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WO2024224161A1 - Connection system for modular construction of multi-storey buildings - Google Patents

Connection system for modular construction of multi-storey buildings Download PDF

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Publication number
WO2024224161A1
WO2024224161A1 PCT/IB2023/062698 IB2023062698W WO2024224161A1 WO 2024224161 A1 WO2024224161 A1 WO 2024224161A1 IB 2023062698 W IB2023062698 W IB 2023062698W WO 2024224161 A1 WO2024224161 A1 WO 2024224161A1
Authority
WO
WIPO (PCT)
Prior art keywords
connection system
plate
previous
end plate
wedge
Prior art date
Application number
PCT/IB2023/062698
Other languages
French (fr)
Inventor
Luís Alberto PROENÇA SIMÕES DA SILVA
David GOMES ANDRADE
Sree SABARI SHUNMUGAM
Jorge CONDE CONDE
Filip LJUBINKOVIĆ
Ana Francisca HENRIQUES PARENTE DOS SANTOS
Original Assignee
Universidade De Coimbra
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Universidade De Coimbra filed Critical Universidade De Coimbra
Publication of WO2024224161A1 publication Critical patent/WO2024224161A1/en

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Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/348Structures composed of units comprising at least considerable parts of two sides of a room, e.g. box-like or cell-like units closed or in skeleton form
    • E04B1/34815Elements not integrated in a skeleton
    • E04B1/3483Elements not integrated in a skeleton the supporting structure consisting of metal

Definitions

  • the present invention relates to the field of fabricated building structure construction technology, and more particularly to a connection system for the modular construction of multi-storey buildings.
  • This invention is related to a connection system for the modular construction of multistorey buildings.
  • the invention provides a single connection system that allows for the coupling of pre-made 3D cuboid modules, enabling the efficient and cost-effective construction of multi-storey buildings.
  • the connection system is designed to withstand both vertical and horizontal loads, ensuring the structural integrity and stability of the building.
  • the connection system of the present invention also allows for remote inter-module connectivity, eliminating the need for direct access during construction, which is suitable for connecting eight modules at two-storey levels, significantly reducing construction time.
  • the system is easily disassembled, allowing for reconfiguration or disassembly of the building if needed.
  • Another advantage of the present invention is that it optimizes the usable space within the building. This is achieved through a unique design that maximises the connectivity of the modules while minimising the gaps between them.
  • This connection also provides exceptional levels of horizontal and vertical tolerance, seamlessly accommodating imperfections that may arise during fabrication and erection processes.
  • Modular construction is a contemporary approach to constructing structures by stacking prefabricated modules to build single or multi-storey buildings. Modular construction is becoming increasingly popular worldwide due to its advantages, such as reduced construction time, cost-effectiveness, reusability, waste reduction, and recyclability.
  • a module includes rectangular frames on the outer edge that connect to the walls and floors. The function of these frames is: to give the module its structural stability and to connect to the adjacent stacked modules.
  • the interconnection between the modules is a critical region since it determines the structural integrity and stability of the building.
  • modules are semi-finished at the factory, whereas the leftover processes, such as mechanical fastening, welding, grouting, installations of walls, floors, electrical and plumbing units, and finishing processes (e.g., painting and interior decorations), are completed at the building site, which involves high manpower and longer construction time.
  • finishing processes e.g., painting and interior decorations
  • the patent number CN106460384A refers to a connecting system suitable for modules that are semi-finished at the factory, consisting of a frame connecting box and steel rod anchors.
  • the system is only suitable for frame-level construction, which requires expensive logistics and a workforce during the on-site construction.
  • the presented invention allows for modules with walls, floors, and other associated units fully built at the factory level, significantly reducing the on-site construction cost.
  • the patent application CN115822094A refers to an invention for modular construction that includes a module frame and a connecting structure. This comprises a first mounting piece, a second mounting piece, an intermediate piece, and a structure that is resistant to shear forces.
  • the first mounting piece is designed for connecting to the first structure, the second mounting piece for connecting to the second structure, and the first mounting piece connects to the second through a connecting piece.
  • This design may introduce high-stress concentration at the shearing region since the grove size is more than 50 % of the frame depth.
  • the presented invention has limited and small groves that overcome the problems of the stress concentration present in the existing system.
  • the patent document KR20170086458A refers to an embodiment where a first unit module features a first connecting pillar. Additionally, a second unit module is included, housing a second connecting pillar. The assembly also incorporates a first installation tool designed to be inserted into the first installation hole located within the first connection pillar. Similarly, a second installation tool is provided, intended for placement into the second installation hole within the second connection pillar. Finally, the structure is completed with a connection module encompassing a first connection plate.
  • no solutions are presented for any possible adjustment for horizontal and vertical tolerances to accommodate imperfections that may arise during the fabrication and erection processes of the modular building components. The solution also requires external wires to ensure the rigidity of the 3D modular units, which may often be undesirable for aesthetic reasons.
  • connection plates externally to the 3D modules, whereby direct access to the connection sites is required, which is unsuitable for connecting eight modules at two-storey, with walls, floors, and other associated units fully built at the factory level.
  • the patent application CN206706737U refers to a vacuum preloading handle for soft soil foundation. It aims to provide a connector that ensures airtightness during vacuum preloading to consolidate the ground underwater.
  • the airtight type butting connector consists of two water-drawing pipelines to prevent osmosis membrane. It features an upper flange with two recessed rings and an embedded O-type sealing collar, fastened to a lower flange dish using a series of screw bolts and nuts. Additionally, both ends of the pipelines are equipped with quick pneumatic connectors for easy installation.
  • this invention is particularly suitable for sealing the hole that passes through when preventing osmosis membrane in a vacuum tube system, it does not apply to structural components, more precisely to connect 3D modules for multi-storey buildings.
  • the patent number JPH05202563A refers to an assembly method using a specially designed jointing metal fixture for panel structures, such as a foundation or a unit room.
  • the fixture denoted as jointing metal fixture
  • jointing metal fixture is securely affixed to the recessed end of a floor panel within a unit room, using fitting holes located on both the right and left sides.
  • a bolt extending from the wall panel is inserted and secured into the upper jointing hole of the fixture.
  • a bolt protruding from a foundation or another unit room that needs to be joined is inserted and fastened into the lower jointing hole of the same fixture.
  • the utility model CN206233372U refers to a prestressed connection and positioning device for steel modular construction so that the modular building can be fixed without the use of welding and bolts.
  • the system's main disadvantage is that no disassembly provision is provided.
  • application number CN115787834A designed an energy-dissipating and shockabsorbing structure for a modular self-resetting steel frame that enables the structure to deform and recover after an earthquake.
  • application number CN115748981A refers to a modular building, which is detachably arranged on the foundation of the building. Limit ropes are connected to the fastening elements to hold the modules at tension. Due to poor rigidity, the above two connecting systems are not suitable for high- rise buildings.
  • the patent document WO2022241263A2 refers to a locking system for building construction that includes a locking body and locking extension that engages with other locking assemblies on modular building units for secure attachment and stable connection between units.
  • the patent document WO2019057147A1 refers to a built-a- connection device and building module device to enable quick, precise stacking and connection of building modules.
  • the application number KR101278983B1 describes a modular unit and modular structure designed to simplify the assembly and disassembly of joint module structures to move and construct modules.
  • application number CN104328839A refers to a connecting structure for column-bearing integrated building modules that includes a steel tube internal butt connector and a shear-resistant connector with horizontal connecting steel plates and vertical pull rods.
  • application number WO2015164975A1 refers to a connector system with an upper connector coupled to a lower connector and a gusset plate sandwiched between them.
  • the above- mentioned applications require direct access to the connection sites.
  • the current invention is meant to develop an inter-modular connector (IMC) to seamlessly integrate the readymade modules that are entirely fabricated in the factory and can be instantly installed at the building site.
  • IMC inter-modular connector
  • connection system of the invention is designed to be easily demountable, allowing for the disassembly and reconfiguration of modules as needed. This makes it highly flexible and adaptable to changing requirements, such as modifications to building layouts or relocation of modules. It also facilitates future expansion or reconfiguration of the building without significant disruption or damage to the modules or the connection system.
  • connection system is designed to minimize non-usable space between modules, resulting in efficient use of available floor area and aligning with the advantages of modular construction, which include faster construction timelines, reduced labor costs, improved quality control, and reduced waste generation.
  • the developed system also admits high levels of horizontal and vertical tolerance, seamlessly accommodating imperfections that may arise during both fabrication and erection processes, among others.
  • Figure 1 shows the inner connection for modular construction: in figure la, a global view of the connected modules; in figure lb, a exploded view of the connection.
  • Figure 2 shows the column geometry
  • Figure 3 shows the end plate: in figure 3a, the end plate insertion on the column; in figure 3b, the endplate geometry.
  • Figure 4 shows the guide plate: in figure 4a, the end guide insertion on the column; in figure 4b, the guide plate geometry.
  • Figure 5 shows the connecting plate: in figure 5a, four-column connecting plate geometry; in figure 5b, detail of assemblage to modules for the four-column embodiment; in figure 5c, one-column connecting plate embodiment; in figure 5d, two- column connecting plate embodiment; in figure 5e three-column connecting plate embodiment.
  • Figure 6 shows the wedge: in figure 6a, wedge mechanism filling the horizontal gap between the joining bloc and the 3D module column; in figure 6b, wedge geometry.
  • Figure 7 shows the placement of the top 3D modules with the wedge.
  • Figure 8 shows an embodiment for the horizontal movement lock between the bottom 3D module column and the connecting plate using the blocker part: in figure 8a, connecting plate with through-thickness holes; in figure 8b, blocker part geometry with a thinner parallelepiped part and a thicker parallelepiped part; in figure 8c, assembly.
  • Figure 9 shows the levelling sheets geometry.
  • Figure 10 shows the fastener: in figure 10a, detail of fastener parts; in figure 10b, installation of fasteners in the unlocked position; in figure 10c, fasteners in the locked position.
  • Figure 11 shows the assembling process: figure Ila shows the placement of intermediate four modules onto level n-1; figure 11b shows the connecting intermediate modules with the bottom modules using fasteners passing end plate slotted holes and guide plate slotted hole; figure 11c shows the inserting connecting plate; figure lid shows the vertical stacking of top modules onto the intermediate modules at level n; figure lie shows the protrusions of the connecting plate entering the bottom part of the columns; figure Ilf shows the connecting top modules with the intermediate modules using fasteners passing through holes.
  • Figure 12 shows the guiding system: in figure 12a, vertical guiding part geometry; in figure 12b transition guiding part geometry; in figure 12c, assembly of the guiding system inside the columns.
  • rectangular shape is meant is a rectangle closed 2D shape, having 4 sides, 4 corners, and 4 substantially right angles (90°). The opposite sides of a rectangle are substantially equal and parallel. Length is the longer side of the rectangle and width is the shorter side.
  • connection system for the modular construction of multi-storey buildings of the invention solves this problem since it allows connecting the fourth module without direct access.
  • This unique solution has several advantages, such as vertical and horizontal load transfer, no need for direct access, ease of assembly, and the possibility of being disassembled.
  • 3D cuboid module refers to a hexahedral modular unit formed by four vertical columns (C) on the four vertical edges (referred to as “3D module column”), four horizontal beams on the edges of the bottom level of the aforementioned columns (C), and four horizontal beams on the edges of the top level of the columns (C).
  • These 12 members constitute the edges of the hexahedral unit, and they are joined rigidly by conventional means namely, but not exclusively, weldment and bolting.
  • These basic units are intended to be stacked and joined to form larger sets. During the assembly process of these sets, the faces of each unit may be filled with constructive elements namely, but not exclusively, slabs, walls, and ceilings, thus limiting the access to the internal joints between units.
  • the module columns (C) are made of hollow section members. In the top and bottom parts of the element, column (C) has threaded holes (C.l) along its four surfaces.
  • the system of the invention solves this issue by providing vertical and horizontal connections between prefabricated modules that can be assembled and disassembled using only the top level.
  • the system can be adapted to any joint configuration and provides tensile resistance, which is essential for robustness.
  • FIG 1 A full view of the inner connection is shown in figure 1, featuring a global view of the joined modules in figure la and the exploded view of the connection in figure lb.
  • the present invention refers to a connection system for modular construction of multi-storey buildings comprising a 3D connector, consisting of the following main components: an end plate (1) and a guide plate (2) attached to a module column (C), a connecting plate (3), a wedge (4), levelling sheets (5), fasteners (6), a blocker part (7) and a guiding system (8).
  • the end plate (1) is a plate with chamfered corners, welded to the inner part of the substantially square hollow section columns (C) and placed at a slightly recessed position to the column top surface (figure 3a).
  • the end plate (1) has four end plate slotted holes (1.1), four end plate circular holes (1.2), and eight cuboid protrusions (1.3), as shown in figure 3b.
  • two end plate slotted holes (1.1) have their long side parallel to the main direction of the module; the other two end plate slotted holes (1.1) have their long side substantially perpendicular to the same direction. This hole orientation must be kept throughout the whole structure so that any two end plates (1) along the vertical of the same column (C) present perfectly aligned end plate slotted holes (1.1).
  • the guide plate (2) is a plate with chamfered corners, connected to the inner part of the hollow section of the column (C) and placed at a slightly recessed position to the column bottom surface (figure 4a).
  • the guide plate (2) has four guide plate slotted holes (2.1) and four guide plate circular holes (2.2).
  • the guide plate slotted holes (2.1) must be substantially vertically aligned with the end plate slotted holes (1.1) throughout the whole structure.
  • the connecting plate (3) is a symmetrical thick plate machined to present a thin central core (3.1), machined protrusions (3.2) on both sides, a horizontal flap (3.3) at mid-height, and a ladder wedge plate (3.4) on all top surfaces of the protrusions (figure 5a).
  • the connecting plate (3) can be adapted for the three-column (figure 5c), two-column (figure 5d), and one-column (figure 5e) cases very easily.
  • a wedge (4) part To lock the horizontal movement between the bottom 3D modules and the connecting plate (3), a wedge (4) part must be placed between the exterior wall of the connecting plate (3) and the interior wall of the column (C) (figure 6a), which will act as a shear key.
  • the wedge (4) is flat on one side with a grooved slot (4.1), while the opposite side has a ladder wedge (4.2) configuration (figure 6b).
  • the wedge (4) is pre-installed at the bottom part of the column (C) in the threaded holes (C.l) through a fixating bolt (4.3).
  • the fixating bolt (4.3) is designed to allow a free vertical movement of the wedge (4), along the grooved slot (4.1) length while, at the same time, no horizontal movement is allowed due to physical constrain of the grooved slot (4.1) that holds the bolt head.
  • the ladder wedge (4.2) is in contact with the ladder wedge plate (3.4) part of the connecting plate (3).
  • At the top part of the wedge (4) is a hole that accommodates a shaft (4.4) where comprising a compression spring (4.5) is installed. The compression spring (4.5) keeps the wedge (4) in position.
  • the shaft (4.4) is concentric with the end plate circular holes (1.2).
  • the same wedge (4) is used as a shear key, to transmit the horizontal loading between the top 3D modules with the connecting plate (3) (figure 7).
  • the shaft (4.4) is concentric with the guide plate circular holes (2.2).
  • the system of the present invention may lock the horizontal movement between the bottom 3D modules and the connecting plate (3) (figure 8).
  • the connecting plate (3) presents through-thickness holes (3.5) along the protrusion surfaces (figure 8a). In this embodiment, using the wedge (4) is unnecessary. Instead, a blocker part (7) is used (figure 8b).
  • the blocker part (7) comprising two merged parallelepipeds with different thicknesses, a thinner part (7.1) and a thicker part (7.2).
  • the blocker part (7) will pass through the through-thickness hole (3.5), while the thicker part (7.2) will be placed in contact with the top surface of column (C), and the thinner part will fill the horizontal gap between the connecting plate (3) and the column (C) (figure 8c).
  • the blocker part (7) has different thicknesses to accommodate a wide range of tolerances between the connecting plate (3) and the column (C).
  • Levelling between 3D modules at the same storey level is also possible through levelling sheets (5).
  • the levelling sheets (5) have a substantially square hollow shape that fits the surface of the connecting plate (3). Placing several levelling sheets (5) on top of each other allows the 3D modules to be levelled at the same storey level before stacking the 3D modules on the upper floor (figure 9).
  • Each fastener (6) (figure 10) is a long-threaded rod (6.5), slightly longer than the module height. On its top end, has a machined rod (6.1) with a rectangular shape (figure 10a). On the bottom end, the rod presents a spatula (6.2) head parallel to the rectangular shape of top end.
  • the 3D modules are interconnected using both an unlocked and a locked mechanism. When parallel to the hole elongation, the spatula (6.2) fits the end plate slotted holes (1.1) and to the guiding plate slotted holes (2.1), and the mechanism is unlocked (figure 10b), i.e., there is no vertical load transmission between two vertical adjacent 3D modules.
  • FIG. 10c When rotated 90°, it acts as a simple locking mechanism (figure 10c), i.e., there is vertical load transmission between two vertical adjacent 3D modules.
  • a conventional washer (6.3) and a tightening nut (6.4) are added (figure 10a).
  • the objective of the top machining is two-fold: on one hand, it serves to control the orientation of the spatula (6.2) head and thus allows control of the lock (that happens when the spatula (6.2) is perpendicular to the slot, i.e., when the rectangular shape is also perpendicular to the slot); on the other hand, using a special tightening key, the rectangular shape can be gripped from the top to ensure that the rod does not rotate when tightening the nut (6.4).
  • the cuboid protrusions (1.3) from the end plate (1) also prevent the rotation of the spatula (6.2) and, consequently, of the fastener (6) while tightening the nut (6.4). Furthermore, due to the long length of the fastener (6), any horizontal deviations between the upper and lower 3D module that may arise during construction have negligible impact on the fastener (6) distortion.
  • the connecting plate (3) is inserted into the top of the bottom columns (C), joining them together (figure 11c).
  • the modules corresponding to the next level are assembled one by one (figure lid), whereupon the machined protrusions (3.2) of the connecting plate (3) enter the bottom part of the columns (C) (figure lie).
  • the fasteners (6) are inserted from the top into the end plate slotted holes (1.1) and into the guide plate slotted holes (2.1).
  • the orientation of the rod spatula (6.2) is parallel to the long dimension of the end plate slotted holes (1.1) and the guide plate slotted holes (2.1).
  • the rectangular shape at the top is rotated by 90°, to ensure active locking of the bolt (the spatula (6.2) is then rotated 90° to the hole length) (figure Ilf).
  • the nut (6.4) By gripping the top part of the bolt, the nut (6.4) can be tightened or preloaded. Pre- loading ensures a certain level of friction between the bottom of the column (C) and the connecting plate (3), providing a more rigid connection.
  • the guiding system (8) comprises of two main parts, a vertical guiding part (8.1) and a transition guiding part (8.2).
  • the vertical guiding part (8.1) has a length substantially equal to the distance between the end plate (1) and the guide plate (2), being assembled between those parts.
  • the transition guiding part (8.2) has a substantially square hollow section, that along its length, is transitioned to an end plate slotted hole (1.1), thus facilitating the insertion of the fastener spatula (6.2) into the end plate slotted holes (1.1).
  • the end plate (1), the guide plate (2), the connecting plate (3), the wedge (4), the levelling sheets (5), the fasteners (6) and the blocker part (7) are made of steel.
  • connection system for the modular construction of multi-storey buildings is engineered to withstand vertical and horizontal loads, making it highly suitable for multi-storey buildings where structural integrity and stability are paramount. This ensures the building maintains its structural integrity even when subjected to varying loads, such as wind and seismic actions.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Joining Of Building Structures In Genera (AREA)

Abstract

The present invention refers to a connection system for the modular construction of multi-story steel buildings, that provides a single connection system that allows for the coupling of pre-made 3D cuboid modules, enabling efficient and cost-effective construction. The connection system is designed to withstand vertical and horizontal loads, ensuring the structural integrity and stability of the building, allowing for remote inter-module connectivity, optimising the usable space within the building, eliminating the need for direct access during construction, which is suitable for connecting eight modules at two storey levels. The system is easily disassembled, allowing for reconfiguration or disassembly of the building It also provides levels of horizontal and vertical tolerance, accommodating imperfections that may arise during fabrication and assembly processes. This is achieved through end plate (1), guide plates (2) plates (3) and wedges (4), connected to the columns.

Description

DESCRIPTION
CONNECTION SYSTEM FOR MODULAR CONSTRUCTION OF MULTI-STOREY BUILDINGS
Technical field
The present invention relates to the field of fabricated building structure construction technology, and more particularly to a connection system for the modular construction of multi-storey buildings.
Scope of invention
This invention is related to a connection system for the modular construction of multistorey buildings. The invention provides a single connection system that allows for the coupling of pre-made 3D cuboid modules, enabling the efficient and cost-effective construction of multi-storey buildings. In addition, the connection system is designed to withstand both vertical and horizontal loads, ensuring the structural integrity and stability of the building. The connection system of the present invention also allows for remote inter-module connectivity, eliminating the need for direct access during construction, which is suitable for connecting eight modules at two-storey levels, significantly reducing construction time. In addition, the system is easily disassembled, allowing for reconfiguration or disassembly of the building if needed. Another advantage of the present invention is that it optimizes the usable space within the building. This is achieved through a unique design that maximises the connectivity of the modules while minimising the gaps between them. This connection also provides exceptional levels of horizontal and vertical tolerance, seamlessly accommodating imperfections that may arise during fabrication and erection processes.
Background of invention
Modular construction is a contemporary approach to constructing structures by stacking prefabricated modules to build single or multi-storey buildings. Modular construction is becoming increasingly popular worldwide due to its advantages, such as reduced construction time, cost-effectiveness, reusability, waste reduction, and recyclability. Typically, a module includes rectangular frames on the outer edge that connect to the walls and floors. The function of these frames is: to give the module its structural stability and to connect to the adjacent stacked modules. In a multi-storey modular construction, the interconnection between the modules is a critical region since it determines the structural integrity and stability of the building.
Moreover, these regions are critical from a manufacturing and assembly point of view due to the poor accessibility and lack of design flexibility. Therefore, in most of the current modular construction solutions, the modules are semi-finished at the factory, whereas the leftover processes, such as mechanical fastening, welding, grouting, installations of walls, floors, electrical and plumbing units, and finishing processes (e.g., painting and interior decorations), are completed at the building site, which involves high manpower and longer construction time. The development of fully finished readymade modules is the best solution for all the challenges mentioned above. To achieve this, a functional interconnection system should be developed that supports and connect the readymade modules.
Conventional inter-module connections typically involve welded plates and bolts installed from the outside, often requiring adequate bolting or welding space. Perimeter connections can be easily made from the outside of the building, eliminating the need for additional working space or construction gaps.
The patent number CN106460384A, refers to a connecting system suitable for modules that are semi-finished at the factory, consisting of a frame connecting box and steel rod anchors. The system is only suitable for frame-level construction, which requires expensive logistics and a workforce during the on-site construction. Unlike this invention, the presented invention allows for modules with walls, floors, and other associated units fully built at the factory level, significantly reducing the on-site construction cost.
The patent application CN115822094A refers to an invention for modular construction that includes a module frame and a connecting structure. This comprises a first mounting piece, a second mounting piece, an intermediate piece, and a structure that is resistant to shear forces. The first mounting piece is designed for connecting to the first structure, the second mounting piece for connecting to the second structure, and the first mounting piece connects to the second through a connecting piece. This design may introduce high-stress concentration at the shearing region since the grove size is more than 50 % of the frame depth. The presented invention has limited and small groves that overcome the problems of the stress concentration present in the existing system.
The patent document KR20170086458A refers to an embodiment where a first unit module features a first connecting pillar. Additionally, a second unit module is included, housing a second connecting pillar. The assembly also incorporates a first installation tool designed to be inserted into the first installation hole located within the first connection pillar. Similarly, a second installation tool is provided, intended for placement into the second installation hole within the second connection pillar. Finally, the structure is completed with a connection module encompassing a first connection plate. However, in this invention, no solutions are presented for any possible adjustment for horizontal and vertical tolerances to accommodate imperfections that may arise during the fabrication and erection processes of the modular building components. The solution also requires external wires to ensure the rigidity of the 3D modular units, which may often be undesirable for aesthetic reasons. There is also the need to use connection plates externally to the 3D modules, whereby direct access to the connection sites is required, which is unsuitable for connecting eight modules at two-storey, with walls, floors, and other associated units fully built at the factory level.
The patent application CN206706737U refers to a vacuum preloading handle for soft soil foundation. It aims to provide a connector that ensures airtightness during vacuum preloading to consolidate the ground underwater. The airtight type butting connector consists of two water-drawing pipelines to prevent osmosis membrane. It features an upper flange with two recessed rings and an embedded O-type sealing collar, fastened to a lower flange dish using a series of screw bolts and nuts. Additionally, both ends of the pipelines are equipped with quick pneumatic connectors for easy installation. Although this invention is particularly suitable for sealing the hole that passes through when preventing osmosis membrane in a vacuum tube system, it does not apply to structural components, more precisely to connect 3D modules for multi-storey buildings.
The patent number JPH05202563A refers to an assembly method using a specially designed jointing metal fixture for panel structures, such as a foundation or a unit room. The fixture, denoted as jointing metal fixture, is securely affixed to the recessed end of a floor panel within a unit room, using fitting holes located on both the right and left sides. To accomplish the jointing process, a bolt extending from the wall panel is inserted and secured into the upper jointing hole of the fixture. Simultaneously, a bolt protruding from a foundation or another unit room that needs to be joined is inserted and fastened into the lower jointing hole of the same fixture. This innovative method streamlines the process of joining panel structures, although the invention mentioned above requires direct access to the connection sites, contrary to the current proposed solution.
The utility model CN206233372U refers to a prestressed connection and positioning device for steel modular construction so that the modular building can be fixed without the use of welding and bolts. The system's main disadvantage is that no disassembly provision is provided.
Moreover, application number CN115787834A designed an energy-dissipating and shockabsorbing structure for a modular self-resetting steel frame that enables the structure to deform and recover after an earthquake. Similarly, application number CN115748981A refers to a modular building, which is detachably arranged on the foundation of the building. Limit ropes are connected to the fastening elements to hold the modules at tension. Due to poor rigidity, the above two connecting systems are not suitable for high- rise buildings.
The patent document WO2022241263A2 refers to a locking system for building construction that includes a locking body and locking extension that engages with other locking assemblies on modular building units for secure attachment and stable connection between units. Furthermore, the patent document WO2019057147A1 refers to a built-a- connection device and building module device to enable quick, precise stacking and connection of building modules. The application number KR101278983B1 describes a modular unit and modular structure designed to simplify the assembly and disassembly of joint module structures to move and construct modules. Also, application number CN104328839A refers to a connecting structure for column-bearing integrated building modules that includes a steel tube internal butt connector and a shear-resistant connector with horizontal connecting steel plates and vertical pull rods. Finally, application number WO2015164975A1 refers to a connector system with an upper connector coupled to a lower connector and a gusset plate sandwiched between them. However, the above- mentioned applications require direct access to the connection sites.
The competitiveness of modular construction technology can be improved by applying the novel interconnection that provides the best-for-all solution. To address this, the current invention is meant to develop an inter-modular connector (IMC) to seamlessly integrate the readymade modules that are entirely fabricated in the factory and can be instantly installed at the building site.
Advantages of the invention
The connection system of the invention is designed to be easily demountable, allowing for the disassembly and reconfiguration of modules as needed. This makes it highly flexible and adaptable to changing requirements, such as modifications to building layouts or relocation of modules. It also facilitates future expansion or reconfiguration of the building without significant disruption or damage to the modules or the connection system.
Additionally, the connection system is designed to minimize non-usable space between modules, resulting in efficient use of available floor area and aligning with the advantages of modular construction, which include faster construction timelines, reduced labor costs, improved quality control, and reduced waste generation. The developed system also admits high levels of horizontal and vertical tolerance, seamlessly accommodating imperfections that may arise during both fabrication and erection processes, among others.
Brief description of the drawings
These and other features can be easily understood in the attached drawings, which should be considered mere examples and in no way restrict the scope of the invention. In the drawings, and for illustrative purposes, the measurements of some of the constituent parts may be exaggerated and not drawn to scale. The absolute dimensions and the relative dimensions do not correspond to the actual ratios for the invention.
In a preferred embodiment of the invention:
Figure 1 shows the inner connection for modular construction: in figure la, a global view of the connected modules; in figure lb, a exploded view of the connection.
Figure 2 shows the column geometry.
Figure 3 shows the end plate: in figure 3a, the end plate insertion on the column; in figure 3b, the endplate geometry.
Figure 4 shows the guide plate: in figure 4a, the end guide insertion on the column; in figure 4b, the guide plate geometry.
Figure 5 shows the connecting plate: in figure 5a, four-column connecting plate geometry; in figure 5b, detail of assemblage to modules for the four-column embodiment; in figure 5c, one-column connecting plate embodiment; in figure 5d, two- column connecting plate embodiment; in figure 5e three-column connecting plate embodiment.
Figure 6 shows the wedge: in figure 6a, wedge mechanism filling the horizontal gap between the joining bloc and the 3D module column; in figure 6b, wedge geometry.
Figure 7 shows the placement of the top 3D modules with the wedge.
Figure 8 shows an embodiment for the horizontal movement lock between the bottom 3D module column and the connecting plate using the blocker part: in figure 8a, connecting plate with through-thickness holes; in figure 8b, blocker part geometry with a thinner parallelepiped part and a thicker parallelepiped part; in figure 8c, assembly.
Figure 9 shows the levelling sheets geometry.
Figure 10 shows the fastener: in figure 10a, detail of fastener parts; in figure 10b, installation of fasteners in the unlocked position; in figure 10c, fasteners in the locked position.
Figure 11 shows the assembling process: figure Ila shows the placement of intermediate four modules onto level n-1; figure 11b shows the connecting intermediate modules with the bottom modules using fasteners passing end plate slotted holes and guide plate slotted hole; figure 11c shows the inserting connecting plate; figure lid shows the vertical stacking of top modules onto the intermediate modules at level n; figure lie shows the protrusions of the connecting plate entering the bottom part of the columns; figure Ilf shows the connecting top modules with the intermediate modules using fasteners passing through holes.
Figure 12 shows the guiding system: in figure 12a, vertical guiding part geometry; in figure 12b transition guiding part geometry; in figure 12c, assembly of the guiding system inside the columns.
In the drawings are marked the elements and components of the equipment of the present invention, as well as the elements and components necessary for the proper functioning of the invention:
1. end plate
1.1. end plate slotted holes
1.2. end plate circular holes
1.3. cuboid protrusions
2. guide plate
2.1. guide plate slotted holes 2.2. guide plate circular holes
3. connecting plate
3.1. central core
3.2. machined protrusion
3.3. horizontal flap
3.4. ladder wedge plate
3.5. through-thickness hole
4. wedge
4.1. grooved slot
4.2. ladder wedge
4.3. fixating bolt
4.4. shaft
4.5. spring
5. levelling sheets
6. fasteners
6.1. machined rod
6.2. spatula
6.3. washer
6.4. nut
6.5. threaded rod
7. blocker part
7.1. thinner part
7.2. thicker part
8. guiding system
8.1. vertical guiding part
8.2. transition guiding part
C. columns
C. l. threaded holes
Detailed Description
The term "substantially" is understood to mean that the description of the shape or position of an element of the present invention is not mathematically or geometrically exact, but that the shape or position of an element of the present invention is recognized by an expert in the field as having generically or approximately the described shape or position.
By "rectangular shape" is meant is a rectangle closed 2D shape, having 4 sides, 4 corners, and 4 substantially right angles (90°). The opposite sides of a rectangle are substantially equal and parallel. Length is the longer side of the rectangle and width is the shorter side.
As can be clear to a person skilled in the art, the application of the principles described herein is not limited to the embodiments shown. Possible changes that can occur in the present invention, defined in number, remain within the scope of the present invention.
Additionally, although some embodiments present multiple new features, and as can be seen throughout this document, all features can be independent, and not all have to be used in a single embodiment.
Additionally, the embodiments described herein are merely examples of the effect intended with the present invention, so other ways known from the state of the art to achieve the same technical effect are equally applicable to other embodiments.
Most modular constructions follow a basic layout in which the connections between modules are mainly concentrated along the perimeter. However, connecting the fourth module becomes a challenge without sufficient working space or a suitable opening. This problem is even more pronounced if the already-made 3D module has walls, floors, and ceilings, severely restricting the working space. To address this, the modular construction process requires improved on-site assembly methods.
The connection system for the modular construction of multi-storey buildings of the invention solves this problem since it allows connecting the fourth module without direct access. This unique solution has several advantages, such as vertical and horizontal load transfer, no need for direct access, ease of assembly, and the possibility of being disassembled.
In the following description, the wording "3D cuboid module" refers to a hexahedral modular unit formed by four vertical columns (C) on the four vertical edges (referred to as "3D module column"), four horizontal beams on the edges of the bottom level of the aforementioned columns (C), and four horizontal beams on the edges of the top level of the columns (C). These 12 members constitute the edges of the hexahedral unit, and they are joined rigidly by conventional means namely, but not exclusively, weldment and bolting. These basic units are intended to be stacked and joined to form larger sets. During the assembly process of these sets, the faces of each unit may be filled with constructive elements namely, but not exclusively, slabs, walls, and ceilings, thus limiting the access to the internal joints between units.
The module columns (C) are made of hollow section members. In the top and bottom parts of the element, column (C) has threaded holes (C.l) along its four surfaces.
When complete prefabricated modules with partitions, floors, and ceilings are stacked on top of each other, accessibility to the connection at the bottom level of the added modules is impossible. The system of the invention solves this issue by providing vertical and horizontal connections between prefabricated modules that can be assembled and disassembled using only the top level. The system can be adapted to any joint configuration and provides tensile resistance, which is essential for robustness.
A full view of the inner connection is shown in figure 1, featuring a global view of the joined modules in figure la and the exploded view of the connection in figure lb.
According to the drawings, the present invention refers to a connection system for modular construction of multi-storey buildings comprising a 3D connector, consisting of the following main components: an end plate (1) and a guide plate (2) attached to a module column (C), a connecting plate (3), a wedge (4), levelling sheets (5), fasteners (6), a blocker part (7) and a guiding system (8).
In an embodiment, the end plate (1) is a plate with chamfered corners, welded to the inner part of the substantially square hollow section columns (C) and placed at a slightly recessed position to the column top surface (figure 3a). In an embodiment, the end plate (1) has four end plate slotted holes (1.1), four end plate circular holes (1.2), and eight cuboid protrusions (1.3), as shown in figure 3b. In an embodiment, two end plate slotted holes (1.1) have their long side parallel to the main direction of the module; the other two end plate slotted holes (1.1) have their long side substantially perpendicular to the same direction. This hole orientation must be kept throughout the whole structure so that any two end plates (1) along the vertical of the same column (C) present perfectly aligned end plate slotted holes (1.1).
In an embodiment, the guide plate (2) is a plate with chamfered corners, connected to the inner part of the hollow section of the column (C) and placed at a slightly recessed position to the column bottom surface (figure 4a). The guide plate (2) has four guide plate slotted holes (2.1) and four guide plate circular holes (2.2). The guide plate slotted holes (2.1) must be substantially vertically aligned with the end plate slotted holes (1.1) throughout the whole structure. In an embodiment, the connecting plate (3) is a symmetrical thick plate machined to present a thin central core (3.1), machined protrusions (3.2) on both sides, a horizontal flap (3.3) at mid-height, and a ladder wedge plate (3.4) on all top surfaces of the protrusions (figure 5a). Large substantially square holes with rounded corners are machined on the connecting plate (3) through its whole thickness, substantially horizontally aligned with the centreline of every column (C) connected. Its size matches the envelope of the column hollow section(C). The machined protrusion (3.2) is inserted in the module columns (C) (Figure 5b). The external width of the machined protrusion (3.2) should be inferior to the width of the columns (C) hollow section, existing a horizontal gap between them, i.e., between the machined protrusion (3.2) and the columns (C). This gap allows for high tolerances during the assembling of the 3D modules, accommodating imperfections that may arise during the fabrication, and erection processes, among others. The thin part of the plate is continuous and allows for the horizontal connection of the four columns (C). The connecting plate (3) can be adapted for the three-column (figure 5c), two-column (figure 5d), and one-column (figure 5e) cases very easily.
To lock the horizontal movement between the bottom 3D modules and the connecting plate (3), a wedge (4) part must be placed between the exterior wall of the connecting plate (3) and the interior wall of the column (C) (figure 6a), which will act as a shear key. The wedge (4) is flat on one side with a grooved slot (4.1), while the opposite side has a ladder wedge (4.2) configuration (figure 6b). The wedge (4) is pre-installed at the bottom part of the column (C) in the threaded holes (C.l) through a fixating bolt (4.3). The fixating bolt (4.3) is designed to allow a free vertical movement of the wedge (4), along the grooved slot (4.1) length while, at the same time, no horizontal movement is allowed due to physical constrain of the grooved slot (4.1) that holds the bolt head. As the connecting plate (3) is being put in place, the wedge(4) will move vertically to fill the gap between the bottom part of column (C) with the connecting plate (3). The ladder wedge (4.2) is in contact with the ladder wedge plate (3.4) part of the connecting plate (3). At the top part of the wedge (4) is a hole that accommodates a shaft (4.4) where comprising a compression spring (4.5) is installed. The compression spring (4.5) keeps the wedge (4) in position. For the wedge (4) to move freely in the vertical direction, the shaft (4.4) is concentric with the end plate circular holes (1.2).
When the top 3D module is put in place, the same wedge (4) is used as a shear key, to transmit the horizontal loading between the top 3D modules with the connecting plate (3) (figure 7). In this embodiment, the shaft (4.4) is concentric with the guide plate circular holes (2.2). In another embodiment, the system of the present invention may lock the horizontal movement between the bottom 3D modules and the connecting plate (3) (figure 8). In this embodiment, the connecting plate (3) presents through-thickness holes (3.5) along the protrusion surfaces (figure 8a). In this embodiment, using the wedge (4) is unnecessary. Instead, a blocker part (7) is used (figure 8b). The blocker part (7) comprising two merged parallelepipeds with different thicknesses, a thinner part (7.1) and a thicker part (7.2). The blocker part (7) will pass through the through-thickness hole (3.5), while the thicker part (7.2) will be placed in contact with the top surface of column (C), and the thinner part will fill the horizontal gap between the connecting plate (3) and the column (C) (figure 8c). The blocker part (7) has different thicknesses to accommodate a wide range of tolerances between the connecting plate (3) and the column (C).
Levelling between 3D modules at the same storey level is also possible through levelling sheets (5). The levelling sheets (5) have a substantially square hollow shape that fits the surface of the connecting plate (3). Placing several levelling sheets (5) on top of each other allows the 3D modules to be levelled at the same storey level before stacking the 3D modules on the upper floor (figure 9).
Each fastener (6) (figure 10) is a long-threaded rod (6.5), slightly longer than the module height. On its top end, has a machined rod (6.1) with a rectangular shape (figure 10a). On the bottom end, the rod presents a spatula (6.2) head parallel to the rectangular shape of top end. The 3D modules are interconnected using both an unlocked and a locked mechanism. When parallel to the hole elongation, the spatula (6.2) fits the end plate slotted holes (1.1) and to the guiding plate slotted holes (2.1), and the mechanism is unlocked (figure 10b), i.e., there is no vertical load transmission between two vertical adjacent 3D modules. When rotated 90°, it acts as a simple locking mechanism (figure 10c), i.e., there is vertical load transmission between two vertical adjacent 3D modules. At the top part, a conventional washer (6.3) and a tightening nut (6.4) are added (figure 10a). The objective of the top machining is two-fold: on one hand, it serves to control the orientation of the spatula (6.2) head and thus allows control of the lock (that happens when the spatula (6.2) is perpendicular to the slot, i.e., when the rectangular shape is also perpendicular to the slot); on the other hand, using a special tightening key, the rectangular shape can be gripped from the top to ensure that the rod does not rotate when tightening the nut (6.4). The cuboid protrusions (1.3) from the end plate (1) also prevent the rotation of the spatula (6.2) and, consequently, of the fastener (6) while tightening the nut (6.4). Furthermore, due to the long length of the fastener (6), any horizontal deviations between the upper and lower 3D module that may arise during construction have negligible impact on the fastener (6) distortion.
In another embodiment, the connecting plate (3) is inserted into the top of the bottom columns (C), joining them together (figure 11c). The modules corresponding to the next level are assembled one by one (figure lid), whereupon the machined protrusions (3.2) of the connecting plate (3) enter the bottom part of the columns (C) (figure lie).
The fasteners (6) are inserted from the top into the end plate slotted holes (1.1) and into the guide plate slotted holes (2.1). The orientation of the rod spatula (6.2) is parallel to the long dimension of the end plate slotted holes (1.1) and the guide plate slotted holes (2.1). After inserting the fastener (6), the rectangular shape at the top is rotated by 90°, to ensure active locking of the bolt (the spatula (6.2) is then rotated 90° to the hole length) (figure Ilf).
By gripping the top part of the bolt, the nut (6.4) can be tightened or preloaded. Pre- loading ensures a certain level of friction between the bottom of the column (C) and the connecting plate (3), providing a more rigid connection.
To guide the fasteners (6) insertion in the end plate slotted hole (1.1), a pre-installed guiding system (8) may be placed inside the columns (C). According to figures 12a and 12b, the guiding system (8) comprises of two main parts, a vertical guiding part (8.1) and a transition guiding part (8.2). The vertical guiding part (8.1) has a length substantially equal to the distance between the end plate (1) and the guide plate (2), being assembled between those parts. On the other hand, the transition guiding part (8.2) has a substantially square hollow section, that along its length, is transitioned to an end plate slotted hole (1.1), thus facilitating the insertion of the fastener spatula (6.2) into the end plate slotted holes (1.1).
In a preferred embodiment, the end plate (1), the guide plate (2), the connecting plate (3), the wedge (4), the levelling sheets (5), the fasteners (6) and the blocker part (7) are made of steel.
The connection system for the modular construction of multi-storey buildings is engineered to withstand vertical and horizontal loads, making it highly suitable for multi-storey buildings where structural integrity and stability are paramount. This ensures the building maintains its structural integrity even when subjected to varying loads, such as wind and seismic actions.

Claims

1. Connection system for modular construction of multi-storey buildings comprising of:
- an end plate (1) in a recessed position on the inside of a hollow section of a module column (C), with end plate slotted holes (1.1), circular holes (1.2) and cuboid protrusions (1.3);
- a guide plate (2) in a recessed position on the inside of the hollow section of the columns (C) with guide plate slotted holes (2.1) and circular holes (2.2);
- a connecting plate (3) horizontally aligned with the centreline of every column (C) connected, comprising a central core (3.1), machined protrusions (3.2) on both sides, a horizontal flap (3.3) and a ladder wedge plate (3.4) on all the upper surfaces of the machined protrusions (3.2) and a through-thickness hole (3.5);
- fasteners (6) inserted in the end plate slotted holes (1.1) and guide plate slotted plates (2.1); and
- a guiding system (8) inside the module columns (C) to guide a fastener (6) insertion in the top in the end plate slotted holes (1.1).
2. Connection system according to the previous claim wherein it further comprises levelling sheets (5) having a square hollow shape that adapts to the surface of the connecting plate (3).
3. Connection system according to any of the previous claim wherein the end plate (1) is a plate with chamfered corners, welded to the inner part of the square hollow section columns (C).
4. Connection system according to any of the previous claims wherein the end plate (1) feature four end plate slotted holes (1.1), four circular holes (1.2) eight cuboid protrusions (1.3) and the guide plate (2) feature four guide plate slotted holes (2.1) and four circular holes (2.2).
5. Connection system according to any of the previous claims wherein the top and bottom of the hollow section members of module columns (C) has threaded holes (C.l) along its four surfaces.
6. Connection system according to any of the previous claims wherein comprising additionally a wedge (4) between the exterior wall of the connecting plate (3) and the interior wall of the column (C) with a flat face with grooved slot (4.1), while the opposite side has a ladder wedge (4.2) configuration in contact with the ladder wedge plate (3.4) of the connecting plate (3) and at the top of the wedge (4) has a hole that comprises a shaft (4.4) where comprising a compression spring (4.5).
7. Connection system according to the previous claim wherein the wedge (4) is at the bottom part of the column (C) in the threaded holes (C.l) through a fixating bolt (4.3).
8. Connection system according to claim 6 wherein the shaft (4.4) is concentric with the circular holes (1.2) of the end plate (1) or the shaft (4.4) is concentric with the circular holes (2.2) of the guide plate (2).
9. Connection system according to any of the previous claims wherein the connecting plate (3) is a symmetrical thick plate machined.
10. Connection system according to any of the previous claims wherein the machined protrusion (3.2) is inserted in module columns (C) and the external width of machined protrusion (3.2) is inferior to the external width of the columns (C) hollow section.
11. Connection system according to any of the previous claims wherein the fastener (6) is a long-threaded rod (6.5) longer than the module height and on its top end has a machined rod at top (6.1) with a rectangular shape, while the bottom end has a spatula (6.2) head parallel to the rectangular shape top end.
12. Connection system according to the previous claim wherein at the top part of the fasteners (6) additionally has a washer (6.3) and a tightening nut (6.4).
13. Connection system according to any of the previous claims wherein the 3D modules are interconnected using both an unlocked and a locked mechanism.
14. Connection system according to any of the previous claims wherein a blocker part
(7) comprising two merged parallelepipeds with different thicknesses and is through the connecting through-thickness hole (3.5) in the connecting plate (3).
15. Connection system according to any of the previous claims wherein the guiding system (8) comprising a vertical part guiding part (8.1) has a length equal to the distance between the end plate (1) and the guide plate (2), and the guiding system
(8) comprising additionally a transition guiding part (8.2) with a square hollow section, that along its length, is transitioned to an end plate slotted hole (1.1).
16. Connection system according to any of the previous claims wherein the end plate (1), the guide plate (2), the connecting plate (3), the wedge (4), the levelling sheets (5), the fasteners (6) and the blocker part (7) are made of steel.
PCT/IB2023/062698 2023-04-28 2023-12-14 Connection system for modular construction of multi-storey buildings WO2024224161A1 (en)

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