Design and Production of building structures and infrastructures using dimensionally predetermined adaptable socket array systems

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent Application 63/676,800 filed Jul. 29, 2024, which is incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to dimensionally predetermined socket array systems integral to construction building blocks or standalone, attachable socket array systems for methods of (mass-)producing building structures and construction systems and infrastructure.

BACKGROUND OF THE INVENTION

The current cost of construction of adequate dwellings for every person is prohibitive of a scalable solution to the current lack of housing and the predicted demand for dwellings adequate to accommodate the predicted additional ˜1.5 billion people by 31 Dec. 2050.

The lack of a standard format for designing and implementing the fabrication and installation of all the systems required for a building to function is a major contributor to that prohibitive cost. The amount and diversity of materials used to create any form of dwelling is another major contributor to cost. Focusing on the interrelatedness of those two impediments to a scalable solution has resulted in the inventions described, herein.

One of the consequences of that focus is the inadequacy of the architect's grid lines. The well documented, substantial loss on most building projects has its roots in the disconnect from what the architect draws and the ‘as built’ outcomes including all the unintended, unanticipated expenses that emerge during the construction process that could have been avoided with a dimensionally precise, computable, mechanism that ensures high fidelity adherence between design intent and final cost, on-time delivery, customer expectations and a high-fidelity, accessible rendering of what was actually built.

SUMMARY OF THE INVENTION

Definitions

Socket—is a dimensionally defined (width, depth, taper) receptacle that can be machined to accommodate a variety of screws, bolts, rods, and the like. In the present application these sockets are also referred to as protrusions.

Socket Array—is a dimensionally defined number of sockets organized in a variety of configurations, e.g., an X v Y axis set of sockets embedded in any type of structural material.

Socket Gasket—is a dimensionally defined set of sockets assembled into a contiguous pattern that can be embedded in any type of structural material. The Gasket can be comprised of materials that confer specific structural and functional properties to whatever substance they are embedded.

Socket Insert (aka Socket Adapter or Adapter Socket)—is a dimensionally defined object, made from materials such as metal and plastic that has specific functional characteristics (e.g., specific types of screw specifications) that converts a homogenous Socket Gasket into a multipurpose system for the mounting of any type of mechanical, electrical, network, plumbing, and the like, equipment or assemblies thereof.

SocketBlock AdaptaSlot—is a dimensionally precise space within the SocketBlock that can contain a variety of materials to alter the properties of the SocketBlock, e.g., to alter thermal, acoustic, structural performance specifications of the SocketBlock. The socket block is also referring to herein as dwelling structure. Specifically, SocketBlock refers to any building component that when assembled creates a higher order function, e.g. SocketBlock assemblies can be wall (e.g., a SocketPanel, a floor, ceiling, roofing, stairwell, elevator hoist way, gutters, and the like).

The invention is characterized by a dwelling structure that is composed of a building structure block and a socket array. The building structure is a building block or panel, a cement block or panel, a prefabricated building structure, a wall structure, ceiling structure or a floor structure. The socket array has a base plate having a base plate surface from which a plurality of protrusions is organized and extend in a distributed pattern. The distributed pattern is typically an orderly matrix m by n pattern, where m≥1 and n≥2, or m≥2 and n≥1. The socket array is cast in the building structure.

Each of the plurality of protrusions have a distal end. The building structure has a building structure surface at which each of the distal ends of the plurality of protrusions are accessible. One or more, or each of at least a subset of the plurality protrusions are capable of receiving a connector that fits the respective protrusion. The plurality of protrusions are suitable through these connectors to fit mechanical, electrical, network, plumbing devices, equipment, spatial spanners or assemblies.

In a further embodiment, one or more of the plurality of protrusions have a protrusion locking mechanism to lock to the connectors. The connectors would then have a connector locking mechanism to mate or lock with the protrusion locking mechanism of the protrusions.

In that configuration, one or more of the distal ends of the plurality of protrusions are either flush with the building structure surface, shy of the building structure surface, or extend passed the building structure surface. One or more of the plurality of protrusions are circular, square, rectangular, ellipsoidal or any shape depending on the type of application.

One or more of the plurality of protrusions have either a through-hole from the distal end in a direction of the base plate, are solidly closed protrusions from the distal end in the direction of the base plate, or a combination thereof.

Each of the protrusions is individually attached to the base plate, or the plurality of protrusions are uniformly integrated with the base panel through a manufacturing process.

The plurality of protrusions are non-metallic or in some specific applications metallic, and each one of the plurality of protrusions have predesigned thermal, acoustic, electromagnetic energy barrier, vapor barrier, structural performance specifications or combinations thereof that will affect the performance of the dwelling structure.

The building structure has one or more cut-outs or through-holes for the purposes of aligning the dwelling structures, stacking the dwelling structures, connecting socket arrays, connecting base plates or connecting one or more of the plurality of protrusions.

The dwelling structure could further have a lining or a joining mechanism suitable to fit in between two dwelling structures.

The invention is also characterized as a method of manufacturing a building structure. The method distinguishes the steps of having a plurality of building blocks. Each of the building blocks distinguishes a top side, a bottom side, and two lateral sides. Each of the building blocks has at least two through holes from the top side to the bottom side. Each building block has at one or both of the two lateral sides a dimensionally predetermined array of dimensionally specified sockets, where each of the sockets are capable of receiving an infrastructure component. The building blocks are stacked together, and aligned by aligning the through holes for the stacked building blocks. The stacked building blocks are secured by inserting a securing mechanism through the aligned through holes for the stacked building blocks.

In one example, the method further includes attaching one or more infrastructure components to one or more of the sockets.

The infrastructure component is an electrical component, a mechanical component, an HVAC component, a plumbing component, a network component, a cladding component, an elevator component, a hoist railing component, a stair component, a cabinetry component, or a finishing component.

The stacked building blocks form a building structure, wherein the building structure is at least part of a single-family dwelling, at least part of a multitude of dwelling units, at least part an office building, at least part of a datacenter, at least part of a warehouse, at least part of a factory, at least part of a shopping mall, or at least part of an auto-repair shop.

Other embodiments of the invention can be characterized as different methods, systems and building blocks with or without the infrastructure sockets as individual components.

Objective and Advantages

Objective of the invention is to manufacture building structures and infrastructures using dimensionally predetermined socket array systems integral to construction building blocks or as standalone, attachable, dimensionally predetermined socket arrays systems.

The SocketBlock (aka DwelloBlock) intent is to eliminate all studs from any form of wall construction irrespective of the shape, purpose or position of the wall within a structure. This will then allow for mass-production of any type of wall from the minimum number of components. It further allows for mass-production of any type of wall that required minimum effort to assemble. It still further allows for mass-production of any type of wall (interior, exterior, hoist way, stairwell, and the like, as well as floors, ceilings, trusses and other structural components).

The SocketBlock enables any such type wall with standardized, dimensionally precise attachment sockets for any type of equipment, furnishings, coverings, safety devices, rails, signage, and any other functional or structural building component.

The SocketBlock enables mass-production of the ‘elemental’ component of such walls that entirely embodies the necessary intended characteristics described above.

The SocketBlock enables mass-production of such ‘elemental’ components in a manner that enables not just fabrication of rectilinear components, but also variously curved components for purposes not just esthetically comforting but also provide improved function particularly regarding air circulation and lighting.

The SocketBlock enables mass-production of the ‘elemental’ component from geographically dispersed, readily available materials, as well as, equally geographically dispersed production facilities of such materials—thus our focus on concrete though it's readily imaginable that other types of materials that have ‘flow and harden’physical chemistry characteristics could be used.

The SocketBlock enables mass-production of the ‘elemental’ component with equipment designed to impart the maximum number of functional dimensions to each resultant component rather than generating the functional dimensions in separate components then assembling them post fabrication—though we will claim that fabricating any of the integrated characteristics of the ‘elemental’ component, separately, and then connecting them post-fabrication is not a way to subvert the invention.

It is the objective of the invention to leverage the design intent to create computational design, modeling, simulation, rendering tools for engineering, architecture, construction, developer, trades, owner, investor, regulator, insurance, and inspector professionals, as well as, inhabitants.

The inventor refers to such ‘elemental’ components as SocketBlocks (generic) and DwelloBlocks (to indicate the commitment to mass-scale delivery of dignified dwellings).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows according to an exemplary embodiment of the invention a dwelling structure 100 that is composed of a building structure block 110 and a socket array 120. Left is a top or planar view. Right is a side view.

FIGS. 2-3 show according to exemplary embodiments of the invention connectors and that fit protrusions suitable to fit mechanical, electrical, network, plumbing devices, equipment, spatial spanners or assemblies. FIG. 2 shows a planar or top view, whereas FIG. 3 shows a side view.

FIG. 4 shows according to an exemplary embodiment of the invention, in a top or planar view, relative positions of the distal ends of the protrusions with the surface of the building structure and therewith with the dwelling structure.

FIG. 5 shows according to an exemplary embodiment of the invention that protrusions have either a through-hole or lumen from the distal end in a direction of the base plate, are solidly closed protrusions from the distal end in the direction of the base plate. A top or planar view is shown.

FIG. 6 shows according to an exemplary embodiment of the invention cut-outs or through-holes for the purposes of aligning the dwelling structures, stacking these dwelling structures, connecting socket arrays, connecting base plates or connecting one or more of the plurality of protrusions. Top or planar view shows a top view. Middle view shows a side view. Bottom view shows a side view. Noted is that only part of the protrusions are shown for each dwelling block in 620 and 630, but a skilled artisan would appreciate that they can have various arrays and configurations.

FIGS. 7A-C show according to exemplary embodiments of the invention another variation of cut-outs or through-holes for the purposes of aligning the dwelling structures, stacking these dwelling structures, connecting socket arrays, connecting base plates or connecting one or more of the plurality of protrusions. For clarity purposes, as a reader readily appreciates, FIG. 7A does not show base plate 122 for protrusions 126 (see for reference FIG. 1). However, FIGS. 7B-C are added to show SocketGasket Array 730, which is the base plate 122 and the sockets/protrusions 126 embedded in SocketBlock 740.

FIGS. 8A-B show according to exemplary embodiments of the invention a model of two joined sets of pairs of SocketBlocks (FIG. 8A). These can e.g. be thought of as wall panels. FIG. 8B shows a production of a SocketPanel instead of individual SocketBlocks as in FIG. 8A.

FIG. 9 shows according to an exemplary embodiment of the invention that dwelling structures could further have a lining or a joining mechanism suitable to fit in between two dwelling structures (e.g. dwelling structure 1 and 2).

FIG. 10 shows according to an exemplary embodiment of the invention a segment of a socket array gasket with a protrusion lock mechanism as indicated by arrows. Two views of the channel and slot that will to form a universal socket grove 1010 and twist lock 1020 in place mechanism for the insertion of Adapter Sockets.

FIG. 11 shows according to an exemplary embodiment of the invention a depiction of a resultant universal adapter groove and lock mechanism. FIG. 11 shows the connector that would fit the protrusion's lock mechanism as shown in FIG. 10.

FIG. 12 shows according to an exemplary embodiment of the invention a round version of an adapter socket that when inserted and locked into a protrusion of a socket array confers on that socket a specific function (e.g., a screw dimension, a pull strength characteristic, a load characteristic, a magnetic potential, and the like.

DETAILED DESCRIPTION

A method, device and system for building products as well as manufacturing of molds or/and frame-cast components used to fabricate them is provided. The following description is organized by first describing the products and then the fabrication components. For each item in the outline a reference is made to the drawings.

Embodiments of the invention is comprised of the following.

A standardized Socket Array system for the design and installation of all the systems required for a building to meet code requirements and function.

A standardized production mechanism of building blocks capable of being assembled into any type of wall, floor, ceiling, truss, i.e., the necessary components of a building space.

The integration of the standardized Socket Array system with the standardized production mechanism of the building blocks (i.e., the SocketBlock).

The ability to adapt the SocketBlock to a variety of structural and functional capabilities WITHOUT having to alter the production mechanism.

The ability to use the same production mechanism to generate SocketBlocks with different joining properties.

The ability of the production mechanism to render SocketBlocks in a variety of linear and curvilinear shapes.

The production mechanism includes the use of injection molds or/and automated frame casting of the SocketBlocks in a manufacturing process to ensure high output of quality-controlled products.

The SocketBlock can either be assembled into walls and other types of structures in a factory or at the site where the dwellings (or any other form of building) are being constructed.

Structures assembled from SocketBlocks-using typical masonry procedures have on all relevant surfaces the SocketArrays. To those SocketArrays, all building systems are attached be they cladding on the exterior of a building or hot and cold-water pipes on the interior of the building.

Whether formed from a uniform socket dimension gasket or from any number of unique sockets loaded, manually or automatically on s Socket Pedestal, whether that Socketp Pdestal is a component of an injection mold or a frame casting SocketBlock-forming process.

A further embodiment of the SocketArray would be to define unique dimensional and functional (e.g., screw type) and fabricate the SocketArray gasket to those specifications.

The preferred approach would be to manufacture Socket Array gaskets with uniform dimensions and a universal insert-and-turn internal feature thus enabling an unlimited type of adaptors to be inserted either pre-assembly of the SocketBlock into a structure or inserted during the assembly process.

FIG. 1 shows a dwelling structure 100 that is composed of a building structure block 110 and a socket array 120. Building structure 110 is a building block or panel, a cement block or panel, a prefabricated building structure, a wall structure, ceiling structure or a floor structure. Socket array 120 has a base plate 122 having a base plate surface 124 from which a plurality of protrusions 126 extend in a distributed pattern. The distributed pattern is typically an orderly matrix m by n pattern, where m≥1 and n≥2, or m≥2 and n≥1. The socket array is cast within or into the building structure.

Each of the plurality of protrusions have a distal end 126-D. The building structure has a building structure surface 112 at which each of the distal ends 126-D of the plurality of protrusions are accessible. As shown in FIG. 2, one or more or each of at least a subset of the plurality protrusions are capable of receiving one or more connectors 210 that fits the respective protrusion. The plurality of protrusions are suitable to fit mechanical, electrical, network, plumbing devices, equipment, spatial spanners or assemblies as indicated by 220. FIG. 3 shows the planar view of FIG. 2 where only such equipment device or assembly 220 is visible as the connectors are now being behind 220.

In that configuration, one or more of the distal ends of the plurality of protrusions 126 are either flush (412) with the building structure surface, shy (410) of the building structure surface, or extend (414) passed the building structure surface as shown in FIG. 4 by some exemplary protrusions.

As shown in FIG. 5 in a top view, the plurality of protrusions have either a through-hole 510 from the distal end in a direction of the base plate, are solidly closed protrusions 520 from the distal end in the direction of the base plate, or a combination thereof. The protrusions are exemplified as circular protrusions but they don't have to be. They can be square, rectangular, ellipsoidal or any other form that would be suitable for the connector types that would mate the protrusions (see also FIGS. 10-11). Each socket array can either have one type of protrusions or a variety of different types of protrusions, all which depend on the type of application.

In general, the manifestations of the underlying inventive concepts can be any range of shapes or/and sizes of blocks or panels, or protrusions.

The plurality of protrusions are individually attached to the base plate, or the plurality of protrusions are uniformly integrated with the base panel through a manufacturing process.

The plurality of protrusions are non-metallic, and each one of the plurality of protrusions have predesigned thermal, acoustic, electromagnetic energy barrier, vapor barrier, structural performance specifications or combinations thereof that will affect the performance of the dwelling structure.

There could be an exception to non-metallic in a case of an inclusion of a sufficient concentration of tungsten to prevent leakage of EMF frequencies (e.g. X-Ray) used by radiologists, scientist and other certified professionals for specific tasks conducted in spaces formed by an assembly of SocketBlocks, or/and SocketPanels.

A variety of methods of molding (injection, hybrid injection, or the like), open cavity, pre-cast and even cast-in-place systems can be used to produce blocks, panels, and other types of concrete structures all of which become unique because of some version of a SocketArray Gasket is embedded in them. The mold or casting structure can be made of wood, metal, plastic, etc. An exemplary method is described in the priority document, but as pointed out, the invention is not limited to that example.

As shown in FIG. 6, the building structure has one or more cut-outs or through-holes 612 for the purposes of aligning the dwelling structures (e.g. dwelling structure 1 and 2, aka SocketBlocks), stacking these dwelling structures, connecting socket arrays, connecting base plates or connecting one or more of the plurality of protrusions. Top or planar view in FIG. 6 shows a top view with cut-outs or through-holes 612. Middle view of FIG. 6 shows a side view with cut-outs or through-holes 612. Bottom view of FIG. 6 shows a side view with dwelling connectors 632. As a skilled artisan would readily appreciate is that there could be many different joining mechanisms or swivel components. Illustrations of such are provided in the drawings of the priority document. In addition, dwelling structures don't have to be planar either as they can be in any shape or form. With that the invention is not limited to these examples, and illustrations of such as also provided in the drawings of the priority document.

FIGS. 7A-C show a variation of cut-outs or through-holes 612 and 710 for the purposes of aligning the dwelling structures, stacking these dwelling structures, connecting socket arrays, connecting base plates or connecting one or more of the plurality of protrusions. Noted is that cut-outs or through-holes 612 and 710 are in different locations of the dwelling structures so that they can be aligned as shown in FIGS. 8A-B. FIG. 8A shows a model of how sets of pairs of SocketBlocks integrate with one another and a stack of four such integrated sets 810 are an example of how a wall, ceiling, floor or any other type of structure could be assembled from sets of SocketBlocks. FIG. 8B shows a production of a SocketPanel 820 instead of individual SocketBlocks.

For clarity purposes, as a reader readily appreciates, FIG. 7A does not show base plate 122 for protrusions 126 (see for reference FIG. 1). However, FIGS. 7B-C are added to show SocketGasket Array 730, which is the base plate 122 and the sockets/protrusions 126 embedded in SocketBlock 740.

FIG. 9 shows dwelling structures could further have a lining or a joining mechanism 910 suitable to fit in between two dwelling structures (e.g. dwelling structure 1 and 2). This lining or a joining mechanism 910 could be in between stacking dwelling structures or dwelling structures that are adjacent to each other, or at any other place where such lining or a joining mechanism is desired. The purpose of lining could include ensuring a fire stop, vapor barrier, substitute for mortar, prevention of air leaks to name a few.

As mentioned supra the protrusions can mate the connectors. FIGS. 10-11 show an example where the mating also has a locking mechanism as indicated by 1010 and 1020, and 1110. FIG. 10 shows a segment of a socket array gasket with a protrusion lock mechanism. Specifically, a segment of a socket array gasket with a protrusion lock mechanism as indicated by arrows. Two views of the channel and slot that will to form a universal socket grove 1010 and twist lock 1020 in place mechanism for the insertion of Adapter Sockets.

FIG. 11 shows a resultant universal adapter groove and lock mechanism. Connector 1110 would fit, mate and lock with protrusion's lock mechanism 1010. A skilled artisan would readily appreciate that various different mechanisms can be designed to make the protrusion and connector lock, and the example provided herein is by no means limiting to the invention as claimed.

FIG. 12 shows a line drawing of a round version of a protrusion an Adapter Socket that when inserted and locked into a protrusion 1210 of a socket array confers on that socket a specific function. A skilled artisan would recognize all the properties that the bore of the Adapter Socket could be milled to result in specific functional properties (e.g., a screw dimension, a pull strength characteristic, a load characteristic, a magnetic potential, and the like).

In some variations of the embodiments, the invention could not only include use of some form of concrete to comprise the material of SocketBlock/SocketPanel products, but could also include a variety of materials that share the property of flow before they don't, i.e. transition from a liquid phase (or gaseous phase) to a solid entity with sufficient strength (tensile and compressive) to use in a building.

“In some variations of the embodiments, the invention could be applied to building components other than walls, floors, ceilings, hoist ways, stairwells and the like. Given the resilience properties of concrete, and the exceptional properties of concrete formed with non-Portland cement, the inventor anticipates objects like gutters and other drainage systems and many other structural and infrastructural products will benefit from some form of an embedded SocketGasket Array.