Connectors for modular buildings

Abstract

The present application is entitled "Connector for modular buildings". A connector assembly has an upper connector, a latch for coupling the upper connector to a lower connector, and a gusset sandwiched between the upper connector and the lower connector. Also disclosed are a liftable connector assembly, a lifting frame assembly, a coupling system for a modular frame unit, a method for assembling a modular unit using the connector assembly, and a modular frame unit and a building having the connector assembly.

Description

[0001] This application is a divisional application of Chinese patent application 201680052645.7, filed on August 12, 2016, entitled “Connector for Modular Buildings”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 62 / 205,366, entitled CONNECTOR FOR A MODULAR BUILDING, filed on August 14, 2015. The contents of the above patent application are hereby expressly incorporated by reference into the detailed description herein. Technical Field

[0004] The present invention relates to a connector, a connector assembly, a liftable connector assembly using the connector assembly, a lifting frame assembly, a coupling system for modular frame units, a method for coupling modular frame units having the connector assembly, and a method for assembling modular units having the connector assembly and a building having the connector assembly. Background Art

[0005] It is widely recognized that pre-manufacturing modular building units constructed from standardized components in a controlled factory environment may be desirable due to the reductions in cost and improvements in quality that can be obtained compared to performing similar work on an outdoor construction job site.

[0006] Therefore, prefabricated modular building units having floor, wall and roof covering structures and containing all systems and furnishings pre-installed therein are preferred and known in the art. In addition, methods of constructing building assembly systems from component parts and joining two or more modular building units together to form a larger structure are also known in the art.

[0007] Furthermore, devices are known in the art which engage with specially formed apertures in the upper or side surfaces of a structural frame to provide a releasable connection for lifting and moving modular building units.

[0008] A limitation of using factory-built modules to construct slender or tall buildings is that economically constructed modules cannot resist and transmit large moments generated by wind and seismic forces, and large compressive loads generated by the effects of gravity on the building and occupants. In addition, all of these types of forces are amplified by the narrowness of one or both axes of the building. These effects are greatest at the lower floor, and increase in proportion to the increased height and slenderness, so the forces are greatest at the lower floor. The constraining nature of the connections between adjacent modules and the lack of diagonal bracing beyond that necessary for integrity in transit, which is a feature of many modular construction systems, can limit the effectiveness of force transmission through larger assemblies of conventional module types.

[0009] The current state of the art for constructing tall or slender buildings using modules as taught in the art as exemplified herein would maintain economies of scale in production by either: reinforcing the integrity of all modules making up the building so all modules contribute to resisting forces in a distributed manner, like a stack of ocean cargo containers; or using large columns, located inside or outside the walls of all modules, forming alternative load paths; or constructing a frame of supports that bypasses the adjoining or interconnecting modules and transfers large loads to the ground through a secondary structure; or anchoring the modules with tension rods or cables running vertically through the building to resist heave and lateral drift. All of the above noted methods have limitations in the resistance to forces and transmission of forces that can be achieved, or require the erection of additional structures, which in turn can limit the height that can be achieved or increase the amount of material used, thereby increasing costs.

[0010] Additionally, construction methods using large columns, particularly when grouped at corners, or occurring at intermediate locations within a wall, produce larger spaces between modules, and / or produce walls of increased thickness that reduce the useful footprint of the resulting building, and / or produce overhangs that limit the free use of voids and walls for mounting fixtures such as cabinets and shower cubicles and / or impose other restrictions on resident use of the space, thereby reducing the value of the resulting building.

[0011] Additionally, methods of modular building construction using secondary framing increase building assembly time, increase cost and construction duration, and reduce useful floor space, thereby reducing the value of the resulting building.

[0012] Producing multiple dissimilar module types, each with unique details relative to the forces acting on the modules within a building is undesirable because the increased variation increases the number of unique components that must be measured, cut, and inventoried prior to use. Additionally, the setup of the manufacturing tools required to precisely position these parts relative to each other for assembly is prone to error and is therefore typically performed by a skilled artisan, so any increase in the number of setups increases production time and cost.

[0013] Because the components comprising the networked structure must be of nearly identical lengths, creating the many features required to precisely assemble the modules by joining or other means, the subsequent positioning and connection of the subassemblies that make up the modules, rigging and lifting the completed modules, and fastening the modules to form structurally sound groupings that provide redundant and adequate load paths as currently practiced requires multiple precision cutting and assembly operations, which increases costs.

[0014] It is well known in the art that moment connected module frames or building frames reduce the need for diagonal reinforcement elements that otherwise block the view of occupants and hinder the installation and maintenance of building services. However, moment connections that require bulky splice plates as a means of connection require unimpeded access to one or more faces of the module, thereby increasing the amount of enclosure and surface preparation work that must be completed on site.

[0015] Some embodiments of modular buildings that best suit site conditions, occupant needs, and the aesthetic tastes of an architect or owner may be constructed from module forms having non-orthogonal shapes, including wedge shapes, curved shapes, polygonal shapes, etc. However, existing systems for the construction of structural modules suitable for tall building construction are inherently unsuitable for non-orthogonal shapes.

[0016] The different shapes of the modules and the different positions of the walls, fixtures and other components cause the center of gravity of the modules used to construct a building or furnish a single floor of the building to vary. To facilitate placement while minimizing gaps, it is desirable to orient the side walls of the modules as close to vertical as possible during lifting. This is the case with long delays and repeated trial lifts required to make adjustments to the rigging in order to achieve this desired condition. The time required to make the required changes in turn increases the overall duration of the lifting operation, thus increasing labor and equipment (such as crane) costs, as well as delaying the completion of the building.

[0017] The need to place and interconnect modules imprecisely increases the amount of space required between modules, which increases the difficulty of fireproofing the structure and interconnecting components to achieve the greatest possible strength, as well as making it more difficult to integrate modules into structural groups, and wastes space and provides room for sound, smoke and pest circulation.

[0018] The dimensions of the modules and the positioning of their internal components define the location and dimensions of the exterior wall coverings, mechanical services, support structures immediately adjacent to and adjacent to the modules, and beneath the building, and thus there is an interdependent relationship between all elements that make up a modular building.

[0019] The present invention can help address the need for a compact, precise, load-bearing, moment-connected, versatile and complete system for the orientation and assembly of related components for module frames, which can help to quickly and reliably provide rigging and lifting of completed modules, and can provide the necessary components for connecting modules to each other and to the building without the need for excessive unfinished areas so as to fully utilize the advantages of the structural characteristics of the modules, and which limits and reduces the number of parts, provides features without the need to make complex connections in the joint area, excessive precision required for cutting materials, performing difficult welds in difficult locations and multiple precision settings.

[0020] In particular, the present invention consists of a system of components and methods for manufacturing and assembling building modules and interconnecting the modules to form a building composed of those modules, and the methods are used to define the number, selection and articulation of those components to be used to produce modules suitable for a specific configuration.

[0021] The present invention may also help address the need for a system of components and working methods that allow manufacturers to economically and safely construct a wide range of types of buildings, from single-family homes to towers of over 20 stories, in a variety of forms including but not limited to orthogonal, wedge-shaped, radial, and curved shapes. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Reference will now be made, by way of example, to the accompanying drawings which show example embodiments of the present application, and in which:

[0023] Figure 1 An exploded isometric view of a corner connector block disclosed in PCT Application No. PCT / CA2014 / 050110 filed on February 18, 2014, which is incorporated herein by reference;

[0024] Figure 1.1 For Figure 1 A perspective view of the lower corner block shown;

[0025] Figure 1.2 For Figure 1 A side view of the lower corner block is shown, illustrating wedge-positioned coring;

[0026] Figure 1.3 For Figure 1 A perspective view of the upper corner block shown;

[0027] Figure 2 For Figure 1 A perspective view of a gusset plate is shown, and the gusset plate connects four modules ( Figure 2.1 ) and two modules ( Figure 2.2 );

[0028] Figure 3 For use Figure 1 a partially exploded perspective view of a module corner of the connector shown;

[0029] Figure 3.1 For use Figure 1 A partial perspective view of the connector shown connecting between two adjacent module stacks;

[0030] Figure 3.2 For use Figure 1 A vertical section of the HSS of the connector shown passing through the arm, gusset and connection;

[0031] Figure 3.3 For use Figure 1 An isometric view of the connector shown connecting between two modules in a single stack;

[0032] Figure 3.4 For use Figure 1 A partial front view of the connector shown connecting between two adjacent module stacks;

[0033] Figure 4 For use Figure 1 A partial side view of the connector shown connecting between two modules in a single stack;

[0034] Figure 5 An exploded isometric view of a module using a module connector;

[0035] Figure 5.1 is a partial isometric view of the interior of a module corner showing vertical stiffeners and diagonal braces;

[0036] Figure 5.2A and Figure 6 is a group of top section views showing progressive alternative embodiments of reinforcing columns;

[0037] Figure 7 Isometric view of a group of 18 modules joined to form a building with a central corridor on all floors;

[0038] Figure 8 A side view of a group of modules joined to form a building;

[0039] Fig. 9 A transparent perspective view of the corridor slab and an end view of the slab installed in the building;

[0040] Fig.10 is a partial exploded isometric view of the connection between two module stacks and the corridor floor at the connection point between two adjacent corridor slabs;

[0041] Fig.11is an isometric view of the lifting rigging equipment engaged to the module;

[0042] Fig.12 Isometric view of a typical sliding lift point;

[0043] Fig.13 (Top) Top view showing the effect of the jacking point on the mobile jacking frame on the lateral center of gravity, (lower left) combined jacking point, (lower right) end view of the CG offset from center to one side;

[0044] Fig.14 It is a partial perspective view of a corner of the lifting frame;

[0045] Fig.15 is a cross-sectional view through a split column;

[0046] Fig.16 is a cross section through the extendable mating wire washer;

[0047] Fig.17 This is an exploded view of the curtain wall system;

[0048] Fig.18 A partial exploded view of the connection between the upper floor module with built-in reinforcement columns and the lower floor module with built-in modular giant columns;

[0049] Fig.19 The horizontal sections are panelized structures constructed with panels framed by modular mega columns;

[0050] Fig. 20 is an exploded top view of a module stack showing the use of different thicknesses and numbers of gussets to maintain the correct overall height and alignment of the module stack;

[0051] Fig.21 is an exploded horizontal section of a row of modules showing the use of different thicknesses and numbers of shims to maintain the correct overall width and alignment of a row of modules;

[0052] Fig.22a is a cross-sectional view of an embodiment of a connector assembly according to the present specification;

[0053] Figure 22b is a side view of an embodiment of a latch according to the present specification;

[0054] Fig.23 is a perspective view of an embodiment of a first (upper) connector coupled to a plug according to the present specification;

[0055] Fig.24 is an exploded perspective view of an embodiment of a first (upper) connector, a latch, and a gusset according to the present specification;

[0056] Fig.25 is an exploded perspective view of another embodiment of a first (upper) connector, a latch, and a gusset according to the present specification; and

[0057] Fig.26 is a perspective view of an embodiment of a first (upper) connector, a latch and a shackle according to the present specification;

[0058] Fig. 27 is an exploded perspective view of a corner connector assembly according to the present specification;

[0059] Fig.28 is an exploded perspective view of another embodiment of a corner connector assembly according to the present specification;

[0060] Fig.29 is an exploded perspective view of another embodiment of a corner connector assembly according to the present specification;

[0061] Fig.30 is an exploded perspective view of another embodiment of a corner connector assembly according to the present specification;

[0062] Fig.31 is a perspective view of a connector assembly showing in phantom lines the coupling of upper and lower connectors with gussets and latches;

[0063] Fig.32 for Fig.31 a cross-sectional view of a connector assembly; and

[0064] Fig.33 for Fig.31 Exploded cross-sectional view of the connector assembly. DETAILED DESCRIPTION

[0065] The present specification relates to upper connector blocks that can be used to manufacture modular building units, as described in PCT Application No. PCT / CA2014 / 050110 filed on February 18, 2014 and PCT Application No. PCT / CA2015 / 050369 filed on April 30, 2015, both of which are incorporated herein by reference.

[0066] For ease of reading, this specification has been subdivided into sections for each component or group of components.

[0067] Corner Block

[0068] The present invention provides upper load bearing connectors or blocks and lower load bearing connectors or blocks which in one embodiment are corner blocks. In a particular embodiment, the blocks are generally quadrilateral and in other embodiments have polygonal or asymmetrical shapes. These blocks can be mass produced with features that provide multiple functions so as to concentrate precision operations in small numbers and sizes of objects and reduce the amount and complexity of work that must be performed on other components. The upper and lower blocks are of different forms and are located on the upper and lower ends of vertical corner components (pillars) of generally angular, tubular or modular form, which perform the function of multi-layer pillars when the modules so constructed are joined using features on the blocks to form larger or taller structures.

[0069] Likewise, other features on the blocks engage horizontal members of the building and perform the function of a continuous horizontal member when modules so constructed are joined to form a larger or wider structure.

[0070] In certain embodiments, the blocks have arms that taper to project at multiple angles, including but not limited to perpendicular to the face of the block (if adjoining components are positioned and welded at multiple angles). In certain embodiments, the invention thus facilitates the fabrication and erection of modules of shapes including but not limited to orthogonal, wedge-shaped, radial, and curved. Threaded and unthreaded holes in the arms enable the positioning of threaded fasteners, and the vertical walls of the arms provide an increase in load-bearing capacity and the transmission of compressive and tensile forces resulting from forces acting on the building and the action of the fasteners.

[0071] In a particular embodiment, the blocks have holes in both the body and the arms for the passage and reception of bolts with nuts or are threaded to receive bolts so as to provide continuity of vertical tension through the columns and resisting moments of interconnection between adjacent modules or other building structures. The tension resistance created by the connection of the columns in the vertical plane enables the structure to resist uplift forces in the event of uplift forces and creates friction on the gussets to transmit forces to the transverse members in the horizontal plane with a high level of fixity.

[0072] More specifically, during assembly, the surfaces of the arms closest to the inner surface of the HSS resting on the gusset are made tight with full tolerance on the opposite end so that the tension imparted by the action of the bolts on the arms compresses the connecting surfaces without flattening the HSS.

[0073] In certain embodiments, the bolts may enter into a wall cavity or other such location and may be arranged flush with or below the surface so that a removable patch may be easily configured to cover the location of the bolts and ensure continuity of the fireproofing material around the load-bearing structure.

[0074] In a particular embodiment, the block has protruding features on the exterior and interior faces of the block positioned to provide a backing for assembly welding, thereby reducing structural interference of welds with connecting components that are shortened or have angled ends or other defects, thereby reducing the probability of a worker performing an inconsistent weld connection between a corner block and a component welded to the block and thus an angled feature located on the exterior of the block, the angled feature being positioned so as to reduce the likelihood that a weld will protrude beyond the surface and interfere with an adjacent module.

[0075] Holes in the corner blocks provide a means of connecting to tie-downs and lifting devices. In a particular embodiment, the upper face of the block is prepared with an opening into which a latch having an opening can be inserted / coupled / snapped or screwed to provide a means of quickly and independently connecting and disconnecting the module to a lifting device.

[0076] Gusset

[0077] Another component is a plate inserted between the blocks at the top and bottom ends of a column or group of columns, the plate having an opening to permit a latch coupled to the first block to slide through and engage a recess on the underside of a second corner block, thereby positioning the module in the correct position. The plate also provides perforations for bolting adjacent modules to provide structural continuity in the horizontal plane during construction and in the completed building, and by virtue of its ductility, for accommodating slight variations in column lengths in order to ensure a continuous load path equally supported on all members of the group of columns so formed. As will be appreciated by those skilled in the art, the plate may be formed to fit between a single vertical column or between two or more columns arranged in an orthogonal or other arrangement. In a particular embodiment, a shim of similar size and prepared with appropriate holes is placed on one or both sides of the connector to accommodate variations in the final size of the module, thereby maintaining the proper geometry of the module stack.

[0078] Stairwells and elevator shafts

[0079] The system of the present invention allows the manufacture of modules within which stairs or lifting devices can be installed and separated at the mating line between two modules without significant visual or functional disruption.

[0080] Ultra-high module

[0081] The system of the present invention allows for the manufacture of modules that include upper and lower halves of habitable volume that are taller than shipping constraints would normally allow and that join at the mating line between two or more stacked modules without obvious visual or functional disruption.

[0082] corridor

[0083] Another group of components of the present invention is a structural corridor floor made of a suitable material such as reinforced concrete, sandwich panels, wood or formed metal, and a supporting base. In a specific embodiment, the thick plate is composed of reinforced concrete with steel bars placed so that features on the supporting base engage therewith to resist bending of the base, thereby creating a moment connection between the stacks of adjacent modules so connected. The base is provided with holes that align with corresponding holes in the upper corner blocks and lower corner blocks and are used to connect two parallel stacks of modules, as well as to connect adjacent columns within the stack on one side to create a combined load path. The base and floor thick plate can also be connected to the sides or ends of the module stack on one side of the thick plate and to the balcony support frame on the outside to form a balcony or breezeway. The floor thick plate and base assembly can also be used as a convenient carrier for building services such as ducting, pipes and wiring to facilitate the manufacture of these components off-site in a factory environment.

[0084] Lifting

[0085] In another aspect, the specification relates to a releasable compact connector for lifting a module frame using a latch coupled to the connector. A clevis or shackle can be coupled to the latch by engaging a clevis latch or bolt in an opening in the latch and connecting the clevis or shackle to the latch and establishing a coupling between the lifting system and the module frame. This allows the module frame to be lifted from one end (e.g., the top of the module frame) and can help reduce or eliminate the bracing or connection to the opposite end (e.g., the bottom end of the module frame). This system can help reduce the overall work required to connect, disconnect, and lift the module frame units, while also helping to align and connect the module frame units during construction.

[0086] Lifting frame

[0087] Another component of the invention is a lifting device arranged to suspend the load in an ideal attitude for placement in a building, in a particular embodiment, said lifting device being horizontal and providing a rapid adjustment of the position of all the connection points through which the wires pass to the crane wire hooks, in order to compensate for the differences in the center of gravity that occur in the length of the module. The device described also allows to modify the spread between the pairs of cables on one side of the frame, effecting a relative change of angle from the vertical pairs through to the crane wire hooks on one side of the module, in order to move the center of the crane attached to one side of the long axis of the frame, thus compensating for the changes in the center of gravity of the load that occur in the width of the module suspended therefrom.

[0088] Reinforcement components

[0089] Furthermore, the present description relates to a system of standardized reinforcement members connected to each other and to the columns, transverse frames, diagonal braces and corner blocks described herein, eliminating the need for piece-by-piece design and manufacture or customization of reinforcement components.

[0090] Enhanced analysis

[0091] Furthermore, the present description relates to a working method for systematically analyzing the forces acting on a building constructed of modules, defining the optimal locations for applying a standardized reinforcement system, selected from a series of standardized reinforcements with progressive buckling and uplift force resistance, and thereby incorporating only such reinforcements as are minimally necessary to reinforce areas under additional stress, without adding unnecessary structural material to more locations than is needed, without significantly compromising the application of fireproofing materials and without requiring additional thickness of the walls of the modules.

[0092] Combined column

[0093] Additionally, the present description relates to methods for the manufacture and connection of exterior columns so that they are formed into groupings having greater resistance to compressive and tensile forces resulting from loads encountered in constructing tall and / or slender buildings.

[0094] Extendable gasket

[0095] Additionally, the specification relates to washers that extend after the module is placed by action to engage another opposing washer in order to prevent damage to the washer surface during the lifting and placement operations.

[0096] benefit

[0097] Increase height without the need for a frame

[0098] By means of the entire modular building unit thus produced and connected, the component system and working method of the present specification can be used to increase the height of the building that can be constructed without the need for auxiliary external or internal bracing frames, and to increase the floor area available therefor, due to the larger component parts involved in the structural function and the enhanced connection fixity, the creation and guarantee of multiple redundant load paths, the integration of the support frame into the module wall and the resulting efficient transmission of the external, internal and self-loads imposed on the completed building through the adjacent modules and from there to the ground.

[0099] Increase height with frames

[0100] The present description may also be used to increase the height of a building constructed using secondary external or internal braced frames of a given size, by reducing the amount of steel required in the upper floors, and therefore reducing their overall weight.

[0101] Reduce the number of unique parts, number of locations and size of components

[0102] The present specification may also help reduce the cost of such buildings by analyzing the applied loads and more efficiently involving more of the required components that have a structural function, and by limiting the number, size, and location of fire protection requiring unique reinforcement details and associated complexity.

[0103] Reduce accuracy requirements

[0104] The instructions can help reduce the precision with which workers must make parts in a modular production facility, which reduces the cost of manufacturing.

[0105] Reduce complex manufacturing

[0106] The present description brings together many of the complex features required of joining components, lifting modules, and joining modules into a single mass-produced assembly, thereby reducing both the complexity and the requirement for skilled work necessary to construct the module.

[0107] Allows for taller and wider

[0108] In addition, the system may allow the construction of taller modules consisting of two stacked frames, one of which has an opening in the ceiling and the other of which has an opening in the floor, longer modules due to the performance of the diagonal braces, and wider modules due to the improved behavior of the openings in the ends, thus providing greater flexibility to the designer of a building so constructed.

[0109] Reduce wall thickness

[0110] By better distributing load bearing components, the present specification can help reduce the required wall thickness to accommodate structure and service facilities.

[0111] Reduce on-site labor for repairs

[0112] By placing tension connectors within the wall cavity and concentrating the connection members near the studs, the present disclosure may help reduce the number and extent of neglected areas that must subsequently be repaired.

[0113] Eliminates gasket damage during erection

[0114] By shipping and erecting modules with gaskets in a retracted position and then extending the gaskets after erection, the present description may help reduce the likelihood of gasket damage and the concomitant degradation of building envelope performance.

[0115] PCT Application No. PCT / CA2014 / 050110 filed on February 18, 2014, which is incorporated herein by reference, relates to a connector assembly 1 (such as Figure 1 As shown in FIG. 1 , the connector assembly has an upper connector 10 and a lower connector 20 together with a gusset plate 30.

[0116] Figure 1 An embodiment of a connector assembly 1 is disclosed, the connector assembly consisting of an upper connector 10, a lower connector 20, and a gusset 30 sandwiched between the upper connector 10 and the lower connector 20. The terms "upper" and "lower" are relative and interchangeable. However, for the purpose of describing the connector assembly 1, the upper connector 10 refers to the connector that will generally be positioned at the upper corner or upper end of the modular frame, which can be lifted and positioned on the second (or lower) modular frame. And the lower connector 20 refers to the connector that is positioned on the lower corner or lower end of the modular frame and will be closer to the ground or floor (than the upper connector).

[0117] In the illustrated embodiment, the upper corner connector 10 and the lower corner connector 20 may be made of hollow steel castings. In addition, the upper connector 10 has an opening at one end (first end 2) formed to receive a column, post or other structural unit of a modular frame so that the upper connector can be coupled to the end of the first modular frame. The second end 3 of the upper connector 10 is designed to allow the upper connector 10 to be coupled to a gusset 30. The lower connector 20 may also have openings on both the first end 4 and the second end 5; where the first end 4 is suitable for coupling to the gusset 30, the second end 5 allows coupling to the end or corner of the second modular frame. The connector may have mechanical properties (such as tensile strength and ductility) and metallurgical properties equal to or greater than mild steel, so that the connector can be welded to mild steel using standard practices such as structural metal inert gas (MIG) welding.

[0118] In another embodiment, the upper connector (10) and the lower connector (20) each have a hollow body (2, 4). The upper connector hollow body 2 and the lower connector hollow body 4 may have a variety of shapes depending on the design and application requirements. However, in the figure, the upper connector (10) and the lower connector (20) have a hollow body (2, 4) with a square cross-section. A protrusion 6 is provided on the outer surface of the hollow body 2 of the upper connector 10. A similar protrusion 18 is also provided on the outer surface of the hollow body (4) of the lower connector 20.

[0119] The upper connector 10 is provided by at least one pair of arms 11 extending from the protrusion 18. The lower connector 20 is also provided by at least one pair of arms 11 extending from the protrusion 18. In the illustrated embodiment, the arms 11 extend from the surface of the protrusion 18 in a normal direction. In addition, the arms 11 are positioned perpendicular to each other, that is, one arm extends approximately 90° relative to the second arm. However, the position of the arms 11 may be changed depending on the design and application requirements, and the arms 11 may exist at an angle less than or greater than 90°. The arms 11 on the upper connector 10 may be provided with an orifice 12, which may be used to couple the upper connector or the lower connector to the connector assembly 1.

[0120] In one embodiment, the central hollow body (2, 4) is 4" square to accommodate a 4"x4" hollow structural segment (HSS). In another embodiment, the central hollow body (2, 4) is 6" square to accommodate a 6"x6" HSS. The connectors 10 and 20 have appropriate thickness (for the intended function) and details, such as draft angles and uniformity of the segments, which facilitate casting. In a specific embodiment, the casting is drilled and the surface milled to an accuracy of +0 to 0.010 inches (as measured between the center of the orifice 12 and the locating surface of the arm 11) or other tolerances that may be convenient. In another embodiment, the connector is manufactured by assembling one or more of rolled-up segments, flat or brake-forming plates with welding or mechanical components. In another embodiment, the parts are manufactured by casting non-ferrous, plastic, cement, or any other suitable material. In another embodiment, the block portion to which the post and arm will be connected may have features to locate the HSS and facilitate welding.

[0121] The connector assembly 1 can be formed by sandwiching a gusset plate 30 between an upper connector 10 and a lower connector 20. The gusset plate 30 shown has two faces, wherein a first face can contact the lower connector 20, and a second face can contact the upper connector 10. In addition, the gusset plate 30 is provided with through holes 31, which are aligned with the apertures 12 on the upper connector 10 and the lower connector 20, thereby allowing the connectors (10, 20) to be fastened using fastening members. The fastening members are not particularly limited and may include nuts and bolts, screws.

[0122] Figure 1.1 Lower connector 20

[0123] The lower corner connector has a raised portion 18 that provides a backing for the longitudinal and transverse members of the module frame and for the assembly welding. In the embodiment shown, the edges of the hollow bodies of the upper and lower connectors have beveled edges. The bevel 19 provides a location for the outer surface of the weld bead, which allows the weld to be flush and eliminates the need to tilt the connecting parts. The outer surface of the lower connector 20 may have a plurality of holes (or small holes) 21, which are threaded or unthreaded as needed for the situation of connecting column groups, corridor slabs, clamps, lifting members or other useful features by using bolts, latches, clips, joint plates or other fastening members. In another embodiment, the connector 20 is higher and provides additional holes for using additional fasteners or adding additional braces or other features. In another embodiment, the connector 20 has more or less than 4 sides and is not a quadrilateral, but has a trapezoid, parallelogram or other shape to help create round, curved, wedge-shaped, star-shaped or other building forms.

[0124] The lower connector 20 has arms 11 with holes (or apertures) 12 to pass tension bolts 25 through gussets 30 to vertically secure the module and provide a continuous tension and moment connection to transfer loads through the connection between the stacking columns and the horizontal crossbars. In another embodiment, these arms protrude perpendicular to the surface, in another embodiment, they have tapered sides 22 to permit connecting components at an angle, and in another embodiment, the entire arm protrudes at an angle.

[0125] Figure 1.2 Lower connector 20

[0126] In one embodiment, the connector 20 has a Figure 1.2 As depicted by the hidden lines, the bottom surface has openings whose sides are perpendicular or wedge-shaped relative to the bottom surface 23. Several of these openings on the module in radial relationship to the center of the module receive corresponding wedge-shaped locating pins 33 in the gusset 30 below, thus locating the module on top of the module below and placing it in the correct position for connection.

[0127] Figure 1.3 Upper connector 10

[0128] The upper corner connector 10 has a raised portion 18 that provides a backing for positioning the longitudinal and transverse members of the module frame and welding of the assembly. Similar to the lower connector 20, in the illustrated embodiment, the edges of the hollow bodies of the upper and lower connectors have beveled edges. The bevel 19 provides a location for an external weld bead, which allows the weld to be flush and eliminates the need to tilt the connecting parts. The outer surface of the block 10 may have a plurality of holes (or eyelets) 21, which are threaded or unthreaded as needed for connecting column groups, corridor slabs or other useful features by using bolts, latches, clips, joint plates or other fastening members. In another embodiment, the block is taller and provides additional holes for using additional fasteners or adding additional braces or other features. In another embodiment, the block has more or less than 4 sides and is not a quadrilateral, but has a trapezoid, parallelogram or other shape to help create a round, curved, wedge-shaped, star-shaped or other building form. In another embodiment, the arms protrude perpendicular to the surface, in another embodiment they have tapered sides 22 to permit connecting components at an angle, and in another embodiment the entire arm protrudes at an angle.

[0129] In another embodiment, the upper connector 10 has an arm 11 with a threaded hole (or second aperture) 12 closest to the body of the block for receiving the tension bolt 25 and a threaded hole (or first aperture) 13 farthest from the block for receiving the gusset screw 34. In a particular embodiment, these arms protrude perpendicular to the surface, in another embodiment they have a tapered side 22 to permit connecting the components at an angle, and in another embodiment the entire arm protrudes at an angle.

[0130] Figure 2 Shown as used for Figure 1 The gusset plate 30 in the connector assembly.

[0131] In one embodiment, the gusset plate 30 is cut from a steel plate or other material of sufficient thickness and mechanical properties for the intended function. In another embodiment, it is 3 / 8" thick. The gusset plate has a through hole 31, a countersunk hole 32, and a locating pin 33. A grub screw 34 passes through the hole 32 and threads into the hole 13 in the upper connector 10, accurately uniting adjacent columns and thus the entire module. The ductility of the plate 30 in the vertical plane ensures that the column group works together to withstand large loads. The precision of the location of the hole 32 for the grub screw and the corresponding hole in the connector ensures that module to module tolerances are maintained and controlled.

[0132] The gussets 30 can be sized to fit over the top of 1, 2, 3, 4 or more columns, providing equivalent vertical spacing in all positions, and forming groups of 2, 3, 4 or more modules. Figure 2.1As shown, it discloses an embodiment of a gusset plate joining four modules, and Figure 2.2 A gusset 30 is disclosed for joining the two modules. Figure 2.2 In the embodiment of the gusset plate 30 shown in FIG. 1 , the plate is provided with a protruding edge for supporting adjacent components.

[0133] Figure 3 Module Assembly

[0134] To create the floor frame of the module, longitudinal floor rails 41 and transverse floor rails 42 are cut to the appropriate length and provided with holes 43 that generally correspond to, but do not interfere with, the locations of the holes in arms 11 on connector 10. In a particular embodiment, these rails are 3" x 8" HSS for the perimeter and 3" x 6" HSS for the filler components. Because the positioning and welding fixtures described herein ( Fig.17 ) Positioning the pre-machined connection blocks and defining the hole locations and their positions relative to each other, providing the outer dimensions of the assembly, the jig thus ensures that the modules manufactured using the jig conform to the established grid previously described. In addition, features on the blocks ensure that the crossbars do not need to be beveled on the end edges and the operation of cutting to the appropriate length is not critical in terms of length or squareness. The crossbars are slid over the corresponding arms 11 on the lower corner connectors 20 and welded in the manner previously described.

[0135] Those skilled in the art will recognize that assembly of the top plate follows a similar process using appropriately sized components placed in the same fixture. In a particular embodiment, these are 3" x 3" HSS for the perimeter and 2" x 2" HSS for the filler components. Thus, both the top and bottom frames capture the outer dimensions of the same fixture and are coordinated.

[0136] Suitable materials 44 such as fiber cement boards or steel sheet decks and top concrete or steel composite sheet decks are applied to the top surface of the floor rails of the module floor so constructed and appropriately fixed, or concrete or other materials are filled between the frames to support the occupant loads and provide the necessary diaphragm effect to the modules and in turn to the building constructed by the modules. Similarly, materials such as drywall or fireproof board materials and various types of insulation materials are applied to the surfaces of the frames and boards and in the voids in the walls and ceilings to provide various functions such as privacy for the occupants, provide fire protection of the structure and limit the transmission of sound, depending on the conditions.

[0137] Figure 3.1 , 3.2 , 3.3, 3.4 and Figure 4 Vertical connection of modules to form a moment-resistant structure

[0138] As previously described, the lower connector tube 41 has an oversized hole 43 which communicates with the hole in the arm 22 through which the tension bolt 25 passes, which is threaded inside the upper wall frame tube 45 into a threaded hole in the top surface of the arm 11 on the upper block 10, thereby trapping and clamping the gusset plate 30 and transmitting vertical tension loads through the connection.

[0139] When the tension bolts 25 are screwed to the female threads in the holes 12 of the arms 11 on the upper connector 20 of the lower module at the correct torque value, the tension generated draws the upper and lower frame tubes and gussets together so as to establish a continuous moment action (25.1) whereby column by column, through the connection thus formed and by the adjacent frame tubes (especially the deeper parts including the floor frame), are prevented from rotating in the vertical plane. The vibration action characteristic of all buildings subjected to wind, earthquake and other loads is thus reduced. In a particular embodiment, the bolts 25 are composed of high strength steel, for example grade 8, so that the combination of tensile strength and number of the bolts is sufficient to resist the uplift forces induced by wind or earthquake on the structure thus connected.

[0140] Figure 5 Exploded view of a typical frame

[0141] The bottom frame 40 is connected to the top frame 47 by corner columns 50 and intermediate columns 51, which in a particular embodiment are generally perpendicular to the bottom frame and the top frame and are welded in place. In another embodiment, the connection between the upper and lower horizontal members and the intermediate vertical columns is similar to Figure 1.1 and 1.3 4 but with an intermediate connector 49 of opposed arms. In another embodiment, the posts are of various lengths and are mitered to fit to each other or blocks so that a variety of angular relationships between the top and bottom panels are achieved.

[0142] Figure 5.1 View of the side wall bracing

[0143] If the loads acting on the module are great enough to warrant adding diagonal reinforcements, install Figure 5.1 The diagonal reinforcement system consists of vertical reinforcement bars 60, which in a particular embodiment are Figure 5.1 The form shown in Figure 5.1 The position shown in Figure 5.2A6 or other specific embodiments shown in FIG. 6. The diagonal bars 61 are welded or bolted to these components, or in the case of lighter structures with less load, they are welded directly to the vertical or horizontal frame components or both. The modules so formed, when connected to other modules by moment-resistant corner connections, can help create a structure that is resistant to moment and tension, which transfers loads among itself in all axes. In a specific embodiment, the bars are diagonally opposed and have a cross-section of " and acts in tension. In another embodiment, they are diagonally opposed, 1" x 3" in cross section and act in tension. In another embodiment, they are single, 3" x 4" HSS or other dimensions and act in both tension and compression (appropriate to the loads they are resisting).

[0144] Figure 5.2A and 6 Vertical reinforcement

[0145] Figure 5.2A and 6 A diagram of a sequential arrangement showing the progressive construction of a reinforced column to resist buckling and uplift forces, starting from the weakest point at the top and ending with the strongest point at the bottom.

[0146] like Figure 5.2A and Figure 6 As shown in , vertical strengthening and increasing the cross section of the columns in order to increase the load bearing capacity and resistance to buckling and bending without increasing the thickness of the wall or introducing a separate support frame is achieved by any of the means shown and applied in a progressive manner as warranted by load and cost: increasing the wall thickness, filling the columns with grout, adding fins to the corners, grouping the sections, using larger sections and grouping those sections. A specific embodiment is a method of minimizing the increase in the thickness of the wall, especially in cases where the columns are grouped or located in the center of the wall or where useful space would be blocked.

[0147] Figure 7 View of small buildings

[0148] like Figure 3 Modules manufactured as described in are typically connected to form larger structures as shown. In a particular embodiment, a central corridor 90 exists and may allow access to the module ends for fastening, interconnection of mechanical services, and entry and exit of passengers to their units.

[0149] Figure 8 Side view of a small building

[0150] A side view showing a typical structure with a centrally located corridor 76 and Figure 5.1 The diagonal brace 60 described in .

[0151] Fig. 9 View of the Corridor Floor System

[0152] The floor section is shown as being composed of a concrete slab 70 with reinforcing strips 71 and supported by a base 72 which is prevented from rotating by bolting to the connector blocks 10 and 20 by means of holes 74 creating a moment connection and prevented from pulling out of the concrete by shear studs 73 engaging the concrete with the reinforcing strips. In a particular embodiment, the base vertically spans the upper and lower corner connectors and is bolted to the corner connectors, thereby increasing the fixity of the vertical connection between the columns. In another particular embodiment, the slab is long enough so that the base spans two or more adjacent modules, thereby increasing the fixity of the horizontal diaphragm action.

[0153] In another particular embodiment, the corridor planks are comprised of precast panels or any other suitable material such as wood or steel urethane sandwich panels or composites.

[0154] In particular embodiments, the corridor serves as a convenient support and carrier for common service facilities such as electrical or liquid supply lines 75 that are typically found in buildings and thus provides a means for pre-constructing these elements, transporting them to the building site, and hoisting them into position without additional handling.

[0155] exist Fig. 9 In the embodiment shown in FIG. 1 , the base 72 contacts and is positioned on the gusset plate 30. The gusset plate 30 used extends beyond the module frame to provide a surface for placing the base 72 for supporting the plank.

[0156] Fig.10 Exploded isometric view of the connection to the corridor floor system

[0157] When installed as described to serve as the floor of a corridor between two module stacks separated by a suitable space, the structure so formed unites adjacent stacks with moment-resistant connections so that the corridor floor structure increases the resistance of the entire building to lateral loads, thereby reducing the number and size of diagonal reinforcements required.

[0158] In another particular embodiment, the corridor slab structure is connected to the outer surface of the module stack and supported by a grid of columns or diagonal tension braces or diagonal struts to provide breezeways or balconies. Fig.10 In the embodiment shown in FIG. 1 , the bases 72 of the corridors 70 are each provided with a pair of holes 74. The first set of holes 74 in the base located closer to the bottom plate 70 can be coupled to the lower connectors 20 in the upper modular frame. The second set of holes 74 in the base located farther from the bottom plate 70 can be coupled to the upper connectors 10 in the lower modular frame. Fig.10 In the embodiment shown in FIG. 1 , the base is not positioned on the gusset 30, which lacks Fig. 9 The extension shown in .

[0159] Fig.11 and 14 Liftable frame assembly

[0160] A lifting frame is provided for reducing the compressive loads on the module frame members caused by the pyramidal displacement of the lifting wires, and for providing members for accurately leveling the modules during all lifting stages regardless of the length of the wires leading up to the crane, so as to facilitate placement of the modules without inadvertent contact which could damage the frames, seals, insulation and finishes.

[0161] The crossbar 80 is joined by the support 81 using bolts through the flange 82. Eight sliding jacks 83 ( Fig.12 and 14 ), which slides on crossbar 80 and is prevented from moving when locked in place in rows of holes 85 using locking pins 84. Carrying cables 86 pass upward and converge at Fig.13 On the main control lifting accessory 87 shown in .

[0162] exist Fig.11 In the embodiment shown in , the crossbar 80 can be an I-shaped crossbar having an upper end and a lower end. A first set of four jacks 83 are provided on the upper end of the crossbar 80, and a second set of jacks 83 are provided on the lower end of the crossbar 80. The jacks 83 are coupled to the crossbar and can be moved from a first position to a second position (e.g., by sliding the jacks), as may be required to lift the frame. The I-shaped crossbar can also be provided with a plurality of holes near the first and second ends that allow the jacks 83 to be attached to the appropriate positions on the I-shaped crossbar using fasteners such as bolts and nuts.

[0163] A first set of lifting blocks 83 present at the upper end (or first end) of the I-shaped crossbar are attached to load-bearing cables 86 which are attached to Fig.13 The master jacking fitting 87 shown in FIG. The lifting frame structure is balanced to reduce the load on any particular portion of the modular frame by moving the jacking blocks 83 on the I-shaped crossbar 80 and securing the jacking blocks 83 at different locations.

[0164] Fig.13 Lifting geometry

[0165] In preparation for lifting the module, the center of gravity of the module is determined by using a computer program (such as represented as a computer model) capable of calculating the center of gravity based on the recorded weight and position including the mass of the module, or iteratively from one or more test lifts. The data so collected is recorded and provided to the module. A table is prepared using a computer program or trigonometry of the combined center of gravity of the lifting frame system specifying the hole locations to be used to adjust the module and level the module to be lifted. Before connecting the lifting frame to the module, the table is consulted and the sliding blocks are positioned and locked in the appropriate position in the stated positions.

[0166] To move the center of gravity of the system along the long axis of the system, the jacking points 83 are moved toward the load as a group, maintaining an equidistant (quadrilateral) arrangement. To move the center of gravity 88 laterally at right angles to the long axis of the system, the jacking points 83 on only one side of the crossbar 80 are brought together or spread apart to increase or decrease the angle therebetween, thereby changing the angular relationship between the jacking lines passing up to the common jacking point 87.

[0167] In another embodiment, the jacking points are independently moved to achieve other desirable purposes, such as equalizing the loads on the slings or intentionally tilting the load.

[0168] In another embodiment, the frame consists of a single crossbar, and in another embodiment, the frame is not quadrilateral but is triangular, polygonal, or any other shape that can facilitate the purpose of optimally supporting and balancing the load.

[0169] Fig.12 View of a single slider with manufacturing details

[0170] Fig.12 Embodiments of a lifting block according to the present invention are disclosed. The lifting block may be made of a block having a T-shaped channel extending from one face of the block to the other face and having an opening on the upper end of the block. The opening on the upper end extends to the T-shaped opening in the block. The block also has a first flange extending upward from the top face of the block and a second flange extending from the lower end of the block. Each flange is provided with an opening for coupling the block. In a specific embodiment, the block is machined from solid steel or cast or manufactured from another suitable material. In another specific embodiment, the block is welded from plates, as shown in the figure.

[0171] Fig.15 A cross-section through a split column

[0172] Fig.15A specific embodiment of shared structural columns is disclosed. Modular "C" shaped sections 152 spanning the height of the module are bolted to similar sections 151 at multiple locations with bolts 153, forming a twice-wide column, thereby providing greater resistance to buckling forces. A baseplate 156, present at both the top and bottom, forms a transition zone to a lighter column 154 or a heavier column, as required, depending on the load. Diagonal braces 150 are connected to the extended webs of the columns 151 as required. Removable sections of fire wall panels 155 are provided to access bolts during structure erection.

[0173] Fig.16 For the cross section through the extendable mating wire washer

[0174] A particular embodiment of an extendable mating wire gasket is shown. A molded or extruded elastomeric material 168 having a plurality of sealing features is secured to a channel 166 which slides in a gasket 167 secured to the inner surface of a channel 169 and extended by a set screw 164 travelling in a threaded socket 165 and actuated by a rotating head 163. The assembly is mounted to a support channel 160 which may be of any convenient depth to which a sound-deadening, fire-retardant material 170 is secured. Access to the gasket is through a cover 161 which, in a particular embodiment, may be decorative and removably secured to advance the screw.

[0175] To form a seal between the first modular unit and the second modular unit, each of the modular units is provided with a channel 166. In the illustrated embodiment, a gasket 167 is present in the channel 160 together with a toothed connector 168. The toothed connector has a configuration complementary to the toothed configuration in the channel in the second modular unit. In a particular embodiment, the gasket 167 allows the toothed connector 168 to move in only one direction, i.e. away from the modular frame. This can be achieved by, for example, providing an inclined tab extending from the surface of the toothed connector and a corresponding receptacle in the gasket 167 for receiving the tab. Once the tab is inserted into the receptacle, the gasket is locked in place and the toothed connector can be prevented from moving back into the channel 160.

[0176] Initially, the two modular units are brought into contact with each other and the channels are aligned. The toothed connector in the second modular frame may be in an extended position, where it extends beyond the mating line of the two modular frames and also beyond the cavity of the channel 160. Once in position, the toothed connector in the first channel may be extended from a disengaged position, where the toothed connector is positioned within the cavity of the channel, to an engaged position, where it extends outside the cavity of the channel and the teeth of the toothed connector in the first modular frame are engaged and aligned with the complementary teeth of the toothed connector in the second modular frame.

[0177] Fig.17Exploded view of the curtain wall system

[0178] A specific embodiment of a curtain wall system for modular construction and associated structural frames are shown. Structural frame 171 with moment blocks 181 is fireproofed with insulation board layer 172 and finished with base plate 182, and is shown supported by half of progressively strengthened split studs 179 connected to adjacent studs (not shown) using bolts inserted in holes 183. Spacer frame 173 is soundproofed and fireproofed with board layer 178, and is provided with holes 177 to receive washer extension screws 164 ( Fig.16 ). The curtain wall infill and gasket mounting frame 175 is equipped with gasket assemblies 176 and faces the exterior wall panels 174. The transition area to the modular structural studs 179 with friction type bolt connections 183 is shown.

[0179] Fig.18 Exploded view of the vertical transition area at the shared structural column

[0180] A specific embodiment of two halves of a shared structural column at the transition point to a lighter column is shown. Combined "C" shaped sections 152 are bolted to each other to form an "I" shaped section. Components of the structural frame 171 are welded to the "C" shaped channel in place of moment blocks in a frame using "C" shaped sections. The moment blocks 181 rest on a combined shiming and gusset plate 30 (more details can be found in Figure 2 The gusset is fastened to the top of the column 152. The curtain wall frame 173 is similar to Fig.17 fastened to the face of the assembly in a manner that allows the

[0181] Fig.19 Horizontal sections of the structural panelized curtain wall system

[0182] A specific embodiment of a structural curtain wall system for a modular building is shown. Modular sections 152 are joined in the manner previously described by the top and bottom headers to form an assembly with window units 190, but unlike the previously described volume modules, the curtain wall units are shipped and erected separately from the floor and interior walls. Crossbars 191 support the floor slabs 178. Fireproof coverings 178 insulate the steel structure. Curtain wall panels 50 provide insulation and appearance. As will be appreciated by those skilled in the art, 45 degree split corner studs 192 perform a similar function as 90 degree exterior corners. In another specific embodiment, the angle of the split corner studs is greater than or less than 45 degrees to facilitate the construction of structures with variable geometric configurations.

[0183] Fig. 20 Simplified exploded view of a vertical module stack

[0184] As previously described, the upper corner connector 10 is joined to the lower corner connector 20 by bolts through the gusset plate 30. In a particular embodiment, the gusset plate 30 is provided in multiple thicknesses, which can be selected during assembly of the building and inserted in the connector as needed to compensate for variations in module size so that the overall size of the module stack conforms to the correct value as measured at 195. In another particular embodiment, the partial plate 192 is provided with a corresponding hole pattern and multiple thicknesses to compensate for size differences of adjacent modules.

[0185] Fig.21 Simplified exploded view of a row of horizontal modules

[0186] As previously described, modular "C" shaped section columns consisting of two halves 152 are bolted together to join adjacent modules and form larger sections. In certain embodiments, spacers 178 are provided in a variety of thicknesses and have pre-cut holes for the connection bolts to pass through. During assembly of the building, appropriate spacers can be selected and inserted in the connectors as needed to compensate for changes in the cumulative horizontal dimensions of the modules as measured at 196.

[0187] PCT / CA2015 / 050369, filed on April 30, 2015 and incorporated herein by reference, discloses another embodiment of connectors and connector assemblies for use in constructing modular units and buildings. The improvements disclosed herein can be used with the connectors disclosed in the previous PCT applications mentioned herein.

[0188] According to this manual, Fig.22a An embodiment of a connector assembly (10) is shown, the connector assembly having a first (upper) connector (12), a second (lower) connector (14), a latch (16), and a gusset (18) sandwiched between the first (upper) connector (12) and the second (lower) connector (14). The manufacture and use of the connector assembly (10) as disclosed herein, in particular, the second (lower) connector (14) and the gusset (18), are similar to those disclosed in PCT Application No. PCT / CA2014 / 050110 filed on February 18, 2014 and PCT Application No. PCT / CA2015 / 050369 filed on April 30, 2015, both of which are incorporated herein by reference. In addition, a person skilled in the art should be able to use the connector assembly (10) disclosed in the present application and adjust it accordingly based on the above-mentioned patent documents, common knowledge and / or non-inventive routine experiments.

[0189] Figure 22bA latch (16) for coupling a first (upper) connector (12) to a second (lower) connector (14) is disclosed. The latch (16) has a body (44) that is cylindrical in shape in the embodiments disclosed herein, however, other shapes may be manufactured or used depending on design and application requirements. In one embodiment, as disclosed herein, the latch body (44) is threaded (46) at one end and the other opposing end is conical (48). The threaded end (46) of the latch (16) is cylindrical in shape and can be screwed into the first (upper) connector (12), as described herein, for connecting the latch (16) to the first (upper) connector (12).

[0190] The conical end (48) of the plug (16) is insertable into the opening (40) in the second (lower) connector ( Fig.22a and Figure 22b The conical end (48) of the plug can help couple the first (upper) connector (12) with the second (lower) connector while also helping to align the two connectors (12 and 14) to form a connector assembly.

[0191] Although the latch disclosed and described herein is threaded at one end and conical at the other end, those skilled in the art will recognize that there is no absolute requirement for this and the shape of the latch may vary depending on the design and application requirements. For example, but not limited to, instead of having a threaded end, one end of the latch may be smooth so that it can be secured to the first (upper) connector by welding or other attachment means such as screws, bolts or latches, or any other means that allow the latch to be held in place. Additionally, the opposite end of the latch (described herein as a conical end) may be flat, such as more cylindrical similar to the shape of the latch body. In one embodiment, the opposite end of the cylindrical latch may be provided with a beveled edge.

[0192] In one embodiment, the latch (16) is provided with a hole (52) that can be used to assist in lifting the modular frame assembly, as further described herein.

[0193] Fig.23 and 24 Embodiments of a first (upper) connector (12), a latch (16) for coupling, and a gusset for forming a connector assembly (10) are disclosed. The first (upper) connector has a first (upper) connector body (20) and a first (upper) connector arm (30) extending from the first (upper) connector body (20).

[0194] The first (upper) connector body (20) at one end (the first (upper) connector body post receiving end (22)) is adapted to receive a post of a modular structure to connect the first (upper) connector to the modular structure. At the opposite end, the first (upper) connector body has a first (upper) connector body gusset contact end (24) and a first (upper) connector body gusset contact surface (26) at the first (upper) connector body gusset contact end (24). When the connector assembly (10) is formed, the first (upper) connector body gusset contact surface (26) contacts the gusset plate (18).

[0195] The first (upper) connector body (20) at the first (upper) connector body gusset contact surface is also provided with a threaded hole (28) for receiving a threaded end (46) of the plug (16). The threaded end (46) of the plug (16) can be screwed into the threaded hole (28) for coupling the plug (16) with the first (upper) connector (12) (such as Fig.25 ).

[0196] Fig.23 and 24 Also shown in the gusset (18) is an embodiment of a gusset (18) that can be used to form a connector assembly (10). The gusset (18) as shown herein is provided with a channel (50) that allows the pin (16) to pass through the gusset (18) when coupling the first (upper) connector (12) and the second (lower) connector (14). The presence of the channel (50) in the gusset (18) along with the conical shape of the pin (16) can facilitate installation to form the connector assembly (10) and properly align the gusset (18).

[0197] Additional holes (54) may be provided on the gusset plate (18) that align with holes (56) in the first (upper) connector arm (30) on the first (upper) connector gusset contact surface (26). Bolts (58) or other fastening members may be used to attach the gusset plate (18) to the first (upper) connector (12).

[0198] Once the first (upper) connector (12), latch (16) and gusset (18) are coupled together, the assembly can be connected to the second (lower) connector (14) to form a connector assembly.

[0199] Similar to the first (upper) connector (10), the second (lower) connector (12) has a second (lower) connector body (32), the second (lower) connector body having a second (lower) connector body column receiving end (34), a second (lower) connector body gusset contact end (36), and a second (lower) connector body gusset contact surface (38) located at the second (lower) connector body gusset contact end. The second (lower) connector body column receiving end (34) is suitable for coupling to a crossbar or other structure of the module; and the second (lower) connector body gusset contact surface (38) at the second (lower) connector body gusset contact end (36) is suitable for contacting the gusset plate (18) (such as Fig.22a and Figure 22b ).

[0200] The second (lower) connector body (32) has an opening (40) at the second (lower) connector body gusset contact surface ( Figure 1 The conical end (48) of the plug pin (16) can help in assembling the connector assembly (10) and also help in proper alignment of the modules during coupling to form the connector assembly (10).

[0201] Similar to the first (upper) connector, the second (lower) connector (14) also has at least one pair of second (lower) connector arms (42) coupled to and extending from the second (lower) connector body. In addition to the features disclosed herein, the features of the first (upper) connector (12), the second (lower) connector (14), and the gusset (18) may be similar to the features disclosed in PCT Application No. PCT / CA2014 / 050110 filed on February 18, 2014 and PCT Application No. PCT / CA2015 / 050369 filed on April 30, 2015, both of which are incorporated herein by reference.

[0202] Although the present specification has been described as using a first (upper) connector and a second (lower) connector, the first connector may be a lower connector of the modular frame and the second connector may be an upper connector of the modular frame unit. Alternatively, both the first and second connectors may be upper or lower connectors.

[0203] Fig.26A liftable assembly (60) is shown formed of a first (upper) connector (10), a latch (16) and a shackle (formed by a U-shaped member (62) and a latch (64). Once the first (upper) connector has been attached to the first (upper) end of the module and the latch has been connected to the first (upper) connector (as described herein), the latch (64) of the U-shaped member (62) connected to the shackle can be inserted into the latch hole (52) of the latch (16). This allows the module frame to be lifted and moved from one position to another while keeping the module intact. Once the module has been positioned, the latch (64) can be removed and the module frame free from the shackle. The liftable assembly can be used with the liftable components disclosed herein above.

[0204] Figures 27 to 30 An embodiment of an assembled corner connector assembly formed by an upper connector, gusset, latch, and lower connector disclosed herein is shown. During assembly, the threaded end of the latch is screwed into the upper connector, which has a threaded opening on the gusset contact surface of the upper connector. Once coupled to the upper connector, the conical end of the latch passes through the opening in the gusset and is inserted into the opening in the gusset contact surface of the lower connector. This allows for proper alignment of the connector assembly and can avoid the use of latches disclosed in gussets as disclosed in prior PCT applications disclosed herein.

[0205] To couple the upper connector, lower connector, and gusset together to form the connector assembly, screws ( Fig. 27 and 29 ) or bolts( Fig.28 and 30 ). The first set of screws or bolts may pass through the holes in the gusset and engage the upper connector. The second set of screws or bolts may pass through the openings in the arms of the lower connector and then through the holes in the gusset and engage and couple to the upper connector to form a connector assembly.

[0206] Fig. 27 and 28 Embodiments of corner connectors are disclosed wherein a gusset is connected to a single upper connector and a single lower connector. Fig.29 and 30 An alternative embodiment of a gusset is disclosed that engages a pair of adjacent upper connectors and a pair of adjacent lower connectors. This can aid in aligning adjacent module frame units during construction. As one skilled in the art will recognize, the gusset can be modified so that it engages four adjacent module frame units by residing between four adjacent upper connectors and four adjacent lower connectors, such as in the center of a modular building.

[0207] Fig.31An embodiment of an assembled corner connector assembly is shown (in phantom lines) to disclose the latch and how it is positioned. Fig.32 and 33 Shown assembly ( Fig.32 ) and decomposition ( Fig.33 ). As shown, the latch is inserted into the opening in the gusset contact surface of the lower connector, and the conical end of the latch and the latch body with the latch hole can be present in the hollow body of the lower connector.

[0208] As those skilled in the art will appreciate, Fig.22a and Figure 22b to Figure 33 The corner connector disclosed in is different from the corner connector disclosed in the previous figures and may be similar to the connector shown in PCT / CA2015 / 050369 filed on April 30, 2015 and incorporated herein by reference; it allows structural elements such as HSS to be welded to the end of an arm extending from an upper or lower connector.

[0209] In one embodiment as disclosed herein, the circumference or perimeter of the body of the latch allows it to contact or be slightly smaller than the circumference or perimeter of the opening in the second connector. This can help the connector assembly act as a single piece. Additionally, the latch disclosed herein, once engaged with the second connector, can help reduce lateral displacement caused by lateral forces at right angles to the latch, which can cause displacement along the contact plane of the connector.

[0210] As one skilled in the art will appreciate, a modular framework may be formed and used in a manner similar to that disclosed in PCT Application No. PCT / CA2014 / 050110, filed on February 18, 2014, and PCT Application No. PCT / CA2015 / 050369, filed on April 30, 2015, both of which are incorporated herein by reference.

[0211] Certain adaptations and modifications may be made to the described embodiments.Therefore, the embodiments discussed above should be considered illustrative rather than restrictive.

[0212] Parts List

[0213] 10 Connector assembly 12 First (upper) connector 14 Second (lower) connector 16 Latch 18 Gusset 20 First (upper) connector body 22 First (upper) connector body column storage end 24 First (upper) connector body gusset contact end 26 First (upper) connector body gusset contact surface 28 With threaded hole 30 First (upper) connector arm 32 Second (lower) connector body 34 Second (lower) connector body column storage end 36 Second (lower) connector body gusset contact end 38 Second (lower) connector body gusset contact surface 40 opening (not shown) 42 Second (lower) connector arm 44 Latch body 46 Threaded first end 48 Conical second end 50 channels 52 Latch hole 54 Holes in gussets 56 Hole in first (upper) connector arm 58 Bolt 60 Liftable assembly 62 hook 64 Latch

Claims

1. A connector assembly comprising a first connector, a second connector, a latch for coupling the first connector to the second connector, and a gusset sandwiched between the first connector and the second connector, the gusset having a channel adapted to receive the latch, The first connector comprises: a first connector body having a first connector body post receiving end, a first connector body gusset contact end, and a first connector body gusset contact surface at the first connector body gusset contact end, wherein the first connector body gusset contact surface has an aperture; as well as at least one pair of first connector arms, each first connector arm coupled to and extending from the first connector body; The second connector comprises: a second connector body having a second connector body post receiving end, a second connector body gusset contact end, and a second connector body gusset contact surface at the second connector body gusset contact end, wherein the second connector body gusset contact surface has an opening; and at least one pair of second connector arms, each second connector arm coupled to and extending from the second connector body; The latch comprises: a latch body having a first end and an opposed second end, the first end being adapted to couple to the aperture on the gusset contact surface of the first connector body and the second end being adapted to engage the opening on the gusset contact surface of the second connector body; in The first end of the latch body is threaded and engages a threaded aperture in the gusset contact surface of the first connector body; The opposed second ends of the latch are conical; and The latch further includes a latch hole positioned on the latch body.

2. A connector assembly comprising a first connector and a latch coupled to the first connector, The first connector comprises: a first connector body having a first connector body post receiving end, a first connector body gusset contact end, and a first connector body gusset contact surface at the first connector body gusset contact end, wherein the first connector body gusset contact surface has an aperture; as well as at least one pair of first connector arms, each first connector arm coupled to and extending from the first connector body; The latch comprises: a latch body having a first end and an opposed second end, wherein the first end is adapted to couple to the aperture on the gusset contact surface of the first connector body; in The first end of the latch body is threaded and engages a threaded aperture in the gusset contact surface of the first connector body; The opposed second ends of the latch are conical; and The latch further includes a latch hole positioned on the latch body.

3. A liftable connector assembly, comprising the connector assembly according to claim 2 and a lifting device detachably attached to the connector assembly.

4. A liftable connector assembly according to claim 3, wherein the lifting device comprises a shackle removably attached to the latch of the connector assembly.

5. A system for forming modular frame units for a modular building, the system comprising: a first modular frame unit having a first modular frame first end coupled to a first connector; a second modular frame unit having a second modular frame first end coupled to a second connector; as well as The first connector and the second connector are coupled by a latch and sandwich a gusset plate. Wherein the first connector, the second connector, the latch and the gusset are as defined in claim 1.

6. A method for coupling modular frame units for forming a modular building, the method comprising: coupling a first connector to a first connector end of a first modular frame unit; coupling a second connector to a second connector end of a second modular frame unit; as well as The first connector and the second connector are coupled using a latch to form a modular frame unit, wherein the first connector, the second connector, the latch and the gusset are as defined in claim 1.

7. A modular building comprising the connector assembly according to claim 1.

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