Modular building units

Abstract

Disclosed are a modular building unit (10), a modular building assembly (12) including the modular building unit, a building (28) including the modular building unit / assembly, and a method for constructing a building including the modular building unit. The modular building unit (10) includes a structural frame (16). The structural frame includes a floor frame portion (18) having a first depth (D1) and configured to support a planar floor structure (104), a ceiling frame portion (20) having a second depth (D2), and a support structure (22) extending between the floor frame portion and the ceiling frame portion and connecting the two frame portions. The ratio of the first depth (D1) of the floor frame portion to the second depth (D2) of the ceiling frame portion is at least about 1:3. The modular building unit defines a circulating space (42) configured to provide at least one access function to the building including the modular building unit. The building may be a hybrid residential building comprising a first building section (36) and a second building section (38). The first building section is constructed on-site at the final installation site (40) of the building. The second building section comprises modular building units (10). The first and second building sections are joined together at the final installation site to form the building.

Description

Technical Field

[0001] The present invention relates to modular building units, modular building assemblies including modular building units, buildings including modular building units / assemblies, and methods of constructing buildings including modular building units (particularly hybrid buildings). In particular, but not limited to, the present invention relates to modular building units including a floor frame portion, a ceiling frame portion, and a structural frame having a support structure extending between the floor frame portion and the ceiling frame portion to connect the two portions.

Background Art

[0002] Prefabricated buildings (also known as "modular" buildings) are well known in the construction industry, particularly modular residential buildings such as houses, flats or apartments, and hotels. [[ID=十六]]Modular buildings typically include a set of building units that are constructed in a factory, transported to the final installation location (or site) of the building, and then arranged in a predetermined configuration and connected to each other to form a completed building. Modular building units are typically constructed in a substantially assembled form in a factory and can be transported in that form to the final installation location. The construction of a building can include stacking one or more upper modular building units on top of lower modular building units, thereby supporting the upper units with the lower units.

[0003] The applicant has developed a hybrid building that includes a first building section constructed at the final installation location of the building and a second building section including one or more modular building units constructed in a dedicated facility away from the final installation location. This type of hybrid building can offer advantages including: the construction of the first building section is simplified, the more complex parts of the building are located in sections formed by modular building units, and the first building section can house the main living spaces of the building without being constrained by the construction and transportation limitations imposed on modular building units. Hybrid buildings and related construction technologies are disclosed in International Publication No. 2022 / 243696, Search Report No. 2022 / 243695, Search Report No. 2022 / 243694, Search Report No. 2022 / 243693, and Search Report No. 2023 / 222853.

[0004] Most modular building units include floor sections, ceiling sections, and structural frames such as support structures, the of which connect the ceiling section to the floor section and transfer structural loads from the ceiling section to the floor section. Modular building units are typically roughly rectangular (e.g., square) in their floor plans. The support structure includes columns or pillars that extend between the floor and the ceiling. Support posts are typically located at the corners of the unit, with additional posts positioned around them. The support structure may also include lateral bracing struts extending between at least some of the columns. The wall is formed by connecting wall panels or sheets to the columns. A metal frame is an option for the support structure, and it can be manufactured by cold forming (e.g., using light steel), hot forming (e.g., using hot-rolled steel), or a combination of both. A hot-formed metal frame can provide sufficient rigidity, allowing for the omission (or reduction) of additional perimeter supports and bracing struts. Another option is a wooden frame.

[0005] The floor portion of conventional modular building units is relatively deep (when viewed vertically), and is often deeper than the ceiling portion. The floor typically includes a frame formed by many beams and / or joists, and its depth can be 30 cm (about 12 inches) or more. Because modular building units forming the lowest level or base floor of a building are often installed on a concrete foundation, it was traditionally necessary to provide such deep floor frames. Therefore, in order to reduce thermal energy transfer between the foundation and the modular building units, a thick layer of insulation must be incorporated into the floor portion itself. Furthermore, it is believed that a deep floor frame is necessary to give the structure rigidity, including for transportation.

[0006] Modular building units with deep floor frames can cause problems in the hybrid buildings of the types described above. For example, it may be difficult to match the floor level of a building section formed by modular building units with the floor level formed in a section to be constructed at the final building site. Furthermore, the ceiling frames of known modular building units can also be relatively deep. When modular building units are stacked to form multi-story buildings, the intersection between the ceiling of the lower unit and the floor of the upper unit can result in a very deep structure. This makes moving between units via stairs more complicated and also impacts material usage, weight, and cost. It will be understood that these issues can also arise even in fully modular buildings, such as the need to take measures to accommodate deep floors during the construction process. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] International Publication No. 2022 / 243696 [Patent Document 2] International Public Release No. 2022 / 243695 Search Report [Patent Document 3] International Public Release No. 2022 / 243694 Search Report [Patent Document 4] International Public Release No. 2022 / 243693 Search Report [Patent Document 5] International Public Release No. 2023 / 222853 Search Report [Overview of the Initiative]

[0008] According to a first aspect of the present invention, a modular building unit including a structural frame is provided, the structural frame is A floor frame portion having a first depth, which is configured to support a planar floor structure. A ceiling frame portion having a second depth, and A support structure that extends between the floor frame and the ceiling frame, connecting the two frame sections. Includes, The ratio of the first depth of the floor frame to the second depth of the ceiling frame is at least approximately 1:3. The modular building units optionally define a circular space configured to provide at least one access function to the building containing the modular building units.

[0009] The depth of the floor and ceiling frame sections may be considered or measured in a generally vertical direction. Alternatively, the vertical height of the floor and ceiling frame sections (and / or parts of both frame sections) may be referenced.

[0010] Providing modular building units with the described depth relationships may offer certain advantages in the context of the aforementioned types of hybrid buildings. This includes making it easier to match the floor level of building compartments containing modular building units with the floor level of building compartments constructed at the final installation site. For example, both the compartments formed by the modular building units and the compartments constructed at the final installation site may rest on a common foundation. It is sometimes desirable to maintain a common (or uniform) floor level within the constructed building to avoid variations in floor height between building compartments. By providing floor and ceiling frame sections with such depth relationships, it may be possible to make the depth of the floor frame sections relatively shallow, requiring only small height differences to be accommodated. This may offer new advantages in terms of material and cost savings. Furthermore, by arranging both frame sections so that their depths are in the described ratio, it may be possible to make the ceiling frame sections relatively deep without negatively impacting the depth of the floor frame sections. This allows the ceiling frame to provide most of the structural strength to the modular building unit, and can provide space for, for example, utility / building equipment (such as drainage pipes, water supply pipes, ventilation pipes, power cables, and communication cables for plumbing fixtures installed in upper modular building units stacked on top of such lower units). The shallow floor frame can also be useful in reducing the structural depth at the junction between the ceiling of the lower modular building unit and the floor of such upper units.

[0011] The ratio of the first depth to the second depth may be up to approximately 1:6. The ratio may be in the range of approximately 1:3 to approximately 1:6. A ratio within this range can provide a good balance between the relatively thin floor frame portion and the ceiling frame portion, which can provide most of the structural strength for the modular building unit and / or space to accommodate necessary utilities / building equipment. However, this ratio may exceed 1:6, for example, up to about 1:7 or even up to about 1:8.

[0012] The first depth of the floor frame portion may be a maximum of approximately 70 mm (approximately 2.756”). A floor frame portion of this depth may be relatively shallow, and may be significantly shallower than the floor frame portion of conventional modular building units. In a hybrid building comprising a first section to be constructed at the final installation site and a second section containing modular building units, the floor height of the first section may be raised to the floor height of the second section by, for example, applying cementitious screed to the floor support structure of the first section. It may be preferable to keep the first depth to approximately 70 mm or less, and this depth may be the optimal maximum height for such screed. The first depth may be a maximum of approximately 50 mm (approximately 1.968”). The first depth may be in the range of approximately 50 mm to approximately 70 mm. It may be preferable that the depth be within the range of approximately 50 mm.

[0013] The second depth of the ceiling frame portion may be at least approximately 150 mm (approximately 5.906"), the second depth may be up to approximately 300 mm (approximately 11.811"), optionally up to approximately 350 mm, and optionally up to approximately 400 mm. The second depth may be in the range of approximately 150 mm to approximately 300 mm, and preferably in the range of approximately 250 mm to approximately 260 mm.

[0014] A modular building unit having such first and second depths of a floor frame portion and a ceiling frame portion can achieve a good balance of advantages in terms of, for example, minimizing disruption for accommodating the floor frame portion and / or minimizing the structural depth of the transition location between a lower modular building unit and an upper modular building unit, while realizing a sufficiently strong ceiling frame portion and / or the depth of the ceiling frame portion for accommodating utilities / building service equipment.

[0015] The first depth of the floor frame portion may be defined by a part or parts of the floor frame portion within the load path. The second depth of the ceiling frame portion may be defined by a part or parts of the ceiling frame portion within the load path. The load path (which may be a direct load path) may be a path through which a load is transmitted (or passes) from the ceiling frame portion through a support structure to the floor frame portion during normal use of the modular building unit. The load path may be for a load transmitted from another (e.g., upper) modular building unit stacked or placed on the modular building unit and / or the load of the modular building unit itself. For the purposes of this analysis, the depth relationship between D1 and D2 may be determined based on a structure within or on such a load path. Thus, D1 may be based on the depth or height of a part or parts of the floor frame portion within or on the load path, and D2 may be based on the depth or height of a part or parts of the ceiling frame portion within or on the load path.

[0016] The modular building unit may generally be quadrilateral in plan view, generally rectangular, or generally cubic.

[0017] The bed frame portion may include a bed frame. The first depth of the bed frame portion may be defined or depicted by the bed frame. The bed frame may have an upper surface. The bed frame may have a lower surface. The first depth may be defined between the upper surface and the lower surface. The bed frame may include a plurality of elongated frame members, and / or may be formed from a plurality of elongated frame members, or may be defined by a plurality of elongated frame members. The elongated frame members may define the upper surface and / or the lower surface. The bed frame may include a peripheral frame structure (or loop member / structure), and the peripheral frame structure may include an elongated beam. The peripheral frame structure may include a first side beam and a second side beam, and the two side beams may be arranged substantially parallel to each other. The peripheral frame structure may include a first end beam and a second end beam, and the two end beams may be arranged substantially parallel to each other. The first side beam, the second side beam, the first end beam, and the second end beam may together form or define most or all of the peripheral frame structure. The bed frame may include at least one support beam, and the support beam may extend in a direction between the first end beam and the second end beam and may be disposed between the side beams. The bed frame may include at least one support beam, and this support beam may extend in a direction between the first side beam and the second side beam, or in a direction between one of the first side beam and the second side beam and a support beam extending between the end beams. The bed frame may include a plurality of elongated joists. At least one joist may extend in a direction between the first side beam and the second side beam. At least one joist may be configured to have a depth (e.g., shallower) different from the depth of the beam forming the peripheral frame structure (this beam is the first depth).

[0018] The floor frame may be configured to support a planar floor structure. The planar floor structure may define the floor of a modular building unit. The planar floor structure may include one or more planar floor panels, or may be defined by one or more planar floor panels. The first depth of the floor frame portion may not include the planar floor structure, other structural or insulating materials placed on the floor structure, and / or any decorative floor finishes or coverings (e.g., carpet or tiles) placed on the floor structure.

[0019] The ceiling frame portion may include a ceiling frame. The second depth of the ceiling frame portion may be defined or depicted by the ceiling frame. The ceiling frame may have an upper surface, which may be configured to support another modular building unit stacked on top of or placed on top of a modular building unit. The ceiling frame may have a lower surface, which may be seated on a support structure. The second depth may be defined between the upper and lower surfaces. The ceiling frame may include a plurality of elongated frame members and / or may be formed from a plurality of elongated frame members, or may be defined by a plurality of elongated frame members. The elongated frame members may define the upper and / or lower surfaces. The ceiling frame may include a periphery frame structure, which may include elongated beams. The periphery frame structure may include a first side beam and a second side beam, which may be arranged substantially parallel to each other. The periphery frame structure may include a first end beam and a second end beam, and the end beams may be arranged substantially parallel to each other. The first side beam and the second side beam, as well as the first end beam and the second end beam, may together form or define most or all of the periphery frame structure. The ceiling frame may include at least one support beam, which may extend in the direction between the first end beam and the second end beam, and may be positioned between the side beams. The ceiling frame may include a plurality of elongated joists. At least one joist may extend in the direction between the first side beam and the second side beam. At least one joist may be configured to have a depth different from (e.g., shallow) the depth of the beams forming the periphery frame structure.

[0020] The ceiling frame portion may include at least one mounting member, and may include more than one mounting member. The mounting member may serve to attach another (e.g., upper) modular building unit to a modular building unit. At least one mounting member may project or extend from the top surface or extension of one or more frame members forming part of the ceiling frame. At least one mounting member may optionally extend upward and / or substantially vertically from the top surface / extension of the ceiling frame members. At least one mounting member may be in the form of a block, column, stub, pin, or plug.

[0021] At least one mounting member, particularly the upper surface of this mounting member, may be configured to contact the lower surface of another (e.g., upper) modular building unit stacked or placed on top of the modular building unit, particularly the lower surface of the floor frame of this other unit. This may provide the advantage of creating a gap, space, or void between two modular building units using at least one mounting member, where utility / building equipment such as the sewer pipes mentioned above can be accommodated. This gap can be created with minimal additional structure, thus reducing costs and weight. A second depth may be defined between the upper surface of the mounting member and the lower surface of the ceiling portion (which may be defined by the ceiling frame, particularly the lower surface of the elongated frame members). At least one mounting member may be connected to or provided by the ceiling frame (integrated with the ceiling frame). Multiple mounting members may be spaced along the periphery of the modular building unit defined by the ceiling frame. Mounting members may be provided at each corner of the modular building unit, which may be defined by the ceiling frame. The ceiling frame may include multiple mounting members. Openings may be provided between adjacent pairs of mounting members, through which utility / building equipment can be passed. Multiple openings may be provided, each opening defined between adjacent pairs of mounting members.

[0022] The ceiling frame may include or define load-transfer compartments. These load-transfer compartments may be configured to transfer loads to the support structure. The loads may be borne by other (e.g., upper) modular building units that may be stacked on top of or placed on top of the modular building units.

[0023] The load-transfer compartment may include the ceiling frame. The load-transfer compartment may include at least one mounting member.

[0024] The ceiling frame portion, particularly the ceiling frame, may be configured to support a planar ceiling structure. This planar ceiling structure may define the ceiling of a modular building unit. This planar ceiling structure may include or be defined by one or more planar ceiling panels. The second depth of the ceiling frame portion may not include this planar ceiling structure, other structural or insulating materials connected to this planar ceiling structure, and / or decorative finishes or coatings (cement-based coatings) applied to this planar ceiling structure.

[0025] This specification refers to the ceiling frame portion and the ceiling of a modular building unit. The ceiling frame portion (and ceiling) should be interpreted as the superstructure that covers or encloses the interior space of the modular building unit. It will be understood that the ceiling frame portion of a modular building unit does not typically have a weather-resistant roof structure intended to prevent, for example, water from entering the modular building unit. For example, a separate roof structure may be formed and placed on top of the modular building unit to make it weather-resistant. However, a modular building unit can optionally be provided with such a roof by, for example, installing a ceiling frame portion and adding an additional roof to the outside or exterior of the unit. This may be a particular option for, for example, a single-story building containing a modular building unit, or when the unit forms the top floor of a building. A flat roof structure can be cited as a suitable option.

[0026] The ceiling frame portion may include structural (e.g., elongated) frame members. The ceiling frame portion, in particular the load-transfer section, may take the form of a general structure such as a grid or grids. The ceiling frame portion, in particular the load-transfer section, may include: a lower structural member that may define the lower surface of the load-transfer section; an upper structural member that may define the upper surface of the load-transfer section; and at least one connecting member that may extend between the lower and upper structural members and connect the two structural members. The at least one connecting member may serve to transmit the load from the upper structural member to the lower structural member, and thereby to the support structure. There may be multiple connecting members. At least one connecting member may be in the form of a strut and may be positioned substantially perpendicular to the main axis of the upper and / or lower structural member. At least one connecting member may be in the form of a brace and may be positioned transversely to the main axis of the upper and / or lower structural member, preferably at an angle other than 90°.

[0027] The ceiling frame, particularly the load-bearing section, may include several generally elongated sections that combine to define the load-bearing section. The support structure may define several walls of a modular building unit, which may be exterior walls (for example, located on or defining at least part of the perimeter of the unit). Each wall may have a generally elongated section. Each generally elongated section may be seated on a corresponding wall. Each generally elongated section may be positioned transversely (optionally substantially perpendicularly) to at least one adjacent generally elongated section. Each generally elongated section may include corresponding lower and upper structural members, with at least one connecting member extending between the lower and upper structural members to connect them. The upper structural members of the elongated sections may form a periphery frame (or loop member) with each other, which may be an upper periphery frame. The lower structural members of the elongated portion may form a peripheral frame (or loop member) with other members, and this peripheral frame may be a lower peripheral frame.

[0028] Equipment openings may be defined by or between structural members of the ceiling frame. At least one opening may be defined between at least some lower structural members and upper structural members and between connecting members.

[0029] The ceiling frame portion, particularly the load-transfer section, may include a lower surface that may be seated on one or more upper surfaces of the support structure. The load-transfer section may have an upper surface, which may be configured to support another (e.g., upper) modular building unit.

[0030] The ceiling frame portion, particularly the load-transfer section, may have a specific height (which may be a first height), or may be a specific height. This height may be defined between the upper and lower surfaces of the load-transfer section. The (first) height may be in the range of approximately 200 mm to approximately 300 mm, optionally up to approximately 350 mm, and optionally up to approximately 400 mm. It is preferable that the (first) height be in the range of approximately 250 mm to approximately 260 mm.

[0031] The ceiling frame portion may include a ceiling compartment, which may be configured to define or support the ceiling of a modular building unit. The ceiling compartment may be located inside a load-bearing compartment and may be connected to a load-bearing compartment. The ceiling compartment may have a bottom surface, which may be located lower than the top surface of the support structure, particularly the wall of the support structure / wall defined by the support structure.

[0032] The ceiling frame portion may define an equipment space. The equipment space may have an upper boundary, which may be defined or formed by a plane encompassing the upper surface of the load-transfer compartment. The equipment space may have a lower boundary, which may be defined or formed by a plane encompassing the lower surface of the ceiling compartment. The equipment space may be defined between the plane encompassing the upper surface of the load-transfer compartment and the plane encompassing the lower surface of the ceiling compartment.

[0033] The equipment void may have a specific height (which may be a second height) or be of a specific height. The height of the void may be higher than the height of the load transfer compartment. The (second) height may be in the range of approximately 250 mm to approximately 350 mm, or it may be higher. It is preferable that the (second) height be in the range of approximately 275 mm to approximately 295 mm.

[0034] The ceiling compartment may have an upper surface, which may be positioned lower than (and / or below) the upper surface of the load-transfer compartment. The ceiling compartment may have a specific height (which may be a third height), or be of a specific height. This height may be defined between the upper and lower surfaces of the ceiling compartment. The height of the ceiling compartment may be lower than the height of the load-transfer compartment. The third height may be lower than either the first or second height. The (third) height may be in the range of approximately 70 mm to approximately 100 mm. It may be preferable that the (third) height be in the range of approximately 75 mm to approximately 95 mm.

[0035] The height of the opening for equipment is determined by the structural features of the ceiling frame and the dimensions of the structural members, but may be in the range of approximately 120 mm to 175 mm, and preferably approximately 150 mm to 160 mm.

[0036] The ceiling compartment may hang down from the load-transfer compartment, thereby overlapping the upper part of the supporting structure, particularly one or more walls defining the upper surface.

[0037] The load-transfer compartment may form the outer portion of the ceiling frame. The load-transfer compartment may define at least a portion of the outer perimeter of the ceiling frame. The load-transfer compartment may include a perimeter structure, which may extend along the perimeter of the modular building unit. The ceiling compartment may form the inner portion of the ceiling frame. Since the ceiling compartment may be located inside the outer perimeter, it may be located inside the load-transfer compartment. The load-transfer compartment may define or have an inner perimeter. The ceiling compartment may be located inside the inner perimeter. The ceiling compartment may extend below the load-transfer compartment inside the inner perimeter.

[0038] Load-bearing compartments and / or ceiling compartments (especially their structural frame members) may be formed from any suitable material and construction technique, but may be cold-formed (e.g., folded-formed) metal members, particularly light steel (forming light steel frames or LGSF).

[0039] This section refers to the top and bottom surfaces of feature parts of modular building units. It will be understood that such surfaces are considered to be either vertically up or down during the normal use of the modular building unit. Therefore, the corresponding top surface of a feature part can be considered to be higher than its bottom surface, when considered vertically. The height of the feature part may also be referred to. Similarly, such height may be considered to be measured / considered vertically during the normal use of the modular building unit.

[0040] The second depth of the ceiling frame portion may not include ceiling compartments (which may support or define the ceiling). The second depth may be defined or defined by load-bearing compartments. The second depth may be defined or defined by some or more portions of the ceiling frame portion that are substantially in line with and / or seated on the supporting structure (in particular one or more walls defined or defined by the supporting structure).

[0041] The support structure may include at least one column or brace, and may preferably include multiple columns or braces. The columns / braces may be located at one or more corners of the modular building unit, particularly at one or more corners of the floor frame sections. At least one column / brace may be located on the periphery of the floor frame sections, spaced apart from one or more corners. The support structure may include bracing members or support members that extend transversely between adjacent pairs of columns / braces. Other options for the support structure include structural insulation panels (SIPs) and other panels such as cement-based materials.

[0042] Access functions provided by a circulating space (which may also be called a circulating area or moving space / zone) may include: access between upper and lower living spaces of a building (e.g., provided by the upper and lower floors of the building), optionally via stairs or elevator shafts and elevators provided at least partially in modular building units; access between a first living space of a building and at least one other living space, which is optionally separated from each other in another part of the building and optionally at the same height / floor (e.g., via corridors / landings and one or more doorways or passages provided at least partially in modular building units); and access from the outside of the building to the inside of the building (e.g., via one or more doorways or passages, and optionally via corridors provided by modular building units).

[0043] A circulating space may be defined as a whole by its (or a particular) modular building unit. For example, if the circulating space provides access from outside the building, the space may be defined as a whole by such a unit alone. A circulating space may be defined by a combination of multiple modular building units. For example, if the circulating space provides access between upper and lower living spaces, two or more units may work together to establish this access, for example, each unit may form part of a staircase or elevator shaft.

[0044] At least one modular building unit may define at least one room (and it is appropriate to define it completely or entirely), and may define multiple rooms. At least one modular building unit may include an interior space, in which rooms(s) may be defined and may occupy a portion of this space. At least one modular building unit may be configured to have one or more walls, which may define one or more boundaries (optionally all boundaries) of the room. At least one room may include plumbing fixtures, which may be selected from the group including bathrooms, shower rooms, bedroom bathrooms, w / Cs or washrooms, and utility rooms. One or more of the multiple rooms may be configured to include plumbing fixtures.

[0045] At least one modular building unit may be configured to define at least a portion of the perimeter of the building, which may be the outer perimeter. The modular building unit may include one or more walls, and one or more walls of the modular building unit may be positioned to define a portion of this perimeter. One or more walls may be positioned such that their outer surfaces define the outer surface of the building, and their outer surfaces may be covered or surface-treated with finishes / coatings (e.g., panels, brick slip, cement-based primers).

[0046] According to a second aspect of the present invention, a modular building assembly is provided: First modular building unit, and A second modular building unit is positioned on top of the first modular building unit so that the second modular building unit is supported by the first modular building unit. Includes, The first modular building unit includes a structural frame, and the structural frame is A floor frame portion having a first depth, which is configured to support a planar floor structure. A ceiling frame portion having a second depth, and A support structure that extends between the floor frame and the ceiling frame, connecting the two frame sections. Includes, The ratio of the first depth of the floor frame to the second depth of the ceiling frame is at least approximately 1:3. The modular building units optionally define a circular space configured to provide at least one access function to the building containing the modular building units. A modular building assembly is provided.

[0047] The first modular building unit may have any of the other features described above with respect to the first embodiment. The second modular building unit may be a modular building unit according to the first embodiment, and therefore may have any of the other features described above.

[0048] According to a third aspect of the present invention, a building is provided that includes a modular building unit of the first aspect or a modular building assembly of the second aspect.

[0049] The building may be a hybrid building having a first building section and a second building section, in particular a hybrid residential building. The first building section may be constructed on-site at the final installation site of the building. The second building section may be defined by, and / or include, modular building units of the first embodiment or modular building assemblies of the second embodiment. The first and second building sections may be configured to be joined at the final installation site to form a building.

[0050] The building may be a modular building comprising at least one (optionally more) modular building units (at least one of which is a modular building unit according to the first embodiment) or a modular building assembly according to the second embodiment. The interior space of the building may be entirely formed by this unit / one or more assemblies, with the exception of the roof above or outside the building, optionally.

[0051] The building may include a foundation containing load-bearing structures and insulation. Modular building units / assemblies may be positioned on the foundation such that the load-bearing structures serve as structural supports for the modular building units / assemblies, and the insulation provides insulation for the modular building units / assemblies from the ground.

[0052] A circulating space (which may also be called a circulating area or moving space / zone) may be configured to provide one or more access functions selected from the group including: access between upper and lower living spaces of a first building compartment (e.g., between the upper and lower floors of the compartment, via stairs, or elevator shafts and elevators); access between a first living space of a first building compartment and at least one other living space, which is optionally separated from one another within the first building compartment and optionally at the same height / floor of the compartment (e.g., via corridors / landings and one or more doorways or passages); and access from outside the building into the first building compartment, thus access from outside the building into the building (e.g., via one or more doorways or passages, and optionally via corridors).

[0053] The modular building unit may have any of the other features described above with respect to the first embodiment.

[0054] According to a fourth aspect of the present invention, a method for constructing a hybrid building, The process of constructing the first building section at the final installation location of the building. A step of constructing a modular building unit according to the first aspect of the present invention at a location away from the final installation site, thereby bringing it into a substantially assembled state. A process of transporting modular building units to the final installation site in a substantially assembled form, arranging the modular building units to form at least a portion of the second building section of the building, and The process of joining the first building section and the second building section to form a building. A method is provided that includes this.

[0055] The building may be a hybrid residential building.

[0056] The method may include constructing a building foundation, and may include providing load-bearing structures and insulation in the foundation. The method may include placing at least one modular building unit on the foundation, so that the load-bearing structures of the foundation become structural supports for the modular building unit, and the insulation of the foundation insulates the modular building unit from the ground. The method may include arranging a first building section such that the first building section is supported by the foundation.

[0057] This method may include arranging modular building units to form a planar floor structure of a second building compartment, and may include providing an upper support surface for the planar floor structure. This method may include forming a planar floor structure by placing one or more planar floor panels or panels on the floor frame portion of a modular building unit, and arranging these panels to form an upper support surface.

[0058] This method may include providing a floor in the first building compartment, and may include providing an upper support surface on the floor. This method may include arranging the floor of the first building compartment such that the upper support surface of the floor of the first building compartment is at the same or uniform height as the upper support surface of the modular building unit. This method may include making the depth of the floor of the first building compartment equal to the sum of the first depth of the modular building unit and the depth of the planar floor structure of the modular building unit.

[0059] Other features of this method may be derived from other parts of this specification (any of the other embodiments disclosed), in particular from one or more of the first to third embodiments, or from any text written by reference thereto.

[0060] According to a fifth aspect of the present invention, a modular building unit including a structural frame is provided, the structural frame is A floor frame portion configured to support a flat floor structure, the floor frame portion having a maximum depth of approximately 70 mm (2.756”) The ceiling frame section has a depth of at least approximately 150 mm (5.906”), and A support structure that extends between the floor frame and the ceiling frame, connecting the two frame sections. Includes, The modular building units optionally define a circular space configured to provide at least one access function to the building containing the modular building units.

[0061] The depth of the floor and ceiling frame sections may be considered or measured in a generally vertical direction. Alternatively, the vertical height of the floor and ceiling frame sections may be referenced.

[0062] Providing modular building units with the described depth relationships may offer certain advantages in the context of the aforementioned types of hybrid buildings. This includes making it easier to match the floor levels of building sections, including modular building units, with the floor levels of building sections constructed at the final installation site. For example, both the sections formed by modular building units and the sections constructed at the final installation site may be placed on a common foundation. It is sometimes desirable to maintain a common (or uniform) floor level within a constructed building to avoid variations in floor height between building sections. A floor frame section with this depth may end up being relatively shallow, only needing to accommodate slight differences in height. This could offer new advantages in terms of material and cost reduction. Furthermore, it allows for a relatively deeper ceiling frame without negatively impacting the depth of the floor frame. This allows the ceiling frame to provide the majority of the structural strength for the modular building unit, and can provide space to accommodate utility / building equipment such as drainage pipes for plumbing fixtures installed in upper modular building units stacked on top of such lower units. Shallow floor frame sections can also be useful in reducing the structural depth at the junction between the ceiling of the lower modular building unit and the floor of such an upper unit.

[0063] The depth of the floor frame may be a first depth, and the depth of the ceiling frame may be a second depth. The ratio of the first depth of the floor frame to the second depth of the ceiling frame may be at least about 1:3. The ratio of the first depth to the second depth may be up to about 1:6. The ratio of the first depth to the second depth may be in the range of about 1:3 to about 1:6. A ratio within this range may provide a good balance between a relatively thin floor frame and a ceiling frame that can provide most of the structural strength for the modular building unit and / or space to accommodate necessary utilities / building equipment. However, this ratio may exceed 1:6, for example, up to about 1:7 or even up to about 1:8.

[0064] A floor frame section having the depth described can be significantly shallower than the floor frame section of a conventional modular building unit. In a hybrid building comprising a first section to be constructed at the final installation site and a second section containing modular building units, the floor height of the first section may be raised to the floor height of the second section by, for example, applying cementitious screed to the floor support structure of the first section. It may be beneficial to keep the depth of the floor frame section to approximately 70 mm or less, as this may be the optimal maximum height for such screed. The depth may be a maximum of approximately 50 mm (approximately 1.968"), and may be in the range of approximately 50 mm to approximately 70 mm. A depth within the range of approximately 50 mm may be preferred.

[0065] The depth of the ceiling frame may be a maximum of approximately 300 mm (approximately 11.811"), with the depth being in the range of approximately 150 mm to 300 mm, with an optional maximum of approximately 350 mm, and an optional maximum of 400 mm. A depth in the range of approximately 250 mm to 260 mm is preferable.

[0066] Modular building units with such floor and ceiling frame depths can strike a good balance of advantages, for example, by minimizing the disruption required to accommodate the floor frame and / or minimizing the structural depth of the transition area between the lower and upper modular building units, while also providing a sufficiently strong ceiling frame and / or ceiling frame depth for accommodating utility / building equipment.

[0067] The depth of the floor frame portion may be defined by some or more portions of the floor frame portion that lie within the load path. The depth of the ceiling frame portion may be defined by some or more portions of the ceiling frame portion that lie within the load path. The load path (which may be a direct load path) may be the path through which loads are transmitted (or traversed) from the ceiling frame portion through the support structure to the floor frame portion during the normal use of the modular building unit. The load path may be for loads transmitted from another (e.g., upper) modular building unit stacked on or placed on the modular building unit and / or for the load of the modular building unit itself. For the purposes of this analysis, the depth may be determined based on the structure in or above such load path. Thus, the depth of the floor frame portion may be based on the depth or height of some or more portions of the floor frame portion that lie within or above the load path, and the depth of the ceiling frame portion may be based on the depth or height of some or more portions of the ceiling frame portion that lie within or above the load path.

[0068] Modular building units may be roughly quadrilateral, roughly rectangular, or roughly cubic in their plan view.

[0069] The floor frame portion may include a floor frame. The depth of the floor frame portion may be defined or described by the floor frame. The floor frame may have an upper surface. The floor frame may have a lower surface. The depth may be defined between the upper and lower surfaces. The floor frame may include a plurality of elongated frame members and / or be formed from a plurality of elongated frame members, or be defined by a plurality of elongated frame members. The elongated frame members may define the upper and / or lower surfaces. The floor frame may include a periphery frame structure (or loop member / structure), and the periphery frame structure may include elongated beams. The periphery frame structure may include a first side beam and a second side beam, and the side beams may be arranged substantially parallel to each other. The periphery frame structure may include a first end beam and a second end beam, and the end beams may be arranged substantially parallel to each other. The first and second side beams, and the first and second end beams, together may form or define most or all of the periphery frame structure. The floor frame may include at least one support beam, which may extend in the direction between the first and second end beams and may be positioned between the side beams. The floor frame may include at least one support beam, which may extend in the direction between the first and second side beams, or in the direction between either the first or second side beam and the support beam extending between the end beams. The floor frame may include a plurality of elongated joists. At least one joist may extend in the direction between the first and second side beams. At least one joist may be configured to have a depth (e.g., shallow) different from the depth of the beams forming the periphery frame structure (the depth of which the beams are described).

[0070] The floor frame may be configured to support a planar floor structure. The planar floor structure may define the floor of a modular building unit. The planar floor structure may include one or more planar floor panels, or may be defined by one or more planar floor panels. The depth of the floor frame portion may not include the planar floor structure, other structural or insulating materials placed on the floor structure, and / or any decorative floor finishes or coverings (e.g., carpet or tiles) placed on the floor structure.

[0071] The ceiling frame portion may include a ceiling frame. The depth of the ceiling frame portion may be defined or described by the ceiling frame. The ceiling frame may have an upper surface, which may be configured to support another modular building unit stacked on top of or placed on top of a modular building unit. The ceiling frame may have a lower surface, which may be seated on a support structure. The depth may be defined between the upper and lower surfaces. The ceiling frame may include a plurality of elongated frame members and / or may be formed from a plurality of elongated frame members, or may be defined by a plurality of elongated frame members. The elongated frame members may define the upper and / or lower surfaces. The ceiling frame may include a periphery frame structure, which may include elongated beams. The periphery frame structure may include a first side beam and a second side beam, which may be arranged substantially parallel to each other. The periphery frame structure may include a first end beam and a second end beam, and the end beams may be arranged substantially parallel to each other. The first side beam and the second side beam, as well as the first end beam and the second end beam, may together form or define most or all of the periphery frame structure. The ceiling frame may include at least one support beam, which may extend in the direction between the first end beam and the second end beam, and may be positioned between the side beams. The ceiling frame may include a plurality of elongated joists. At least one joist may extend in the direction between the first side beam and the second side beam. At least one joist may be configured to have a depth different from (e.g., shallow) the depth of the beams forming the periphery frame structure.

[0072] The ceiling frame portion may include at least one mounting member, and may include more than one mounting member. The mounting member may serve to attach another (e.g., upper) modular building unit to a modular building unit. At least one mounting member may project or extend from the top surface or extension of one or more frame members forming part of the ceiling frame. At least one mounting member may optionally extend upward and / or substantially vertically from the top surface / extension of the ceiling frame members. At least one mounting member may be in the form of a block, column, stub, pin, or plug.

[0073] At least one mounting member, particularly the upper surface of this mounting member, may be configured to contact the lower surface of another (e.g., upper) modular building unit stacked or placed on top of the modular building unit, particularly the lower surface of the floor frame of this other unit. This may provide the advantage of creating a gap, space, or void between two modular building units using at least one mounting member, where utility / building equipment such as the sewer pipes mentioned above can be accommodated. This gap can be created with minimal additional structure, thus potentially reducing costs and weight. The depth of the ceiling frame portion may be defined between the upper surface of the mounting member and the lower surface of the ceiling portion (which may be defined by the ceiling frame, particularly the lower surface of the elongated frame members). At least one mounting member may be connected to or provided by the ceiling frame (integrated with the ceiling frame). Multiple mounting members may be spaced along the periphery of the modular building unit defined by the ceiling frame. Mounting members may be provided at each corner of the modular building unit, which may be defined by the ceiling frame. The ceiling frame may include multiple mounting members. Openings may be provided between adjacent pairs of mounting members, through which utility / building equipment can be passed. Multiple openings may be provided, each opening defined between adjacent pairs of mounting members.

[0074] The ceiling frame may include or define load-transfer compartments. These load-transfer compartments may be configured to transfer loads to the support structure. The loads may be borne by other (e.g., upper) modular building units that may be stacked on top of or placed on top of the modular building units.

[0075] The load-transfer compartment may include the ceiling frame. The load-transfer compartment may include at least one mounting member.

[0076] The ceiling frame portion, particularly the ceiling frame, may be configured to support a planar ceiling or ceiling structure. This planar ceiling structure may define the ceiling of a modular building unit. This planar ceiling structure may include or be defined by one or more planar ceiling panels. The depth of the ceiling frame portion may not include this planar ceiling structure, other structural materials or insulation connected to this planar ceiling structure, and / or decorative finishes or coatings (cement-based coatings) applied to this planar ceiling structure.

[0077] This specification refers to the ceiling frame portion and the ceiling of a modular building unit. The ceiling frame portion (and ceiling) should be interpreted as the superstructure that covers or encloses the interior space of the modular building unit. It will be understood that the ceiling frame portion of a modular building unit does not typically have a weather-resistant ceiling structure intended to prevent, for example, water from entering the modular building unit. For example, a separate ceiling structure may be formed and placed on top of the modular building unit to make it weather-resistant. However, a modular building unit can optionally be provided with such a ceiling by, for example, installing a ceiling frame portion to provide an additional ceiling on the outside or outside of the unit. This may be a particular option for, for example, a single-story building containing a modular building unit, or when the unit forms the top floor of a building. A suitable option is a flat ceiling structure.

[0078] The ceiling frame portion may include structural (e.g., elongated) frame members. The ceiling frame portion, in particular the load-transfer section, may take the form of a general structure such as a grid or grids. The ceiling frame portion, in particular the load-transfer section, may include: a lower structural member that may define the lower surface of the load-transfer section; an upper structural member that may define the upper surface of the load-transfer section; and at least one connecting member that may extend between the lower and upper structural members and connect the two structural members. The at least one connecting member may serve to transmit the load from the upper structural member to the lower structural member, and thereby to the support structure. There may be multiple connecting members. At least one connecting member may be in the form of a strut and may be positioned substantially perpendicular to the main axis of the upper and / or lower structural member. At least one connecting member may be in the form of a brace and may be positioned transversely to the main axis of the upper and / or lower structural member, preferably at an angle other than 90°.

[0079] The ceiling frame, particularly the load-bearing section, may include several generally elongated sections that combine to define the load-bearing section. The support structure may define several walls of a modular building unit, which may be exterior walls (for example, located on or defining at least part of the perimeter of the unit). Each wall may have a generally elongated section. Each generally elongated section may be seated on a corresponding wall. Each generally elongated section may be positioned transversely (optionally substantially perpendicularly) to at least one adjacent generally elongated section. Each generally elongated section may include corresponding lower and upper structural members, with at least one connecting member extending between the lower and upper structural members to connect them. The upper structural members of the elongated sections may form a periphery frame (or loop member) with each other, which may be an upper periphery frame. The lower structural members of the elongated portion may form a peripheral frame (or loop member) with other members, and this peripheral frame may be a lower peripheral frame.

[0080] Equipment openings may be defined by or between structural members of the ceiling frame. At least one opening may be defined between at least some lower structural members and upper structural members and between connecting members.

[0081] The ceiling frame portion, particularly the load-transfer section, may include a lower surface that may be seated on one or more upper surfaces of the support structure. The load-transfer section may have an upper surface, which may be configured to support another (e.g., upper) modular building unit.

[0082] The ceiling frame portion, particularly the load-transfer section, may have a specific height (which may be a first height), or may be a specific height. This height may be defined between the upper and lower surfaces of the load-transfer section. The (first) height may be in the range of approximately 200 mm to approximately 300 mm, optionally up to approximately 350 mm, and optionally up to approximately 400 mm. It is preferable that the (first) height be in the range of approximately 250 mm to approximately 260 mm.

[0083] The ceiling frame portion may include a ceiling compartment, which may be configured to define or support the ceiling of a modular building unit. The ceiling compartment may be located inside a load-bearing compartment and may be connected to a load-bearing compartment. The ceiling compartment may have a bottom surface, which may be located lower than the top surface of the support structure, particularly the wall of the support structure / wall defined by the support structure.

[0084] The ceiling frame portion may define an equipment space. The equipment space may have an upper boundary, which may be defined or formed by a plane encompassing the upper surface of the load-transfer compartment. The equipment space may have a lower boundary, which may be defined or formed by a plane encompassing the lower surface of the ceiling compartment. The equipment space may be defined between the plane encompassing the upper surface of the load-transfer compartment and the plane encompassing the lower surface of the ceiling compartment.

[0085] The equipment void may have a specific height (which may be a second height) or be of a specific height. The height of the void may be higher than the height of the load transfer compartment. The (second) height may be in the range of approximately 250 mm to approximately 350 mm, or it may be higher. It is preferable that the (second) height be in the range of approximately 275 mm to approximately 295 mm.

[0086] The ceiling compartment may have an upper surface, which may be positioned lower than (and / or below) the upper surface of the load-transfer compartment. The ceiling compartment may have a specific height (which may be a third height), or be of a specific height. This height may be defined between the upper and lower surfaces of the ceiling compartment. The height of the ceiling compartment may be lower than the height of the load-transfer compartment. The third height may be lower than either the first or second height. The (third) height may be in the range of approximately 70 mm to approximately 100 mm. It may be preferable that the (third) height be in the range of approximately 75 mm to approximately 95 mm.

[0087] The height of the opening for equipment is determined by the structural features of the ceiling frame and the dimensions of the structural members, but may be in the range of approximately 120 mm to 175 mm, and preferably approximately 150 mm to 160 mm.

[0088] The ceiling compartment may hang down from the load-transfer compartment, thereby overlapping the upper part of the supporting structure, particularly one or more walls defining the upper surface.

[0089] The load-transfer compartment may form the outer portion of the ceiling frame. The load-transfer compartment may define at least a portion of the outer perimeter of the ceiling frame. The load-transfer compartment may include a perimeter structure, which may extend along the perimeter of the modular building unit. The ceiling compartment may form the inner portion of the ceiling frame. Since the ceiling compartment may be located inside the outer perimeter, it may be located inside the load-transfer compartment. The load-transfer compartment may define or have an inner perimeter. The ceiling compartment may be located inside the inner perimeter. The ceiling compartment may extend below the load-transfer compartment inside the inner perimeter.

[0090] Load-bearing compartments and / or ceiling compartments (especially their structural frame members) may be formed from any suitable material and construction technique, but may be cold-formed (e.g., folded-formed) metal members, particularly light steel (forming light steel frames or LGSF).

[0091] This section refers to the top and bottom surfaces of feature parts of modular building units. It will be understood that such surfaces are considered to be either vertically up or down during the normal use of the modular building unit. Therefore, the corresponding top surface of a feature part can be considered to be higher than its bottom surface, when considered vertically. The height of the feature part may also be referred to. Similarly, such height may be considered to be measured / considered vertically during the normal use of the modular building unit.

[0092] The second depth of the ceiling frame portion may not include ceiling compartments (which may support or define the ceiling). The second depth may be defined or defined by load-bearing compartments. The second depth may be defined or defined by some or more portions of the ceiling frame portion that are substantially in line with and / or seated on the supporting structure (in particular one or more walls defined or defined by the supporting structure).

[0093] The support structure may include at least one column or brace, and may preferably include multiple columns or braces. The columns / braces may be located at one or more corners of the modular building unit, particularly at one or more corners of the floor frame sections. At least one column / brace may be located on the periphery of the floor frame sections, spaced apart from one or more corners. The support structure may include bracing members or support members that extend transversely between adjacent pairs of columns / braces. Other options for the support structure include structural insulation panels (SIPs) and other panels such as cement-based materials.

[0094] Access functions provided by a circulating space (which may also be called a circulating area or moving space / zone) may include: access between upper and lower living spaces of a building (e.g., provided by the upper and lower floors of the building), optionally via stairs or elevator shafts and elevators provided at least partially in modular building units; access between a first living space of a building and at least one other living space, which is optionally separated from each other in another part of the building and optionally at the same height / floor (e.g., via corridors / landings and one or more doorways or passages provided at least partially in modular building units); and access from the outside of the building to the inside of the building (e.g., via one or more doorways or passages, and optionally via corridors provided by modular building units).

[0095] A circulating space may be defined as a whole by its (or a particular) modular building unit. For example, if the circulating space provides access from outside the building, the space may be defined as a whole by such a unit alone. A circulating space may be defined by a combination of multiple modular building units. For example, if the circulating space provides access between upper and lower living spaces, two or more units may work together to establish this access, for example, each unit may form part of a staircase or elevator shaft.

[0096] At least one modular building unit may define at least one room (and it is appropriate to define it completely or entirely), and may define multiple rooms. At least one modular building unit may include an interior space, in which rooms(s) may be defined and may occupy a portion of this space. At least one modular building unit may be configured to have one or more walls, which may define one or more boundaries (optionally all boundaries) of the room. At least one room may include plumbing fixtures, which may be selected from the group including bathrooms, shower rooms, bedroom bathrooms, w / Cs or washrooms, and utility rooms. One or more of the multiple rooms may be configured to include plumbing fixtures.

[0097] At least one modular building unit may be configured to define at least a portion of the perimeter of the building, which may be the outer perimeter. The modular building unit may include one or more walls, and one or more walls of the modular building unit may be positioned to define a portion of this perimeter. One or more walls may be positioned such that their outer surfaces define the outer surface of the building, and their outer surfaces may be covered or surface-treated with finishes / coatings (e.g., panels, brick slip, cement-based primers).

[0098] According to a sixth aspect of the present invention, a modular building assembly is provided: First modular building unit, and A second modular building unit is positioned on top of the first modular building unit so that the second modular building unit is supported by the first modular building unit. Includes, The first modular building unit includes a structural frame, and the structural frame is: A floor frame portion configured to support a flat floor structure, the floor frame portion having a maximum depth of approximately 70 mm (2.756”) The ceiling frame section has a depth of at least approximately 150 mm (5.906”), and A support structure that extends between the floor frame and the ceiling frame, connecting the two frame sections. Includes, The modular building units optionally define a circular space configured to provide at least one access function to the building containing the modular building units. A modular building assembly is provided.

[0099] The first modular building unit may have any of the other features described above with respect to the fifth embodiment. The second modular building unit may be a modular building unit according to the fifth embodiment, and therefore may have any of the other features described above.

[0100] According to a seventh aspect of the present invention, a building is provided that includes a modular building unit of the fifth aspect or a modular building assembly of the sixth aspect.

[0101] The building may be a hybrid building having a first building section and a second building section, in particular a hybrid residential building. The first building section may be constructed on-site at the final installation site of the building. The second building section may be defined by, and / or include, a modular building unit of the fifth embodiment or a modular building assembly of the sixth embodiment. The first and second building sections may be configured to be joined at the final installation site to form a building.

[0102] The building may be a modular building comprising at least one (optionally more) modular building units (at least one of which is a modular building unit according to the fifth aspect) or modular building assemblies according to the sixth aspect. The interior space of the building may be entirely formed by these units / assemblies, with the exception of the roof above or outside the building, optionally.

[0103] The building may include a foundation containing load-bearing structures and insulation. Modular building units / assemblies may be positioned on the foundation such that the load-bearing structures serve as structural supports for the modular building units / assemblies, and the insulation provides insulation for the modular building units / assemblies from the ground.

[0104] A circulating space (which may also be called a circulating area or moving space / zone) may be configured to provide one or more access functions selected from the group including: access between upper and lower living spaces of a first building compartment (e.g., between the upper and lower floors of the compartment, via stairs, or elevator shafts and elevators); access between a first living space of a first building compartment and at least one other living space, which is optionally separated from one another within the first building compartment and optionally at the same height / floor of the compartment (e.g., via corridors / landings and one or more doorways or passages); and access from outside the building into the first building compartment, thus access from outside the building into the building (e.g., via one or more doorways or passages, and optionally via corridors).

[0105] The modular building unit may have any of the other features described above with respect to the fifth embodiment.

[0106] According to the eighth aspect of the present invention, The process of constructing the first building section at the final installation location of the building. A step of constructing a modular building unit according to the fifth aspect of the present invention at a location away from the final installation site, thereby bringing it into a substantially assembled state. A process of transporting modular building units to the final installation site in a substantially assembled form, arranging the modular building units to form at least a portion of the second building section of the building, and The process of joining the first building section and the second building section to form a building. A method for constructing a hybrid building that includes [a specific element] is provided.

[0107] The building may be a hybrid residential building.

[0108] The method may include constructing a building foundation, and may include providing load-bearing structures and insulation in the foundation. The method may include placing at least one modular building unit on the foundation, so that the load-bearing structures of the foundation become structural supports for the modular building unit, and the insulation of the foundation insulates the modular building unit from the ground. The method may include arranging a first building section such that the first building section is supported by the foundation.

[0109] This method may include arranging modular building units to form a planar floor structure of a second building compartment, and may include providing an upper support surface for the planar floor structure. This method may include forming a planar floor structure by placing one or more planar floor panels or panels on the floor frame portion of a modular building unit, and arranging these panels to form an upper support surface.

[0110] This method may include providing a floor in the first building compartment, and may include providing an upper support surface on the floor. This method may include arranging the floor of the first building compartment such that the upper support surface of the floor of the first building compartment is at the same or uniform height as the upper support surface of the modular building unit. This method may include making the depth of the floor of the first building compartment equal to the sum of the depth of the floor frame portion of the modular building unit and the depth of the planar floor structure of the modular building unit.

[0111] Other features of this method may be derived from other parts of this specification (any of the other embodiments disclosed), in particular from one or more of embodiments V through VII, or from any text written by reference thereto.

[0112] See also, and incorporate into this application by reference to, the hybrid buildings and related construction methods disclosed in International Publication No. 2022 / 243696, International Publication No. 2022 / 243695, International Publication No. 2022 / 243694, International Publication No. 2022 / 243693, and International Publication No. 2023 / 222853.

[0113] Next, embodiments of the present invention will be described as mere examples with reference to the accompanying drawings. [Brief explanation of the drawing]

[0114] [Figure 1] This is an isometric view of a modular building unit according to one embodiment of the present invention, and of a modular building assembly including this modular building unit. [Figure 2] Figure 1 shows a modular building unit and a modular building assembly containing this unit, drawn to different scales and cut in the direction of arrow A. [Figure 3] Figure 1 shows an end view of a modular building unit and a modular building assembly containing this unit, drawn to different scales and cut in the direction of arrow B. [Figure 4] This is an enlarged perspective view of a portion of the structural frame of a modular building unit. [Figure 5] This is an enlarged perspective view of a portion of the structural frame of a modular building unit. [Figure 6] This is a perspective view of a hybrid building according to one embodiment of the present invention, including the modular building units (and modular building assemblies) shown in Figures 1 and 2, with the building's outer layers removed. [Figure 7] Figure 6 is a perspective view of the hybrid building, including the outer layers. [Figure 8] These are floor plans of the lower floors of the hybrid building shown in Figures 6 and 7, drawn to different scales. [Figure 9]Figures 6 and 7 are floor plans of the upper floors of the hybrid building, drawn to different scales. [Figure 10] Figure 1 is an isometric view of a simplified wireframe of the modular building assembly, shown relative to the building foundations in Figures 6 and 7. [Figure 11] Figure 10 shows a portion of the foundation and a magnified vertical cross-sectional view of the modular building unit. [Figure 12] Figures 4 and 5 are plan views of the floor frame portion of the structural frame shown. [Figure 13] Figures 4 and 5 are plan views of the ceiling frame portion of the structural frame shown. [Figure 14] This is a wireframe isometric view of a plurality of modular building assemblies configured to form part of a building according to an alternative embodiment of the present invention. [Figure 15] This is an isometric view of a ceiling frame portion that forms part of the structural frame of a modular building unit according to another embodiment of the present invention. [Figure 16] Figure 15 is a magnified view of a portion of the ceiling frame shown. [Figure 17] This is a front cross-sectional view of a modular building assembly including first and second modular building units, the first modular building unit including the ceiling frame portion in Figure 15, and the modular building assembly is a view cut along line AA in Figure 15. [Figure 18] Figure 15 is an isometric view showing building equipment mounted on panels attached to the ceiling frame. [Figure 19] This is another enlarged view showing a modified example of the ceiling assembly shown in Figure 15. [Modes for carrying out the invention]

[0115] First, looking at Figure 1, we see an isometric view of a modular building unit according to one embodiment of the present invention, and this unit is shown throughout by reference numeral 10. The modular building unit 10 is shown in the drawing with certain features removed so that the structure of the unit is visible. The drawings also show a modular building assembly, indicated throughout by reference no. 12, which includes modular building unit 10 and another modular building unit indicated by reference no. 14. Referring also to Figures 2 and 3, these are side and end views of the modular building unit 10 and the modular building assembly 12, respectively, drawn to different scales. These diagrams illustrate the structural features of the walls or faces of unit 10 / assembly 12, which can be viewed in the line of sight.

[0116] The modular building unit 10 includes a structural frame, which is denoted by the number 16 throughout. The structural frame 16 includes a floor structure on a plane (described below), a ceiling frame portion 20, and a floor frame portion 18 configured to support a support structure 22 that extends between the floor frame portion and the ceiling frame portion and connects the two portions. As best shown in the enlarged perspective views of Figures 4 and 5 (showing the lower corner region 24 and upper corner region 26 of the structural frame 16), the floor frame portion 18 has a first depth D1, while the ceiling frame portion 20 has a second depth D2. The ratio of the first depth D1 of the floor frame portion 18 to the second depth D2 of the ceiling frame portion 20 may be at least approximately 1:3. It will be understood that the depths D1 and D2 of the floor frame section and ceiling frame section 18 and 20 are considered or measured in the overall vertical direction. However, the vertical height of the floor frame portion and the ceiling frame portion 18, 20 (and parts thereof) may be referenced.

[0117] There are many options for forming the structural frame 16. A preferred option is a metal frame, which can be made of cold-formed metal or metal alloy (e.g., light steel), hot-formed metal or metal alloy (e.g., hot-rolled steel), or a combination of the two. Hot-formed metal frames can achieve sufficient rigidity, allowing for the omission (or reduction) of additional perimeter supports and bracing struts. Another option is a wood-based frame. However, in the illustrated embodiment, the structural frame 16 is formed by combining hot-formed steel and cold-formed steel, and may be an elongated member with a box-shaped cross-section that is hollow overall, or it may have C-shaped, L-shaped, or U-shaped grooves. Methods for connecting the structural components of a frame include welding (for metal frames), adhesive bonding, and mechanical fastening such as nut and bolt assemblies and rivets.

[0118] Next, referring to Figure 6, this figure is a perspective view of a hybrid building 28 according to one embodiment of the present invention, and includes the modular building unit 10 (and modular building assembly 12) shown in Figures 1 and 2. In Figure 6, the hybrid building 10 is shown with its outer layers removed so that the building's structure is visible. Figure 7 is almost identical to Figure 6, but shows the outer layer 30, which in this embodiment is formed of brick or block.

[0119] In the illustrated embodiment, the hybrid building 28 is a house, and more specifically, a detached house. However, the principle of the present invention is also applicable to other types of housing, such as semi-detached houses, terraced houses, and single-story houses (bungalows). Furthermore, the principle of the present invention is applicable to other residential buildings such as apartments and hotels, and is actually applicable to non-residential buildings such as industrial or commercial buildings.

[0120] The hybrid building 28 includes a first building section 36 and a second building section 38. The first building section 36 is constructed on-site at the final building location 40 and is generally L-shaped in the floor plan (however, it is not limited to this shape). To show the interior of this section, a portion of the first building section 36 has been removed in the diagram. The second building section 38 includes a modular building unit 10 that is roughly rectangular in its floor plan. Unit 10 is constructed in a form that is substantially assembled, for example, in a dedicated factory or facility, away from the final installation site 40. Unit 10 is transported to the final installation site 40 in a substantially assembled form and positioned to form at least a portion of the second building section 38. In the illustrated embodiment, the second building section 38 is actually formed by a modular building assembly 12 and therefore includes both a modular building unit 10 and another modular building unit 14. Another unit 14 is preferably a unit according to the present invention, and therefore has substantially the same characteristics as unit 10 and shares the same reference number with the suffix "'". As described in detail in International Publication No. 2022 / 243696, International Publication No. 2022 / 243695, International Publication No. 2022 / 243694, International Publication No. 2022 / 243693, and International Publication No. 2023 / 222853, the hybrid building 28 is formed by connecting a first building section 36 and a second building section 38 together at the final installation site 40.

[0121] As can be seen from Figure 6, the second building section 38 conforms to the generally L-shaped first building section 36, forming a generally rectangular building in the floor plan. Of course, other shapes are also possible. The modular building unit 10 can be made to any suitable dimensions, but generally, it is a requirement that it needs to be transported from the factory to the final installation site 40, for example, by road or rail. The illustrated unit 10 has a length of approximately 5300-5400 mm and a width of approximately 2500-2600 mm, making it particularly suitable for this type of transport. Because Unit 10 is smaller than many conventional modular building units, it can be easier to transport and handle. This makes it easy to install the relatively thin floors described herein, resulting in savings in materials, weight, and cost. Although the illustrated unit 10 extends only to a portion of the space between the front and back of the building 28, other units according to the present invention may extend along the entire length of the building, and therefore, for example, their length may be larger.

[0122] The modular building unit 10 defines a circulating space configured to provide one or more access functions to the hybrid building 28. This is best illustrated in Figures 8 and 9, which are floor plans of the lower floor 32 and upper floor 34 of the hybrid building 28, respectively, drawn to different scales. The circulation space is denoted by the number 42 and is shown in the drawing with dashed lines and crosshatching. In the illustrated embodiment, the circulation space 42 provides three access functions. One such function is access between the lower living spaces 44 and the upper living spaces 46 of the building 28, provided by the lower and upper floors 32 and 34. This is achieved using the stairs 48 of the modular building unit 10 (however, it can also be achieved using elevator shafts and elevators, etc.). Living space 44 will be a lounge or living room, and living space 46 will be a bedroom. Therefore, the circulating space 42 provides access between these different living spaces.

[0123] Another such function is access between a first living space of a building and at least one other living space, where both living spaces are located separately within different parts of the building. As can be seen in Figure 8, the first building section 36 includes a living space 44 (lounge or living room) and another living space 50 that forms an open-plan kitchen-dining room. The circulation space 42 provides access between the living spaces 44 and 50 via passage openings 52, 54 and corridor 55. It should be noted that the exact configuration of the passageway opening shown in Figures 8 and 9 is slightly different from that shown in Figures 1 to 3 of Unit 10. This shows possible alternative locations for the opening. The circulating space 42 further provides access between the lower living spaces 44 (and space 50 as well) and the upper living spaces 46, which are actually separated from each other within the first building section 36. Additionally, separate living spaces 56 and 58 (which also serve as bedrooms) are located on the upper floor 34 of the first building section 36, and the circulation space 42 provides access both between these separate living spaces 56 and 58 and between the lower living spaces 44 / 50 and these separate living spaces.

[0124] Another such function is access from the outside 60 of the building to the inside of the building 28 via an entrance or passage 62 of unit 10, where the entrance is the main entrance of the building. Entrance 62 leads to corridor 55 and provides access to staircase 48 (for access to upper living spaces 46, 56 and 58) and internal passages 52 and 54 (for access to lower living spaces 44 and 50).

[0125] The illustrated modular building unit 10 includes a circulating space 42 that provides all three of the aforementioned access functions, but it will be understood that, depending on the modification, it may provide only one or some of the functions described.

[0126] Providing modular building units 10 with a depth relationship (in practice, D2 ≥ 3D1 is required) between the floor portion 18 and the ceiling portion 20 of the structural frame may be particularly advantageous in the context of the aforementioned hybrid building 28. This includes making it easier to match the floor level of the second building section 38 to the floor level of the first section 36 constructed at the final installation site 40. In particular, the first building section 36 and the second building section 38 may be on a common foundation. This is shown in Figure 10, which is an isometric view of a simplified wireframe of the modular building assembly 12 of Figure 1, shown relative to the foundation 64 of the building 28. The foundation 64 supports both the second building section 38 (defined by the modular building assembly 12) and the first building section 36, which is omitted in this diagram.

[0127] To avoid changes in floor height between building sections 36 and 38, it is sometimes desirable to maintain a common (or uniform) floor level within the constructed building 28. If the structural frame 16 of the modular building unit is provided with the frame portions of the floor 18 and ceiling 20 having the depth relationship described, the depth D1 of the floor frame portion can be made relatively shallow, which may result in only a slight difference in height needing to be adjusted in the first building section 36. This could offer advantages in terms of reducing materials and costs. Furthermore, by configuring the depths D1 and D2 of the floor 18 and ceiling 20 frames to be in the ratios described, it may be possible to make the ceiling frame relatively deep without negatively affecting the depth of the floor frame. As a result, the ceiling frame portion 20 accounts for the majority of the structural strength of the modular building unit 10, and can also provide space for accommodating utility / building equipment for inspecting the upper modular building units 14 that are stacked and hanging down on top of the (lower) unit 10. Utility / building equipment may include drainage pipes, water supply pipes, ventilation pipes, and power and communication cables for plumbing fixtures, particularly those installed in the upper modular building units 14. The shallow floor frame portion can also be useful in reducing the structural depth D3 (Figure 5) of the boundary between the ceiling portion 20 of the (lower) modular building unit 10 and the floor portion 18' of the upper unit 14.

[0128] The ratio of the first depth D1 of the floor portion 18 of the structural frame to the second depth D2 of the ceiling portion 20 of the frame may be at most about 1:6, and may be in the range of about 1:3 to about 1:6. If the ratio falls within this range, a good balance can be achieved between the relatively thin floor portion 18 and the ceiling portion 20, which can account for the majority of the structural strength of the modular building unit 10, and / or the space for accommodating necessary utilities / building equipment. However, this ratio may exceed 1:6, for example, up to about 1:7 or even 1:8.

[0129] The first depth D1 of the floor frame portion 18 may be a maximum of approximately 70 mm (approximately 2.756”). A floor frame section 18 of this depth can be relatively shallow, and can be significantly shallower than the floor frame sections of conventional modular building units. Referring to Figure 11, this figure is an enlarged vertical cross-sectional view of a portion of the foundation and modular building unit 10 shown in Figure 10. The foundation 64 is an insulated foundation and includes a load-bearing structure 68 and insulation material 70. The modular building unit 10 is positioned on a foundation 64 such that the load-bearing structure 68 serves as the structural support for the unit, and the insulation material 70 insulates the modular building unit from the ground 72.

[0130] As shown in Figure 11, the height of the floor 74 of the first building compartment 36 may be raised to the height of the floor frame portion 18 of the modular building unit 10 (which forms part of the second building compartment 38) by, for example, applying cementitious screed 76 to the floor support structure of the first compartment (in this case, the load-bearing foundation structure 68). The first depth D1 of the floor frame portion 18 may preferably be kept to approximately 70 mm or less, which may be the optimal maximum height of the screed 76. However, a particularly preferred option is that the first depth D1 may be up to approximately 50 mm (approximately 1.968"), but generally a depth in the range of approximately 50 mm to approximately 70 mm may be appropriate.

[0131] There are various options for forming the insulation material 70, for example, it can be made from a series of blocks (not shown) formed from an appropriate insulation material that can withstand the load of the completed building 10. For example, there is the Isoquick® insulation block, commercially available in the UK from Build Homes Better Ltd, which can be positioned to form an insulated slab foundation or insulation pad. This block is formed from a water-resistant polymer foam material, particularly Peripor®, which is available from BASFSE. The blocks forming the thermal insulation material 64 are typically arranged in two connecting layers 70a / b, and connecting mechanisms (not shown), such as protrusions or recesses, are provided at the boundary between the layers.

[0132] The thermal insulation material 70 provides a surface 78 on which the load-bearing structure 68 can be placed, and in the illustrated embodiment, it provides a substantially continuous surface. The load-bearing structure 68 is installed on the surface 78 after the insulation material 70 is installed on the ground 72. The load-bearing structure 68 is insulated from the ground 72 by the insulation material 70, thus suppressing the transfer of thermal energy between the load-bearing structure and the ground. This insulates the modular building unit 10 (installed on the foundation 64) from the ground 72, reducing / preventing thermal bridges between the unit and the ground.

[0133] The load-bearing structure 68 can take the form of a reinforced concrete layer, which can be formed in a conventional manner at the final installation site 40 of the building. A moisture barrier (not shown) can be placed below the insulation material 70 and between the upper surface 78 of the insulation material and the lower surface of the load-bearing structure 68. The moisture barrier may take any suitable form known in the field of the present invention. A particularly suitable option is a moisture-resistant sheet, which may be a substantially impermeable membrane made of a polymer material such as polyethylene.

[0134] In one modified example, the foundation 64 may be formed by installing a load-bearing structure 68 on or in the ground 72, installing insulation material 70 on the load-bearing structure, and supporting the modular building unit 10 (and the first building compartment 36). It will be understood that the insulation material in this case needs to have sufficient load-bearing capacity to withstand the structural loads received by the modular building unit 10 and, in fact, by the rest of the building 28. In another variation, the load-bearing structure may be formed from precast blocks or beams (not shown).

[0135] The second depth D2 of the ceiling frame portion 20 may be at least about 150 mm (about 5.906"), and in some embodiments may be up to about 300 mm (about 11.811"), but in other embodiments it may be up to about 350 mm, and optionally up to about 400 mm. Therefore, the second depth D2 may be in the range of approximately 150 mm to approximately 300 mm, and optionally up to approximately 400 mm. However, it is preferable that the depth be within the range of approximately 250 mm to 260 mm.

[0136] Such modular building units, having a first depth D1 and a second depth D2 in the floor frame portion 18 and the ceiling frame portion 20, can strike a good balance of advantages, for example, by minimizing disruption (during the construction process of the first building section 36) for accommodating the floor frame portion 18, and / or minimizing the structural depth of the transition area between the lower modular building unit 10 and the upper modular building unit 14, while also providing a sufficiently strong ceiling frame portion 20 and / or a ceiling frame depth for accommodating utility / building equipment.

[0137] As described above, the upper modular building unit 14 is a unit according to the present invention. Therefore, unit 14 includes a structural frame 16' having a floor frame portion 18', a ceiling frame portion 20', and a support structure 22'. The structural depth D3 of the boundary between the ceiling portion 20 of the lower unit and the floor portion 18' of the upper unit is typically in the range of 200mm to 300mm, taking into account the depth ranges of D1 and D2 as options mentioned above. This can be particularly beneficial in terms of saving materials and reducing the complexity of movement when a staircase 48 is to be passed between the two units 10 and 14. The upper unit 14 is placed on top of the lower unit 10 at the final installation location 40, after the lower unit has been placed on the foundation 64.

[0138] Further details of the structure of the modular building unit 10 are described below with reference to Figures 12 and 13. Both diagrams are plan views of only the floor frame section 18 and the ceiling frame section 20, respectively.

[0139] The floor frame portion 18 includes a floor frame 80 that defines a first depth D1. The floor frame 80 has an upper surface 82 and a lower surface 84 (Figures 2 and 4), and a first depth D1 is defined between this upper surface and the lower surface. The floor frame 80 is formed from a plurality of elongated frame members that define the upper and lower surfaces 82 and 84. In the illustrated embodiment, the floor frame 80 has a peripheral frame structure 86 comprising elongated beams, specifically, a first side beam 88 and a second side beam 90 arranged substantially parallel to each other, and a first end beam 92 and a second end beam 94 arranged substantially parallel to each other. The first support beam 96 also extends in the direction between the first end beam 92 and the second end beam 94, and is positioned between the side beams 88 and 90. A second support beam 97 and a third support beam 99 are provided, with the second support beam 97 extending between the side beam 88 and the first support beam 96, and the third support beam 99 extending between the first support beam 96 and the side beam 82. The support beams 96, 97, and 99 provide additional structural rigidity and can support the interior wall structure within the modular building unit 10.

[0140] The floor frame 80 also includes several elongated joists, which extend in the direction between the first side beam 88 and the second side beam 90. The first set of joists and the second set of joists (numbered 98 and 100, respectively) extend between the side beam 90 and the support beam 96. The third joist group (indicated as number 102) extends between the side beam 88 and the support beam 96. Typically, the joist assemblies 98-102 are the same depth (D1) as the beams of the perimeter frame 86, but at least some of their depths may be different (e.g., shallower) from the depth of the beams forming the perimeter frame.

[0141] The side beams and end beams 88-94, as well as the support beams 96-99, are typically made of hot-formed metal (e.g., steel) and are preferably box-shaped in cross-section. The joists of the first joist rigging 98 and the second joist rigging 100, in contrast, are typically made of lightweight metal (e.g., bent steel) and may have a U-shaped cross-section. Because joists 98 and 100 support the floor structure of the modular building unit 10, they do not need to support loads as high as, for example, the side beams and end beams 88-94, and the support beams 96-99, but as mentioned above, they may need to support interior walls (and optionally loads transmitted through interior walls).

[0142] The various beams forming the floor frame 80 can be positioned to directly transmit loads to the foundation, or they can be positioned to receive line loads and distribute such loads evenly across the entire foundation (compared to point load structures such as lightweight structures, for example). In particular, each of the side beams and end beams 88-94 can be positioned in contact with the load-bearing structure 68 of the foundation to more uniformly transfer the load from the modular building unit 10 to the foundation. This can be optimally achieved by constructing the floor frame, for example, from the hot-formed metal material mentioned earlier, and the load on the beams is distributed more uniformly along their length than in a point-load structure. In this way, not only the load of the modular building unit 10 itself, but also the load applied by, for example, the upper modular building unit 14, can be transmitted more uniformly by the load-bearing structure 68 of the foundation. This can also be applied to, for example, support beams 96, 97, and 99, which may similarly be made of hot-formed metal material and may be positioned in contact with the load-bearing structure 68 of the foundation. The support beams 96, 97, and 99 may be positioned substantially in line with the structural features of the upper modular building unit 14, particularly similar support beams in the floor frame portion of the upper unit, and / or the interior walls of the upper unit (which may transmit loads to the lower modular building unit 10 via the floor frame portion of the upper unit). By arranging the floor frame 80 in this manner, it may be possible to obtain the advantage of reducing the density of the material forming the insulation 70 and / or reducing its compressive strength. Generally, insulation materials with high density and / or high compressive strength tend to be more expensive, so this can be beneficial.

[0143] The floor frame 80 is configured to support the planar floor structure 104 shown in Figures 4 and 11. The planar floor structure 104 defines the floor of the modular building unit 10 and is defined by one or more planar floor panels (one of which is shown as number 106). There are many options for forming the floor structure 104, but preferred options include wood-based materials for the panel 106, such as chipboard, fiberboard, and plywood. The first depth D1 of the floor frame portion 18 does not include the planar floor structure 104, or any other structural or insulating material actually placed on this floor structure, and / or any decorative floor finish or covering material (such as carpet or tiles) placed on this floor structure.

[0144] As explained above, the screed 76 that forms the floor 74 of the first building section 36 is usually the same depth D1 as the floor frame section 18 (and therefore the frame 80). The floor 74 may be raised to the height achieved by the modular planar floor structure 104 by placing another floor structure 108 on top of the screed floor 74. Similarly, by using a panel base made of wood, for example, uniformity can be ensured throughout the entire building sections 36 and 38. However, it will be understood that there are various other options, including the possibility of positioning the top surface of the screed 74 to coincide with the top surface created by the modular planar floor structure 104.

[0145] The ceiling frame portion 20 includes a ceiling frame 110 that defines a second depth D2. The ceiling frame 110 has an upper surface 112 and a lower surface 114, and a second depth D2 is defined between these two surfaces. The ceiling frame 110 is formed from a plurality of elongated frame members that define the upper and lower surfaces 112 and 114. The ceiling frame 110 includes a periphery frame structure 116, which includes a first side beam 118 and a second side beam 120 arranged substantially parallel to each other, and a first end beam 122 and a second end beam 124 arranged substantially parallel to each other. A support beam 126 also extends in the direction between the first end beam 122 and the second end beam 124, and the support beam is positioned between the side beams 118 and 120. This support beam 126 provides additional structural rigidity to the floor support beam 96 and can support the interior wall structure of the modular building unit 10.

[0146] The ceiling frame 110 also includes several elongated joists, which extend in the direction between the first side beam 118 and the second side beam 120. The first set of joists and the second set of joists (denoted by numbers 128 and 130, respectively) extend between the side beam 116 and the support beam 126. The third and fourth sets of joists (numbered 132 and 134, respectively) extend between the side beam 118 and the support beam 126. Typically, the depth of the joists in sets 128-134 is shallower than the depth (D2) of the beams in the peripheral frame 116, but at least some of the joists can be the same depth.

[0147] The side beams and end beams 118-124, as well as the support beam 126, are also typically made of hot-formed steel with a box-shaped cross-section, for example, and the sets of the first to fourth joists 128-134 are typically made of lightweight steel with a U-shaped cross-section, for example.

[0148] The ceiling frame portion 20 defines a load transmission section configured to transmit the load to the support structure 22. This load is the load imposed by the upper modular building units 14 stacked on top of the lower modular building units 10.

[0149] The ceiling frame portion 20 also includes at least one mounting member, which serves to attach another (upper) modular building unit 14 to the modular building unit 10. In the illustrated embodiment, the ceiling frame portion 20 includes a plurality of mounting members 136a to d, each of which is positioned at a corner of the ceiling frame 110. Furthermore, mounting members 136e to h are positioned along the end beams 122 and 124 and the side beams 118 and 120, spaced apart from the associated corner mounting members. Furthermore, at least one mounting member can be provided on the support beam 126, and Figure 1 shows two such mounting members 136i and 136j. These support a portion of the upper modular building unit 14, particularly the interior wall structure. The mounting members 136a to 136j protrude or extend from the upper surface or extension (indicated as 138 in Figure 5) of the beam forming the ceiling frame 110. The mounting members 136a to j extend generally vertically from the upper surface 138 and are in the form of blocks, posts, stubs, pins, or plugs as appropriate.

[0150] The upper surfaces of the mounting members 136a to j are configured to contact the lower surface of another (upper) modular building unit 14, and the other (upper) modular building unit is stacked or placed on top of the modular building unit 10 and connected to the mounting members. Referring to Figure 5, which shows the mounting member 136c, this mounting member defines the aforementioned upper surface 112, which abuts against the lower surface 140 of the floor frame of the other unit (defined by the side frame member 18') mentioned above. This creates a gap, space, or void 142 between the two modular building units 10 and 14, which may offer the advantage of accommodating utility / building equipment such as the aforementioned sewer pipes. The locations of these conduits are shown by dashed lines in Figure 2 and are consistently numbered 144 throughout. These conduits 144 may be connected to the plumbing facilities of the upper modular building unit 14, as described below, and may ultimately lead to the sewer (not shown) via the inspection module 146 of unit 10. The void 142 can be created with minimal additional structure, leading to cost and weight reductions. The second depth D2 of the ceiling frame portion 20 is defined between the upper surfaces 112 of the mounting members 136a to j and the lower surface 114 of the ceiling portion (defined by the ceiling frame 110, particularly the lower surface of the frame members). Mounting members 136a to j are typically joined to the ceiling frame 110 or provided by the ceiling frame (for example, integrated with the ceiling frame).

[0151] As can be seen from the diagram, the ceiling frame portion 20 includes multiple mounting members 136a to h. At least one opening is provided between adjacent pairs of mounting members, through which utility / building equipment can be passed. For example, referring to Figure 1, an opening 145 is defined between adjacent mounting members 136b and 136g, and utility / building equipment can be passed through this opening into, for example, the first building compartment 36, thereby providing utility / inspection work to the first building compartment.

[0152] The upper modular building unit 14 is connected to the lower unit 10 to form an assembly 12, and in particular, it suppresses the lateral movement of the units relative to each other. There are various options for connecting units 10 and 14, including welding, bonding, and mechanical fastening. Suitable mechanical fasteners may include nut and bolt assemblies, pins, and positioning sockets.

[0153] The ceiling frame portion 20, in particular the ceiling frame 110, is configured to support the flat ceiling or flat ceiling structure 148 shown in Figure 5. The planar ceiling structure 148 defines the ceiling of the modular building unit 10 and is defined by one or more planar ceiling panels (one of which is indicated by the number 150). There are many options for forming the ceiling structure 148, but gypsum board panels or sheets are preferred options. The second depth D2 of the ceiling frame section 20 does not include the planar ceiling structure 148, any other structural or insulating materials connected to this planar ceiling structure, and / or decorative finishes or coverings (such as plaster undercoats).

[0154] This specification refers to the ceiling frame portion of the modular building unit 10 and the ceiling of this unit. The ceiling frame portion 20 (and ceiling) should be interpreted as meaning the superstructure that covers or encloses the interior space of the modular building unit 10. It will be understood that the ceiling frame portion 20 of the modular building unit 10 does not typically have a weather-resistant roof structure intended, for example, to prevent water from entering the modular building unit. Therefore, referring to Figure 6, for example, a separate roof structure 150 is shown, which is constructed from multiple roof trusses 152. The roof structure 150 connects the first building section 36 and the second building section 38, making the building 28 weather-resistant. However, the modular building unit 10 can optionally be equipped with such a roof by, for example, installing a ceiling frame to add an external or exterior roof to the unit. This could be a particularly viable option for, for example, a single-story building that includes modular building units, or when the units form the top floor of the building. A flat roof structure can be considered a suitable option.

[0155] In the illustrated lightweight steel frame (LGSF) structure frame 16, the support structure 22 is relatively complex and will not be explained in detail. However, to put it simply, the support structure 22 includes multiple support columns or pillars 154a to c (Figure 1), each of which is located at the corner of the frame 16 and extends between the floor frame portion 18 and the ceiling frame portion 20, connecting to both frame portions. Other supports or columns are provided at several points around the perimeter of the floor frame section 18, and are installed away from one or more corners. Other such supports are indicated by numbers 154d-k.

[0156] To facilitate construction, various support columns 154a to k are each connected at one end to a floor mounting member and at the other end to a ceiling mounting member, forming a wall structure that can be connected to the floor and ceiling sections 18 and 20. Figure 1 shows the outer surface or outer wall 155 of unit 10 defined by the support structure 22, which is located inside the constructed building 28. Floor mounting members 157 are attached to the side beams 88 of the floor, and ceiling mounting members 159 are attached to the side beams 118 of the ceiling. The illustrated support columns 154b, 154d, and 154g-k are connected between the floor mounting member 157 and the ceiling mounting member 59, and extend (and support) between the floor portion 18 and the ceiling portion 20 of the assembled unit 10. Note that the floor mounting members should not extend across any portion of the peripheral frame structure 116 of unit 10 that serves as an entrance or passageway for accessing the first building compartment 36. For example, see corridor 52, which provides access to open-plan room 50. This is to make the floor levels between the first building section 36 and the second building section 38, as described above with reference to Figure 11, uniform.

[0157] The support structure 22 also includes lateral bracing members or support members. Multiple bracing members (each designated as number 156) extend roughly perpendicular to the columns between adjacent pairs of columns / posts 154. Diagonal bracing members (one designated as number 158) extend between several support columns 154 and either the floor frame section 18 or the ceiling frame section 20.

[0158] Other options exist for the support structure 22, including structural insulation panels (SIPs) and other panels made of cement-based materials, for example.

[0159] As can be seen from Figures 8 and 9, the modular building unit 10 defines multiple rooms within the building 28, at least some of which are provided with plumbing facilities in the form of a W / C or washroom 160 and a utility room 162. Unit 10 is configured to have an interior wall that defines one or more boundaries between the washroom 160 and the utility room 162. For example, referring to bathroom 160, unit 10 has interior walls 162-166 that define the space forming the bathroom. The washroom (160) can be accessed from the corridor (55) of the circulation space (42), and the utility room can be accessed directly from the open-plan room (50).

[0160] Similarly, the upper modular building unit 14 has rooms that provide bathroom facilities in the form of a bathroom 168 accessible via a landing 172 of the circulation space 42, and a bathroom 170 accessible from the bedroom 58. As mentioned above, the sewer pipe 144, which connects to the washroom and toilet facilities of the bathroom 168 and the bedroom bathroom 170, can be at least partially housed in the gap 142 between units 14 and 10. This may include, for example, sewer connections for the toilet 174, bathtub 176, and sink 178 within the bathroom 168.

[0161] In the illustrated building 28, the modular building units 10 and 14 are surrounded by an outer brick layer 30. The walls of units 10 and 14 are formed by connecting wall panels or wall sheets to structural support frames 16 and 16' (particularly columns and bracing members). For example, as shown in Figure 6, panels 180 to 184 can form the outer wall 186 of the modular unit 10. However, the modular building units 10 and 14 can be arranged to define at least a portion of the perimeter of the building, particularly the outer perimeter. This can be achieved by arranging panels 180-184 as exterior panels.

[0162] In a modified example of the illustrated embodiment, the building 28 may be a modular building comprising a plurality of modular building units that form all (or at least most) of the interior space of the building. This is shown in Figure 14, which is a wireframe isometric view of multiple modular building assemblies configured to form part of a 28" building. Components of building 28 and similar buildings 28" share the same reference number and are prefixed with the suffix "". The building 28" includes a plurality of modular building units, at least one of which is a modular building unit according to the present invention. In a particularly preferred option, all modular building units are units according to the present invention.

[0163] The modular building units are configured in a stacked assembly state, as described above with respect to the modular building assembly 12. Therefore, the modular building assembly 12" includes a lower modular building unit 10" and an upper modular building unit 14" stacked on top of this lower unit. Another modular building assembly 12a” similarly includes a lower modular building unit 10a” and an upper modular building unit 14a” stacked on top of this lower unit. In between these, the modular building units of assemblies 12” and 12a” define the entire interior space of the building 28” but do not include a roof (not shown) on or outside the building, which may be formed at the final installation site of the building (in the case of roof structure 150) or as a modular (transportable) structure.

[0164] Next, Figure 15 shows an isometric view of the ceiling frame portion 20b according to another embodiment of the present invention. See also Figure 16, which is an enlarged view of a portion of the ceiling frame (viewed from a different angle), and Figure 17 is a front cross-sectional view of the modular building assembly 12b, which includes the first (lower) modular building unit 10b and the second (upper) modular building unit 14b, cut along line AA in Figure 15. The first modular building unit 10b includes a ceiling frame portion 20b. Components of modular building assembly 12 and similar modular building assembly 12b (including ceiling frame portion 20b) share the same reference number and are prefixed with the suffix 'b'.

[0165] In this embodiment, the ceiling frame portion 20b includes a load-transfer compartment 188, which is in the form of a grid or grid-like structure. The load transfer section 188 includes an elongated structural frame member, which includes a lower structural member in the form of a beam 278, a lower structural member in the form of a beam 280, and at least one connecting member, the connecting member extending between the lower structural member and the upper structural member and connecting the two structural members. In the illustrated embodiment, the load transfer section 188 includes a plurality of connecting members in the form of struts 282 positioned approximately perpendicular to the lower structural member 278 and the upper structural member 280, and a plurality of lateral bracing members 284 positioned at angles not perpendicular to the lower structural member 278 and the upper structural member 280 (angles other than 90°, for example, approximately 20° to approximately 45° is appropriate).

[0166] The lower structural member 278 defines the lower surface 286 of the load transmission section 188, and the upper structural member 280 defines the upper surface 288. The lower structural member 278 and the upper structural member 280, as well as the connecting members 282 and 284, actually form the sides of the load transmission section 188. The connecting members 282 and 284 transmit the load from the upper structural member 280 to the lower structural member 278, thereby also transmitting it to the support structure 22b of the lower modular building unit 10b (which defines the outer wall of the modular building unit 10b).

[0167] The load transfer section 188 includes several generally elongated parts, which combine to define the load transfer section. In the illustrated embodiment, the load transfer compartment 188 is roughly quadrilateral (roughly rectangular) in plan view and includes a left elongated portion 290 and a right elongated portion 292, as well as a front elongated portion 294 and a rear elongated portion 296. The number of elongated sections roughly corresponds to the number of walls provided by the support structure 22b of the modular building unit 10b, one such wall 155b is shown in Figure 17. It will be understood that the remaining parts of the modular building unit 10b, such as the floor frame and side structures, are essentially as described above with respect to Figures 1 to 13. Therefore, I will not explain it again here.

[0168] The elongated sections 290-296 are roughly aligned in a straight line with their corresponding walls, such as 155b, and therefore are essentially on the same plane. Each elongated section 290-296 is placed on a corresponding wall, for example, 155b, and is configured to be positioned laterally (appropriately substantially perpendicular) to adjacent elongated sections. Each of the generally elongated sections 290-296 includes its respective lower structural member 278 and upper structural member 280, as well as connecting members 282 and 284. The elongated upper structural members 280 of the slender sections 290-296 form an upper peripheral frame or upper loop member 116b of the load transmission section 188, and the lower structural members 278 form a lower loop member 116b' of the load transmission section.

[0169] In this embodiment, the load transfer compartment 188 is configured to have multiple openings 145b through which utility / building equipment can pass. This is shown in Figure 16, which shows, for example, that the opening 145b is sized to allow a ventilation conduit (e.g., 220) to pass through. This facilitates the connection of building equipment (collectively numbered 190 in Figure 15) installed in the equipment gap 142b between stacked modular building units 10b and 14b to the first building section of the building (e.g., the first building section 36 of building 28), which includes the modular building assembly 12b, as well as to the lower modular building units and the upper modular building units themselves (and / or the items / equipment contained within them). Building equipment 190 will not be described in further detail, but it may include any of the options considered in this specification. Therefore, the building equipment 190 is housed within the equipment void 142b and can be connected through the opening 145b, and it is not necessary to route the equipment generally downward through the lower modular building unit 10b or generally upward through the upper modular building unit 14b that is stacked on top of or placed on the lower unit (unless it is specifically desirable to perform building work in / through the lower unit or in / through the upper unit).

[0170] The opening 145b is defined by the structural members of the ceiling frame portion (particularly its load-bearing section 188), or between these structural members, specifically between at least some of the lower structural members and upper structural members 278, 280 and the connecting members 282, 284. For example, referring to the opening labeled 145b in Figure 16, the opening is defined between the upper beam 280, the lateral bracing member 284, and the strut 282, and / or bordered by these three. To examine this, another opening, denoted by reference numeral 145b', is defined between the lower beam 278, another lateral bracing member 284, and another strut 282, and / or bordered by these three. In particular, as can be seen from Figure 15, a series of openings 145b are defined along the perimeter of the ceiling frame portion 20b.

[0171] The lower surface 286 defined by the load transfer section 188 rests on the upper surface 298 of the support structure 22b (particularly the wall defined by the support structure, e.g., 155b), as best shown in Figure 17. The load transfer section 188 also includes the upper surface 300, which supports the upper modular building unit 14b, specifically the floor frame portion 18b' of the upper unit. The load transfer compartment 188 has a first height (or depth) H1 defined between the upper surface 300 and the lower surface 286, which is usually in the range of approximately 200 mm to approximately 300 mm. It is preferable that the height H1 be within the range of approximately 250 mm to 260 mm.

[0172] As mentioned above, the floor frame portion (not shown) of the modular building unit 10b corresponds to the floor frame portion 18 of unit 10, and is therefore made of hot-formed metal material. Its depth is the same as the range D1 mentioned above, that is, it is usually in the range of approximately 50 mm to approximately 70 mm. In this embodiment, the height H1 of the load transfer section 188 may define or represent the depth D2 of the ceiling frame section 20b. Therefore, the depth range and the ratio of the depth of the floor frame portion to the depth of the ceiling frame portion fall within the depth and range range described above for the embodiments shown in Figures 1 to 13.

[0173] The ceiling frame portion 20b also includes a ceiling compartment 302, which is configured to define or support the ceiling 304 of the modular building unit 10b. In this embodiment, the ceiling compartment 302 has a lower surface 306 that supports a series of generally planar ceiling components, which are in the form of ceiling panels (one of which is shown numbered 308 in Figure 17), and the ceiling panels are configured to form a ceiling 304. Panel 308 is connected to the ceiling compartment 302 and is positioned below the bottom surface 306.

[0174] The lower surface 306 of the ceiling compartment 302 is located at the very bottom of the ceiling compartment and defines the lower limit of the ceiling compartment. The ceiling section 302 actually has multiple lower surfaces, and these lower surfaces combine to form the lower surface. In the illustrated embodiment, the ceiling compartment 302 has a plurality of elastic mounting bars, and the ceiling 304 is attached to the ceiling compartment by these mounting bars. Figure 17 shows one such elastic mounting bar 310, which has a lower surface defining a lower portion 312, and the lower portion together with other such mounting bars (not shown) forms a lower surface 306. The elastic mounting bar 310 is of a type known in the industry and has a generally corrugated mounting portion defining its lower surface portion 312, which provides a sound-absorbing / sound-dampening function that reduces the transmission of vibrations (and therefore sound) through the ceiling 304 between the stacked modular building units 10b and 14b.

[0175] The ceiling compartment 302 is located inside the load transfer compartment 188 and is connected to the load transfer compartment. As can be seen in Figure 17, the lower surface 306 of the ceiling compartment is positioned lower than the upper surface 298 of the support structure 22b (for example, wall 155b). The ceiling assembly 302 actually defines an equipment void 142b, which has an upper boundary defined or formed by a plane 314 encompassing the upper surface 300 of the load transfer compartment 188, and a lower boundary defined or formed by a plane 316 encompassing the lower surface 306 of the ceiling compartment 302. The equipment void 142b has a second height (or depth) H2 that is greater than the height H1 of the load transfer compartment 188. The second height, H2, is typically in the range of approximately 250mm to 350mm. It is preferable that the second height H2 is within the range of approximately 275 mm to approximately 295 mm.

[0176] The ceiling compartment 302 has an upper surface 318 that is positioned lower than the upper surface 300 of the load transfer compartment 188. The ceiling compartment 302 has a third height (or depth) H3 defined between the upper surface 318 and the lower surface 306 of the ceiling compartment. The height H3 of the ceiling compartment 302 is lower than either the first height H1 or the second height H2, and may be within the range of approximately 70 mm to approximately 100 mm. It is preferable that the third height H3 is within the range of approximately 75 mm to approximately 95 mm. If the ceiling compartment 302 itself defines the ceiling 308, the lower surface 306 that defines the boundary of the equipment space 142b may be formed on the upper surface of the ceiling. The maximum height (or depth) H4 of the opening 145b is determined by the structural features of the ceiling assembly 20b (including heights H1, H2, and H3) and the dimensions of the structural members 278-284, but may be in the range of approximately 120mm to approximately 175mm, with a preferred dimension of approximately 150mm to 160mm. Of course, the structural members forming the opening include lateral bracing members 284. These bracing members 284 extend between the upper structural member 280 and the lower structural member 278 at the angle shown, thereby limiting the height of the opening toward the end adjacent to the upper structural member. However, such an opening 145b having a maximum height H4 may be sufficient to accommodate most or all of the different types of equipment (e.g., pipes or conduits) that may be placed in the space 142b.

[0177] The ceiling compartment 302 hangs down from the load-transfer compartment 188, thereby overlapping the upper part of the support structure 22b (e.g., wall 155b) that defines the upper surface 298, which is in the form of an upper frame member or beam 319 of the support structure / wall. The load transfer section 188 forms the outer portion of the ceiling assembly and defines the outer perimeter 320 of the ceiling assembly 20b. The load transfer section 188 actually includes a perimeter structure, which is defined by various elongated sections 290-296 that form a grid frame and may extend along the perimeter of the modular building unit 10b. The ceiling compartment 302 forms the inner portion of the ceiling frame portion 20b and is located inside the load transmission compartment 188 and inside the outer perimeter 320 of the load transmission compartment. The load transfer compartment 188 also defines the inner circumference 322, and the ceiling compartment 302 is located inside this inner circumference. The ceiling compartment 302 extends inward of the inner circumference 322 below the load transfer compartment 188.

[0178] The ceiling compartment 302 also includes a perimeter structure 324 (Figure 16) that defines the outer perimeter 326 of the ceiling compartment. The periphery structure 324 is connected to the load-transmission section 188, in particular to the lower structural members 278 of several generally elongated sections 290-296. The load transfer section 188 further includes a plurality of bracing sections extending between opposing pairs of generally elongated sections, three such bracing sections 328, 330 and 332 are shown. Bracing sections 328-332 have a similar design to the elongated sections 290-296 and will not be described here. The periphery structure 324 can be connected to one or more of these bracing portions 328-332, and in the illustrated embodiment, it is connected to bracing portion 328. The peripheral structure 324 of the ceiling section is in the form of a structural frame and may include structural (e.g., elongated) frame members 334 (FIG. 17), the frame members defining a frame and having elastic bars 310 that define a lower surface 306 joined to the frame members (although alternatively the elastic bars themselves could form the lower surface).

[0179] In the illustrated embodiment, the ceiling section 302 includes a plurality of sub - sections that together form the ceiling section. These are shown in FIG. 15 and are numbered 336, 338, 340, and 342. Each sub - section 336 - 342 forms part of the ceiling section 302 and has its own peripheral structure as described above. The ceiling sub - sections 336 - 342 can each be connected independently or separately to the load - transfer section 188 during the construction process of the ceiling assembly 20b. The load - transfer section 188 defines separate regions or spaces, each region being configured to receive one of the ceiling sub - sections 336 - 342. These regions are defined by two or more of the elongated portions 290 - 296 and one or more of the bracing portions 328 - 332, or are defined between these two portions. Referring to, for example, sub - section 336, the region 344 is defined by the side portions 290 and 292, the end portion 294, and the bracing portion 328.

[0180] One or more of the sub - sections 336 - 342 can include building service equipment 190, and the building service equipment of each such sub - section may be appropriately attached to a corresponding board or panel shaped to fit within a equipment void 142b in the corresponding region, e.g., within region 344. Referring to FIG. 18, for example, building service equipment 190 attached to a panel 192 is shown. The illustrated equipment includes a main intake pipe and exhaust pipes 216, 218, an air supply duct 220 and exhaust ducts 222, 224, hot water pipes and cold water pipes 252, 254, a data cable 345, and a part of a power cable 347. Panel 192 may be attached to the ceiling section 302 where various equipment 190 is installed, or may be attached to the ceiling section before connecting the equipment. This may be either before or after connecting the ceiling section 302 to the load-bearing section 188.

[0181] An upper panel 194 is provided to cover the building equipment 190. FIG. 18 is an exploded view before integrally and optionally sealing together the lower panel 192 and the upper panel 194 (which becomes an upper platform within the ceiling frame portion) to form a cartridge or module 196 for building equipment. A side portion 198 (which may be in the form of a wall, may be a part, and / or may have an opening through which equipment can pass) is shown and extends between the upper panel 194 and the lower panel 192. The cartridge or module 196 for building equipment may be permanently coupled or coupled in a detachable form to the structural part of the ceiling assembly 20b either during the process of manufacturing the module off-site or when stacking modular building assemblies 12b.

[0182] When there are a plurality of ceiling sub-sections 336 - 342, the sub-sections may be configured to cooperate for installing / setting equipment within the void 142b (each sub-section defines a part of the void). As shown in FIG. 18, each sub-section may accommodate / support a part or a plurality of parts of the equipment 190, and the equipment needs to be connected to another part or a plurality of other parts that are accommodated / supported in another sub-section. For example, the air supply duct 216 and the exhaust duct 218 for ventilation pass through sub-sections 338 and 336 along the length of the ceiling frame portion 20b. The ducts may be connected after the building equipment has been installed in the subcompartments (either in the form of cartridges / modules or separately as described above). This may require the use of connectors at the joints or intersections between some of the equipment installed in each sub-compartment. For example, see connector 343, which serves to connect portions of the exhaust duct 216 installed in sub-compartments 340 and 338. It will be understood that each ceiling subcompartment 336-342 may have or house the corresponding panels 192, 194 (and therefore the equipment cartridges).

[0183] In a modified example shown in another enlarged view of the ceiling assembly 20b shown in Figure 19, at least one opening 145b” can be provided without the lateral bracing member 284, thereby defining (or being bounded by) the upper structural member 280, an adjacent pair of struts 282, and the lower structural member 278. This makes it possible to create a larger opening between adjacent struts 222 that has a maximum height H4 across its entire width. This can be useful, for example, when an opening is needed to accommodate large equipment such as ventilation supply pipes 220 and 222.

[0184] Figure 17 further shows a portion of the first building compartment 201 connected to a modular building assembly 1b, specifically to one of a plurality of joists 346 that extend between at least one side of the modular building unit / assembly and the wall of the first building compartment and support the upper floor 348 of the first building compartment. As indicated by 353 and 355 in Figure 17, soundproofing and / or heat insulating materials are provided in the wall 155b (and load transfer compartment 188) and the wall 155b' of the upper unit 14b, as well as in the void 142b. It will be understood that the insulation material 353, if provided, will be installed around all equipment, and may be omitted depending on factors such as the number and dimensions of equipment passing through the opening 145b. The maximum height H4 of the opening 145b is, naturally, lower than the height H2 of the space 142b. The opening 145b may be partially blocked by the insulation 355, but in this case, the insulation 355 may be omitted or the height of the insulation in the area of ​​the opening (through which the equipment passes) may be reduced.

[0185] The floor frame portion 18b' of the upper modular building unit 14b may also be made of hot-formed metal material as described above, and may have a height (or depth) H5 in the range of approximately 50 mm to approximately 70 mm, with approximately 50 mm being a preferred option. The total height between the load transfer compartment 9b and the floor assembly 18b' may be the sum of heights H2 and H5. This may define the structural depth D3 at the joint between the ceiling assembly 20b of the lower modular building unit 10b and the floor assembly 105b of the upper modular building unit 14b, and may be approximately 300mm to approximately 500mm, optionally approximately 300mm to approximately 400mm, and optionally approximately 350mm. It is preferable that the depth be within the range of approximately 250 mm to 370 mm.

[0186] In normal use, it will be understood that the load transfer compartment 188, the support structure 22b (particularly the walls, e.g., 155b), and the floor frame portion of the lower modular building unit 10b (corresponding to the floor frame portion 18 in Figure 1) are in the load path of the loads transferred from the upper modular building unit 14b to the lower modular building unit. Since the ceiling compartment 302 is located inside the load transfer compartment 188 and the support structure 22b, it is not above or in the load path.

[0187] For the purposes of this invention, the depth relationship between D1 and D2 may be determined based on a structure in or above such a load path. Therefore, in this embodiment, D1 may be based on the height of the floor frame portion (for example, the floor frame portion 18 in Figure 1), and D2 may be based on the height H1 of the load transfer section 188, and these are structures that are involved in the load path.

[0188] Options for constructing the ceiling frame section 20b, particularly the load transfer section 188 and the ceiling section 302, may include any of the options discussed elsewhere in this specification. Therefore, as a construction option, cold-formed (e.g., folded-formed) metal members such as lightweight steel materials (forming lightweight steel frames or LGSF) can be cited.

[0189] Various modifications can be made to the above without departing from the spirit or scope of the present invention.

[0190] Features of one or more aspects and / or embodiments disclosed herein may be combined with other aspects and / or embodiments of the present invention. Therefore, such other aspects and / or embodiments may include one or more features selected from one or more aspects or embodiments of the present invention disclosed herein.

[0191] Unless expressly suggested or stated in the context herein, the features of any method or process disclosed herein do not necessarily have to be performed in the order described in the relevant text and / or drawings. Therefore, where circumstances permit, the methods or processes disclosed herein may be performed in an order other than that specifically described in the relevant text / drawings.

[0192] Features disclosed herein (including the attached claims, abstract, and drawings) may be replaced by alternative features serving the same, equivalent, or similar purposes unless expressly otherwise stated. Therefore, the features disclosed herein may be considered merely examples of a comprehensive set of equivalent or similar features.

Claims

1. A modular building unit including a structural frame, wherein the structural frame is A floor frame portion having a first depth, which is configured to support a planar floor structure. A ceiling frame portion having a second depth, and A support structure that extends between the floor frame portion and the ceiling frame portion and connects the two frame portions, Includes, The ratio of the first depth of the floor frame portion to the second depth of the ceiling frame portion is at least about 1:

3. The modular building unit defines a circulating space configured to provide at least one access function to the building including the modular building unit. Modular building units.

2. The modular building unit according to claim 1, wherein the ratio of the first depth to the second depth is at most about 1:

6.

3. The modular building unit according to claim 1 or 2, wherein the first depth of the floor frame portion is a maximum of approximately 70 mm (approximately 2.756")

4. The modular building unit according to claim 1 or 2, wherein the first depth of the floor frame portion is a maximum of approximately 50 mm (approximately 1.968")

5. The modular building unit according to any one of claims 1 to 4, wherein the second depth of the ceiling frame portion is at least about 150 mm (about 5.906")

6. The modular building unit according to any one of claims 1 to 5, wherein the second depth of the ceiling frame portion is a maximum of approximately 300 mm (approximately 11.811")

7. The first depth is defined by a portion or more of the floor frame portion that is located within a load path for transmitting load from the ceiling frame portion through the support structure to the floor frame portion. The second depth is defined by a portion or more of the ceiling frame portion located within the load path. A modular building unit according to any one of claims 1 to 6.

8. The modular building unit according to any one of claims 1 to 7, wherein the floor frame portion includes a floor frame, the floor frame has an upper surface and a lower surface, and the first depth is defined between the upper surface and the lower surface.

9. The modular building unit according to claim 8, wherein the floor frame includes a peripheral frame structure comprising an elongated beam of the first depth.

10. The modular building unit according to any one of claims 1 to 9, further comprising the planar floor structure, wherein the planar floor structure defines the floor of the modular building unit, and the first depth of the floor frame portion does not include the planar floor structure.

11. The modular building unit according to any one of claims 1 to 10, wherein the ceiling frame portion includes a ceiling frame, the ceiling frame has an upper surface and a lower surface, and the second depth is defined between the upper surface and the lower surface.

12. A modular building unit according to claim 11, comprising a plurality of mounting members that serve to attach another modular building unit on top of the aforementioned modular building unit, wherein the mounting members protrude from the upper surface of one or more frame members that form at least a portion of the ceiling frame, and the upper surface of the mounting members is configured to contact the lower surface of the other modular building unit to form a gap between the modular building units.

13. The modular building unit according to claim 12, wherein the second depth is defined between the upper surface of the mounting member and the lower surface of one or more of the ceiling frame members.

14. The modular building unit according to any one of claims 1 to 10, wherein the ceiling frame portion includes or takes the form of a lattice structure.

15. The aforementioned ceiling frame portion includes a load transmission section, and the load transmission section is A lower structural member defining the lower surface of the load transmission section, wherein the lower surface is seated on the upper surface of the support structure, An upper structural member defining the upper surface of the load transmission compartment, wherein the upper surface is configured to support another modular building unit, and At least one connecting member that extends between the lower structural member and the upper structural member, connecting the two structural members, and transmitting load from the upper structural member to the lower structural member, thereby also transmitting it to the support structure. A modular building unit according to claim 14, including the above.

16. The modular building unit according to claim 15, wherein the ceiling frame portion includes a ceiling compartment configured to define or support the ceiling of the modular building unit, the ceiling compartment being located inside and connected to the load-transmission compartment.

17. The modular building unit according to claim 16, wherein the ceiling compartment has a lower surface positioned lower than the upper surface of the support structure.

18. The modular building unit according to any one of claims 1 to 17, wherein the access function is selected from the group including access between the upper and lower living spaces of the building, access between the first living space of the building and at least one other living space, wherein the two living spaces are separated from each other in another part of the building, and access from the outside to the inside of the building.

19. The modular building unit according to any one of claims 1 to 18, wherein the modular building unit includes one or more walls that define at least one room and form the boundary of the room.

20. The modular building unit according to claim 19, wherein at least one room includes plumbing fixtures, the room being selected from the group including a bathroom, shower room, bedroom bathroom, w / C or washroom, and utility room.

21. A modular building assembly, First modular building unit, and A second modular building unit is positioned on top of the first modular building unit so that the second modular building unit is supported by the first modular building unit. Includes, The first modular building unit includes a structural frame, and the structural frame is A floor frame portion having a first depth, which is configured to support a planar floor structure. A ceiling frame portion having a second depth, and A support structure that extends between the floor frame portion and the ceiling frame portion and connects the two frame portions, Includes, The ratio of the first depth of the floor frame portion to the second depth of the ceiling frame portion is at least about 1:

3. The modular building unit defines a circulating space configured to provide at least one access function to the building including the modular building unit. Modular building assembly.

22. The modular building assembly according to claim 21, wherein the first modular building unit is a modular building unit according to any one of claims 1 to 20.

23. The modular building assembly according to claim 22, wherein the second modular building unit is a modular building unit according to any one of claims 1 to 22.

24. A building comprising a modular building unit according to any one of claims 1 to 20, or a modular building assembly according to any one of claims 21 to 23.

25. The building according to claim 24, wherein the building is a hybrid residential building having a first building section and a second building section, the first building section is constructed on-site at the final installation site of the building, the second building section includes the modular building unit, and the first building section and the second building section are joined at the final installation site to form the building.

26. The building according to claim 24, wherein the building is a hybrid residential building comprising a first building section and a second building section, the first building section being constructed on-site at the final installation site of the building, the second building section being defined by the modular building assembly, and the first building section and the second building section being joined at the final installation site to form the building.

27. A building comprising a plurality of modular building units, at least one of which is a modular building unit according to any one of claims 1 to 20, wherein the interior space of the building is substantially formed by the plurality of modular building units.

28. A building according to any one of claims 24 to 27, comprising a foundation including a load-bearing structure and insulation, wherein the modular building unit is placed on the foundation, so that the load-bearing structure becomes a structural support for the modular building unit, and the insulation insulates the modular building unit from the ground.

29. The building according to any one of claims 24 to 28, wherein the circulating space is arranged to provide one or more access functions selected from the group including access between the upper and lower living spaces of the first building compartment, access between the first living space of the first building compartment and at least one other living space, wherein both living spaces are provided with one or more access functions selected from the group including access separated from each other within the first building compartment and access to the first building compartment from outside the building.

30. A method for constructing hybrid buildings, A process of constructing the first building section at the final installation site of the building, A step of constructing a modular building unit according to any one of claims 1 to 20 at a location away from the aforementioned final installation site, thereby substantially assembling the unit. A step of transporting the modular building unit in the substantially assembled form to the final installation site, arranging the modular building unit to form at least a portion of the second building section of the building, and The process of joining the first building section and the second building section to form the building. Methods that include...

31. The construction of the foundation of the aforementioned building, which includes providing load-bearing structures and insulation materials to the foundation. The modular building unit is placed on the foundation, thereby the load-bearing structure of the foundation becomes a structural support for the modular building unit, and the insulation material of the foundation insulates the modular building unit from the ground, and Arranging the first building section such that it is supported by the foundation. The method according to claim 30, including the method described in claim 30.

32. Arranging the modular building units to form a planar floor structure of the second building compartment, including providing an upper support surface for the planar floor structure. Providing a floor in the first building compartment, including providing an upper support surface on the floor, and The floor of the first building compartment is positioned such that the upper support surface of the floor of the first building compartment is at the same height as the upper support surface of the modular building unit. The method according to claim 30 or 31, including the method described in claim 30 or 31.

33. The method according to claim 32, further comprising making the depth of the floor of the first building compartment equal to the sum of the first depth of the modular building unit and the depth of the planar floor structure of the modular building unit.

34. A modular building unit including a structural frame, wherein the structural frame is A floor frame portion configured to support a flat floor structure, the floor frame portion having a maximum depth of approximately 70 mm (2.756") The ceiling frame section has a depth of at least approximately 150 mm (5.906"), and A support structure extending between the floor frame portion and the ceiling frame portion, connecting the two frame portions. Includes, The modular building unit defines a circulating space configured to provide at least one access function to the building including the modular building unit. Modular building units.

35. The modular building unit according to claim 34, wherein the first depth of the floor frame portion is a maximum of approximately 50 mm (approximately 1.968")

36. The modular building unit according to any one of claims 1 to 35, wherein the depth of the ceiling frame portion is a maximum of approximately 300 mm (approximately 11.811")

37. The depth of the floor frame portion is defined by a portion or more of the floor frame portion that lies within a load path for transmitting load from the ceiling frame portion through the support structure to the floor frame portion. The depth of the ceiling frame portion is defined by a portion or more of the ceiling frame portion located within the load path. A modular building unit according to any one of claims 34 to 36.

38. The modular building unit according to any one of claims 1 to 37, wherein the floor frame portion includes a floor frame, the floor frame has an upper surface and a lower surface, and the depth of the floor frame portion is defined between the upper surface and the lower surface.

39. The modular building unit according to claim 38, wherein the floor frame includes a peripheral frame structure that includes an elongated beam of the floor frame portion having the depth described above.

40. The modular building unit according to claim 38 or 39, wherein the floor frame is defined by a plurality of elongated frame members defining the upper and lower surfaces.

41. The modular building unit according to any one of claims 34 to 40, further comprising the planar floor structure, wherein the planar floor structure defines the floor of the modular building unit, and the depth of the floor frame portion does not include the planar floor structure.

42. The modular building unit according to any one of claims 34 to 41, wherein the ceiling frame portion includes a ceiling frame, the ceiling frame has an upper surface and a lower surface, and the depth of the ceiling frame portion is defined between the upper surface and the lower surface.

43. A modular building unit according to claim 42, comprising a plurality of mounting members that serve to attach another modular building unit on top of the aforementioned modular building unit, wherein the mounting members protrude from the upper surface of one or more frame members that form at least a portion of the ceiling frame, and the upper surface of the mounting members is configured to contact the lower surface of the other modular building unit to form a gap between the modular building units.

44. The modular building unit according to claim 43, wherein the depth of the ceiling frame portion is defined between the upper surface of the mounting member and the lower surface of one or more of the ceiling frame members.

45. The modular building unit according to any one of claims 34 to 41, wherein the ceiling frame portion includes or takes the form of a lattice structure.

46. The aforementioned ceiling frame portion includes a load transmission section, and the load transmission section is A lower structural member defining the lower surface of the load transmission section, wherein the lower surface is seated on the upper surface of the support structure, An upper structural member defining the upper surface of the load transmission compartment, wherein the upper surface is configured to support another modular building unit, and At least one connecting member that extends between the lower structural member and the upper structural member, connecting the two structural members, and transmitting load from the upper structural member to the lower structural member, thereby also transmitting it to the support structure. A modular building unit according to claim 45, including the above.

47. The modular building unit according to claim 46, wherein the ceiling frame portion includes a ceiling compartment configured to define or support the ceiling of the modular building unit, the ceiling compartment being located inside and connected to the load-transmitting compartment.

48. The modular building unit according to claim 47, wherein the ceiling compartment has a lower surface positioned lower than the upper surface of the support structure.

49. The modular building unit according to any one of claims 34 to 48, wherein the access function is selected from the group including access between the upper and lower living spaces of the building, access between the first living space of the building and at least one other living space, wherein the two living spaces are separated from each other in another part of the building, and access from the outside to the inside of the building.

50. The modular building unit according to any one of claims 34 to 49, wherein the modular building unit includes one or more walls that define at least one room and form the boundary of the room.

51. The modular building unit according to claim 50, wherein at least one room includes plumbing fixtures, the room being selected from the group including a bathroom, shower room, bedroom bathroom, w / C or washroom, and utility room.

52. A modular building assembly, First modular building unit, and A second modular building unit is positioned on top of the first modular building unit so that the second modular building unit is supported by the first modular building unit. Includes, The first modular building unit includes a structural frame, and the structural frame is A floor frame portion configured to support a flat floor structure, the floor frame portion having a maximum depth of approximately 70 mm (2.756") The ceiling frame section has a depth of at least approximately 150 mm (5.906"), and A support structure that extends between the floor frame portion and the ceiling frame portion and connects the two frame portions, Includes, The modular building unit defines a circulating space configured to provide at least one access function to the building including the modular building unit. Modular building units.

53. The modular building assembly according to claim 52, wherein the first modular building unit is a modular building unit according to any one of claims 34 to 51.

54. The modular building assembly according to claim 52, wherein the second modular building unit is a modular building unit according to any one of claims 34 to 51.

55. A building comprising a modular building unit according to any one of claims 34 to 51, or a modular building assembly according to any one of claims 52 to 54.

56. The building according to claim 55, wherein the building is a hybrid residential building having a first building section and a second building section, the first building section is constructed on-site at the final installation site of the building, the second building section includes the modular building unit, and the first building section and the second building section are configured to be joined at the final installation site to form the building.

57. The building according to claim 55, wherein the building is a hybrid residential building comprising a first building section and a second building section, the first building section being constructed on-site at the final installation site of the building, the second building section being defined by the modular building assembly, and the first building section and the second building section being joined at the final installation site to form the building.

58. A building comprising a plurality of modular building units, wherein at least one of the modular building units is a modular building unit according to any one of claims 34 to 51, and the interior space of the building is substantially formed entirely by the units.

59. A building according to any one of claims 55 to 58, comprising a foundation including a load-bearing structure and insulation material, wherein the modular building unit is placed on the foundation, so that the load-bearing structure becomes a structural support for the modular building unit, and the insulation material insulates the modular building unit from the ground.

60. The building according to any one of claims 55 to 59, wherein the circulating space is arranged to provide one or more access functions selected from the group including access between the upper and lower living spaces of the first building compartment, access between the first living space of the first building compartment and at least one other living space, wherein the two living spaces are arranged to provide one or more access functions selected from the group including access separated from each other within the first building compartment, and access to the first building compartment from outside the building.

61. A method for constructing hybrid buildings, A process of constructing the first building section at the final installation site of the building, A step of constructing a modular building unit according to any one of claims 34 to 51 at a location away from the aforementioned final installation site, thereby bringing it into a substantially assembled state. A step of transporting the modular building unit in the substantially assembled form to the final installation site, arranging the modular building unit to form at least a portion of the second building section of the building, and The process of joining the first building section and the second building section to form the building. Methods that include...

62. The construction of the foundation of the aforementioned building, which includes providing load-bearing structures and insulation materials to the foundation. The at least one modular building unit is placed on the foundation, thereby the load-bearing structure of the foundation becomes a structural support for the modular building unit, and the insulation material of the foundation insulates the modular building unit from the ground, and Arranging the first building section such that it is supported by the foundation. The method according to claim 61, including the method described in claim 61.

63. Arranging the modular building units to form a planar floor structure of the second building compartment, including providing an upper support surface for the planar floor structure. Providing a floor in the first building compartment, including providing an upper support surface on the floor, The floor of the first building compartment is positioned such that the upper support surface of the floor of the first building compartment is at the same height as the upper support surface of the modular building unit. The method according to claim 61 or 62, including the method described in claim 61 or 62.

64. The method according to claim 63, further comprising making the depth of the floor of the first building compartment equal to the depth obtained by adding the depth of the planar floor structure of the modular building unit to the depth of the floor frame portion of the modular building unit.

Images