WALL ANCHOR STRUCTURES AND ASSOCIATED WALLS AND METHODS

Description

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application Ser. No. 63/710,742, filed Oct. 23, 2024, the disclosure of which is hereby incorporated herein in its entirety by this reference.

TECHNICAL FIELD

Embodiments of the present disclosure generally relate to modular wall structures. In particular, embodiments of the present disclosure relate to wall anchor structures and associated wall structures and methods.

BACKGROUND

Buildings, such as houses and commercial buildings, include multiple walls defining the space within the associated structure. Some buildings may be built using modular construction. Modular construction uses prefabricated structures to construct the associated structure. For example, walls, ceilings, roofs, floors, or even complete rooms, may be fabricated in a remote location, such as a factory or construction yard and then transported to the location of the associated building, where the prefabricated structures are assembled to construct the associated building.

Modular construction may increase efficiency of the construction of a building. For example, building the modular structures in a factory or construction yard may facilitate building the structures in a more efficient manner. Furthermore, all the raw materials may be handled at the factory or construction yard, which may reduce the transportation or shipping costs.

BRIEF SUMMARY

Embodiments of the disclosure include a wall anchor structure. The wall anchor structure includes an enclosure defining a cavity within the enclosure. The wall anchor structure further includes an aperture in a panel of the enclosure. The wall anchor structure also includes an open face configured to provide access to the cavity within the enclosure. The wall anchor structure further includes a wall side bracket configured to receive hardware through the aperture in the panel of the enclosure.

Another embodiment of the disclosure includes a wall. The wall includes a framework. The wall further includes an anchor structure secured to a structure separate from the framework. The anchor structure includes an aperture facing the framework. The wall also includes a bracket secured to the framework. The bracket is configured to interface with hardware through the aperture in the anchor structure.

Other embodiments of the disclosure include a method of securing a modular wall to a separate structure. The method includes securing a bracket to a framework of the modular wall. The method further includes securing an anchor structure to the separate structure. The method also includes passing threaded hardware element through an aperture in the anchor structure. The method further includes securing the bracket to the anchor structure with a complementary threaded hardware element joined to the threaded hardware element.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing out and distinctly claiming embodiments of the present disclosure, the advantages of embodiments of the disclosure may be more readily ascertained from the following description of embodiments of the disclosure when read in conjunction with the accompanying drawings in which:

FIG. 1 illustrates an exploded view of a modular wall of the structure in accordance with embodiments of the disclosure;

FIG. 2 illustrates a perspective view of the modular wall of FIG. 1 in accordance with embodiments of the disclosure;

FIGS. 3 and 4 illustrate enlarged views of portions of the modular wall of FIG. 1 in accordance with embodiments of the disclosure;

FIG. 5 illustrates a perspective view of a junction of the modular wall of FIG. 1 in accordance with embodiments of the disclosure;

FIG. 6 illustrates a schematic cross-sectional view of an embodiment of the anchor structure of the modular wall of FIG. 1 in accordance with embodiments of the disclosure;

FIGS. 7A and 7B illustrate schematic cross-sectional views of an embodiment of the anchor structure of the modular wall of FIG. 1 in different stages of installation in accordance with embodiments of the disclosure;

FIG. 8 illustrates a schematic cross-sectional view of an embodiment of the anchor structure of the modular wall of FIG. 1 in accordance with embodiments of the disclosure;

FIG. 9 illustrates a perspective view of an embodiment of a modular wall in accordance with embodiments of the disclosure;

FIG. 10 illustrates an enlarged perspective view of a portion of the modular wall of FIG. 9, in accordance with embodiments of the disclosure; and

FIG. 11 illustrates an enlarged perspective view of a portion of the modular wall of FIG. 9, at a subsequent processing step in accordance with embodiments of the disclosure.

DETAILED DESCRIPTION

The following description provides specific details, such as material compositions, shapes, and sizes, in order to provide a thorough description of embodiments of the disclosure. However, a person of ordinary skill in the art would understand that the embodiments of the disclosure may be practiced without employing these specific details. Indeed, the embodiments of the disclosure may be practiced in conjunction with conventional techniques employed in the industry.

Drawings presented herein are for illustrative purposes only and are not meant to be actual views of any particular material, component, structure, device, or system. Variations from the shapes depicted in the drawings as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein are not to be construed as being limited to the particular shapes or regions as illustrated, but include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as box-shaped may have rough and/or nonlinear features, and a region illustrated or described as round may include some rough and/or linear features. Moreover, sharp angles that are illustrated may be rounded, and vice versa. Thus, the regions illustrated in the figures are schematic in nature, and their shapes are not intended to illustrate the precise shape of a region and do not limit the scope of the present claims. The drawings are not necessarily to scale. Additionally, elements common between figures may retain the same numerical designation.

As used herein, the term “substantially” in reference to a given parameter means and includes to a degree that one skilled in the art would understand that the given parameter, property, or condition is met with a small degree of variance, such as within acceptable manufacturing tolerances. By way of example, depending on the particular parameter, property, or condition that is substantially met, the parameter, property, or condition may be at least 90.0 percent met, at least 95.0 percent met, at least 99.0 percent met, at least 99.9 percent met, or even 100.0 percent met.

As used herein, “about” in reference to a numerical value for a particular parameter is inclusive of the numerical value and a degree of variance from the numerical value that one of ordinary skill in the art would understand is within acceptable tolerances for the particular parameter. For example, “about” in reference to a numerical value may include additional numerical values within a range of from 90.0 percent to 110.0 percent of the numerical value, such as within a range of from 95.0 percent to 105.0 percent of the numerical value, within a range of from 97.5 percent to 102.5 percent of the numerical value, within a range of from 99.0 percent to 101.0 percent of the numerical value, within a range of from 99.5 percent to 100.5 percent of the numerical value, or within a range of from 99.9 percent to 100.1 percent of the numerical value.

As used herein, relational terms, such as “below,” “lower,” “bottom,”“ ” “above,” “upper,” “top,” and the like, may be used for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the drawings. Unless otherwise specified, the spatially relative terms are intended to encompass different orientations of the materials in addition to the orientation depicted in the figures. For example, if materials in the figures are inverted, elements described as “below” or “under” or “on bottom of” other elements or features would then be oriented “above” or “on top of” the other elements or features. Thus, the term “below” can encompass both an orientation of above and below, depending on the context in which the term is used, which will be evident to one of ordinary skill in the art. The materials may be otherwise oriented (e.g., rotated 90 degrees, inverted, flipped) and the spatially relative descriptors used herein interpreted accordingly.

As used herein, the terms “vertical,” “longitudinal,” “horizontal,” and “lateral” are in reference to a major plane of a structure and are not necessarily defined by earth's gravitational field. A “horizontal” or “lateral” direction is a direction that is substantially parallel to the major plane of the structure, while a “vertical” or “longitudinal” direction is a direction that is substantially perpendicular to the major plane of the structure. The major plane of the structure is defined by a surface of the structure having a relatively large area compared to other surfaces of the structure. With reference to the drawings, a “horizontal” or “lateral” direction may be perpendicular to an indicated “Z” axis, and may be parallel to an indicated “X” axis and/or parallel to an indicated “Y” axis; and a “vertical” or “longitudinal” direction may be parallel to an indicated “Z” axis, may be perpendicular to an indicated “X” axis, and may be perpendicular to an indicated “Y” axis.

As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

As used herein, the term “and/or” means and includes any and all combinations of one or more of the associated listed items.

As used herein, the term “enclosure” means and includes a box, sleeve, channel, rail, or other body defining an interior cavity or passage defined by walls.

Modular construction may increase efficiency of the construction of a building. While modular construction may reduce the costs of construction, modular construction may also reduce the quality of the resulting structure. Modular construction may reduce the efficiency of the structure. For example, a modularly constructed structure may have lower insulation factors, such that the structures are less efficient at maintaining an interior temperature.

Embodiments of the disclosure are directed to modular construction structures that provide greater insulation factors than conventionally constructed walls and modular walls. Thus, the modular structures of the disclosure facilitate modular construction of higher quality structures or buildings. When installing modularly constructed walls, hardware may pass into the interior region of the wall to secure the wall to a base structure. Thus, access to the interior of the wall may be needed to fully install the modularly constructed walls. Thus, portions of the wall may not be completed until the wall is secured to the base structure. Embodiments of the disclosure may facilitate securing fully constructed walls to a base structure without access to the interior portion of the walls, such that no portions of the wall are left unfinished before installing the modular wall.

FIG. 1 illustrates a partially exploded view of a wall 100 of a structure. The wall 100 is formed from modular segments 102. Embodiments of the disclosure may be used in modular building construction, such as those disclosed in Application Ser. No. 63/710,732, filed on even date herewith, and titled “MODULAR CONSTRUCTION STRUCTURES AND ASSOCIATED BUILDINGS AND METHODS,” the disclosure of which is incorporated herein in its entirety by this reference. Each modular segment 102 has a width 104 and a height 106 that are substantially the same. The modular segments 102 may have different features, such as different configurations (e.g., openings, doors, windows, etc.), different pre-installed utilities, etc. Thus, the modular segments 102 may be configured to be installed in any location along the wall 100. Each modular segment 102 includes a framework 108 of studs 110 providing structural support for the modular segment 102.

The framework 108 may be formed from full-size studs 110 (e.g., conventional wood studs, 2×4 studs, 2×6 studs, metal studs, etc.) and/or smaller studs 110, such as an alignment structure 112 formed from sheet materials (e.g., dry wall sheet, plywood sheet, etc.) that may reduce the weight and/or cost of the framework 108. For example, the full-size studs 110 may form an outer framework 114 of the framework 108 configured to support an outer surface 120 (e.g., sheeting material forming an outer planar surface of the wall 100) and smaller alignment structures 112 may form an inner framework 116 of the framework 108 configured to support an inner surface 122 (e.g., sheeting material forming an inner planar surface of the wall 100). In some embodiments, the outer framework 114 is joined to the inner framework 116 through a spacer 118. The spacer 118 may be configured to define a space between the outer framework 114 and the inner framework 116. The space defined by the spacer 118 may be used for running utilities within the walls and/or for securing insulation between the outer surface 120 and the inner surface 122. The spacers 118 may include spacers such as those disclosed in Application Ser. No. 63/710,724, filed on even date herewith, and titled “SPACERS, WALLS, AND METHODS OF CONSTRUCTING A WALL,” the disclosure of which is incorporated herein in its entirety by this reference.

The modular segments 102 may join together at joints 124. Each of the modular segments 102 may include similar structures on opposing ends of the modular segments 102 to form the joints 124. Terminal structures 126 may be included on ends of the wall 100, such as at corners between two adjoining walls 100 or lateral ends of the wall 100. The terminal structures 126 may include similar structures to form joints 124 between the adjacent modular segments 102 and the terminal structures 126.

In the embodiment illustrated in FIG. 1, the joints 124 are formed by a protrusion 128 extending from an end of one of the modular segments 102 or the terminal structures 126 and a receiving structure 130, such as a complementary groove or recess, in the adjoining modular segment 102 or terminal structure 126. The joints 124 may be substantially the same on all modular segments 102, such that different modular segments 102 may be interchangeably positioned adjacent to other modular segments 102 and/or terminal structures 126.

The wall 100 may be built over a base 132, such as a foundation, footings, slab-on-grade, etc. The base 132 may include junctions 134 configured to facilitate a connection between the modular segments 102 of the exterior wall 100 and the base 132. In some embodiments, the junctions 134 may further facilitate passing utilities (e.g., electrical wires, water lines, pipes, etc.) between a cavity defined in the base 132 and the modular segments 102 of the wall 100.

The junctions 134 may be uniformly spaced about the base 132. The distance 136 between the junctions 134 may be less than or equal to the width 104 of the modular segments 102, such that at least one junction 134 is positioned beneath each modular segment 102 of the wall 100. In the embodiment illustrated in FIG. 1, the distance 136 between the junctions 134 is about 50% of the width 104 of the modular segments 102, such that two junctions 134 are positioned beneath each of the modular segments 102.

FIG. 2 illustrates the wall 100 assembled over the base 132. The framework 108 of the modular segments 102 of the wall 100 may include brackets 202. The position of the brackets 202 may substantially match the position of the junctions 134 in the base 132 when the modular segments 102 are assembled over the base 132. For example, the brackets 202 may be spaced within the modular segments 102 at substantially a same spacing as the distance 136 between the junctions 134 in the base 132. The brackets 202 may combine with the junctions 134 to form anchor structures 204 configured to secure the modular segments 102 of the wall 100 to the base 132.

The brackets 202 are secured to studs 110 in the framework 108. For example, the brackets 202 may be secured to a plate 206 that is secured to one or more studs 110 of the framework 108. In the embodiments illustrated in FIGS. 1 and 2, the plate 206 is secured to a reinforced framework structure 208. The reinforced framework structure 208 may include multiple stacked studs 110 or may be formed from larger studs 110 than other portions of the framework 108. For example, reinforced framework structures 208 near lateral ends of each modular segment 102, such as near the joint 124 or near the terminal structures 126, may be formed from stacked studs 110. The embodiments illustrated in FIGS. 1 and 2 also include a reinforced framework structure 208 near a lateral middle of each modular segment 102. The reinforced framework structure 208 near the lateral middle of the modular segment 102 may include a full-size stud 110 in both the outer framework 114 of the modular segment 102 and another full-size stud 110 the inner framework 116 of the modular segment 102, such that the inner and outer studs 110 combine to form a reinforced framework structure 208 in the lateral middle of the modular segment 102. The plate 206 may span between the outer stud 110 and the inner stud 110.

The brackets 202 may be configured to receive hardware inserted through the junctions 134. For example, as discussed in further detail below, the brackets 202 may include receiving hardware configured to facilitate a connection between the brackets 202 and the junctions 134 without complete access to the brackets 202 through the modular segments 102 of the wall 100. Thus, the modular segments 102 may be fully constructed and/or insulated including the installation of both the outer surface 120 and the inner surface 122 before installing the modular segments 102 on the base 132.

FIGS. 3 and 4 illustrate enlarged views of the wall 100 around the anchor structure 204 between the modular segments 102 of the wall 100 and the base 132. FIG. 3 illustrates an enlarged view of the wall 100 at the joint 124 between the modular segments 102. The framework 108 of each modular segment 102 may include a termination structure 302 at each end of the modular segment 102. The termination structure 302 may be formed from multiple studs 110 connected together to form a reinforced framework structure 208 at the lateral ends of the associated modular segment 102.

The termination structures 302 may be configured to secure adjacent modular segments 102 to each other. For example, the termination structures 302 in adjacent modular segment 102 may combine to define anchor structures 304. The anchor structures 304 may include a recess defined in both of the termination structures 302 of the adjacent modular segments 102 that are configured to receive an anchor to secure the adjacent modular segments 102 vertically (e.g., in the Z-direction) and/or laterally (e.g., in the X-direction).

The termination structures 302 may also be configured to secure the modular segments 102 to the base 132 through the brackets 202. As discussed above, the brackets 202 may be secured to the termination structures 302 through a plate 206. As illustrated in FIG. 3, the bracket 202 may be connected to the termination structure 302 of one modular segment 102 and the adjacent modular segment 102 may be secured to the bracket 202 through the anchor structures 304 across the joint 124. Thus, in the full wall 100, each modular segment 102 may be secured to the base 132 through one termination structure 302 on each modular segment 102 and the opposing termination structure 302 of each modular segment 102 may be secured to the base 132 through the termination structure 302 of the adjacent modular segment 102.

The brackets 202 may include a lateral leg 306 and a vertical leg 308. The lateral leg 306 and the vertical leg 308 may define an angle between the lateral leg 306 and the vertical leg 308. The angle may be about 90 degrees. The vertical leg 308 may be secured to the plate 206. For example, the vertical leg 308 may be secured to the plate 206 through hardware (e.g., nails, screws, bolts, nuts, etc.) or an adhesive (e.g., glue, epoxy, etc.). The lateral leg 306 may be positioned over a lateral stud 310 of the framework 108. The lateral leg 306 may include a receiver 312 configured to receive securing hardware from the junction 134. The receiver 312 may be a reinforced opening. For example, the material of the bracket 202 at the receiver 312 may have a greater thickness than the other portions of the bracket 202. In some embodiments, the receiver 312 may be a through hole configured to receive expandable hardware, such as spring anchors or spring clamps, that have an end that can be compressed when passing through the hole in the receiver 312 and expands once it passes through the hole in the receiver 312, such that the expandable end anchors against the lateral leg 306 of the bracket 202 around the receiver 312. In another embodiment, the receiver 312 may be a threaded hole configured to receive threaded hardware, such as a bolt. For example, the receiver 312 may be a threaded bung formed in or attached to (e.g., welded to) the lateral leg 306 of the bracket 202. In other embodiments, the receiver 312 may be a protruding feature configured to protrude from the bracket 202 through the lateral stud 310 into the junction 134. For example, the receiver 312 may be a threaded stud configured to extend into the junction 134 and receive a nut or other threaded fastener to secure the modular segment 102 to the base 132.

FIG. 4 illustrates an enlarged view of an intermediate reinforced framework structure 402 of a modular segment 102 of the wall 100. As discussed above, the intermediate reinforced framework structure 402 may be positioned proximate the lateral middle of the modular segment 102. The intermediate reinforced framework structure 402 includes a full-size stud 110 in both the outer framework 114 and the inner framework 116. As discussed above, the surrounding studs 110 in the inner framework 116 are alignment structures 112 formed from thinner sheeting materials. The thicker full-sized stud 110 in the inner framework 116 at the intermediate reinforced framework structure 402 may provide greater strength to the modular segment 102 at the location of the intermediate reinforced framework structure 402.

The studs 110 of the outer framework 114 and the inner framework 116 may be tied together by one or more plates 206 at the intermediate reinforced framework structure 402. In the embodiment illustrated in FIG. 4, two plates 206 are secured to the studs 110 of the outer framework 114 and the inner framework 116 at the intermediate reinforced framework structure 402, with one plate 206 positioned on each lateral side of the intermediate reinforced framework structure 402.

The bracket 202 may be secured to the intermediate reinforced framework structure 402 through one of the plates 206. The bracket 202 may be positioned in the outer framework 114. As discussed above, the bracket 202 includes a vertical leg 308 and a lateral leg 306. The vertical leg 308 may be secured to the plate 206 through a hardware connection (e.g., nails, screws, bolts, nuts, rivets, etc.) or an adhesive connection (e.g., glue, epoxy, etc.). The lateral leg 306 includes a receiver 312 configured to secure the bracket 202 to the anchor structure 204. In the embodiment illustrated in FIG. 4, the receiver 312 includes a hole 404 configured to receive hardware from the junction 134 through the lateral stud 310. The receiver 312 may be a threaded bung welded to the bracket 202 or formed into the bracket 202. The threaded bung may be configured to receive complementary threaded hardware, such as a bolt, from the junction 134 through the lateral stud 310 to secure the modular segment 102 to the base 132. In other embodiments, hole 404 in the receiver 312 may be substantially free of threads and configured to receive expandable hardware.

FIG. 5 illustrates the junction 134. The junction 134 is formed from an enclosure 502 having an open face 504 and an aperture 506 in an upper panel 508. In the embodiment illustrated in FIG. 5, the enclosure 502 is a box having a rectangular shape. The enclosure 502 may be formed from a thin high strength material, such as a metal (e.g., steel, aluminum, stainless steel, etc.), composite materials (e.g., fiberglass or carbon fiber), or a polymer (e.g., polyvinyl chloride (PVC), polyethylene, polypropylene, etc.). The enclosure 502 may be configured to be encased within the material of the base 132 (FIG. 1). For example, the base 132 (FIG. 1) may be formed from concrete and the enclosure 502 may be configured to be encased by the concrete of the base 132 (FIG. 1). When positioned in the concrete of the base 132 (FIG. 1), the enclosure 502 may be positioned such that the open face 504 is positioned on a side of the base 132 (FIG. 1), such that the interior 510 of the enclosure 502 is accessible after the base 132 (FIG. 1) is formed.

The junction 134 may also include one or more legs 512 extending from the enclosure 502. The legs 512 may include a straight portion 514 and an angled portion 516. The legs 512 may be configured to be disposed in the base 132 (FIG. 1), such as to provide an additional anchor between the enclosure 502 and the base 132 (FIG. 1). The straight portion 514 of the legs 512 may extend in a vertical direction (e.g., the Z-direction) substantially parallel with sides 518 of the enclosure 502. The angled portion 516 of the legs 512 may extend at an outward angle 520 away from the plane of the sides 518 of the enclosure 502. The angle 520 may be in a range from about 10° to about 90°, such as from about 20° to about 45°.

The legs 512 may be configured to increase a surface area of the junction 134 that is in contact with or surrounded by the material of the base 132 (FIG. 1). Increasing the surface area of the junction 134 that is surrounded by the material of the base 132 (FIG. 1) may increase the strength of the interface between the junction 134 and the base 132 (FIG. 1), which may similarly increase the strength of the joint between the base 132 (FIG. 1) and the modular segment 102 (FIG. 1). The legs may be formed from a material having a relatively high tensile strength, such as metal (e.g., steel, aluminum, stainless steel, etc.), fiber composites (e.g., fiberglass or carbon fiber), or other materials.

The aperture 506 defined in the upper panel 508 of the junction 134 may have an elongated shape. For example, in the embodiment illustrated in FIG. 5, the aperture 506 defined in the upper panel 508 of the junction 134 has an elongated oval shape. The elongated shape may be configured to accommodate standard building tolerances while still facilitating the alignment between the aperture 506 of the junction and the hole 404 (FIG. 4) in the receiver 312 (FIG. 4.).

FIGS. 6-8 illustrate schematic cross-sections of different embodiments of the anchor structure 204 formed between the modular segments 102 (FIG. 1) and the base 132 (FIG. 1). FIG. 6 illustrates an anchor structure 204 including a threaded bung 602 as the receiver 312 of the bracket 202. The threaded bung 602 may be configured to receive a bolt 604 from the interior 510 of the junction 134. The bolt 604 extends through the lateral stud 310 and threads into the threaded bung 602 with complementary threads 606. The bolt 604 may pass through a washer 608 in the interior 510 of the junction 134. The washer 608 may interface with a head 610 of the bolt 604 spreading the load of the head 610 across a larger area of the junction 134 around the aperture 506. As the head 610 is tightened into the threaded bung 602, the bolt 604 may sandwich the lateral stud 310 between the bracket 202 and the junction 134, securing the associated modular segment 102 (FIG. 1) to the base 132 (FIG. 1).

The threaded bung 602 may include gussets 612 extending between the threaded bung 602 and the bracket 202. The gusset 612 may provide additional strength to the receiver 312. As discussed above, the threaded bung 602 may be attached to the bracket 202, such as by welding. In other embodiments, the threaded bung 602 may be formed into the bracket 202, such as through one or more of machining, forging, casting, etc. Similarly, the gussets 612 may be welded between the threaded bung 602 and the bracket 202 or may be formed into the bracket 202.

With the threaded bung 602 attached to or formed into the bracket 202, the bolt 604 may be secured to the bracket 202 through the junction 134 and the lateral stud 310, without external access to the receiver 312. For example, the bolt 604 may be inserted into the receiver 312 through the aperture 506 in the junction 134 and tightened by turning the head 610 of the bolt 604 with a tool inserted through the open face 504 (FIG. 5) of the junction 134 without inserting any tools into the modular segment 102 (FIG. 1) to interface with the receiver 312. Tightening the bolt without directly interfacing with the receiver 312 may facilitate fully forming the modular segment 102 (FIG. 1), including both the outer surface 120 (FIG. 1) and the inner surface 122 (FIG. 1), before attaching the modular segment 102 (FIG. 1) to the base 132 (FIG. 1).

FIGS. 7A and 7B illustrate an embodiment of an anchor structure 204 including an open bung 702 as the receiver 312 of the bracket 202. The open bung 702 may be configured to receive an expandable fastener 704 from the interior 510 of the junction 134. The expandable fastener 704 extends through the lateral stud 310 and includes clamps 706 that expand and apply a clamping force to an upper surface of the receiver 312. The expandable fastener 704 may pass through a washer 708 in the interior 510 of the junction 134. The washer 708 may interface with a head 710 of the expandable fastener 704 spreading the load of the head 710 across a larger area of the junction 134 around the aperture 506. As the clamps 706 are tightened, the expandable fastener 704 may sandwich the lateral stud 310 between the bracket 202 and the junction 134, securing the associated modular segment 102 (FIG. 1) to the base 132 (FIG. 1).

The open bung 702 may include gussets 712 extending between the open bung 702 and the bracket 202. The gusset 712 may provide additional strength to the receiver 312. As discussed above, the open bung 702 may be attached to the bracket 202, such as by welding. In other embodiments, the open bung 702 may be formed as part of the bracket 202, such as through one or more of machining, forging, casting, etc. Similarly, the gussets 712 may be welded between the open bung 702 and the bracket 202 or may be formed into the bracket 202. In some embodiments, the open bung 702 may be an open hole in the bracket 202, without any additional portion extending above an upper surface of the bracket 202, such that the clamps 706 apply the clamping force to the upper surface of the bracket 202.

The expandable fastener 704 may be secured to the bracket 202 through the junction 134 and the lateral stud 310, without external access to the receiver 312. For example, the expandable fastener 704 may be inserted into the receiver 312 through the aperture 506 in the junction 134 and tightened by turning the head 710 of the expandable fastener 704 with a tool inserted through the open face 504 (FIG. 5) of the junction 134 without inserting any tools into the modular segment 102 (FIG. 1) to interface with the receiver 312. Tightening the expandable fastener 704 without directly interfacing with the receiver 312 may facilitate fully forming the modular segment 102 (FIG. 1), including both the outer surface 120 (FIG. 1) and the inner surface 122 (FIG. 1), before attaching the modular segment 102 (FIG. 1) to the base 132 (FIG. 1).

FIG. 8 illustrates an embodiment of an anchor structure 204 including a rod 802 as the receiver 312 of the bracket 202. The rod 802 may be configured to extend into the interior 510 of the junction 134. The rod 802 includes threads 804 and extends through the lateral stud 310 into the interior 510 of the junction 134. The rod 802 may be attached to the bracket 202, such as by welding. In other embodiments, the rod 802 may be formed as part of the bracket 202, such as through one or more of machining, forging, casting, etc.

The rod 802 may pass through a washer 808 in the interior 510 of the junction 134. A threaded fastener 806 may have complementary threads to the threads 804 of the rod 802. The threaded fastener 806 may be threaded onto the rod 802 and interface with the washer 808 spreading the load of the threaded fastener 806 across a larger area of the junction 134 around the aperture 506. As the threaded fastener 806 is tightened over the rod 802, the lateral stud 310 may be sandwiched between the bracket 202 and the junction 134, securing the associated modular segment 102 (FIG. 1) to the base 132 (FIG. 1).

The rod 802 may be secured to the junction 134 through the lateral stud 310, without external access to the bracket 202. For example, the rod 802 may be inserted into the junction 134 through the aperture 506 in the junction 134 and tightened by turning the threaded fastener 806 with a tool inserted through the open face 504 (FIG. 5) of the junction 134 without inserting any tools into the modular segment 102 (FIG. 1) to interface with the bracket 202. Tightening the threaded fastener 806 without directly interfacing with the bracket 202 may facilitate fully forming the modular segment 102 (FIG. 1), including both the outer surface 120 (FIG. 1) and the inner surface 122 (FIG. 1), before attaching the modular segment 102 (FIG. 1) to the base 132 (FIG. 1).

In some embodiments, a cover is placed over the open face 504 after the fastener (e.g., bolt 604, expandable fastener 704, threaded fastener 806, etc.) are inserted and/or tightened. In some embodiments, the cover is a removable cover. In other embodiments, the cover may be substantially permanent, such as a cement encasement, a welded cover, etc.

FIG. 9 illustrates another embodiment of the wall 100 assembled over the base 132. As discussed above, the wall 100 includes a framework 108 formed from studs 110. The framework 108 includes an outer framework 114 and an inner framework 116. Lateral studs 310 extend laterally across a bottom of the outer framework 114 and the inner framework 116. The studs 110 are connected to the lateral stud 310 at regular intervals. In some embodiments, the junction 902 is positioned in the framework 108 of the wall 100 at a position that is configured to substantially align with the junctions 134 (FIG. 1) in the base 132. In other embodiments, the junctions 902 are positioned in the framework 108 of the wall 100 to interface with other structures in the base 132 that do not include the junctions 134 (FIG. 1).

In the embodiment illustrated in FIG. 9, the wall 100 includes a junction 902. The junction 902 is positioned within the framework 108 of the wall 100. The junction 902 is positioned at a joint between one of the studs 110 of the outer framework 114 and the lateral stud 310 of the outer framework 114. The junction 902 may be configured to provide a space for connecting the wall 100 to the base 132, similar to the junction 134 of FIGS. 1-8.

FIG. 10 illustrates an enlarged perspective view of the wall 100 of FIG. 9. In the embodiment illustrated in FIG. 10, the studs 110 are metal studs. In other embodiments, the studs 110 may be formed from wood, sheeting material, high strength polymers, etc. As illustrated in FIG. 10, the junction 902 is positioned at a corner formed by a joint between one of the studs 110 and the lateral stud 310 in the outer framework 114. The junction 902 includes lateral walls 904 and an upper wall 906 that combine to define an open face 910 and a lower opening 908.

The lower opening 908 may facilitate the insertion of hardware for joining the wall 100 to the base 132, such as bolts, screws, studs, brackets, etc. The open face 910 may be configured to facilitate access to the hardware for joining the wall 100. For example, at least a portion of the hardware may be passed through open face 910 before being inserted through the lower opening 908 or before interfacing with another portion of the hardware that has already been inserted through the lower opening 908. The open face 910 may also be configured to facilitate access of the hardware with a tool, such as a hand tool (e.g., wrench, screw driver, socket, ratchet, etc.) or a power tool (e.g., power drill, impact driver, power ratchet, nail gun, etc.).

The junction 902 may be configured to maintain an opening in the wall 100 for access to and insertion of the hardware. The junction 902 may facilitate completing the assembly of the wall 100 before installation, including filling the framework 108 with insulation and applying the outer surface 120 (FIG. 1) and inner surface 122 (FIG. 1) materials to the wall 100. The junction may be formed from structural materials, such as metal materials (e.g., steel, aluminum, copper, brass, etc.), wood materials (e.g., pine, fir, etc.), engineered woods (e.g., plywood, medium-density fiberboard (MDF), etc.), corrugated fiberboard (e.g., cardboard, paperboard, wax-coated cardboard, polymer coated fiberboard, etc.), or polymer materials (e.g., polyvinyl chloride (PVC), polyethylene, polypropylene, acrylonitrile butadiene styrene (ABS), polystyrene, poly(methyl methacrylate) (PMMA) and polycarbonate, polybutylene terephthalate (PBT), and polytetrafluoroethylene (PTFE), etc.).

The junction 902 may be secured to at least one of the stud 110 and the lateral stud 310. In some embodiments, the junction 902 is secured to both the stud 110 and the lateral stud 310. For example, the junction 902 may be secured to the stud 110 and the lateral stud 310 through a hardware connection (e.g., nails, screws, staples, bolts, etc.), a thermal connection (e.g., welding, soldering, etc.), or an interference connection (e.g., complementary geometry, retaining clips, retaining clamps, etc.). In some embodiments, additional materials, such as a backing board, or sheeting material, are positioned between the outer framework 114 and the inner framework 116. In such embodiments, the junction 902 may also be secured to the additional materials.

FIG. 11, illustrates the wall 100 of FIGS. 9 and 10, at a subsequent processing step. In the embodiment illustrated in FIG. 11, the framework 108 is filled with an insulation 912. The insulation 912 may include fibrous batts or blankets (e.g., glass fiber, mineral/rock wool), loose-fill materials (e.g., cellulose, glass fiber), spray-applied foams (e.g., open-cell or closed-cell polyurethane), and rigid or semi-rigid boards (e.g., expanded polystyrene, extruded polystyrene, polyisocyanurate), as well as reflective or radiant-barrier foils.

As illustrated in the embodiment of FIG. 11, the junction 902 maintains an open area in the wall 100. The insulation 912 rests against the lateral walls 904 and the upper wall 906 of the junction 902, such that the interior portion of the junction 902 remains substantially free of insulation 912. Thus, the junction 902 maintains access to the lower opening 908 and the open face 910. Thus, the junction 902 may facilitate the full construction of the wall 100 before the wall 100 is secured to the base 132 (FIG. 9). As discussed above, the open face 910 and the lower opening 908, may facilitate the installation or insertion of hardware for connecting the wall 100 to the base 132 as well as access to the hardware with a tool for completing the installation of the hardware and securing the wall 100 to the base 132.

After the wall 100 is installed and secured to the base 132, the open face 910 of the junction 902 may be covered. In some embodiments, the cover may be removably attached to the junction 902, such as through a hardware connection. In other embodiments, the cover may be substantially permanently installed. For example, the cover may be a portion of the outer wall covering (e.g., the outer surface 120).

Embodiments of the disclosure may facilitate securing fully constructed modular wall segments to a base or foundation without access to an interior portion of the modular wall segments. This may facilitate fully constructing the modular wall segments at a remote site, which may further increase the efficiency gains of the modular construction. Increasing the efficiency of the construction may decrease the cost of building the associated structure. Furthermore, the modular wall segments may be formed to have greater insulative characteristics when not leaving access to the interior portion of the modular wall segments. This may increase the efficiency of the climate control systems of the associated structure. Increasing the efficiency of the structure may decrease the energy usage of the structure resulting in further cost savings.

The embodiments of the disclosure described above and illustrated in the accompanying drawing figures do not limit the scope of the invention, since these embodiments are merely examples of embodiments of the invention, which is defined by the appended claims and their legal equivalents. Any equivalent embodiments are intended to be within the scope of this disclosure. Indeed, various modifications of the disclosure, in addition to those shown and described herein, such as alternative useful combinations of the elements described, may become apparent to those skilled in the art from the description. Such modifications and embodiments are also intended to fall within the scope of the appended claims and their legal equivalents.