Modular building assembly and wall cladding system

Abstract

A modular building assembly may include one or more chassis blocks coupled together in a predetermined arrangement to form a structural frame of a building. The chassis blocks include a plurality of metal sections forming a rectangular prism. Each chassis block is configured to support wall, floor, and ceiling assemblies that form the sides of the chassis block. The wall assemblies include a frame fastened to a side of the chassis and a plurality of wall panels fastened to the frame. The wall panels are fastened to the frame flush with each other having butt joints adjoining adjacent edges of the wall panels. In some examples, each of the wall panels is prefabricated to a predetermined shape and size and configured to be fastened to the frame at a predetermined position, such that the panels are configured to fit together to form a cohesive wall surface on the frame.

1 . A modular building assembly comprising:
 a modular chassis including a plurality of metal beams forming a rectangular prism; and   an interior wall cassette installed on the chassis, the wall cassette comprising:
 a frame nested in a first side of the chassis; and 
 a plurality of non-paperfaced wall panels fastened to the frame; 
   wherein adjacent ones of the wall panels are flush and butt-jointed with each other, such that the plurality of wall panels collectively form a cohesive wall surface without further construction materials.   
     
     
         2 . The building assembly of  claim 1 , wherein the frame includes a plurality of metal studs extending vertically from a top edge to a bottom edge of the first side of the chassis. 
     
     
         3 . The building assembly of  claim 2 , wherein the frame includes one or more Z-shaped channel segments fastened to the plurality of metal studs and extending horizontally across the frame. 
     
     
         4 . The building assembly of  claim 3 , wherein the plurality of wall panels are fastened to the one or more Z-shaped channel segments of the frame. 
     
     
         5 . The building assembly of  claim 1 , wherein each of the wall panels is prefabricated to a predetermined shape and size and configured to be fastened to the frame at a predetermined position, such that the plurality of wall panels are configured to fit together to form the cohesive wall surface on the wall of the frame. 
     
     
         6 . The building assembly of  claim 1 , wherein each of the wall panels is fastened to the frame using exposed fasteners. 
     
     
         7 . The building assembly of  claim 1 , further comprising an exterior wall assembly fastened to the interior wall cassette. 
     
     
         8 . The building assembly of  claim 7 , wherein the exterior wall assembly comprises:
 an exterior sheathing fastened to an exterior side of the frame; and   an exterior cladding assembly fastened to the exterior sheathing;   wherein framing of the exterior wall assembly includes an air gap between the exterior sheathing and the exterior cladding.   
     
     
         9 . The building assembly of  claim 8 , wherein the exterior sheathing forms a weather resistant barrier configured to provide insulation and prevent wind and water from penetrating the exterior sheathing. 
     
     
         10 . The building assembly of  claim 1 , wherein each of the wall panels comprises magnesium oxide. 
     
     
         11 . The building assembly of  claim 1 , further comprising a ceiling panel assembly installed on a top side of the chassis and a floor panel assembly installed on a bottom side of the chassis. 
     
     
         12 . (canceled) 
     
     
         13 . The building assembly of  claim 1 , further comprising a second modular chassis coupled to the first modular chassis. 
     
     
         14 . The building assembly of  claim 1 , wherein the frame comprises:
 a plurality of metal studs oriented in a first direction, wherein insulation is disposed between adjacent pairs of the metal studs; and   a plurality of metal channels oriented in a second direction transverse to the first direction, each of the metal channels being secured to one or more of the metal studs;   wherein the plurality of non-paperfaced wall panels are fastened to the metal channels, such that the non-paperfaced wall panels are spaced from the metal studs by the metal channels; and   wherein an air gap exists between each of the panels and the insulation.   
     
     
         15 . The building assembly of  claim 1 , wherein each of the wall panels is prefinished having a finished face surface and a finished edge surface. 
     
     
         16 . The building assembly of  claim 14 , wherein each of the metal channels comprises a Z-shaped metal channel. 
     
     
         17 . The building assembly of  claim 14 , wherein each of the metal channels comprises a hat-shaped metal channel. 
     
     
         18 . The building assembly of  claim 1 , wherein each of the wall panels comprises magnesium oxide. 
     
     
         19 - 20 . (canceled)