Construction panel transport systems and methods

Abstract

Systems and methods for transportation of construction panels. A system for transporting housing panels comprises pre-assembled construction panels having respective construction panel straps, framing panels having respective framing panel straps, and a transportation container dimensioned to accommodate the construction panels and the framing panels. A method for transporting housing panels comprises lifting the construction panels and the framing panels by respective construction panel straps and framing panel straps into an open area of the transportation container through the top of the transportation container, securing the construction panels and framing panels into the transportation container, moving the transportation container from one location to another, unsecuring the construction panels and the framing panels from the transportation container, and lifting the construction panels and framing panels out of the open area of the transportation container through the top end of the transportation container using the respective construction panel straps and framing panel straps.

Description

TECHNICAL FIELD

[0001] Example embodiments relate to a pre-assembled construction panel for modular housing units.BACKGROUND

[0002] Though once equal, housing prices have increased dramatically in comparison to disposable income, and the average house price can be more than 5 times more expensive than 25 years ago. Large cities can have median house prices more than 10 times the median annual gross income of a household, making purchasing a house largely inaccessible for many individuals and families.

[0003] A potential solution for lowering housing costs is modular housing. Generally, with conventional house construction, all pre-construction costs are carried by each project, which can rise over time with increasing labor and material costs. Each housing project carries a significant pre-construction cost, as housing designs must be developed, materials must be procured, and individual designs must be built on a case-by case-basis. Ideally, with modular housing, the majority of the pre-construction cost is incurred during prototyping, as a modular design is generated and iterated. Then, multiple similar projects can be created, and money can be saved on developing designs and building individual unique houses.

[0004] However, many modular housing concepts simply move the unique construction process to the factory instead of performing the construction on site. While this saves installation time on site, the inefficiencies associated with unique designs remain, and pre-construction costs remain high. Combined with rising materials costs, some modular construction projects can be even more expensive than conventional constructions projects, due to difficulties in generating and manufacturing a modular design.

[0005] There is thus a need in the art for a modular housing system which provides easy assembly and construction based on set designs, lowering the costs of production and making the houses more affordable. The houses should be easy and quick to set up using very few components, and elements of the housing design should be pre-incorporated into the walls during manufacturing and assembly of the walls of the house to expedite on-site assembly and minimize costs associated with production of each individual housing unit.SUMMARY

[0006] In accordance with one embodiment, a system for transporting housing panels, comprises one or more pre-assembled construction panels, each of the one or more pre-assembled construction panels including one or more respective constructive panel straps disposed within a respective inner layer of the one or more pre-assembled construction panels; one or more framing panels, each of the one or more framing panels including one or more respective framing panel straps disposed within a respective inner layer of the one or more framing panels; and a transportation container having a top edge side defining an open access area accessible through a top of the transport container and dimensioned to accommodate the one or more pre-assembled construction panels and the one or more framing panels.

[0007] In accordance with another embodiment, which may be used alone or in combination with another embodiment, a method for transporting housing panels comprises, at a first location, lifting one or more pre-assembled construction panels into an open access area defined by a top edge side of a transportation container and accessible through a top of the transport container using one or more respective construction panel straps disposed within a respective inner layer of each of the one or more pre-assembled construction panels; at the first location, securing the one or more pre-assembled construction panels into the transportation container; at the first location, lifting one or more framing panels into the open access area of the transportation container using one or more respective framing panel straps disposed within a respective framing panel inner layer of each of the framing panels; at the first location, securing the one or more pre-assembled construction panels into the open access area of the transportation container; moving the transportation container from the first location to a second location; at the second location, unsecuring the one or more pre-assembled construction panels from the open access area; at the second location, lifting the one or more pre-assembled construction panels out of the open access area defined by the top edge side of the transportation container using the one or more respective construction panel straps; at the second location, unsecuring the one or more framing panels from the open access area; and at the second location, lifting the one or more framing panels out of the open access area defined by the top edge side of the transportation container using the one or more respective framing panel straps.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:

[0009] FIG. 1 is a front view of an example pre-assembled construction panel.

[0010] FIG. 2A is a top view of the example pre-assembled construction panel of FIG. 1.

[0011] FIG. 2B is a front view of a lifting strap secured in the pre-assembled construction panel of FIG. 1.

[0012] FIG. 3 is a front view of an exampled electrical layout of the pre-assembled construction panel of FIG. 1.

[0013] FIG. 4 is a front view of an example heating, ventilation, and air conditioning (HVAC) layout of the pre-assembled construction panel of FIG. 1.

[0014] FIG. 5 is a front view of an example drain-waste-vent (DWV) layout of the pre-assembled construction panel of FIG. 1.

[0015] FIG. 6 is a front view of an example waterline layout of the pre-assembled construction panel of FIG. 1.

[0016] FIG. 7 is a front view of the pre-assembled construction panel of FIG. 1 which contains all of the utility services of FIGS. 3-6.

[0017] FIG. 8 is a perspective view of multiple pre-assembled construction panels connected to each other to form a housing unit.

[0018] FIG. 9 is a perspective view of multiple pre-assembled construction panels arranged in a transportation unit.

[0019] FIG. 10 is a top view of multiple pre-assembled construction panels arranged in a transportation unit.

[0020] FIG. 11 is a top perspective view of a transportation unit with a flexible material covering the top of the container.

[0021] FIG. 12A is a top perspective view of a transportation unit with a retractable roof in a retracted position.

[0022] FIG. 12B is a top perspective view of the transportation unit of FIG. 12A with the retractable roof in a closed position.

[0023] FIG. 13 is a flowchart describing the process for making, transporting, and assembling multiple pre-assembled construction panels to form a housing unit.DESCRIPTION OF EXAMPLE EMBODIMENTS

[0024] Reference is made with reference to the accompanying drawings, in which example embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout.

[0025] Throughout the following, specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well-known elements may not have been shown or described in detail. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0026] Example embodiments relate to a pre-assembled construction panel wherein various services, as well as cosmetic or functional items, are factory installed.

[0027] Referring to FIG. 1, an example pre-assembled construction panel 100 is illustrated, viewed from the outer surface of the panel 100. In an embodiment, the outer surface of the panel 100 may face outdoors when constructed into a housing unit. The panel 100 may have a horizontal trim 102 on a ceiling edge side of the panel 100, a flooring edge side of the panel 100, or both. The panel 100 may further have a vertical trim 104 on one edge side of the panel 100, a second edge side of the panel 100, or both. In an embodiment, the horizontal trim 102 and vertical trim 104 may be made out of the same material. In an embodiment, the horizontal trim 102 and vertical trim 104 may be made out of polyvinyl chloride (PVC). In an embodiment, the horizontal trim 102 and vertical trim 104 may be made out of different materials.

[0028] The panel 100 may further include at least one door 106, each door 106 surrounded by a corresponding doorframe 108. Each door 106 may be made out of any suitable material, such as wood, steel, fiberglass, vinyl, aluminum, composite, glass, or any other material commonly used to produce doors. Similarly, each doorframe 108 may be made out of any suitable material, such as wood, aluminum, fiberglass, composite, or any other material commonly used to produce doorframes. In an embodiment, each doorframe 108 is made out of the same material as either horizontal trim 102, vertical trim 104, or both. Each door 106 and doorframe 108 may be located anywhere along the panel 100.

[0029] The panel 100 may further include at least one window 110, each window 110 surrounded by a corresponding window frame 112. Each window 110 may be made out of any suitable material, such as glass, plastic, or any other material commonly used to produce windows. Each window frame 112 may be made out of any suitable material, such as wood, aluminum, fiberglass, composite, or any other material commonly used to produce window frames. In an embodiment, each window frame 112 is made out of the same material as horizontal trim 102, vertical trim 104, or doorframe 108. Each window 110 and window frame 112 may be located anywhere along the panel 100.

[0030] The panel 100 may further include any number of electrical components, such as an electrical outlet 114 or a lighting element 116. The electrical components may be located anywhere along the outer surface of the panel 100. The outer surface of the panel 100 may be covered by a material such as board and batten vertical vinyl siding 118. In an embodiment, the outer surface of the panel 100 may be covered by any other suitable material that is durable, weather resistant, sustainable, and easy to handle, cut, and install.

[0031] The ceiling edge side of the panel 100 may include one or more constructive panel straps 120. In an embodiment, the ceiling edge side of the panel may include two constructive panel straps 120. The constructive panel straps 120 may be attached to the panel 100 by a friction fit, nails, screws, glue, and / or any other method of attachment. In an embodiment, the constructive panel straps 120 are disposed within an inner layer of the panel 100 (as seen in FIG. 2B). As shown, the constructive panel straps 120 may be attached to a first wooden stud via a fastener, and secured in a friction fit between the first wooden stud and an adjacent second stud. In an embodiment, the constructive panel straps 120 are used for lifting the panel 100 using a crane, forklift, or any other hoisting mechanism. In an embodiment, the constructive panel straps 120 are made of nylon, polyester, or any other strong, durable, lightweight, weather resistant material. In an embodiment, the constructive panel straps 120 each have a width of 2 inches. In an embodiment, the constructive panel straps 120 each have a working load limit of approximately 1500 kg. In an embodiment, the constructive panel straps 120 each have a working load limit of over 1350 kg. In an embodiment, the constructive panel straps 120 each have a tensile strength of approximately 70 MPa. In an embodiment, the constructive panel straps 120 each have a tensile strength of over 60 MPa. A person of skill in the art understands that the constructive panel straps 120 may have a higher or lower width, working load limit, and tensile strength, as long as the constructive panel straps 120 are strong enough to safely lift panel 100. Similarly, a person of skill in the art understands that any number of constructive panel straps 120 may be present to safely lift panel 100. The constructive panel straps 120 may be disposed anywhere along the ceiling edge side of the panel 100. In an embodiment, the constructive panel straps 120 are evenly distributed along the ceiling edge side of the panel 100. Once the panel 100 has been placed on the floor panel (FIG. 8), the constructive panel straps may be removed or cut once lifting is no longer required.

[0032] The panel 100 may weigh up to 2300 kg. In an embodiment, the panel 100 weighs between 900 kg and 1800 kg. The panel 100 may be up to 16 m long, at least 2.4 m tall, and up to 25 cm thick. In an embodiment, the panel 100 is between 6 m and 12 m long inclusive. In an embodiment, the panel 100 is between 2.4 m and 2.5 m high inclusive. In an embodiment, the panel 100 is between 15 cm and 25 cm thick inclusive.

[0033] Referring to FIG. 2A, the panel 100 may have any number of layers of materials. In an embodiment, the outer surface of the panel may comprise the board and batten vertical vinyl siding 118. The panel 100 may comprise an air pocket 202 between the board & batten vertical vinyl siding 118 and an oriented strand board (OSB) 204. In an embodiment, the OSB 204 has a thickness of 7 / 16 inches. However, other thicknesses of the OSB 204 may be possible. The panel may further comprise a rigid insulation layer 206, and one or more constructive panel straps 120 for lifting the panel. In an embodiment, the rigid insulation layer 206 has a thickness of 2 inches. However, other thicknesses of the rigid insulation layer 206 may be possible.

[0034] Next to the rigid insulation layer 206 and one or more constructive panel straps 120, the panel 100 may include a plurality of wooden studs 208 positioned between the ceiling edge side of the panel 100 and the flooring edge side of the panel 100. The wooden studs 208 may be spaced equidistant from each other or may be spaced unevenly. A plurality of utility service channels may be disposed in the layer consisting of the wooden studs 208, as will be described in later figures. The space between wooden studs not containing utility service channels may be filled with spray insulation 210 (spray foam). In an embodiment, one or more continuous utility straps may be attached to the one or more wooden studs. The continuous utility straps may be disposed towards an inner surface of the panel opposite the outer surface of the panel 100, the outer surface of the panel 100, or both. In an embodiment, the continuous utility straps are attached on a diagonal from the ceiling edge side of the panel to the flooring edge side of the panel 100. In an embodiment, the spray insulation 210 (spray foam) is disposed prior to assembly of the housing unit.

[0035] The inner surface of the panel 100 may be made from gypsum board 212. In an embodiment, the gypsum board 212 has a thickness of ⅝ inches. In an embodiment, the gypsum board 212 may be Type X gypsum board. However, other thicknesses and types of gypsum board may be possible.

[0036] FIG. 3 illustrates an example electrical layout of panel 100. The electrical components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The electrical components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. A main electrical panel 302 may be disposed in the center of the panel 100, or may be disposed anywhere else between the first edge side and the second edge side of the panel 100. The main electrical panel 302 may be configured to fit between two wooden studs 208. The main electrical panel 302 may be connected to a conduit that runs along panel 100. The conduit may house electrical wires or a pull string. The panel 100 may include various fused direct connections (FSD), including a water heater FSD, a packaged terminal air conditioner (PTAC) FSD, a range hood FSD, or a force flow heater FSD.

[0037] The panel 100 may include outlets 304 related to various appliances, including a fridge outlet, a dishwasher outlet, a stove outlet, a dryer outlet, and a washer outlet. The panel 100 may include lighting strips 306, as well as a lighting strip switch 308. The panel 100 may include a smoke detector. The electrical components described may all be in electrical communication with the main electrical panel 302. The electrical components described may be secured to wooden studs 208 by any suitable attachment method. The electrical components described may be positioned anywhere along panel 100.

[0038] FIG. 4 illustrates an example heating, ventilation, and air conditioning (HVAC) layout of panel 100. The HVAC components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The HVAC components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. An energy recovery ventilator (ERV) 402 may be disposed in panel 100, and may be configured to be attached to and fit between two wooden studs 208. The ERV 402 may be connected to an intake 404, exhaust 408, bath vent, or fresh air vent via pipes various respective pipes. In an embodiment, the intake 404, exhaust 408, bath vent and fresh air vent may be accessible at the inner surface or outer layer of the panel 100. The panel 100 may further include a dryer vent, which may be accessible by at the inner surface of panel 100. The dryer vent may be located nearby to the dryer outlet located in the electrical layout. The panel 100 may further include a PTAC, disposed close to the PTAC FSD. The PTAC may be located on the inner surface of the panel 100. The HVAC components described may be secured to wooden studs 208 by any suitable attachment method.

[0039] FIG. 5 illustrates an example drain-waste-vent (DWV) layout of panel 100. The DWV components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The DWV components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. A PTAC drain may be connected to PTAC and to washer box 502 via a sanitation pipe 504. Washer box 502 may be located nearby to washer outlet as described in the electrical layout. Sanitation pipe 504 may be additionally connected to a kitchen sink drain, a bath sink drain, a toilet drain, and a shower drain. One end of sanitation pipe 504 may be positioned higher than the opposite end of sanitation pipe 504, such as to allow fluid and solid waste to flow along the pipe using gravity. In an embodiment, the sanitation pipe 504 may exit through a flooring edge side of panel 100.

[0040] The DWV layout may also include one or more ventilation pipes connected to the sanitation pipe 504. The ventilation pipes 506 may be positioned above sanitation pipe 504. In an embodiment, the ventilation pipes 506 may exit through a ceiling edge side of panel 100. A person of skill in the art understands that various layouts of sanitation pipes 504 and ventilation pipes 506 may be possible. In addition, a person of skill in the art understands that various thicknesses and lengths of sanitation pipes 504 and ventilation pipes 506 may be possible.

[0041] FIG. 6 illustrates an example waterline layout of panel 100. The waterline components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The waterline components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. A water heater 602 may be connected to a water box 604 via a pipe. The water box 604 may be located nearby to the washer box 502. The water heater 602 may be further connected to a kitchen sink inlet, a bath sink inlet, and a toilet inlet via a second pipe. The second pipe may exit through a flooring edge side of panel 100.

[0042] FIG. 7 illustrates an exemplary panel 100 that includes the utility service channels as described in FIGS. 3-6. As illustrated, the panel 100 may be configured to include all utility service channels, without obstructing the functioning of any individual channel. Each component or utility service channel may be disposed on the same plane between a plurality of wooden studs 208, or may be closer to the front or back of panel 100. Each of the utility components may be disposed anywhere along the length of panel 100, between the first edge and the second edge, or all components may be grouped in a single area of panel 100. Further, each utility service channel may include any number of components listed. Although the layouts are represented in a certain manner and with certain components in the figures, it will be appreciated by a person skilled in the art that any number of layouts and any combination of components for the utility service channels are possible. By pre-assembling the construction panels 100 with the relevant utility service channels, the time and expense for on-site construction can be vastly reduced, as on-site construction and assembly requires only simple connections of pre-existing components.

[0043] FIG. 8 illustrates a plurality of panels 100 that are assembled together to form a housing unit 800. The housing unit may include at least 4 panels 100, a floor panel (not pictured), a ceiling panel (not pictured), and a plurality of roofing panels 802 assembled to form a roof 804. The ceiling panel may be securely attached to the ceiling edge side of the panel 100, and the floor panel may be securely attached at the flooring edge side to the panel 100. In an embodiment, none of the utility services channels as previously described are present in either the floor panel or the ceiling panel. As shown, the panels 100 may be connected to each other at 90-degree angles to create corners. The panels 100 may be secured to each other at a 90-degree angle using wood screws, or any other applicable method of fastening. In an embodiment, panels 100 can be connected to each other side by side. As shown in FIG. 8, the horizontal trim 102 of each panel 100 may overlap in the corners. Additionally, the vertical trim 104 of each panel 100 may overlap in the corners. The floor panel may include L shaped bracket members to hold the panels 100 in place. In an embodiment, the floor panel may instead include U shaped bracket members to hold the panels 100 in place.

[0044] Alternately, the housing unit 800 may be formed by one panel 100 and at least 3 framing panels, a floor panel (not pictured), a ceiling panel (not pictured), and a plurality of roofing panels 802 assembled to form a roof 804. In an embodiment, the framing panels may not include any of the utility service channels as previously described. The framing panels may be connected to each other and / or to the first or second edge side of panel 100 at 90-degree angles to create corners, may be connected side by side, and may be secured to each other or to panel 100 using wood screws or any other applicable method of fastening. The framing panels may be held in place on the floor panel via the bracket members as described above.

[0045] In an embodiment, each panel 100 may have utility service channels of a same type, such as electrical, HVAC, DWV, or waterline, which are configured to connect to other panels. For example, each panel 100 may have electrical wiring and components disposed in the layer consisting of the wooden studs 208 as described in FIG. 2A. The panels may be configured such that the electrical components in one panel are connected to components in another panel. For example, one panel may house the main electrical panel 302, while other panels house electrical components such as a smoke detector or a fridge outlet, which are connected to the main electrical panel 302.

[0046] In an embodiment, only one of the panels includes the services once the housing unit is assembled. The ceiling panel, the floor panel, and the remaining panels 100 do not include any services prior to and after assembly of the housing unit.

[0047] FIGS. 9 and 10 illustrate a system and transportation container 902 for storage and transportation of panels 100. As shown, A plurality of panels 100 may be arranged on the floor 905 in an open access area 904 of a transportation container 902. The open access area 904 may be defined by the top side edge 903 of the transportation container 902, such that the open access area is accessible through the top of the transportation container 902. The panels 100 may be substantially parallel to each other, may be arranged perpendicular to each other, or may be arranged in any other manner to provide safe and efficient transportation. In an embodiment, the panels 100 are arranged in a manner such that the constructive panel straps 120 are accessible from the top of the transportation container 902. In an embodiment, the panels 100 are secured into bracket members 908 in the transportation container 902. The transportation container 902 may be made of any sufficiently rigid and durable material, such as steel. In an embodiment, the transportation container 902 does not have a covering, and the top remains open. In an embodiment, the transportation container 902 may be approximately 16 m long, approximately 2.5 m tall, and approximately 2.5 m wide. In an embodiment, the transportation container 902 may be between 14 m and 18 m long. In an embodiment, the transportation container may be between 2 m and 3 m tall. In an embodiment, the transportation container may be between 2 m and 3 m wide. However, a person of skill in the art would appreciate that any suitable dimensions for a transportation container may be used, and that these values are exemplary and not limiting. In an embodiment, the transportation container 902 may also transport a plurality of interior walls 906, which may be arranged in the transportation container 902 in a similar manner as panels 100 as previously described.

[0048] FIG. 11 illustrates an embodiment of the transportation container 902 in which the transportation container has a flexible covering 910. The flexible covering 910 may be made of any flexible, water-resistant material, such as canvas, polyester coated with polyurethane, or a plastic such as polyethylene, polypropylene, vinyl, or nylon. In an embodiment, the flexible covering 910 may be attached via one or more lines 912 to one or more hooks 914 which may be removably or permanently affixed to an outside edge of transportation container 902. The one or more lines 912 may be made of rope, cable, plastic cord, elastic bungee cord, or any other suitable fastener. In an embodiment, the one or more lines 912 may be tightened around the one or more hooks 914 to secure the flexible covering 910 onto the top of the transportation container 902.

[0049] Alternately or in addition, the transportation container 902 may be covered by a fitted retractable roof 916, as illustrated in FIGS. 12A and 12B. The retractable roof 916 may be made of plastic, metal, fabric, or any other strong, water-resistant material that can sufficiently protect the panels 100 from environmental damage. As illustrated in FIG. 12B, in a retracted position, the retractable roof 916 rolls or folds towards a lateral edge side 918 of the transportation container 902, such that the open access area 904 of the transportation container 902 is accessible from the top. In a covered position as illustrated in FIG. 12A, the retractable roof extends from the retracted position from one lateral edge side 918 of the transportation container 902 towards the other, to cover the open access area 904 of the transportation container 902. The retractable roof may be manually extended and retracted, or may be actuated by an electric motor to extend and retract.

[0050] FIG. 13 illustrates a process 1300 for creating, transporting, and installing panels 100 to form a housing unit. At step 1302, The panels 100, ceiling, and roofing panels 802 are fabricated in a factory or warehouse. As described previously, the panels 100 may have one or more of the utility service channels described above. In an embodiment, interior walls 906 may also be fabricated in the same factory or warehouse at the same time as panels 100. The interior walls 906 may have one or more windows 110, one or more window frames 112, one or more doors 106, and / or one or more doorframes 108. In an embodiment, the interior walls 906 do not contain any of the utility service channels described above. In an embodiment, the interior walls 906 are predominantly composed of gypsum board. In an embodiment, the interior walls 906 may have one or more wooden studs disposed between a front layer and a rear layer of the interior walls 906. In an embodiment, the interior walls 906 may include one or more interior wall straps disposed between the front layer and the rear layer of the interior wall 906.

[0051] The ceiling panel may be composed predominantly or completely of cross-laminated timber (CLT). In an embodiment, the ceiling may further have one or more wooden studs secured to the CLT panel.

[0052] At step 1304, the panels 100, framing panels, and interior walls 906 are loaded into the transportation container 902. In an embodiment, the roof 804 and the ceiling are also loaded into the transportation container 902. In an embodiment, the framing panels each have one or more framing panel straps. In an embodiment, the panels 100, framing panels, and interior walls 906 are lifted into the transportation container 902 using the one or more constructive panel straps 120, framing panel straps, or interior wall straps respectively. In an embodiment, the panels 100, interior walls 906, and framing panels are lifted via constructive panel straps 120, framing panel straps, or interior wall straps respectively using a telescopic handler, a crane, or a forklift. In an embodiment, the telescopic handler, crane, or forklift may lift a spreader beam which is attached to constructive panel straps 120, framing panel straps, or interior wall straps in order to evenly provide lifting force along the length of the panel 100, framing panel, or interior wall 906 respectively. In an embodiment, the interior wall straps and framing panel straps may have a similar width, working load, and tensile strength as constructive panel straps 120, and may be made of the same material. In an embodiment, the panel 100 is lowered into the open access area 904 of the transportation container 902 through an opening in the top of the transportation container 902. In an embodiment, the interior walls 906 and framing panels, may be loaded into the transportation container 902 by the same method as previously described for loading the panels 100 into the transportation container 902. All above elements may be loaded into the open access area 904 of transportation container 902 in any order, and may be loaded into any spot of open access area 904. In an embodiment, the panels 100, interior walls 906 and framing panels are loaded into the open access area 904 of transportation container 902 in a specific order. In an embodiment, the panels 100, interior walls 906 and framing panels may be loaded into specific spots in open access area 904.

[0053] At step 1306, the panels 100, framing panels and interior walls 906 are secured to the transportation container 902 to prevent movement. The panels 100, framing panels and interior walls 906 may be secured directly to the transportation container 902 via screws, nails, staples, rivets, or any other fasteners. The panels 100, framing panels and interior walls 906 may be secured directly to the transportation container 902 via adhesive, such as glue, tape, epoxy, or any other suitable adhesive. In an embodiment, the transportation container 902 may include grooves, rails, channels, or any other feature that may guide movement and location of panels 100, framing panels and interior walls 906 disposed within open access area 904. In an embodiment, the grooves, rails, or channels may have a fixed location within the open access area 904 of transportation container 902. In an embodiment, the grooves, rails, or channels may be movable within the open access area 904 of transportation container 902 to accommodate different sizes of panels 100, framing panels, or interior walls 906. In an embodiment, open access area 904 of the transportation container 902 may include bracket members that secure panels 100, framing panels and interior walls 906 in place. In an embodiment, the bracket members may have a fixed location within the open access area 904 of transportation container 902. In an embodiment, the bracket members may be movable within the open access area 904 of transportation container 902. In an embodiment, the panels 100, framing panels and interior walls 906 may be secured to the bracket members through fasteners or adhesives as described above, or through a friction fit between two bracket members. In an embodiment, the ceiling panel and roof 804 may additionally be secured in the open access area 904 of transportation container 902 through any of the attachment methods described above.

[0054] At step 1308, the transportation container 902 containing secured panels 100, framing panels and interior walls 906 may be loaded onto any appropriately sized transportation vessel, such as a truck, ship, or aircraft. In an embodiment, the transportation container 902 additionally contains the ceiling panel and roof 804. In an embodiment, the ceiling panel and roof 804 are loaded onto the transportation vessel separate from the transportation container 902. In an embodiment, the ceiling and roof 804 are transported separately from the transportation container 902. In an embodiment, the transportation container 902 is loaded and secured onto the bed of a flatbed truck. As described previously, the transportation container 902 may be uncovered, covered by a tarp, or covered by a retractable roof. In an embodiment, the transportation container 902 may become covered or uncovered during transport. In an embodiment, the open access area 904 of transportation container 902 may be accessible by a side door so as not to disturb the covering.

[0055] At step 1310, the panels 100, framing panels and interior walls 906 are unloaded from the transportation container 902. In an embodiment, the panels 100, framing panels and interior walls 906 are lifted out of the transportation container 902 via the constructive panel straps 120, framing panel straps, or interior wall straps respectively in the same manner as loading described in step 1304. In an embodiment, the panels 100, framing panels and interior walls 906 are unloaded in a specific order. After a panel 100, framing panel or interior wall 906 has been unloaded from the transportation container 902, it is secured to a floor panel. In an embodiment, the panel 100, framing panel or interior wall 906 is secured to the floor panel via fasteners or adhesives as described previously. In an embodiment, the panel 100, framing panel or interior wall 906 is secured to a groove, rail or channel disposed on the floor panel. In an embodiment, the panel 100, framing panel, or interior wall 906 is secured to a bracket member on the floor panel, such as a “U” bracket member or an “L” bracket member. In an embodiment, the panel 100, framing panel, or interior wall 906 is secured to more than one bracket member on the floor panel. The bracket member may form part of the floor panel, or may be a separate component attached to the floor panel. The panels 100, framing panels, or interior walls 906 may be attached to each other as described previously with reference to FIG. 8.

[0056] At step 1312, the ceiling panel is unloaded and secured to the panels 100, framing panels, and interior walls 906. In an embodiment, the ceiling panel is unsecured and unloaded from transportation container 902. In an embodiment, the ceiling panel is unloaded from the transportation vessel, whether the same transportation vessel as transported transportation 902 or a separate transportation vessel. The ceiling panel may be secured to panels 100, framing panels, and interior walls 906 via fasteners as described above, adhesives as described above, or a combination of both.

[0057] At step 1314, the roof 804 is unloaded and secured to the ceiling panel. In an embodiment, the roof 804 is unsecured and unloaded from transportation container 902. In an embodiment, the roof 804 is unloaded from the transportation vessel, whether the same transportation vessel as transported transportation 902 or a separate transportation vessel. The roof 804 may be secured to the ceiling panel via fasteners as described above, adhesives as described above, or a combination of both.

[0058] At the end of the process 1300, a housing unit 800 is created by manufacturing, transporting, and assembling pre-assembled construction panels 100, framing panels, interior walls 906, a roof 804, and a ceiling panel. The process 1300 provides a streamlined approach to assembling the housing unit 800, wherein the assembly is much quicker than typical due to the pre-assembly of the construction panels 100 and the modular nature of the panels 100, framing panels, and interior walls 906. The result is faster turnaround, more efficient assembly, and cheaper production cost than in usual processes.

[0059] Variations may be made to some example embodiments, which may include combinations and sub-combinations of any of the above. The various embodiments presented above are merely examples and are in no way meant to limit the scope of the examples. Variations of the innovations described herein will be apparent to persons of ordinary skill in the art having the benefit of the examples, such variations being within the intended scope of the example embodiments. In particular, features from one or more of the above-described embodiments may be selected to create alternative embodiments comprised of a sub-combination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and sub-combinations would be readily apparent to persons skilled in the art upon review of the example embodiments as a whole. The subject matter described herein intends to cover and embrace all suitable changes in technology.

[0060] Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.

Examples

Embodiment Construction

[0024]Reference is made with reference to the accompanying drawings, in which example embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout.

[0025]Throughout the following, specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well-known elements may not have been shown or described in detail. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0026]Example embodiments relate to a pre-assembled construction panel wherein various services, as well as cosmetic or functional items, are factory installed.

[0027]Referring to FIG. 1, an example pre-assembled construction panel 100 is illustrated, viewed from the...

TECHNICAL FIELD

[0001] Example embodiments relate to a pre-assembled construction panel for modular housing units.BACKGROUND

[0002] Though once equal, housing prices have increased dramatically in comparison to disposable income, and the average house price can be more than 5 times more expensive than 25 years ago. Large cities can have median house prices more than 10 times the median annual gross income of a household, making purchasing a house largely inaccessible for many individuals and families.

[0003] A potential solution for lowering housing costs is modular housing. Generally, with conventional house construction, all pre-construction costs are carried by each project, which can rise over time with increasing labor and material costs. Each housing project carries a significant pre-construction cost, as housing designs must be developed, materials must be procured, and individual designs must be built on a case-by case-basis. Ideally, with modular housing, the majority of the pre-construction cost is incurred during prototyping, as a modular design is generated and iterated. Then, multiple similar projects can be created, and money can be saved on developing designs and building individual unique houses.

[0004] However, many modular housing concepts simply move the unique construction process to the factory instead of performing the construction on site. While this saves installation time on site, the inefficiencies associated with unique designs remain, and pre-construction costs remain high. Combined with rising materials costs, some modular construction projects can be even more expensive than conventional constructions projects, due to difficulties in generating and manufacturing a modular design.

[0005] There is thus a need in the art for a modular housing system which provides easy assembly and construction based on set designs, lowering the costs of production and making the houses more affordable. The houses should be easy and quick to set up using very few components, and elements of the housing design should be pre-incorporated into the walls during manufacturing and assembly of the walls of the house to expedite on-site assembly and minimize costs associated with production of each individual housing unit.SUMMARY

[0006] In accordance with one embodiment, a system for transporting housing panels, comprises one or more pre-assembled construction panels, each of the one or more pre-assembled construction panels including one or more respective constructive panel straps disposed within a respective inner layer of the one or more pre-assembled construction panels; one or more framing panels, each of the one or more framing panels including one or more respective framing panel straps disposed within a respective inner layer of the one or more framing panels; and a transportation container having a top edge side defining an open access area accessible through a top of the transport container and dimensioned to accommodate the one or more pre-assembled construction panels and the one or more framing panels.

[0007] In accordance with another embodiment, which may be used alone or in combination with another embodiment, a method for transporting housing panels comprises, at a first location, lifting one or more pre-assembled construction panels into an open access area defined by a top edge side of a transportation container and accessible through a top of the transport container using one or more respective construction panel straps disposed within a respective inner layer of each of the one or more pre-assembled construction panels; at the first location, securing the one or more pre-assembled construction panels into the transportation container; at the first location, lifting one or more framing panels into the open access area of the transportation container using one or more respective framing panel straps disposed within a respective framing panel inner layer of each of the framing panels; at the first location, securing the one or more pre-assembled construction panels into the open access area of the transportation container; moving the transportation container from the first location to a second location; at the second location, unsecuring the one or more pre-assembled construction panels from the open access area; at the second location, lifting the one or more pre-assembled construction panels out of the open access area defined by the top edge side of the transportation container using the one or more respective construction panel straps; at the second location, unsecuring the one or more framing panels from the open access area; and at the second location, lifting the one or more framing panels out of the open access area defined by the top edge side of the transportation container using the one or more respective framing panel straps.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:

[0009] FIG. 1 is a front view of an example pre-assembled construction panel.

[0010] FIG. 2A is a top view of the example pre-assembled construction panel of FIG. 1.

[0011] FIG. 2B is a front view of a lifting strap secured in the pre-assembled construction panel of FIG. 1.

[0012] FIG. 3 is a front view of an exampled electrical layout of the pre-assembled construction panel of FIG. 1.

[0013] FIG. 4 is a front view of an example heating, ventilation, and air conditioning (HVAC) layout of the pre-assembled construction panel of FIG. 1.

[0014] FIG. 5 is a front view of an example drain-waste-vent (DWV) layout of the pre-assembled construction panel of FIG. 1.

[0015] FIG. 6 is a front view of an example waterline layout of the pre-assembled construction panel of FIG. 1.

[0016] FIG. 7 is a front view of the pre-assembled construction panel of FIG. 1 which contains all of the utility services of FIGS. 3-6.

[0017] FIG. 8 is a perspective view of multiple pre-assembled construction panels connected to each other to form a housing unit.

[0018] FIG. 9 is a perspective view of multiple pre-assembled construction panels arranged in a transportation unit.

[0019] FIG. 10 is a top view of multiple pre-assembled construction panels arranged in a transportation unit.

[0020] FIG. 11 is a top perspective view of a transportation unit with a flexible material covering the top of the container.

[0021] FIG. 12A is a top perspective view of a transportation unit with a retractable roof in a retracted position.

[0022] FIG. 12B is a top perspective view of the transportation unit of FIG. 12A with the retractable roof in a closed position.

[0023] FIG. 13 is a flowchart describing the process for making, transporting, and assembling multiple pre-assembled construction panels to form a housing unit.DESCRIPTION OF EXAMPLE EMBODIMENTS

[0024] Reference is made with reference to the accompanying drawings, in which example embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout.

[0025] Throughout the following, specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well-known elements may not have been shown or described in detail. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0026] Example embodiments relate to a pre-assembled construction panel wherein various services, as well as cosmetic or functional items, are factory installed.

[0027] Referring to FIG. 1, an example pre-assembled construction panel 100 is illustrated, viewed from the outer surface of the panel 100. In an embodiment, the outer surface of the panel 100 may face outdoors when constructed into a housing unit. The panel 100 may have a horizontal trim 102 on a ceiling edge side of the panel 100, a flooring edge side of the panel 100, or both. The panel 100 may further have a vertical trim 104 on one edge side of the panel 100, a second edge side of the panel 100, or both. In an embodiment, the horizontal trim 102 and vertical trim 104 may be made out of the same material. In an embodiment, the horizontal trim 102 and vertical trim 104 may be made out of polyvinyl chloride (PVC). In an embodiment, the horizontal trim 102 and vertical trim 104 may be made out of different materials.

[0028] The panel 100 may further include at least one door 106, each door 106 surrounded by a corresponding doorframe 108. Each door 106 may be made out of any suitable material, such as wood, steel, fiberglass, vinyl, aluminum, composite, glass, or any other material commonly used to produce doors. Similarly, each doorframe 108 may be made out of any suitable material, such as wood, aluminum, fiberglass, composite, or any other material commonly used to produce doorframes. In an embodiment, each doorframe 108 is made out of the same material as either horizontal trim 102, vertical trim 104, or both. Each door 106 and doorframe 108 may be located anywhere along the panel 100.

[0029] The panel 100 may further include at least one window 110, each window 110 surrounded by a corresponding window frame 112. Each window 110 may be made out of any suitable material, such as glass, plastic, or any other material commonly used to produce windows. Each window frame 112 may be made out of any suitable material, such as wood, aluminum, fiberglass, composite, or any other material commonly used to produce window frames. In an embodiment, each window frame 112 is made out of the same material as horizontal trim 102, vertical trim 104, or doorframe 108. Each window 110 and window frame 112 may be located anywhere along the panel 100.

[0030] The panel 100 may further include any number of electrical components, such as an electrical outlet 114 or a lighting element 116. The electrical components may be located anywhere along the outer surface of the panel 100. The outer surface of the panel 100 may be covered by a material such as board and batten vertical vinyl siding 118. In an embodiment, the outer surface of the panel 100 may be covered by any other suitable material that is durable, weather resistant, sustainable, and easy to handle, cut, and install.

[0031] The ceiling edge side of the panel 100 may include one or more constructive panel straps 120. In an embodiment, the ceiling edge side of the panel may include two constructive panel straps 120. The constructive panel straps 120 may be attached to the panel 100 by a friction fit, nails, screws, glue, and / or any other method of attachment. In an embodiment, the constructive panel straps 120 are disposed within an inner layer of the panel 100 (as seen in FIG. 2B). As shown, the constructive panel straps 120 may be attached to a first wooden stud via a fastener, and secured in a friction fit between the first wooden stud and an adjacent second stud. In an embodiment, the constructive panel straps 120 are used for lifting the panel 100 using a crane, forklift, or any other hoisting mechanism. In an embodiment, the constructive panel straps 120 are made of nylon, polyester, or any other strong, durable, lightweight, weather resistant material. In an embodiment, the constructive panel straps 120 each have a width of 2 inches. In an embodiment, the constructive panel straps 120 each have a working load limit of approximately 1500 kg. In an embodiment, the constructive panel straps 120 each have a working load limit of over 1350 kg. In an embodiment, the constructive panel straps 120 each have a tensile strength of approximately 70 MPa. In an embodiment, the constructive panel straps 120 each have a tensile strength of over 60 MPa. A person of skill in the art understands that the constructive panel straps 120 may have a higher or lower width, working load limit, and tensile strength, as long as the constructive panel straps 120 are strong enough to safely lift panel 100. Similarly, a person of skill in the art understands that any number of constructive panel straps 120 may be present to safely lift panel 100. The constructive panel straps 120 may be disposed anywhere along the ceiling edge side of the panel 100. In an embodiment, the constructive panel straps 120 are evenly distributed along the ceiling edge side of the panel 100. Once the panel 100 has been placed on the floor panel (FIG. 8), the constructive panel straps may be removed or cut once lifting is no longer required.

[0032] The panel 100 may weigh up to 2300 kg. In an embodiment, the panel 100 weighs between 900 kg and 1800 kg. The panel 100 may be up to 16 m long, at least 2.4 m tall, and up to 25 cm thick. In an embodiment, the panel 100 is between 6 m and 12 m long inclusive. In an embodiment, the panel 100 is between 2.4 m and 2.5 m high inclusive. In an embodiment, the panel 100 is between 15 cm and 25 cm thick inclusive.

[0033] Referring to FIG. 2A, the panel 100 may have any number of layers of materials. In an embodiment, the outer surface of the panel may comprise the board and batten vertical vinyl siding 118. The panel 100 may comprise an air pocket 202 between the board & batten vertical vinyl siding 118 and an oriented strand board (OSB) 204. In an embodiment, the OSB 204 has a thickness of 7 / 16 inches. However, other thicknesses of the OSB 204 may be possible. The panel may further comprise a rigid insulation layer 206, and one or more constructive panel straps 120 for lifting the panel. In an embodiment, the rigid insulation layer 206 has a thickness of 2 inches. However, other thicknesses of the rigid insulation layer 206 may be possible.

[0034] Next to the rigid insulation layer 206 and one or more constructive panel straps 120, the panel 100 may include a plurality of wooden studs 208 positioned between the ceiling edge side of the panel 100 and the flooring edge side of the panel 100. The wooden studs 208 may be spaced equidistant from each other or may be spaced unevenly. A plurality of utility service channels may be disposed in the layer consisting of the wooden studs 208, as will be described in later figures. The space between wooden studs not containing utility service channels may be filled with spray insulation 210 (spray foam). In an embodiment, one or more continuous utility straps may be attached to the one or more wooden studs. The continuous utility straps may be disposed towards an inner surface of the panel opposite the outer surface of the panel 100, the outer surface of the panel 100, or both. In an embodiment, the continuous utility straps are attached on a diagonal from the ceiling edge side of the panel to the flooring edge side of the panel 100. In an embodiment, the spray insulation 210 (spray foam) is disposed prior to assembly of the housing unit.

[0035] The inner surface of the panel 100 may be made from gypsum board 212. In an embodiment, the gypsum board 212 has a thickness of ⅝ inches. In an embodiment, the gypsum board 212 may be Type X gypsum board. However, other thicknesses and types of gypsum board may be possible.

[0036] FIG. 3 illustrates an example electrical layout of panel 100. The electrical components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The electrical components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. A main electrical panel 302 may be disposed in the center of the panel 100, or may be disposed anywhere else between the first edge side and the second edge side of the panel 100. The main electrical panel 302 may be configured to fit between two wooden studs 208. The main electrical panel 302 may be connected to a conduit that runs along panel 100. The conduit may house electrical wires or a pull string. The panel 100 may include various fused direct connections (FSD), including a water heater FSD, a packaged terminal air conditioner (PTAC) FSD, a range hood FSD, or a force flow heater FSD.

[0037] The panel 100 may include outlets 304 related to various appliances, including a fridge outlet, a dishwasher outlet, a stove outlet, a dryer outlet, and a washer outlet. The panel 100 may include lighting strips 306, as well as a lighting strip switch 308. The panel 100 may include a smoke detector. The electrical components described may all be in electrical communication with the main electrical panel 302. The electrical components described may be secured to wooden studs 208 by any suitable attachment method. The electrical components described may be positioned anywhere along panel 100.

[0038] FIG. 4 illustrates an example heating, ventilation, and air conditioning (HVAC) layout of panel 100. The HVAC components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The HVAC components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. An energy recovery ventilator (ERV) 402 may be disposed in panel 100, and may be configured to be attached to and fit between two wooden studs 208. The ERV 402 may be connected to an intake 404, exhaust 408, bath vent, or fresh air vent via pipes various respective pipes. In an embodiment, the intake 404, exhaust 408, bath vent and fresh air vent may be accessible at the inner surface or outer layer of the panel 100. The panel 100 may further include a dryer vent, which may be accessible by at the inner surface of panel 100. The dryer vent may be located nearby to the dryer outlet located in the electrical layout. The panel 100 may further include a PTAC, disposed close to the PTAC FSD. The PTAC may be located on the inner surface of the panel 100. The HVAC components described may be secured to wooden studs 208 by any suitable attachment method.

[0039] FIG. 5 illustrates an example drain-waste-vent (DWV) layout of panel 100. The DWV components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The DWV components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. A PTAC drain may be connected to PTAC and to washer box 502 via a sanitation pipe 504. Washer box 502 may be located nearby to washer outlet as described in the electrical layout. Sanitation pipe 504 may be additionally connected to a kitchen sink drain, a bath sink drain, a toilet drain, and a shower drain. One end of sanitation pipe 504 may be positioned higher than the opposite end of sanitation pipe 504, such as to allow fluid and solid waste to flow along the pipe using gravity. In an embodiment, the sanitation pipe 504 may exit through a flooring edge side of panel 100.

[0040] The DWV layout may also include one or more ventilation pipes connected to the sanitation pipe 504. The ventilation pipes 506 may be positioned above sanitation pipe 504. In an embodiment, the ventilation pipes 506 may exit through a ceiling edge side of panel 100. A person of skill in the art understands that various layouts of sanitation pipes 504 and ventilation pipes 506 may be possible. In addition, a person of skill in the art understands that various thicknesses and lengths of sanitation pipes 504 and ventilation pipes 506 may be possible.

[0041] FIG. 6 illustrates an example waterline layout of panel 100. The waterline components described herein may be disposed in the layer of panel 100 consisting of the wooden studs 208 as described in FIG. 2A. The waterline components described herein may be completely hidden, or may be accessible at the inner surface of panel 100. A water heater 602 may be connected to a water box 604 via a pipe. The water box 604 may be located nearby to the washer box 502. The water heater 602 may be further connected to a kitchen sink inlet, a bath sink inlet, and a toilet inlet via a second pipe. The second pipe may exit through a flooring edge side of panel 100.

[0042] FIG. 7 illustrates an exemplary panel 100 that includes the utility service channels as described in FIGS. 3-6. As illustrated, the panel 100 may be configured to include all utility service channels, without obstructing the functioning of any individual channel. Each component or utility service channel may be disposed on the same plane between a plurality of wooden studs 208, or may be closer to the front or back of panel 100. Each of the utility components may be disposed anywhere along the length of panel 100, between the first edge and the second edge, or all components may be grouped in a single area of panel 100. Further, each utility service channel may include any number of components listed. Although the layouts are represented in a certain manner and with certain components in the figures, it will be appreciated by a person skilled in the art that any number of layouts and any combination of components for the utility service channels are possible. By pre-assembling the construction panels 100 with the relevant utility service channels, the time and expense for on-site construction can be vastly reduced, as on-site construction and assembly requires only simple connections of pre-existing components.

[0043] FIG. 8 illustrates a plurality of panels 100 that are assembled together to form a housing unit 800. The housing unit may include at least 4 panels 100, a floor panel (not pictured), a ceiling panel (not pictured), and a plurality of roofing panels 802 assembled to form a roof 804. The ceiling panel may be securely attached to the ceiling edge side of the panel 100, and the floor panel may be securely attached at the flooring edge side to the panel 100. In an embodiment, none of the utility services channels as previously described are present in either the floor panel or the ceiling panel. As shown, the panels 100 may be connected to each other at 90-degree angles to create corners. The panels 100 may be secured to each other at a 90-degree angle using wood screws, or any other applicable method of fastening. In an embodiment, panels 100 can be connected to each other side by side. As shown in FIG. 8, the horizontal trim 102 of each panel 100 may overlap in the corners. Additionally, the vertical trim 104 of each panel 100 may overlap in the corners. The floor panel may include L shaped bracket members to hold the panels 100 in place. In an embodiment, the floor panel may instead include U shaped bracket members to hold the panels 100 in place.

[0044] Alternately, the housing unit 800 may be formed by one panel 100 and at least 3 framing panels, a floor panel (not pictured), a ceiling panel (not pictured), and a plurality of roofing panels 802 assembled to form a roof 804. In an embodiment, the framing panels may not include any of the utility service channels as previously described. The framing panels may be connected to each other and / or to the first or second edge side of panel 100 at 90-degree angles to create corners, may be connected side by side, and may be secured to each other or to panel 100 using wood screws or any other applicable method of fastening. The framing panels may be held in place on the floor panel via the bracket members as described above.

[0045] In an embodiment, each panel 100 may have utility service channels of a same type, such as electrical, HVAC, DWV, or waterline, which are configured to connect to other panels. For example, each panel 100 may have electrical wiring and components disposed in the layer consisting of the wooden studs 208 as described in FIG. 2A. The panels may be configured such that the electrical components in one panel are connected to components in another panel. For example, one panel may house the main electrical panel 302, while other panels house electrical components such as a smoke detector or a fridge outlet, which are connected to the main electrical panel 302.

[0046] In an embodiment, only one of the panels includes the services once the housing unit is assembled. The ceiling panel, the floor panel, and the remaining panels 100 do not include any services prior to and after assembly of the housing unit.

[0047] FIGS. 9 and 10 illustrate a system and transportation container 902 for storage and transportation of panels 100. As shown, A plurality of panels 100 may be arranged on the floor 905 in an open access area 904 of a transportation container 902. The open access area 904 may be defined by the top side edge 903 of the transportation container 902, such that the open access area is accessible through the top of the transportation container 902. The panels 100 may be substantially parallel to each other, may be arranged perpendicular to each other, or may be arranged in any other manner to provide safe and efficient transportation. In an embodiment, the panels 100 are arranged in a manner such that the constructive panel straps 120 are accessible from the top of the transportation container 902. In an embodiment, the panels 100 are secured into bracket members 908 in the transportation container 902. The transportation container 902 may be made of any sufficiently rigid and durable material, such as steel. In an embodiment, the transportation container 902 does not have a covering, and the top remains open. In an embodiment, the transportation container 902 may be approximately 16 m long, approximately 2.5 m tall, and approximately 2.5 m wide. In an embodiment, the transportation container 902 may be between 14 m and 18 m long. In an embodiment, the transportation container may be between 2 m and 3 m tall. In an embodiment, the transportation container may be between 2 m and 3 m wide. However, a person of skill in the art would appreciate that any suitable dimensions for a transportation container may be used, and that these values are exemplary and not limiting. In an embodiment, the transportation container 902 may also transport a plurality of interior walls 906, which may be arranged in the transportation container 902 in a similar manner as panels 100 as previously described.

[0048] FIG. 11 illustrates an embodiment of the transportation container 902 in which the transportation container has a flexible covering 910. The flexible covering 910 may be made of any flexible, water-resistant material, such as canvas, polyester coated with polyurethane, or a plastic such as polyethylene, polypropylene, vinyl, or nylon. In an embodiment, the flexible covering 910 may be attached via one or more lines 912 to one or more hooks 914 which may be removably or permanently affixed to an outside edge of transportation container 902. The one or more lines 912 may be made of rope, cable, plastic cord, elastic bungee cord, or any other suitable fastener. In an embodiment, the one or more lines 912 may be tightened around the one or more hooks 914 to secure the flexible covering 910 onto the top of the transportation container 902.

[0049] Alternately or in addition, the transportation container 902 may be covered by a fitted retractable roof 916, as illustrated in FIGS. 12A and 12B. The retractable roof 916 may be made of plastic, metal, fabric, or any other strong, water-resistant material that can sufficiently protect the panels 100 from environmental damage. As illustrated in FIG. 12B, in a retracted position, the retractable roof 916 rolls or folds towards a lateral edge side 918 of the transportation container 902, such that the open access area 904 of the transportation container 902 is accessible from the top. In a covered position as illustrated in FIG. 12A, the retractable roof extends from the retracted position from one lateral edge side 918 of the transportation container 902 towards the other, to cover the open access area 904 of the transportation container 902. The retractable roof may be manually extended and retracted, or may be actuated by an electric motor to extend and retract.

[0050] FIG. 13 illustrates a process 1300 for creating, transporting, and installing panels 100 to form a housing unit. At step 1302, The panels 100, ceiling, and roofing panels 802 are fabricated in a factory or warehouse. As described previously, the panels 100 may have one or more of the utility service channels described above. In an embodiment, interior walls 906 may also be fabricated in the same factory or warehouse at the same time as panels 100. The interior walls 906 may have one or more windows 110, one or more window frames 112, one or more doors 106, and / or one or more doorframes 108. In an embodiment, the interior walls 906 do not contain any of the utility service channels described above. In an embodiment, the interior walls 906 are predominantly composed of gypsum board. In an embodiment, the interior walls 906 may have one or more wooden studs disposed between a front layer and a rear layer of the interior walls 906. In an embodiment, the interior walls 906 may include one or more interior wall straps disposed between the front layer and the rear layer of the interior wall 906.

[0051] The ceiling panel may be composed predominantly or completely of cross-laminated timber (CLT). In an embodiment, the ceiling may further have one or more wooden studs secured to the CLT panel.

[0052] At step 1304, the panels 100, framing panels, and interior walls 906 are loaded into the transportation container 902. In an embodiment, the roof 804 and the ceiling are also loaded into the transportation container 902. In an embodiment, the framing panels each have one or more framing panel straps. In an embodiment, the panels 100, framing panels, and interior walls 906 are lifted into the transportation container 902 using the one or more constructive panel straps 120, framing panel straps, or interior wall straps respectively. In an embodiment, the panels 100, interior walls 906, and framing panels are lifted via constructive panel straps 120, framing panel straps, or interior wall straps respectively using a telescopic handler, a crane, or a forklift. In an embodiment, the telescopic handler, crane, or forklift may lift a spreader beam which is attached to constructive panel straps 120, framing panel straps, or interior wall straps in order to evenly provide lifting force along the length of the panel 100, framing panel, or interior wall 906 respectively. In an embodiment, the interior wall straps and framing panel straps may have a similar width, working load, and tensile strength as constructive panel straps 120, and may be made of the same material. In an embodiment, the panel 100 is lowered into the open access area 904 of the transportation container 902 through an opening in the top of the transportation container 902. In an embodiment, the interior walls 906 and framing panels, may be loaded into the transportation container 902 by the same method as previously described for loading the panels 100 into the transportation container 902. All above elements may be loaded into the open access area 904 of transportation container 902 in any order, and may be loaded into any spot of open access area 904. In an embodiment, the panels 100, interior walls 906 and framing panels are loaded into the open access area 904 of transportation container 902 in a specific order. In an embodiment, the panels 100, interior walls 906 and framing panels may be loaded into specific spots in open access area 904.

[0053] At step 1306, the panels 100, framing panels and interior walls 906 are secured to the transportation container 902 to prevent movement. The panels 100, framing panels and interior walls 906 may be secured directly to the transportation container 902 via screws, nails, staples, rivets, or any other fasteners. The panels 100, framing panels and interior walls 906 may be secured directly to the transportation container 902 via adhesive, such as glue, tape, epoxy, or any other suitable adhesive. In an embodiment, the transportation container 902 may include grooves, rails, channels, or any other feature that may guide movement and location of panels 100, framing panels and interior walls 906 disposed within open access area 904. In an embodiment, the grooves, rails, or channels may have a fixed location within the open access area 904 of transportation container 902. In an embodiment, the grooves, rails, or channels may be movable within the open access area 904 of transportation container 902 to accommodate different sizes of panels 100, framing panels, or interior walls 906. In an embodiment, open access area 904 of the transportation container 902 may include bracket members that secure panels 100, framing panels and interior walls 906 in place. In an embodiment, the bracket members may have a fixed location within the open access area 904 of transportation container 902. In an embodiment, the bracket members may be movable within the open access area 904 of transportation container 902. In an embodiment, the panels 100, framing panels and interior walls 906 may be secured to the bracket members through fasteners or adhesives as described above, or through a friction fit between two bracket members. In an embodiment, the ceiling panel and roof 804 may additionally be secured in the open access area 904 of transportation container 902 through any of the attachment methods described above.

[0054] At step 1308, the transportation container 902 containing secured panels 100, framing panels and interior walls 906 may be loaded onto any appropriately sized transportation vessel, such as a truck, ship, or aircraft. In an embodiment, the transportation container 902 additionally contains the ceiling panel and roof 804. In an embodiment, the ceiling panel and roof 804 are loaded onto the transportation vessel separate from the transportation container 902. In an embodiment, the ceiling and roof 804 are transported separately from the transportation container 902. In an embodiment, the transportation container 902 is loaded and secured onto the bed of a flatbed truck. As described previously, the transportation container 902 may be uncovered, covered by a tarp, or covered by a retractable roof. In an embodiment, the transportation container 902 may become covered or uncovered during transport. In an embodiment, the open access area 904 of transportation container 902 may be accessible by a side door so as not to disturb the covering.

[0055] At step 1310, the panels 100, framing panels and interior walls 906 are unloaded from the transportation container 902. In an embodiment, the panels 100, framing panels and interior walls 906 are lifted out of the transportation container 902 via the constructive panel straps 120, framing panel straps, or interior wall straps respectively in the same manner as loading described in step 1304. In an embodiment, the panels 100, framing panels and interior walls 906 are unloaded in a specific order. After a panel 100, framing panel or interior wall 906 has been unloaded from the transportation container 902, it is secured to a floor panel. In an embodiment, the panel 100, framing panel or interior wall 906 is secured to the floor panel via fasteners or adhesives as described previously. In an embodiment, the panel 100, framing panel or interior wall 906 is secured to a groove, rail or channel disposed on the floor panel. In an embodiment, the panel 100, framing panel, or interior wall 906 is secured to a bracket member on the floor panel, such as a “U” bracket member or an “L” bracket member. In an embodiment, the panel 100, framing panel, or interior wall 906 is secured to more than one bracket member on the floor panel. The bracket member may form part of the floor panel, or may be a separate component attached to the floor panel. The panels 100, framing panels, or interior walls 906 may be attached to each other as described previously with reference to FIG. 8.

[0056] At step 1312, the ceiling panel is unloaded and secured to the panels 100, framing panels, and interior walls 906. In an embodiment, the ceiling panel is unsecured and unloaded from transportation container 902. In an embodiment, the ceiling panel is unloaded from the transportation vessel, whether the same transportation vessel as transported transportation 902 or a separate transportation vessel. The ceiling panel may be secured to panels 100, framing panels, and interior walls 906 via fasteners as described above, adhesives as described above, or a combination of both.

[0057] At step 1314, the roof 804 is unloaded and secured to the ceiling panel. In an embodiment, the roof 804 is unsecured and unloaded from transportation container 902. In an embodiment, the roof 804 is unloaded from the transportation vessel, whether the same transportation vessel as transported transportation 902 or a separate transportation vessel. The roof 804 may be secured to the ceiling panel via fasteners as described above, adhesives as described above, or a combination of both.

[0058] At the end of the process 1300, a housing unit 800 is created by manufacturing, transporting, and assembling pre-assembled construction panels 100, framing panels, interior walls 906, a roof 804, and a ceiling panel. The process 1300 provides a streamlined approach to assembling the housing unit 800, wherein the assembly is much quicker than typical due to the pre-assembly of the construction panels 100 and the modular nature of the panels 100, framing panels, and interior walls 906. The result is faster turnaround, more efficient assembly, and cheaper production cost than in usual processes.

[0059] Variations may be made to some example embodiments, which may include combinations and sub-combinations of any of the above. The various embodiments presented above are merely examples and are in no way meant to limit the scope of the examples. Variations of the innovations described herein will be apparent to persons of ordinary skill in the art having the benefit of the examples, such variations being within the intended scope of the example embodiments. In particular, features from one or more of the above-described embodiments may be selected to create alternative embodiments comprised of a sub-combination of features which may not be explicitly described above. In addition, features from one or more of the above-described embodiments may be selected and combined to create alternative embodiments comprised of a combination of features which may not be explicitly described above. Features suitable for such combinations and sub-combinations would be readily apparent to persons skilled in the art upon review of the example embodiments as a whole. The subject matter described herein intends to cover and embrace all suitable changes in technology.

[0060] Certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.

Examples

Embodiment Construction

[0024]Reference is made with reference to the accompanying drawings, in which example embodiments are shown. However, many different embodiments may be used, and thus the description should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete. Like numbers refer to like elements throughout.

[0025]Throughout the following, specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well-known elements may not have been shown or described in detail. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

[0026]Example embodiments relate to a pre-assembled construction panel wherein various services, as well as cosmetic or functional items, are factory installed.

[0027]Referring to FIG. 1, an example pre-assembled construction panel 100 is illustrated, viewed from the...

Claims

1. A system for transporting housing panels, the system comprising:one or more pre-assembled construction panels, each of the one or more pre-assembled construction panels including one or more respective constructive panel straps disposed within a respective inner layer of the one or more pre-assembled construction panels;one or more framing panels, each of the one or more framing panels including one or more respective framing panel straps disposed within a respective inner layer of the one or more framing panels; anda transportation container having a top edge side defining an open access area accessible through a top of the transport container and dimensioned to accommodate the one or more pre-assembled construction panels and the one or more framing panels.

2. The system of claim 1, wherein the one or more constructive panel straps and the one or more framing panel straps are made from nylon or polyester.

3. The system of claim 1, wherein each of the one or more constructive panel straps and the one or more framing panel straps are positioned in the transport container to be accessible through the open access area accessible through the top of the transport container.

4. The system of claim 3, further comprising one or more interior walls to be accommodated by the transportation container, wherein each of the one or more interior walls further comprise one or more respective interior wall straps disposed within a respective interior wall inner layer of each of the one or more interior walls.

5. The system of claim 2, further comprising a spreader beam configured to lift the one or more pre-assembled construction panels by the one or more respective constructive panel straps, and the one or more framing panels by the respective one or more framing panel straps.

6. The system of claim 5, further comprising a hoisting mechanism configured to lift the spreader beam.

7. The system of claim 6, wherein the hoisting mechanism is a crane, forklift, or telescopic handler.

8. The system of claim 7, wherein the one or more construction panel straps and the one or more framing panel straps are configured to be removable by cutting.

9. The system of claim 1, wherein the transportation container is between 14 m and 18 m long, between 2 m and 3 m wide, and between 2 m and 3 m tall.

10. The system of claim 1, wherein the one or more pre-assembled construction panels and the one or more framing panels are between 6 m and 12 m long, between 2.4 m and 2.5 m high, and between 15 cm and 25 cm thick.

11. The system of claim 1, wherein the one or more pre-assembled construction panels have a plurality of utility service channels disposed within the respective inner layer of each of the pre-assembled construction panels.

12. The system of claim 11, wherein the utility service channels comprise waterline, drain-waste-vent, electrical, and heating, ventilation, and air conditioning.

13. The system of claim 12, wherein the utility service channels are configured to span horizontally between a first edge side and a second edge side of the pre-assembled construction panel.

14. The system of claim 12, further comprising spray foam disposed in areas in the respective inner layer of each of the pre-assembled construction panels where the plurality of utility services channels are not disposed.

15. The system of claim 11, wherein the one or more framing panels do not contain any utility service channels.

16. The system of claim 1, wherein the top edge side of the transportation container further comprises a roof covering for covering the open access area.

17. The system of claim 16, wherein the roof covering comprises a flexible material.

18. The system of claim 17, wherein the flexible material is canvas, polyester coated with polyurethane, polyethylene, polypropylene, vinyl, or nylon.

19. The system of claim 18, wherein the roof covering further comprises one or more lines.

20. The system of claim 19, wherein the roof covering is configured to be secured to the transportation container via the one or more lines to one or more hooks affixed to an outside edge of the transportation container.

21. The system of claim 20, wherein the one or more lines are made of rope, cable, plastic cord, or elastic bungee cord.

22. The system of claim 16, wherein the roof covering comprises a retractable roof which, in a first position, covers the entire length and width of the transportation container, and in a second position, rolls or folds towards a lateral edge side of the transportation container.

23. The system of claim 22, wherein the retractable roof is configured to be actuated via an electric motor to move from the first position to the second position.

24. A method for transporting housing panels, the method comprising:at a first location, lifting one or more pre-assembled construction panels into an open access area defined by a top edge side of a transportation container and accessible through a top of the transport container using one or more respective construction panel straps disposed within a respective inner layer of each of the one or more pre-assembled construction panels;at the first location, securing the one or more pre-assembled construction panels into the transportation container;at the first location, lifting one or more framing panels into the open access area of the transportation container using one or more respective framing panel straps disposed within a respective framing panel inner layer of each of the framing panels;at the first location, securing the one or more pre-assembled construction panels into the open access area of the transportation container;moving the transportation container from the first location to a second location;at the second location, unsecuring the one or more pre-assembled construction panels from the open access area;at the second location, lifting the one or more pre-assembled construction panels out of the open access area defined by the top edge side of the transportation container using the one or more respective construction panel straps;at the second location, unsecuring the one or more framing panels from the open access area; andat the second location, lifting the one or more framing panels out of the open access area defined by the top edge side of the transportation container using the one or more respective framing panel straps.

25. The method of claim 24, further comprising positioning the pre-assembled construction panels in the transportation container so that the one or more respective construction panel straps are accessible by the open access area defined by the top edge side of the transportation container.

26. The method of claim 24, further comprising positioning the one or more framing panels in the transportation container so that the one or more framing panel straps are accessible by the open access area defined by the top edge side of the transportation container.

27. The method of claim 24, further comprising:at the first location, lifting one or more interior walls into the open access area of the transportation container using one or more respective interior wall straps disposed within a respective inner layer of each of the one or more interior walls, and securing the one or more interior walls into the open access area defined by the top edge side of the transportation container; andat the second location, unsecuring the one or more interior walls from the open access area of the transportation container, and lifting the one or more interior walls out of the open access area of the transportation container using the one or more respective interior wall straps.

28. The method of claim 24, wherein the lifting of the one or more pre-assembled construction panels is via the respective one or more construction panel straps using a spreader beam, the spreader beam being lifted by a hoisting mechanism, and the lifting of the one or more framing panels is via the respective one or more framing panel straps using the spreader beam, the spreader beam being lifted by the hoisting mechanism.

29. The method of claim 24, wherein the one or more pre-assembled construction panels and the one or more framing panels are secured in the open access area of the transportation container between a respective two bracket members, the bracket members being secured to the transportation container.

30. The method of claim 24, further comprising lifting a ceiling panel into the open access area of the transportation container at the first location, and lifting the ceiling panel out of the open access area of the transportation container at the second location.

31. The method of claim 24, further comprising lifting a roof into the open access area of the transportation container at the first location, and lifting the roof out of the open access area of the transportation container at the second location.

32. The method of claim 24, wherein the moving of the transportation container from the first location to the second location is via a truck, ship, or aircraft.

33. The method of claim 24, wherein the one or more pre-assembled construction panels have a plurality of utility service channels disposed within the respective inner layer of each of the pre-assembled construction panels.

34. The method of claim 33, further comprising applying spray foam in the areas of the respective inner layer of each of the pre-assembled construction panels where the plurality of utility services channels are not disposed, the spray foam being applied prior to lifting at the first location.

Images