DEVICES, SYSTEMS, AND METHODS FOR SECURE ATTACHMENT AND ALIGNMENT OF MODULAR BUILDING UNITS

TECHNICAL FIELD

The present disclosure relates generally to attaching modular building units together. In particular, the present disclosure relates to devices, systems, and methods for secure attachment and alignment of modular building units.

BACKGROUND

In the field of modular construction, buildings are constructed from a plurality of prefabricated modular building units assembled together according to a plan of assembly for the final structure of the building. Such modular building units can include, for example, one or more rooms within the building. Such modular building units are pre-fabricated at a location (e.g., a factory) away from the site where the building (e.g., any suitable structure, including a temporary or permanent structure) is being constructed, are transported to the building site, and are assembled per the specifications of the building being constructed.

SUMMARY

Disclosed herein are devices, systems, and methods for aligning and securely attaching together adjacent modular building units of a building constructed from a plurality of such modular building units.

A system of brackets for secure attachment and alignment of modular construction units includes one or more lock brackets on a first modular building unit. Each of the one or more lock brackets includes a lock bracket base plate, a lock bracket protrusion extending from the lock bracket base plate, wherein the lock bracket protrusion includes a locking tab having a locking tab profile including an aligning portion and a locking portion, and one or more receiver brackets on a second modular building unit. Each the one or more receiver brackets includes a receiver bracket base plate and an alignment hole extending through the receiver bracket base plate, wherein the lock bracket protrusion is inserted into the alignment hole as the second modular building unit is lowered onto the first modular building unit, and the one or more receiver brackets slide vertically and laterally along the aligning portion and the locking portion of the locking tab profile as the lock bracket protrusion is inserted into the alignment hole, and the locking portion prevents vertical movement of the second modular building unit without a corresponding lateral movement.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be apparent from the following, more particular, description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

FIG. 1 is an isometric view of an example embodiment of a self-aligning and locking system of brackets for use in securing together modular building units assembled adjacent to each other during construction of a building comprising such modular building units.

FIG. 2 is an exploded view of a lock bracket of the system of brackets shown in FIG. 1.

FIG. 3 is a perspective view of the system of brackets shown in FIG. 1.

FIG. 4 is a rear isometric view of the lock bracket of the system of brackets shown in FIG. 1.

FIG. 5 is an isolated front view of the system of brackets in an installed position.

FIG. 6 is a side view of the system of brackets being used to align vertically adjacent modular building units and to positionally lock laterally adjacent modular building units together.

FIG. 7 is a side perspective view of the arrangement shown in FIG. 6.

FIG. 8 is a front plan view showing the system of brackets of FIG. 1 being used to align and to secure together a plurality of modular building units during construction of a building.

FIGS. 9 and 10 are respective enlarged front plan views of the plurality of modular buildings shown in FIG. 8, showing engagement of the system of brackets to laterally abut the modular building unit being installed against a previously positioned laterally adjacent modular building unit to resist removal of the previously positioned laterally adjacent modular building unit.

FIG. 11A is a perspective view of a receiver bracket of a system of brackets, according to another embodiment.

FIG. 11B is a top plan view of the receiver bracket of FIG. 11A, according to the present disclosure.

FIG. 11C is a side view of the receiver bracket of FIG. 11A, according to the present disclosure.

FIG. 11D is a front view of the receiver bracket of FIG. 11A, according to the present disclosure.

FIG. 12A is a perspective view of a lock bracket of the system of brackets of FIG. 11A, according to another embodiment.

FIG. 12B is a top plan view of the lock bracket of FIG. 12A, according to the present disclosure.

FIG. 12C is a front view of the lock bracket of FIG. 12A, according to the present disclosure.

FIG. 12D is a side view of the lock bracket of FIG. 12A, according to the present disclosure.

FIG. 13 is a perspective view of a lock bracket mounting plate of the lock bracket of FIG. 12A, according to the present disclosure.

FIG. 14 is a perspective view of a lock bracket base plate of the lock bracket of FIG. 12A, according to the present disclosure.

FIG. 15 is a perspective view of a locking tab of the lock bracket of FIG. 12A, according to the present disclosure.

FIG. 16 is a perspective view of a lock bracket aligning tab and a lock bracket reinforcing tab of the lock bracket of FIG. 12A, according to the present disclosure.

FIG. 17A is a perspective view of a lock bracket of a system of brackets, according to another embodiment.

FIG. 17B is a top plan view of the lock bracket of FIG. 17A, according to the present disclosure.

FIG. 17C is a front view of the lock bracket of FIG. 17A, according to the present disclosure.

FIG. 17D is a side view of the lock bracket of FIG. 17A, according to the present disclosure.

FIG. 18 is a perspective view of a locking tab of the lock bracket of FIG. 17A, according to the present disclosure.

FIG. 19 is a perspective view of a lock bracket aligning tab and a lock bracket reinforcing tab of the lock bracket of FIG. 17A, according to the present disclosure.

FIG. 20A is a perspective view of a lock bracket of a system of brackets, according to another embodiment.

FIG. 20B is a top plan view of the lock bracket of FIG. 20A, according to the present disclosure.

FIG. 20C is a front view of the lock bracket of FIG. 20A, according to the present disclosure.

FIG. 20D is a side view of the lock bracket of FIG. 20A, according to the present disclosure.

FIG. 21 is a flow diagram of a method of secure attachment and alignment of modular building units, according to the present disclosure.

FIG. 22 is a flow diagram of a method of using a system of brackets for aligning and interlocking together a plurality of modular building units to form a modular structure, according to the present disclosure.

DETAILED DESCRIPTION

Various embodiments are discussed in detail below. While specific embodiments are discussed, this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the present disclosure.

As used herein, the terms “first,” “second,”, “third,” “fourth,” etc., may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components.

The terms “coupled,” “fixed,” “attached,” “connected,” and the like, refer to both direct coupling, fixing, attaching, or connecting as well as indirect coupling, fixing, attaching, or connecting through one or more intermediate components or features, unless otherwise specified herein.

The singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.

Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” “approximately,” “generally,” and “substantially” is not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value, or the precision of the methods or the machines for constructing the components or the systems or manufacturing the components or the systems. For example, the approximating language may refer to being within a one, a two, a four, a ten, a fifteen, or a twenty percent margin in either individual values, range(s) of values or endpoints defining range(s) of values.

As mentioned above, modular building units, also referred to as modular construction units, are assembled together to form a building. In order to ensure that the modular building units are sufficiently rigidly attached to each other when construction of the building is completed, it is necessary to interlock the modular building units with each other. Additionally, when assembling adjacent modular building units together during construction of the building, it is necessary to align such adjacent modular building units with each other to within a prescribed degree, or tolerance, so that the shape and structural rigidity of the resulting building are achieved.

At present, aligning adjacent modular units with sufficient precision is a labor-intensive process and it is further necessary to apply a plurality of different types of fasteners to secure the adjacent modular units together during construction of the building. As such, a need exists for a sufficiently rigid connector that can ensure precise alignment of adjacent modular units while also holding the modular units together in a manner that resists loads that would cause the modular units to separate after assembly and also are able to allow for the precise alignment of a cladding over the exterior surface of the modular unit.

Accordingly, disclosed herein are devices and systems for use in laterally aligning and removably securing together modular building units being assembled together. The devices and systems disclosed herein include a plurality of brackets including a male bracket and a female bracket. The male bracket is attached to a top of a first modular building unit and the female bracket is attached to a bottom of a second modular building unit. As the second modular building unit is lowered onto the first modular building unit (e.g., by a crane) to stack the modular building units, the brackets guide, align, and secure the second modular building unit to the first modular building unit. The devices, systems, and methods herein thus provide for reducing an amount of time for stacking the modular building units, improving alignment of the modular building units, and adding a binding strength for the building, as compared to attachment devices and systems without the benefit of the present disclosure.

Referring now to the drawings, FIGS. 1 to 5 show aspects of an example embodiment of a system of brackets 100 that are self-aligning and engage together in an inclined direction (e.g., relative to a vertical direction, or a direction of a gravity vector), such that the direction of engagement of the brackets 100 has both a lateral vector component and a vertical vector component. Thus, disengagement of the system of brackets 100 requires movement opposite the inclined direction, such that disengagement also has both a lateral vector component and a vertical vector component and, as such, requires simultaneous vertical and lateral movement of the brackets 100 being disengaged from each other. The installation of a further modular building unit laterally adjacent to a previously installed modular building unit is thus, due to the inclined nature of the direction of engagement, directly adjacent to (e.g., in direct contact with) the previously installed modular building unit and physically blocks the lateral movement of the previously installed modular building unit that is necessary for disengagement of the system of brackets 100 between the previously installed modular building unit and a modular building unit installed directly underneath the previously installed modular building unit.

As shown in FIG. 1, the system of brackets 100 comprises a receiver bracket 102 and a lock bracket 120. At a minimum, the system of brackets 100 includes one receiver bracket 102 and one lock bracket 120. The quantity of receiver brackets 102 and the quantity of lock brackets 120 are the same. Thus, as shown in FIGS. 8 to 10, the system of brackets comprises a plurality of brackets 100, also referred to as bracket pairs, and each bracket pair comprises one receiver bracket 102 and one lock bracket 120. The receiver bracket 102 and the lock bracket 120 of the same bracket pair are formed to engage with each other in the vertical and lateral directions. Preferably, each modular building unit includes four brackets 100 (bracket pairs), as detailed further below.

The receiver bracket 102 comprises a base plate, also referred to as a receiver bracket base plate 104, which has an alignment hole 106 formed therein (e.g., through the entire thickness of the receiver bracket base plate 104) and a mounting plate, also referred to as a receiver bracket mounting plate 108, attached to the receiver bracket base plate 104. The alignment hole 106 has a central longitudinal axis 101 extending substantially through a center of the alignment hole 106. The receiver bracket mounting plate 108 is secured to a structure (e.g., a framing assembly or a framing element) of the modular building unit being positioned. In particular, the receiver bracket mounting plate 108 includes one or more mounting holes, also referred to as one or more receiver bracket mounting holes 110 formed through the entire thickness of the receiver bracket mounting plate 108. The receiver bracket mounting plate 108 is secured to the structure of the modular building unit by passing one or more fasteners 30 (FIG. 6) through the one or more receiver bracket mounting holes 110. Any suitable fastener 30 can be used to secure the receiver bracket mounting plate 108 to the structure, including, for example, nails, helically threaded screws or bolts, etc. In some embodiments, the receiver bracket mounting plate 108 is secured to the structure of the modular building unit by, for example, welding, adhesive, stamping, or any suitable joining and/or forming method. In some embodiments, the receiver bracket mounting plate 108 is formed with the modular building unit such that the modular building unit and the receiver bracket mounting plate 108 form a single, unitary component.

The receiver bracket mounting plate 108 and the receiver bracket base plate 104 are connected to each other at substantially a 90° angle (e.g., allowing for misalignments of about ±1°, about ±2°, or about ±5°, such as may be caused by manufacturing tolerances). The receiver bracket mounting plate 108 and the receiver bracket base plate 104 can be arranged, depending on the angle of the structure to which the receiver bracket mounting plate is to be installed, at any suitable acute or obtuse angle. The receiver bracket 102 has, in the example embodiment shown, a reinforcing tab, also referred to as a receiver bracket reinforcing tab 112, that extends between and is rigidly connected to the receiver bracket mounting plate 108 and the receiver bracket base plate 104 to resist deformation of the receiver bracket mounting plate 108 and the receiver bracket base plate 104 in the angular direction. The receiver bracket base plate 104, the receiver bracket mounting plate 108, and the receiver bracket reinforcing tab 112 are rigidly connected (e.g., via welding, adhesive, stamping, or any suitable joining and/or forming method) to each other. In some embodiments, the receiver bracket reinforcing tab 112 can be omitted.

The lock bracket 120 comprises a mounting plate, also referred to as a lock bracket mounting plate 130, and a base plate, also referred to as a lock bracket base plate 140, that are rigidly connected (e.g., via welding, adhesive, stamping, or any suitable joining and/or forming method) to each other. The lock bracket mounting plate 130 is secured to a structure (e.g., a framing assembly or a framing element) of a previously installed modular building unit that is positioned vertically below (e.g., directly vertically below) the position in which the modular building unit with the receiver bracket 102 is being installed. In particular, the lock bracket mounting plate 130 includes one or more mounting holes, also referred to as one or more lock bracket mounting holes 132 formed through an entire thickness of the lock bracket mounting plate 130. In FIGS. 1 to 5, the one or more lock bracket mounting holes 132 include four lock bracket mounting holes 132. The lock bracket mounting plate 130 is secured to the structure of the modular building unit by passing the one or more fasteners 30 (FIG. 6) through the one or more lock bracket mounting holes 132. Any suitable fastener 30 can be used to secure the lock bracket mounting plate 130 to the structure, including, for example, nails, helically threaded screws, or bolts, etc. In some embodiments, the lock bracket mounting plate 130 is secured to the structure of the modular building unit by, for example, welding, adhesive, stamping, or any suitable joining and/or forming method. In some embodiments, the lock bracket mounting plate 130 is formed with the modular building unit such that the modular building unit and the lock bracket mounting plate 130 form a single, unitary component.

The lock bracket mounting plate 130 and the lock bracket base plate 140 are connected to each other at substantially a 90° angle (e.g., allowing for misalignments of about ±1°, about ±2°, or about ±5°, such as may be caused by manufacturing tolerances). The lock bracket mounting plate 130 and the lock bracket base plate 140 can be arranged, depending on the angle of the structure to which the lock bracket mounting plate 130 is to be installed, at any suitable acute or obtuse angle.

The lock bracket 120 has a locking tab, also referred to as a locking tab 150, an aligning tab, also referred to as a lock bracket aligning tab 160, and a reinforcing tab, also referred to as a lock bracket reinforcing tab 170, that are rigidly assembled together, along with the lock bracket base plate 140 and the lock bracket mounting plate 130, to form the lock bracket 120. As shown in FIG. 2, the lock bracket aligning tab 160 and the lock bracket reinforcing tab 170 are made in a unitary, or monolithic, manner and are formed from a single piece. Each of the lock bracket base plate 140, the lock bracket mounting plate 130, the lock bracket aligning tab 160, the locking tab 150, and the lock bracket reinforcing tab 170 are formed using a laser-cutting technique, but can also be made using any suitable forming technique.

Each of the lock bracket base plate 140, the lock bracket mounting plate 130, the lock bracket aligning tab 160, the locking tab 150 have a respective assembly slot formed in a portion thereof. In particular, the lock bracket mounting plate 130 has a mounting plate assembly slot 134, the lock bracket base plate 140 has a base plate assembly slot 142, the lock bracket locking tab 150 has a locking tab assembly slot 152, and the lock bracket aligning tab 160 has an aligning tab assembly slot 162. The mounting plate assembly slot 134 extends along a longitudinal length of the lock bracket mounting plate 130. The base plate assembly slot 142 extends along a longitudinal length of the lock bracket base plate 140. The locking tab assembly slot 152 extends along a longitudinal length of the locking tab 150. The aligning tab assembly slot 162 extends along a longitudinal length of the lock bracket aligning tab 160.

The lock bracket reinforcing tab 170 has a reinforcing assembly tab 172 that is inserted and secured (e.g., using welding, adhesive, or any suitable joining technique) within the mounting plate assembly slot 134 of the lock bracket mounting plate 130. The lock bracket aligning tab 160 is slid (e.g., inserted) and secured (e.g., using welding, adhesive, or any suitable joining technique) within the base plate assembly slot 142 of the lock bracket base plate 140. The lock bracket base plate 140 and the lock bracket mounting plate 130 are advantageously rigidly connected together (e.g., using welding, adhesive, or any suitable joining technique). The aligning tab assembly slot 162 and the locking tab assembly slot 152 allow for a sliding engagement with each other, in a direction coaxial to a direction of extension of the aligning tab assembly slot 162 and the locking tab assembly slot 152. In particular, the locking tab 150 is slid in a vertical direction downwards and over the lock bracket aligning tab 160. The lock bracket aligning tab 160 and the locking tab 150 are secured together (e.g., using welding, adhesive, or any suitable joining technique). The locking tab 150 may also be secured (e.g., using welding, adhesive, or any suitable joining technique) to a top surface of the lock bracket base plate 140 for increased rigidity. Together, the locking tab 150 and the lock bracket aligning tab 160 define a lock bracket protrusion 161. When aligned, the longitudinal axis 101 of the alignment hole may also represent a central longitudinal axis of the lock bracket protrusion 161.

The lock bracket aligning tab 160 has an aligning profile 164 that is generally triangular in shape (e.g., having inclined opposing sides, such that the width of the lock bracket aligning tab 160 decreases as a function of distance from the lock bracket base plate 140). In particular, the lock bracket aligning tab 160 has a first aligning profile side 164a and a second aligning profile side 164b that define the aligning profile 164 of the lock bracket aligning tab 160. An aligning tab tip 165 of the triangular shape of the aligning profile 164 may be truncated to provide enhanced safety. The width of the aligning profile 164 is substantially the same as, or smaller than, the width of the alignment hole 106 in the receiver bracket base plate 104 of the receiver bracket 102 in the same plane of extension.

The locking tab 150 has a locking tab profile 154 that is a multi-part profile. The locking tab profile 154 is defined by lateral edges or lateral sides 151 of the locking tab 150. The lateral sides 151 of the locking tab 150 include a first lateral side 151a and a second lateral side 151b. The second lateral side 151b is spaced from the first lateral side 151a in a z-direction. A first part of the locking tab profile 154 of the locking tab 150, coincident with and extending vertically away from the top surface of the lock bracket base plate 140, to which the locking tab 150 is connected, is referred to as a locking portion 156 of the locking tab profile 154. A second part of the locking tab profile 154 of the locking tab 150 begins at the end of the locking portion 156 of the locking tab profile 154 and extends to a locking tab tip 155 (e.g., a distal end) of the locking tab 150 and is called an aligning portion 158 of the locking tab profile 154. The aligning portion 158 of the locking tab profile 154 of the locking tab 150 is shaped substantially identically to the aligning profile 164 of the lock bracket aligning tab 160. In particular, the locking tab 150 has a first locking portion 156a and a second locking portion 156b that define the locking portion 156 of the locking tab profile 154 of the locking tab 150. The locking portion 156 includes an angled shape that has various geometric regions or portions, as detailed further below. When assembled, the locking tab tip 155 and the aligning tab tip 165 are aligned to form a flat surface at a top end of the lock bracket protrusion 161.

The angled shape of the locking portion 156 of the locking tab profile 154 is advantageous because, instead of requiring an independent lateral movement of the modular building unit during installation thereof (e.g., by a user or an operator), the force of gravity causes the receiver bracket 102 to slide, at the edge of the alignment hole 106, along the locking portion 156 (e.g., along the first locking portion 156a) of the locking tab profile 154 to generate the lateral movement vector during engagement of the lock bracket 120 with the receiver bracket 102. In this way, the locking portion 156 helps to guide the receiver bracket 102 onto the lock bracket 120 as the modular building unit is lowered onto the previously installed modular building unit.

As shown in FIG. 3, the locking tab 150 has a substantially unitary or monolithic structure and is rigidly attached to the lock bracket base plate 140 of the lock bracket 120. The locking tab 150 disclosed herein has four (4) geometric regions or geometric portions. In particular, the locking tab 150 has a first geometric portion 180, a second geometric portion 182, a third geometric portion 184, and a fourth geometric portion 186. The geometric portions of the locking tab 150 define different widths of the locking tab 150 from the first lateral side 151a to the second lateral side 151b. The first geometric portion 180 of the locking tab 150 is closest to the lock bracket base plate 140, extends away (e.g., in a positive y-direction) from the lock bracket base plate 140, and has a generally rectangular shape. The lateral sides 151 of the first geometric portion 180 of the locking tab 150 extend in a substantially vertical direction (e.g., in the y-direction). The first geometric portion 180 has a substantially constant width (D1), that is defined as extending in the z-direction.

The second geometric portion 182 of the locking tab 150 begins where the lateral sides 151 of the first geometric portion 180 terminate and extends (e.g., in the positive y-direction) away from the first geometric portion 180. The second geometric portion 182 has a profile in the shape of a quadrilateral (e.g., the second geometric portion 182 has a quadrilateral shape), with the lateral sides 151 of the second geometric portion 182 being inclined at an angle relative to the y-direction. In the example embodiment disclosed herein, the lateral sides 151 (e.g., the first lateral side 151a and the second lateral side 151b) of the second geometric portion 182 are inclined at different angles relative to the y-direction and also to each other (i.e., are not parallel to each other). Thus, the first lateral side 151a is formed at an angle relative to the y-direction greater than the angle relative to the y-direction at which the second lateral side 151b is formed. Since the angle of inclination of the lateral sides 151 is different between the lateral sides 151 of the second geometric portion 182, the width of the second geometric portion 182 changes along the height (e.g., in the y-direction) of the locking tab 150.

The third geometric portion 184 of the locking tab 150 begins where the first lateral side 151a of the second geometric portion 182 terminates and extends (e.g., in the positive y-direction) away from the second geometric portion 182. The third geometric portion 184 has a profile in the shape of a quadrilateral (e.g., the third geometric portion 184 has a quadrilateral shape), with the one of the lateral edges or sides (e.g., the first lateral side 151a) of the third geometric portion 184 being oriented substantially vertically (e.g., extending only in the y-direction) and the other, opposing lateral edge or side (e.g., the second lateral side 151b) of the third geometric portion 184 being inclined at an angle relative to the y-direction. Thus, the lateral sides 151 of the third geometric portion 184 of the locking tab 150 are inclined relative to each other (e.g., the second lateral side 151b is inclined relative to the first lateral side 151a of the third geometric portion 184), so as to not be parallel to each other. In the example embodiment disclosed herein, the second lateral side 151b of the second geometric portion 182 and the second lateral side 151b of the third geometric portion 184 of the locking tab 150 are inclined at the same angle with respect to the y-direction, so as to be not only parallel with each other but also coaxial. Since one of the lateral edges or sides (e.g., the first lateral side 151a) is vertically oriented and the other lateral edge or side (e.g., the second lateral side 151b) is inclined at an angle relative to the y-direction, the width of the third geometric portion 184 changes along the height (e.g., in the y-direction) of the locking tab 150.

Thus, the third geometric portion 184 has, at an upper boundary thereof (e.g., where the third geometric portion 184 intersects with the fourth geometric portion 186), an engagement width (D1′). The engagement width (D1′) can be the same as, or different from, (e.g., larger than) the width (D1) of the first geometric portion 180 of the locking tab 150. The engagement width (D1′) can be substantially similar to (e.g., having at least 95% of the width of) a width (D2) of the alignment hole 106 of the receiver bracket 102. In some embodiments, the engagement width (D1′) is different from (e.g., larger or smaller than) the width (D2) of the alignment hole 106 of the receiver bracket 102. This arrangement, in which the width of the third geometric portion 184 decreases as a function of distance from the lock bracket base plate 140 is advantageous, in some instances where the width (D2) of the alignment hole 106 of the receiver bracket 102 is substantially similar to the engagement width (D1′), because it reduces mechanical binding between the edges or sides of the alignment hole 106 and the lateral sides 151 of the second geometric portion 182 and third geometric portion 184 of the locking tab 150.

In some embodiments, the second geometric portion 182 of the locking tab 150 can be shaped as a parallelogram, in which both of the lateral sides 151 of the second geometric portion 182 are inclined relative to the y-direction at the same angle, so as to be parallel with each other. In such an embodiment, the third geometric portion 184 of the locking portion 156 can be in the shape of a rectangle, in which the lateral sides 151 are vertically oriented (e.g., so as to extend only in the y-direction).

The fourth geometric portion 186 of the locking tab 150 begins where the respective lateral sides 151 of the third geometric portion 184 terminate and extends (e.g., in the positive y-direction) away from the third geometric portion 184. Thus, a base of the fourth geometric portion 186 of the locking tab 150 is coextensive with the engagement width (D1′) of the locking tab 150. The fourth geometric portion 186 has a profile in the shape of a trapezoid (e.g., the fourth geometric portion 186 has a trapezoidal shape), such that the opposing lateral sides 151 of the fourth geometric portion 186 are inclined towards each other (e.g., the first lateral side 151a and the second lateral side 151b of the fourth geometric portion 186 are inclined towards each other), such that the fourth geometric portion 186 has a generally tapered shape, with the width of the fourth geometric portion 186 decreasing as a function of distance away from the lock bracket base plate 140. At a distal end of the fourth geometric portion 186 (i.e., the end furthest from the lock bracket base plate 140), the width of the fourth geometric portion 186 is smaller than the engagement width (D1′) and, preferably, is reduced at least by half from the engagement width (D1′).

It is advantageous for the fourth geometric portion 186 of the locking tab 150 to have such a tapered shape because the tapered shape allows for greater misalignments between the receiver bracket 102 and the lock bracket 120 when the lock bracket protrusion 161 first passes through the alignment hole 106 of the receiver bracket 102. Then, after the distal end of the lock bracket protrusion 161 has passed through the alignment hole 106, if the receiver bracket 102 is misaligned (e.g., in the z-direction) relative to the lock bracket 120, as the lock bracket protrusion 161 is progressively inserted further through the alignment hole 106, the edges of the alignment hole 106 will contact and slide along one of the lateral sides 151 (e.g., the first lateral side 151a or the second lateral side 151b) of the fourth geometric portion 186 of the locking tab 150. This sliding movement has both vertical (e.g., in the y-direction) and lateral (e.g., in the z-direction) motion components, such that, when the edge of the alignment hole 106 is in contact with one of the lateral sides 151 of the fourth geometric portion 186 of the locking tab 150, the receiver bracket 102 moves laterally relative to the lock bracket 120 in the z-direction simultaneous with the progressive insertion of the lock bracket protrusion 161 through the alignment hole 106 in the y-direction. This lateral aligning movement of the receiver bracket 102 relative to the lock bracket 120 only occurs when the receiver bracket 102 is sufficiently misaligned (e.g., in the z-direction) relative to the lock bracket 120 so as to cause the edge of the alignment hole 106 to contact one of the lateral sides 151 of the fourth geometric portion 186 of the locking tab 150. Thus, the fourth geometric portion 186 can also be referred to herein as an alignment portion, also referred to as the aligning portion 158, and at least the second geometric portion 182 and the third geometric portion 184 can be referred to herein together as the locking portion 156. In some instances, the first geometric portion 180 can also be included, along with the second geometric portion 182 and the third geometric portion 184, as a part of the locking portion 156.

During engagement of the receiver bracket 102 and the lock bracket 120 with each other, the lock bracket protrusion 161 is inserted through the alignment hole 106 so far that the entirety of the fourth geometric portion 186 of the locking tab 150 passes into and through the alignment hole 106, at which point, due to the engagement width (D1′) being substantially similar to the width (D2) of the alignment hole 106, the receiver bracket 102 and the lock bracket 120 are in an intermediate aligned position, shown in FIG. 9. Then, as the lock bracket protrusion 161 is inserted further through the alignment hole 106, the third geometric portion 184 of the locking tab 150 passes into and through the alignment hole 106 until the lower edge of the alignment hole 106 contacts the first (left, in the views of FIGS. 5 and 9) inclined lateral side (e.g., the first lateral side 151a) of the second geometric portion 182 of the locking tab 150. The receiver bracket 102 then proceeds, as the lock bracket protrusion 161 is further inserted through the alignment hole 106, to slide along the first inclined lateral side (e.g., the first lateral side 151a) of the second geometric portion 182. Thus, as the edge of the alignment hole 106 slides along this first inclined lateral side (e.g., the first lateral side 151a) of the second geometric portion 182 of the locking tab 150, the receiver bracket 102 moves, relative to the lock bracket 120, at the same angle as the angle at which the first inclined lateral side (e.g., the first lateral side 151a) of the second geometric portion 182 is inclined. Stated somewhat differently, as the edge of the alignment hole 106 slides along this first inclined lateral side of the second geometric portion 182 of the locking tab 150, the receiver bracket 102 moves simultaneously vertically and laterally relative to the lock bracket 120. This inclined, sliding movement of the receiver bracket 102 along the first inclined lateral side of the second geometric portion 182 of the locking tab 150 continues until all of the second geometric portion 182 of the locking tab 150 has been inserted into and through the alignment hole 106.

After the entire second geometric portion 182 of the locking tab 150 is inserted into the alignment hole 106, at least a part of the first geometric portion 180 is inserted into the alignment hole 106. The amount of the first geometric portion 180 that is inserted into the alignment hole 106 depends on the particular application. Once the entire second geometric portion 182 of the locking tab 150 has been inserted into the alignment hole 106, the movement of the receiver bracket 102 relative to the lock bracket 120 is substantially vertical (e.g., in the y-direction). The fully installed position of the receiver bracket 102 relative to the lock bracket 120 can have any part (e.g., including all) of the first geometric portion 180 of the locking tab 150 inserted into the alignment hole 106. In some embodiments, such as is shown in FIG. 5, in the fully installed position, there is a first gap 190 between the receiver bracket base plate 104 of the receiver bracket 102 and the lock bracket base plate 140 of the lock bracket 120. This is advantageous in instances where, for example, a vibration damping material is to be provided between the receiver bracket base plate 104 and the lock bracket base plate 140 and/or between the modular building units being assembled together. An example of such a damping material (e.g., in the form of a damping layer) between the receiver bracket base plate 104 and the lock bracket base plate 140 and also between vertically adjacent modular building units, is shown in FIGS. 6 and 7.

As shown in FIGS. 6 and 7, a modular structure 10 includes a plurality of modular building units 12 including a first modular building unit 12a and a second modular building unit 12b. Each of the plurality of modular building units 12 includes a framing assembly 14 that provides a frame of each of the plurality of modular building units 12. In particular, each of the plurality of modular building units 12 includes a ceiling framing assembly 14a and a floor framing assembly 14b. In FIGS. 6 and 7, only the ceiling framing assembly 14a of the first modular building unit 12a and the floor framing assembly 14b of the second modular building unit 12b are shown. Each of the plurality of modular building units 12 also includes a framing cavity 16 defined between the framing assembly 14. In particular, the ceiling framing assembly 14a defines a ceiling framing cavity 16a between adjacent ceiling framing assemblies 14a. The floor framing assembly 14b defines a floor framing cavity 16b between adjacent floor framing assemblies 14b.

The system of brackets 100 is coupled within the framing cavity 16 of the modular building units 12. In particular, the lock bracket 120 is coupled within the ceiling framing cavity 16a of the first modular building unit 12a and the receiver bracket 102 is coupled within the floor framing cavity 16b of the second modular building unit 12b. For example, the lock bracket 120 is coupled to the ceiling framing assembly 14a by the fasteners 30, and the receiver bracket 102 is coupled to the floor framing assembly 14b by the fasteners 30, as discussed above. The second modular building unit 12b is being installed onto the first modular building unit 12a, such that the first modular building unit 12a is referred to as the previously installed modular building unit.

A damping layer 20 may be positioned adjacent to a cover layer 22. Both the damping layer 20 and the cover layer 22 are positioned between the receiver bracket base plate 104 and the lock bracket base plate 140 and also between vertically adjacent modular building units 12 (e.g., between the first modular building unit 12a and the second modular building unit 12b). In some embodiments, such as is shown in FIG. 10, there is no, or a negligible, gap between the receiver bracket base plate 104 and the lock bracket base plate 140 and/or between the modular building units 12 being assembled together.

It is noted herein that, while various references are made herein regarding relative movement between the lock bracket 120 and the receiver bracket 102, for example, or the lock bracket protrusion 161 and the alignment hole 106, for another example, the description of a first structure (e.g., the second modular building unit 12b) moving relative to a second structure (e.g., the first modular building unit 12a) is non-limiting and embodiments in which the second structure (e.g., the first modular building unit 12a) moves relative to the first structure (e.g., the second modular building unit 12b) are encompassed fully in this application. Furthermore, embodiments in which the first and second structures are both moving are also encompassed fully in this application.

Separation of the receiver bracket 102 from the lock bracket 120 is the opposite of installation. Thus, from the fully installed position, the receiver bracket 102 moves in the vertical direction (i.e., in the y-direction) relative to the lock bracket 120 until the upper lateral edge of the alignment hole 106 contacts the second inclined lateral side (e.g., the second lateral side 151b) of the second geometric portion 182 of the locking tab 150, at which point the upper lateral edge of the alignment hole 106 begins to slide along this second inclined lateral side (e.g., the second lateral side 151b) of the second geometric portion 182 of the locking tab 150. Thus, as the upper lateral edge of the alignment hole 106 slides along the second inclined lateral side (e.g., the second lateral side 151b) of the second geometric portion 182 of the locking tab 150, the receiver bracket 102 (and the modular building unit to which it is attached) must move both vertically (e.g., in the y-direction) and laterally (e.g., in the z-direction) as the receiver bracket 102 moves away from the lock bracket 120 (and the modular building unit to which it is attached). Thus, vertically adjacent modular units cannot be separated vertically from each other without also being moved laterally.

As can be seen in FIG. 10, however, the second modular building unit 12b is positioned laterally adjacent to a third modular building unit 12c. As described herein, in order for the third modular building unit 12c (and the receiver bracket 102 rigidly attached thereto) to be disengaged (e.g., vertically separated) from a fourth modular building unit 12d (and the lock bracket 120 rigidly attached thereto), the third modular building unit 12c must move, as the upper edge of the alignment hole 106 slides along the second inclined lateral side (e.g., the second lateral side 151b), in the positive z-direction, towards the second modular building unit 12b. However, as can readily be seen in FIG. 10, the position of the second modular building unit 12b blocks the third modular building unit 12c from undergoing any such lateral movement. Thus, the receiver bracket 102 and the lock bracket 120 are configured such that a laterally positioned modular building unit blocks removal of separation of the receiver bracket 102 from the lock bracket 120.

The lateral direction of the modular building unit that blocks such disengagement of the receiver bracket 102 and the lock bracket 120 is the same direction in the z-direction as the slope of the second inclined lateral side (e.g., the second lateral side 151b) of the second geometric portion 182 of the locking tab 150. Thus, in the example shown in FIG. 10, since the slope of the second inclined lateral side (e.g., the second lateral side 151b) of the second geometric portion 182 of the locking tab 150 is in the positive y-direction and the positive z-direction, positioning the second modular building unit 12b laterally against the third modular building unit 12c in the positive z-direction blocks disengagement of the receiver bracket 102 and the lock bracket 120 attached to the third modular building unit 12c and the fourth modular building unit 12d, respectively. However, in some embodiments, the slope of the second inclined lateral side (e.g., the second lateral side 151b) of the second geometric portion 182 of the locking tab 150 may be in the positive y-direction and the negative z-direction, in which case positioning the third modular building unit 12c laterally against the second modular building unit 12b in the negative z-direction blocks disengagement of the receiver bracket 102 and the lock bracket 120 attached to the first modular building unit 12a and the second modular building unit 12b, respectively. In short, a laterally adjacent modular building unit (e.g., the second modular building unit 12b) prevents any lateral movement of the third modular building unit 12c that would be necessary for the third modular building unit 12c to be vertically separated from the fourth modular building unit 12d during a disengagement of the receiver bracket 102 attached to the third modular building unit 12c from the lock bracket 120 attached to the fourth modular building unit 12d.

As shown in FIG. 3, a projection width (D3) of the lock bracket protrusion 161 is defined that is larger than the width (D2) of the alignment hole 106, which physically blocks disengagement of the receiver bracket 102 and the lock bracket 120 through only vertical movement therebetween.

The lock bracket 120 also comprises, arranged at an angle relative to the locking tab 150, the lock bracket aligning tab 160. In the example shown, the lock bracket aligning tab 160 is at a substantially perpendicular angle (e.g., allowing for misalignments that may occur during assembly of the lock bracket 120) to the locking tab 150. The lock bracket aligning tab 160 has a generally similar structure to the locking tab 150, but without the inclined edges or sides that prevent disengagement of the receiver bracket 102 and the lock bracket 120 from each other using only a vertical movement. As shown, a first aligning tab portion 163 of the lock bracket aligning tab 160 is closest to the lock bracket base plate 140, extends away (e.g., in the positive y-direction) from the lock bracket base plate 140, and has a generally rectangular shape. The lateral edges or lateral sides (e.g., spaced apart from each other in the z-direction) of the first aligning tab portion 163 of the lock bracket aligning tab 160 are extend in a substantially vertical direction (e.g., in the y-direction). The first aligning tab portion 163 has a substantially constant width, which is defined as extending in the z-direction.

At a distal end (e.g., the end furthest from the lock bracket base plate 140) of the first aligning tab portion 163, the lock bracket aligning tab 160 has a second aligning tab portion 167 that extends away from the first aligning tab portion 163, in the manner of an extension of the first aligning tab portion 163. The first aligning tab portion 163 and the second aligning tab portion 167 are advantageously formed as unitary, monolithic structures. The second aligning tab portion 167 of the lock bracket aligning tab 160 thus begins where the respective lateral sides of the first aligning tab portion 163 terminate and extends (e.g., in the positive y-direction) away from the first aligning tab portion 163. The second aligning tab portion 167 of the lock bracket aligning tab 160 has a profile in the shape of a trapezoid (e.g., the second aligning tab portion 167 has a trapezoidal shape), such that the opposing lateral edges or lateral sides of the second aligning tab portion 167 are inclined towards each other, such that the second aligning tab portion 167 has a generally tapered shape, with the width of the second aligning tab portion 167 decreasing as a function of distance away from the lock bracket base plate 140. At a distal end of the second aligning tab portion 167 (i.e., the end furthest from the lock bracket base plate 140), the width of the second aligning tab portion 167 is smaller than the width of the first aligning tab portion 163 and, preferably, is reduced at least by half from the width of the first aligning tab portion 163. In some embodiments, the distal end of the first aligning tab portion 163 may be at a same height (e.g., distance from the lock bracket base plate 140, as measured in the y-direction) as the distal end of the third geometric portion 184 of the locking tab 150.

It is advantageous for the second aligning tab portion 167 of the lock bracket aligning tab 160 to have such a tapered shape because the tapered shape allows for greater misalignments between the receiver bracket 102 and the lock bracket 120 when the lock bracket protrusion 161 first passes through the alignment hole 106 of the receiver bracket 102. Then, after the distal end of the lock bracket protrusion 161 has passed through the alignment hole 106, if the receiver bracket 102 is misaligned (e.g., in the x-direction) relative to the lock bracket 120, as the lock bracket protrusion 161 is progressively inserted further through the alignment hole 106, the edges of the alignment hole 106 will contact and slide along one of the lateral edges or lateral sides of the second aligning tab portion 167 of the lock bracket aligning tab 160. This sliding movement has both vertical (e.g., in the y-direction) and lateral (e.g., in the x-direction) motion components, such that, when the edge of the alignment hole 106 is in contact with one of the lateral sides of the second aligning tab portion 167 of the lock bracket aligning tab 160, the receiver bracket 102 moves laterally relative to the lock bracket 120 in the x-direction simultaneous with the progressive insertion of the lock bracket protrusion 161 through the alignment hole 106 in the y-direction. This lateral, aligning movement of the receiver bracket 102 relative to the lock bracket 120 only occurs when the receiver bracket 102 is sufficiently misaligned (e.g., in the x-direction) relative to the lock bracket 120 as to cause the edge of the alignment hole 106 to contact one of the lateral sides of the second aligning tab portion 167 of the lock bracket aligning tab 160. Thus, the second aligning tab portion 167 can also be referred to herein as an alignment portion.

During engagement of the receiver bracket 102 and the lock bracket 120 with each other, the lock bracket protrusion 161 is inserted through the alignment hole 106 so far that the entirety of the second aligning tab portion 167 of the lock bracket aligning tab 160 passes into and through the alignment hole 106, at which point the receiver bracket 102 and the lock bracket 120 are in the intermediate aligned position and there is a first gap 190 and a second gap 192 between the modular building units, shown in FIG. 9. The first gap 190 is in the vertical y-direction and the second gap 192 is in the horizontal x-direction. Then, as the lock bracket protrusion 161 is inserted further through the alignment hole 106, the first aligning tab portion 163 of the lock bracket aligning tab 160 passes into and through the alignment hole 106. The amount of the first aligning tab portion 163 of the lock bracket aligning tab 160 that is inserted into the alignment hole 106 depends based on the application. Thus, as the edge of the alignment hole 106 slides along this first inclined lateral side (e.g., the first lateral side 151a) of the second geometric portion 182 of the locking tab 150, the receiver bracket 102 moves, relative to the lock bracket 120, at the same angle as the angle at which the first inclined lateral side (e.g., the first lateral side 151a) is inclined. Stated somewhat differently, as the edge of the alignment hole 106 slides along this first inclined lateral side of the second geometric portion 182 of the locking tab 150, the receiver bracket 102 moves simultaneously vertically and laterally relative to the lock bracket 120. This inclined, sliding movement of the receiver bracket 102 along the first inclined lateral side of the second geometric portion 182 of the locking tab 150 continues until all of the second geometric portion 182 of the locking tab 150 has been inserted into the alignment hole 106.

The lock bracket aligning tab 160 and the locking tab 150 are substantially planar structures. The lock bracket aligning tab 160 is positioned in the X-Y plane and the locking tab 150 is positioned in the Y-Z plane when the lock bracket 120 is assembled together.

FIGS. 8 to 10 schematically show installation of the modular building units 12 using the system of brackets 100 including the receiver brackets 102 and the lock brackets 120 disclosed herein. Advantageously, there is one lock bracket 120 for each receiver bracket 102 and each lock bracket 120 is installed on one modular building unit 12 at a position so as to be coaxial with a corresponding receiver bracket 102 installed on another modular building unit 12, the two modular building units 12 being designated for being installed vertically adjacent to each other in a modularly-constructed structure (e.g., a modular building).

In a first step, a modular building unit 12 (e.g., the second modular building unit 12b) having at least one receiver bracket 102 is positioned vertically above an already-installed modular building unit 12 (e.g., the first modular building unit 12a) having at least one lock bracket 120. In a second step, the modular building unit 12 having the receiver bracket 102 is lowered vertically into the intermediate aligned position, shown in FIG. 9, in which the lock bracket protrusion 161 of the lock bracket 120 is inserted at least partially within and through the alignment hole 106 of the corresponding receiver bracket 102. From the intermediate aligned position, the modular building unit 12, as well as the receiver bracket 102 attached thereto, move in an inclined, or angled, direction, as indicated by the arrow D shown in FIG. 9 until in the fully installed position shown in FIG. 10.

In some embodiments, the lock bracket aligning tab 160 can be replaced with a second locking tab 150 that is substantially similar to or different from the locking tab 150 shown in the presently disclosed example embodiment, the second locking tab 150 and the locking tab 150 being arranged at an angle (e.g., perpendicular, as shown in the embodiment of FIGS. 1 to 10) relative to each other. In such an embodiment in which the lock bracket 120 comprises two locking tabs 150, the receiver bracket 102 (and the modular building unit 12 to which it is rigidly attached) cannot be separated or disengaged from the lock bracket 120 without undergoing (e.g., sequentially or simultaneously) lateral movements in the x-direction and the z-direction while the receiver bracket 102 moves away from the lock bracket 120 in the y-direction.

FIG. 11A is a perspective view of a receiver bracket 202 of a system of brackets 200, according to another embodiment. FIG. 11B is a top plan view of the receiver bracket 202 of FIG. 11A, according to the present disclosure. FIG. 11C is a side view of the receiver bracket 202 of FIG. 11A, according to the present disclosure. FIG. 11D is a front view of the receiver bracket 202 of FIG. 11A, according to the present disclosure. The system of brackets 200 is substantially similar to the system of brackets 100 of FIGS. 1 to 10. Similar reference numerals will be used for components of the system of brackets 200 that are the same as or similar to the components of the system of brackets 100, discussed above. The description of these components above also applies to this embodiment, and a detailed description of these components is omitted here.

With reference to FIGS. 11A to 11D, the system of brackets 200 includes a receiver bracket 202 having a receiver bracket base plate 204, an alignment hole 206, a receiver bracket mounting plate 208, one or more receiver bracket mounting holes 210, and a receiver bracket reinforcing tab 212. The receiver bracket 202 is substantially similar to the receiver bracket 102 of FIGS. 1 to 10. The one or more receiver bracket mounting holes 210, however, include three receiver bracket mounting holes 210. The three receiver bracket mounting holes 210 include two receiver bracket mounting holes 210 on a first longitudinal half of the receiver bracket mounting plate 208 and one receiver bracket mounting holes 210 on a second longitudinal half of the receiver bracket mounting plate 208. Although the receiver bracket mounting plate 208 is illustrated as having three receiver bracket mounting holes 210, more may be provided. For example, four receiver bracket mounting holes 210 may be provided. In such an example, the fourth receiver bracket mounting hole 210 may be located on the second longitudinal half aligned with the top bracket mounting hole 210 on the first longitudinal half (e.g., such that a line drawn through the receiver bracket mounting holes 210 forms a square).

FIG. 12A is a perspective view of a lock bracket 220 of the system of brackets 200, according to another embodiment. FIG. 12B is a top plan view of the lock bracket 220 of FIG. 12A, according to the present disclosure. FIG. 12C is a front view of the lock bracket 220 of FIG. 12A, according to the present disclosure. FIG. 12D is a side view of the lock bracket 220 of FIG. 12A, according to the present disclosure. FIG. 13 is a perspective view of a lock bracket mounting plate 230 of the lock bracket 220, according to the present disclosure. FIG. 14 is a perspective view of a lock bracket base plate 240 of the lock bracket 220, according to the present disclosure. FIG. 15 is a perspective view of a locking tab 250 of the lock bracket 220, according to the present disclosure. FIG. 16 is a perspective view of a lock bracket aligning tab 260 and a lock bracket reinforcing tab 270 of the lock bracket 220, according to the present disclosure. The lock bracket 220 is substantially similar to the lock bracket 120 of FIGS. 1 to 10. Similar reference numerals will be used for components of the lock bracket 220 that are the same as or similar to the components of the lock bracket 120, discussed above. The description of these components above also applies to this embodiment, and a detailed description of these components is omitted here.

With reference to FIGS. 12A to 16, the lock bracket 220 includes a lock bracket mounting plate 230, one or more lock bracket mounting holes 232, a lock bracket base plate 240, a locking tab 250, a lock bracket aligning tab 260, and a lock bracket reinforcing tab 270. The locking tab 250 and the lock bracket aligning tab 260 together define a lock bracket protrusion 261. The lock bracket mounting plate 230 is substantially similar to the lock bracket mounting plate 130 of FIGS. 1 to 10. The one or more lock bracket mounting holes 232, however, include three lock bracket mounting holes 232 (FIGS. 12C and 13). The three lock bracket mounting holes 232 include two lock bracket mounting holes 232 on a first longitudinal half of the lock bracket mounting plate 230 and one lock bracket mounting hole 232 on a second longitudinal half of the lock bracket mounting plate 230. The lock bracket mounting plate 230 also includes a mounting plate assembly slot 234. Although the lock bracket 220 is illustrated as having three lock bracket mounting holes 232, more may be provided. For example, four lock bracket mounting holes 232 may be provided. In such an example, the fourth lock bracket mounting holes 232 may be located on the second longitudinal half aligned with the lock bracket mounting holes 232 on the first longitudinal half (e.g., such that a line drawn through the lock bracket mounting holes 232 forms a square).

With reference to FIG. 14, the lock bracket base plate 240 includes a base plate assembly slot 242. With reference to FIG. 15, the locking tab 250 includes lateral sides 251, a locking tab assembly slot 252, and a locking tab profile 254 having a locking portion 256 and an aligning portion 258. The locking tab profile 254 is substantially similar to the locking tab profile 154 of the locking tab 150 of FIGS. 1 to 10. With reference to FIG. 16, the lock bracket aligning tab 260 includes an aligning tab assembly slot 262, an aligning profile 264 having a first aligning tab portion 263 and a second aligning tab portion 267, and an aligning tab tip 265. The aligning profile 264 is substantially similar to the aligning profile 164 of the lock bracket aligning tab 160 of FIGS. 1 to 10. The lock bracket reinforcing tab 270 has a lock bracket assembly tab 272. The lock bracket assembly tab 272 has an assembly tab notch 273. The tab notch 273 mates with the mounting plate assembly slot 234 (FIG. 13) to provide alignment between the lock bracket reinforcing tab 270 and the lock bracket mounting plate 230, which are required to be aligned with each other prior to welding. The tab notch 273 allows for alignment with the mounting plate assembly slot 234 without the need for measurement devices or tools.

FIG. 17A is a perspective view of a lock bracket 320 of a system of brackets 300, according to another embodiment. FIG. 17B is a top plan view of the lock bracket 320 of FIG. 17A, according to the present disclosure. FIG. 17C is a front view of the lock bracket 320 of FIG. 17A, according to the present disclosure. FIG. 17D is a side view of the lock bracket 320 of FIG. 17A, according to the present disclosure. FIG. 18 is a perspective view of a locking tab 350 of the lock bracket 320, according to the present disclosure. FIG. 19 is a perspective view of a lock bracket aligning tab 360 and a lock bracket reinforcing tab 370 of the lock bracket 320, according to the present disclosure. The system of brackets 300 is substantially similar to the system of brackets 100 of FIGS. 1 to 10. Similar reference numerals will be used for components of the system of brackets 300 that are the same as or similar to the components of the system of brackets 100, discussed above. The description of these components above also applies to this embodiment, and a detailed description of these components is omitted here.

With reference to FIGS. 17A to 19, the lock bracket 320 includes a lock bracket mounting plate 330, one or more lock bracket mounting holes 332 (three lock bracket mounting holes 332), a lock bracket base plate 340, a locking tab 350, a lock bracket aligning tab 360, and a lock bracket reinforcing tab 370. The locking tab 350 and the lock bracket aligning tab 360 together define a lock bracket protrusion 361.

With reference to FIG. 18, the locking tab 350 includes lateral sides 351, a locking tab assembly slot 352, and a locking tab profile 354 having a locking portion 356 and an aligning portion 358. The locking tab profile 354 is substantially similar to the locking tab profile 154 of the locking tab 150 of FIGS. 1 to 10. The locking tab 350 includes a locking tab tip 355 that is different than the locking tab tip 155 of FIGS. 1 to 10. In particular, the locking tab tip 355 includes corners that are fillets (e.g., the corners at the locking tab tip 355 are rounded). The fillets reduce the likelihood of the receiver bracket base plate 204 snagging or catching on the lock bracket 320. For example, the corners between the aligning portion 358 and the locking tab tip 355 are fillets. With reference to FIG. 19, the lock bracket aligning tab 360 includes an aligning tab assembly slot 362, an aligning profile 364 having a first aligning tab portion 363 and a second aligning tab portion 367, and an aligning tab tip 365. The aligning profile 364 is substantially similar to the aligning profile 164 of the lock bracket aligning tab 160 of FIGS. 1 to 10. The aligning tab tip 365 is different than the aligning tab tip 165 of FIGS. 1 to 10. In particular, the aligning tab tip 365 includes corners that are fillets (e.g., the corners at the aligning tab tip 365 are rounded). For example, the corners between the second aligning tab portion 367 and the aligning tab tip 365 are fillets. The lock bracket reinforcing tab 370 has a lock bracket assembly tab 372 having an assembly tab notch 373.

FIG. 20A is a perspective view of a lock bracket 420 of a system of brackets 400, according to another embodiment. FIG. 20B is a top plan view of the lock bracket 420 of FIG. 20A, according to the present disclosure. FIG. 20C is a front view of the lock bracket 420 of FIG. 20A, according to the present disclosure. FIG. 20D is a side view of the lock bracket 420 of FIG. 20A, according to the present disclosure. The system of brackets 400 is substantially similar to the system of brackets 100 of FIGS. 1 to 10 and the system of brackets 300 of FIGS. 17A to 19. Similar reference numerals will be used for components of the system of brackets 400 that are the same as or similar to the components of the system of brackets 100 and 300, discussed above. The description of these components above also applies to this embodiment, and a detailed description of these components is omitted here.

The lock bracket 420 includes a lock bracket mounting plate 430, one or more lock bracket mounting holes 432 (three lock bracket mounting holes 432), a lock bracket base plate 440, a locking tab 450, a lock bracket aligning tab 460, and a lock bracket reinforcing tab 470. The locking tab 450 and the lock bracket aligning tab 460 together define a lock bracket protrusion 461.

The locking tab 450 includes lateral sides 451 having a first lateral side 451a and a second lateral side 451b, a locking tab profile 454 having a locking portion 456 and an aligning portion 458, and a locking tab tip 455 (e.g., having fillets similar to the locking tab tip 355 of FIGS. 17A to 19). The aligning portion 458 is substantially similar to the aligning portion 158 of the locking tab 150 of FIGS. 1 to 10. The lock bracket aligning tab 460 includes an aligning profile 464 and an aligning tab tip 465 (e.g., having fillets). The aligning profile 464 is substantially similar to the aligning profile 164 of the lock bracket aligning tab 160 of FIGS. 1 to 10. The locking portion 456 of the locking tab profile 454 is different than the locking portion 156 of the locking tab 150 of FIGS. 1 to 10.

The first lateral side 451a and the second lateral side 451b are located on an opposite side as the first lateral side 151a and the second lateral side 151b of the locking tab 150 of FIGS. 1 to 10. In this way, the locking portion 456 is opposite the locking portion 156 such that the locking portion 456 is flipped or mirrored compared to the locking portion 156 of FIGS. 1 to 10. In this way, the first modular building unit 12a (FIGS. 6 to 9) can include the lock bracket 120 (a first lock bracket) of FIGS. 1 to 10 mounted on a first side of the first modular building unit 12a and the lock bracket 420 (a second locket bracket) on a second side of the first modular building unit 12a such that the locking portion 156 and the locking portion 456 are complimentary. In this way, the second modular building unit 12b (FIGS. 6 to 9) can move vertically and laterally (as discussed above) to align the receiver bracket 102 thereof onto the lock bracket 120 and the lock bracket 420 as the second modular building unit 12b is installed onto the first modular building unit 12a. Preferably, the first modular building unit 12a includes two lock brackets 120 on the first side and two lock brackets 420 on the second side, and the second modular building unit 12b includes four receiver brackets 102 (and/or receiver brackets 202) that align with the lock brackets 120 and the lock brackets 420, respectively.

FIG. 21 is a flow diagram of a method 2100 of secure attachment and alignment of modular building units 12, according to the present disclosure. While the method 2100 is described in relation to the system of brackets 100, the method 2100 is applicable to any of the system of brackets disclosed herein. The method 2200 can include any of the operations detailed herein. The modular building units 12 include a first modular building unit 12a and a second modular building unit 12b. The first modular building unit 12a includes one or more lock brackets 120, and the second modular building unit 12b includes one or more receiver brackets 102. The one or more lock brackets 120 include a lock bracket protrusion 161 having a locking tab profile 154, and the one or more receiver brackets 102 include an alignment hole 106.

In step 2105, the method 2100 includes aligning the one or more receiver brackets 102 with the one or more lock brackets 120.

In step 2110, the method 2100 includes lowing the second modular building unit 12b onto the first modular building unit 12a.

In step 2115, the method 2100 includes inserting the lock bracket protrusion 161 into the alignment hole 106 as the second modular building unit 12b is lowered onto the first modular building unit 12a.

In step 2120, the method 2100 includes sliding the one or more receiver brackets 102 vertically and laterally along the locking tab profile 154 as the lock bracket protrusion 161 is inserted into the alignment hole 106.

FIG. 22 is a flow diagram of a method 2200 of using a system of brackets 100 for aligning and interlocking together a plurality of modular building units 12 to form a modular structure 10, according to the present disclosure. While the method 2200 is described in relation to the system of brackets 100, the method 2200 is applicable to any of the system of brackets disclosed herein. The method 2200 can include any of the operations detailed herein.

The method 2200 includes providing a plurality of modular building units 12 comprising a first modular building unit, a second modular building unit, a third modular building unit, and a fourth modular building unit. In step 2205, the method 2200 includes providing the system of brackets 100. The system of brackets 100 includes a plurality of first brackets (e.g., the lock bracket 120). Each of the first brackets includes a mounting plate (e.g., the lock bracket mounting plate 130) configured for attachment to one of the first modular building unit and the second modular building unit, a base plate (e.g., the lock bracket base plate 140) that is connected to the mounting plate and is arranged transverse to the mounting plate, a first tab (e.g., the lock bracket aligning tab 160), and a second tab (e.g., the locking tab 150) that is transverse to the first tab, the second tab comprising a profile (e.g., the locking tab profile 154) that comprises an aligning portion 158 and a locking portion 156. The first tab and the second tab are interconnected with each other. The system of brackets 100 also includes a plurality of second brackets (e.g., the receiver bracket 102). Each of the second brackets includes a mounting plate (e.g., the receiver bracket mounting plate 108) configured for attachment to one of the third modular building unit and the fourth modular building unit, a base plate (e.g., the receiver bracket base plate 104) that is connected to the mounting plate of the second bracket, and an alignment hole 106 formed in the base plate.

In step 2210, the method 2200 includes attaching the plurality of first brackets to the first modular building unit and the second modular building unit. For example, the

In step 2215, the method 2200 includes attaching the plurality of second brackets to the third modular building unit and the fourth modular building unit.

In step 2220, the method 2200 includes arranging the first modular building unit and the second modular building unit laterally adjacent to each other.

In step 2225, the method 2200 includes stacking the third modular building unit on top of the first modular building unit by inserting the first tab and the second tab of each of the first brackets that are attached to the first modular building unit through the alignment hole of a corresponding one of the second brackets to align the first and third modular building units with each other in a first direction and a second direction, respectively.

In step 2230, the method 2200 includes stacking the fourth modular building unit on top of the second modular building unit by inserting the first tab and the second tab of each of the first brackets that are attached to the second modular building unit through the alignment hole of a corresponding one of the second brackets to align the second and fourth modular building units with each other in the first direction and the second direction, respectively.

The profile of the second tab of each of the first brackets is shaped such a vertical movement of the third modular building unit away from the first modular building unit is blocked unless the fourth modular building unit is moved vertically away from the second modular building unit, such that all of the first brackets of the second modular building unit are disengaged from all of the second brackets of the fourth modular building unit.

Each of the plurality of first brackets is attached to an upper edge of the first modular building unit or to an upper edge of the second modular building unit. Each of the plurality of second brackets is attached to a lower edge of the third modular building unit or to a lower edge of the fourth modular building unit. The upper edge of the first modular building unit is directly below the lower edge of the third modular building unit and/or the lower edge of the fourth modular unit. The upper edge of the second modular building unit is directly below the lower edge of the third modular building unit and/or the lower edge of the fourth modular building unit.

The first tab comprises a tapered shape extending away from the base plate, the tapered shape being widest at a junction with the base plate. The first tab and the second tab each protrude away from, and terminate at, a substantially similar distance away from the base plate.

The second tab is formed as a locking tab 150 and has an outer profile that is defined by opposing lateral edges (e.g., the lateral sides 151) thereof, the opposing lateral edges being spaced apart from each other in the second direction. The outer profile of the second tab comprises an alignment portion (e.g., the aligning portion 158) and a locking portion 156, the locking portion 156 being adjacent to the base plate and the alignment portion being spaced apart from the base plate by the locking portion 156. The opposing lateral edges of the second tab comprise, within the locking portion 156 and extending away from the base plate, a first segment (e.g., the first geometric portion 180) and a second segment (e.g., the second geometric portion 182). The first segment of each of the opposing lateral edges is substantially perpendicular to the mounting plate and the second segment of each of the opposing lateral edges is inclined at an angle greater than 0° with respect to the first segment on a same opposing lateral edge. The opposing lateral edges of the second tab, within the alignment portion (e.g., the aligning portion 158) and extending away from the locking portion 156, are inclined towards each other such that, within the alignment portion, the opposing lateral edges are inclined towards each other and the second tab has a tapered shape.

Each of the plurality of first brackets comprises a reinforcing tab (e.g., the lock bracket reinforcing tab 170) that extends between the mounting plate and the base plate thereof to provide support therebetween. Each of the plurality of second brackets comprises a reinforcing tab (e.g., the receiver bracket reinforcing tab 112) that extends between the mounting plate and the base plate thereof to provide support therebetween. The reinforcing tab of the each of the plurality of first brackets is formed as a unitary, or monolithic, structure with the first tab thereof, such that the reinforcing tab and the first tab of a same one of the plurality of first brackets are formed in a single piece.

The first bracket and the second brackets are rigidly and fixedly interconnected with each other, such as via a welding process. The first bracket and/or the second bracket have a unitary, or monolithic, construction.

Further aspects of the present disclosure are provided by the subject matter of the following clauses.

A system of brackets for simultaneously aligning and interlocking together a first structure and a second structure that are adjacent with each other to form an assembly, the system comprising a plurality of first brackets and a plurality of second brackets. Each of the first brackets comprises a mounting plate configured for attachment to the first structure, a base plate that is connected to the mounting plate and is arranged transverse to the mounting plate, a first tab, and a second tab that is transverse to the first tab. The second tab comprises a profile that comprises an alignment portion and a locking portion. The first and second tabs are interconnected with each other. Each of the second brackets comprises a mounting plate configured for attachment to the second structure, a base plate that is connected to the mounting plate of the second bracket, and an alignment hole formed in the base plate. Each first bracket of the plurality of first brackets is configured to receive and interlock with a corresponding second bracket of the plurality of second bracket. In aligning each of the first brackets with a corresponding one of the second brackets, the first tab is configured for insertion within the alignment hole of the corresponding second bracket to align the first and second structures with each other in a first direction, the second tab is configured for insertion within the hole of the corresponding second bracket to align the first and second structures with each other in a second direction, transverse to the first direction. The profile of the second tab of each of the first brackets is shaped such that the corresponding second bracket cannot be disengaged from the first bracket without the second structure and the second brackets attached thereto first moving in a direction of the longitudinal axis of the first bracket and also moving in the second direction.

A system of brackets for secure attachment and alignment of modular construction units includes one or more lock brackets on a first modular building unit. Each of the one or more lock brackets includes a lock bracket base plate and a lock bracket protrusion extending from the lock bracket base plate, wherein the lock bracket protrusion includes a locking tab having a locking tab profile including an aligning portion and a locking portion; and one or more receiver brackets on a second modular building unit. Each the one or more receiver brackets includes a receiver bracket base plate and an alignment hole extending through the receiver bracket base plate, wherein the lock bracket protrusion is inserted into the alignment hole as the second modular building unit is lowered onto the first modular building unit, and the one or more receiver brackets slide vertically and laterally along the aligning portion and the locking portion of the locking tab profile as the lock bracket protrusion is inserted into the alignment hole, and the locking portion prevents vertical movement of the second modular building unit without a corresponding lateral movement.

The system of any preceding clause, wherein the lock bracket protrusion further includes a lock bracket aligning tab having an aligning profile that is generally triangular.

The system of any preceding clause, wherein the lock bracket aligning tab has an aligning tab tip that is truncated.

The system of any preceding clause, wherein the aligning tab tip has edges that are fillets.

The system of any preceding clause, wherein the aligning portion of the locking tab profile is generally triangular.

The system of any preceding clause, wherein the locking tab has a first geometric portion, a second geometric portion, a third geometric portion, and a fourth geometric portion, and the first geometric portion, the second geometric portion, and the third geometric portion define the locking portion of the locking tab profile, and wherein: the first geometric portion is closest to the lock bracket base plate and has a generally rectangular shape that extends in a y-direction, the second geometric portion extends from the first geometric portion and has a quadrilateral shape with a first lateral side and a second lateral side of the second geometric portion being inclined at an angle relative to the y-direction, the third geometric portion extends from the second geometric portion and has a quadrilateral shape with the first lateral side of the third geometric portion extending substantially vertically in the y-direction and the second lateral side of the third geometric portion being inclined at an angle relative to the y-direction, and the fourth geometric portion extends from the third geometric portion and defines the aligning portion of the locking tab profile.

The system of any preceding clause, wherein the first lateral side of the second geometric portion is inclined at a different angle as the second lateral side of the second geometric portion.

The system of any preceding clause, wherein the second lateral side of the third geometric portion is inclined at a same angle as the incline of the second lateral side of the second geometric portion.

The system of any preceding clause, wherein a width of the third geometric portion decreases as a function of distance from the lock bracket base plate in the y-direction.

The system of any preceding clause, wherein a width of the fourth geometric portion decreases as the fourth geometric portion extends from the third geometric portion to a locking tab tip of the locking tab.

The system of any preceding clause, wherein the first geometric portion has a substantially constant width D1 in a z-direction as the first geometric portion extends in the y-direction.

The system of any preceding clause, wherein the third geometric portion has an engagement width D1′ extending in the z-direction where the third geometric portion intersects with the fourth geometric portion, and the engagement width D1′ is similar to a width D2 of the alignment hole of the one or more receiver brackets.

The system of any preceding clause, wherein each of the one or more lock brackets includes a lock bracket mounting plate coupled to the lock bracket base plate for coupling each of the one or more lock brackets to the first modular building unit.

The system of any preceding clause, wherein the lock bracket mounting plate includes one or more lock bracket mounting holes configured to receive one or more fasteners for coupling each of the one or more lock brackets to the first modular building unit.

The system of any preceding clause, wherein each of the one or more lock brackets includes a lock bracket reinforcing tab that extends between the lock bracket mounting plate and the lock bracket base plate to provide support therebetween.

The system of any preceding clause, wherein each of the one or more receiver brackets includes a receiver bracket mounting plate coupled to the receiver bracket base plate for coupling each of the one or more receiver brackets to the second modular building unit.

The system of any preceding clause, wherein the receiver bracket mounting plate includes one or more receiver bracket mounting holes configured to receive one or more fasteners for coupling each of the one or more receiver brackets to the second modular building unit.

The system of any preceding clause, wherein each of the one or more receiver brackets includes a receiver bracket reinforcing tab that extends between the receiver bracket mounting plate and the receiver bracket base plate to provide support therebetween.

The system of any preceding clause, wherein the one or more lock brackets include a first lock bracket having a first locking tab profile with a first locking portion and a second lock bracket having a second locking tab profile with a second locking portion that is opposite the first locking portion.

The system of brackets of any preceding clause, wherein each of the first brackets is configured for attachment at an upper edge of the first structure and each of the second brackets is configured for attachment at a lower edge of the second structure.

The system of brackets of any preceding clause, wherein the upper edge of the first structure is directly below the lower edge of the second structure.

The system of brackets of any preceding clause, wherein the second tab is formed as a locking tab and has an outer profile that is defined by opposing lateral edges thereof, the opposing lateral edges being spaced apart from each other in the second direction, and optionally, the outer profile of the second tab comprises an alignment portion and a locking portion, the locking portion being adjacent to the base plate and the alignment portion being spaced apart from the base plate by the locking portion.

The system of brackets of any preceding clause, wherein the opposing lateral edges of the second tab comprise, within the locking portion and extending away from the base, a first segment and a second segment, the first segment of each of the opposing lateral edges being substantially perpendicular to the mounting plate and the second segment of each of the opposing lateral edges being inclined at an angle greater than 0° with respect to the first segment on a same opposing lateral edge.

The system of brackets of any preceding clause, wherein the opposing lateral edges of the second tab, within the alignment portion and extending away from the locking portion, are inclined towards each other such that, within the alignment portion, the opposing lateral edges are inclined towards each other and the second tab has a tapered shape.

The system of brackets of any preceding clause, wherein the first structure is directly beneath the second structure.

The system of brackets of any preceding clause, wherein the first tab comprises a tapered shape extending away from the base plate, the tapered shape being widest at a junction with the base plate.

The system of brackets of any preceding clause, wherein the first tab and the second tab each protrude away from, and terminate at, a substantially similar distance away from the base plate.

The system of brackets of any preceding clause, wherein each of the plurality of first brackets comprises a reinforcing tab that extends between and is configured to provide support between the mounting plate and the base plate thereof, and/or each of the plurality of second brackets comprises a reinforcing tab that extends between and is configured to provide support between the mounting plate and the base plate thereof.

The system of brackets of any preceding clause, wherein the reinforcing tab of the each of the plurality of first brackets is formed as a unitary, or monolithic, structure with the first tab thereof, such that the reinforcing tab and the first tab of a same one of the plurality of first brackets are formed in a single piece.

The system of brackets of any preceding clause, wherein the first and second brackets are rigidly and fixedly interconnected with each other, such as via a welding process.

The system of brackets of any preceding clause, wherein the first and/or the second brackets have a unitary, or monolithic, construction.

The system of brackets of any preceding clause, wherein the first structure is a first modular building unit and the second structure is a second modular building unit, the first and second modular building units being configured for assembly with other modular building units to form a modular structure or building, the first and second modular building units being vertically adjacent to each other in the modular structure of building.

A modular structure comprising a plurality of modular building units that are assembled together to form the modular structure and a system of brackets. The plurality of modular building units comprising a first modular building unit, a second modular building unit positioned laterally adjacent to the first modular building unit, a third modular building unit positioned vertically above the first modular building unit, and a fourth modular building unit positioned laterally adjacent to the third modular building unit and vertically above the second modular building unit. The system of brackets comprises a plurality of first brackets and a plurality of second brackets. Each of which are attached to the first modular building unit or to the second modular building unit. Each of the first brackets comprises a mounting plate configured for attachment to one of the first and second modular building units, a base plate that is connected to the mounting plate and is arranged transverse to the mounting plate, a first tab, and a second tab that is transverse to the first tab, the second tab comprising a profile. The first and second tabs are interconnected with each other. The plurality of second brackets each are attached the third modular building unit or to the fourth modular building unit. Each of the second brackets comprises a mounting plate configured for attachment to one of the third and fourth modular building units, a base plate that is connected to the mounting plate of the second bracket, and an alignment hole formed in the base plate. For each of the first brackets attached to the first modular building unit the first tab is insertable through the alignment hole of a corresponding second bracket attached to the third modular building unit for aligning the first and third modular building units with each other in a first direction, and the second tab is insertable through the alignment hole of the corresponding second bracket attached to the third modular building unit for aligning the first and third modular building units with each other in a second direction. For each of the first brackets attached to the second modular building unit the first tab is insertable through the alignment hole of the corresponding second bracket attached to the fourth modular building unit for aligning the second and fourth modular building units with each other in the first direction, and the second tab is insertable through the alignment hole of the corresponding second bracket attached to the fourth modular building unit for aligning the second and fourth modular building units with each other in the second direction. The first and second directions are transversely oriented to each other. The profile of the second tab of each of the first brackets is shaped such a vertical movement of the third modular building unit away from the first modular building unit is blocked unless the fourth modular building unit is moved vertically away from the second modular building unit, such that all of the first brackets of the second modular building unit are disengaged from all of the second brackets of the fourth modular building unit.

The modular structure of the preceding clause, wherein each of the plurality of first brackets is attached to an upper edge of the first modular building unit or to an upper edge of the second modular building unit, and each of the plurality of second brackets is attached to a lower edge of the third modular building unit or to a lower edge of the fourth modular building unit.

The modular structure of any preceding clause, wherein the upper edge of the first modular building unit is directly below the lower edge of the third modular building unit and/or the lower edge of the fourth modular unit, and the upper edge of the second modular building unit is directly below the lower edge of the third modular building unit and/or the lower edge of the fourth modular building unit.

The modular structure of any preceding clause, wherein the second tab is formed as a locking tab and has an outer profile that is defined by opposing lateral edges thereof, the opposing lateral edges being spaced apart from each other in the second direction, and optionally, the outer profile of the second tab comprises an alignment portion and a locking portion, the locking portion being adjacent to the base plate and the alignment portion being spaced apart from the base plate by the locking portion.

The modular structure of any preceding clause, wherein the opposing lateral edges of the second tab comprise, within the locking portion and extending away from the base, a first segment and a second segment, the first segment of each of the opposing lateral edges being substantially perpendicular to the mounting plate and the second segment of each of the opposing lateral edges being inclined at an angle greater than 0° with respect to the first segment on a same opposing lateral edge.

The modular structure of any preceding clause, wherein the opposing lateral edges of the second tab, within the alignment portion and extending away from the locking portion, are inclined towards each other such that, within the alignment portion, the opposing lateral edges are inclined towards each other and the second tab has a tapered shape.

The modular structure of any preceding clause, wherein the first structure is directly beneath the second structure.

The modular structure of any preceding clause, wherein the first tab comprises a tapered shape extending away from the base plate, the tapered shape being widest at a junction with the base plate.

The modular structure of any preceding clause, wherein the first tab and the second tab each protrude away from, and terminate at, a substantially similar distance away from the base plate.

The modular structure of any preceding clause, wherein each of the plurality of first brackets comprises a reinforcing tab that extends between and is configured to provide support between the mounting plate and the base plate thereof, and/or each of the plurality of second brackets comprises a reinforcing tab that extends between and is configured to provide support between the mounting plate and the base plate thereof.

The modular structure of any preceding clause, wherein the reinforcing tab of the each of the plurality of first brackets is formed as a unitary, or monolithic, structure with the first tab thereof, such that the reinforcing tab and the first tab of a same one of the plurality of first brackets are formed in a single piece.

The modular structure of any preceding clause, wherein the first and second brackets are rigidly and fixedly interconnected with each other, such as via a welding process.

The modular structure of any preceding clause, wherein the first and/or the second brackets have a unitary, or monolithic, construction.

A method of using a system of brackets for aligning and interlocking together a plurality of modular building units to form a modular structure, the method comprising providing the plurality of modular building units comprising a first modular building unit, a second modular building unit, a third modular building unit, and a fourth modular building unit, providing a system of brackets comprising a plurality of first brackets, each of the first brackets comprising a mounting plate configured for attachment to one of the first and second modular building units, a base plate that is connected to the mounting plate and is arranged transverse to the mounting plate, a first tab, a second tab that is transverse to the first tab, the second tab comprising a profile that comprises an alignment portion and a locking portion, wherein the first and second tabs are interconnected with each other, and a plurality of second brackets, each of the second brackets comprising a mounting plate configured for attachment to one of the third and fourth modular building units, a base plate that is connected to the mounting plate of the second bracket, and an alignment hole formed in the base plate, attaching the plurality of first brackets to the first modular building unit and the second modular building unit, attaching the plurality of second brackets to the third modular building unit and the fourth modular building unit, arranging the first and second modular building units laterally adjacent to each other, stacking the third modular building unit on top of the first modular building unit by inserting the first tab and the second tab of each of the first brackets that are attached to the first modular building unit through the alignment hole of a corresponding one of the second brackets to align the first and third modular building units with each other in a first direction and a second direction, respectively, and stacking the fourth modular building unit on top of the second modular building unit by inserting the first tab and the second tab of each of the first brackets that are attached to the second modular building unit through the alignment hole of a corresponding one of the second brackets to align the second and fourth modular building units with each other in the first direction and the second direction, respectively. The profile of the second tab of each of the first brackets is shaped such a vertical movement of the third modular building unit away from the first modular building unit is blocked unless the fourth modular building unit is moved vertically away from the second modular building unit, such that all of the first brackets of the second modular building unit are disengaged from all of the second brackets of the fourth modular building unit.

A method of secure attachment and alignment of modular building units using the system of brackets of any preceding clause, the method includes aligning the one or more receiver brackets with the one or more lock brackets by aligning the second modular building unit over the first modular building unit, lowering the second modular building unit onto the first modular building unit, inserting the lock bracket protrusion into the alignment hole as the second modular building unit is lowered onto the first modular building unit, and sliding the one or more receiver brackets vertically and laterally along the locking tab profile as the lock bracket protrusion is inserted into the alignment hole.

The method of any preceding, wherein the lock bracket protrusion further includes a lock bracket aligning tab having an aligning profile that is generally triangular, and the method further comprises sliding the one or more receiver brackets vertically and laterally along the aligning profile of the lock bracket aligning tab.

The method of any preceding, wherein the aligning portion of the locking tab profile is generally triangular, and the method further comprises sliding the one or more receiver brackets in a first lateral direction along the aligning portion of the locking tab profile as the one or more receiver brackets slide vertically along the locking tab profile.

The method of any preceding, wherein the locking tab has a first geometric portion, a second geometric portion, a third geometric portion, and a fourth geometric portion, and the first geometric portion, the second geometric portion, and the third geometric portion define the locking portion of the locking tab profile, and wherein: the first geometric portion is closest to the lock bracket base plate and has a generally rectangular shape that extends in a y-direction, the second geometric portion extends from the first geometric portion and has a quadrilateral shape with a first lateral side and a second lateral side of the second geometric portion being inclined at an angle relative to the y-direction, the third geometric portion extends from the second geometric portion and has a quadrilateral shape with the first lateral side of the third geometric portion extending substantially vertically in the y-direction and the second lateral side of the third geometric portion being inclined at an angle relative to the y-direction, and the fourth geometric portion extends from the third geometric portion and defines the aligning portion of the locking tab profile.

The method of any preceding, further comprising sliding the one or more receiver brackets laterally along the second lateral side of the fourth geometric portion in a first lateral direction with respect to a z-direction.

The method of any preceding, further comprising sliding the one or more receiver brackets laterally along the second lateral side of the third geometric portion in a second lateral direction with respect to the z-direction that is opposite the first lateral direction.

The method of any preceding, further comprising sliding the one or more receiver brackets laterally along the first lateral side and the second lateral side of the second geometric portion in the second lateral direction.

The method of any preceding, further comprising sliding the one or more receiver brackets vertically along the first lateral side or the second lateral side of the first geometric portion.

The method of any preceding, wherein each of the one or more lock brackets includes a lock bracket mounting plate coupled to the lock bracket base plate, and the method further comprises coupling the one or more lock brackets to the first modular building unit with the lock bracket mounting plate.

The method of any preceding, wherein each of the one or more lock brackets includes a lock bracket reinforcing tab that extends between the lock bracket mounting plate and the lock bracket base plate, and the method further comprises supporting the lock bracket mounting plate and the lock bracket base plate with the lock bracket reinforcing tab.

The method of any preceding, wherein each of the one or more receiver brackets includes a receiver bracket mounting plate coupled to the receiver bracket base plate, and the method further comprises coupling the one or more receiver brackets to the second modular building unit with the lock bracket mounting plate.

The method of any preceding, wherein each of the one or more receiver brackets includes a receiver bracket reinforcing tab that extends between the receiver bracket mounting plate and the receiver bracket base plate, and the method further comprises supporting the receiver bracket mounting plate and the receiver bracket base plate with the receiver bracket reinforcing tab.

The method of any preceding, wherein the one or more lock brackets include a first lock bracket having a first locking tab profile with a first locking portion and a second lock bracket having a second locking tab profile with a second locking portion that is opposite the first locking portion.

The method of any preceding clause, wherein each of the plurality of first brackets is attached to an upper edge of the first modular building unit or to an upper edge of the second modular building unit, and each of the plurality of second brackets is attached to a lower edge of the third modular building unit or to a lower edge of the fourth modular building unit.

The method of any preceding clause, wherein the upper edge of the first modular building unit is directly below the lower edge of the third modular building unit and/or the lower edge of the fourth modular unit, and the upper edge of the second modular building unit is directly below the lower edge of the third modular building unit and/or the lower edge of the fourth modular building unit.

The method of any preceding clause, wherein the second tab is formed as a locking tab and has an outer profile that is defined by opposing lateral edges thereof, the opposing lateral edges being spaced apart from each other in the second direction, and optionally, the outer profile of the second tab comprises an alignment portion and a locking portion, the locking portion being adjacent to the base plate and the alignment portion being spaced apart from the base plate by the locking portion.

The method of any preceding clause, wherein the opposing lateral edges of the second tab comprise, within the locking portion and extending away from the base, a first segment and a second segment, the first segment of each of the opposing lateral edges being substantially perpendicular to the mounting plate and the second segment of each of the opposing lateral edges being inclined at an angle greater than 0° with respect to the first segment on a same opposing lateral edge.

The method of any preceding clause, wherein the opposing lateral edges of the second tab, within the alignment portion and extending away from the locking portion, are inclined towards each other such that, within the alignment portion, the opposing lateral edges are inclined towards each other and the second tab has a tapered shape.

The method of any preceding clause, wherein the first structure is directly beneath the second structure.

The method of any preceding clause, wherein the first tab comprises a tapered shape extending away from the base plate, the tapered shape being widest at a junction with the base plate.

The method of any preceding clause, wherein the first tab and the second tab each protrude away from, and terminate at, a substantially similar distance away from the base plate.

The method of any preceding clause, wherein each of the plurality of first brackets comprises a reinforcing tab that extends between the mounting plate and the base plate thereof to provide support therebetween, and/or each of the plurality of second brackets comprises a reinforcing tab that extends between the mounting plate and the base plate thereof to provide support therebetween.

The method of any preceding clause, wherein the reinforcing tab of the each of the plurality of first brackets is formed as a unitary, or monolithic, structure with the first tab thereof, such that the reinforcing tab and the first tab of a same one of the plurality of first brackets are formed in a single piece.

The method of any preceding clause, wherein the first and second brackets are rigidly and fixedly interconnected with each other, such as via a welding process.

The method of any preceding clause, wherein the first and/or the second brackets have a unitary, or monolithic, construction.

The present subject matter can be embodied in other forms without departure from the spirit and essential characteristics thereof. The embodiments described therefore are to be considered in all respects as illustrative and not restrictive. Although the present subject matter has been described in terms of certain preferred embodiments, other embodiments that are apparent to those of ordinary skill in the art are also within the scope of the present subject matter. Moreover, features described in connection with one embodiment may be used in conjunction with other embodiments, even if not explicitly stated above.

DEVICES, SYSTEMS, AND METHODS FOR SECURE ATTACHMENT AND ALIGNMENT OF MODULAR BUILDING UNITS

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CROSS REFERENCE TO RELATED APPLICATIONS

Provisional Applications (1)