Methods, systems, and components for modular construction of multi-storey buildings

Abstract

A modular system of interconnected modular blocks having columns with male and female ends, structural space frames comprising horizontal structural sections arranged in a rectangle with a connector at each corner. The structural space frames and columns are collapsed into a modular sandwich for transportation where male ends of connectors connect with respective female ends of connectors between structural steel space frames and when the modular block is erected from the sandwich, a male connector of a lower structural space frame couples with a female end of a column of and a female connector of a top structural space frame connects with a male end of a column. The modular system is transported in collapsed form to a building site and is erected into a building structure by lifting a higher space frame, erecting the columns to create a modular unit and repeating to create stack of modular units of desired building height.

What is claimed is: 
     
         1 . A modular system of interconnected modular blocks, the system comprising:
 a plurality of columns each having male and female ends, and   a plurality of structural space frames each comprising horizontal structural sections arranged in a rectangle with a connector at each corner;   wherein the structural space frames and columns are collapsed into a modular sandwich for transportation where male ends of connectors connect with respective female ends of connectors between structural steel space frames and when the modular block is erected from the sandwich, a male connector of a lower structural space frame of the plurality of structural space frames couples with a female end of a column of the plurality of columns and a female connector of a top structural space frame of the plurality of structural space frames connects with a male end of a column of the plurality of columns.   
     
     
         2 . The modular system of interconnected blocks of  claim 1 , wherein the female connector of each column is located on a lower end. 
     
     
         3 . The modular system of interconnected blocks of  claim 1 , wherein the top structural space frame of the plurality of space frames forms a ceiling fitted with mechanical, electrical, and/or plumbing infrastructure. 
     
     
         4 . The modular system of interconnected blocks of  claim 1 , further comprising flip-up walls collapsed into the modular sandwich wherein at least one of the flip-up walls is fitted with mechanical, electrical, and/or plumbing infrastructure. 
     
     
         5 . The modular system of interconnected blocks of  claim 1 , wherein the structural space frames are welded at joints between horizontal structural sections and connectors. 
     
     
         6 . The modular system of interconnected blocks of  claim 1 , wherein the plurality of structural space frames comprises at least one intermediate structural space frame wherein the connectors at the corners of the intermediate structural space frames have male ends on a top side of the intermediate structural space frame and female ends on a bottom side of the intermediate structural space frame. 
     
     
         7 . The modular system of interconnected blocks of  claim 6 , wherein the lower structural space frame may comprise a corner casting compatible with a twist lock fastener. 
     
     
         8 . The modular system of interconnected blocks of  claim 6 , wherein the plurality of structural space frames when collapsed in a modular sandwich have a length, width, and height capable of being transported by a flatbed truck or semi-trailer truck to a building site. 
     
     
         9 . The modular system of interconnected blocks of  claim 8 , wherein the columns are positioned within the sandwich for transportation. 
     
     
         10 . A method of forming a building of n stories, comprising steps of:
 (a) providing the modular system of interconnected blocks of  claim 1  in collapsed form;   (b) lifting the top structural space frame;   (c) erecting each of the columns;   (d) coupling each of the columns with the to structural space frame;   (e) flipping up each of the flip-up walls into predetermined positions to form a modular block;   (f) lifting the modular block;   (g) optionally repeating steps (a)-(f) n number of times to form a building stack;   (h) positioning the assembled modular block or stack into a prepared foundation.   
     
     
         11 . The method of forming a building of n stories of  claim 10 , wherein the method further comprises the following steps:
 (i) forming, lifting and positioning additional assembled modular blocks adjacent to a completed stack of assembled modular blocks; and   (j) coupling the additional assembled modular blocks to the completed stack of assembled modular blocks.   
     
     
         12 . The method of forming a building of n stories of  claim 10 , wherein, in step (f) and step (h), the lifting is done through a crane or forklift. 
     
     
         13 . The method of forming a building of n stories of  claim 11 , wherein adjacent modular blocks are linked together.