WO2025008330A1

WO2025008330A1 - Building comprising modular building unit

Info

Publication number: WO2025008330A1
Application number: PCT/EP2024/068565
Authority: WO
Inventors: Edward Ross SHENTON; David Lee JONES
Original assignee: Sano Development Ltd
Current assignee: Sano Development Ltd
Priority date: 2023-07-05
Filing date: 2024-07-02
Publication date: 2025-01-09
Anticipated expiration: 2026-01-05
Also published as: WO2025008332A1; WO2025008324A1; WO2025008334A1; WO2025008327A1; WO2025008328A1; WO2025008319A1; WO2025008325A1; WO2025008335A1

Abstract

There is disclosed a building comprising a modular building unit, and a method of constructing a building comprising a modular building unit. One disclosed building (10) comprises a first building section (12) comprising at least one modular building unit (14, 18), and a second building section (20) at least partly enclosing the at least one modular building unit. The modular building unit comprises a plurality of external walls (22, 24, 26, 28), at least one of the external walls (22, 26) being an insulated external wall comprising a layer (30, 32) of insulating material. The second building section comprises a plurality of external walls (34, 36, 38, 40), the external walls comprising a layer (42, 44, 46, 48) of insulating material. At least one external wall (34, 38) of the second building section is positioned adjacent to the insulated external wall of the modular building unit, so that an external wall of the building defined at least partly by the adjacent external walls of the second building section and the modular building unit at least partly comprises a double layer of insulation.

Description

BUILDING COMPRISING MODULAR BUILDING UNIT

The present invention relates to a building comprising a modular building unit, and a method of constructing a building comprising a modular building unit. In particular, but not exclusively, the present invention relates to a building comprising a first building section comprising at least one modular building unit, and a second building section enclosing the at least one 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 portion, a ceiling portion, and a support structure which serves to connect the ceiling portion to the floor portion, and to transmit structural loading from the ceiling portion to the floor portion. Many modular building units comprise a structural frame defining the floor portion, ceiling portion 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.

The use of modular building units speeds construction of a building at its final location, but can make insulation of the building challenging. For example, buildings incorporating modular building units having metallic structural frames can be difficult to adequately insulate, as the metallic materials forming the frame have high thermal conductivities. This can lead to significant thermal energy transfer occurring between the interior and exterior of the building. This is a particular issue in buildings incorporating modular building units forming at least part of its external perimeter. A significant factor impacting insulation of modular building units is the need to keep the overall size and weight of the unit to a minimum, so that it can be transported from a construction location (e.g. a factory) to the final location of the building.

According to a first aspect, there is provided a building comprising: a first building section comprising at least one modular building unit; and a second building section at least partly enclosing the at least one modular building unit; in which the modular building unit comprises a plurality of external walls, at least one of the external walls being an insulated external wall comprising a layer of insulating material; in which the second building section comprises a plurality of external walls, the external walls comprising a layer of insulating material; and in which at least one external wall of the second building section is positioned adjacent to an insulated external wall of the modular building unit, so that an external wall of the building defined at least partly by the adjacent external walls of the second building section and the modular building unit at least partly comprises a double layer of insulation.

The building of the first aspect may provide the advantage that it effectively comprises a double insulation barrier for the external building wall defined by the insulated external wall of the modular building unit, and the adjacent external wall of the second building section. This may address difficulties with insulating modular building units (particularly those comprising metallic structural frames) which have been encountered in the past. The modular building unit may be at least partly insulated at a final construction site for the building, by the external wall of the second building section positioned adjacent to its insulated external wall. This may provide effective insulation for the modular building unit, whilst keeping the size and/or weight of the modular building unit down, which is beneficial for reasons including transport.

Reference is made to external walls of the modular building unit. This should be taken to mean walls of the modular building unit which are at, and/or which define, at least part of an external perimeter or boundary of the modular building unit. It should not be taken to mean that the external walls are positioned externally or exteriorly of the building during normal use. Also, it does not encompass walls which are positioned within an internal volume of the modular building unit, for example to divide the internal volume up into two or more subvolumes, which may define at least part of different rooms or areas within the modular building unit. It will be understood that at least part of a perimeter of the modular building unit may be substantially or entirely open, e.g. to provide open access between the modular building unit and the second building section. Such open perimeter parts may not be considered to define an external wall as such.

Reference is made to external walls of the second building section, and of the building itself. Again, this should be taken to mean walls of the second building section or building which are at, and/or which define, at least part of its external perimeter or boundary. At least some of the external walls will face to the exterior of the building during normal use, e.g. defining front, back or side faces of the section/building. However, one or more external wall may not face to the exterior of the building during normal use, e.g. in the case of building in the form of a semi-detached house (which will be described in more detail below), where an external party wall is shared by and separates adjacent houses.

The at least one external wall of the second building section may be positioned adjacent to the insulated external wall of the modular building unit in that it may at least partly overlap an outer face or surface (or outwardly facing surface) defined or described by the insulated external wall of the modular building unit. An inner face or surface (or inwardly facing surface) of the external wall of the second building section may face towards the outer face or surface of said modular building unit external wall.

The modular building unit may comprise a plurality of insulated external walls, each comprising a layer of insulating material. The first and second building sections may be arranged so that each insulated external wall of the modular building unit has an external wall of the second building section disposed adjacent to it.

The second building section may fully or completely enclose the at least one modular building unit. The second building section may comprise or define an internal volume, and the at least one modular building unit may be disposed entirely (or substantially entirely) within said internal volume so that the modular building unit is enclosed by the second building section. The internal volume may be defined or described at least partly by the external walls of the second building section. Outer surfaces or faces of the building may be defined entirely /primarily by the second building section, in particular its external walls.

The building may be a residential building, and may for example take the form of a house or an apartment building. Where the building is a house, the house may be a detached house, a semi-detached house, or a terraced/town house, and may comprise one storey (and so may take the form of a bungalow) or more than one storey. It will be understood that a detached house is a stand-alone structure that does not share external walls with another house or building. Semi-detached houses, and terraced/town houses, share at least one external wall with another house or building. In the case of a semi-detached house, an external party wall separates adjacent houses. In the case of a terraced/town house, there can be two such external party walls (excepting an end-terrace house, which may have only a single party wall).

The modular building unit may be generally quadrilateral shape in plan-view.

The modular building unit may have a first insulated external wall, and a second insulated external wall. The second insulated external wall may be disposed transverse to, in particular substantially perpendicular to, the first insulated external wall. Alternatively, the second insulated external wall may be disposed substantially parallel to the first insulated external wall.

The modular building unit may have a first insulated external wall, a second insulated external wall, and a third insulated external wall. The second insulated external wall may be disposed transverse to, in particular substantially perpendicular to, the first insulated external wall. The third insulated external wall may be disposed transverse to, in particular substantially perpendicular to, the second insulated external wall. The third insulated external wall may be disposed substantially parallel to the first insulated external wall.

It will be understood that the number of insulated external walls defined by the modular building unit depends on factors including: the size/shape of the modular building unit; the size/shape of the second building section; the type or nature of the building (e.g. detached house, semi-detached, terraced); and a position of the modular building unit within the second building section.

The insulated external wall of the modular building unit may be insulated along substantially its entire length. The layer of insulating material may therefore extend along substantially the entire length of the wall. The external wall of the building may therefore comprise a double layer of insulation extending along substantially an entire interface between the external wall of the second building section and the insulated external wall of the modular building unit.

The insulated external wall of the modular building unit may be insulated along a portion, or portions, of its length. The layer of insulating material may therefore extend along part or parts of the length of the insulated external wall. The external wall of the building may therefore comprise a double layer of insulation extending along part of an interface between the external wall of the second building section and the insulated external wall of the modular building unit. This may provide a double layer of insulation for certain internal areas or zones of the modular building unit. These may be areas or zones that tend to be cooler and/or to experience greater thermal energy transitions e.g. due to air movement within the building. Examples include circulation or transition zones, which may provide an access function within the building, and which can comprise or define one or more of a stairwell, a lift shaft, a hallway and a landing. Where the insulated external wall is insulated along portions of its length, the portions may be spaced apart along the length of the wall, and/or separated by a non-insulated portion.

The external wall of the second building section positioned adjacent to the insulated external wall of the modular building unit may comprise a first portion of a first wall thickness, and a second portion of a second wall thickness which is e.g. less than the first wall thickness. The second portion of the external wall may be disposed adjacent to the insulated external wall of the modular building unit. The first and second building sections may be arranged so that the first portion of said external wall at least partly overlaps (considered in a depth direction of the external building wall) an edge region of the insulated external wall of the modular building unit. The insulated external wall of the modular building unit may have a wall thickness which is less than the first wall thickness. The insulated external wall of the modular building unit may have a wall thickness which is up to around the second wall thickness. A total thickness of the external building wall (comprising the second portion of the external wall of the second building section, and the insulated external wall of the modular building unit) may be up to around the first wall thickness. This may provide the benefit that a comparable depth of insulation can be provided in a part of the external building wall comprising the first portion of the second building section external wall, and the part comprising the second portion of the second building section external wall and the insulated external wall of the modular building unit. This can be achieved without increasing an overall depth of the building external wall, which may provide cost and space-saving benefits.

The second building section, in particular its external wall or walls, may comprise a recess or slot in which the modular building unit is located. The recess or slot may be defined by a second portion of at least one external wall of the second building section. The recess or slot may be defined jointly by a second portion of a first external wall of the second building section, and a second portion of at least one further external wall of the second building section. The second portion of the at least one further external wall may be disposed adjacent to and transverse (optionally substantially perpendicular) to the second portion of the first external wall. The second portion of the at least one further external wall may be disposed spaced apart from, and optionally substantially parallel to, the second portion of the first external wall.

The layer of insulating material of the modular building unit insulated external wall may extend along substantially an entire height of the wall.

The modular building unit may comprise a floor portion, a ceiling portion, and a support structure which may serve to connect the ceiling portion to the floor portion, and to transmit structural loading from the ceiling portion to the floor portion. The support structure may comprise or define the unit’s external walls, including the insulated external wall. The insulated external wall defined by the support structure may comprise at least one cavity or recess extending along a plane of the wall, and the cavity/recess may contain (and may be substantially filled with) an insulating material. The modular building unit may comprise a structural frame defining the floor portion, ceiling portion and support structure. The support structure may comprise a plurality of support posts or columns. The support structure may define the cavity or recess, which may extend along a length of the structure. The cavity may be defined between an adjacent pair of support posts. There may be a plurality of cavities, and each cavity may be defined between a respective pair of adjacent support posts. The structural frame may be of a metallic material.

The insulated external wall of the modular building unit may comprise a first portion of a first wall thickness, and a second portion of a second wall thickness which is greater than the first wall thickness. This may facilitate the provision of a thicker layer of insulation for certain internal areas or zones of the modular building unit, such areas being bordered by the second portion of the wall. These may be areas or zones that tend to be cooler and/or to experience greater thermal energy transitions, as discussed above.

The external wall of the second building section may be connected to the adjacent insulated external wall of the modular building unit. Loading in or on the building wall may be borne at least partly by the external wall of the second building section, and by the modular building unit. Loading in or on the modular building unit may be borne at least partly by the external wall of the second building section. Connection may occur at the final location for the building, during its construction. This may help to minimise the size and/or weight of the modular building unit requiring transportation to the final location. The external walls of the second building section may comprise, and/or may be formed from, at least one insulated load bearing panel or panel assembly.

The external walls of the second building section may be formed from an insulated load bearing panel assembly comprising one or more structural insulated panel (SIP). As is known in the construction industry, a SIP comprises inner and outer facing components in the form of facing sheets, with a layer of insulating material sandwiched between the inner and outer facing sheets. SIPs are capable of supporting structural loading so that it is not necessary to provide the wall with a separate load-bearing component or structure. The structural loading is borne primarily by the facing sheets, which are typically of a timber-based material such as oriented strand board (OSB) or plywood, although many alternative material options exist including metallic materials and composites such as fibre -reinforced polymeric materials. The insulating layer is typically of a polymeric material such as expanded polystyrene (EPS), extruded polystyrene (XPS) or a rigid polyurethane foam.

The external walls of the second building section may be formed from an insulated load bearing panel assembly comprising a structural frame/support structure, and one or more insulated panel connected to the structural frame. Options for the structural frame include metallic materials, particularly a light gauge steel frame (LGSF) comprising cold-formed steel structural elements, as well as timber-based materials. The insulated panel typically comprises a core of an insulating material covered with relatively thin inner and outer facing components in the form of facing sheets, typically of a metallic material. The insulating layer is typically of a composite material such as mineral wool (also known as rock wool and stone wool). The facing sheets enable connection of the insulated panel to the structural frame, and of exterior weatherproofing components (such as tiles, slips or facade panels) to the insulated panel.

The insulation material forming the insulating layer in the modular building unit external wall(s) may be of any suitable type, including polymeric materials such as EPS and XPS, mineral wool, and polymeric wool products including glass wool.

The insulating material forming the insulating layers in the modular building unit external wall(s), and the second building section external walls (e.g. their load bearing panels/panel assemblies), acts primarily as a thermal insulator. Said insulating materials may however additionally act as an acoustic (sound) insulator. In a variation, a separate acoustic (sound) insulating layer or layers may be provided.

The at least one external wall of the second building section may comprise a first portion containing insulation material having a first thermal conductivity, and a second portion containing insulation material having a second thermal conductivity which is less than the first conductivity. The second portion of the external wall may be disposed adjacent to the insulated external wall of the modular building unit. This may provide the benefit of a reduced thermal conductivity (and so thermal energy transfer) in the portion of the second building section external wall adjacent to the insulated external wall of the modular building unit. This may help to mitigate e.g. cold bridging effects resulting from use of a metallic frame for the modular building unit, whilst minimising costs (since insulation material having relatively low thermal conductivity is typically more expensive than higher conductivity materials).

A first external wall of the second building section may be arranged so that it is non-adjacent to the (or an) insulated external wall of the modular building unit. A second external wall of the second building section may be positioned adjacent to the (or an) insulated external wall of the modular building unit, and may interface with the insulated external wall of the modular building unit along substantially an entire length of said second wall. Said first wall may contain insulation material having a first thermal conductivity, and said second wall may contain insulation material having a second thermal conductivity which is less than the first conductivity. This may provide a similar benefit to that set out in the preceding paragraph.

The at least one insulated external wall of the modular building unit may comprise a first portion containing insulation material having a first thermal conductivity, and a second portion containing insulation material having a second thermal conductivity which is less than the first conductivity. This may provide a more thermally efficient layer of insulation for certain internal areas or zones of the modular building unit, such areas being bordered by the second portion of the wall. These may be areas or zones that tend to be cooler and/or to experience greater thermal energy transitions, as discussed above.

The first building section may comprise a plurality of modular building units, each of which may have the features of the modular building unit described above, and which may be arranged in the same way relative to the second building section. The first building section may comprise a modular building assembly comprising a first or lower modular building unit, and a second or upper modular building unit which may be stacked or seated upon the lower unit. The building may be a multi-storey building.

The at least one modular building unit may be configured to support at least part of at least one external wall of the second building section, said part of the wall optionally being connected to said modular building unit during construction of the unit. As will be described elsewhere in this document, said modular building unit may be constructed away from a final location for the building, and so said part of the external wall may be connected to said modular building unit away from the final location, and transported to the final location connected to said modular building unit.

The building may be a hybrid building, in particular a hybrid residential building. The second building section may be an on-site construction at a final location for the building. The first and second building sections may be configured to be arranged at the final location to form the building, and may be connected. The second building section may define a main or primary part of the living space within the building.

The modular building unit may define at least part of a circulation space configured to provide at least one access function for a building comprising the modular building unit. The access function provided by the circulation space (which may also be referred to as a circulation zone or transition space/zone) may be selected from the group comprising: access between upper and lower living spaces of the building (e.g. provided by upper and lower storeys of the building), optionally via a staircase or a lift shaft and lift, provided at least partly in the modular building unit; access between a first living space and at least one further living space of the building, said living spaces optionally being isolated from one another within another part of the building and optionally on a same level/storey (e.g. via a hallway /landing and one or more doorway or walkway provided at least partly in the modular building unit); and access into the building from an exterior of the building (e.g. via one or more doorway or walkway, and optionally also a hallway, provided by the modular building unit).

The circulation space may be defined wholly by the (or a) modular building unit. For example, where the circulation space provides access from the outside of the building, the space may be defined wholly by a single such unit. The circulation space may be defined in combination by a plurality of modular building units. For example, where the circulation space provides access between upper and lower living spaces, two or more units may cooperate to define the access, e.g. each may form part of a staircase or lift shaft.

The at least one modular building unit may define (and suitably may completely or entirely define) at least one room, and may define a plurality of rooms. The at least one modular building unit may comprise an internal volume, and the room(s) may be defined within, and may accommodate part of, said volume. One or more wall of the at least one modular building unit may define a boundary or boundaries (optionally all boundaries) of said room. At least one room may contain a wet facility, which may be selected from the group comprising a bathroom, a shower room, an ensuite, a W/C or washroom, and a utility room. One or more further room of the plurality of rooms may be arranged to contain a wet facility.

The building may be a modular building, in particular a modular residential building, comprising a plurality of modular building units. The modular building units may together form all (or substantially all) of the living space within the building. The second building section may define an internal volume in which the modular building units are located.

According to a second aspect, there is provided a modular building unit configured to form at least part of a first building section of a building, the modular building unit comprising: a plurality of external walls, at least one of the external walls being an insulated external wall comprising a layer of insulating material; and at least part of at least one external wall of a second building section of the building, said part of the second building section external wall comprising a layer of insulating material; in which said part of the second building section external wall is positioned adjacent to an insulated external wall of the modular building unit and connected to the modular building unit, so that an external wall of the building defined at least partly by the adjacent external walls of the second building section and the modular building unit at least partly comprises a double layer of insulation. The at least one modular building unit may be configured to support said part of the second building section external wall, which may be connected to the modular building unit during construction of the unit. As will be described elsewhere in this document, the modular building unit may be constructed away from a final location for the building, and said part of the external wall of the second building section may be connected to the modular building unit away from the final location, and transported to the final location connected to the modular building unit.

According to a third aspect, there is provided a building assembly comprising a first modular building unit according to the second aspect, and a second modular building unit according to the second aspect, the second modular building unit being stacked or seated on the first modular building unit.

Further features of the modular building unit or units of the second and third aspects may be derived from the text set out elsewhere in this document, particularly in or with reference to the first aspect.

According to a fourth aspect, there is provided a method of constructing a building comprising the steps of: constructing a modular building unit to a substantially assembled form, comprising providing the modular building unit with a plurality of external walls, and arranging at least one of the external walls as an insulated external wall comprising a layer of insulating material; transporting the modular building unit to a final location for the building, and arranging the modular building unit so that it forms at least part of a first building section of the building; constructing a second building section of the building at the final location, comprising providing the second building section with a plurality of external walls, the external walls comprising a layer of insulating material; arranging the second building section so that it at least partly encloses the first building section; and positioning at least one external wall of the second building section adjacent to an insulated external wall of the modular building unit, so that an external wall of the building is defined at least partly by the adjacent external walls of the second building section and the modular building unit, said external building wall at least partly comprising a double layer of insulation.

The (insulated) external walls of the second building section may be formed from, or may comprise, at least one insulated load bearing panel or panel assembly.

Further features of the method may be derived from the text set out elsewhere in this document, particularly in or with reference to the first aspect.

Reference is also made to the hybrid building and associated construction methods disclosed in International patent publication nos. WO2022/243696, WO2022/243695, WO2022/243694 WO2022/243693 and WO2023/222853, the disclosures of which are incorporated herein by this reference. According to a further aspect, there is provided a modular building unit configured to form at least part of a first section of a building, the modular building unit having any one or more features of the modular building unit defined elsewhere in this document, particularly in or with reference to the first aspect. The modular building unit may comprise at least part of at least one external wall, and which external wall is configured to form part of a second building section which encloses the first building section during use. Said part of the external wall may be connected to the modular building unit, optionally prior to transport of said unit to a final location for the building, and/or location of said unit on a foundation of the building.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

Fig. 1 is an isometric view of a building according to an embodiment of the invention, comprising a first building section having at least one modular building unit, and a second building section enclosing the modular building unit;

Fig. 2 is a wire-frame isometric view of a modular building assembly forming the first building section of Fig. 1, comprising a pair of stacked modular building units, showing the arrangement of the first building section on a foundation of the building;

Fig. 3 is a more detailed isometric view of the first building section of Figs. 1 and 2, showing part of the second building section connected to the modular building units;

Figs. 4 and 5 are plan views of lower and upper storeys respectively of the building shown in Fig. 1 ;

Fig. 4A is an enlarged cross-sectional view through part of a left side wall of the building of Fig. 4, rotated through 90° and showing a variation on the embodiment of Fig. 4;

Figs. 6 and 7 are plan views of lower and upper storeys respectively of a building according to another embodiment of the invention;

Fig. 8 is a plan view of a lower storey of a building according to a further embodiment of the invention;

Figs. 8 A and 8B are enlarged views of portions of the building shown in Fig. 8, which are indicated in broken outline and marked ‘A’ and ‘B’ respectively in Fig. 8;

Fig. 9 is a plan view of an upper storey of the building shown in Fig. 8, and presented on the same sheet;

Figs. 10, 11 and 12 are schematic plan views of lower storeys of buildings according to still further embodiments of the invention; Fig. 13 is an enlarged view of a portion of an alternative wall structure for the building shown in Figs. 1 to 5;

Fig. 14 is a floorplan of an alternative modular building unit, which can form part of the building shown in Figs. 1 to 5;

Fig. 15 is a floorplan of a further alternative modular building unit, which can form part of the building shown in Figs. 1 to 5;

Fig. 16 is a plan view of a lower storey of another building according to a still further embodiment of the invention; and

Fig. 17 is a wire -frame isometric view of a plurality of modular building assemblies, configured to form part of a building according to a yet further embodiment of the invention.

Turning firstly to Fig. 1, there is shown an isometric view of a building according to an embodiment of the invention, the building indicated generally by reference numeral 10. In the illustrated embodiment, the building 10 is a residential building, in particular a hybrid residential building in the form of a detached house. The principles of the invention can however apply to other types of house, including semi-detached, terraced and townhouses, as well as single storey houses (bungalows). In addition, the principles of the invention can apply to other residential buildings such as flats/apartments and hotels, and indeed to non-residential buildings, e.g. industrial or commercial buildings.

The building 10 comprises a first building section which is shown in solid outline in Fig. 1, and indicated by reference numeral 12. The first building section 12 comprises at least one modular building unit 14, and in the illustrated embodiment comprises two modular building units, arranged as a modular building assembly 16.

The modular building assembly 16 is shown separately in the wire -frame isometric view of Fig. 2, in relation to a foundation 17 of the building 10. The modular building assembly 16 comprises the modular building unit 14, which forms a lower unit of the assembly, and a further modular building unit 18, which forms an upper unit of the assembly. The upper modular building unit 18 is stacked on the lower modular building unit 14. The building 10 also comprises a second building section, shown in broken outline in Fig. 1 and indicated by reference numeral 20. The second building section 20 encloses the modular building unit 14, and so effectively also the upper modular building 18.

Fig. 3 is a more detailed isometric view of the first building section 12 of Figs. 1 and 2, showing part of the second building section 20 connected to the modular building units 14 and 18 forming the assembly 16. Reference is also made to Figs. 4 and 5, which are plan views of lower 21 and upper 23 storeys respectively of the building shown in Fig. 1. As can be seen, the modular building unit 14 comprises a plurality of external walls, and in the illustrated embodiment, comprises front wall 22, back wall 24, left side wall 26 and right side wall 28. At least one external wall of the modular building unit 14 is an insulated external wall comprising a layer of insulating material. In the illustrated embodiment, both the front wall 22 and the left side wall 26 form such insulated external walls, the front wall comprising a layer 30 of insulating material, and the left side wall a layer 32 of insulating material.

The second building section 20 also comprises a plurality of external walls, and in the illustrated embodiment comprises front wall 34, back wall 36, left side wall 38 and right side wall 40. The external walls 34-40 can each be formed from at least one insulated load bearing panel or panel assembly, and comprise a layer of insulating material which is indicated respectively by numerals 42, 44, 46 and 48. As can be seen particularly from Figs. 3 and 4, at least one external wall of the second building section 20 is positioned adjacent to an insulated external wall of the modular building unit. In the illustrated embodiment, the front wall 34 of the second building section 20 is positioned adjacent the front wall 22 of the modular building unit 14, and the left side wall 38 of the second building section adjacent the left side wall 26 of the modular building unit. In this way, a front external wall of the building 10 (defined partly by the adjacent front wall 34 of the second building section 20 and the front wall 22 of the modular building unit 14) comprises a double layer of insulation. This is also the case for a left side external wall of the building 10, defined partly by the adjacent left side wall 38 of the second building section 20 and the left side wall 26 of the modular building unit 14.

As mentioned above, the hybrid building 10 comprises the first building section 12 and the second building section 20. The second building section 20 is an on-site construction at a final location 50 for the building, a main living space 52 defined by the section being generally L-shaped in plan view (although not restricted to that shape). This can be seen particularly in Fig. 1, in which an L-shaped footprint or floor plan of the main living space 52 has been cross-hatched and given the numeral 54. The first building section 12, comprising the modular building unit 14, is generally rectangular shape in plan view, as indicated in cross-hatching at 56 in Fig. 1. The unit 14 is constructed to a substantially assembled form away from the final location 50, for example in a dedicated factory or facility. The unit 14 is transported to the final location 50 in its substantially assembled form, and arranged to form part of the first building section 12. The upper unit 18 is also a unit according to the invention, and so has similar features to the unit 14. As explained in detail in International patent publication nos. WO2022/243696, WO2022/243695, WO2022/243694, WO2022/243693 and WO2023/222853, the hybrid building 10 is formed by fitting/connecting the first and second building sections 12 and 20 together at the final location 50.

As can be seen from Fig. 4, the second building section 20, defined by the external walls 34-40, is generally rectangular shaped in plan view. Other shapes are of course possible. The modular building units 14 and 18 can have any suitable dimensions, with the proviso that they will generally be required to be transported e.g. by road or rail from the factory to the final location 50. The illustrated units 14, 18 are around 5300 to 5400mm in length, and around 2500 to 2600mm in width, which is particularly suited to such transportation. The units 14, 18 are smaller than many conventional modular building units, which can facilitate transportation and handling, and can also provide material, weight and cost savings. Although the illustrated units 14, 18 extend only part way between the front and back of the building 10, other units according to the invention extend the full length of the building, and so may e.g. have a greater length dimension. The modular building unit 14 defines a circulation space configured to provide one or more access function for the hybrid building 10. This is best shown in Figs. 4 and 5 in which the circulation space is indicated by numeral 58, shown in broken outline and cross-hatched. In the illustrated embodiment, the circulation space 58 provides three access functions. One such function is access between lower 60 and upper 62 living spaces of the building 10, provided respectively by the lower and upper storeys 21, 23 (and which form parts of the main living space 52 discussed above). This is achieved by means of a stairwell 64 in the modular building unit 10, which contains a staircase 66 (but could be achieved e.g. via a lift shaft and lift). The living space 60 forms an open plan kitchen-dining room, whilst the living space 62 forms a master bedroom, and the circulation space 58 therefore provides access between these different living spaces.

Another such function is access between a first living space and at least one further living space of the building, the living spaces being isolated from one another within another part of the building. As can be seen in Fig. 5, the main living space 52 defined by the first building section 20 comprises the living space 62 (master bedroom), and further living spaces 68 and 70, which form further bedrooms. The circulation space 58 provides access between these living spaces 62, 68 and 70, by means of walkway openings 72, 74, 76 and a landing 78. The circulation space 58 additionally provides access between the lower kitchen living space 60 (and also a living space 80 forming a lounge or sitting room connected to the kitchen 60) and the upper bedroom living spaces 62, 68 and 70.

Another such function is access into the building 10 from an exterior 82 of the building, via a doorway or walkway 84 of the unit 14, which in this case forms a front doorway for the building. The doorway 84 opens on to a hallway 86 to provide access to the staircase 66 (for access to upper living spaces 62, 68 and 70), and an internal walkway 88 (for access to the lower living spaces 60 and 80).

Whilst the illustrated modular building unit 10 comprises a circulation space 58 which provides all three access functions described above, it will be understood that variations may provide only one or only some of the stated functions.

As can be seen in Figs. 4 and 5, the modular building unit 14 defines a plurality of rooms within the building 10, at least one of which provides wet facilities, in the form of a W/C or washroom 90. The unit also forms a further room in the form of a technical room 92, which contains equipment including a water heater 94, hot water tank 96 and ventilation system 98. The unit 14 is arranged so that it comprises internal walls which define a boundary or boundaries of the washroom 90 and the technical room 92. Referring for example to the washroom 90, the unit 14 includes an internal wall 100 which defines a space that forms the washroom. The washroom 90 and the technical room 92 are both accessed from the hallway 86 of the circulation space 58.

In a similar fashion, the upper modular building unit 18 comprises rooms providing wet facilities in the form of a bathroom 102 which is accessed via the landing 78 of the circulation space 58. Sewerage conduits (not shown) connecting to washing and toilet facilities in the bathroom 102 can be accommodated at least partly in a void 104 (Fig. 3) between the stacked units 14 and 18. This can include, for example, sewerage connections for a toilet 106, bath 108 and sink 110 in the bathroom 102.

The second building section 20 fully or completely encloses the modular building units 14, 18. The second building section 20 (specifically its external walls 34-40) defines an internal volume 122 having a generally cuboid shape. The modular building units 14, 18 are disposed entirely within the internal volume so that the modular building units are enclosed by the second building section, as best shown in Figs. 4 and 5. Outer surfaces or faces of the building 10 are therefore defined entirely or primarily by the second building section 20, in particular its external walls. See Fig. 4 showing front 114, back 116, left side 118 and right side 120 surfaces of the building 10 defined respectively by the front wall 34, back wall 36, left side wall 38 and right side external wall 40.

As shown in Fig. 4, the left side external wall 26 of the modular building unit 14 is disposed substantially perpendicularly relative to the front external wall 22. The front wall 22 and left side wall 26 of the modular building unit 14 are insulated along substantially their entire lengths. The layers 30 and 32 of insulating material therefore extend along substantially the entire lengths of the walls 22 and 26. This of course excludes any apertures provided in or through the walls, such as to accommodate the external doorway 84. The external walls of the building 10 (defined respectively by the front wall 22 of the unit 14 and the front wall 34 of the second building section 20, and the left side wall 26 of the unit 14 and the left side wall 38 of the second building section 20) therefore comprise a double layer of insulation. This double insulation layer extends along substantially entire interfaces between the external walls 34, 38 of the second building section 20 and the insulated external walls 22, 26 of the modular building unit 14.

As discussed above, the upper modular building unit 18 is of substantially the same construction as the lower modular building unit 14, and so will not be described in detail here. It will be noted however that the upper unit 18 similarly comprises front 122, back 124, left side 126 and right side 128 external walls. The front wall 122 and the left side wall 126 are insulated walls, comprising respective insulation layers 130, 132 which extend along substantially the entire lengths of the walls (save for a window aperture 134 through the front wall 122 of the unit 18). This continues the double insulation layer upwardly along the building walls from the lower building unit 14 to the upper building unit 18.

In the building 10 shown in Figs. 1 to 5, the insulated front and left side walls 34 and 38 of the second building section 20 are arranged relative to the respective front and let side walls 22 and 26 of the modular building unit 14 (and of course the upper unit 18) so that the respective walls of the second building and the modular building units are either in contact, or as close as can be achieved under typical construction tolerances. However, an air gap can be provided between the respective walls if desired. This is shown in Fig. 4A, which is an enlarged cross-sectional view through part of a left side wall of the building 10 of Fig. 4 formed by the left side wall 38 of the second building section 20, and the left side wall of the modular building unit 14 (rotated through 90°). As shown, an air gap or cavity 135 is provided between an outer surface 137 of the modular unit left side wall 26, and an inner surface 139 of the second building section left side wall 38. The cavity 135 provides for air circulation between the adjacent walls to help prevent moisture build-up, and/or to allow drainage of any condensation that has formed e.g. on the inner surface 139. The cavity 135 can be of any suitable depth bearing in mind that the adjacent walls will typically be connected as described elsewhere in this document. A typical depth may be perhaps 10-50mm.

Turning now to Figs. 6 and 7, there are shown plan views of lower and upper storeys respectively of a building 10a according to another embodiment of the invention. Like components of the building 10a with the building 10 shown in Figs. 1 to 5 share the same reference numerals, with the addition of the suffix ‘a’. The building 10a is of substantially the same shape and construction as the building 10, and so only the substantive differences will be described here.

The building 10a again takes the form of a detached house, comprising a first building section 12a, which is formed from a lower modular building unit 14a and an upper modular building unit 18a stacked on the lower unit (to form a modular building assembly 16a defining the first building section). The lower modular building unit 14a again has external walls comprising front wall 22a, back wall 24a, left side wall 26a and right side wall 28a. In this embodiment the left side wall 26a is insulated, although along only a portion of its length. A layer 32a of insulating material therefore extends along a part of the length of the wall 26a, so that a left side external wall of the building 10a comprises a double layer of insulation extending along part of the interface between a left side external wall 38a of the second building section 20a, and the left side insulated external wall 26a of the modular building unit 14a. This provides a double layer of insulation for certain internal areas or zones of the modular building unit 14a, particularly for an area or zone that tends to be cooler and/or to experience greater thermal energy transitions e.g. due to air movement within the building 10a.

In the specific example shown, the internal zone is a circulation or transition zone which provides an access function within the building, in this case a stairwell 64a containing a staircase 66a (forming part of a circulation space 58a). It will be understood that, depending on factors including a size and shape of the modular building unit 14a, and an internal layout or configuration, the insulated external wall (or walls) may be insulated along more than one portion of its length, the portions being spaced apart along the length of the wall, and/or separated by a non-insulated portion.

The back wall 24a of the lower modular building unit 14a can also optionally be insulated, particularly at its junction with the left side wall 26a, as shown in Fig. 6. This can help to counteract potential thermal bridging occurring at the interface between the left side wall 26a at its interface with the left side wall 38a of the second building section 20a. An insulation layer 138 in the back wall 24a extends part way along the wall from a junction 140 with the left side wall 26a, for example along around a Im length of the wall. An internal wall 142 of the modular building unit 14a may similarly comprise an insulation layer 144, in order to counteract potential thermal bridging, but also to further insulate the internal zone containing the stairwell 64a. The insulation layers 138 and 144 may also provide acoustic (sound) insulation on rising services, which may be located within or closely adjacent to the respective walls 24a and 142, particularly in a washroom 90a and technical room 92a. The upper modular building unit 18a is again of similar construction, and so comprises an insulated left side wall 126a (containing an insulation layer 132a) adjacent to the stairwell 64a, thereby continuing the double insulation layer into the upper unit. The insulation layer 132a extends along part of the wall 126a to encompass a utility cupboard 136, which can serve various functions including as a passage for utility conduits, indicated generally at 138 in the drawing. In the same way as the lower unit 14a, a back wall 124a of the upper unit 18a can optionally be insulated at its junction with the left side wall 126a, and an internal wall 146 may be insulated. Again, this may : counteract potential thermal bridging; further insulate the internal zone containing the stairwell 64a; and provide acoustic (sound) insulation on rising services, which may be located within or closely adjacent to the internal wall 146, particularly in the utility cupboard 136 and a bathroom 102a.

Turning now to Figs. 8 and 9, there are shown plan views of lower and upper storeys respectively of a building 10b according to another embodiment of the invention. Like components of the building 10b with the building 10 shown in Figs. 1 to 5 share the same reference numerals, with the addition of the suffix ‘b’. The building 10b is of substantially the same shape and construction as the building 10, and so only the substantive differences will be described here.

The building 10b again takes the form of a detached house, comprising a first building section 12b, which is formed from a lower modular building unit 14b and an upper modular building unit 18b stacked on the lower unit (to form a modular building assembly 16b defining the first building section). The lower modular building unit 14b again has external walls comprising front wall 22b, back wall 24b, left side wall 26b and right side wall 28b. In this embodiment, as in the unit 14a, the front and left side walls 22b and 26b are insulated, containing insulation layers 30b and 32b which extend along substantially the entire lengths of the walls (save for at a main doorway aperture 84b. A front wall of the building 10b therefore comprises a double layer of insulation extending along the interface between the front wall 22b of unit 14a and a front wall 34b of second building section 20b. Similarly, a left side wall of the building 10b comprises a double layer of insulation extending along the interface between the left side wall 26b of unit 14a and a left side wall 34b of second building section 20b.

In this embodiment however, one or more external wall of the second building section 20b positioned adjacent to the insulated external wall of the modular building unit 14b comprises portions having different wall thicknesses. Reference is made here to Figs. 8A and 8B, which are enlarged views of portions of the building 10b indicated in broken outline and marked ‘A’ and ‘B’ respectively in Fig. 8 (the view of Fig. 8A being rotated through 90°). As can be seen, the side wall 38b of the second building section 20b has a first portion 148 of a first wall thickness Ti, and a second portion 150 of a second wall thickness T2 which is less than the first wall thickness. The second portion 150 of the side wall 38b is disposed adjacent to the insulated side wall 26b of the lower modular building unit 14b. The first and second building sections 12b, 20b are arranged so that the first portion 148 of the second section side wall 38b at least partly overlaps (considered in a depth or thickness direction of the external building wall) an edge region of the insulated external wall 26b of the modular building unit 14b. Similarly, the front wall 34b of the second section 20b has a first portion 152 of a first wall thickness (also Ti), and a second portion 154 of a second wall thickness (also T2) which is less than the first wall thickness. The second portion 154 of the front wall 34b is disposed adjacent to the insulated front wall 22b of the lower modular building unit 14b. The first and second building sections 12b, 20b are again arranged so that the first portion 152 of the second section front wall 34b at least partly overlaps (considered in a depth or thickness direction of the external building wall) an edge region of the insulated front wall 22b of the modular building unit 14b.

As can be seen particularly from Fig. 8A, the insulated side wall 26b of the modular building unit 14b has a third wall thickness T3 which is less than the first wall thickness Ti, and suitably up to around the second wall thickness T2. In the illustrated embodiment however, the third wall thickness T3 is less than the second wall thickness T2. A total thickness T4 of the building side wall comprising the second portion 150 of the second building section side wall 38b and the insulated side wall 26b of the modular building unit 14b can be up to around the first wall thickness, and optionally slightly greater as shown in Fig. 8A. This may provide the benefit that a comparable depth of insulation can be provided in the part of the external building wall comprising the first portion 148 of the second building section side wall 38b, and the part comprising the second portion 150 of the second building section side wall and the insulated external wall 26b of the modular building unit 14b. This can be achieved without increasing an overall depth of the building external wall, which may provide cost and space-saving benefits.

Typical values for the respective wall thicknesses may be as follows:

In the embodiments of Figs. 1 to 7, it will be understood that typical values for the thicknesses of external walls of the second building sections 20 and 20a will be along the lines of TI set out in the table above, whilst typical values for the thicknesses of external walls of the modular building units 14/18 and 14a/18a will be along the lines of T2 above. A total thickness of external walls of the buildings formed from the adjacent external walls of the second building sections 20 and 20a modular building units 14/18 and 14a/18a will therefore be greater than T4 above, and typically in a range of about 325 to 400mm. It will be noted that these thicknesses do not include external weather shielding components (such as facade panels, slips, tiles or the like), or indeed internal decorative finishings such as plasterboard panels, as well as any associated mounting equipment for these components such as mounting frames. As will be understood from Figs. 8, 8A and 8B, the second building section 20b effectively comprises a recess or slot in which the modular building units 14b, 18b are located. The recess is indicated generally at 156 in the drawings, and is defined by the second portions 150 and 154 of the front 34b and left side 38b walls of the second building section 20b, which are disposed adjacent to and transverse (suitably substantially perpendicular) to one another. The upper modular building unit 18b is again of similar construction, and so comprises an insulated front wall 122b (containing an insulation layer 130b) and an insulated left side wall 126b (containing an insulation layer 132b). The upper unit 18b is also located within the recess 156.

Turning now to Figs. 10, 11 and 12, there are shown schematic plan views of lower storeys of buildings 10c, lOd and lOe, respectively, according to still further embodiments of the invention. Like components of the buildings 10c, d and e with the building 10 shown in Figs. 1 to 5 share the same reference numerals, with the addition of the appropriate suffix ‘c/d/e’. The buildings 10c, d and e are of substantially the same shape and construction as the building 10, and so only the substantive differences will be described here.

The building 10c shown in Fig. 10 again takes the form of a detached house, comprising a first building section 12c, which is formed from a lower modular building unit 14c and an upper modular building unit (not shown) stacked on the lower unit, to form a modular building assembly 16c defining the first building section. The lower modular building unit 14c again has external walls comprising front wall 22c, back wall 24c, left side wall 26c and right side wall 28c. In this embodiment, the front, rear and left side walls 22c, 24c and 26c are all insulated, containing insulation layers 30c, 138c and 32c which extend along substantially the entire lengths of the walls (save e.g. for at a main doorway aperture 84c). Front, left side and rear walls of the building 10c therefore comprise double layers of insulation extending along the interface between the respective walls 22c, 24c and 26c of unit 14a, and front 34c, rear 36c and left side 38c walls of second building section 20c.

The building lOd shown in Fig. 1 1 again takes the form of a detached house, comprising a first building section 12d, which is formed from a lower modular building unit 14d and an upper modular building unit (not shown) stacked on the lower unit, to form a modular building assembly 16d defining the first building section. The lower modular building unit 14d again has external walls comprising front wall 22d, back wall 24d, left side wall 26d and right side wall 28d. The front, rear and left side walls 22d, 24d and 26d are all insulated, containing insulation layers 30d, 138d and 32d which extend along substantially the entire lengths of the walls (save e.g. for at a main doorway aperture 84d). Front, left side and rear walls of the building lOd therefore comprise double layers of insulation extending along the interface between the respective walls 22d, 24d and 26d of unit 14a, and front 34d, rear 36d and left side 38d walls of second building section 20d.

In this embodiment, as in the building 10b of Figs. 8-9, external walls of the second building section 20d positioned adjacent to the insulated external walls of the modular building unit 14d comprises portions having different wall thicknesses. The front wall 34d of the second building section 20d has a first portion 148d of a first wall thickness Ti, and a second portion 150d of a second wall thickness T2 which is less than the first wall thickness. The second portion 150d of the front wall 34b is disposed adjacent to the insulated front wall 22d of the lower modular building unit 14d. The rear wall 36d of the second building section 20d has a first portion 158 of the first wall thickness Ti, and a second portion 160 of the second wall thickness T2. The second portion 160 of the rear wall 36d is disposed adjacent to the insulated rear wall 24d of the lower modular building unit 14d. The first and second building sections 12d, 20d are arranged so that the first portions 148d and 158 of the second section front and rear walls 34d and 36d at least partly overlap (considered in a depth or thickness direction of the external building wall) the respective insulated external wall 22d and 24d of the modular building unit 14d. The left side wall 38d of the second building section 20d in contrast is of substantially uniform thickness along its length, which will typically be the second thickness T2. The second wall portions 150 and 160 of the front and back walls 34d and 36d, and the left side wall 38d, may define a recess 156d which receives the modular building unit 14d (and the upper unit stacked on it).

The building lOe shown in Fig. 12 takes the form of a semi-detached house. An adjacent house lOf sharing a party wall with the building lOe (which will be described below) is of like construction but mirror image, and will not be described here. The building lOe comprises a first building section 12e, which is formed from a lower modular building unit 14e and an upper modular building unit (not shown) stacked on the lower unit, to form a modular building assembly 16e defining the first building section. The lower modular building unit 14e again has external walls comprising front wall 22e, back wall 24e, left side wall 26e and right side wall 28e. In this embodiment, the front, rear and right side walls 22e, 24e and 28e are all insulated, containing insulation layers 30e, 138e and 162 which extend along substantially the entire lengths of the walls (save e.g. for at a main doorway aperture 84e). Front and rear walls of the building lOe therefore comprise double layers of insulation extending along the interface between the respective walls 22e and 24e of unit 14e, and front 34e and rear 36e walls of second building section 20e.

The party wall referenced above is shown at 164, and effectively formed jointly by the right side wall 28e of the modular building unit 14e, and a left side wall 26f of a module building unit 14f of the building lOf. A cavity 166 between the adjacent module walls 28e and 26f is substantially filled with insulation material 168 to form an insulation layer in the cavity 166, with more rigid insulated panels 170 and 172 adjacent the front and back walls, to provide a fixed clearance between the walls 28e and 26f, as well as to restrict thermal bridging at the ends of the cavity.

In this instance the second building section 20e is effectively common to both of the semi-detached houses, and forms an internal volume 122e which contains the different modular building units (14e, 14f and their respective stacked upper units) forming first building sections 12e, 12f of the two houses.

A variation on the embodiment shown in Fig. 12 may take the form of a townhouse (not shown), in which at least one further property is formed adjacent to (e.g. to the right of) the building lOe or lOf. A party wall will therefore be shared between the building lOe/f and the adjacent townhouse.

Figs. 4 to 12 illustrate various optional embodiments. It will be understood that further embodiments may comprise features derived from one or more of the illustrated embodiments. For example, the semi-detached building lOe shown in Fig. 12 may comprise a first building section 12e having modular building units arranged according to any of the alternative options set out in Figs. 6 and 7, Figs. 8 and 9 or Fig. 11. In the embodiment of Fig. 11, the left side wall 38d of the second building section 20d may be arranged to have a greater wall thickness than the wall portions 150 and/or 160, and may have the same wall thickness as the portions 158 and/or 148d. In that case, the recess 156d which receives the modular building unit 14d may be defined purely by the second wall portions 150 and 160 of the front and back walls 34d and 36d.

Referring now back to Figs. 1 to 5, the structure modular building unit 14 forming part of the first building section 12, and of the second building section 20, will be described in more detail. It will be understood that the following description applies to the modular building units, plus first and second building sections of all the embodiments disclosed in this document.

As best shown in Fig. 3, the modular building unit 14 comprises a floor portion 174, a ceiling portion 176, and a support structure 178 which serves to connect the ceiling portion to the floor portion, and to transmit structural loading from the ceiling portion to the floor portion. The support structure 178 define the external walls 22-28 of the unit, and so including the insulated front and left side walls 22 and 26. The insulated external walls comprise at least one cavity or recess extending along a plane of the wall, which are substantially filled with an insulating material. This can be seen particularly in Fig. 4, where a cavity 180 in the front wall 22 is shown which contains the insulating material forming the layer 30.

The modular building unit 14 comprises a structural frame defining the floor portion 174, ceiling portion 176 and support structure 178, which is typically of a metallic material (metal or metal alloy), but could be of alternative materials including timber. The floor portion 174 comprises a perimeter (or ring) beam 182, and the ceiling portion 176 a perimeter (or ring) beam 184. These are typically of a metallic material (e.g. a metal alloy such as steel), and may in particular comprise hot-formed metallic material. This may provide a relatively rigid structure for supporting structural loads in and on the unit 14.

The support structure 178 comprises a plurality of support posts or columns, a number of which are shown in the drawings. For example and as shown in Fig. 3, the right side wall 28 of the modular building unit 14 comprises 186-198. K-braces 200 and 202 are provided at respective ends of the side wall 28, and a number of horizontal braces 204-208. These together act to support longitudinally directed loading in the wall 28, as well as torsional loading. The support posts 186- 198 and K-braces 200, 202 are all received in elongate lower and upper channels 210, 212 connected to the floor and ceiling perimeter frames 174, 176 respectively. All of the structural features save the floor and ceiling perimeter frames 174, 176 will typically be of a light gauge metal e.g. steel, to form a composite hot steel and light gauge steel frame structure. Connection of components forming the support structure 178 can be achieved by welding, bonding or using mechanical connectors. Connection of the support structure 178 to the floor and ceiling perimeter frames 174 and 176 can similarly be achieved using welding, bonding or mechanical connectors.

The support structure 178 defines a number of cavities or recesses which extend along a length of the structure, for receiving the insulation material. For example and referring to the front wall 22, the cavity 180 is defined between a pair of adjacent support posts 214 and 216. One or more of the insulated walls can contain a plurality of cavities, as can be seen for example with the left side wall 26. In each case, the layers of insulating material in the modular building unit 14 are arranged so that they extend along substantially an entire height of the respective wall 22, 26.

The external walls 34 and 38 of the second building section 20 which are positioned adjacent to the walls 22 and 26 of the modular building unit 14 may be connected to the adjacent unit’s walls, for example using mechanical connectors. Loading in or on the building walls may therefore be borne at least partly by the external walls 34, 38 of the second building section 20, and partly by the modular building unit 14. Loading in or on the modular building unit 14 may similarly be borne at least partly by the external walls 34, 38 of the second building section 20. Connection of the external walls 34, 38 of the second building section 20 may occur at the final location 50, during its construction. This may help to minimise the size and/or weight of the modular building unit requiring transportation to the final location.

The external walls 34-40 of the second building section 20 are each defined by an insulated load bearing panel assembly, which can comprise one or more structural insulated panel (SIP). Referring to Fig.3, portions of the front 34 and left side 38 walls can be seen. The front wall portion shown in the drawing comprises lower SIPs 218-222 connected to the lower modular building unit 14, and upper SIPs 224-230 connected to the upper modular building unit 18. The left side wall portion 38 similarly comprises lower SIPs (one shown at 232), and upper SIPs 234-242.

As is well known in the construction industry, a SIP comprises inner and outer facing components in the form of facing sheets, with a layer of insulating material sandwiched between the inner and outer facing sheets.

Referring for example to the front wall SIP 222 as shown in Fig. 4, inner and outer facing sheets 244 and 246 are shown, which sandwich the insulation layer 42. SIPs are capable of supporting structural loading so that it is not necessary to provide the external walls with a separate load-bearing component or structure. The structural loading is borne primarily by the facing sheets, which are typically of a timber-based material such as oriented strand board (OSB) or plywood, although many alternative material options exist including metallic materials and composites such as fibre -reinforced polymeric materials. The insulating layer is typically of a polymeric material such as expanded polystyrene (EPS), extruded polystyrene (XPS) or a rigid polyurethane foam. The SIPs are interconnected as appropriate at their edge regions to form the walls, to laterally and/or vertically positioned SIPs in the wall structure.

A moisture barrier is applied to outer surfaces of the SIPs, part of such a barrier shown in Fig. 3 separated from the left side wall of the building 10, and indicated by numeral 247. The moisture barrier 247 will typically be vapour permeable e.g. of a polymeric material, to allow any moisture within the structure to escape, but to restrict entry of liquid water. Any suitable external weatherproofing surface finish can be mounted to the SIPs over the moisture barrier 247, including for example tiles, slips or facade panels. In an alternative, the external walls 34-40 of the second building section 20 may be formed from an insulated load bearing panel assembly comprising a structural frame or support structure, and one or more insulated panel connected to the structural frame. This is shown in Fig. 13, which is an enlarged view of a portion of an alternative left side wall structure 38g for the building 10, rotated through 90°. Like components share the same reference numerals with the addition of the suffix ‘g’. The left side wall 26 of the module can be seen at the lower part of the drawing, with an internal decorative (e.g. plasterboard) sheet 248 connected to it. The load bearing panel assembly is indicated at 250 and comprises a support frame 252 connected to structural elements of the modular building unit structural frame, in particular to support posts (two shown and given numerals 254 and 256) of its support structure 178. The support frame 252 comprises structural support elements including vertical support posts (two shown and given numerals 253 and 255) which transfer loading to the foundation 17, as well as transverse bracing struts (not shown) connected between and bracing the support posts. Options for the support frame 252 include metallic materials, particularly a light gauge steel frame (LGSF) comprising cold- formed steel structural elements, as well as timber-based materials. An insulated panel 258 comprises a core 44g of an insulating material covered with relatively thin inner and outer facing components, in the form of facing sheets 260 and 262, typically of a metallic material. The insulating core 44g is typically of a composite material such as mineral wool (also known as rock wool and stone wool). The facing sheets 260, 262 enable connection of the insulated panel 258 to the support frame 252, and of exterior weatherproofing components (such as tiles, slips or I’acade panels) to the insulated panel. One such optional facade panel 264 is shown, mounted on the outer facing sheet 262 via battens or frame members 266. One suitable such suitable insulated load bearing panel assembly includes the Karrier panel system commercially available from the Kingspan Group.

The insulation material forming the insulating layers 30 and 32 in the modular building unit external walls 22 and 26 may be of any suitable type, including polymeric materials such as EPS and XPS, mineral wool, and polymeric wool products including glass wool.

Turning now to Fig. 14, there is shown a plan view of an alternative modular building unit 14h according to an embodiment of the invention, similar to Fig. 4 but drawn to a larger scale. The modular building unit 14h is based on the unit 14 shown in Figs. 1 to 5, and like components share the same reference numerals, with the addition of the suffix ‘h’. The modular building unit 14h may however form part of any one of the buildings shown in Figs. 6 to 12. It may also of course form the basis for the upper modular building unit 18.

In this embodiment, the modular building unit 14h again has front, back, left side and right side walls 22h-28h. The front and left side walls 22h and 26h are the insulated external walls in this embodiment. As can be seen, the left side wall 26h comprises a first portion 268 of a first wall thickness T5, and a second portion 270 of a second wall thickness Te which is greater than the first wall thickness. Insulation in the first portion 268 forms a an insulation layer 32h, whilst insulation in the second portion 270 forms an insulation layer 272. In this way, a thicker layer of insulation 272 can be provided for certain internal areas or zones of the modular building unit 14h, such areas being bordered by the second portion 270 of the wall 26h. These may be areas or zones that tend to be cooler and/or to experience greater thermal energy transitions, such as a stairwell 64h, as discussed above.

Turning now to Fig. 15, there is shown a plan view of another alternative modular building unit 14i according to an embodiment of the invention, which is similar to Fig. 14. The modular building unit 14i is based on the unit 14 shown in Figs. 1 to 5, and like components share the same reference numerals, with the addition of the suffix ‘i’. The modular building unit 14i may however form part of any one of the buildings shown in Figs. 6 to 12. It may also of course form the basis for the upper modular building unit 18.

In this embodiment, the modular building unit 14i again has front, back, left side and right side walls 22i-28i. The front and left side walls 22i and 26i are the insulated external walls in this embodiment. The left side wall 26i comprises a first portion 274 containing insulation material 275 having a first thermal conductivity, and a second portion 276 containing insulation material 277 having a second thermal conductivity which is less than the first conductivity. This may provide a layer of insulation having greater thermal efficiency for certain internal areas or zones of the modular building unit 14i, such areas being bordered by the first portion 274 of the wall 26i. These may be areas or zones that tend to be cooler and/or to experience greater thermal energy transitions, such as a stairwell 64i, as discussed above. Typical thermal conductivities of suitable insulation materials range from around 0.014W/m.K to around 0.06W/m.K. Insulation materials can include polymeric materials such as EPS and XPS (conductivity ~ 0.034-0.04W/m.K), mineral wool (~0.032-0.044W/m.K), polymeric wool products including glass wool (~0.035W/m.K), and polymeric foams (0.020-0.039W/m.K). Materials having better thermal efficiency (lower conductivity) tend to be higher cost, and so providing more thermally insulative materials for e.g. cooler areas, and less thermally insulative materials in other areas can provide a good balance of performance versus cost.

Turning now to Fig. 16, there is shown a plan view of a lower storey of another building lOj according to another embodiment of the invention. The building lOj is essentially of the same construction as the building 10, and like components share the same reference numerals, with the addition of the suffix ‘j’. The building comprises a first building section 12j, which is formed from a lower modular building unit 14j and an upper modular building unit (not shown), and second building section 20j enclosing the modular building unit. The lower modular building unit 14j again has external walls comprising an insulated front wall 22j, back wall 24j, insulated left side wall 26j and right side wall 28j. A front wall of the building lOj again comprises a double layer of insulation extending along the interface between the front wall 22j of unit 14j and a front wall 34j of second building section 20j. A left side wall of the building lOj comprises a double layer of insulation extending along the interface between the left side wall 26j of unit 14j and a left side wall 34f of second building section 20.

In this embodiment, the front wall 34j and the left side wall 38j of the second building section 20j contains insulation material having a first thermal conductivity, whilst rear wall 36j and right side wall 40j contain insulation material having a second thermal conductivity which is less than the first conductivity. This may provide a similar benefit to that set out above in relation to Fig. 15. Alternatively, one or more of the external walls 34j-40j comprise portions containing insulation materials having different conductivities. For example and considering the left side wall 38j , this may comprise a first portion 274 containing insulation material 275 having a first thermal conductivity, and a second portion 276 containing insulation material 277 having a second thermal conductivity which is less than the first conductivity.

Referring back to Figs. 1 to 5, a method of constructing the building 10 (which is generally common to all embodiments disclosed in this document) typically comprises preparing the foundation 17 at the final location 50 ready to receive the first and second building sections 12 and 20. The modular building units 14 and 18 forming the assembly 16 (and so first building section 12) are manufactured in a dedicated facility such as a factory, disposed away from the final location 50, which may be remote from a building site containing the final location, or on the site distanced from the final location. The modular building units 14, 18 are manufactured to a substantially assembled form in which they can be safely transported. The units 14 and 18 are located on the foundation 17, stacked as shown in Fig. 3 and connected together. The second building section 20 is then constructed around the first building section 12 formed by the stacked units 14 and 18, and located on the foundation 17. The various SIP panels forming the second section 20 are connected to the first and/or second modular building units 14, 18 as appropriate. A roof structure 282 is typically assembled on site, extending over the first and second sections 12, 20 and connected to them. Numerous options exist including forming the roof structure 282 from roof trusses (not shown), or as a modular (transportable) structure. Floor joists (not shown) forming ceilings of the lower and upper storeys 21 and 23 and connected to and supported by the lower modular building unit 14, and the upper modular building unit 18, respectively. The lower storey ceiling joists will typically be connected to the lower unit 14 prior to building up the SIP panels forming the upper storey and connecting them to the upper unit 18.

In one alternative construction option, the lower modular building unit 14 may be located on the foundation 17 and the SIP panels forming a lower storey of the second building section 20 connected to the lower unit prior to stacking of the upper modular building unit 18 on the lower unit, and subsequent positioning of upper SIPs forming the upper storey portion of the second building section. In another alternative construction option, the second building section 20 is formed on the foundation 17 and the modular building units 14, 18 then positioned within the second section and connected to it as discussed above. The second building section 20 in this option may be built up to the height of the lower storey 21 and the lower modular building unit 14 then located within the second section and connected to it. The second section 20 may then be built up to the height of the upper storey 23 and the upper modular building unit 18 then located within the second section and connected to it. Alternatively, the second section 20 may be built up to the height of the upper storey 23 before either of the modular building units 14, 18 are located within it. Benefits to a module first approach however include that the second building section 20 can be connected to the lower unit 18 as it is constructed, so that the lower unit supports the SIP panel structure, easing construction.

Another alternative construction option will be described, with reference again to Fig. 3. In this further option, the modular building units 14 and 18 are configured to support at least part of at least one external wall of the second building section 20. In this example, the units 14 and 18 support the front wall 34 of the second building section 20 formed by the various SIPs 218-230. The SIPs 218-230 can be connected to the modular building units 14, 18 during construction e.g. in the factory. The front wall 34 can therefore be connected to the modular building units 14, 18 away from the final location 50, and transported to the final location connected to the modular building units. The front wall 34 formed by the SIPs can then be connected to further walls of the second building section 20 at the final location 50, including the left side wall 38 shown in the drawing. It will be understood of course that only parts of one or more wall may be connected to the building units 14, 18 in this way. Connection of the SIPs forming the wall or wall part will of course add to the size and weight of the structure that has to be transported to the final location, which may only be desirable in certain constructions e.g. for a relatively small/lightweight modular building unit.

Fig. 17 is a wire -frame isometric view of a plurality of modular building assemblies, configured to form part of a building 10k according to a yet further embodiment of the invention. In this embodiment, modular building units are arranged in assemblies stacked as discussed above in relation to the modular building assembly 12. Thus a first modular building assembly 12k comprises a lower modular building unit 14k and an upper modular building unit 18k stacked on the lower unit. A further modular building assembly 12k' similarly comprises a lower modular building unit 14k' and an upper modular building unit 18k' stacked on the lower unit. Between them, the modular building units of the assemblies 12k and 12k' define the entire internal living space volume of the building 10k, with the exception of an upper or outer roof of the building (not shown), which may be formed at a final location for the building (as for the roof structure 282), or formed as a modular (transportable) structure. A second building section 20k of the building 10k encloses the building assemblies 12k and 12k' in the same way as described above.

Various modifications may be made to the foregoing without departing from the spirit or scope of the present invention.

Further aspects and/or embodiments of the invention may combine the features of one or more aspect and/or embodiment disclosed in this document. Accordingly, such further aspects and/or embodiments may comprise one or more feature selected from one or more aspect or embodiment of the invention disclosed in this document.

Unless explicitly implied by context or stated in the document, the features of any method or process disclosed in this document need not necessarily be performed in the precise order set out in the relevant text and/or drawings. Accordingly, any method or process disclosed in this document may be capable of being performed in an order other than that specifically set out in the relevant text/drawings, if circumstances permit.

Features disclosed in this document (including any accompanying claims, abstract and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Accordingly, features disclosed in this document may represent only one example of a generic series of equivalent or similar features.

Claims

1. A building comprising: a first building section comprising at least one modular building unit; and a second building section at least partly enclosing the at least one modular building unit; in which the modular building unit comprises a plurality of external walls, at least one of the external walls being an insulated external wall comprising a layer of insulating material; in which the second building section comprises a plurality of external walls, the external walls comprising a layer of insulating material; and in which at least one external wall of the second building section is positioned adjacent to an insulated external wall of the modular building unit, so that an external wall of the building defined at least partly by the adjacent external walls of the second building section and the modular building unit at least partly comprises a double layer of insulation.

2. A building as claimed in claim 1, in which the modular building unit comprises a plurality of insulated external walls each comprising a layer of insulating material, and in which the first and second building sections are arranged so that each insulated external wall of the modular building unit has an external wall of the second building section disposed adjacent to it.

3. A building as claimed in any preceding claim, in which the modular building unit has a first insulated external wall, and a second insulated external wall disposed transverse to the first insulated external wall.

4. A building as claimed in either of claims 1 or 2, in which the modular building unit has a first insulated external wall, and a second insulated external wall disposed substantially parallel to the first insulated external wall.

5. A building as claimed in either of claims 1 or 2, in which the modular building unit has a first insulated external wall, a second insulated external wall, and a third insulated external wall, the second insulated external wall disposed transverse to the first insulated external wall, and the third insulated external wall disposed transverse to the second insulated external wall and substantially parallel to the first insulated external wall.

6. A building as claimed in any preceding claim, in which at least one insulated external wall of the modular building unit is insulated along substantially its entire length.

7. A building as claimed in any preceding claim, in which at least one insulated external wall of the modular building unit is insulated along a portion or portions of its length, to provide a double layer of insulation extending along part of an interface between the external wall of the second building section and the insulated external wall of the modular building unit.

8. A building as claimed in claim 7, in which said insulated external wall provides a double layer of insulation for a circulation zone within the modular building unit which provides an access function within the building.

9. A building as claimed in any preceding claim, in which the external wall of the second building section positioned adjacent to said insulated external wall of the modular building unit comprises a first portion of a first wall thickness, and a second portion of a second wall thickness which is less than the first wall thickness, and in which the second portion of the external wall is disposed adjacent to the insulated external wall of the modular building unit.

10. A building as claimed in claim 9, in which the first and second building sections are arranged so that the first portion of said external wall at least partly overlaps an edge region of the insulated external wall of the modular building unit.

11. A building as claimed in either of claims 9 or 10, in which said insulated external wall of the modular building unit has a wall thickness which is up to around the second wall thickness.

12. A building as claimed in any claim one of claims 9 to 11, in which a total thickness of a portion of the external building wall comprising the second portion of the external wall of the second building section, and the insulated external wall of the modular building unit, is up to around the first wall thickness.

13. A building as claimed in any preceding claim, in which at least one external wall of the second building section comprises a recess in which the modular building unit is located.

14. A building as claimed in any one of claims 9 to 12, in which the second portion of the external wall of the second building section comprises a recess in which the modular building unit is located.

15. A building as claimed in any one of claims 9 to 12, in which a recess is defined jointly by a second portion of a first external wall of the second building section and a second portion of at least one further external wall of the second building section, and in which the modular building unit is located in the recess.

16. A building as claimed in claim 15, in which: the second portion of the at least one further external wall is disposed adjacent to and transverse to the second portion of the first external wall; or the second portion of the at least one further external wall is disposed spaced apart from, and substantially parallel to, the second portion of the first external wall.

17. A building as claimed in any preceding claim, in which said insulated external wall of the modular building unit comprises a first portion of a first wall thickness, and a second portion of a second wall thickness which is greater than the first wall thickness.

18. A building as claimed in any preceding claim, in which the external wall of the second building section is connected to the adjacent insulated external wall of the modular building unit.

19. A building as claimed in any preceding claim, in which the at least one external wall of the second building section comprises a first portion containing insulation material having a first thermal conductivity, and a second portion containing insulation material having a second thermal conductivity which is less than the first conductivity, and in which the second portion of the external wall is disposed adjacent to the insulated external wall of the modular building unit.

20. A building as claimed in claim 19, in which said second portion provides a double layer of insulation for a circulation zone within the modular building unit which provides an access function within the building.

21. A building as claimed in any preceding claim, in which: a first external wall of the second building section is arranged so that it is non-adjacent to an insulated external wall of the modular building unit; a second external wall of the second building section is positioned adjacent to the insulated external wall of the modular building unit, and interfaces with the insulated external wall of the modular building unit along substantially an entire length of said second external wall; and said first external wall contains insulation material having a first thermal conductivity, and said second external wall contains insulation material having a second thermal conductivity which is less than the first conductivity.

22. A building as claimed in any preceding claim, in which the at least one insulated external wall of the modular building unit comprises a first portion containing insulation material having a first thermal conductivity, and a second portion containing insulation material having a second thermal conductivity which is less than the first thermal conductivity.

23. A building as claimed in claim 22, in which said second portion provides a double layer of insulation for a circulation zone within the modular building unit which provides an access function within the building.

24. A building as claimed in any preceding claim, in which the at least one modular building unit is configured to support at least part of at least one external wall of the second building section, said part of the wall being connected to said modular building unit during construction of the unit away from a final location for the building, so that said part of the external wall is transportable to the final location connected to said modular building unit.

25. A building as claimed in any preceding claim, in which the modular building unit is a lower modular building unit, and the first building section is formed by a modular building assembly comprising the lower modular building unit and an upper modular building unit stacked upon the lower modular building unit.

26. A building as claimed in any preceding claim, in which the building is a hybrid residential building, the second building section being an on-site construction at a final location for the building, and the first and second building sections configured to be arranged at the final location to form the building and connected together.

27. A building as claimed in any one of claims 1 to 25, in which the building is a modular residential building comprising a plurality of modular building units which together form substantially all of the living space within the building, and in which the second building section defines an internal volume in which the modular building units are located.

28. A building as claimed in any preceding claim, in which the external walls of the second building section are formed from at least one insulated load bearing panel.

29. A modular building unit configured to form at least part of a first building section of a building, the modular building unit comprising: a plurality of external walls, at least one of the external walls being an insulated external wall comprising a layer of insulating material; and at least part of at least one external wall of a second building section of the building, said part of the second building section external wall comprising a layer of insulating material; in which said part of the second building section external wall is positioned adjacent to an insulated external wall of the modular building unit and connected to the modular building unit, so that an external wall of the building defined at least partly by the adjacent external walls of the second building section and the modular building unit at least partly comprises a double layer of insulation.

30. A method of constructing a building comprising the steps of: constructing a modular building unit to a substantially assembled form, comprising providing the modular building unit with a plurality of external walls, and arranging at least one of the external walls as an insulated external wall comprising a layer of insulating material; transporting the modular building unit to a final location for the building, and arranging the modular building unit so that it forms at least part of a first building section of the building; constructing a second building section of the building at the final location, comprising providing the second building section with a plurality of external walls, the external walls comprising a layer of insulating material; arranging the second building section so that it at least partly encloses the first building section; and positioning at least one external wall of the second building section adjacent to an insulated external wall of the modular building unit, so that an external wall of the building is defined at least partly by the adjacent external walls of the second building section and the modular building unit, said external building wall at least partly comprising a double layer of insulation.