Modular construction components and methods

Abstract

A variable strength modular concrete building component for constructing residential and commercial buildings, the variable strength modular concrete building component having regions of different strengths defined therein and strategically positioned within a concrete structure within the variable strength modular concrete building component. For example, the regions may include materials having differing compressive strength and / or different densities.

Description

529760.000024MODULAR CONSTRUCTION COMPONENTS AND METHODSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No.63 / 746,687, filed January 17, 2025 and U.S. Provisional Patent Application No. 63 / 746,700, filed January 17, 2025, the entire contents and disclosures of which are incorporated herein by reference.FIELD OF THE DISCLOSURE

[0002] This present disclosure relates generally to modular building systems, which are designed for efficient construction through prefabricated components that can be assembled on-site.BACKGROUND OF THE DISCLOSURE

[0003] Despite the clear benefits of modular construction, its adoption in North America has been limited, with less than 4% of current housing stock utilizing these techniques. This contrasts sharply with countries like Japan, where approximately 15% of homes are modular, and Nordic countries, where the figure rises to 45%. The potential for growth in the North American modular construction sector is significant, provided that industry stakeholders recognize and adapt to the unique requirements and advantages of modular systems.SUMMARY OF THE DISCLOSURE

[0004] The present disclosure provides a variable strength modular concrete building component for constructing residential and commercial buildings, the variable strength modular concrete building component having regions of different strengths defined therein and strategically positioned within a concrete structure within the variable strength modular concrete building component.

[0005] In a first embodiment of the disclosure, a modular component is disclosed. The modular component includes a composite concrete structure having at least two layers. The composite concrete structure includes a first concrete layer formed from a first material having a first compressive strength and a first density and a second concrete layer formed from a second material having a second compressive strength and a second density. The second compressive 1DMS_US.375413482.3529760.000024strength is less than the first compressive strength. The second concrete layer is positioned adjacent to the first concrete layer. The modular component also includes a support assembly coupled to at least one of the first concrete layer and the second concrete layer.

[0006] In another embodiment of the disclosure, a method of making a modular component having a layered composite concrete structure is disclosed. The method includes casting a first concrete layer having a first compressive strength between at least two second concrete layers. Each of the at least two second concrete layers have a second compressive strength. The second compressive strength is less than the first compressive strength. The first concrete layer and the at least two second concrete layers form a multi-layered composite concrete structure. The method further includes incorporating a support assembly during the casting step and defining a reinforcement location in the support assembly to receive a reinforcement member. The reinforcement location extends through each of the first concrete layer and the at least two second concrete layers.

[0007] In yet another embodiment of the disclosure, a modular construction assembly is disclosed. The modular construction assembly includes a plurality of modular components including at least a first modular component and a second modular component. Each modular component includes a composite concrete structure and a support assembly. The composite concrete structure includes a first concrete layer formed from a first material having a first compressive strength and a first density and a second concrete layer formed from a second material having a second compressive strength and a second density. The second compressive strength is less than the first compressive strength. The support assembly is coupled to at least one of the first concrete layer and the second concrete layer.

[0008] In yet another embodiment of the disclosure, a composite concrete structure is disclosed. The composite concrete structure includes a layered concrete subcomponent comprising a first concrete subcomponent and a second concrete subcomponent and a support assembly. The first concrete subcomponent may be different from the second concrete subcomponent such that the first concrete subcomponent has a first compressive strength, and the second concrete subcomponent has a second compressive strength. The first compressive strength is greater than the second compressive strength. The second concrete subcomponent surrounds at least a portion of a perimeter of the first concrete subcomponent at one or more2DMS_US.375413482.3529760.000024locations within the composite concrete structure. The support assembly is coupled to the second concrete subcomponent.

[0009] In yet another embodiment of the disclosure, a method of making a modular construction component has a composite concrete structure. The method includes arranging a first concrete subcomponent relative to a second concrete subcomponent within a mold; casting the first concrete subcomponent and the second concrete subcomponent to form a composite concrete structure with interspersed regions of high-strength and low-strength concrete; incorporating a support assembly into the composite concrete structure during the casting process, the support assembly defining one or more reinforcement locations; and installing a reinforcement member at the one or mor reinforcement locations to engage the composite concrete structure.

[0010] In various embodiments, the composite concrete structure may include a third concrete layer, wherein the first concrete layer may be positioned between the second concrete layer and the third concrete layer.

[0011] In various embodiments, the first compressive strength may be at least twice the second compressive strength.

[0012] In various embodiments, the first concrete layer may have a density between and including 90 and 250 pounds per cubic foot, and the second concrete layer may have a density between and including 35 and 70 pounds per cubic foot.

[0013] In various embodiments, the first compressive strength may be between and including 3000 and 20,000 pounds per square inch, and the second compressive strength may be between and including 750 and 2000 pounds per square inch.

[0014] In various embod9iments, the support assembly may include a frame defining a reinforcement location within the composite concrete structure. The reinforcement location may be an aperture positioned to receive a reinforcement member extending through each of the first concrete layer and the second concrete layers. The reinforcement member may be a composite rod or tube spanning between at least two sides of the frame. The reinforcement member may be formed of a composite material having a density of 20 pounds per cubic foot or less.

[0015] In various embodiments, the modular component may further include a conduit embedded within at least one of the first concrete layer and the second concrete layer. The conduit may be configured to facilitate passage of a medium through the modular component.3DMS_US.375413482.3529760.000024

[0016] In various embodiments, the method may include embedding a conduit within at least one of the first concrete layer and the at least two second concrete layers, the conduit configured to facilitate the passage of utilities through the modular component.

[0017] In various embodiments, the method may include installing the reinforcement member after the casting step. The reinforcement member may extend through the first concrete layer and the at least two second concrete layers to engage the support assembly.

[0018] In various embodiments, the support assembly may include a frame at least partially defining one or more reinforcement locations. Each o the one or more reinforcement locations may be configured to receive at least a portion of a reinforcement member. The reinforcement member may be configured to engage the concrete composite structure. The one or more reinforcement locations may be defined as apertures. The one or more reinforcement locations may include a plurality of opposed aperture pairs and a corresponding reinforcement member for each of the aperture pairs in the plurality of aperture pairs. The reinforcement member may be formed of a material having a density of 20 pounds per cubic foot or less. The reinforcement member may be configured to span between at least two sides of the frame. The reinforcement member may have a circular cross section. The frame may have a polygonal profile.

[0019] In various embodiments, the first concrete subcomponent may have a density between and including 90 and 150 pounds per cubic food. The second concrete subcomponent may have a density between and including 35 and 70 pounds per cubic food.

[0020] In various embodiments, the first compressive strength may be between and including 3000 to 20,000 pounds per square inch. The second compressive strength may be between and including 750 to 2000 pounds per square inch.

[0021] In various embodiments, the composite concrete structure may include a conduit defined by at least one of the composite concrete structure and the support assembly. The conduit may be configured to allow passage of a medium through at least a portion of the composite concrete structure.

[0022] In various embodiments, the first concrete subcomponent may have two or more times the density of the second concrete subcomponent.

[0023] In various embodiments, the first concrete subcomponent may have at least three times the compressive strength of the second concrete subcomponent.4DMS_US.375413482.3529760.000024

[0024] In various embodiments, the method may include defining a conduit within at least one of the composite concrete structure and the support assembly. The conduit may be configured to facilitate passage of a medium through the composite concrete structure. The medium may be one of electrical wiring or plumbing.

[0025] In various embodiments, the reinforcement member may be formed of a composite material with a density less than 20 pounds per cubic foot. The reinforcement member may span between two or more sides of the support assembly.

[0026] In various embodiments, at least one of the first material and the second material includes barium.

[0027] In various embodiments, at least one of the first concrete subcomponent and the second concrete subcomponent includes barium.

[0028] In various embodiments, the at least two second concrete layers include barium.

[0029] Additional features and advantages of the present invention will become apparent to those skilled in the art upon consideration of the following detailed description of the illustrative embodiments exemplifying the best mode of carrying out the invention as presently perceived.BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The foregoing aspects and many of the intended advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description when taken in conjunction with the accompanying drawings.

[0031] FIG. 1 illustrates a perspective view of a modular structure.

[0032] FIG. 2 illustrates a top-down perspective view of the modular structure of FIG. 1.

[0033] FIG. 3A illustrates a reinforcement tube of a modular panel.

[0034] FIG. 3B illustrates a frame of the modular panel incorporated with the reinforcement tube of FIG. 3A.

[0035] FIG. 3C illustrates the modular panel, including a composite concrete structure incorporated with the frame of FIG. 3B and the reinforcement tube of FIG. 3 A.

[0036] FIG. 4 illustrates a composite concrete structure having a multilayered structure.

[0037] FIG. 5 illustrates a composite concrete structure having a framed design.

[0038] FIG. 6 illustrates a first method of manufacturing a modular panel.5DMS_US.375413482.3529760.000024

[0039] FIG. 7 illustrates a second method of manufacturing a modular panel.

[0040] Corresponding reference characters indicate corresponding parts throughout several views. Although the drawings represent embodiments of various features and components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present disclosure. The exemplification set out herein illustrates an embodiment of the invention, and such and exemplification is not to be construed as limiting the scope of the invention in any manner.DETAILED DESCRIPTION

[0041] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, which are described below. The embodiments disclosed below are not intended to be exhaustive or limit the invention to the precise form disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. It will be understood that no limitation of the scope of the invention is thereby intended. The invention includes any alterations and further modifications in the illustrative devices and described methods and further applications of the principles of the invention which would normally occur to one skilled in the art to which the invention relates.

[0042] Modular buildings have revolutionized construction by providing numerous advantages over traditional methods. Unlike conventional on-site construction, where each element is built from scratch, modular construction involves prefabricated components that are assembled into complete structures. These components, known as modules, are designed to endure transportation and installation stresses. Once assembled, the modules seamlessly integrate to form cohesive wall, floor, and roof assemblies. This precision engineering ensures not only structural integrity but also the aesthetic uniformity of the completed building. Modular construction continues to gain popularity in industries requiring fast, reliable, and efficient building solutions.6DMS_US.375413482.3529760.000024

[0043] Each module is meticulously engineered to withstand the rigors of transportation and installation, ensuring enhanced structural strength. Modules are built using advanced materials like galvanized steel and reinforced composites, which provide durability and resistance to wear. These materials ensure that the modules retain their shape and structural integrity during transit, even over long distances. The assembly process further enhances stability, as the modules lock into one another with precision-engineered joints and connections. This process allows modular buildings to meet or exceed the structural standards of traditional site-built structures. As a result, modular buildings are ideal for areas prone to environmental stresses, such as high winds or seismic activity.

[0044] Modular components are manufactured in controlled factory settings, providing numerous benefits in quality and efficiency. These environments are unaffected by external factors such as weather, which can delay traditional on-site construction. Factories employ rigorous quality assurance and control measures, including automated systems to monitor every production stage. Inspection protocols ensure that each module adheres to exacting specifications, minimizing the potential for defects. This controlled environment not only enhances the quality of the modules but also reduces waste, as materials are precisely measured and efficiently used. By centralizing manufacturing, modular construction provides greater predictability in project timelines.

[0045] Factories that produce modular components implement stringent inspection and testing protocols to maintain high standards. Every module undergoes structural testing to ensure it can endure the stresses of transportation and assembly. Utility systems, such as electrical wiring and plumbing, are pre-installed and tested for functionality and safety. This precertification process ensures that all modules meet regulatory compliance standards before reaching the construction site. By addressing potential issues during manufacturing, the need for on-site corrections is significantly reduced. This quality-first approach results in buildings that perform reliably over their lifespan.

[0046] One of the standout advantages of modular construction is its ability to minimize on-site disruption. Traditional construction requires significant site preparation, ongoing labor, and material deliveries, which can be noisy and intrusive. In contrast, modular construction shifts up to 80% of these activities off-site to manufacturing facilities. This reduces vehicular traffic, noise, and waste at the construction site, creating a safer and more controlled environment. Such7DMS_US.375413482.3529760.000024benefits are particularly valuable in sensitive areas, such as hospitals, schools, and residential neighborhoods, where minimizing disruption is critical. By reducing on-site activity, modular construction also speeds up project timelines.

[0047] Modular construction offers substantial cost savings compared to traditional methods, with overall costs often being up to 20% lower. This reduction stems from factors such as improved labor productivity, shorter project timelines, and streamlined supply chains. Prefabrication reduces the need for skilled labor, as components arrive pre-assembled and ready for installation. Moreover, modular construction minimizes delays caused by weather or material shortages, which are common in traditional building projects. The efficient use of materials in factories further contributes to cost savings by reducing waste. As a result, modular construction provides an economically viable solution for both residential and commercial projects.

[0048] Modular systems are inherently adaptable, offering extensive design flexibility to meet diverse project requirements. Architects and designers can choose from various styles, finishes, and configurations to create unique structures that align with client preferences.Whether it’s a modern office building or a traditional-style home, modular construction can accommodate various architectural aesthetics. Customization options include interior layouts, facade designs, and specialized features such as energy-efficient windows. By integrating modular components, designers can experiment with creative layouts that traditional construction methods may not support. This versatility ensures that modular buildings are suitable for a wide range of applications.

[0049] The scalability of modular construction is another significant advantage. Modules can be easily added, removed, or reconfigured to adapt to changing needs. For instance, a modular school building can expand by adding more classrooms as enrollment increases.Similarly, modular offices can accommodate growing businesses by integrating additional workspaces. This adaptability makes modular buildings a cost-effective solution for dynamic environments. The ability to scale up or down without significant structural changes provides long-term value and flexibility to building owners. This feature is particularly beneficial in industries with fluctuating demands, such as healthcare and retail.

[0050] Modular construction significantly reduces project timelines, often by as much as 50%. By manufacturing modules off-site while site preparation occurs simultaneously, the overall construction process is expedited. Traditional delays caused by adverse weather8DMS_US.375413482.3529760.000024conditions or labor shortages are virtually eliminated. Once the modules arrive at the site, assembly is swift, with cranes and pre-engineered connections ensuring quick installation. This accelerated timeline allows businesses and institutions to occupy their buildings sooner, improving return on investment. The speed of modular construction also makes it an ideal choice for emergency projects, such as disaster relief housing or temporary medical facilities.

[0051] The standardization inherent in modular construction minimizes the likelihood of errors during production and assembly. Factory-controlled processes ensure that each module is built to precise specifications, reducing variations that can lead to costly on-site adjustments. High levels of standardization also simplify the assembly process, as components fit together seamlessly without the need for extensive modifications. This reduction in errors contributes to lower failure costs and higher construction quality. The use of computer-aided design (CAD) software further enhances precision, ensuring that all elements align perfectly during manufacturing and installation.

[0052] Modular construction offers a more environmentally friendly alternative to traditional building methods. The process utilizes recyclable materials such as steel, reducing the demand for non-renewable resources. Additionally, factory-based manufacturing generates less waste compared to on-site construction, as materials are cut and used with precision. The reduced need for concrete, a major source of carbon emissions, further enhances the environmental benefits of modular construction. Transportation efficiencies also contribute to sustainability, as fewer deliveries are required, and modules are shipped in bulk. Together, these factors make modular buildings an eco-conscious choice for developers aiming to reduce their environmental footprint.

[0053] Modular buildings are designed with energy efficiency in mind, incorporating features such as advanced insulation and energy-efficient windows. The controlled factory setting ensures that these components are installed to exacting standards, minimizing air leaks and thermal bridging. Many modular buildings also integrate renewable energy systems, such as solar panels, to reduce operational energy costs. Smart building technologies, including automated lighting and HVAC systems, can be seamlessly incorporated into modular designs. These features contribute to lower energy consumption, making modular buildings not only cost-effective but also environmentally sustainable in their long-term operation.9DMS_US.375413482.3529760.000024

[0054] Efficient logistics and transportation are crucial to the success of modular construction projects. Modules are designed to be compactly transported, maximizing space in shipping containers or flatbed trucks. Advanced planning ensures that transportation routes accommodate the dimensions and weight of the modules, reducing the risk of delays. Once onsite, cranes and specialized equipment quickly position the modules for assembly, minimizing the need for extensive material handling. This streamlined process reduces overall project costs and carbon emissions associated with transportation. The modular approach’s logistical efficiency makes it particularly suitable for remote or urban areas where on-site material storage is limited.

[0055] The assembly process for modular buildings is straightforward and designed to minimize labor complexity. Modules are pre-engineered with numbered components, ensuring proper fitting during installation. Pre-drilled openings for utilities like plumbing and electrical systems further simplify the process. The less labor-intensive nature of modular assembly broadens workforce accessibility, attracting a diverse range of workers, including those with limited construction experience. By reducing the reliance on specialized labor, modular construction helps to address labor shortages in the construction industry. This streamlined assembly process also enhances safety by reducing on-site risks such as falls and heavy equipment accidents.

[0056] Modular construction is categorized into volumetric and non-volumetric methods, each with distinct advantages. Volumetric construction involves the prefabrication of three-dimensional modules, such as entire rooms or units, which are transported and assembled on-site. This method is commonly used for residential apartments, hotels, and healthcare facilities, where repetitive layouts are prevalent. Non-volumetric construction, on the other hand, focuses on individual building elements, such as wall panels or structural beams, which are assembled at the site. While volumetric modules offer faster installation, non-volumetric components provide greater flexibility in design and transportation. Projects often combine these methods to balance speed, cost, and customization.

[0057] Many modular projects integrate volumetric and non-volumetric components to optimize construction outcomes. For example, a hotel project might use volumetric modules for guest rooms while employing non-volumetric elements for lobbies and conference areas. This hybrid approach allows designers to achieve both efficiency and architectural complexity. Non-10DMS_US.375413482.3529760.000024volumetric components can be transported more compactly, reducing shipping costs, but they require additional assembly on-site. Despite this added step, the overall time and labor costs remain lower than traditional methods. The ability to combine modular techniques ensures flexibility in addressing diverse project requirements.

[0058] Modular construction is particularly advantageous in the healthcare sector, where speed and hygiene are critical. Prefabricated modules allow hospitals to expand rapidly, accommodating growing patient needs or emergency situations. Specialized modules can be designed for operating rooms, isolation wards, or diagnostic facilities, incorporating features like advanced ventilation systems and sterile surfaces. The controlled factory environment ensures that these modules meet stringent healthcare standards before arriving on-site. By minimizing on-site construction activity, modular methods also reduce the risk of contamination, making them ideal for healthcare settings. Additionally, the flexibility of modular design allows for future reconfiguration as medical technologies evolve.

[0059] Educational institutions benefit significantly from modular construction, particularly in rapidly growing communities. Schools can quickly add classrooms, laboratories, or administrative spaces using prefabricated modules, minimizing disruption to ongoing activities. Modular buildings are also well-suited for temporary facilities, such as portable classrooms, during renovation or expansion projects. Customization options enable the integration of features like soundproofing and energy-efficient lighting, creating conducive learning environments. The cost savings associated with modular construction allow educational institutions to allocate more resources to teaching and student services. Furthermore, the scalability of modular buildings ensures that schools can adapt to changing enrollment needs over time.

[0060] The hospitality industry has embraced modular construction for its speed and efficiency. Hotels, motels, and resorts can be constructed in record time by using prefabricated modules for guest rooms and suites. These modules are often delivered fully furnished, complete with beds, bathrooms, and decor, reducing the time required for interior finishing. Modular construction also allows hospitality businesses to maintain consistent quality across multiple locations, as components are manufactured to standardized specifications. By accelerating project timelines, modular methods enable faster revenue generation, making them a strategic11DMS_US.375413482.3529760.000024choice for hotel developers. Additionally, modular designs can accommodate unique architectural themes, enhancing the guest experience.

[0061] Modular construction plays a crucial role in disaster relief and emergency response scenarios. Prefabricated shelters and medical units can be rapidly deployed to areas affected by natural disasters or humanitarian crises. These structures provide immediate housing, healthcare, or administrative support, enabling relief efforts to stabilize communities quickly. Modular designs are often portable and easy to assemble, allowing them to be relocated as needed. The durable materials used in modular construction ensure that these facilities withstand harsh conditions, providing reliable support in challenging environments. The speed and flexibility of modular construction make it an indispensable tool for emergency management.

[0062] Referring to FIGS. 1-2, a modular construction 100 is illustrated. As shown, modular construction 100 may include structural frame elements 102 which serve as the primary load-bearing elements. Modular panels 104 are fitted between structural frame elements 102 to form walls of modular construction 100 and may include a plurality of composite materials, including materials suited for insulation, weather resistance, and load distribution. Modular construction 100 may further include a roof 106 supported by structural frame elements 102 and / or modular panels 104 to provide protection from environmental elements to persons or objects within modular construction 100. As shown, modular panels 104 may include one or more openings 108 to allow for placement of doors and / or windows.

[0063] Structural frame elements 102 together form a framing system 110 configured to facilitate connection of modular panels 104 to form modular construction 100. Structural frame elements 102 further define reinforcement locations to facilitate future enhancements or modifications to modular construction 100, as discussed above. Utilities, such as electrical conduits or plumbing systems, may be embedded within modular panels 104 or framing system 110 during assembly.

[0064] Now referring to FIGS. 3A-3C, an exploded view of a modular panel 104 (FIG.3C) is provided. For example, as shown in FIG. 3A, modular panel 104 may include a reinforcement tube 112. Reinforcement tube 112 may be formed of a lightweight composite material in integrated into modular panel 104 to provide structural stability. In particular, reinforcement tube 112 maybe formed of a low-density material which may reduce the overall weight of modular panel 104 while maintaining high tensile strength. For example, in some12DMS_US.375413482.3529760.000024embodiments, reinforcement tube may be formed of a material having a density of about 20 pounds per cubic foot or less. Each modular panel 104 may include one or more reinforcement tube 112, wherein the reinforcement tubes 112 are positioned at designated reinforcement locations within modular panel 104 relative to a frame 114 (FIG. 3B) as described further here in to distribute loads substantially evenly across modular panel 104. For example, in some embodiments, reinforcement tube(s) 112 may be positioned strategically in areas within modular panel 104 which may experience a higher level of stress or load concentrations. In other embodiments, reinforcement tube(s) 112 may be positioned strategically for routing of utility components as described further herein.

[0065] For example, reinforcement tube 112 may be a hollow structure to provide openings 116 through modular panel 104 (FIG. 3C), which may reduce material usage and / or facilitate routing of utility materials such as electrical wiring, plumbing, and / or HVAC systems. In other embodiments, alternative conduits may be formed through modular panel 104 to allow for such routing of utility materials. Reinforcement tube may be comprised of basalt fiber reinforced with polydicyclopentadiene (PDCPD) resin, metals such as steel or aluminum, or other composite materials. In some embodiments, openings 116 may be approximately 3 inches in diameter. In other embodiments, openings 116 may be larger or smaller depending on the context of usage.

[0066] Now referring to FIG. 3B, frame 114 is illustrated. While frame 114 is illustrated as having a rectangular form, frame 114 may define another polygonal shape, a circular shape, or another shape which suits the application of frame 114. Frame 114 may be formed of a high strength, high density material, such as steel or another high-strength metal or composite material, configured to support other components of modular panel 104 (FIG. 3C) and provide structure and shape to modular panel 104.

[0067] As shown, frame 114 may form one or more openings 118 along the top member 120 and the bottom member 122 of frame 114 to facilitate the positioning of one or more reinforcement tube(s) 112 as described above. For example, reinforcement tube(s) 112 may be received within openings 118 of both the top member 120 and the bottom member 122 of frame 114 for strategic placement within modular panel 104 and / or to maintain an opening 116 through modular panel 104 upon application of composite modular materials 124. While reinforcement tube(s) 112 are illustrated as running generally vertically between top member 120 and bottom13DMS_US.375413482.3529760.000024member 122 of frame 114, in some embodiments, reinforcement tube(s) 112 may be arranged to span between alternative and / or multiple sides of frame 114. While openings 118, 116 and reinforcement tube(s) 112 are illustrated as having circular cross-sectional shapes, in other embodiments, the openings 118, 116, and reinforcement tube(s) 112 may have alternative cross-sectional shapes and sizes to accommodate utility components or for other functions described further herein.

[0068] In some embodiments, frame 114 may include one or more caps 146 which are configured to secure a plurality of modular panels 104 to one another. For example, a first cap 146 may fit along a first edge of a first modular panel 104 and be configured to couple to a second edge of a second modular panel 104 to couple the first modular panel 104 to the second modular panel 104. Cap 146 may be an integral part of frame 114 in some embodiments. In other embodiments, cap 146 may couple to frame 114. The addition of caps 146 to modular panel 104 may facilitate rapid assembly of panels as well as structural stability across an array of multiple modular panels 104. The caps 146 may further facilitate centralized utility routing by facilitating alignment of conduits and / or reinforcement tubes 112 as described further herein.

[0069] As shown in FIG. 3C, modular panel 104 includes composite modular materials 124 which make up the body 126 of modular panel 104 so that reinforcement tube 112 is embedded within composite modular materials 124. In some embodiments, openings are defined within composite modular materials 124 during a casting process, and reinforcement tube(s) 112 are inserted into the openings during or after the casting process.

[0070] In some embodiments, frame 114 is embedded within composite modular materials 124. In some embodiments, frame 114 may define an outer edge of modular panel 104 while being partially or substantially covered by composite modular materials 124. In other embodiments, frame 114 may form the outer edge of modular panel 104 while being located outside of, or uncovered by, composite modular materials 124.

[0071] Composite modular materials 124 may include a composite concrete structure 128 including both high strength and low-density materials in a layered or interspersed structural format. For example, referring to FIG. 4, a cross-section of composite concrete structure 128 may be a layered structure. A first material subcomponent, e.g., first layer 130, may be located on an outermost portion of composite concrete structure 128 and is formed of a first material. In some embodiments, the first material may include one or more low-density materials which may14DMS_US.375413482.3529760.000024provide insulation, lightweight properties, and / or soundproofing. In other embodiments, the first material may include a high-strength concrete material. First layer 130 may serve as a protective exterior or functional interface for modular panel 104.

[0072] A second material subcomponent, e.g., second layer 132, or a central layer, acts as the structure core of modular panel 104 and is formed of a second material. In some embodiments, the first material and the second material are different materials and / or have differing density and / or strength properties. In some embodiments, the second material may include high-strength materials to provide rigidity and load-bearing capacity needed to stabilize the overall structure of modular panel 104 and corresponding modular construction 100 (FIGS.1-2). In other embodiments, the second material may include a lightweight foamed concrete.

[0073] A third material subcomponent, e.g., third layer 134 may be located opposite of first layer 130 relative to second layer 132 and may be located on an innermost portion of composite concrete structure 128. Third layer 134 may mirror first layer 130. In other words, in some embodiments, third layer 134 may be formed of the same first material which forms first layer 130. The mirroring of first layer 130 and third layer 134 may facilitate balancing of weight across modular panel 104 and / or offer other benefits as described above.

[0074] In some embodiments, each of the first layer 130, the second layer 132, and / or the third layer 134 are formed of foamed concrete comprised of alternative materials or having a differing density in view of each layer’s density and / or strength requirements. In some embodiments, composite concrete structure 128 may include an outer skin 136 which may be applied to an outer surface 138 of first layer 130, an outer surface 140 of third layer 134, or both the outer surface 138 of first layer 130 and the outer surface 140 of third layer 134. In some embodiments, outer skin 136 may be a non-foamed concrete skin. In other embodiments, outer skin 136 may be comprised of alternative materials.

[0075] In some embodiments, outer skin 136 may be combined with or consistent with first layer 130 and third layer 134. In other words, in some embodiments, outer skin 136 may comprise first layer 130 and third layer 134 with second layer 132 formed in between. For example, first layer 130 and third layer 134 may be formed of non-foamed concrete while second layer 132 is formed of foamed concrete. Outer skin 136 may be applied via spray or precast methods.15DMS_US.375413482.3529760.000024

[0076] Although composite concrete structure 128 is illustrated as having a layered sandwich structure in FIG. 4 (e g., a central core or second layer 132 surrounded by mirrored third layers 130, 134), composite concrete structure 128 may include other layered structures. For example, in some embodiments, composite concrete structure 128 may include multiple alternating layers (e.g., first layer consistent with first layer 130, second layer consistent with second layer 132, third layer consistent with third layer 134, fourth layer consistent with second layer 132, fifth layer consistent with first layer 130 or third layer 134, etc.). Such arrangement may allow for incorporation of multiple high-strength and low-density layers in pursuit of customized performance characteristics, allowing for optimization of weight, strength, and thermal performance.

[0077] Now referring to FIG. 5, an alternative “framed” structure of composite concrete structure 128 is provided in a schematic illustration. As shown in FIG. 5, composite concrete structure may include an outer perimeter area 142, or a first material subcomponent, formed of a first material and an inner area 144, or a second material subcomponent, formed of a second material. In some embodiments, the first material and the second material are different materials and / or have differing density and / or strength properties. For example, in some embodiments, the first material may include one or more low-density materials. In other embodiments, the first material may include a high-strength concrete material. In some embodiments, the second material may include high-strength materials. In other embodiments, the second material may include a lightweight foamed concrete. During manufacture the outer perimeter area 142 may be cast using high-strength concrete, while foamed concrete is then cast within outer perimeter area 142 to form inner area 144.

[0078] Referring to FIGS. 4-5, the first material and the second material of composite concrete structure 128 may differ significantly in material properties. For example, in some embodiments, the first material may be formed of a high-strength concrete with densities ranging between and including 90-150 pounds per cubic foot and compressive strengths from and including 3000-20,000 pounds per square inch. The first material may be configured for locations within modular construction 100 (FIGS. 1-2) expected to experience higher load demands, such as foundation points or load-bearing walls.

[0079] In some embodiments, the second material may be formed of a foamed concrete material or another concrete material with densities ranging between and including 35-70 pounds16DMS_US.375413482.3529760.000024per cubic foot and compressive strengths between and including 750-2000 pounds per square inch. The second material may be configured for use in locations within modular construction 100 (FIGS. 1-2) expected to be subjected to lighter loads, such as partitions or non-structural elements. In other words, the first material may exhibit two to three times the density and at least three times the strength of the second material.

[0080] Compressive strength may be measured using the ASTM C39 test, as known in the art. The cylinder for said test may be weighed and the volume calculated to determine the corresponding density.

[0081] Alternatively, the first material may be formed of the foamed concrete material or another low-density concrete material having the above corresponding material properties, while the second material may be formed of the high-strength concrete having the above corresponding material properties.

[0082] In some embodiments, at least one of the first material and the second material may include barium. In some embodiments, only the first material includes barium. In other embodiments, only the second material includes barium. In yet other embodiments, both the first material and the second material may include barium. In such embodiments, the first material may include higher levels of barium than the second material.

[0083] The composition of each composite concrete structure 128 and / or modular panel 104 of modular construction 100 (FIGS. 1-2) may vary within modular construction 100 depending on the needs of the individual modular construction 100 and / or the location within modular construction 100.

[0084] The composite concrete structures 128 as disclosed in relation to FIGS. 4-5 may offer numerous advantages, including heigh strength-to-weight ratios, corrosion resistance, thermal stability, and efficient utility integration. The combination of lightweight materials and layered or framed structures may reduce construction timelines, lower transportation costs, and improve adaptability of a modular system for various building applications, as the modular panel design provides a scalable, efficient, and sustainable construction solutions.

[0085] Now referring to FIG. 6, a method 600 for manufacturing a modular panel (e.g., consistent with modular panel 104) is illustrated. In some embodiments, one or more steps of method 600 may be performed by a modular construction manufacturing device or system.17DMS_US.375413482.3529760.000024

[0086] At block 602, a first material subcomponent (e.g., consistent with first layer 130 or outer perimeter area 142) may be arranged within a mold relative to a second material subcomponent (e.g., consistent with second layer 132 or inner area 144). The first material subcomponent may be positioned at one or more locations within the mold which correspond with one or more locations in a composite concrete structure (e.g., consistent with composite concrete structure 128) which is expected to experience higher loads.

[0087] At block 604, the first material subcomponent and the second material subcomponent may be casted to form a composite concrete structure with interspersed regions of high-strength and low-strength concrete.

[0088] At block 606, a support assembly (e.g., consistent with frame 114) may be incorporated into the composite concrete structure during the casting process. The support assembly may define one or more reinforcement locations.

[0089] At block 608, a reinforcement member (e.g., consistent with reinforcement tube 112) may be installed at one or more reinforcement locations defined by the support assembly to engage the composite concrete structure. The reinforcement member may facilitate structural integrity and modular integration.

[0090] Method 600 may include additional steps, such as any single step or any combination of steps described below and / or in connection with one or more other methods described elsewhere herein. In some embodiments, the support assembly may be pre-fabricated. In some embodiments, the support assembly may define a polygonal profile. In some embodiments, the support assembly may define apertures configured to receive and secure one or more reinforcement members during the casting process.

[0091] In some embodiments, method 600 may include a step of embedding a conduit within at least one of the composite concrete structure and the support assembly. The conduit may be configured to facilitate passage of a medium, such as electrical wiring or plumbing, through the composite concrete structure. In some embodiments, the conduit may be defined by a hollow reinforcement member. In some embodiments, the reinforcement member may be formed of a composite material with a density of less than 20 pounds per cubic foot. In some embodiments, the reinforcement member may span between two or more sides of the support assembly to provide lateral reinforcement within the composite concrete structure.18DMS_US.375413482.3529760.000024

[0092] Although FIG. 6 provides example steps of method 600, in some implementations, method 600 may include additional steps, fewer steps, different steps, or differently arranged steps than those depicted in FIG. 6. Additionally or alternatively, two or more of the steps of method 600 may be performed in parallel.

[0093] Now referring to FIG. 7, a method 700 for manufacturing a modular panel (e.g., consistent with modular panel 104) is illustrated. In some embodiments, one or more steps of method 700 may be performed by a modular construction manufacturing device or system.

[0094] At block 702, a first concrete layer (e.g., consistent with second layer 132) may be cast between at least two second concrete layers (e.g., consistent with first layer 130 and third layer 134) to form a multi-layered composite concrete structure (e.g., consistent with composite concrete structure 128). In some embodiments, the first concrete layer may have greater rigidity and strength compared to the at least two second concrete layers. In other embodiments, the first concrete layer may have a lesser rigidity and strength compared to the at least two second concrete layers. In some embodiments, the at least two second concrete layers may be casted using high-strength concrete, followed by the first concrete layer being cast within or between the at least two second concrete layers using foamed concrete to form the core.

[0095] At block 704, a support assembly (e.g., consistent with frame 114) may be incorporated with the first concrete layer and the at least two second concrete layers during the casting process to provide structural support.

[0096] At block 706, one or more reinforcement locations (e.g., consistent with openings 118) may be defined by the support assembly to receive one or more reinforcement members (e.g., consistent with reinforcement tube(s) 112) extending through the layers of the composite concrete structure.

[0097] Method 700 may include additional steps, such as any single step or any combination of steps described below and / or in connection with one or more other methods described elsewhere herein. In some embodiments, method 700 may include a step of embedding a conduit within at least one of the composite concrete structure and the support assembly. The conduit may be configured to facilitate passage of a medium, such as electrical wiring or plumbing, through the composite concrete structure. In some embodiments, the conduit may be defined by a hollow reinforcement member.19DMS_US.375413482.3529760.000024

[0098] In some embodiments, the first concrete layer may be cast with a thickness sufficient to withstand greater bending or compressive loads than the adjacent second concrete layers.

[0099] Although FIG. 7 provides example steps of method 700, in some implementations, method 700 may include additional steps, fewer steps, different steps, or differently arranged steps than those depicted in FIG. 7. Additionally or alternatively, two or more of the steps of method 700 may be performed in parallel.

[0100] In some embodiments, the reinforcement members may be installed after casting and extend through the first and second concrete layers to engage the support assembly to increase structural strength of the composite concrete structure.

[0101] The foregoing detailed description has been provided for illustrative purposes and is not intended to limit the scope of the invention. It is understood that various changes, modifications, and adaptations may be made to the described embodiments without departing from the spirit and scope of the invention as defined by the claims. The invention encompasses any alternatives, equivalents, and variations that fall within the meaning and range of the claims, as well as all modifications that are within the skill of those in the relevant art.

[0102] The following practical examples illustrate specific embodiments and applications of the invention, demonstrating its utility and advantages in various real-world scenarios. These examples are provided to further clarify the technical aspects, performance characteristics, and potential implementations of the disclosed invention. While the examples focus on particular configurations, materials, or processes, they are not intended to limit the scope of the claims. Instead, they showcase how the disclosure can be adapted across a range of use cases to achieve desired outcomes, highlighting both the versatility and innovative nature of the disclosed technology.

[0103] In Example 1, a modular component comprising: a composite concrete structure having at least two layers, the composite concrete structure including: a first concrete layer formed from a first material having a first compressive strength and a first density; and a second concrete layer formed from a second material having a second compressive strength and a second density, the second compressive strength being less than the first compressive strength, and the second concrete layer positioned adjacent to the first concrete layer; and a support assembly coupled to at least one of the first concrete layer and the second concrete layer.20DMS_US.375413482.3529760.000024

[0104] In Example 2, the modular component of Example 1 , wherein the composite concrete structure includes a third concrete layer, wherein the first concrete layer is positioned between the second concrete layer and the third concrete layer.

[0105] In Example 3, the modular component of any of Examples 1-2, wherein the first compressive strength is at least twice the second compressive strength.

[0106] In Example 4, the modular component of any of Examples 1-3, wherein the first concrete layer has a density between and including 90 and 250 pounds per cubic foot, and the second concrete layer has a density between and including 35 and 70 pounds per cubic foot.

[0107] In Example 5, the modular component of any of Examples 1-4, wherein the first compressive strength is between and including 3000 and 20,000 pounds per square inch, and the second compressive strength is between and including 750 and 2000 pounds per square inch.

[0108] In Example 6, the modular component any of Examples 1-5, wherein the support assembly includes a frame defining a reinforcement location within the composite concrete structure.

[0109] In Example 7, the modular component of Example 6, wherein the reinforcement location is an aperture positioned to receive a reinforcement member extending through each of the first concrete layer and the second concrete layers.

[0110] In Example 8, the modular component of Example 7, wherein the reinforcement member is a composite rod or tube spanning between at least two sides of the frame.

[0111] In Example 9, the modular component of any of Examples 7-8, wherein the reinforcement member is formed of a composite material having a density of 20 pounds per cubic foot or less.

[0112] In Example 10, the modular component of any of Examples 1-9, further comprising a conduit embedded within at least one of the first concrete layer and the second concrete layer, the conduit configured to facilitate passage of a medium through the modular component.

[0113] In Example 11, a method of making a modular component having a layered composite concrete structure, the method comprising: casting a first concrete layer having a first compressive strength between at least two second concrete layers, each of the at least two second concrete layers having a second compressive strength, the second compressive strength being less than the first compressive strength, and the first concrete layer and the at least two second21DMS_US.375413482.3529760.000024concrete layers forming a multi-layered composite concrete structure; incorporating a support assembly during the casting step; and defining a reinforcement location in the support assembly to receive a reinforcement member, the reinforcement location extending through each of the first concrete layer and the at least two second concrete layers.

[0114] In Example 12, the method of Example 11, further comprising embedding a conduit within at least one of the first concrete layer and the at least two second concrete layers, the conduit configured to facilitate the passage of utilities through the modular component.

[0115] In Example 13, the method of any of Examples 11-12, further comprising installing the reinforcement member after the casting step, the reinforcement member extending through the first concrete layer and the at least two second concrete layers to engage the support assembly.

[0116] In Example 14, a modular construction assembly comprising: a plurality of modular components including at least a first modular component and a second modular component, each modular component comprising: a composite concrete structure, the composite concrete structure comprising: a first concrete layer formed from a first material having a first compressive strength and a first density; and a second concrete layer formed from a second material having a second compressive strength and a second density, the second compressive strength being less than the first compressive strength; and a support assembly coupled to at least one of the first concrete layer and the second concrete layer; and a cap configured to couple the first modular component to the second modular component.

[0117] In Example 15, a composite concrete structure comprising: a layered concrete subcomponent comprising a first concrete subcomponent and a second concrete subcomponent wherein the first concrete subcomponent is different from the second concrete subcomponent such that the first concrete subcomponent has a first compressive strength and the second concrete subcomponent has a second compressive strength, the first compressive strength being greater than the second compressive strength, and wherein the second concrete subcomponent surrounds at least a portion of a perimeter of the first concrete subcomponent at one or more locations within the composite concrete structure; and a support assembly coupled to the second concrete subcomponent.

[0118] In Example 16, the composite concrete structure of Example 15, wherein the support assembly comprises a frame at least partially defining one or more reinforcement22DMS_US.375413482.3529760.000024locations.

[0119] In Example 17, the composite concrete structure of Example 16, wherein each of the one or more reinforcement locations is configured to receive at least a portion of a reinforcement member, the reinforcement member configured to engage the concrete composite structure.

[0120] In Example 18, the composite concrete structure of Example 17, wherein the one or more reinforcement locations are defined as apertures.

[0121] In Example 19, the composite concrete structure of Example 18, wherein the one or more reinforcement locations comprise a plurality of opposed aperture pairs and a corresponding reinforcement member for each of the aperture pairs in the plurality of aperture pairs.

[0122] In Example 20, the composite concrete structure of any of Examples 17-19, wherein the reinforcement member is formed of a material having a density of 20 pounds per cubic foot or less.

[0123] In Example 21, the composite concrete structure of any of Examples 17-20, wherein the reinforcement member is configured to span between at least two sides of the frame.

[0124] In Example 22, the composite concrete structure of any of Examples 17-21, wherein the reinforcement member has a circular cross section.

[0125] In Example 23, the composite concrete structure of any of Examples 15-22, wherein the frame has a polygonal profile.

[0126] In Example 24, the composite concrete structure of any of Examples 15-23, wherein the first concrete subcomponent has a density between and including 90 and 150 pounds per cubic foot, and the second concrete subcomponent has a density between and including 35 and 70 pounds per cubic foot.

[0127] In Example 25, the composite concrete structure of any of Examples 15-24, wherein the first compressive strength is between and including 3000 to 20,000 pounds per square inch and the second compressive strength is between and including 750 to 2000 pounds per square inch.

[0128] In Example 26, the composite concrete structure of any of Examples 15-25, further comprising a conduit defined by at least one of the composite concrete structure and the support assembly, the conduit configured to allow passage of a medium through at least a portion23DMS_US.375413482.3529760.000024of the composite concrete structure.

[0129] In Example 27, the composite concrete structure of any of Examples 15-26, wherein the first concrete subcomponent has two or more times the density of the second concrete subcomponent.

[0130] In Example 28, the composite concrete structure of any of Examples 15-27, wherein the first concrete subcomponent has at least three times the compressive strength of the second concrete subcomponent.

[0131] In Example 29, a method of making a modular construction component having a composite concrete structure, the method including: arranging a first concrete subcomponent relative to a second concrete subcomponent within a mold; casting the first concrete subcomponent and the second concrete subcomponent to form a composite concrete structure with interspersed regions of high-strength and low-strength concrete; incorporating a support assembly into the composite concrete structure during the casting process, the support assembly defining one or more reinforcement locations; and installing a reinforcement member at the one or more reinforcement locations to engage the composite concrete structure.

[0132] In Example 30, the method of Example 29, wherein the support assembly comprises a frame having a polygonal profile and apertures defined therein to receive and secure the reinforcement member during the casting process.

[0133] In Example 31, the method of any one of Examples 29-30, further comprising defining a conduit within at least one of the composite concrete structure and the support assembly, the conduit configured to facilitate passage of a medium through the modular construction component.

[0134] In Example 32, the method of Example 31, wherein the medium is one of electrical wiring or plumbing.

[0135] In Example 33, the method of any one of Examples 29-32, wherein the reinforcement member is formed from a composite material with a density less than 20 pounds per cubic foot, and the reinforcement member spans between two or more sides of the support assembly.

[0136] In Example 34, the modular component of any of Examples 1-10 and 14, wherein at least one of the first concrete layer and the second concrete layer includes barium.24DMS_US.375413482.3529760.000024

[0137] In Example 35, the method of any of Examples 11-13, wherein the at least two second concrete layers include barium.

[0138] In Example 36, the composite concrete structure of any of Examples 15-33, wherein at least one of the first concrete subcomponent and the second concrete subcomponent includes barium.

[0139] Unless otherwise indicated, all terms used in the claims are intended to be interpreted in their broadest reasonable sense, consistent with the underlying principles of the invention and the ordinary meaning of the terms in the relevant field. Where ranges or values are provided, it should be understood that all intermediate values and subranges are also contemplated, as well as any combination or permutation of the described elements, steps, or features.

[0140] The descriptions of specific examples and embodiments are intended to be illustrative and not limiting. It should be understood that the invention is not limited to the specific configurations, methods, or materials disclosed but includes any combinations, modifications, or equivalents that fall within the scope of the claims. The scope of the claims is intended to cover all novel and non-obvious aspects of the invention, whether expressly described herein or inherently present.

[0141] Furthermore, it is noted that any features or elements described with reference to a particular embodiment may be combined with features or elements of other embodiments unless explicitly stated otherwise or where such combinations would be incompatible. Accordingly, the invention should not be limited to the examples set forth herein but should be construed in a manner consistent with the claims and their equivalents.25DMS_US.375413482.3

Claims

529760.000024CLAIMSWhat is claimed is:

1. A modular component comprising:a composite concrete structure having at least two layers, the composite concrete structure including:a first concrete layer formed from a first material having a first compressive strength and a first density; anda second concrete layer formed from a second material having a second compressive strength and a second density, the second compressive strength being less than the first compressive strength, and the second concrete layer positioned adjacent to the first concrete layer; anda support assembly coupled to at least one of the first concrete layer and the second concrete layer.

2. The modular component of claim 1, wherein at least one of the first concrete layer and the second concrete layer includes barium.

3. The modular component of claim 1, wherein the composite concrete structure includes a third concrete layer, wherein the first concrete layer is positioned between the second concrete layer and the third concrete layer.

4. The modular component of claim 1, wherein the first compressive strength is at least twice the second compressive strength.

5. The modular component of claim 1, wherein the first concrete layer has a density between and including 90 and 250 pounds per cubic foot, and the second concrete layer has a density between and including 35 and 70 pounds per cubic foot.

6. The modular component of claim 1, wherein the first compressive strength is between and including 3000 and 20,000 pounds per square inch, and the second compressive strength is between and including 750 and 2000 pounds per square inch.26DMS_US.375413482.3529760.0000247. The modular component of claim 1, wherein the support assembly includes a frame defining a reinforcement location within the composite concrete structure.

8. The modular component of claim 7, wherein the reinforcement location is an aperture positioned to receive a reinforcement member extending through each of the first concrete layer and the second concrete layers.

9. The modular component of claim 8, wherein the reinforcement member is a composite rod or tube spanning between at least two sides of the frame.

10. The modular component of claim 8, wherein the reinforcement member is formed of a composite material having a density of 20 pounds per cubic foot or less.

11. The modular component of claim 1, further comprising a conduit embedded within at least one of the first concrete layer and the second concrete layer, the conduit configured to facilitate passage of a medium through the modular component.

12. A method of making a modular component having a layered composite concrete structure, the method comprising:casting a first concrete layer having a first compressive strength between at least two second concrete layers, each of the at least two second concrete layers having a second compressive strength, the second compressive strength being less than the first compressive strength, and the first concrete layer and the at least two second concrete layers forming a multilayered composite concrete structure;incorporating a support assembly during the casting step; anddefining a reinforcement location in the support assembly to receive a reinforcement member, the reinforcement location extending through each of the first concrete layer and the at least two second concrete layers.

13. The method of claim 12, wherein the at least two second concrete layers include barium.27DMS_US.375413482.3529760.00002414. The method of claim 12, further comprising embedding a conduit within at least one of the first concrete layer and the at least two second concrete layers, the conduit configured to facilitate the passage of utilities through the modular component.

14. The method of claim 12, further comprising installing the reinforcement member after the casting step, the reinforcement member extending through the first concrete layer and the at least two second concrete layers to engage the support assembly.

15. A modular construction assembly comprising:a plurality of modular components including at least a first modular component and a second modular component, each modular component comprising:a composite concrete structure, the composite concrete structure comprising: a first concrete layer formed from a first material having a first compressive strength and a first density; anda second concrete layer formed from a second material having a second compressive strength and a second density, the second compressive strength being less than the first compressive strength; anda support assembly coupled to at least one of the first concrete layer and the second concrete layer; anda cap configured to couple the first modular component to the second modular component.

16. The modular construction assembly of claim 15, wherein at least one of the first concrete layer and the second concrete layer include barium.28DMS_US.375413482.3

Images