A wall joint, method and system to form the wall joint with a mechanical connector

Abstract

Disclosed herein is a wall joint with a mechanical connector and methods of assembly. The wall joint comprises a pair of walls, each wall comprises a first surface and at least one stud protruding from the first surface, wherein the first surfaces face each other with a gap in between; a mechanical connector having at least one pair of slots, wherein the at least one pair of slots are engaged with the at least one stud of each wall; and cured grout in the gap. The assembly method comprises providing a pair of walls, each wall comprises a first surface and at least one stud protruding from the first surface; arranging the first surfaces to face each other with a gap in between; inserting a mechanical connector into the gap, the mechanical connector comprises at least one pair of slots; engaging the studs with the at least one pair of slots; dispensing grout into the gap; and curing the grout to join the walls to form the wall joint.

1 - 30 . (canceled) 
     
     
         31 . A wall joint comprising
 a pair of walls, each wall comprises a first surface and at least one stud protruding from the first surface, wherein the first surfaces face each other with a gap in between;   a mechanical connector having a pair of vertical plates attached together by a connecting element, each vertical plate having at least one slot to form at least one pair of slots, wherein the at least one pair of slots are engaged with the at least one stud of each wall, at least one edge of each slot forms an angle at an opening of the slot with a vertical edge of one of the vertical plates; and   cured grout in the gap, wherein the first surfaces are front faces and the wall joint joins the pair of walls to form a composite structural wall.   
     
     
         32 . The wall joint according to  claim 31 , wherein the at least one pair of slots physically and directly contact the at least one stud of each wall in the engagement. 
     
     
         33 . The wall joint according to  claim 31 , wherein a groove is arranged on the first surface of each wall, and the at least one stud protrudes from the groove. 
     
     
         34 . The wall joint according to  claim 31  further comprising a support structure in each wall, wherein a first end of the at least one stud is attached to the support structure and a second opposing end of the at least one stud is a head. 
     
     
         35 . The wall joint according to  claim 34 , wherein the support structure includes at least a rod or a plate. 
     
     
         36 . The wall joint according to  claim 31 , wherein each slot is linear or bent. 
     
     
         37 . The wall joint according to  claim 31 , wherein the angle is between 30° and 60°. 
     
     
         38 . The wall joint according to  claim 31 , wherein each wall comprises a plurality of studs and each vertical plate has a plurality of slots to form a plurality of pair of slots. 
     
     
         39 . The wall joint according to  claim 31 , wherein the connecting element is any one selected from the group consisting of a connecting plate, a bolt and nut system, and a cable system. 
     
     
         40 . The wall joint according to  claim 31 , wherein the connecting element is attached to the pair of vertical plates at the middle of each vertical plate, an edge of the pair of plates, or opposites edges of the pair of plates. 
     
     
         41 . The wall joint according to  claim 31 , wherein a length of each vertical plate is substantially the same as a height of the first surface. 
     
     
         42 . The wall joint according to  claim 31 , wherein the mechanical connector comprises a first plate attached substantially perpendicularly to the pair of vertical plates, the first plate having a pair of silts, each slit is configured to receive a rod extending out of a top surface of one of the walls. 
     
     
         43 . The wall joint according to  claim 31 , further comprises at least one gap rod in the gap. 
     
     
         44 . The wall joint according to  claim 31 , wherein each wall is part of a prefabricated construction module. 
     
     
         45 . A building structure comprises at least one wall joint according to  claim 31 . 
     
     
         46 . A method of assembling a wall joint, the method comprises providing a pair of walls, each wall comprises a first surface and at least one stud protruding from the first surface;
 arranging the first surfaces to face each other with a gap in between;   inserting a mechanical connector into the gap, the mechanical connector comprises a pair of vertical plates attached together by a connecting element, each vertical plate having at least one slot to form at least one pair of slots, wherein at least one edge of each slot forms an angle at an opening of the slot with a vertical edge of one of the vertical plates;   engaging the studs with the at least one pair of slots, wherein engaging the studs with the at least one pair of slots comprises aligning the opening of the slots to the studs and receiving the studs into the slots;   dispensing grout into the gap; and   curing the grout to join the walls to form the wall joint, wherein the first surfaces are front faces and the wall joint joins the pair of walls to form a composite structural wall.   
     
     
         47 . A mechanical connector which secures a pair of walls arranged with a grouted gap therebetween, each wall comprises a first surface and at least one stud protruding from the first surface wherein the first surfaces are front faces and the pair of walls are secured to form a composite structural wall, the mechanical connector comprises a pair of vertical plates attached together by a connecting element, each vertical plate having at least one slot to form at least one pair of slots which engage with the at least one stud of each wall, at least one edge of each slot forms an angle at an opening of the slot with a vertical edge of one of the vertical plates. 
     
     
         48 . The mechanical connector according to  claim 47 , wherein the connecting element is any one selected from the group consisting of a connecting plate, a bolt and nut system, and a cable system. 
     
     
         49 . The mechanical connector according to  claim 48 , wherein the connecting element is attached to the pair of vertical plates at the middle of each vertical plate, an edge of the pair of plates, or opposite edges of the pair of vertical plates. 
     
     
         50 . The mechanical connector according to  claim 47  further comprises a first plate attached perpendicularly to the pair of vertical plates, the first plate having a pair of silts, each silt is configured to receive a rod extending out of a top surface of one of the walls. 
     
     
         51 . The mechanical connector according to  claim 47 , wherein each vertical plate has a plurality of slots to form a plurality of pair of slots to engage with a plurality of studs in each wall. 
     
     
         52 . The mechanical connector according to  claim 47 , wherein a length of each vertical plate is substantially the same as a height of the first surface.