Module with moment frame and composite panels for a building structure

Abstract

A module for building structure includes a moment frame, a set of four top corner pieces, and a set of two or more composite panels. The moment frame is comprised of beams and columns jointed to form a top, a bottom and four sides. Each top corner piece is located at a corner of the top of the moment frame. The set of two or more composite panels is attached to the bottom of the moment frame to provide a sub-floor of the building structure. A first composite panel, of the set, is adapted to transfer a load to a second abutting composite panel of the set, in response to a deflection of the moment frame. Each composite panel is comprised of a core element encased in a metal frame, which includes two face sheets, two end cap pieces, and two side pieces.

1 . A module for a building structure comprising:
 a moment frame comprised of beams and columns joined to form a top, a bottom and four sides;   a set of four top corner pieces, each top corner piece located at a corner of the top of the moment frame, each top corner piece having a coupler element to interface with a lifting mechanism that lifts the module; and   a set of two or more composite panels attached to the bottom of the moment frame to provide a sub-floor of the building structure, wherein a first composite panel of the set is adapted to transfer a load to a second abutting composite panel of the set, in response to a deflection of the moment frame, wherein each composite panel comprises:
 a metal frame having two face sheets, two end cap pieces and two side pieces, wherein the two face sheets are substantially parallel, the two end cap pieces are substantially perpendicular to the face sheets, and the two side pieces are substantially perpendicular to both the face sheets and the end cap pieces; and 
 a core element encased within the metal frame, wherein the core element is bonded to the two metal face sheets. 
   
     
     
         2 . The module of  claim 1 , wherein each side piece is a metal sheet formed to create an interlocking joint piece, wherein the interlocking joint piece includes a channel shape and a protrusion shape extending the length of the interlocking joint piece. 
     
     
         3 . The module of  claim 2 , wherein the channel shape of an interlocking joint piece of the first composite panel interconnects with protrusion shape of the interlocking joint piece of the second composite panel. 
     
     
         4 . The module of  claim 3 , wherein the interlocking joint piece is adapted to provide vertical support for a second composite panel abutting the first composite panel. 
     
     
         5 . The module of  claim 3 , wherein the interlocking joint piece of the first composite panel is further adapted to transfer a compression load to the second composite panel abutting the first composite panel. 
     
     
         6 . The module of  claim 3 , wherein the composite panels are adapted to support a compression load in response to the module being subjected to a moment load. 
     
     
         7 . The module of  claim 1 , wherein the metal frame is made of steel, and wherein the core element is made of foam. 
     
     
         8 . The module of  claim 1 , further comprising, a second set of two or more composite panels,
 wherein the second set of two or more composite panels is attached to the top of the moment frame to provide a ceiling of the building structure.   
     
     
         9 . The module of  claim 8 , wherein the second set of composite panels that provide the sub-floor comprises different materials than the set of composite panels that provide the ceiling. 
     
     
         10 . The module of  claim 1 , further comprising, ledgers attached to at least two beams in the frame,
 wherein the set of two or more composite panels is attached to the ledgers.   
     
     
         11 . The module of  claim 1 , wherein the set of two or more composite panels provide the sub-floor of a first module and the same composite panels provide a ceiling of a second module, wherein the second module is mounted below the first module. 
     
     
         12 . The module of  claim 1 , wherein each of the set of four top corner pieces having a coupler element comprises: three external faces and three slotted holes, each slotted hole extending inward from each of the three external faces. 
     
     
         13 . The module of  claim 1 , wherein each of the four top corner pieces is comprised of an ISO corner casting. 
     
     
         14 . The module of  claim 1 , further comprising, a set of four bottom corner pieces, each bottom corner piece located at a corner of the bottom of the moment frame, each bottom corner piece having a coupler element to interface with a securing mechanism that secures the module. 
     
     
         15 . The module of  claim 14 , wherein each of the set of four bottom corner pieces having a coupler element comprises: three external faces and three slotted holes, each slotted hole extending inward from each of the three external faces. 
     
     
         16 . The module of  claim 14 , wherein each of the four bottom corner pieces is comprised of an ISO corner casting. 
     
     
         17 . The module of  claim 1 , wherein the bottom of the moment frame has approximately the footprint of a standard 8×20 cargo container. 
     
     
         18 . The module of  claim 1 , wherein the bottom of the moment frame has approximately the footprint of a standard 8×40 cargo container. 
     
     
         19 . The module of  claim 1 , wherein the bottom of the moment frame has an outside width of approximately 8 feet and an outside length of about 20 feet. 
     
     
         20 . The module of  claim 1 , wherein the bottom of the moment frame has an outside width of approximately 8 feet and an outside length of about 40 feet. 
     
     
         21 . The module of  claim 1 , wherein the beams are comprised of a steel channel with a cross-section ranging between 150 mm to 250 mm in height and between 60 mm and 120 mm in width. 
     
     
         22 . The module of  claim 1 , wherein the columns are comprised of a steel rectangular tube with a cross-section ranging between 120 mm to 180 mm in height and width. 
     
     
         23 . The module of  claim 1 , further comprising, a roof panel section, wherein the roof panel section includes one or more corrugated steel sheet pieces, each sheet piece welded along the edge to create a water resistant seam. 
     
     
         24 . The module of  claim 23 , wherein the roof panel section is formed into a convex shape to direct water to the edges of the module. 
     
     
         25 . The module of  claim 1 , further comprising, a pitched-roof section, wherein the pitched roof includes at least one flat panel piece and at least one weather resistant sheet attached to the top of the flat panel piece. 
     
     
         26 . The module of  claim 25 , wherein the flat panel piece is a composite panel. 
     
     
         27 . The module of  claim 25 , wherein the pitched-roof section includes a single pitch of ⅛ inch rise per foot of length. 
     
     
         28 . The module of  claim 25 , wherein the pitched-roof section includes a double-pitch section of ¼ inch rise per foot of length, and wherein the top of the double-pitch section is in a center of the module. 
     
     
         29 . The module of  claim 1 , wherein another set of two or more composite panels form a side wall of the module. 
     
     
         30 . The module of  claim 29 , wherein a first composite panel of the set forming the side wall interconnects with an abutting second composite panel of the set forming the side wall. 
     
     
         31 . A modular system for constructing a building structure, comprising:
 two or more modules joined together to form a portion of the building structure, each module comprising:
 a moment frame comprised of beams and columns joined to form a top, a bottom, and four sides; 
 a set of four top corner pieces, each corner piece located at a corner of the top of the moment frame, each corner piece having a coupler element to interface with a lifting mechanism that lifts the module; and 
 a set of two or more composite panels attached to the bottom of the moment frame to provide a sub-floor of the building structure, wherein each composite panel comprises:
 a metal frame having two face sheets, two end cap pieces and two side pieces, wherein the two face sheets are substantially parallel, the two end cap pieces are substantially perpendicular to the face sheets, and the two side pieces are substantially perpendicular to both the face sheets and the end cap pieces; and 
 a core element encased within the metal frame, wherein the core element is bonded to the two metal face sheets. 
 
   
     
     
         32 . The modular system of  claim 31 , wherein the two or more modules are joined side-by-side to one another to form a portion of one story of the building structure. 
     
     
         33 . The modular system of  claim 31 , wherein the sets of two or more composite panels of the two or more modules are attached to the bottoms of the two or more modules, and wherein adjacent sides of side-by-side modules are left open to create a clear span for the building structure. 
     
     
         34 . The modular system of  claim 31 , wherein the two or more modules are joined one on top of another to form multiple stories of the building structure. 
     
     
         35 . The module system of  claim 34 , wherein the two or more modules comprise:
 a first type of modules, wherein the first type of modules forms an upper most story of the building structure, wherein the sets of two or more composite panels of the first type of modules are attached to the top of the moment frame with top metal face sheets of the sets of the two or more composite panels being substantially flush with tops of the beams that form the top of the first type of modules.   
     
     
         36 . A module for a building structure comprising:
 a moment frame comprised of beams and columns joined to form a top, a bottom and four sides;   a set of four top corner pieces, each top corner piece located at a corner of the top of the moment frame, each top corner piece having a coupler element to interface with a lifting mechanism that lifts the module; and   a set of four bottom corner pieces, each bottom corner piece located at a corner of the bottom of the moment frame, each bottom corner piece having a coupler element to interface with a securing mechanism that secures the module.