Self-Aligning Lock Brackets for Modular Building Units
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Solution Overview
Problem
The current methods for aligning and securing modular building units are labor-intensive and require multiple fasteners, lacking a precise and efficient way to ensure rigid connection and alignment, which affects the structural integrity and efficiency of modular construction.
Innovation Solution
A system of brackets comprising lock brackets with a locking tab profile and receiver brackets with an alignment hole, allowing for self-aligning and locking of modular units by sliding vertically and laterally, ensuring secure attachment and alignment without the need for extensive lateral movement during installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fastening methods are used to secure modular building units, then structural connection is achieved, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The bracket system transitions from static fastening to dynamic self-aligning and self-locking. The receiver bracket's alignment hole and the lock bracket's protrusion with locking tab create a dynamic interaction where the lock bracket automatically aligns and locks onto the receiver bracket as the modular units are brought together, eliminating manual alignment and fastening operations.
Solution Approach 2:
The bracket system performs self-alignment and self-locking functions. The geometric configuration of the alignment hole and locking tab profile enables the lock bracket to automatically position itself relative to the receiver bracket and engage without external intervention, allowing the structure to secure itself during assembly.
2Strength
If multiple fasteners are used to ensure secure attachment, then connection strength is improved, but device complexity increases
Solution Approach 1:
The invention merges multiple functions into a single integrated bracket assembly. The lock bracket combines alignment features (alignment hole), locking features (locking tab with profile), and connection features into one component that replaces multiple separate fasteners, achieving both simplified complexity and maintained strength.
Solution Approach 2:
The bracket system serves multiple functions simultaneously: it provides structural connection, ensures precise alignment, prevents vertical separation, and enables lateral movement control. This multi-functionality is achieved through the geometric design of the alignment hole and locking tab profile working together as a single mechanism.
3Manufacturing precision
If precise alignment is achieved through traditional methods, then manufacturing precision is improved, but the alignment process becomes more complex
Solution Approach 1:
The alignment hole and locking tab profile are designed with asymmetric geometric features that guide the lock bracket into precise alignment. The non-symmetric shape of the locking tab interacts with the alignment hole to automatically position the brackets correctly, eliminating the need for complex alignment procedures or additional alignment tools.
4Stability of the object's composition
If rigid connection is ensured between modular units, then structural integrity is improved, but ease of assembly is reduced
Solution Approach 1:
The bracket system provides dynamic behavior during assembly, allowing the lock bracket to move freely during alignment then automatically locking into place. The geometric configuration enables the connection to transition from a movable state during assembly to a rigid locked state during operation, maintaining both ease of assembly and structural integrity.
Data Source
AI summary
Device, systems, and methods for secure attachment and alignment of modular building units. The system includes one or more lock brackets on a first modular building unit and one or more receiver brackets on a second modular building unit. The lock brackets include a lock bracket protrusion. The lock bracket protrusion includes a locking tab having a locking tab profile including an aligning portion and a locking portion. The receiver brackets include an alignment hole. The lock bracket protrusion is inserted into the alignment hole as the second modular building unit is lowered onto the first modular building unit. The receiver brackets slide vertically and laterally along the aligning portion and the locking portion as the lock bracket protrusion is inserted into the alignment hole. The locking portion prevents vertical movement of the second modular building unit without a corresponding lateral movement.