EP-4739859-A1 - MODULAR BUILDING UNIT

Abstract

There is disclosed a modular building unit (12) comprising a side structure (100) and a ceiling assembly (102) connected to the side structure. The side structure comprises an upper surface (104). The ceiling assembly is connected to the side structure, and comprises: a load transfer section (106) configured to transfer a load to the side structure, the load transfer section comprising a lower surface (112) seated on the upper surface of the side structure; and a ceiling section (108) configured to define or support a ceiling (110) of the modular building unit. The ceiling section is disposed inwardly of the load transfer section and connected to it, and comprises a lower surface (114) disposed at a position that is lower than the upper surface of the side structure. There is also disclosed a modular building assembly (14) comprising the modular building unit (12), and a building (10) comprising the modular building unit. A method of constructing a modular building unit, and a method of constructing a building comprising a modular building unit, are also disclosed.

Inventors

• SHENTON, Edward Ross
• JONES, David Lee

Assignees

• SANO DEVELOPMENT LIMITED

Dates

Publication Date

20260513

Application Date

20240702

Claims (20)

1. 1. A modular building unit comprising: a side structure comprising an upper surface; and a ceiling assembly connected to the side structure, the ceiling assembly comprising: a load transfer section configured to transfer a load to the side structure, the load transfer section comprising a lower surface seated on the upper surface of the side structure; and a ceiling section configured to define or support a ceiling of the modular building unit, the ceiling section disposed inwardly of the load transfer section and connected to it, and the ceiling section comprising a lower surface disposed at a position that is lower than the upper surface of the side structure.
2. 2. A modular building unit as claimed in claim 1, in which the load transfer section comprises an upper surface configured to support a structure positioned above the modular building unit.
3. 3. A modular building unit as claimed in claim 2, in which the modular building unit is a first modular building unit, and the structure is a further modular building unit stacked on the first modular building unit.
4. 4. A modular building unit as claimed in any preceding claim, in which the ceiling assembly comprises a space configured to receive building services equipment.
5. 5. A modular building unit as claimed in claim 4, in which the space comprises an upper boundary defined by a plane containing an upper surface of the load transfer section, and a lower boundary defined by a plane containing the lower surface of the ceiling section.
6. 6. A modular building unit as claimed in either of claims 4 or 5, in which the building services equipment comprises one or more of: an electricity supply cable; a data cable; a cold water conduit; a hot water conduit; a soil conduit; a gas conduit; and an air ventilation conduit.
7. 7. A modular building unit as claimed in any preceding claim, in which the ceiling section depends from the load transfer section so that the ceiling section overlaps a top part of the side structure defining the upper surface.
8. 8. A modular building unit as claimed in any preceding claim, in which the load transfer section comprises at least one aperture configured to accommodate one or more item of building services equipment so that the item can pass or connect through the aperture.
9. 9. A modular building unit as claimed in any preceding claim, in which the load transfer section forms an outer part of the ceiling assembly and defines at least part of an outer perimeter of the ceiling assembly, and in which the ceiling section forms an inner part of the ceiling assembly and is disposed within the outer perimeter.
10. 10. A modular building unit as claimed in claim 9, in which the load transfer section comprises an inner perimeter, and the ceiling section extends below the load transfer section within the inner perimeter.
11. 11. A modular building unit as claimed in claim 4, in which: the load transfer section is of a first height; and the space is of a second height which is greater than the first height.
12. 12. A modular building unit as claimed in claim 11 , in which the ceiling section is of a third height which is less than both the first and second heights.
13. 13. A modular building unit as claimed in any preceding claim, in which the load transfer section is of a height in the range of about 200mm to about 300mm.
14. 14. A modular building unit as claimed in claim 4, in which the space is of a height in the range of about 250mm to about 350mm.
15. 15. A modular building unit as claimed in any preceding claim, in which the ceiling section is of a height in the range of about 70mm to about 100mm.
16. 16. A modular building unit as claimed in any preceding claim, in which: the side structure defines part of one or more external wall of the modular building unit; the load transfer section comprises a plurality of generally elongate portions which together define the load transfer section; and a generally elongate portion is provided for each external wall part defined by the side structure.
17. 17. A modular building unit as claimed in claim 16, in which the generally elongate portions are generally aligned with the respective external wall part of the side structure.
18. 18. A modular building unit as claimed in either of claims 16 or 17, in which the generally elongate portions are each seated on a respective external wall part of the side structure.
19. 19. A modular building unit as claimed in any one of claims 16 to 18, in which each external wall of the modular building unit is provided jointly by an external wall part of the side structure and a generally elongate portion of the load transfer structure.
20. 20. A modular building unit as claimed in claim 8, in which: the load transfer section describes an outer face and an inner face, the outer face and the inner face disposed substantially parallel to one another; and the one or more aperture extends through the load transfer section between its inner and outer faces.

Description

MODULAR BUILDING UNIT The present invention relates to a modular building unit comprising a side structure and a ceiling assembly connected to the side structure. The present invention also relates to a modular building assembly comprising the modular building unit, and a building comprising the modular building unit. The present invention further relates to a method of constructing a modular building unit, and a method of constructing a building comprising a modular building unit. Prefabricated buildings (also known as ‘modular’ buildings) are well known in the construction industry, particularly modular residential buildings such as houses, flats or apartments, and hotels. Modular buildings typically comprise a series of building units which are constructed in a factory, transported to a final location (or site) for the building, and then arranged in a predetermined configuration and coupled together to form the finished building. The modular building units are typically constructed to a substantially assembled form in the factory, in which they can be transported to the final location. Construction of the building can involve stacking one or more upper modular building unit on a lower such unit, so that the upper unit is supported by the lower unit. Hybrid buildings have been developed by the applicant which comprise a first building section that is constructed at a final location for the building, and a second building section comprising one or more modular building unit constructed in a dedicated facility, away from the final location. A hybrid building of this type can provide advantages including that: construction of the first building section is simplified, with more complex parts of the building provided in the section formed by the modular building unit(s); and the first building section can provide the primary living space in the building, without being constrained by construction and transport limitations imposed on the modular building unit(s). The hybrid buildings and associated construction techniques are disclosed in International patent publication nos. WO2022/243696, WO2022/243695, WO2022/243694, WO2022/243693 and WO2023/222853. Modular building units generally comprise a floor assembly, a ceiling assembly, and a support structure which serves to connect the ceiling assembly to the floor assembly, and to transmit structural loading from the ceiling assembly to the floor assembly. Many modular building units comprise a structural frame defining the floor assembly, ceiling assembly and support structure. Options for the structural frame include metallic frames formed from a metal or metal alloy, and timber-based structural frames. Metallic frames are generally preferred as they provide a good balance of a structural strength and relatively low weight. When a hybrid building is constructed, there is a need to interconnect building services such as heating, ventilation, power, communications, water, and drainage, between the first (site-built) building section and the second (modular, or off-site constructed) building section, as well as between modular building units if a plurality of units are used in the construction. Such interconnections can require wires, pipes, or ducts to pass from one building section to another. Also, for fully modular buildings, there is a similar requirement for such interconnections between modular building units. Current solutions to interconnecting building services, including for fully modular buildings, often required holes to be formed, and/or or ducting to be passed, through walls, floor or ceiling assemblies of the modular building unit. This can interfere with the structural integrity of those structures, or otherwise impact on the building, for instance by compromising insulation, or restricting architectural freedom in arranging rooms and doorways. According to a first aspect, there is provided a modular building unit comprising: a side structure comprising an upper surface; and a ceiling assembly connected to the side structure, the ceiling assembly comprising: a load transfer section configured to transfer a load to the side structure, the load transfer section comprising a lower surface seated on the upper surface of the side structure; and a ceiling section configured to define or support a ceiling of the modular building unit, the ceiling section disposed inwardly of the load transfer section and connected to it, and the ceiling section comprising a lower surface disposed at a position that is lower than the upper surface of the side structure. In the modular building unit of the first aspect, both the load transfer section and the ceiling section of the ceiling assembly are effectively supported on or by the side structure of the modular building unit. This is achieved via the connection between the ceiling section and the load transfer section, and between the load transfer section and the side structure. The ceiling section is therefore indire