IMPROVED DESIGN FOR MODULAR PREFABRICATED CONCRETE STRUCTURES

Abstract

The present invention relates to an improved design for modular prefabricated concrete structures, focusing on rapid assembly, enhanced durability, and adaptability for various architectural applications. The invention comprises modular concrete units with unique interlocking mechanisms, advanced joint connections, and integrated utility channels that simplify construction and reduce on-site labor requirements. The interlocking mechanism ensures secure and precise alignment of each module, while the joint connections are designed to absorb and dissipate stresses from environmental forces, such as seismic activity and temperature fluctuations. In certain embodiments, the modular units feature a vertical load distribution system, enabling stackable configurations for multi-story construction. This innovation in modular prefabricated concrete structures not only provides robust structural integrity but also allows for flexible reconfiguration, expansion, and customization, making it suitable for a wide range of residential, commercial, and industrial applications.

Specification

Description:In the following description, for the purposes of explanation, various specific details are set forth in order to provide a thorough understanding of embodiments of the present disclosure. It will be apparent, however, that embodiments of the present disclosure may be practiced without these specific details. Several features described hereafter can each be used independently of one another or with any combination of other features. An individual feature may not address all of the problems discussed above or might address only some of the problems discussed above. Some of the problems discussed above might not be fully addressed by any of the features described herein.

The ensuing description provides exemplary embodiments only and is not intended to limit the scope, applicability, or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing an exemplary embodiment. It should be understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the disclosure as set forth.
Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, circuits, systems, networks, processes, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known circuits, processes, algorithms, structures, and techniques may be shown without unnecessary detail to avoid obscuring the embodiments.

Also, it is noted that individual embodiments may be described as a process that is depicted as a flowchart, a flow diagram, a data flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process is terminated when its operations are completed but could have additional steps not included in a figure. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination can correspond to a return of the function to the calling function or the main function.

The word "exemplary" and/or "demonstrative" is used herein to mean serving as an example, instance, or illustration. For the avoidance of doubt, the subject matter disclosed herein is not limited by such examples. In addition, any aspect or design described herein as "exemplary" and/or "demonstrative" is not necessarily to be construed as preferred or advantageous over other aspects or designs, nor is it meant to preclude equivalent exemplary structures and techniques known to those of ordinary skill in the art. Furthermore, to the extent that the terms "includes," "has," "contains," and other similar words are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the term "comprising" as an open transition word without precluding any additional or other elements.

Reference throughout this specification to "one embodiment" or "an embodiment" or "an instance" or "one instance" means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, the appearances of the phrases "in one embodiment" or "in an embodiment" in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising," when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

This invention discloses an improved modular prefabricated concrete structure designed to enhance the efficiency, adaptability, and durability of prefabricated buildings. The structure is composed of modular concrete units featuring interlocking edges, advanced joint mechanisms, and integrated channels for utilities, all aimed at simplifying assembly, increasing structural integrity, and providing flexibility in configuration. The following embodiments illustrate different aspects of the modular system and the improvements achieved through unique design features.

In first embodiment, each modular unit is designed as a self-contained concrete block with specially contoured interlocking edges. The interlocking edges use a dovetail design that allows adjoining modules to securely fit into one another without the need for additional fasteners or adhesives. This design significantly enhances the alignment accuracy of the modules during assembly, ensuring a stable and secure connection with minimal effort.

The modular unit includes reinforced edges embedded with high-strength composite materials, such as fiber-reinforced polymer (FRP), which bolster the structural integrity of the unit and reduce the risk of cracking under load. The reinforcement extends along the entire perimeter of the unit, particularly focusing on the interlocking edges where stress is most likely to concentrate. Additionally, a weather-resistant coating is applied to the unit, protecting the concrete from moisture ingress, which is a common issue in conventional prefabricated structures.

Each unit is designed with integrated channels for utility installations, including wiring and piping. These channels are pre-installed within the concrete during the manufacturing process and are strategically positioned to facilitate easy connection across adjacent modules. By eliminating the need for drilling or cutting post-assembly, this embodiment allows for a more efficient and streamlined utility installation process, reducing labor costs and minimizing construction time.

The second embodiment focuses on enhancing the joint mechanisms between modular units, with particular attention to resilience against seismic activity. In this embodiment, the modular units are equipped with flexible joint connections that allow for slight movement between adjoining units. These connections use elastomeric materials or shock-absorbing inserts within the joints, enabling the structure to absorb and dissipate seismic energy, reducing the risk of structural failure during an earthquake.

The joints are designed to be easily connected on-site, allowing modules to slide into position with minimal manual adjustment. A locking pin mechanism secures the modules in place, ensuring that the units remain connected during normal use but can absorb lateral and vertical forces when subjected to sudden shocks, such as those caused by earthquakes. This locking pin system can be disengaged if reconfiguration of the building layout is required, adding to the adaptability of the structure.
The flexible joint connections also provide additional benefits in terms of thermal expansion and contraction. As the concrete expands and contracts due to temperature changes, the joint mechanisms accommodate these minor shifts without causing stress fractures, which are a common issue in rigid, monolithic concrete structures. This embodiment is especially useful in regions with high seismic activity or extreme temperature fluctuations, providing a resilient, long-lasting solution for modular concrete construction.

In third embodiment, the modular prefabricated concrete units are designed for stackable configurations, allowing for multi-story construction. Each unit incorporates a vertical load distribution system within the concrete structure, which efficiently transfers loads from the upper units down to the foundation. This system is achieved through pre-stressed reinforcement rods that are embedded vertically in each unit and extend from the base to the top of the module, enabling a seamless load path throughout the structure.

The modular units are stacked with the assistance of a guide rail system, which aligns each unit precisely over the unit below it, ensuring uniform distribution of weight across the structure. The guide rails are manufactured from durable steel alloys and are coated with anti-corrosion material to prevent degradation over time. Additionally, vertical locking connectors are installed at each corner of the units, providing stability and preventing lateral movement within the stack.

To further enhance stability in multi-story applications, this embodiment includes bracing elements that connect horizontally adjacent units at each floor level. These bracing elements distribute lateral forces, such as wind loads, across the entire structure, increasing resistance to buckling and improving overall structural stability. The modular units in this embodiment are ideally suited for high-rise construction applications, where vertical load-bearing capacity and lateral stability are critical considerations.

While considerable emphasis has been placed herein on the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiments of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter to be implemented merely as illustrative of the invention and not as limitation. , Claims:1.A modular prefabricated concrete structure, comprising:
a plurality of prefabricated concrete modules, each configured to interlock with at least one adjacent module via a modular interlocking mechanism;
wherein each concrete module includes an interlocking edge featuring [e.g., a tenon-and-mortise, dovetail joint, or unique interlocking contour] for securing adjacent modules;
a reinforcement system embedded within each module to improve load-bearing capacity and resistance to environmental stress;
and a customizable arrangement of modules allowing the structure to adapt to various architectural configurations.

2.The modular prefabricated concrete structure of claim 1, wherein the interlocking mechanism includes an adjustable locking system to enable easy disassembly and reconfiguration of the structure.

3.The modular prefabricated concrete structure of claim 1, further comprising a joint mechanism designed to allow movement in response to seismic activity, thereby enhancing the structure's resilience.

4.The modular prefabricated concrete structure of claim 1, wherein each module includes an integrated reinforcement grid composed of a composite material to reduce cracking under stress.

5.The modular prefabricated concrete structure of claim 1, wherein each module has pre-installed channels for electrical and plumbing utilities, facilitating faster on-site installation.

6.The modular prefabricated concrete structure of claim 1, further including a weather-resistant coating applied to each module to improve durability and longevity of the structure in harsh environments.

7.A method for constructing a modular prefabricated concrete structure, comprising:
positioning a plurality of prefabricated concrete modules on a prepared foundation;
interlocking the modules by aligning their interlocking edges and applying force to secure the connection;
joining the modules with a coupling mechanism at the joints to enhance structural integrity;
and configuring the assembled modules to form a predetermined architectural layout.

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