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CA-3167181-C - SYSTEMS AND METHODS FOR MODULAR CONSTRUCTION

CA3167181CCA 3167181 CCA3167181 CCA 3167181CCA-3167181-C

Abstract

A connection assembly for modular construction includes an upper junction connector coupled to an upper end of a column. The upper junction connector includes an upper end that has a planar upper surface, a recessed surface, and at least one connector sidewall extending between the upper surface and the recessed surface. The recessed surface and the at least one connector sidewall define a contiguous recessed area in the upper end that extends to second, third, and fourth edges of the upper end of the connector. A slot extends through the upper end adjacent to an interior surface of a column sidewall. A transverse bore extends through the first column sidewall proximate to and aligned with the slot.

Inventors

  • Julian L. W. Bowron

Assignees

  • VECTOR META INC.

Dates

Publication Date
20260505
Application Date
20210219
Priority Date
20200220

Claims (16)

  1. CLAIMS: 1. A connection assembly for modular construction, the assembly comprising: at least one column having an upper end, a lower end, and a first column sidewall, a second column sidewall, a third column sidewall, and a fourth column sidewall, the first, second, third, and fourth column sidewalls extending between the upper end and the lower end, wherein the fourth column sidewall defines a longitudinal gap therein, the longitudinal gap extending along a length of the fourth column sidewall; at least one upper junction connector coupled to the upper end of the at least one column, each of the at least one upper junction connector comprising: an upper end having first, second, third, and fourth edges, wherein the first edge overlies the first column sidewall, the second edge overlies the second column sidewall, the third edge overlies the third column sidewall, and the fourth edge overlies the fourth column sidewall, wherein the upper end has a planar upper surface, a recessed surface, and at least one connector sidewall extending between the upper surface and the recessed surface, the recessed surface and the at least one connector sidewall defining a contiguous recessed area in the upper end that extends to the second, third, and fourth edges of the upper end of the connector, wherein a slot extends through the upper end adjacent to an interior surface of the first column sidewall, and wherein a bore extends through the recessed surface; a first lateral connector extending generally perpendicular to the first column sidewall proximate the upper end of the at least one column; and a second lateral connector extending generally perpendicular to one of the second and third column sidewall proximate the upper end of the at least one column; wherein a transverse bore extends through the first column sidewall proximate to and aligned with the slot.
  2. 2. The connection assembly of claim 1, wherein the at least one column comprises an open steel section that is brake-formed and/or roll formed. 52 9102985 Date Rec;ue/Date Received 2024-02-12
  3. 3. The connection assembly of claim 1 or claim 2, wherein at least one sidewall of the slot is tapered inwardly.
  4. 4. The connection assembly of any one of claims 1 to 3, wherein a portion of the interior surface of the first column sidewall proximate the slot is angled.
  5. 5. The connection assembly of any one of claims 1 to 4, wherein at least a portion of the at least one connector sidewall is tapered inwardly.
  6. 6. The connection assembly of any one of claims 1 to 5, further comprising at least one reinforcing plate positioned between opposing column sidewalls, generally perpendicular to the upper end of the first connector, and proximate a lower end of the first lateral connector.
  7. 7. The connection assembly of any one of claims 1 to 6, wherein the upper end of the at least one upper junction connector, the first lateral connector, and the second lateral connector are integrally formed.
  8. 8. The connection assembly of any one of claims 1 to 7, further comprising: an electrically powered actuator configured to drive a securement bolt through the transverse bore and through a corresponding transverse bore in a securement tab extending from an upper junction connector and through the slot.
  9. 9. The connection assembly of claim 8, wherein the actuator is at least one of a linear actuator and a rotary actuator.
  10. 10. The connection assembly of any one of claims 1 to 9, wherein: 9102985 the at least one column comprises a first column and a second column; the at least one upper junction connector comprises a first upper junction connector and a second upper junction connector, wherein the first upper junction connector is coupled to the upper end of the first column, and wherein the second upper junction connector is coupled to the upper end of the second column; and further comprising: a lateral tie member for securing the first upper junction connector and the second upper junction connector in a fixed orientation, the lateral tie member comprising a generally planar body having an upper surface, a lower 53 Date Rec;ue/Date Received 2024-02-12 surface, and an outer perimeter face extending from the upper surface to the lower surface, wherein a first portion of the lateral tie member is dimensioned to seat within the recessed area of the first upper junction connector, wherein a first portion of the outer perimeter face abuts the at least one connector sidewall of the first upper junction connector, and wherein the upper surface of the first portion of the lateral tie member is flush with or recessed from the upper surface of the upper end of the first upper junction connector, and wherein a second portion of the lateral tie member is dimensioned to seat within the recessed area of the second upper junction connector, wherein a second portion of the outer perimeter face abuts the at least one connector sidewall of the second upper junction connector, and wherein the upper surface of the second portion of the lateral tie member is flush with or recessed from the upper surface of the upper end of the second upper junction connector.
  11. 11. The connection assembly of claim 10, wherein: the at least one column further comprises a third column, the at least one upper junction connector further comprises a third upper junction connector coupled to the upper end of the third column, and wherein a third portion of the lateral tie member is dimensioned to seat within the recessed area of the third upper junction connector, wherein a third portion of the outer perimeter face abuts the at least one connector sidewall of the third upper junction connector, and wherein the upper surface of the third portion of the lateral tie member is flush with or recessed from the upper surface of the upper end of the third upper junction connector.
  12. 12. The connection assembly of claim 11, wherein: 9102985 the at least one column further comprises a fourth column, the at least one upper junction connector further comprises a fourth upper junction connector coupled to the upper end of the fourth column, and wherein a fourth portion of the lateral tie member is dimensioned to seat within the recessed area of the fourth upper junction connector, wherein a fourth portion of the outer perimeter face abuts the at least one connector sidewall of the fourth upper junction connector, and wherein the upper surface of the 54 Date Rec;ue/Date Received 2024-02-12 fourth portion of the lateral tie member is flush with or recessed from the upper surface of the upper end of the fourth upper junction connector.
  13. 13. The connection assembly of any one of claims 1 to 9, further comprising: 9102985 an upper column having an upper end, a lower end, and a first column sidewall, a second column sidewall, a third column sidewall, and a fourth column sidewall, the first, second, third, and fourth column sidewalls extending between the upper end and the lower end, wherein the fourth column sidewall defines a longitudinal gap therein, the longitudinal gap extending along a length of the fourth column sidewall; a lower junction connector coupled to the lower end of the upper column, the lower junction connector comprising: a lower end having first, second, third, and fourth edges, wherein the first edge overlies the first column sidewall of the second column, the second edge overlies the second column sidewall of the second column, the third edge overlies the third column sidewall of the second column, and the fourth edge overlies the fourth column sidewall of the second column, wherein the lower end has a planar lower surface, and a securement tab projecting downwardly from the lower end, the securement tab having a transverse bore; and a securement bolt for securing one of the at least one upper junction connector and the lower junction connector in a fixed orientation, wherein, when the securement tab of the lower junction connector is received in the slot of the one of the at least one upper junction connector, and the lower surface of the lower end of the lower junction connector abuts the upper surface of the upper end of the one of the at least one upper junction connector, the securement bolt is positioned in both the transverse bore that extends through the first column sidewall and through the transverse bore of the securement tab, such that the one of the at least one upper junction connector and the lower junction connector are secured to each other in a fixed orientation. 55 Date Rec;ue/Date Received 2024-02-12
  14. 14. The connection assembly of claim 13, wherein the securement tab is mechanically coupled to the lower junction connector.
  15. 15. A connection assembly for modular construction, the assembly comprising: an upper junction connector coupled to the upper end of a column, the column having a column sidewall, the upper junction connector comprising: an upper end having first, second, third, and fourth edges, and a planar upper surface wherein a slot extends through the upper end adjacent to an interior surface of the column sidewall, and wherein a transverse bore extends through the column sidewall proximate to and aligned with the slot; and at least one lateral connector extending generally perpendicular to the column sidewall proximate the upper end of the column; and a powered actuator configured to drive a securement bolt through the transverse bore and through a corresponding transverse bore in a securement tab extending from a lower junction connector and through the slot.
  16. 16. The connection assembly of claim 15, wherein the actuator is at least one of a linear actuator and a rotary actuator. 56 9102985 Date Rec;ue/Date Received 2024-02-12

Description

WO 2021/163804 PCT /CA2021/050188 FIELD [0001] SYSTEMS AND METHODS FOR MODULAR CONSTRUCTION This disclosure relates generally to systems and methods for modular construction, and more specifically to systems and methods for creating hoistable, self- 5 bracing and non-self bracing structural modular units, for hoisting structural modular units, and for joining adjacent structural modular units to form buildings. INTRODUCTION [0002] Residential, commercial, and/or industrial buildings may be constructed using volumetric module frames made from metal (e.g. steel). Typically, module frames 1 0 incorporate interconnection details that enable the on-site assembly of modules that are pre-fabricated (e.g. in an off-site factory) to form some or all of the frame of a building. Typically, the module frames are designed to meet building construction regulations and standards, to be non-combustible and resistant to decay, to resist wind loads, seismic loads, occupant loads and the loads of building systems such as cladding, elevators, etc. 15 [0003] In some cases, volumetric module frames may be assembled on-site and then the resulting structure may be fitted out. In other cases, pre-fabricated volumetric module frames may be fitted with one or more of: an interior floor; one or more interior partitions; a ceiling; fire-proofing; insulation; mechanical, plumbing, communication, and/or electrical systems; and exterior cladding, prior to being assembled into a building 20 structure (e.g. off-site). [0004] It is known to use structural steel (such as "I" beams, channels, angles and square, rectangular hollow steel sections, and the like) as the main load-bearing elements of a volumetric module frame by joining appropriate members directly to each other and/or to pre-fabricated connections, using mechanical fasteners, welding or other suitable 25 methods). [0005] It is also known that roll-formed and/or brake-formed light steel sections can be used for vertical, diagonal, and horizontal load-bearing elements of a building. These elements can be joined to each other (e.g. in a factory or other off-site location) to form pre-fabricated panels. Such pre-fabricated panels may be shipped to the site and 30 assembled to form part of a building frame using threaded fasteners, rivets and the like, which may be driven through the light steel sections or through connections that are welded or otherwise fastened to the light steel sections. CA 03167181 2022-8-5 WO 2021/163804 PCT /CA2021/050188 [0006] It is also known that roll-formed and/or brake-formed light steel sections can be assembled in a factory setting to produce the frame of a hoistable module, which can be fit out in the factory and connected to other modules at a site to produce buildings of one or more stories. 5 SUMMARY [0007] The following introduction is provided to introduce the reader to the more detailed discussion to follow. The introduction is not intended to limit or define any claimed or as yet unclaimed invention. One or more inventions may reside in any combination or sub-combination of the elements or process steps disclosed in any part of this document 10 including its claims and figures. [0008] The systems and methods disclosed herein may facilitate providing a system of components for the fabrication of self-bracing or externally braced volumetric module frames using predominantly light-weight, brake-formed and/or roll-formed open steel sections, and may also facilitate connecting light steel joists and studs to brake 15 formed plate that results in a relatively strong moment connection (which may be referred to herein as a 'high fixity' connection). Such systems and methods may have one or more advantages. [0009] For example, using light steel framing may produce a structure that is lighter in weight and easier to join than a corresponding structure made with structural steel. 20 However, the inability of mechanical fasteners to handle large point loads, and/or the relative weakness of the members used in light steel framing can make it difficult to fasten the members to each other such that a moment or high-fixity connection is created. As a result, it is difficult to rig and hoist volumetric module frames made of such framing without damage due to excessive distortion or fastener shear, especially when hoisting is effected 25 through a connection to the top face of the module frame (e.g. without the use of supporting slings under the module). Typically, such slings interfere with efficient and rapid building assembly. CA 03167181 2022-8-5 [001 O] The systems and methods disclosed herein may also provide a more secure connection between volumetric module frames both vertically and horizontally. [0011] The systems and methods disclosed herein may also provide a more secure connection that can provide a distributed or 'flush' connection between vertically adjacent volumetric module frames when assembled, or that can alternatively provide a more WO 2021/1