Modular building systems, components, and methods

Abstract

Pre-fabricated components such as beams, beam nodes, floor panels, wall panels, and roof panels are useful for constructing buildings such as houses. In some cases, conservation of materials, ease of construction, and superior structural integrity appear.

I claim: 
     
         1 . A beam useful in modular construction comprising:
 one or more vertical support members supporting and separating   an upper horizontal support member and   a lower horizontal support member; and   at least one ledger adapted to support a vertical load.   
     
     
         2 . The beam of  claim 1 , wherein the upper horizontal support member further comprises at least one registration element. 
     
     
         3 . The beam of  claim 2 , wherein the at least one registration element is adapted to receive at least one corresponding registration element of a floor panel, wall panel, ceiling panel, or a combination thereof. 
     
     
         4 . The beam of  claim 2 ,
 wherein the beam has a first end and a second end, and the first end comprises a first beam node coupling element.   
     
     
         5 . The beam of  claim 4 , wherein the second end comprises a second beam node coupling element. 
     
     
         6 . The beam of  claim 1 , wherein the beam comprises an engineered wood product. 
     
     
         7 . The beam of  claim 6 , wherein the engineered wood product comprises oriented strand board. 
     
     
         8 . The beam of  claim 1 , further comprising insulation. 
     
     
         9 . The beam of  claim 2 , wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least two wall panels. 
     
     
         10 . The beam of  claim 2 , wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least three wall panels. 
     
     
         11 . The beam of  claim 2 , wherein the upper support member comprises the at least one registration element in sufficient number to receive the corresponding registration elements of at least four wall panels. 
     
     
         12 . The beam of  claim 1 , wherein the at least one ledger adapted to support a vertical load is attached to a first vertical face of the one or more vertical support members. 
     
     
         13 . The beam of  claim 1 , wherein the at least one ledger adapted to support a vertical load comprises two ledgers, wherein the first ledger is attached to a first vertical face of the one or more vertical support members, and the second ledger is attached to a second vertical face of the one or more vertical support members. 
     
     
         14 . A method of manufacturing a beam useful in modular construction comprising:
 constructing a beam comprising   one or more vertical support members supporting and separating   an upper horizontal support member and   a lower horizontal support member; and   at least one ledger adapted to support a vertical load,   thereby manufacturing the beam.   
     
     
         15 . The method of  claim 14 , wherein constructing the beam comprises:
 joining together two vertical support members;   affixing the upper horizontal support member to the two vertical support members; affixing the lower horizontal support member to the two vertical support members; and affixing a first ledger to one of the two vertical support members.   
     
     
         16 . The method of  claim 15 , further comprising a second ledger to another of the two vertical support members. 
     
     
         17 . The method of  claim 15 , further comprising:
 before the affixing the upper horizontal support member, creating one or more registration elements in the upper horizontal support member.   
     
     
         18 . The method of  claim 15 , further comprising:
 creating a beam node coupling element in a first end of the beam.   
     
     
         19 . The method of  claim 15 , further comprising:
 creating a beam node coupling element in a second end of the beam.   
     
     
         20 . The method of  claim 15 , wherein the beam comprises an engineered wood product.