Modular Building System

Abstract

Redefining modular construction, our Modular Building System surpasses existing methods of both traditional and modular construction. Every component, meticulously crafted such that it may be robotically produced and assembled, ensures unmatched precision and efficiency. Each panel, guarantees seamless integration and flawless finishes. Fully-finished in factory settings, they drastically simplify the construction process by eliminating many traditional materials and components, while retaining ease of construction and transportability from factory to building site, for final assembly. Our system's prowess extends to design flexibility, enabling construction of expansive living spaces with ease. Furthermore, its eco-conscious design facilitates effortless deconstruction and reuse, reducing environmental impact and waste. Revolutionizing the industry, this comprehensive solution heralds a new era of construction efficiency, adaptability, and sustainability, setting the standard for future developments, and aligning the construction industry more closely with modern automotive manufacturing and aerospace production industries.

1 . A method of forming a connection between two or more components of a modular building system, comprising:
 positioning at least first and second components proximate each other such that there is a void therebetween; and   placing a liquid polyurethane (PU) foam between said first and second components in said void; and   curing said PU foam so as to form a connection between said first and second components.   
     
     
         2 . The method of  claim 1 , wherein said first and second components are individual modular external wall panels, and comprising performing said method on two or more individual modular external wall panels so as to form an external wall panel of a desired length. 
     
     
         3 . The method of  claim 1 , further comprising placing a first metal siding layer adjoining said first component and a second metal siding layer adjoining said second component, wherein said connection is weathertight. 
     
     
         4 . The method of  claim 1 , comprising positioning three or more of said components proximate each other serially such that there is a void between serial components, and wherein PU foam is placed in voids between only some of the adjoining components. 
     
     
         5 . The method of  claim 1 , wherein said first and second components are individual modular internal wall panels, comprising performing said method on two or more individual modular internal wall panels so as to form an internal wall panel of a desired length. 
     
     
         6 . The method of  claim 1 , further comprising forming a structural attachment between a panel comprising a floor panel, mid-floor panel, or roof panel, and one or more structural joint members on either side of said panel, thereby distributing any load in the first and second components over a spanning distance of the panel via the PU foam. 
     
     
         7 . The method of  claim 1 , wherein said first and second components comprise window panels, further comprising positioning said first and second components proximate a structural metal frame, such that said connection is made between said first component and said structural metal frame and between said second component and said structural metal frame, wherein said window panels are non-structural. 
     
     
         8 . The method of  claim 1 , wherein said first component is a window panel and said second component is an individual modular external wall panel. 
     
     
         9 . The method of  claim 1 , further comprising connecting said first and second components to structural studs and/or vertical connection rods. 
     
     
         10 . The method of  claim 1 , wherein said PU foam is also positioned between said first and second components and one or more structural members of said modular building system in order to reinforce said one or more structural members. 
     
     
         11 . A method of forming part of a modular building system structure, comprising joining a first preassembled panel comprising one or more first connection mechanisms to a second preassembled panel comprising one or more second connection mechanisms, wherein the one or more first connection mechanisms are connected to respective second connection mechanisms, and wherein either the one or more first connection mechanisms or the one or more second connection mechanisms are slid within the other such that the first and second connection mechanisms become interlocked. 
     
     
         12 . The method of  claim 11 , further comprising applying one or more finishing materials to each of said first and second preassembled panels prior to joining said first and second preassembled panels. 
     
     
         13 . The method of  claim 11 , wherein said first preassembled panel and said second preassembled panel are floor panels, mid-floor panels, or roof panels, wherein said first connection mechanisms are positioned on a joint of said first preassembled panel, wherein said second connection mechanisms are positioned on a joist of said second preassembled panel, wherein said first connection mechanisms are inserted into said second connection mechanisms by sliding said first preassembled panel toward said second preassembled panel. 
     
     
         14 . The method of  claim 11 , wherein said one or more second connection mechanisms are within a sliding lock plate of a structural floor joining bracket, and said one or more first connection mechanisms are on a bottom side of one or more vertical connection rods within an internal wall panel, such that the bottom side of said one or more vertical connection rods may insert into said one or more second connection mechanisms, such that said sliding lock plate is movable within a rectangular hollow section, such that said one or more first connection mechanisms become captive with said one or more second connection mechanisms, such that a connection is formed between said structural floor joining bracket and said internal wall panel. 
     
     
         15 . The method of  claim 11 , further comprising affixing said one or more first connection mechanisms to an end of a first internal wall panel, and locating said second connection mechanisms on a face of an external wall panel or a second internal wall panel, such that said first internal wall panel is attachable at a 90 degree angle to said external wall panel or said second internal wall panel. 
     
     
         16 . The method of  claim 11 , wherein one or more of said first or second connection mechanisms comprises a sloped edge or sloped face, such that when said first and second connection mechanisms interlock said sloped edge or sloped face causes the first and second connection mechanisms to tighten with one another, thereby drawing said first and second preassembled panels closer together and forming a tensioned joint. 
     
     
         17 . The method of  claim 11 , wherein said first connection mechanisms are male or female, and wherein corresponding ones of said second connection mechanisms are the other of male and female. 
     
     
         18 . A method of adjoining a first panel to a second panel using a pinned connection, wherein said first panel is an internal wall panel and said second panel is a floor panel, mid-floor panel, or roof panel, comprising inserting vertical connection rods of the first panel into holes in the second panel such that when ends of the second panel become fixed, the first panel becomes captive to the second panel to enable use of the pinned connection in a non-invasive manner. 
     
     
         19 . The method of  claim 17 , further comprising applying pre-finished surfaces to each of said first and second panels prior to said inserting.