BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a transportable structure kit most often referred to as a modular or kit home. While this invention is described in the context of such homes, it has broader application and is not limited to this particular use.

2. Prior Art

Modular or kit homes are those that utilize pre-fabricated components generally assembled off site, which are then transported to a site and assembled. Relative to standard forms of residential construction, modular or kit homes hold the promise of being less expensive, and easier and quicker to assemble on site. However, much of the promise of this type of home has yet to be realized: modular homes are often as costly as standard constructions and they often require specialized machinery and/or expertise that reduce the efficiency of construction. Many of these structures are also relatively difficult to transport to site.

Relatedly, shipping containers have many advantages as a kind of “raw material” for the construction of homes. They are, of course, easily transported, but also quite strong, inexpensive (in their unmodified form), resistant to weather, stackable, etc. For these reasons, shipping containers have become popular as the primary components of modular home designs. However, while their dimensions and solidity are optimal for their primary use as transport containers, these traits are, in many ways, less than optimal for use as habitation without major modification to their structure. Additionally, their use for habitation often requires heavy machinery for positioning or for performing structural modifications. Consequently, shipping container homes are often difficult to design and build, and frequently just as costly as conventional structures.

Many efforts have been made to utilize the general form of the ISO shipping container for transportable modular homes or buildings. These efforts generally aim to provide inexpensive, easy-to-assemble structures, whether for temporary or permanent placement. These inventions attempt to address the shortcomings of both shipping container homes and modular or kit homes in general. However, these inventions generally feature (highly) modified versions of the general form of the shipping container rather than utilizing the strengths of unmodified containers. And in certain cases shipping containers are used for transport only, rather than being integral to the final structure.

Most relevant, U.S. Pat. No. 5,950,373 describes a modular/kit home structure that is transportable in the general form of shipping container. Rather than using an unmodified ISO container, this invention utilizes a unique construction that is preferably but not necessarily compatible with normal transportation methods associated with unmodified ISO containers. This invention also utilizes a specialized foundation and uses the walls and other portions of the container as parts of the primary structure.

U.S. Pat. No. 9,920,512 B1 describes a two level structure using a modified container in the general form of a shipping container. The container used in this invention is a highly-modified version of a container with a telescopic method of forming a second level of the structure. Also, this invention does not necessarily comply with ISO standards for intermodal shipping containers and therefore might require specialized modes of transport.

U.S. Pat. No. 9,115,504 B2 describes a variety of structures and methods of construction utilizing convertible containers transportable in accordance with ISO intermodal standards. However, the final structures are comprised of the steel components that form the walls, ceilings, etc. of the shippable containers, and the method of construction is specific to the design of the component-based containers, rather than being conventional.

U.S. Pat. No. 4,075,814 describes a modular housing invention that utilizes prefabricated housing components that can be shipped inside standard ISO containers. This invention uses the ISO containers for transport only, not as part of the resultant structures.

BRIEF SUMMARY OF THE INVENTION

In accordance with embodiments of the invention, a modular building kit is included. The modular building kit is operable to be delivered to a building site and contains within a single shipping container the materials needed for construction of a modular building. Materials included in the modular building kit are the shipping container itself, prefabricated floor joist panels, prefabricated floor sheathing, prefabricated wall sheathing, prefabricated wall panels, prefabricated roof rafters, prefabricated roof sheathing, and foundation posts.

In accordance with embodiments of the invention, a modular building is provided. The modular building includes a shipping container that is shipped containing the materials needed for construction of the modular building and is placed in a permanent position at a construction site. A plurality of foundation posts are secured in a perimeter surrounding the shipping container. A plurality of floor joist panels are positioned on top of the shipping container and on top of the plurality of foundation posts. The plurality of floor joist panels form a second story floor. Floor sheathing is attached to the top surface of the plurality of floor joist panels. A plurality of wall panels are attached around a periphery of the floor joist panels and form an enclosure. Wall sheathing is attached to the outer perimeter of the plurality of wall panels. A plurality of roof rafters are positioned on top of the enclosure formed by the plurality of wall panels. Roof sheathing is attached to the top of the roof rafters, fully enclosing the structure.

In one embodiment, the modular building includes a kit for building a kitchen. In another embodiment, the modular building kit includes a kit for building a bathroom. In another embodiment, the modular building kit includes a kit for constructing a plurality of windows. In another embodiment, the modular building kit includes a kit for constructing a staircase. In another embodiment, the modular building kit includes a kit for constructing a ramp. In another embodiment, the modular building kit includes a kit for constructing a plurality of doors.

In accordance with embodiments of the invention, a method for building a structure is provided. The method includes a first step (a) delivering a modular building kit to a construction site, the modular building kit comprising, a shipping container containing a plurality of foundation posts, a plurality of floor joist panels, a plurality of wall panels, a floor sheathing, and a wall sheathing, and a plurality of roof rafters. The method includes a second step (b) of positioning the shipping container via mechanical or manual lifts to a permanent location. The method includes a third step (c) of positioning the plurality of foundation posts offset from the sides of the shipping containers and the foundation posts are operable to support a periphery of the floor joist panels. The method includes a fourth step (d) of positioning said plurality of floor joist panels on top of the shipping container and foundation posts and the floor joist panels form an upper floor. The method includes a step (e) of attaching the floor sheathing to the top of the floor joists. The method includes a step (f) of attaching the plurality of wall panels around a periphery of the floor joists and the plurality of wall panels form an enclosure. The method includes a step (g) of attaching the wall sheathing to the outer perimeter of the wall panels. The method includes a step (h) of positioning the plurality of roof rafters on top of the enclosure formed by the plurality of wall panels. The method includes a step (i) of attaching the roof sheathing to the top of the roof rafters.

In one embodiment, the method for building a modular structure includes a preceding step of preparing a foundation upon which the shipping container is placed.

In one embodiment, the method for building a modular structure includes a step intervening between steps (f) and (g), during which plumbing connections are installed into the modular structure.

