Kits, systems, and methods for forming construction structures

Abstract

Kits, systems, and methods for forming construction structures from panels cut from one or more sheets of material. A set of side panels, at least one back panel, one or more bracing elements, and one or more reinforcement components formed from residual cutouts generated during cutting operations are used to create an open box structure defining an interior cavity, with the bracing elements extending diagonally within the structure to provide reinforcement.

Description

Attomev Docket No.: 105091-201KTTS, SYSTEMS, AND METHODS FOR FORMING CONSTRUCTION STRUCTURESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 742,531, filed January 7th, 2025, and to U.S. Provisional Patent Application No. 63 / 955,496, filed January 7, 2026, the contents of which are incorporated herein by reference in their entireties.FIELD

[0002] The present disclosure relates generally to construction technologies, and more particularly to kits, systems, and methods for forming construction structures, such as rectangular blocks, from panels cut from one or more sheets of material.BACKGROUND

[0003] Sustainable and low-carbon construction materials have received increased attention as the building industry seeks to reduce embodied carbon, material waste, and environmental impact. Bio-aggregate composite materials, such as mixtures formed from biomass aggregates and mineral binders, have been explored for their thermal performance, moisture regulation properties, and potential for reduced carbon intensity when compared to conventional construction materials.

[0004] In practice, incorporation of bio-aggregate composites into building structures has often relied on on-site formwork, monolithic casting, or spray-applied installation techniques. Such approaches may require extended curing times, significant on-site labor, and temporary construction assemblies that limit fabrication efficiency and repeatability. These constraints can complicate integration with prefabrication workflows and may reduce the feasibility of reuse or disassembly of structural components.

[0005] Separately, panelized and flatpack construction approaches have been developed to support off-site fabrication, transportation efficiency, and rapid on-site assembly. In some cases, such approaches utilize CNC-based fabrication techniques to cut panels and structural components133043324.1Attomev Docket No.: 105091-201from sheet materials with high dimensional accuracy. However, conventional flatpack systems may generate material waste during cutting operations and may not be configured to reuse residual material as functional structural components.

[0006] There is also growing interest in construction strategies that support Design for Disassembly (DfD), material circularity, and reuse of components at end of life. While various modular and panelized construction systems have been proposed, challenges remain in providing fabrication workflows that intentionally integrate residual material reuse, structural reinforcement, and flexible assembly configurations within a single construction framework.

[0007] Accordingly, there remains a need for construction kits and methods that facilitate efficient fabrication of panelized components from sheet materials, reduce material waste by repurposing residual cutouts as reinforcement components, and support flexible assembly and disassembly of construction structures. Providing such solutions would enable improved integration of sustainable materials, off-site fabrication, and adaptable construction practices across a range of building applications.SUMMARY

[0008] According to a first aspect of the present technology, a kit is provided for forming construction structures comprising one or more sheets of material comprising a set of markings. The markings define a set of side panels, at least one back panel, one or more bracing elements, and one or more reinforcement components formed from residual cutouts generated during cutting operations. The panels are configured to be assembled into an open box structure defining an interior cavity, with the bracing elements extending diagonally within the structure in some embodiments to provide reinforcement.

[0009] According to a second aspect of the present technology, a method for forming construction structures is provided. The method comprises cutting a set of side panels, at least one back panel, at least one bracing element, and reinforcement components from one or more sheets of material. In certain embodiments, the cutting is performed by executing CNC machining instructions on a CNC cutting machine. In some embodiments, use of residual cutouts to create233043324.1Attomev Docket No.: 105091-201the reinforcement components for securing panels or bracing elements during assembly reduces material waste.

[0010] In some embodiments, the method further comprises assembling the side panels and back panel to form an open box structure, positioning one or more bracing elements diagonally within the structure, and securing the components using reinforcement components formed from the residual cutouts. In some embodiments, the interior cavity of the assembled structure receives an infill material that cures to form the construction structure. In some embodiments, the construction structure is a rectangular block.

[0011] According to another aspect of the present technology, a set of machine-readable instructions for forming the components of an open box structure for forming a construction structure are provided. In some embodiments, the components include a set of side panels, at least one back panel, at least one bracing element, and reinforcement components. In some embodiments, the machine instructions comprise instructions for a CNC machine.

[0012] According to another aspect of the present technology, a system for forming a construction structure is provided. The system includes a set of side panels, at least one back panel, at least one bracing element, and reinforcement components. The set of side panels and back panel is configured to form an open box structure. The reinforcement components are configured to secure the side panels, back panel, or bracing element. In some embodiments, the system includes an amount of curable infill configured to fill the open box structure and form the construction structure.

[0013] Some embodiments of the present technology support efficient fabrication, reduced material waste through reuse of residual cutouts, and flexible assembly across a range of building applications.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 shows a perspective view a kit for forming a construction structure according to a first embodiment of the present technology.333043324.1Attomev Docket No.: 105091-201

[0015] FIG. 2 shows a perspective view of components of the kit according to the embodiment of FIG. 1.

[0016] FIG. 3A shows an exploded view of components of the kit according to the embodiment of FIG. 1.

[0017] FIG. 3B shows an exploded view of components of the kit according to the embodiment of FIG. 1.

[0018] FIG. 4 shows an exploded view of components of the kit according to the embodiment of FIG. 1.

[0019] FIG. 5 is a perspective view of components of the kit according to the embodiment of FIG. 1 shown in an assembled state.

[0020] FIG. 6 is an exploded view of components of the kit according to the embodiment of FIG. 1.

[0021] FIG. 7 shows a perspective view of the embodiment of FIG. 1, partially filled with infill.

[0022] FIG. 8 shows a perspective view of the embodiment of FIG. 1 in a partially disassembled state.

[0023] FIGs. 9A and 9B each show a perspective view of a construction structure according to the embodiment of FIG. 1.

[0024] FIG. 10 is an exploded view illustrating a wall assembly incorporating construction structures according to the embodiment of FIG. 1.DETAILED DESCRIPTION

[0025] An embodiment of the present technology will now be described with reference to FIGs. 1-10. According to a first embodiment, a kit 100 for forming a construction structure is provided. As used herein, a “construction structure” includes a structural block or panel, such as a rectangular block, suitable for integration into a larger building assembly. The kit 100 comprises433043324.1Attomev Docket No.: 105091-201one or more sheets 110. As used herein, the term “sheet” refers to a generally planar piece of material from which panels, bracing elements, and reinforcement components can be cut. In some embodiments, the sheets 110 are formed from wood-based materials, such as plywood, composite materials, or other suitable construction materials. In the embodiment shown in FIG. 1, the kit 100 comprises three sheets of material, however, the kit comprises one, two, four, or other numbers of sheets in other embodiments.

[0026] As shown in FIG. 1, the one or more sheets 110 comprise a set of markings 160 that define a set of side panels 120, at least one back panel 130, and one or more bracing elements 140. The side panels 120 and back panel 130 are configured to form an open box structure 170 defining an interior cavity 180, as shown, for example, in FIG. 5. In some embodiments, the markings 160 comprise perforations that enable the marked components to be punched or pressed out of the sheets 110. In other embodiments, the markings comprise inking, branding, or other suitable means for defining the component geometries to guide cutting the components from the sheets. In some embodiments, the markings are generated by a machine executing programming instructions to create the markings on the sheets 110, such as a CNC machine.

[0027] As also shown in FIG. 1, the markings define at least one residual cutout 150. As used herein, the term “residual cutout” refers to material from the sheets 110 that is cut away from the panels and bracing elements used to form the open box structure and any formwork panels. For example, the side and back panels and the bracing elements in the embodiment of FIG. 1 include circular openings 162 from which circular sections are removed to improve the vapor permeability of the panels. The circular sections comprise residual cutouts generated during cutting operations. Other portions of the sheets 110 that are cut away are also considered residual cutouts.

[0028] In the embodiment of FIG. 1, residual cutouts 150 are configured to form at least one reinforcement component for securing the side panels, back panel, or bracing element. FIG.2 shows residual cutouts 150 are portions of the circular sections removed from the panels 120, back panel 130, or bracing elements 140 during cutting operations. The circular residual cutouts are further cut to form disc sectors of the desired size.533043324.1Attomev Docket No.: 105091-201

[0029] In some embodiments, the residual cutouts 150 are further processed to form reinforcement components 152 rather than being discarded as waste material. In some embodiments, the reinforcement components 152 include semicircular pieces 154 and / or sector pieces 156. Sector pieces are disc sections typically smaller than a semicircle, though the disclosure is not limited in this regard. In some embodiments, multiple residual cutouts are used in a stack to form a reinforcement component. In some embodiments, the cutouts are glued together in a stack. The size of the sector pieces is variable depending on the intended use of the reinforcement component. As shown in FIGs. 3B and 4, differently sized sector piece reinforcement components have different applications in building the open box structure. For corner reinforcement, quarter-disc sector pieces are used. For securing bracing panels, l / 8thdisc sectors are used, or other smaller or larger fractions depending on the overall geometry of the panels and open box structure.

[0030] FIGS. 3B-6, for example, show the use of reinforcement components 152, 154 to secure panels to form an open box structure 170. In this embodiment, a semicircle reinforcement component 154 is used to secure a side panel 120 to the back panel 130. Sector reinforcement components 152 are used to secure two bracing elements 140 in a diagonal configuration to the side panels 120, in this embodiment.

[0031] FIGs. 3-4 show the assembly of the open box structure 170. Bracing elements 140 are positioned against the back panel 130 diagonally. In some embodiments, only a single bracing element is used, and in other embodiments, three or more bracing elements are used. In some embodiments, the bracing element is configured to extend diagonally inside the four side panels in the completed open box structure. In some embodiments, the bracing elements 140 are configured to improve structural rigidity or resistance to deformation of the open box structure 170 during handling, assembly, or subsequent construction steps. In the embodiment shown, a single back panel is used, but, in other embodiments, multiple-piece back panels are used to form the back panel, such as a back panel comprised of two, three, or four panels.

[0032] In the embodiment shown, the back panel 130 includes joint locations 185 for joining the edges of the bracing elements, and adhesive and / or appropriate fasteners are used to secure the bracing elements 140. In this embodiment, the set of side panels 120 comprises four633043324.1Attorney Docket No.: 105091-201side panels. As shown in FIG. 3B, side panels 120 have reinforcement components 152, 154 attached via adhesive and / or suitable fasteners.

[0033] In FIG. 4, the positioning of the side panels 120a-d is shown. In some embodiments, the side panels 120 are joined together using biscuit joints. In this embodiment, the first bracing element 140a is configured to extend diagonally from a first side panel 120a to a first joint between a second side panel 120b and a third side panel 120c, and the second bracing element 140b is configured to extend diagonally from the first side panel 120a to a second joint between a third side panel 120c and a fourth side panel 120d.

[0034] FIG. 5 shows the completed open box structure 170 formed from the side panels, back panel, and bracing elements. The open box structure 170 contains an interior cavity 180 and includes at least one open face.

[0035] FIG. 6 shows an exploded view of formwork panels 175 being positioned around the sides and back of the open box structure. In some embodiments, the formwork panels are also cut from the one or more sheets 110. The formwork panels keep the cementitious infill inside the open box structure 170 despite the circular openings on the panels.

[0036] FIG. 7 shows an infill material 190 partially filling the cavity 180, after the formwork panels have been secured. In some embodiments, bio-aggregate composite infill, such as hemp-line, is spray-applied into the cavity 180, and then allowed to cure. In some embodiments, the infill is cementitious. FIG. 8 shows the formwork panels removed from the cured construction structure 200.

[0037] In this embodiment, the construction structure is a rectangular block, which can be used along with other structures 200 as modular building blocks for walls, roofs, etc. FIG. 9 shows different views of a completed construction structure 200. FIG. 9A shows a front perspective view and FIG. 9B shows a rear perspective view.

[0038] FIG. 10 shows construction structures 200 used in a larger building-scale assembly, such as a wall or enclosure.733043324.1Attorney Docket No.: 105091-201

[0039] Another embodiment of the present technology provides a method of forming a construction structure comprising cutting a set of side panels 120, at least one back panel 130, and at least one bracing element 140 from one or more sheets 110, and cutting one or more reinforcement components 152 / 154 from a residual cutout 150 from the one or more sheets 110, the set of side panels, the least one back panel, or the at least one bracing element.

[0040] In some embodiments, the cutting is performed by executing CNC machine instructions on a CNC cutting machine. In some embodiments, the CNC machining instructions are generated from software instructions or digital design data defining component geometry, cutting paths, perforations, and / or sequencing of cutting operations. In other embodiments, the cutting is performed manually.

[0041] In some embodiments, the set of side panels comprises four side panels, and the method further comprises positioning the four side panels 120a-d relative to one another and joining the side panels to form an open box structure. In some embodiments, the method further comprises positioning the at least one bracing element 140 diagonally inside the open box structure 170. In some embodiments, the method further comprises positioning first and second bracing elements 140a and 140b diagonally inside the open box structure, wherein the first bracing element 140a is configured to extend diagonally from a first side panel 120a to a firstjoint between a second side panel 120b and a third side panel 120c, and wherein the second bracing element 120b is configured to extend diagonally from the first side panel 120a to a second joint between a third side panel 120c and a fourth side panel 120d.

[0042] In some embodiments, the step of cutting one or more reinforcement components 152 / 154 from a residual cutout 150 comprises cutting at least one circular section from at least one of the side panels, back panel, or bracing elements to create the residual cutout. In some embodiments, the method further comprises cutting at least one semicircle piece from the residual cutout to form at least one first reinforcement component 154 configured to secure one or more side panels to the back panel. In some embodiments, the method further comprises cutting at least one sector piece from the residual cutout to form at least one second reinforcement component 152 configured to secure the bracing elements to one or more side panels.833043324.1Attomev Docket No.: 105091-201

[0043] In some embodiments, the method further comprises fdling the open box structure 170 with a bio-aggregate composite infill 190. The terms bio-aggregate composite infill includes any composite with a binder mix (being cementitious or not) and bio-aggregate (being hemp hurd or not). In some embodiments the infill is hemp-based, such as hempcrete or hemplime.

[0044] According to another embodiment, a set of machine-readable instructions are provided for forming the components of an open box structure for forming a construction structure. The instructions include those described above and in relation to the drawings for cutting components from at least one sheet of material. In some embodiments, the instructions are provided on one or more non-transitory machine-readable media.

[0045] According to another embodiment, a system for forming a construction structure is provided, the system comprising a set of side panels, at least one back panel, at least one bracing element configured to form an open box structure, and a set of reinforcement components for securing the side panels, back panel, or bracing elements. In some embodiments, the system comprises four side panels, one back panel, and two bracing elements, the bracing elements configured to extend diagonally inside the open box structure. In some embodiments, the set of reinforcement components are formed from residual cutouts from creation of the side panels, back panel, and / or bracing elements. In some embodiments, the set of reinforcement components comprise one or more semicircle pieces for securing the one or more side panels to the back panel. In some embodiments, the set of reinforcement components comprise one or more sector pieces configured to secure the bracing elements to one or more side panels.

[0046] As will be apparent to those skilled in the art, various modifications, adaptations, and variations of the foregoing specific disclosure can be made without departing from the scope of the technology claimed herein. The various features and elements of the technology described herein may be combined in a manner different than the specific examples described or claimed herein without departing from the scope of the technology. In other words, any element or feature may be combined with any other element or feature in different embodiments, unless there is an obvious or inherent incompatibility between the two, or it is specifically excluded.

[0047] References in the specification to “one embodiment,” “an embodiment,” etc., indicate that the embodiment described may include a particular aspect, feature, structure, or933043324.1Attorney Docket No.: 105091-201characteristic, but not every embodiment necessarily includes that aspect, feature, structure, or characteristic. Moreover, such phrases may, but do not necessarily, refer to the same embodiment referred to in other portions of the specification. Further, when a particular aspect, feature, structure, or characteristic is described in connection with an embodiment, it is within the knowledge of one skilled in the art to affect or connect such aspect, feature, structure, or characteristic with other embodiments, whether or not explicitly described.

[0048] The singular forms “a,” “an,” and “the” include plural reference unless the context clearly dictates otherwise. Thus, for example, a reference to “a plant” includes a plurality of such plants. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for the use of exclusive terminology, such as “solely,” “only,” and the like, in connection with the recitation of claim elements or use of a “negative” limitation. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition, or step being referred to is an optional (not required) feature of the technology.

[0049] The term “and / or” means any one of the items, any combination of the items, or all of the items with which this term is associated. The phrase “one or more” is readily understood by one of skill in the art, particularly when read in context of its usage.

[0050] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges recited herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. A recited range (e g., weight percents of carbon groups) includes each specific value, integer, decimal, or identity within the range. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third, and upper third, etc.

[0051] As will also be understood by one skilled in the art, all language such as “up to,” “at least,” “greater than,” “less than,” “more than,” “or more,” and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into sub-ranges as1033043324.1Attomev Docket No.: 105091-201discussed above. In the same manner, all ratios recited herein also include all sub-ratios falling within the broader ratio. Accordingly, specific values recited for radicals, substituents, and ranges, are for illustration only; they do not exclude other defined values or other values within defined ranges for radicals and substituents.

[0052] One skilled in the art will also readily recognize that where members are grouped together in a common manner, such as in a Markush group, the technology encompasses not only the entire group listed as a whole, but each member of the group individually and all possible subgroups of the main group. Additionally, for all purposes, the technology encompasses not only the main group, but also the main group absent one or more of the group members. The technology therefore envisages the explicit exclusion of any one or more of members of a recited group. Accordingly, provisos may apply to any of the disclosed categories or embodiments whereby any one or more of the recited elements, species, or embodiments, may be excluded from such categories or embodiments, for example, as used in an explicit negative limitation.1133043324.1

Claims

Attorney Docket No.: 105091-201CLAIMSWhat is claimed is:

1. A kit for forming a construction structure, comprising:one or more sheets comprising a set of markings that define:a set of side panels and at least one back panel that are configured to form an open box structure;at least one bracing element; andat least one residual cutout configured to form at least one reinforcement component for securing the side panels, back panel, or bracing element.

2. The kit of claim 1, wherein the markings comprise perforations in the one or more sheets.

3. The kit of claim 1, wherein the set of side panels comprises four side panels.

4. The kit of claim 3, wherein the bracing element is configured to extend diagonally inside the four side panels in the open box structure.

5. The kit of claim 4, further comprising a first and a second bracing element, wherein the first bracing element is configured to extend diagonally from a first side panel to a first joint between a second side panel and a third side panel, andwherein the second bracing element is configured to extend diagonally from the first side panel to a second joint between a third side panel and a fourth side panel.

6. The kit of claim 1, wherein at least one of the side panels, back panels, and bracing elements includes at least one circular section forming the residual cutout.

7. The kit of claim 6, wherein the residual cutouts comprise a set of semicircle pieces configured to secure one or more side panels to the back panel.

8. The kit of claim 6, wherein the residual cutouts comprise one or more sector pieces configured to secure the bracing elements to one or more side panels.

9. A method of forming a construction structure, comprising:cutting a set of side panels, at least one back panel, and at least one bracing element, from one or more sheets; and1233043324.1Attorney Docket No.: 105091-201cutting one or more reinforcement components from a residual cutout from the one or more sheets, the set of side panels, the at least one back panel, and the at least one bracing element;wherein the one or more reinforcement components are configured for securing at least one of the side panels, back panel, or bracing element.

10. The method of claim 9, wherein the cutting steps comprise executing CNC machine instructions on a CNC cutting machine.

11. The method of claim 9, wherein the set of side panels comprises four side panels, and the method further comprises positioning the four side panels relative to one another and joining the side panels to form an open box structure.

12. The method of claim 11, further comprising positioning the at least one bracing element diagonally inside the open box structure.

13. The method of claim 12, further comprising positioning a first and a second bracing elements diagonally inside the open box structure,wherein the first bracing element is configured to extend diagonally from a first side panel to a first joint between a second side panel and a third side panel, andwherein the second bracing element is configured to extend diagonally from the first side panel to a second joint between a third side panel and a fourth side panel.

14. The method of claim 9, wherein the step of cutting one or more reinforcement components from a residual cutout comprises cutting at least one circular section from at least one of the side panels, back panel, or bracing elements to create the residual cutout.

15. The method of claim 14, further comprising cutting at least one semicircle piece from the residual cutout to form at least one first reinforcement component configured to secure one or more side panels to the back panel.

16. The method of claim 15, further comprising cutting at least one sector piece from the residual cutout to form at least one second reinforcement component configured to secure the bracing elements to one or more side panels.

17. The method of claim 16, further comprising filling the open box structure with a bioaggregate composite infill.1333043324.1

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