. The fasteners 75 attach the top plate assembly 21 of the side wall assembly 15 to the ceiling plate 62 of the ceiling assembly 13. In particular, the fasteners 75 penetrate the header 39 of the top plate assembly 21 of the side wall assembly 15 and are inserted into the ceiling plate 62 of the ceiling assembly 13. The fasteners 75 are positioned between the ceiling joists 61 so that they do not extend through the ceiling joists 61. In the illustrated embodiment, each header section between the first studs 25A includes a plurality of fasteners 75 spaced vertically along the header. For example, each header section includes a single row of fasteners with a spacing of 2 inches (5 cm) between each adjacent fastener. However, the fasteners 75 may be positioned on the header 29 in other ways without departing from the scope of this disclosure. Furthermore, other means of attaching the ceiling assembly 13 to the side wall assembly 15 may be used without departing from the scope of this disclosure.

[0073] Referring to Figures 14A and 14B, the fasteners 79 attach the top portion of the end wall assembly 19 to the ceiling joists 61 of the ceiling assembly 13. In particular, the fasteners 79 penetrate the support blocks 57 on the top plate 45 of the end wall assembly 19 and are inserted into the ceiling joists 61 of the ceiling assembly 13. In the illustrated embodiment, each support block 57 includes a pair of fasteners 79 spaced horizontally across the support block. For example, each pair of fasteners may have a spacing of 8 inches (20.3 cm) between the fasteners 79. However, the fasteners 79 may be positioned on the support blocks 57 in other ways without departing from the scope of the disclosure. Furthermore, other means of attaching the ceiling assembly 13 to the end wall assembly 19 may be utilized without departing from the scope of the disclosure. The ceiling panel 63 may be attached to the side wall assembly 15 by fasteners 81 so that the ceiling panel covers the ceiling joists 61 (Figure 13B). In one embodiment, the fastener 81 comprises a 10d nail or other suitable fastener.

[0074] Referring to Figures 1 to 3, the second module 14 of the modular assembly 11 comprises a pair of side wall assemblies 115, a ceiling assembly 113 that can be attached to the top of the side wall assemblies, a floor assembly 117 that can be attached to the bottom of the side wall assemblies, and an end wall assembly 119 that can be attached to the side wall assemblies, floor assemblies, and ceiling assemblies. The side wall assemblies 115 and the end wall assemblies 119 are configured to support the floor assemblies 117 and ceiling assemblies 113, so that the floor assemblies and ceiling assemblies may be suspended from the sides of the wall assemblies. Therefore, the second module 14 may be constructed appropriately, like the first module 12, by attaching the wall assemblies 115 and 119 separately to the floor assemblies 117, and then attaching the ceiling assembly 113 to the wall assemblies. Other mounting sequences of assemblies 113, 115, 117, and 119 are also conceivable without departing from the scope of this disclosure. In one embodiment, the second module 14 incorporates balloon framing similar to the structure of the first module 12 in the construction of the module.

[0075] Referring to Figures 1 to 3 and Figure 15, each side wall assembly 115 comprises a top plate assembly or beam assembly 121, a bottom plate assembly or beam assembly 123, and a plurality of vertical members or studs 125A, 125B, 125C extending between the top and bottom plate assemblies. The top and bottom plate assemblies 121, 123 extend parallel to each other, and the studs 125A, 125B, 125C extend parallel to each other. The first stud 125A constitutes the majority of the stud and is spaced inward from the longitudinal ends of the top and bottom plate assemblies 121, 123. The first stud 125A extends into the top and bottom plate assemblies 121, 123 such that the first stud passes the bottom of the top plate assembly and extends below the top of the bottom plate assembly. One of the second studs 125B defines at least partially one end of the side wall assembly 115. The second stud 125B is positioned overall between the top and bottom plate assemblies 121, 125 such that the second stud extends from the top surface of the bottom plate assembly to the bottom surface of the top plate assembly. As will be described in more detail below, this configuration facilitates the attachment of the second module 14 to the first module 12. A partition stud 125C may be provided on the opposite side of one of the second studs 125B. Nogging 126 (Figure 27) may also be provided within the side wall assembly 115. In the illustrated embodiment, the first ends of the top and bottom plate assemblies 121, 123 are coplanar with one of the second studs 125B at one end of the side wall assembly, and the second ends of the top and bottom plate assemblies extend laterally past the second stud 125B at the opposite end of the side wall assembly 115. The first ends are configured for attachment to the first module 12, and the second ends are configured for attachment to the third module 16, as will be discussed in more detail below.

[0076] The lengths of the top and bottom plate assemblies 121 and 123 may define the length of the second module 14. The horizontal spacing between the studs 125A, 125B, and 125C may vary. These dimensions are illustrative only, and it should be understood that the components of the side wall assembly 115 may have other dimensions and spacings depending on the desired size and shape of the module 14. In the illustrated embodiment, each of the top and bottom plate assemblies 121 and 123 and the studs 125A, 125B, and 125C is constructed from a rectangular wooden member. However, the plate assemblies 121 and 123 and the studs 125A, 125B, and 125C may have other configurations without departing from the scope of the present disclosure.

[0077] Referring to Figures 15 and 16, the bottom plate assembly 123 may comprise a first bottom plate 127 defining the bottom of the side wall assembly 115, a header 129 positioned on top of the first bottom plate, and a plurality of spaced-apart second bottom plates 128 positioned on the header. In the illustrated embodiment, a single first bottom plate 127 and a single header 129 extend along the entire length of the side wall assembly 115. In the illustrated embodiment, the end of the header 129 extends outward from the partition stud 125C and does not have a second bottom plate 128. The portion of the header 129 extending past the partition stud 125C has a length configured to attach the side wall assembly 115 to another module, as will be discussed in more detail below. The second stud 125B rests on top of one of the second bottom plates 128, which is positioned at one end of the bottom plate assembly 123. The first stud 125A extends past the second bottom plate 128 and rests on the top of the first bottom plate 127 so that the second bottom plate is spaced apart by the first stud. In particular, the first stud 125A includes a notch at its bottom edge so that the bottom edge of the stud extends past the header 129 to the first bottom plate 127. The width or thickness of the first and second bottom plates 127, 128 and the first stud 125A is greater than the width / thickness of the header 129 so that the bottom plate assembly 123 defines a plurality of bottom recesses 130 spaced apart along the length of the side wall assembly 115. Fasteners 136 (Figures 31A and 31B) extending through the first and second bottom plates 127, 128 may attach the header 129 to the first and second bottom plates. In one embodiment, the fastener 136 is equipped with a 3-inch (7.6 cm) screw. Other suitable fasteners may be used.

[0078] The top plate assembly 121 may comprise a first top plate 137 defining the top of the side wall assembly 115, a second top plate 138 positioned at the bottom of the first top plate, a header 139 positioned at the bottom of the second top plate, and a plurality of third top plates 141 positioned at the bottom of the header. In the illustrated embodiment, the two first top plates 137 are spaced apart by a gap aligned with the partition studs 125C, and a single second top plate 138 and a single header 139 extend along the entire length of the side wall assembly 115 (Figure 15). In the illustrated embodiment, the ends of the header 139 extend outward from the partition studs 125C and do not have third top plates 141. The portion of the header 139 extending past the partition studs 125C has a length configured for attaching the side wall assembly 115 to another module, as will be discussed in more detail below. The second stud 125B contacts the bottom of the third top plate 141, which is located at the end of the top plate assembly 121. The first stud 125A extends past the third top plate 141 and contacts the bottom of the second top plate 138, so that the third top plate is spaced apart by the first stud. In particular, the first stud 125A includes a notch at its top edge so that the top edge of the stud extends past the header 139 to the second top plate 138. The width or thickness of the second and third top plates 138, 141 is greater than the width / thickness of the header 139 so that the top plate assembly 121 defines a plurality of top recesses 142 spaced apart along the length of the side wall assembly 115. Fasteners 144 (Figure 31C) extending through the first, second, and third top plates 137, 138, and 141 may attach the header 139 to the first, second, and third top plates. In one embodiment, the fasteners 144 are fitted with 5-inch (12.7 cm) screws. Other suitable fasteners may be used.

[0079] Referring to Figures 17 and 18, the end wall assembly 119 comprises a first top plate 145, a second top plate 146, a bottom plate 147, a plurality of vertical members or studs 149 extending between the top and bottom plates, and noggings 151 extending between the studs. The top and bottom plates 145, 146, and 147 extend parallel to each other, the studs 149 extend parallel to each other, and the noggings 151 extend parallel to each other. The studs 149 are arranged overall between the second top plate 146 and the bottom plate 147 such that the studs extend from the top surface of the bottom plate to the bottom surface of the second top plate. At least one header 153 may extend between the studs 149 along the length of the end wall assembly 119, and together with a footer 154 positioned below the header and extending between the same two studs, define an opening (i.e., a door opening) in the end wall assembly. Support blocks 157 may be provided on the bottom surface of the second top plate 146 and / or the top surface of the bottom plate 147. In the illustrated embodiment, the first top plate 145 extends laterally through the studs 149 on both sides of the end wall assembly 119. The position and size of the gap between the first top plates 137 described above are precisely controlled. As a result, the top plate 145 of the end wall 119 is housed in the gap (see Figure 22). In this way, the position of the end wall 119 is precisely controlled without measurement. The proper positioning of the end wall assembly 119 and wall assembly 115 is achieved by positioning the top plate 145 in the gap between the first top plates 137 of the wall assembly. The end wall assembly 119 may have other configurations without departing from the scope of this disclosure.

[0080] The lengths of the top and bottom plates 145, 146, and 147 may define the width of the second module 14. The horizontal spacing between the studs 149 may vary. These dimensions are illustrative only, and it should be understood that the components of the end wall assembly 119 may have other dimensions and spacings depending on the desired size and shape of the module 14. In the illustrated embodiment, each of the top and bottom plates 145, 146, and 147, the studs 149, the nogging 151, the header 153, the footer 154, and the support block 157 is constructed from a rectangular wooden member. However, the components of the end wall assembly may have other configurations without departing from the scope of the present disclosure.

[0081] Referring to Figures 19 to 21, the ceiling assembly 113 comprises a plurality of parallel ceiling joists 161A, 161B extending across the width of the ceiling assembly and spaced apart along the length of the ceiling assembly, a pair of ceiling plates 162 positioned on the opposite side of the ceiling assembly and extending along the length of the ceiling assembly, and a plurality of ceiling panels 163 covering the joists and plates. The first joist 161A extends partially across the ceiling assembly 113 along a first width segment of the ceiling assembly, and the second joist 161B extends partially across the ceiling assembly from the first joist along a second width segment of the ceiling assembly. Together, each pair of ceiling joists 161A, 161B extends across the entire width of the ceiling assembly 113. In the illustrated embodiment, the first joist 161A comprises a truss assembly having a first height, and the second joist 161B comprises a truss assembly having a second height greater than the first height. However, the joists 161A and 161B may have other configurations without departing from the scope of this disclosure. The joists 161A and 161B are attached to the inner surface of the ceiling plate 162 so as to connect the joists to each other, thereby forming the ceiling assembly 113.

[0082] The horizontal spacing between pairs of joists 161A, 161B along the length of the ceiling assembly 113 may vary. These ranges are illustrative only, and it is understood that the components of the ceiling assembly 113 may have other dimensions and spacings depending on the desired size and shape of the module 14. The joists 161A, 161B preferably extend in a direction perpendicular to the axis over which the wall assembly 115 extends. In the illustrated embodiment, each of the first and second ceiling joists 161A, 161B comprises a rectangular truss assembly including a plurality of truss members. In one embodiment, the first and second ceiling joists 161A, 161B comprise posi-joists manufactured by MiTek, Chesterfield, Missouri. The ceiling joists 161A, 161B may have other configurations without departing from the scope of the present disclosure.

[0083] Referring to Figures 20 and 21, the second ceiling joist 161B includes an MEP (mechanical, electrical, and plumbing) support incorporated into the joist to assist in the installation of MEP components 164 into module 14. In the illustrated embodiment, the MEP support comprises one or more support blocks 165 attached to the truss members of the joist 161B. For example, the ceiling joist 161B may comprise longitudinal truss members extending along the length of the ceiling joist and transverse truss members extending between the longitudinal truss members. The support block 165 may be mounted on a longitudinal truss member between two adjacent transverse truss members. Thus, the support block 165 provides additional structure to the truss members that constitute the structural support of the joist 161B. The support block 165 has a support surface for supporting the MEP components 164 that extend through the joist 161B. The support blocks 165 may have various sizes and / or be combined (for example, stacked on top of each other) to position the support surfaces of the support blocks at an appropriate height for the MEP components 164, thereby positioning the MEP components within the truss members. In one embodiment, the support blocks 165 include a marker 167 for instructing the installer which MEP components should be placed in that location. Furthermore, the marker 167 informs the installer where and how the MEP components 164 should extend through the joists 161B. For example, the marker 167 may include colored markings, arrows, descriptions, etc., that explain to the installer which MEP components 164 should pass along the support blocks 165 and in what direction and pitch the MEP components should extend. More specifically, MEP components 164 and 165 are sized and molded so that, during installation, the piping installed within the ceiling assembly 113 and resting on top of the MEP components automatically has the appropriate slope (for example, for gravity drainage). Therefore, MEP component 164 may be pre-installed within the ceiling assembly 113 before the ceiling assembly is attached to the other assemblies of the module. Similar markings may be provided on the wall assembly 115 to indicate the installation of electrical / piping components. Furthermore, the ceiling assembly 13 of the first module 12 may be equipped with MEP supports.

[0084] Referring to Figure 15, the floor assembly 117 comprises a plurality of parallel floor joists (not shown) spaced apart along the length of the floor assembly, floor plates 172 attached to the sides of the floor joists and positioned around the periphery of the floor assembly, and a plurality of floor panels 173 covering the joists and floor plates. The floor assembly 117 is configured similarly to the floor assembly 17 of the first module 12. In particular, the floor joists extend across the width of the floor assembly 117. In one embodiment, the joists may comprise rectangular timber members. In another embodiment, the joists may comprise rectangular truss assemblies. The joists may have other configurations without departing from the scope of the present disclosure. The joists are attached to the inner surfaces of the floor plates 172 so as to connect the joists to one another, thereby forming the floor assembly 117.

[0085] Referring to Figures 15 and 16, the floor assembly 117 is attached to the side wall assembly 115 along the side of the floor assembly by fasteners 175. In the illustrated embodiment, the fasteners 175 comprise screws (e.g., 3-inch (7.6 cm) screws) or other suitable fasteners. The fasteners 175 attach the bottom plate assembly 123 of the side wall assembly 115 to the floor plate 172 of the floor assembly 117. In particular, the fasteners 175 penetrate the header 129 of the side wall assembly 115 and are inserted into the floor plate 172 of the floor assembly 117. The fasteners 175 are positioned between floor joists so that they do not extend through the floor joists. In the illustrated embodiment, each header section between studs 125A includes a plurality of fasteners 175 spaced vertically along the header section. For example, each header section includes a single row of fasteners with a spacing of 3 inches (7.6 cm) between each adjacent fastener. However, the fasteners 175 may be positioned on the header 129 in other ways without departing from the scope of this disclosure. Furthermore, other means of attaching the floor assembly 117 to the side wall assembly 115 may be used without departing from the scope of this disclosure.

[0086] Referring to Figures 17, 18, and 22 through 23B, the end wall assembly 119 is attached to the side wall assembly 115 along the side of the end wall assembly by fasteners 177, and to the floor assembly at the end of the floor assembly 119 by fasteners 179. In the illustrated embodiment, the fasteners 177 are equipped with screws (e.g., 5-inch (12.7 cm) screws). The fasteners 177 attach the partition studs 125C of the side wall assembly 115 to the end studs 149 of the end wall assembly 119. In particular, the fasteners 177 penetrate the partition studs 125C of the side wall assembly 115 and are inserted into the end studs 149 of the end wall assembly 119. In the illustrated embodiment, the fasteners 177 are arranged in horizontally spaced pairs, with each pair being vertically spaced along the height of the side wall assembly 115. For example, each adjacent pair of fasteners is spaced approximately 12 inches (30.5 cm) apart. However, the fasteners 177 may be positioned on the partition studs 125C in other ways without departing from the scope of the disclosure. Furthermore, other means of attaching the end wall assembly 119 to the side wall assembly 115 may be utilized without departing from the scope of the disclosure.

[0087] Referring to Figures 17 and 18, the fastener 179 comprises a screw (e.g., a 3-inch (7.6 cm) screw) or other suitable fastener. The fastener 179 attaches the bottom portion of the end wall assembly 119 to the floor plate 172 of the floor assembly 117. In particular, the fastener 179 penetrates the bottom nogging 151 of the end wall assembly 119 and is inserted into the floor plate 172 of the floor assembly 117. In the illustrated embodiment, each nogging 151 includes a pair of fasteners 179 spaced horizontally across the nogging. For example, each pair of fasteners may have an 8-inch (20.3 cm) gap between the fasteners 179. However, the fasteners 179 may be positioned on the nogging 151 in other ways without departing from the scope of the disclosure. Furthermore, other means of attaching the floor assembly 117 to the end wall assembly 119 may be utilized without departing from the scope of the disclosure.

[0088] Referring to Figures 24 to 25B, the ceiling assembly 113 is attached to the side wall assembly 115 along the side of the ceiling assembly by fasteners 178. In the illustrated embodiment, the fasteners 178 comprise screws (e.g., 5-inch (12.7 cm) screws) or other suitable fasteners. The fasteners 178 attach the top plate assembly 121 of the side wall assembly 115 to the ceiling assembly 113. In particular, the fasteners 178 are inserted into the ceiling plate 162 of the ceiling assembly 113, passing through pre-drilled holes in the first and second top plates 137, 138 of the top plate assembly 121 and the studs 125A of the side wall assembly 115. In the illustrated embodiment, the first and second top plates 137, 138 include a plurality of fasteners 178 spaced horizontally along the top plates. For example, the first and second top plates 137 and 138 each include a single row of fasteners with a spacing of 12 inches (30.5 cm) between adjacent fasteners. A third row of fasteners with a spacing greater than 12 inches (30.5 cm) between adjacent fasteners is provided within the studs 125A. However, the fasteners 178 may be arranged in other ways on the side wall assembly 115 without departing from the scope of this disclosure. Furthermore, other means of attaching the ceiling assembly 113 to the side wall assembly 115 may be utilized without departing from the scope of this disclosure.

[0089] In some embodiments, the ceiling assemblies 13, 113 may be positioned on the wall assemblies 15, 115 and held in place at least temporarily. The top plates 37, 137 may be divided into segments, leaving gaps between adjacent segments of the top plate. The position and size of these gaps may be precisely controlled. In the ceiling assemblies 13, 113, the top cords of the extended lengths of the ceiling joists 161A, 161B, located at the opposite ends of the ceiling assemblies, can be placed in the gaps. This action results in the ceiling assemblies 13, 113 being precisely positioned in the correct location relative to the wall assemblies 15, 115 without measurement by the workers assembling modules 12, 112. This may be confirmed with respect to Figure 3 in the upper left corner of the drawing. Another advantage of this structure is that the ceiling assemblies 13, 113 may be self-supporting. The ceiling assemblies 13 and 113 may be temporarily held in place by the wall assemblies 15 and 115 until fasteners permanently connect these components.

[0090] Referring to Figure 26, the fasteners 179 also attach the top portion of the end wall assembly 119 to the ceiling plate 162 of the ceiling assembly 113. In particular, the fasteners 179 penetrate the support block 157 on the top plate 145 of the end wall assembly 119 and are inserted into the ceiling plate 162 of the ceiling assembly 113. In the illustrated embodiment, each support block 157 includes a pair of fasteners 179 spaced horizontally across the support block. For example, each pair of fasteners may have a spacing of 8 inches (20.3 cm) between the fasteners 179. However, the fasteners 179 may be positioned on the support block 157 in other ways without departing from the scope of the disclosure. Furthermore, other means of attaching the ceiling assembly 113 to the end wall assembly 119 may be utilized without departing from the scope of the disclosure.

[0091] Referring to Figures 27 to 30B, the third module 16 is attachable to the end of the second module 14 opposite to the end of the second module to which the first module is attached. In one embodiment, the third module 16 comprises a corridor frame. Therefore, the third module 16 may function as a connecting module between two module assemblies 11, 11'. Thus, the third module 16 may be considered as part of the module assemblies 11, 11', or as a separate module for connecting the two module assemblies. For example, the third module 16 may connect the two module assemblies 11, 11' in an end-to-end configuration, as shown in Figure 32.

[0092] The third module 16 may comprise a corridor floor assembly 217 that can be attached to the bottom of the second module 14, and a corridor ceiling assembly 213 that can be attached to the top of the second module. The ceiling assembly 213 comprises a plurality of parallel ceiling joists 261 that extend across the width of the ceiling assembly and are spaced apart along the length of the ceiling assembly, a pair of ceiling plates 262 that are located on the opposite side of the ceiling assembly and extend along the length of the ceiling assembly, and a plurality of ceiling panels 263 that cover the joists and plates. In the illustrated embodiment, the joists 261 comprise rectangular wooden members. However, the joists 261 may have other configurations without departing from the scope of the present disclosure. The joists 261 are attached to the inner surfaces of the ceiling plates 262 so as to connect the joists to each other, thereby forming the ceiling assembly 213.

[0093] The floor assembly 217 comprises a plurality of parallel floor joists 271 spaced apart along the length of the floor assembly, a pair of floor plates 272 positioned on the opposite side of the floor joists and extending along the length of the floor assembly, and a plurality of floor panels 273 covering the joists and floor plates. The floor assembly 217 is configured similarly to the ceiling assembly 213. In particular, the floor joists 271 extend across the width of the floor assembly 217. In the illustrated embodiment, the joists 271 comprise rectangular wooden members. However, the joists 271 may have other configurations without departing from the scope of the present disclosure. The joists 271 are attached to the inner surfaces of the floor plates 272 so as to connect the joists to each other, thereby forming the floor assembly 217.

[0094] Referring to Figures 27 to 28B, the floor assembly 217 of the third module 16 is attached to the side wall assembly 115 of the second module 14 at the side of the floor assembly by fasteners 177 and to the end wall assembly 119 of the second module at the end of the floor assembly by fasteners 179. In the illustrated embodiment, the fasteners 177 are equipped with screws (e.g., 5-inch (12.7 cm) screws). The fasteners 177 attach the bottom plate assembly 123 of the side wall assembly 115 to the floor assembly 217. The splice plate 185 is positioned on top of the header 129 so that the header is sandwiched between the splice plate 185 and the end floor joist 271. In particular, the fasteners 177 are inserted into the end floor joist 271 of the floor assembly 217, passing through the splice plate 185 and header 129 of the side wall assembly 115 (Figure 28A). In the illustrated embodiment, the fasteners 177 are arranged in vertically spaced pairs, with each pair spaced horizontally along the length of the side wall assembly 115. For example, each adjacent pair of fasteners is spaced more than 12 inches (30.5 cm) apart. However, the fasteners 177 may be arranged in other ways on the header 129 without departing from the scope of the disclosure. Furthermore, other means of attaching the floor assembly 217 to the side wall assembly 115 may be utilized without departing from the scope of the disclosure.

[0095] Referring to Figures 27 and 28B, the fasteners 179 comprise screws (e.g., 3-inch (7.6 cm) screws) or other suitable fasteners. The fasteners 179 attach the bottom portion of the end wall assembly 119 to the floor plate 272 of the floor assembly 217. In particular, the fasteners 179 are inserted into the studs 149 of the end wall assembly 119 by passing through pre-drilled holes in the floor plate 272 of the floor assembly 217. In the illustrated embodiment, a pair of vertically spaced fasteners 179 are driven into the studs 149. For example, each pair of fasteners may have a spacing of 4 inches (10 cm) between the fasteners 179. However, the fasteners 179 may be arranged in other ways without departing from the scope of the disclosure. Furthermore, other means of attaching the floor assembly 217 to the end wall assembly 119 may be utilized without departing from the scope of the disclosure.

[0096] Referring to Figures 29 to 30B, the ceiling assembly 213 is attached to the side wall assembly 115 along the side of the ceiling assembly by fasteners 177. In the illustrated embodiment, the fasteners 177 are threaded (e.g., 5-inch (12.7 cm) threads). The fasteners 177 attach the top plate assembly 121 of the side wall assembly 115 to the ceiling assembly 213. In particular, the fasteners 177 penetrate the header 139 of the side wall assembly 115 and are inserted into the end ceiling joists 261 of the ceiling assembly 213. In the illustrated embodiment, the fasteners 177 are arranged in vertically spaced pairs, with each pair spaced horizontally along the length of the side wall assembly 115. For example, each adjacent pair of fasteners is spaced more than 12 inches (30.5 cm) apart. However, the fasteners 177 may be arranged in other ways in the header 139 without departing from the scope of the present disclosure. Furthermore, other means of attaching the ceiling assembly 213 to the side wall assembly 115 may be used without departing from the scope of this disclosure.

[0097] Referring to Figures 30A and 30B, the fasteners 179 attach the top portion of the end wall assembly 119 to the ceiling plate 262 of the ceiling assembly 213. In particular, the fasteners 179 are inserted into the studs 149 of the end wall assembly 119 by passing through pre-drilled holes in the ceiling plate 262 of the ceiling assembly 213. In the illustrated embodiment, a pair of vertically spaced fasteners 179 are driven into the studs 149. For example, each pair of fasteners may have a spacing of 4 inches (10 cm) between the fasteners 179. However, the fasteners 179 may be arranged in other ways without departing from the scope of the disclosure. Furthermore, other means of attaching the ceiling assembly 213 to the end wall assembly 119 may be utilized without departing from the scope of the disclosure.

[0098] Referring to Figures 1 to 3 and Figures 31A to 31C, the first module 12 may be attached to the second module 14 along the top and bottom plate assemblies 21, 23, 121, and 123 of the first and second modules. In particular, a top splice plate (not shown) may be used to attach the top plate assemblies 21 and 121 of the first and second modules 12 and 14, respectively, and a bottom splice plate 85 may be used to attach the bottom plate assemblies 23 and 123 of the first and second modules, respectively (Figure 31A). The top splice plate is housed in the recess 43 at the module connection end of the first module 12 and the recess 142 at the module connection end of the second module 14 when the first and second modules are butted together (Figure 1). Similarly, the bottom splice plate 85 is housed in the recess 33 at the module connection end of the first module 12 and the recess 130 at the module connection end of the second module 14 when the first and second modules are butted together. Fasteners 87 are housed within the headers 29, 39, passing through the top and bottom splice plates to secure the splice plate to the top and bottom plate assemblies 21, 23, 121, 123, thereby securing the first and second modules 12, 14 to each other. In the illustrated embodiment, the splice plate comprises a rectangular plate member. However, the splice plate may have other configurations without departing from the scope of the present disclosure. Furthermore, only a single splice plate (either the top or bottom splice plate) may be used to connect the first and second modules 12, 14. Therefore, a single rectangular connecting plate may be provided for attaching the modules 12, 14 to each other.

[0099] Referring to Figure 32, the first module assembly 11 may be attached to the second module assembly 11' to form a double module assembly configuration. First, the third module 16 may be attached to the second module 14 of the first module assembly 11. For example, the floor assembly 217 of the third module 16 may be attached to the end wall assembly 119 of the second module 14 of the first module assembly 11, as previously described. The ceiling assembly 213 of the third module 16 is then attached to the end wall assembly 119 of the second module 14 of the first module assembly 11, as previously described. The second module assembly 11' may then be attached to the third module 16 on the side opposite to the first module assembly 11. In particular, the second module 14' of the second module assembly 11' may be attached to the third module 16, as previously described for the first module assembly 11. Therefore, the first and second module assemblies 11, 11' are mounted end-to-end in a facing orientation, having a third module 16 between the two module assemblies that forms a framework for a corridor. Thus, multiple double module assemblies may be arranged in parallel to form a framework for a single floor of an apartment building / hotel. Furthermore, the first and second module assemblies 11, 11' may be shipped in pairs to facilitate the construction of buildings containing multiple pairs of module assemblies.

[0100] When introducing elements of the present invention or preferred embodiments thereof, the articles “a,” “an,” “the,” and “said” are intended to indicate that there is one or more elements. The terms “equipped with,” “contains,” and “possessing” are intended to be inclusive and mean that additional elements other than those listed may exist.

[0101] Based on the above, it is understood that several objectives of the present invention are achieved and other advantageous results can be obtained.

[0102] Various modifications may be made to the above-described structures, products, and methods without departing from the scope of the present invention, so all matters contained herein and shown in the accompanying drawings are intended to be interpreted as illustrative rather than restrictive.

Claims

1. For constructing a building, one or more additional wooden modules and attachable wooden modules, wherein the modules are Wooden ceiling assembly and A plurality of wooden side wall assemblies are configured for attachment to the opposite side of the aforementioned wooden ceiling assembly, A wooden floor assembly configured to be attached to the wooden side wall assembly, wherein the wooden side wall assembly extends to the top of the wooden ceiling assembly and to the bottom of the wooden floor assembly, such that when the wooden ceiling assembly and the wooden floor assembly are attached to the wooden side wall assembly, the ceiling assembly and the wooden floor assembly come into contact with the inner surface of the wooden side wall assembly. A module equipped with [the necessary components].

2. The module according to claim 1, further comprising a wooden end wall assembly configured for attachment to the ends of the wooden ceiling assembly, the wooden side wall assembly, and the wooden floor assembly.

3. The module according to claim 1, wherein the wooden side wall assembly each includes a top plate assembly, a bottom plate assembly, and a plurality of studs extending between the top plate assembly and the bottom plate assembly.

4. The module according to claim 3, wherein the plurality of studs comprises first studs extending between the top plate assembly and the bottom plate assembly, and at least one second stud extending between the top plate assembly and the bottom plate assembly, each of the first studs having a length longer than the at least one second stud.

5. The module according to claim 4, wherein each first stud includes a bottom portion extending past the bottom of the top plate assembly and a top portion extending past the top of the bottom plate assembly, and the at least one second stud extends to the bottom of the top plate assembly and to the top of the bottom plate assembly.

6. The module according to claim 4, wherein the at least one second stud is located at the end of the side wall assembly.

7. The module according to claim 3, wherein the bottom plate assembly comprises a first bottom plate and a header directly mounted on the top of the first bottom plate.

8. The module according to claim 7, wherein the first stud extends past the header to the bottom plate.

9. The module according to claim 8, wherein the first stud has a notch formed therein, and the end portion of the first stud is configured to wrap around the header and extend to the bottom plate.

10. The module according to claim 9, wherein the end portion is attached to the header at two positions spaced apart along the length of the first stud.

11. The module according to claim 7, wherein the top plate assembly comprises a top plate and a header directly mounted on the bottom of the top plate.

12. The module according to claim 11, further comprising fasteners extending through the header to attach the wooden side wall assembly to the wooden ceiling assembly and the wooden floor assembly.

13. The module according to claim 7, wherein the bottom plate assembly comprises a second bottom plate positioned directly on the top of the header, and the at least one second stud is positioned on the top of the second bottom plate.

14. The module according to claim 13, wherein the recess is formed between the first bottom plate, one of the first studs, and the second bottom plate.

15. The module according to claim 14, further comprising a splice plate that can be positioned in the recess for attaching the module to another module.

16. A wall assembly for use in modules for constructing a building, wherein the wall assembly is A top plate assembly including a top plate and a header directly mounted on the bottom of the top plate, A bottom plate assembly comprising a bottom plate and a header directly mounted on the top of the bottom plate, A plurality of studs extending between the top plate assembly and the bottom plate assembly, wherein the plurality of studs comprises a first stud extending between the top plate assembly and the bottom plate assembly, and at least one second stud extending between the top plate assembly and the bottom plate assembly, and the first stud each having a length longer than the length of the at least one second stud, An assembly comprising the components.

17. The assembly according to claim 16, wherein the top plate, the bottom plate, and the header extend continuously along the entire length of the wall assembly.

18. The assembly according to claim 16, wherein the first stud extends past the bottom of the top plate assembly and past the top of the bottom plate assembly, and the at least one second stud extends to the bottom of the top plate assembly and to the top of the bottom plate assembly.

19. The assembly according to claim 16, wherein the at least one second stud is located at the end of the side wall assembly.

20. The assembly according to claim 16, wherein the first stud extends through the header on the top plate to the top plate in the top plate assembly, and extends through the header to the bottom plate in the bottom plate assembly.

21. The assembly according to claim 20, wherein the first stud comprises a first notch formed therein, wherein the bottom portion of the first stud extends around the header on the bottom plate, and a second notch formed therein, wherein the top portion of the first stud extends around the header on the top plate.

22. A ceiling assembly for use in modules for constructing a building, wherein the ceiling assembly is The extending first ceiling plate, The extending second ceiling plate, A plurality of ceiling joists extending between the first ceiling plate and the second ceiling plate, each ceiling joist comprising a truss assembly including a plurality of truss members, A support block attached to at least one of the truss members, the support block having a support surface for supporting MEP (mechanical, electrical, and plumbing) components extending through the ceiling joists, An assembly comprising the components.

23. The assembly according to claim 22, further comprising a marker on the support block to indicate a method for extending the MEP component through the ceiling joist.

24. The assembly according to claim 23, wherein the markings provide information regarding direction and pitch so as to extend the MEP components.

25. The assembly according to claim 23, wherein the sign comprises at least one of a colored marking, an arrow, or a description.

26. The assembly according to claim 22, further comprising the MEP components pre-placed on the ceiling assembly before installation of the ceiling assembly within the module.

27. The assembly according to claim 22, wherein the support block is positioned at a desired location on the MEP component before the MEP component is installed.

28. A first wooden module comprising a first wooden ceiling assembly, a plurality of first wooden side wall assemblies configured for attachment to the opposite side of the first wooden ceiling assembly, and a first wooden floor assembly configured for attachment to the first wooden wall assemblies, A second wooden module comprising a second wooden ceiling assembly, a plurality of second wooden side wall assemblies configured for attachment to the opposite side of the second wooden ceiling assembly, and a second wooden floor assembly configured for attachment to the second wooden wall assemblies, wherein the first wooden module is attached to the second wooden module in the first wooden side wall assemblies and the second wooden side wall assemblies, A wooden modular assembly equipped with [specific features / features].

29. The assembly according to claim 27, further comprising a splice plate for connecting the first wooden module to the second wooden module.

30. The assembly according to claim 27, further comprising a third wooden module attached to the second wooden module.

31. The assembly according to claim 29, wherein the third wooden module comprises a wooden floor assembly and a wooden ceiling assembly, and the third wooden module does not have a wall assembly.

32. The assembly according to claim 27, wherein the first wooden module comprises a dry module so that the first wooden module does not have a piping duct, and the second wooden module comprises a wet module so that the second wooden module includes piping components.

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