METHOD AND ARRANGEMENT FOR INTERCONNECTING HORIZONTAL PRECAST STRUCTURES

Description

FIELD OF THE INVENTION

The present disclosure generally relates to construction technology. In particular, the present disclosure relates to connection assembly mechanisms for coupling horizontal structures for use in construction technology.

BACKGROUND OF THE INVENTION

Existing construction technologies involve one-off (e.g., customized) build-on site approaches in which construction material is brought to the construction site where the actual construction is performed. This has been the traditional methodology and approach for many years but has certain inherent challenges, including non-availability of skilled workers (e.g., manual labor), heavy and expensive on-site machinery, incorrect estimate of completion time of construction projects, delays in delivery of projects, inclement weather, poor quality and wastage of materials, noise and air pollution, and cost involved in disposal of debris. This approach is also “one-off” as it provides no repeatability or scalability leverage. Each building is constructed, and each project is performed differently, and results vary widely, which may be undesirable considering present day demand for symmetrical construction projects with enhanced look and feel. However, constructing or casting each individual component of a building on site incurs significant expenditures in time and resources. It also increases a project's vulnerability to unforeseen factors, such as poor weather, worksite accidents, improper pour, etc.

Such traditional methodologies and approaches use connection methods that typically require shuttering for beam and wall structures. However, such connection methods are time and manpower intensive during installation. Further, on-site rebar binding makes such connection methods quite cumbersome to handle. Furthermore, substantial waiting time may also be observed by using such connection methods for slab and beam elements to gain sufficient strength before starting the next level of work.

In order to address the previously mentioned shortfalls of such build or cast-on site approaches, some construction projects use precast modules. Examples of the precast modules may include walls, beams, slabs, and the like, which are built in factories under factory scaling, repeatability, and in-factory conditions. The precast modules are then delivered to a building site and installed using standard connection mechanisms. Such standard connection mechanisms take less time as compared to the connection methods for the build-on site approaches.

However, even standard connection mechanisms have different challenges for several types of interconnections. In an example for slab-to-beam connections, such standard connection mechanisms increase the depth and width of the beam structure, thereby detracting from the aesthetic look of the interior of the building.

Accordingly, there remains a need in the art for an improved and compact connection assembly mechanism that not only allows for lesser skilled workers on site and saves cost and time in the installation process, but also ensures the structural continuity of the whole structure and transfer of forces between the prefabricated building modules during ultimate load conditions.

SUMMARY OF THE INVENTION

Embodiments for a connection assembly mechanism for coupling horizontal precast structures in construction technology are disclosed that address at least some of the above challenges and issues. In an aspect, the present disclosure is directed to a connection assembly mechanism. The connection assembly mechanism includes a first member configured for flush mounting with a lateral surface of a first structure. The first member has opposing first and second surfaces. The connection assembly mechanism further includes a plurality of connectors having opposing first and second ends. Each first end is coupled to the first surface of the first member, and each second end extends from the first surface of the first member. Each second end is configured for embedding within the first structure. The connection assembly mechanism further includes a second member that extends from the second surface of the first member and has opposing top and bottom surfaces. The top surface is configured for supporting a second structure, thereby coupling the first and second structures.

In some embodiments of the present disclosure, each of the plurality of connectors includes an aperture.

In some embodiments of the present disclosure, each of the plurality of connectors comprises at least partially overlapping segments of first and second connector elements.

In some embodiments of the present disclosure, a first segment of each of the plurality of connectors has a rounded corner, a second segment of each of the plurality of connectors is U-shaped, or both.

In some embodiments of the present disclosure, the overlapping segments of the first and the second connector elements are inverted with respect to each other. Each of the plurality of connectors is embedded within the first structure during casting.

In some embodiments of the present disclosure, the connection assembly mechanism further comprises a plurality of support members coupled to the bottom surface of the second member and the second surface of the first member, wherein the plurality of support members is configured for supporting the second member.

In some embodiments of the present disclosure, the bottom surface of the second structure is coupled to the top surface of the second member along the lateral surface of the first structure in accordance with a lateral orientation.

In some embodiments of the present disclosure, the bottom surface of the second structure is coupled to the top surface of the second member along the lateral surface of the first structure in accordance with a transverse orientation.

In some embodiments of the present disclosure, the first structure corresponds to a beam structure.

In some embodiments of the present disclosure, the second structure corresponds to a slab structure.

In some embodiments of the present disclosure, each of the first structure and the second structure corresponds to a precast concrete structure that extends in a horizontal direction.

In an aspect, the present disclosure is directed to a connection method that includes flush-mounting a first member with a lateral surface of a first structure, the first member having opposing first and second surfaces. A plurality of connectors has opposing first and second ends, each first end is coupled to the first surface of the first member, each second end extends from the first surface of the first member. Each second end is configured for embedding within the first structure. A second member extends from the second surface of the first member and has opposing top and bottom surfaces, wherein the top surface is configured to support a second structure, thereby coupling the first and second structures. The connection method further includes coupling the first structure and the second structure based on a support provided by the top surface of the second member to the second structure. The connection method further includes applying a screed on top surfaces of the first structure and the second structure together.

In some embodiments of the present disclosure, the method further includes determining a quantity, a type, and a size of a connection assembly mechanism for coupling the first structure with one or more second structures based on a first plurality of parameters associated with the connection assembly mechanism and a second plurality of parameters associated with at least one of the first structure and the second structure.

In some embodiments of the present disclosure, the first plurality of parameters includes material specifications of the connection assembly mechanism.

In some embodiments of the present disclosure, the material specifications of the connection assembly mechanism correspond to at least tensile strength and hardness of the connection assembly mechanism.

In some embodiments of the present disclosure, the second plurality of parameters includes at least one of a location, an orientation, a weight, and an installation level of at least one of the first structure and the second structure.

In some embodiments of the present disclosure, the method further includes coupling a plurality of support members to the bottom surface of the second member and the second surface of the first member, wherein the plurality of support members is configured for supporting the second member.

In some embodiments of the present disclosure, the method further includes coupling the bottom surface of the second structure to the top surface of the second member along the lateral surface of the first structure in accordance with a lateral orientation.

In some embodiments of the present disclosure, the method further includes coupling the bottom surface of the second structure to the top surface of the second member along the lateral surface of the first structure in accordance with a transverse orientation.

In some embodiments of the present disclosure, the bottom surface of the second structure is coupled to the top surface of the second member at a construction site.

BRIEF DESCRIPTION OF THE DRAWINGS

Further advantages of the disclosure will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings. In the drawings, identical numbers refer to the same or a similar element.

FIG. 1A is a perspective view of an enclosure structure, in accordance with some embodiments.

FIG. 1B is an enlarged, detailed view of a connection assembly, in accordance with some embodiments.

FIG. 2A is a side view of the connection assembly mechanism coupling horizontal precast structures, in accordance with some embodiments.

FIG. 2B is a perspective view of the connection assembly mechanism coupling horizontal precast structures, in accordance with some embodiments.

FIG. 3A is a perspective view of the connection assembly mechanism embedded in a beam structure, in accordance with some embodiments.

FIG. 3B is a perspective view of the connection assembly mechanism embedded in a beam structure coupling with a slab structure, in accordance with some embodiments.

FIG. 4 illustrates a block diagram of an exemplary system for designing, installing, and interconnecting connection assembly mechanisms, in accordance with embodiments.

FIG. 5 illustrates the steps of a method of coupling horizontal precast structures, in accordance with some embodiments.

DETAILED DESCRIPTION

The following detailed description is presented to enable any person skilled in the art to make and use the disclosure. For purposes of explanation, specific details are set forth to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required to practice the disclosure. Descriptions of specific applications are provided only as representative examples. Various modifications to the preferred embodiments will be readily apparent to one skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the scope of the disclosure. The present disclosure is not intended to be limited to the embodiments shown but is to be accorded the widest possible scope consistent with the principles and features disclosed herein.

With modernization in construction-related methodologies and technologies, there has been a rapid shift from normal customized build on-site construction methodologies to construction using modules or blocks that may be built off-site and then assembled on-site to form a construction or a building. However, in the latter case, suitable connection assembly mechanisms for each service, environmental and ultimate load conditions are of utmost importance. The role of a connection assembly mechanism is not only to fix the prefabricated structures together, but also to ensure the structural continuity of the whole structure and to transfer forces between the prefabricated structures when the system is loaded.

Conventional connection methods for build or cast-on site approaches may be too time consuming and labor intensive for execution. Further, on-site rebar binding and shuttering for beam and wall structures makes such connection methods quite cumbersome to handle. Furthermore, substantial waiting time may also be observed by using such connection methods for slab and beam elements to gain sufficient strength before starting the next level of work.

Further, standard connection mechanisms for standard precast modules are also not able to address the previously mentioned shortfalls of conventional connection methods. In an example for slab-to-beam connection, such standard connection mechanisms increase depth and width of the beam structure thereby detracting from the aesthetic look of the interior of the building.

Current connection assemblies and technologies fail to address many concerns, as described hereinbefore. This is especially true for advanced precast structures, which are lightweight due to less material requirements, are more economical (due to less labor, accelerated manufacturing, and reduced cost), and have better performance, factors that together meet today's requirements of enhanced, efficient, and robust connection assembly mechanisms.

The embodiments of the present disclosure address these concerns by providing improved and better-quality connection assembly mechanism allowing for lesser-skilled workers on site and saving cost and time in the installation process. Further, such connection assembly mechanisms also ensure the structural continuity of the whole structure and the transfer of forces between the prefabricated structures during ultimate load conditions.

The disclosed architecture/solution provides several other objects and advantages, some of which are discussed below. The present disclosure supports rapid construction of a structure including precast (prefabricated) modules accommodating erratic site constraints/conditions and/or tight construction schedules. Further, the present disclosure provides for the distribution of at least pre-compression forces across such connection assembly mechanisms for better load distribution, thus improving the durability of enclosure structure. Additionally, an increase in the load resistance of the structure may be obtained by means of embodiments in accordance with the present disclosure. In particular, the disclosed connection assembly mechanisms have very minimal settlement and little or no future challenges, hence, little, or no future maintenance is required. At the least this durability makes the structure economical and also helps reduce the construction times.

Connection assembly mechanisms, in accordance with the disclosure, provide advantages in their compactness and simplicity of manufacture and system performance. By leveraging a controlled environment production, these connection assembly mechanisms ensure quality, cost reduction, and speedy installation.

Further, connection assembly mechanisms in accordance with the present disclosure exhibit substantial fire resistance owing to metallic body, which in turn reduces insurance costs due to increased safety, security, reliability, and structural soundness.

Structurally, connection assembly mechanisms in accordance with the present disclosure provide substantial loading capacity and further offer the enclosure structure a remarkably high resistance to wind, hurricanes, floods, and other damaging environmental occurrences.

Certain terms and phrases have been used throughout the disclosure and will have the following meanings in the context of the ongoing disclosure.

“Cast-in-place concrete” or “Cast-in-situ concrete” is a building-construction technology where elements of an enclosure structure are cast at the site in formwork.

“Pre-cast structure” refers to a construction product produced by casting concrete in a reusable mold or form which is then cured in a controlled environment at an offsite location, transported to a construction site, and maneuvered into a targeted place. Examples may include pre-cast beams, slabs, wall panels, and the like.

“Wall panel” refers to a prefabricated multi-layered wall fabricated at an offsite location and installed on-site, wherein “on-site” denotes a construction site and “offsite” denotes a location away from the construction site. The wall panel may be with or without door or window openings based on the design of the enclosure structure.

“Slab” refers to a prefabricated structure formed at an offsite location and installed on-site. A slab includes a concrete base and a structural topping. The structural toppings, also referred to as topping screeds, are specialized materials applied to an existing concrete base of the slab to enhance performance, durability, and aesthetics.

“Beam” refers to a construction element that is made by casting concrete into a mold and then curing it in a controlled environment at the offsite location. Beams may be used for both load-bearing and non-load bearing applications and may be made in a variety of shapes and sizes.

“Sealant” refers to substances used to seal, block, or close gaps between enclosure structures to prevent fluids, air, and pests from passing through. These materials seal joints where dissimilar materials meet and fill any irregularities that may exist between the two surfaces.

“Modular” refers to individual and independent blocks or any mechanism or procedure for arranging them.

“Lattice girders” refer to three-dimensional, industrially prefabricated reinforcing elements. They consist of an upper chord, two lower chords, and continuous truss wires (e.g., diagonal chords). Typically, the continuous truss wires are connected to the chords by means of electric resistance welding.

FIG. 1A is a perspective view of an enclosure structure 100, in accordance with some embodiments. Referring to FIG. 1A, there are shown at least a foundation structure 102 and multiple precast structures, including a first wall structure 104, a second wall structure 106, a slab structure 108, a beam structure 110, a staircase slab 112, and a connection assembly mechanism 114. The precast structures may be prefabricated at an offsite location away from a construction site and installed on-site at the construction site.

The foundation structure 102 may correspond to a monolithic cast-in-place foundation structure. The foundation structure 102 is the lowest part of the enclosure structure 100 that is in direct contact with the soil and transfers loads from the enclosure structure 100 to the soil safely. To construct the foundation structure 102, trenches are dug deeper into the soil till a hard stratum is reached. Reinforcement cages are incorporated, and concrete is poured. Because the foundation structure 102 is a cast-in-place module and is poured all at once, it is erected much faster, thereby keeping labor costs low. The foundation structure 102 is designed to account for the characteristics of the underlying soil and local environment (e.g., slope of underlying soil, soil type, compactness, local weather conditions, etc.) such that the underlying soil below the foundation structure 102 does not undergo shear failure.

The first wall structure 104 may correspond to a level-1 wall which is installed directly on the foundation structure 102. The first wall structure 104 may be a multi-layered precast structure that can withstand load, climate changes, and daily wear and tear as may be subjected to the enclosure structure 100. It will be appreciated that the first wall structure 104 obtained due to the construction technology is high quality, forming repeatable and scalable building structures.

It will be appreciated that the enclosure structure 100 is merely illustrative of some embodiments. For example, in some embodiments, the first wall structure 104 may be installed indirectly on the foundation structure 102, such as by intermediate elements, another wall structure may be installed indirectly on the first wall structure 104, or both.

The first wall structure 104 may form an IECC energy compliant high-performance envelope. In an exemplary scenario, the first wall structure 104 may be, for example, an 8-inch precast insulated wall. The second wall structure 106 may be similar to the first wall structure 104 and may be installed vertically above the first wall structure 104 at level 2 of the enclosure structure 100. It will be appreciated that in other embodiments, the first wall structure 104 may have other thicknesses and dimensions.

The slab structure 108 may correspond to a precast structure that includes a concrete base and a structural topping. The structural topping may be specialized materials applied to the existing concrete base of the slab structure 108 to enhance performance, durability, and aesthetics. In some embodiments, the slab structure 108 may be a lattice girder slab that may act as permanent formwork and as precast soffits for robust, high-capacity composite slabs. The slab structure 108 may be cast with most, if not all, of the bottom reinforcement; the top reinforcement may be fixed in situ.

The beam structure 110 may correspond to a precast horizontal structure that may be able to withstand vertical loads, shear forces, and bending moments. The beam structure 110 may transfer loads that are imposed along its length to its endpoints, such as the foundation structure 102, the first wall structure 104, and the like. The beam structure 110 may be used for both load-bearing and non-load bearing applications and may be made in a variety of shapes and sizes.

The staircase slab 112 may be a precast structure designed to provide a vertical access from one level to another in the enclosure structure 100. The staircase slab 112 may be made up of reinforced concrete that eliminates the trouble of adjusting the number of steps, rise, run and width of each stair flight. The staircase slab 112 may include a single precast unit containing all the flights and landings or separate precast flights and landings.

The connection assembly mechanism 114 may include various components, such as members and connectors, which are embedded in the beam structure 110, which when interconnected with the slab structure 108 at the construction site, results in a robust installation of ceiling portions of various levels of the enclosure structure 100.

FIG. 1B shows, on the left-hand side, a perspective view of the connection assembly mechanism 114 and, on the right-hand side, an enlarged perspective view of a component of the connection assembly 114. A connector 129 comprises a first connector element 126 and a second connector element 128 described below with respect to two arbitrary axes ‘X1’ and ‘X2’ included to show how connector elements 126 and 128 are oriented with respect to other components of the assembly 114. The connection assembly mechanism 114 includes a first member 120 with a first surface 122 and opposing second surface 124, the pair of connector elements 126 and 128, a second member 130 with a top surface 132 and a bottom surface 134, and a plurality of support members 136, bracing the top surface 132 to support a load, such as an end of a beam structure. The first member 120 of the connection assembly mechanism 114 may correspond to an upright part of the connection assembly mechanism 114 that may be flush-mounted with a lateral surface of a first horizontal precast structure, e.g., the beam structure 110. The first horizontal precast structure may be interchangeably referred to as a first structure. The lateral surface may correspond to a side face (length-wise or width-wise) of the first horizontal precast structure, e.g., the beam structure 110. The first member 120 of the connection assembly mechanism 114 has the first surface 122 which is coupled to at least the pair of connector elements 126 and 128. The second member 130 extends from the second surface 124 of the first member 120 and configured for embedding within the first horizontal precast structure (or the first structure).

The pair of connector elements 126 and 128 may be located at the first surface 122 of the first member 120 of the connection assembly mechanism 114 and is embedded within the first horizontal precast structure, e.g., the beam structure 110. The pair of connector elements 126 and 128 may be embedded within the beam structure 110 during casting in a factory setting. It will be appreciated that for brevity only one pair of connector elements 126 and 128 has been described, however, there are multiple instances similar to the pair of connector elements 126 and 128 that are located at the first surface 122 of the first member 120 of the connection assembly mechanism 114, as illustrated in FIG. 1A. The number of such connector elements may vary based on, for example, the length of the first surface 122 of the first member 120 of the connection assembly mechanism 114, which may be determined by an exemplary system using various parameters, as described in detail in FIG. 4.

As shown in the right-hand portion of FIG. 1B, the first segments 126A and 128A of the connector elements 126 and 128, respectively, are coupled to the first surface 122 along a first axis ‘X1’. The first segments 126A and 128A are coupled in opposite directions juxtaposing next to each other. Next to the first segments 126A and 128A, the respective connector elements 126 and 128 bend at right angles with, for example, rounded corners, and extend outwardly as middle segments 126C and 128C in a second direction along a second axis ‘X2’. The second axis ‘X2’ is orthogonal to the first axis ‘X1’. The middle segments 126C and 128C of the connector elements 126 and 128, respectively, extend in the second direction along the second axis ‘X2’ and terminate in terminal segments 126B and 128B, respectively. Thereafter, the terminal segments 126B and 128B of the connector elements 126 and 128, respectively, are bent in a U-shape and extend towards each other to partially overlap and form partial or segmented racetrack in oval/oblong shape, as illustrated in FIG. 1B. Referring to FIG. 1B, in some embodiments, the connector elements 126 and 128 are structurally similar or identical, whereby the first segment 126A of the connector element 126 coincides with the other first segment 126B of the other connector element 128 by a rotation along the second axis ‘X2’, such that the first segments 126A and 128A are “inverted” or “reversed” relative to each other.

In some embodiments, the second member 130 of the connection assembly mechanism 114 may correspond to a horizontal shelf member of the connection assembly mechanism 114 that extends from the second surface 124 of the first member 120 of the connection assembly mechanism 114. The second member 130 of the connection assembly mechanism 114 laterally extends from the second surface 124 along the second axis ‘X2’ in the second direction, opposite to the first direction.

The plurality of support members 136 is coupled to the bottom surface 134 of the second member 130 and the second surface 124 of the first member 120 of the connection assembly mechanism 114. The plurality of support members 136 provides adequate support to the second member 130 of the connection assembly mechanism 114 to bear the load of the other horizontal structure, e.g., the slab structure 108.

Once the connection assembly mechanism 114 is embedded in the beam structure 110, and the beam structure 110 is coupled with the first wall structure 104 or columns/pillars of the enclosure structure 100, the top surface 132 of the second member 130 of the connection assembly mechanism 114 is adaptable to support a second horizontal precast structure, e.g., the slab structure 108, at the construction site. The second horizontal precast structure may be interchangeably referred to as a second structure.

With reference to the building blocks disclosed in FIG. 1A, in some embodiments, various connection methodologies and/or technologies, such as the connection assembly mechanism 114, are utilized to couple horizontal precast structures and make the enclosure structure 100 structurally and environmentally seamless. The connection assembly mechanism 114, as described herein, may speed up installation processes and reduce the need for skilled labor and allow a high degree of precast structure completion in the factory, enabling repeatability with higher quality levels than traditional methodologies.

Since the enclosure structure 100, in accordance with the embodiments of the present disclosure, is a modular construction, the precast structures are installed in an ordered manner so as to not create a load decompensation, the precast structures sequentially erected vertically increasing the height as per the pre-designed layout for the enclosure structure 100. Once the installation corresponding to the structural work has finished, the placement of doors and windows, bathroom fittings are then carried out in order for a final painting job. It may be contemplated by the present disclosure that the connection assembly mechanism 114 may be employed in any commercial or residential structure having a variety of dimensions and stories.

FIG. 2A is a side view 200A and FIG. 2B is a perspective view 200B of two instances of the connection assembly mechanism 114 embedded in a horizontal structure, in accordance with some embodiments. Referring to FIGS. 2A and 2B, there is shown the beam structure 110 having one side, e.g., a first lateral side 110A and an opposite side, e.g., a second lateral side 110B. Embedded within the first lateral side 110A and the second lateral side 110B of the beam structure 110 are a first connection assembly mechanism 114A and a second connection assembly mechanism 114B, respectively. The first member 120A, 120B of each connection assembly mechanisms 114A, 114B flush-mounts with a corresponding lateral surface of the beam structure 110.

Coupled to the top surfaces 132A and 132B of the second members 130A and 130B of the first connection assembly mechanism 114A and the second connection assembly mechanism 114B, respectively, are a first slab structure 108A and a second slab structure 108B, respectively. As illustrated in FIGS. 2A and 2B, the first slab structure 108A may be a half slab, with a well-spaced 3D lattice girder truss 202A of height ‘h1’ protruding out of the top surface of the first slab structure 108A. On the other hand, the second slab structure 108B may be a thick slab, with another well-spaced 3D lattice girder truss 202B of lesser height ‘h2’< ‘h1’ protruding out of the top surface of the second slab structure 108B. The first slab structure 108A and the second slab structure 108B may be cast with most, if not all, of bottom reinforcement; the top reinforcement may be fixed in situ, referred to as screed 204. The screed 204 may be a structural topping that may include specialized materials applied to an existing concrete base of the first slab structure 108A, the second slab structure 108B, and the beam structure 110 together to enhance performance, durability, and aesthetics.

FIGS. 3A and 3B are three-dimensional perspective views 300A and 300B, respectively, of multiple instances of the connection assembly mechanism 114 embedded in a horizontal structure, in accordance with some embodiments. As shown in FIGS. 3A and 3B, a plurality of connection assembly mechanisms 114A, . . . , 114D, may be embedded within both the lateral sides of the beam structure 110 such that a first member of each connection assembly flush-mounts with a corresponding lateral surface of the beam structure 110. The first connection assembly mechanism 114A and the second connection assembly mechanism 114B have already been described in detail in FIGS. 2A and 2B. Other connection assembly mechanisms 114C and 114D may have varied sizes as compared to the first connection assembly mechanism 114A and the second connection assembly mechanism 114B. In some embodiments, the type, quantity, and sizes of connection assembly mechanisms for coupling horizontal precast structures may be determined by an exemplary system based on a first and a second plurality of parameters, as described in detail in FIG. 4.

In some embodiments, as shown in FIG. 3B, the coupling of the second horizontal precast structure, e.g., the first slab structure 108A, to the top surface 132A of the second member 130A of the first connection assembly mechanism 114A along the length of the first horizontal precast structure, e.g., the beam structure 110, is in accordance with a lateral orientation. In other words, the first slab structure 108A may be coupled width-wise to the second member 130A of the first connection assembly mechanism 114A that is flush-mounted along the length of the beam structure 110. In another embodiment, the coupling of the second horizontal precast structure, e.g., the first slab structure 108A, to the top surface 132A of the second member 130A of the first connection assembly mechanism 114A along the length of the first horizontal precast structure, e.g., the beam structure 110, is in accordance with a transverse orientation. In other words, the first slab structure 108A may be coupled length-wise to the top surface 132A of the second member 130A of the first connection assembly mechanism 114A that is flush-mounted along the length of the beam structure 110.

However, it will be appreciated that the above embodiments are merely for exemplary purposes and should not be construed to be limiting. Without deviating from the scope of the disclosure, other embodiments may also be possible. For example, in some embodiments, the coupling of the second horizontal precast structure, e.g., the first slab structure 108A, to the top surface 132A of the second member 130A of the first connection assembly mechanism 114A may be along the width of the first horizontal precast structure, e.g., the beam structure 110. In other words, the first slab structure 108A may be coupled width-wise to the second member 130A of the first connection assembly mechanism 114A that is flush-mounted along the width of the beam structure 110.

While FIGS. 1B, 2A, and 2B show one example of a connector 129 with connector elements 126 and 128 for embedding into a beam or other structure, other connector configurations are within the scope of the disclosure. For example, in some embodiments the middle segments 126C and 128C extend to the terminal segments 126B and 128B, respectively, over rounded corners, such as illustrated by the middle segment 126C to the terminal segment 126B; over right-angled corners; over angled corners, such that ends of the modified terminal segments 126B and 128B meet, forming sides of a triangle, naming only a few examples. In some embodiments, such as shown in FIGS. 1B, 2A, and 2B, the connector elements 126 and 128 include a central aperture or a void, such that, when the connector elements 126 and 128 are embedded in the beam structure 110 during off-site casting, interior and exterior portions of the connector elements 126 and 128 are encased in the beam structure 100, anchoring the connection assembly mechanism 114 to the beam structure 110 when the material of the beam structure 110 sets. In other embodiments, the connector 129 does not contain a central void, instead, in cross-section, forming a continuous structure. In still other embodiments, the connector 129 is formed as a single integrated component, rather than formed from separate, adjacent connector elements 126 and 128. Those skilled in the art will recognize other structures and designs for the connector 129 in accordance with the disclosure.

FIG. 4 illustrates a block diagram of an exemplary system 400 for designing, installing, and interconnecting connection assembly mechanisms in accordance with embodiments of the present disclosure. The system 400 includes a processor 402, a memory 404, input/output (I/O) devices 406, a network interface 408, and a Computer-Aided Utilities (CAU) module 410 that includes an intelligent recommendation module 412 and a computer-aided manufacturing module 414. The system 400 may be further communicatively coupled with a computer numerical control (CNC) machine 416 via the communication network 418, such as over the network interface 408.

The processor 402 may comprise suitable logic, circuitry, and interfaces that may be configured to execute instructions stored in the memory 404 or commands provided by a user. The processor 402 may also collect information for processing, store it in the memory 404, and transmit it to other modules, such as the CAU module 410 and the I/O devices 406. In some embodiments, the computing functionalities of the processor 402 disclosed herein may be implemented in one or more silicon cores in a RISC processor, an ASIC processor, a CISC processor, FPGAs, and other semiconductor chips, processors, or control circuits.

The memory 404 may comprise suitable logic, circuitry, and interfaces that may be configured to store data supporting various functionalities performed by the processor 402 and the CAU module 410. The memory 404 may store information and/or instructions, various application programs or applications, and a set of data and commands for various operations performed by the processor 402 and the CAU module 410. The memory 404 may include volatile and non-volatile memory, such as a random-access memory (RAM) and a read only memory (ROM). Several program modules may be stored on the hard disk, external disk, the RAM, or the ROM, including an operating system, one or more application programs, and program data. The RAM may be of any type, such as SRAM, DRAM, or SDRAM. A BIOS containing the basic routines that may transfer information between elements within the system, such as during start-up, may be stored in the ROM.

The I/O devices 406 may include input devices, such as keyboard, mouse, microphone, camera, light pen, gesture recognition devices, scanner, touch screen and the like, which may be used to provide input to the system 400. The input may include user-defined settings, a layout of the enclosure structure 100, a weight of the slab structure 108 and the beam structure 110, a quality of the concrete, and the like. The user-defined settings may include structure and design of the connection assembly mechanism 114. The I/O devices 406 may further include output devices, such as touch screen, printer, display screen, and the like. The output may include recommendations for the type, quantity, size, location, and spacing pertaining to multiple instances of the connection assembly mechanism 114 to be used for coupling the horizontal precast structures.

The network interface 408 may be configured to transmit/receive the data from the I/O devices 406 over the communication network 418 to/from other network interfaces of other devices. In some embodiments, the network interface 408 may transmit the code files to other platforms, such as the CNC machine 416, for fabricating or manufacturing the connection assembly mechanism 114 with desired geometry, structure, and design. The network interface 408 may include wired communication interfaces, wireless communication interfaces, cellular communication interfaces, and other communication interfaces to provide communication via other modalities, known in the art.

The CAU module 410 may comprise suitable logic, circuitry, and interfaces that may be configured to perform various functionalities to intelligently manage the fabrication, locations, and/or manufacturing of the connection assembly mechanism 114 based on the requirement and the layout of the enclosure structure 100.

In some embodiments, the CAU module 410 may include the intelligent recommendation module 412 programmed, for example, with a rules-based algorithm retrieved from the memory 404 and user-defined settings received from the I/O devices 406. Accordingly, the CAU module 410 may automatically incorporate local rules, knowledge, geographical information, content, and design of the connection assembly mechanism 114 for indicating type, quantity, locations, and sizes of different components of the connection assembly mechanism 114 for coupling horizontal precast structures based on a first and a second plurality of parameters. The types of materials for the connection assembly mechanism 114 may be based on carbon content, content based on different alloying elements, or environmentally safe content. The quantity of the connection assembly mechanism 114 may correspond to how many connection assembly mechanisms are required for coupling horizontal precast structures. The size of the connection assembly mechanism 114 may refer to the dimensions of each component in proportion to each other. In some embodiments, the intelligent recommendation module 412 of the CAU module 410 may further recommend locations and the spacing between various instances of the connection assembly mechanism 114 along the beam structure 110 based on the first and the second plurality of parameters.

The first plurality of parameters may include, for example, material specifications of the metal used for the connection assembly mechanism 114. Material specifications may include, for example, tensile strength, yield strength, minimum elongation, and hardness of the connection assembly mechanism 114. For example, if the tensile strength of the material is low, then a greater number of connection assembly mechanisms may be required and vice versa. The second plurality of parameters may include at least one of, for example, a location, an orientation, a weight of the horizontal precast structures, e.g., the slab structure 108 and the beam structure 110, an installation level of at least one of the first horizontal precast structure and the second horizontal precast structure, and various environmental conditions, such as those corresponding to hurricane sensitive or earthquake sensitive zones. For example, if the enclosure structure 100 is in a hurricane sensitive zone, then a greater number of connection assembly mechanisms of higher tensile strength may be required. Thus, the intelligent recommendation module 412 may automatically apply local rules to conform with regulations, building codes, local preferences, and user-defined settings for the manufacture, fabrication, and/or installation of the connection assembly mechanism 114.

The intelligent recommendation module 412 may save the information relating to the recommendation of the connection assembly mechanism 114 to computer files that may be stored in the memory 404.

In some embodiments, the computer-aided manufacturing module 414 may translate the information, relating to the recommendation of the connection assembly mechanism 114 corresponding to the fabrication and installation of the connection assembly mechanism 114, to a machine tool code language. By way of non-limiting example, G-Code, based on the RS-274 standard may be used as a machine tool code language. The computer-aided manufacturing module 414 may save the information relating to the machine tool code language in code files that may be stored in the memory 404.

The CNC machine 416 may be configured to process a piece of material, such as a metal, to meet specifications by following coded programmed instructions and without a manual operator directly controlling the machining operation. The coded programmed instructions may be received by the CNC machine 416 in the form of a sequential program of machine control instructions, such as G-code or M-code. Such coded programmed instructions may be executed by the CNC machine 416 to control various machine tools, such as drills, lathes, mills, presses, power saws, and the like, for manufacturing various products, such as various components of the connection assembly mechanism 114.

It will be appreciated that the various components of the connection assembly mechanism 114 may be manufactured automatically by using the machine tools controlled by the CNC machine 416, as described above, in accordance with some embodiments. However, the disclosure is not so limited, and in accordance with other embodiments, the components of the connection assembly mechanism 114 may be manufactured manually by using hand tools as well, or by a combination of automatic and manual steps, without any deviation from the scope of the disclosure.

In some embodiments, the communication network 418 may comprise suitable logic, circuitry, and interfaces that may be configured to facilitate communication of data between different components, systems and/or sub-systems in a computing environment that includes the system 400 and other devices, such as machine tools. In some embodiments, the communication network 418 includes the Internet, a local area network (LAN), or any type of network of one or more computers that communicatively couples multiple computers, to name only a few examples. The communication data may be transmitted or received via at least one communication channel of a plurality of communication channels. The communication channels may include, but are not limited to, a wireless channel, a wired channel, or a combination of wireless and wired channels thereof. The wireless or wired channels may be associated with a data standard which may be defined by one of a Local Area Network (LAN), a Personal Area Network (PAN), a wireless personal LAN (WPLAN), a Wireless Local Area Network (WLAN), a Wireless Sensor Network (WSN), a WAN, and a Wireless Wide Area Network (WWAN), the Internet, cellular networks, Wireless Fidelity (Wi-Fi) networks, short-range networks (for example, Bluetooth®, WiGig, Zwave®, ZigBee®, IrDA, and the like), and/or any other wired or wireless communication networks or mediums.

FIG. 5 illustrates the steps of a method 500 of coupling horizontal precast structures in accordance with some embodiments of the present disclosure. Although specific operations are disclosed in FIG. 5, such operations are examples and are non-limiting. In different embodiments, to name only a few examples, the method 500 includes other steps, the sequence of the steps is modified, some steps are omitted, or any combination of these variations may be incorporated. The steps of method 500 may be automated or semi-automated. In various embodiments, one or more of the operations of the method 500 can be controlled or managed by software, by firmware, by hardware, or by any combination thereof. FIG. 5 will be explained in conjunction with the descriptions of FIGS. 1A to 4.

In some embodiments, the method 500 includes processes in accordance with the present disclosure which can be controlled or managed by a processor(s) (e.g., the processor 402) and electrical components under the control of a computer or computing device including computer-readable media containing computer-executable instructions or code. The readable and executable instructions (or code) may reside, for example, in data storage (e.g., the memory 404) such as volatile memory, non-volatile memory, and/or mass data storage, as only some examples.

At a step 502, the method 500 may include determining a quantity, a type, and a size of the connection assembly mechanism 114 for coupling the first structure, e.g., the beam structure 110, with one or more second structures, e.g., the slab structure 108. The determination may be based on a first plurality of parameters associated with the connection assembly mechanism 114 and a second plurality of parameters associated with at least one of the slab structure 108 and the beam structure 110. As described in the description of FIG. 4, the first plurality of parameters may include material specifications of the connection assembly mechanism 114. The material specifications of the connection assembly mechanism 114 may correspond to at least tensile strength and hardness of the connection assembly mechanism 114. The second plurality of parameters includes at least one of a location, an orientation, a weight, and an installation level of at least one of the slab structure 108 and the beam structure 110.

At a step 504, the method 500 may include flush-mounting the first member 120 of the connection assembly mechanism 114 with a lateral surface of the first structure, e.g., the beam structure 110. The first member 120 may have opposing first surface 122 and the second surface.

As described in detail in FIGS. 1A and 1B, the pair of connector elements 126 and 128, located at the first surface 122 of the first member 120 of the connection assembly mechanism 114, are embedded within the beam structure 110. Portions of the first ends of each pair of connector elements 126 and 128 are coupled to the first surface 122. The second ends of each pair of connector elements 126 and 128 extend outwardly in parallel and then towards each other to be juxtaposed and form an oval/oblong shape. The second member 130 of the connection assembly mechanism 114 extends from the second surface 124 of the first member 120 of the connection assembly mechanism 114. The plurality of support members 136 is coupled to the bottom surface 134 of the second member 130 and the second surface 124 of the first member 120 of the connection assembly mechanism 114.

At a step 506, the method 500 may include coupling the second structure, e.g., the slab structure 108, at a top surface 132 of the second member 130 of the connection assembly mechanism 114 at a construction site.

In some embodiments, as shown in FIG. 3B, the second structure, e.g., the first slab structure 108A, may be coupled width-wise to the top surface 132A of the second member 130A of the first connection assembly mechanism 114A along the length of the first structure, e.g., the beam structure 110, in accordance with a lateral orientation. In other words, the first slab structure 108A may be coupled width-wise to the second member 130A of the first connection assembly mechanism 114A that is flush-mounted along the length of the beam structure 110. Without deviating from the scope of the disclosure, other embodiments, as discussed above in reference to FIG. 3B, may also be possible.

At a step 508, the method 500 may include applying the screed 204 on top surfaces of the first structure, e.g., the beam structure 110, and the second structure, e.g., the first slab structure 108A, together. The screed 204 may be structural topping that may be specialized materials applied to an existing concrete base of the first slab structure 108A, the second slab structure 108B, and the beam structure 110 together to enhance performance, durability, and aesthetic.

Advantageously, by using the connection assembly mechanism 114 as disclosed herein, construction of the enclosure structure 100 is rapid, with the desired structural integrity and strength. Further, as described above, this process of construction provides stability for the enclosure structure 100, making it durable, and weatherproof, among other such advantages mentioned in detail above.

The terms “comprising,” “including,” and “having,” as used in the specification herein, shall be considered as indicating an open group that may include other elements not specified. The terms “a,” “an,” and the singular forms of words shall be taken to include the plural form of the same words, such that the terms mean that one or more of something is provided. The term “one” or “single” may be used to indicate that one and only one of something is intended. Similarly, other specific integer values, such as “two,” may be used when a specific number of things is intended. 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 disclosure. The term “connecting” includes connecting, either directly or indirectly, and “coupling,” including through intermediate elements.

The disclosure has been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while remaining within the spirit and scope of the disclosure. It will be apparent to one of ordinary skill in the art that methods, devices, device elements, materials, procedures, and techniques other than those specifically described herein may be applied to the practice of the disclosure as broadly disclosed herein without resort to undue experimentation. All art-known functional equivalents of methods, devices, device elements, materials, procedures, and techniques described herein are intended to be encompassed by this disclosure. Whenever a range is disclosed, all subranges and individual values are intended to be encompassed. This disclosure is not to be limited by the embodiments disclosed, including any shown in the drawings or exemplified in the specification, which are given by way of example and not of limitation. Additionally, it should be understood that the various embodiments of the building blocks described herein contain optional features that may be individually or together applied to any other embodiment shown or contemplated here to be mixed and matched with the features of that building block.

While the disclosure has been described with respect to a limited number of embodiments, those skilled in the art, having benefit of this disclosure, will appreciate that other embodiments may be devised which do not depart from the spirit and scope of the disclosure as disclosed herein.