Devices, systems, and methods for secure attachment and alignment of modular building units

Abstract

Device, systems, and methods for secure attachment and alignment of modular building units. The system includes one or more lock brackets on a first modular building unit and one or more receiver brackets on a second modular building unit. The lock brackets include a lock bracket protrusion. The lock bracket protrusion includes a locking tab having a locking tab profile including an aligning portion and a locking portion. The receiver brackets include an alignment hole. The lock bracket protrusion is inserted into the alignment hole as the second modular building unit is lowered onto the first modular building unit. The receiver brackets slide vertically and laterally along the aligning portion and the locking portion as the lock bracket protrusion is inserted into the alignment hole. The locking portion prevents vertical movement of the second modular building unit without a corresponding lateral movement.

1 . A system of brackets for secure attachment and alignment of modular construction units, the system comprising:
 one or more lock brackets on a first modular building unit, each of the one or more lock brackets comprising:
 a lock bracket base plate; and 
 a lock bracket protrusion extending from the lock bracket base plate, wherein the lock bracket protrusion includes a locking tab having a locking tab profile including an aligning portion and a locking portion; and 
   one or more receiver brackets on a second modular building unit, each the one or more receiver brackets comprising:
 a receiver bracket base plate; and 
 an alignment hole extending through the receiver bracket base plate, 
   wherein the lock bracket protrusion is inserted into the alignment hole as the second modular building unit is lowered onto the first modular building unit, and the one or more receiver brackets slide vertically and laterally along the aligning portion and the locking portion of the locking tab profile as the lock bracket protrusion is inserted into the alignment hole, and the locking portion prevents vertical movement of the second modular building unit without a corresponding lateral movement.   
     
     
         2 . The system of  claim 1 , wherein the lock bracket protrusion further includes a lock bracket aligning tab having an aligning profile that is generally triangular. 
     
     
         3 . The system of  claim 2 , wherein the lock bracket aligning tab has an aligning tab tip that is truncated. 
     
     
         4 . The system of  claim 3 , wherein the aligning tab tip has edges that are fillets. 
     
     
         5 . The system of  claim 1 , wherein the aligning portion of the locking tab profile is generally triangular. 
     
     
         6 . The system of  claim 1 , wherein the locking tab has a first geometric portion, a second geometric portion, a third geometric portion, and a fourth geometric portion, and the first geometric portion, the second geometric portion, and the third geometric portion define the locking portion of the locking tab profile, and wherein:
 the first geometric portion is closest to the lock bracket base plate and has a generally rectangular shape that extends in a y-direction,   the second geometric portion extends from the first geometric portion and has a quadrilateral shape with a first lateral side and a second lateral side of the second geometric portion being inclined at an angle relative to the y-direction,   the third geometric portion extends from the second geometric portion and has a quadrilateral shape with the first lateral side of the third geometric portion extending substantially vertically in the y-direction and the second lateral side of the third geometric portion being inclined at an angle relative to the y-direction, and   the fourth geometric portion extends from the third geometric portion and defines the aligning portion of the locking tab profile.   
     
     
         7 . The system of  claim 6 , wherein the first lateral side of the second geometric portion is inclined at a different angle as the second lateral side of the second geometric portion. 
     
     
         8 . The system of  claim 6 , wherein the second lateral side of the third geometric portion is inclined at a same angle as the incline of the second lateral side of the second geometric portion. 
     
     
         9 . The system of  claim 6 , wherein a width of the third geometric portion decreases as a function of distance from the lock bracket base plate in the y-direction. 
     
     
         10 . The system of  claim 6 , wherein a width of the fourth geometric portion decreases as the fourth geometric portion extends from the third geometric portion to a locking tab tip of the locking tab. 
     
     
         11 . The system of  claim 6 , wherein the first geometric portion has a substantially constant width D 1  in a z-direction as the first geometric portion extends in the y-direction. 
     
     
         12 . The system of  claim 11 , wherein the third geometric portion has an engagement width D 1 ′ extending in the z-direction where the third geometric portion intersects with the fourth geometric portion, and the engagement width D 1 ′ is similar to a width D 2  of the alignment hole of the one or more receiver brackets. 
     
     
         13 . The system of  claim 1 , wherein each of the one or more lock brackets includes a lock bracket mounting plate coupled to the lock bracket base plate for coupling each of the one or more lock brackets to the first modular building unit. 
     
     
         14 . The system of  claim 13 , wherein the lock bracket mounting plate includes one or more lock bracket mounting holes configured to receive one or more fasteners for coupling each of the one or more lock brackets to the first modular building unit. 
     
     
         15 . The system of  claim 13 , wherein each of the one or more lock brackets includes a lock bracket reinforcing tab that extends between the lock bracket mounting plate and the lock bracket base plate to provide support therebetween. 
     
     
         16 . The system of  claim 1 , wherein each of the one or more receiver brackets includes a receiver bracket mounting plate coupled to the receiver bracket base plate for coupling each of the one or more receiver brackets to the second modular building unit. 
     
     
         17 . The system of  claim 16 , wherein the receiver bracket mounting plate includes one or more receiver bracket mounting holes configured to receive one or more fasteners for coupling each of the one or more receiver brackets to the second modular building unit. 
     
     
         18 . The system of  claim 16 , wherein each of the one or more receiver brackets includes a receiver bracket reinforcing tab that extends between the receiver bracket mounting plate and the receiver bracket base plate to provide support therebetween. 
     
     
         19 . The system of  claim 1 , wherein the one or more lock brackets include a first lock bracket having a first locking tab profile with a first locking portion and a second lock bracket having a second locking tab profile with a second locking portion that is opposite the first locking portion. 
     
     
         20 . A method of secure attachment and alignment of modular building units using the system of brackets of  claim 1 , the method comprising:
 aligning the one or more receiver brackets with the one or more lock brackets by aligning the second modular building unit over the first modular building unit;   lowering the second modular building unit onto the first modular building unit;   inserting the lock bracket protrusion into the alignment hole as the second modular building unit is lowered onto the first modular building unit;   sliding the one or more receiver brackets vertically and laterally along the locking tab profile as the lock bracket protrusion is inserted into the alignment hole.   
     
     
         21 . The method of  claim 20 , wherein the lock bracket protrusion further includes a lock bracket aligning tab having an aligning profile that is generally triangular, and the method further comprises sliding the one or more receiver brackets vertically and laterally along the aligning profile of the lock bracket aligning tab. 
     
     
         22 . The system of  claim 20 , wherein the aligning portion of the locking tab profile is generally triangular, and the method further comprises sliding the one or more receiver brackets in a first lateral direction along the aligning portion of the locking tab profile as the one or more receiver brackets slide vertically along the locking tab profile. 
     
     
         23 . The method of  claim 20 , wherein the locking tab has a first geometric portion, a second geometric portion, a third geometric portion, and a fourth geometric portion, and the first geometric portion, the second geometric portion, and the third geometric portion define the locking portion of the locking tab profile, and wherein:
 the first geometric portion is closest to the lock bracket base plate and has a generally rectangular shape that extends in a y-direction,   the second geometric portion extends from the first geometric portion and has a quadrilateral shape with a first lateral side and a second lateral side of the second geometric portion being inclined at an angle relative to the y-direction,   the third geometric portion extends from the second geometric portion and has a quadrilateral shape with the first lateral side of the third geometric portion extending substantially vertically in the y-direction and the second lateral side of the third geometric portion being inclined at an angle relative to the y-direction, and   the fourth geometric portion extends from the third geometric portion and defines the aligning portion of the locking tab profile.   
     
     
         24 . The method of  claim 23 , further comprising sliding the one or more receiver brackets laterally along the second lateral side of the fourth geometric portion in a first lateral direction with respect to a z-direction. 
     
     
         25 . The method of  claim 24 , further comprising sliding the one or more receiver brackets laterally along the second lateral side of the third geometric portion in a second lateral direction with respect to the z-direction that is opposite the first lateral direction. 
     
     
         26 . The method of  claim 25 , further comprising sliding the one or more receiver brackets laterally along the first lateral side and the second lateral side of the second geometric portion in the second lateral direction. 
     
     
         27 . The method of  claim 26 , further comprising sliding the one or more receiver brackets vertically along the first lateral side or the second lateral side of the first geometric portion. 
     
     
         28 . The method of  claim 20 , wherein each of the one or more lock brackets includes a lock bracket mounting plate coupled to the lock bracket base plate, and the method further comprises coupling the one or more lock brackets to the first modular building unit with the lock bracket mounting plate. 
     
     
         29 . The method of  claim 28 , wherein each of the one or more lock brackets includes a lock bracket reinforcing tab that extends between the lock bracket mounting plate and the lock bracket base plate, and the method further comprises supporting the lock bracket mounting plate and the lock bracket base plate with the lock bracket reinforcing tab. 
     
     
         30 . The method of  claim 28 , wherein each of the one or more receiver brackets includes a receiver bracket mounting plate coupled to the receiver bracket base plate, and the method further comprises coupling the one or more receiver brackets to the second modular building unit with the lock bracket mounting plate. 
     
     
         31 . The method of  claim 30 , wherein each of the one or more receiver brackets includes a receiver bracket reinforcing tab that extends between the receiver bracket mounting plate and the receiver bracket base plate, and the method further comprises supporting the receiver bracket mounting plate and the receiver bracket base plate with the receiver bracket reinforcing tab. 
     
     
         32 . The method of  claim 20 , wherein the one or more lock brackets include a first lock bracket having a first locking tab profile with a first locking portion and a second lock bracket having a second locking tab profile with a second locking portion that is opposite the first locking portion.