Connection of Modular Building Units
A locking assembly for use in building construction includes a locking body configured to be mounted on a first modular building unit and extend in a first direction away from the first modular building unit. The locking body is configured to receive and engage another locking assembly of a second modular building unit for locating the first modular building unit and the second modular building unit with respect to each other. A locking extension is configured to be mounted on the first modular building unit and extend in a second direction, opposite the first direction, away from the first modular building unit. The locking extension is configured to engage another locking body on a third modular building unit to lock the first modular building unit to the third modular building unit.
This application claims priority to U.S. Provisional Patent Application Ser. No. 63/188,840, filed May 14, 2021, and which is hereby incorporated by reference in its entirety.
BACKGROUNDThe present disclosure is directed to modular building units for use in the construction of a building. The modular building unit provides a modular system configured for rapidly erecting a building at a construction site or work site. In particular, the modular building unit facilitates stacking multiple units on top of each other to erect the building.
SUMMARYIn one aspect, a method of constructing a building generally comprises providing a first modular building unit including a locking assembly integrated into the first modular building unit. Providing a second modular building unit including a locking assembly integrated into the second modular building unit. Placing the first and second modular building units in adjoining relation to each other at a building site. Engaging the locking assembly of the first modular building unit with the second modular building unit to position the second modular building unit relative to the first modular building unit. Engaging the locking assembly of the second modular building unit with the locking assembly of the first modular building unit to connect the second modular building unit to the first modular building unit.
In another aspect, a modular building unit assembly for use in constructing a building generally comprises a first modular building unit and a locking assembly mounted on the first modular building unit. The locking assembly is configured to position a second modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
In yet another aspect, a locking assembly for use in building construction generally comprises a locking body configured to be mounted on a first modular building unit and extend in a first direction away from the first modular building unit. The locking body is configured to receive and engage another locking assembly of a second modular building unit for locating the first modular building unit and the second modular building unit with respect to each other. A locking extension is configured to be mounted on the first modular building unit and extend in a second direction, opposite the first direction, away from the first modular building unit. The locking extension is configured to engage another locking body on a third modular building unit to lock the first modular building unit to the third modular building unit.
In still another aspect, a locking body for use in a locking assembly of a modular building unit is configured for mounting on a modular building unit and extending in a first direction away from the modular building unit when the locking body is mounted on the modular building unit. The locking body comprises a top wall, a pair of opposing side walls, a pair of opposing end walls, and a bottom. At least one of the side walls and the end walls is tapered such that a lateral dimension of the locking body at the bottom is greater than a corresponding lateral dimension of the locking body at the top wall. The locking body is configured to receive and engage a locking assembly of another modular building unit for locating said other modular building unit with respect to the modular building unit.
In yet another aspect, a building generally comprises a plurality of modular building units. Each modular building unit includes an integrated locking assembly locking a first modular building unit to a second modular building unit below the first modular building unit. The integrated locking assembly is configured to position a third modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
In still another aspect, a method of constructing a building generally comprises providing a first modular building unit. Providing a second modular building unit including a locking assembly integrated into the second modular building unit. Placing the first and second modular building units in adjoining relation to each other at a building site. The step of placing including engaging first structure of the first modular building unit with second structure of the second modular building unit so that the engagement of the first structure and the second structure guides movement of the first and second modular building units relative to each other.
In yet another aspect, a building component for use in constructing a building generally comprises a first building component including an integrated locking assembly mounted on the building component. The integrated locking assembly is configured to position a second building component located above the first building component relative to the first building component, and connect the first building component to a locking assembly of the second building component.
In still another aspect, a method of constructing a building generally comprises providing a first building unit including a locking assembly integrated into the first building unit. Providing a second building unit including a locking assembly integrated into the second building unit. Placing the first and second building units in adjoining relation to each other at a building site. Engaging the locking assembly of the second building unit with the locking assembly of the first building unit to connect the second building unit to the first building unit. The engagement between the locking assemblies being free of a threaded connection.
Corresponding reference characters indicate corresponding parts throughout the several views of the drawings.
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The reception of the key box 55 within the bottom cross member 23 of the top building unit can facilitate transfer of horizontal forces through multiple modular building units. In practice, the modular building units would be arranged both one on top of the other, but also next to other modular building units stacked on each other to form a building. In practice, building units that are side-by-side can be connected at the ceiling, but not at the floor. A lateral load applied to a top building unit can still be transferred to the adjacent top building unit. At the side on the floor of the first top building unit, the lateral load would pass from the first top building unit to the first bottom unit by virtue of the fit of the key box 55 within the bottom cross member 23 of the top building unit. The first bottom building unit is connected at its ceiling to a second bottom building unit located to the side of the first. The lateral force transferred from the first top building unit to the first bottom building unit can be transferred to the second bottom building unit through its connection with the first bottom building unit. A component of that lateral force can then be transferred from the second bottom building unit to a second top building unit by virtue of the key box rigidly attached to the second bottom building unit and tightly received in a bottom cross member of the second top building unit. In this way substantial lateral stability of a building constructed from modular building units may be achieved without requiring welding or otherwise attaching plates to the horizontally adjacent building units.
The removable tubes 91 of the locking assemblies 19 of the top modular building unit 11 can then be removed causing the locking bars 57 to drop into place such that the washers 89 engage the top surfaces of the top cross members 21 of the wall assemblies 15. This will also position the keys 83 on the locking bars 57 within the interior space 79 of the key boxes 55 on the bottom modular building unit 11.
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Therefore, rotation of the nut 87 on the shaft 81 causes upward movement of the shaft which causes the locking bar 57 to apply an upward clamping force to the key box 55 on the bottom modular building unit 11 thereby locking the locking assembly 19 on the top modular building unit 11 to the locking assembly 19 on the bottom modular building unit. In particular, the top surface 98 of the key 83 presses against the top interior edges 99 of the first side openings 71 in the key box 55 of the bottom modular building unit 11. Rotating the nuts 87 in all the locking assemblies 19 on the top modular building unit 11 in this manner fully locks the top modular building unit to the bottom modular building unit 11. Locking of the top modular building unit to the bottom modular building unit can be carried out with threading a component part of one locking assembly into the other locking assembly. While the individual locking assemblies 19 incorporate threaded components, the engagement between the locking assembly on the top modular building unit 11 with the locking assembly on the bottom modular building unit to connect the top modular building unit to the bottom modular building unit is free of any threaded engagements. Therefore, the connection between the modular building units 11 can be accomplished without the use of a threaded rod or bolt connection. Alternatively, a slot (not shown) in a top surface of the shaft 81 may be engaged by a tool to cause rotation of the shaft relative to the nut 87 causing the same clamping force to be applied by the locking bar 57 to the key box 55 on the bottom modular building unit 11. As a result, only one additional tool is needed to lock the top modular building unit 11 to the bottom modular building unit 11.
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Alternatively, the bottom building unit 111 may include only a single beam member 115 or a single column member 113 without departing from the scope of the disclosure. As such, the bottom building unit 111 may comprise a single building component.
A second, top building unit 111′ may be stacked on top of the bottom building unit 111 and also comprises a plurality of column members 113′ (only one is shown), and a plurality of beam members 115′ (only one is shown) attached to the column members. It will be understood that the elements of the top building unit 111′ are given the same reference numerals as for the bottom building unit 111, with the addition of a prime. In particular, a first beam member 115A′ may be attached to a first column member 113A′. In one embodiment, the first beam member 115A′ is welded to the first column member 113A′. However, the beam members 115A′, and column members 113A′ can be attached by any suitable means without departing from the scope of the disclosure. It will be further understood that the top building unit 111′ may include only a single beam member 115′ or a single column member 113′ without departing from the scope of the disclosure. As such, the top building unit 111′ may comprise a single building component.
In the illustrated embodiment, each of the column members 113,113′ and beam members 115, 115′ of the building units 111, 111′ have a hollow rectangular shape (built up box member or HSS tube section). However, the members 113, 113′, 115, 115′ could have other configurations without departing from the scope of the disclosure. For example, the members 113, 113′, 115, 115′ could comprise cold form steel sections.
In one embodiment, the modular building units 111, 111′ are erected in an assembly plant and other components (not shown) are attached to the building units to create the building unit for installation at the construction site. In some circumstances, the building units may have essentially everything needed for a finished room or rooms prior to being assembled with other building units. However, for simplicity only portions of the frames of the building units are shown and described herein. Moreover, it will be understood that the frames can themselves be considered “modular building units,” as can any unit with any increment of finishing from the bare frame to the fully finished room(s). The level of finish applied to the building units can be different at the time the building units are connected together to form a building. Moreover, the person of ordinary skill in the art will appreciate that the configuration of the frame of the building units 111, 111′ may be other than described (often as dictated by the requirements of a particular building project) within the scope of the present invention. For instance, the modular building units 111, 111′ may include only a single building component.
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To stack a building unit 111′ on top of another modular building unit 111, a top building unit is lifted above a bottom building unit and lowered down toward the bottom building unit. As the top building unit 111′ is lowered to a position adjacent the bottom building unit 111, the locking assemblies 119 of the bottom building unit are configured to interact with the top building unit to first locate the top building unit relative to the bottom building unit. During the lowering and locating steps, the locking assemblies 119′ on the top building unit 111′ are in an unlocked configuration. Once the top building unit 111′ is properly seated on the bottom building unit 111, the locking assemblies 119′ on the top building unit can then be operated to move from the unlocked configuration to a locked or coupled configuration whereby the locking assemblies on the top building unit lock with a respective locking assembly on the bottom building unit to lock the top building unit to the bottom building unit.
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Each locking extension 157 is configured to be mounted on a respective locking fixture 159 and extend through an open bottom of the key box through openings in the first beam members 115A such that the locking extension extends below the first beam member. In one embodiment, the second cable tie 189 is sized such that it can be inserted through the center section 170 of the opening 168 in the locking fixture 159 from a bottom side of the locking fixture. For instance, the second cable tie 189 may have a cross-sectional dimension (i.e. diameter) that is slightly smaller than the cross-sectional dimension of the center section 170. The locking extension 157 is then moved laterally within the opening 168 to locate the cable 181 in one of the side sections 172 of the opening. The second cable tie 189 can then be seated on a top side of the center portion 162 of the locking fixture 159. Because the cross-sectional dimension of the second cable tie 189 is larger than the cross-sectional dimension of the side sections 172 of the opening 168, the second cable tie is prevented from falling back out through the opening.
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The top building unit 111′ can then be lowered all the way down to the bottom building unit 111 so that the key boxes 155 of the locking assemblies 119 of the bottom building unit are fully received in respective openings 154′ (
The locking extension 157 of the locking assemblies 119′ on the top building unit 111′ can then be tensioned to remove any slack in cables 181′ so that the cable ties 183′, 189 apply a sufficient amount of force to the key boxes 155 of the building units 111 to secure the building units together. In one embodiment, a tensioning device such as a cable reel (not shown) can be used to tension the locking extension 157. However, any suitable tensioning device/mechanism may be used without departing from the scope of the disclosure. As a result, only one additional tool (i.e., a tensioning device) is needed to lock the top building unit 111′ to the bottom building unit 111. In one embodiment, the locking assemblies 119, 119′ are free of threaded components. Thus, the engagement between the locking assembly 119′ on the top building unit 111′ with the locking assembly 119 on the bottom building unit 111 to connect the top building unit to the bottom building unit is free of any threaded engagements. Therefore, the connection between the building units 111, 111′ can be accomplished without the use of a threaded rod or bolt connection.
In one embodiment, the second cable tie 189 may be considered a live end of the cable 181, and the first cable tie 183′ may be considered a dead end of the cable 181′. For instance, once the second cable tie 189 is connected to the key box 155, the cable 181 can be jacked to a desired tension to meet the load capacity needed for the building unit connection. Additionally, the first cable tie 183′ of the locking extension 157′ on the top building unit 111′ may be coupled to the key box on the bottom building unit 111 prior to locating the bottom of the top building unit adjacent to the top of the bottom building unit. In this instance, the locking extension 157′ may be tensioned as needed to guide movement of the top building unit 111′ into engagement with the bottom building unit 111.
When introducing elements of the present invention or the preferred embodiments(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.
In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.
As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
OTHER STATEMENTS OF THE INVENTIONA1. A method of constructing a building comprising rotating a locking element of a locking assembly of a second modular building unit to lockingly engage a locking assembly of a first modular building unit.
A2. The method set forth in A1, further comprising removing a spacer from the locking assembly of the second modular building unit to cause the locking element to drop into the locking assembly of the first modular building unit.
A3. The method set forth in A1, further comprising rotating a nut of the locking assembly of the second modular building unit causing vertical movement of a shaft of the locking assembly of the second modular building unit so that the locking element of the locking assembly of the second modular building unit engages a key box of the locking assembly of the first modular building unit and applies a clamping force between the locking assemblies to lock the second modular building unit to the first modular building unit.
A4. The method set forth in A1, further comprising inserting a tool into an opening of the locking assembly of the second modular building unit to contact the locking assembly of the second modular building unit for rotating the locking element.
B1. A method of constructing a building comprising attaching a lifting tackle to a locking assembly of a second modular building unit, and lifting the second modular building unit above a first modular building unit using the lifting tackle attached to the locking assembly of the second modular building unit.
C1. A modular building unit assembly for use in constructing a building, the modular building unit assembly comprising a first modular building unit and a locking assembly mounted on the first modular building unit, the locking assembly being configured to position a second modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
C2. The assembly set forth in C1, wherein the first modular building unit comprises a modular building frame.
C3. The assembly set forth in C3, wherein the locking assembly of the first modular building unit is configured to connect the first modular building unit to a third modular building unit located below the first modular building unit.
D1. A locking assembly comprising a key box having a generally trapezoidal shape.
E1. A locking assembly comprising a locking extension including an elongate bar, a key mounted on a first end portion of the bar, and a nut and a washer mounted on a second end portion of the elongate bar, wherein rotation of one of the nut and the bar causes movement of the bar relative to a first modular building unit.
E2. The locking assembly set forth in E1, wherein the nut is threadedly engaged with the bar.
E3. The locking assembly set forth in E1, further comprising a guide sleeve configured to be mounted on the first modular building unit to guide the movement of the elongate bar.
E4. The locking assembly set forth in E3, further comprising a spacer configured to be disposed between a top surface of the first modular building unit and the washer, a spacer spacing the washer from the top surface of the first modular building unit.
F1. A locking assembly comprising a locking extension including an elongate bar and a key mounted on a first end portion of the bar.
G1. A locking assembly comprising a locking extension including a cable and a cable tie mounted on the cable.
H1. A locking assembly comprising a locking body including a bent plate and a pair of support plates attached to the bent plate.
I1. A locking body for use in a locking assembly of a modular building unit comprises a lock box including a pair of openings formed in respective side walls, the openings being configured to receive lifting tackle for use in lifting the modular building unit when the locking body is mounted thereon.
J1. A building comprising a plurality of modular building units, each modular building unit including an integrated locking assembly locking a first modular building unit to a second modular building unit below the first modular building unit, the integrated locking assembly being configured to position a third modular building unit located above the first modular building unit relative to the first modular building unit, and connect the first modular building unit to a locking assembly of the second modular building unit.
J2. The building set forth in I1, wherein the locking assembly of the second modular building unit is mounted on top of the second modular building unit.
J3. The building set forth in I2, wherein locking assembly of the second modular building unit includes a locking body mounted on top of the second modular building unit, the locking body being configured to be received in an opening in a bottom of the first modular building unit.
K1. A method of constructing a building comprising:
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- providing a first modular building unit;
- providing a second modular building unit including a locking assembly integrated into the second modular building unit;
- placing the first and second modular building units in adjoining relation to each other at a building site, said step of placing including engaging first structure of the first modular building unit with second structure of the second modular building unit so that the engagement of the first structure and the second structure guides movement of the first and second modular building units relative to each other.
L1. A building component for use in constructing a building, the building component comprising a first building component including an integrated locking assembly mounted on the building component, the integrated locking assembly being configured to position a second building component located above the first building component relative to the first building component, and connect the first building component to a locking assembly of the second building component.
L2. The building component set forth in K1, wherein the integrated locking assembly is configured to connect the first building component to a locking assembly of a third building component located below the first building component.
M1. A method of constructing a building comprising:
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- providing a first building unit including a locking assembly integrated into the first building unit;
- providing a second building unit including a locking assembly integrated into the second building unit;
- placing the first and second building units in adjoining relation to each other at a building site; and
- engaging the locking assembly of the second building unit with the locking assembly of the first building unit to connect the second building unit to the first building unit, the engagement between the locking assemblies being free of a threaded connection.
M2. The method set forth in L1, wherein engaging the locking assemblies comprises engaging a locking extension of the locking assembly integrated with the second building with a locking body of the locking assembly integrated with the first building unit.
Claims
1. A method of constructing a building comprising:
- providing a first modular building unit including a locking assembly integrated into the first modular building unit;
- providing a second modular building unit including a locking assembly integrated into the second modular building unit;
- placing the first and second modular building units in adjoining relation to each other at a building site; and
- engaging the locking assembly of the first modular building unit with the second modular building unit to position the second modular building unit relative to the first modular building unit, and engaging the locking assembly of the second modular building unit with the locking assembly of the first modular building unit to connect the second modular building unit to the first modular building unit.
2. The method set forth in claim 1, wherein engaging the locking assembly of the second modular building unit with the locking assembly of the first modular building unit comprises extending a locking element of the locking assembly of the second modular building unit toward the first modular building unit.
3. The method set forth in claim 1, wherein engaging the locking assembly of the first modular building unit with the locking assembly of the second modular building unit is completed without the addition of fastening structure to the first or second modular building unit after the second modular building unit is placed in adjoining relation with the first modular building unit.
4. The method set forth in claim 1, wherein the step of placing the first and second modular building units in adjoining relation comprises inserting a portion of the locking assembly of the first modular building unit within an opening in the second modular building unit to locate the second modular building with respect to the first modular building unit.
5. The method set forth in claim 1, wherein engaging the locking assembly of the second modular building unit with the locking assembly of the first modular building unit comprises guiding movement of the locking assembly of the second modular building unit into the locking assembly of the first modular building unit using a guide sleeve mounted on the second modular building unit.
6. The method set forth in claim 1, further comprising engaging a locking element of the locking assembly of the second modular building unit with a key box of the locking assembly of the first modular building unit thereby preventing the second modular building unit from being moved upward away from the first modular building unit.
7. The method set forth in claim 1, wherein placing the first and second modular building units in adjoining relation comprises moving the second modular building unit vertically to mount the second modular building unit on top of the first modular building unit, and then moving the second modular building unit laterally to position the locking assemblies relative to each other.
8. A locking assembly for use in building construction, the assembly comprising:
- a locking body configured to be mounted on a first modular building unit and extend in a first direction away from the first modular building unit, the locking body being configured to receive and engage another locking assembly of a second modular building unit for locating the first modular building unit and the second modular building unit with respect to each other; and
- a locking extension configured to be mounted on the first modular building unit and extend in a second direction, opposite the first direction, away from the first modular building unit, the locking extension being configured to engage another locking body on a third modular building unit to lock the first modular building unit to the third modular building unit.
9. The locking assembly set forth in claim 8, wherein the locking body is configured to be mounted on a top surface of the first modular building unit and extend upward from the top surface, the locking extension being configured to be mounted on the top surface of the first modular building unit and extend downward from the top surface.
10. The locking assembly set forth in claim 8, wherein the locking body comprises a key box including a top wall, a pair of opposing side walls, a pair of opposing end walls, and a bottom.
11. The locking assembly set forth in claim 10, wherein the key box includes a pair of first openings formed in respective side walls.
12. The locking assembly set forth in claim 11, wherein the first openings are offset along a length of the key box.
13. The locking assembly set forth in claim 12, wherein the key box includes a pair of second openings formed in respective side walls, the second openings being configured to receive lifting tackle for use in lifting the first modular building unit when the locking assembly is mounted thereon.
14. The locking assembly set forth in claim 10, wherein the key box includes an opening formed in the top wall, and an opening formed in the bottom.
15. A locking body for use in a locking assembly of a modular building unit, the locking body being configured for mounting on a modular building unit and extending in a first direction away from the modular building unit when the locking body is mounted on the modular building unit, the locking body comprising a top wall, a pair of opposing side walls, a pair of opposing end walls, and a bottom, at least one of the side walls and the end walls being tapered such that a lateral dimension of the locking body at the bottom is greater than a corresponding lateral dimension of the locking body at the top wall, the locking body being configured to receive and engage a locking assembly of another modular building unit for locating said other modular building unit with respect to the modular building unit.
16. The locking body set forth in claim 15, wherein the lateral dimension extends between the end walls or between the side walls.
17. The locking body set forth in claim 15, further comprising a pair of first openings formed in respective side walls.
18. The locking body set forth in claim 17, wherein the first openings are offset along a length of the key box.
19. The locking body set forth in claim 15, wherein the locking body has a generally trapezoidal shape.
20. The locking body set forth in claim 15, wherein the locking body comprises a bent plate and a pair of support plates attached to the bent plate.
Type: Application
Filed: May 13, 2022
Publication Date: Nov 17, 2022
Inventors: Behzad Rafezy (Laguna Niguel, CA), Quang Minh Huynh (San Diego, CA), Henry Gallart (Mission Viejo, CA), Jared J Adams (Mission Viejo, CA)
Application Number: 17/744,366