CONNECTION FOR MODULAR CONSTRUCTION

Field of Invention

This disclosure relates to modular construction. More specifically, the disclosure relates to a connector for connecting modules of a modular structure, a connector for connecting a cladding panel to a module for use in modular construction, a module for use in modular construction, structures comprising such modules and connectors, a method of manufacturing such modules, a manufacturing system for manufacturing such modules, and a method of constructing such structures.

Background

Existing modular construction systems are characterised by the use of a linear sequence of highly specialised, single-purpose machines. These machines are engineered to fulfil a single task and come at a high cost. To manufacture a single modular component, a series of various machines is typically needed. Moreover, modular construction systems employ very little automation; instead they involve primarily manual processes.

Moreover, existing timber modular construction systems typically use modules (such as flat cross-laminated timber (CLT) panels) which must be finished on-site. This limits the speed and flexibility with which these modules can be manufactured and assembled. In addition, such modules are unsuitable for being assembled by automated processes.

The present invention seeks to at least partly ameliorate these problems.

Summary of the Invention

Aspects and embodiments of the present invention are set out in the appended claims. These and other aspects and embodiments of the invention are also described herein.

According to at least one aspect disclosed herein, there is provided a module for use in modular construction, the module having at least one aperture arranged to receive a connector for connecting the module to another module, wherein the aperture comprises: a slotted through hole; and an at least partially blind slot, wherein the slotted through hole and the at least partially blind slot are offset from one another. This aperture enables a connector to pass through the through hole in one orientation, and to be seated in the partially blind slot in another orientation, enabling the module to be connected to another module. Preferably, the slotted through hole and the at least partially blind slot are orientationally offset from one another. In this way, the connector can be rotated from a position where it passes freely through the aperture to a position whether it engages the aperture.

Preferably, the slotted through hole and the at least partially blind slot are oriented perpendicular to one another.

Preferably, the slotted through hole and the at least partially blind slot are arranged to intersect one another.

Preferably, the slotted through hole and the at least partially blind slot are arranged to bisect one another.

Preferably, the width of the partially blind slot is at least the width of the slotted through hole, more preferably less than 20% larger.

Preferably, the length of the partially blind slot is at least the length of the slotted through hole, more preferably less than 20% larger.

Preferably, the slotted through hole and the at least partially blind slot are arranged within a recess.

Preferably, the recess is circular.

Preferably, the diameter of the circular recess is at least the length of the partially blind slot, more preferably less than 20% larger.

Preferably, the module comprises: a cavity; and an opening, wherein the opening is arranged to provide access to the aperture via the cavity, preferably so as to enable securement of a connector to the module from within the cavity. This enables a connector to be connected or disconnected from the module via an internal access within the module.

Preferably, the module comprises a plurality of apertures arranged in an array. The array provides a selection of fixing points for connecting the modules.

Preferably, the array of apertures comprises a first sub-array of apertures having slotted through holes with a first orientation and a second sub-array of apertures having slotted through holes with a second orientation different from the first orientation.

Preferably, the orientation difference is approximately 90 degrees.

Preferably, the module comprises multiple faces, and wherein at least one aperture arranged to receive a connector is provided on at least two of the faces, preferably on every face. According to another aspect disclosed herein, there is provided a kit of parts comprising a module as aforementioned, and a blanking cap arranged to fit within the recess to cover the aperture, preferably wherein the depth of the recess is at least the thickness of the blanking cap, more preferably less than 20% larger.

Preferably, the depth of the at least partially blind slot is deeper than the depth of the recess. Preferably the depth of the at least partially blind slot is less than 50% of the thickness of the panel of the module into which the aperture is formed.

According to another aspect disclosed herein, there is provided a kit of parts comprising a module as aforementioned and a connector for connecting the module to another module.

Preferably, the connector comprises first and second connecting members positioned on a shank. The connecting members may preferably be jaws. The term “jaws” as used herein preferably connotes opposing connecting members arranged to engage an object or surface therebetween. For example, the jaws may be flat plates arranged to be moved relative to one another so as to secure a panel between the plates.

Preferably, the diameter of the circular recess is at least the length of at least one of the first and second connecting members, more preferably less than 20% larger.

Preferably, at least one of the first and second connecting members is arranged to be passed through the slotted through hole.

Preferably, at least one of the first and second connecting members is arranged to be seated in the at least partially blind slot to prevent rotation of the connector.

Preferably, the width of the slotted through hole is at least the width of at least one of the first and second connecting members, more preferably less than 20% larger.

Preferably, the length of the slotted through hole is at least the length of at least one of the first and second connecting members, more preferably less than 20% larger.

Preferably, the first and second connecting members are arranged to be rotatable on or with the shank about a longitudinal axis of the shank.

Preferably, at least one of the first and second connecting members is arranged to be movable along the longitudinal axis of the shank.

Preferably, at least one, preferably each, of the first and second connecting members comprises means, preferably screw holes, for fastening the connecting member to the module via the at least partially blind slot. Any aspect described above may be combined with any aspect described below.

According to another aspect disclosed herein, there is provided a connector for connecting modules of a modular structure by being received through apertures of the modules, wherein: the connector comprises first and second jaws positioned on a shank; the first and second jaws are arranged to be rotatable on or with the shank about a longitudinal axis of the shank; at least one of the first and second jaws is arranged to be movable along the longitudinal axis of the shank; and at least one, preferably each, of the first and second jaws comprises a formation for engaging at least one of the apertures to prevent rotation of the jaw in the aperture.

Preferably, the first jaw is arranged to be movable along the longitudinal axis of the shank, and wherein the second jaw is arranged to be fixed, preferably releasably fixed, in position along the longitudinal axis of the shank.

Preferably, the one of the first and second jaws is arranged to be rotatable on the shank about the longitudinal axis of the shank, and wherein the other of the first and second jaws is arranged to be fixed, preferably releasably fixed, against rotation with respect to the shank.

Preferably, the jaws have bodies, said bodies preferably extending, in use, perpendicular to the longitudinal axis of the shank.

Preferably, the jaw bodies are arranged to engage faces of the modules, and wherein preferably at least one of the first and second jaw bodies is arranged to engage an interior face of one of the modules.

Preferably, at least one, preferably both, of the jaw bodies comprises at least one, preferably elongate, tooth for contacting a face of the modules.

Preferably, wherein the at least one tooth is spaced apart from the shank.

Preferably, wherein the at least one tooth is a portion of the jaw body protruding from the at least one of the jaw bodies.

Preferably, wherein the at least one of the jaw bodies comprises an indented portion between the shank and the at least one tooth.

Preferably, wherein the at least one of the jaw bodies comprises two teeth spaced apart, the shank passing through the at least one of the jaw bodies between the teeth. Preferably, wherein the formation for engaging at least one of the apertures comprises at least one tongue extending from the body of the at least one of the first and second jaws, preferably along or parallel to the longitudinal axis of the shank.

Preferably, the at least one tongue comprises a pair of parallel tongues extending from the body of the at least one of the first and second jaws, preferably along or parallel to the longitudinal axis of the shank.

Preferably, the at least one tongue comprises a tapered portion, said tapered portion preferably tapering towards the tip of the at least one tongue.

Preferably, the body of the at least one of the first and second jaws comprising the formation is formed as a single piece with the tongue(s).

Preferably, the body of the at least one of the first and second jaws comprising the formation has a collar portion.

Preferably, the body of the at least one of the first and second jaws comprising the formation is formed as a single piece with the collar portion.

Preferably, the connector comprises one or more cut out portions positioned between the collar portion and the tongue(s).

Preferably, the formation for engaging at least one of the apertures is arranged to engage the interior of the aperture, preferably to engage walls around the aperture.

Preferably, the shank is threaded.

Preferably, the connector comprises a nut on the threaded shank, the nut being arranged to restrict axial movement of the at least one of the first and second jaws that is arranged to be movable along the longitudinal axis of the shank.

Preferably, the nut is a lock nut, preferably a Nyloc nut.

Preferably, the connector comprises a head at an end of the shank; the first jaw is arranged to be rotatable on the shank about the longitudinal axis of the shank, and movable along the longitudinal axis of the shank; and the head comprises a keyed portion at the end of the shank arranged to interface with a keyed portion of the second jaw so as to fix, preferably releasably fix, the second jaw against rotation relative to the shank about the longitudinal axis of the shank and against axial movement along the longitudinal axis of the shank. Preferably, the first jaw comprises an attachment for attaching the connector to a cladding panel.

Preferably, the connector comprises a spacing element arranged to space the attachment from the first jaw.

Preferably, the attachment comprises a plate having at least one aperture arranged to receive a leg of an R-clip to attach the connector to a corresponding piece on the cladding panel.

Preferably, the attachment is coupled to the first jaw.

Preferably, the attachment is coupled to the stopper by the shank.

Preferably, the first jaw is formed as a stopper extending perpendicular to the longitudinal axis of the shank.

According to another aspect disclosed herein, there is provided a module for use in modular construction comprising: at least one aperture arranged to receive a connector for connecting the module to another module; a cavity; and an opening, wherein the opening is arranged to provide access to the aperture via the cavity to secure the connector to the module from within the cavity.

Preferably, the module comprises multiple cavities divided by one or more slats across the interior of the module.

Preferably, the module comprises a plurality of openings, each opening corresponding to one of the cavities.

Preferably, the module comprises at least one formation arranged to interface with a tool of a robotic arm.

Preferably, the at least one formation arranged to interface with a tool of a robotic arm is at least one of the apertures arranged to receive a connector for connecting the module to another module.

Preferably, the at least one aperture is a slot.

Preferably, the module further comprises a plurality of apertures arranged to receive a connector for connecting the module to another module, the plurality of apertures being arranged in an array.

Preferably, the array of apertures includes adjacent slots arranged with different orientations. Preferably, the array of apertures comprises a first sub-array of slots having a first orientation and a second sub-array of slots having a second orientation different from the first orientation.

Preferably, the first and second sub-arrays are interleaved.

Preferably, the array comprises, preferably consists of, a repeating sub-array of apertures, the repeating sub-array comprising at least: two adjacent slots arranged with different orientations; and two adjacent slots arranged with aligned or parallel orientations.

Preferably, the repeating sub-array of apertures is arranged in a four-by-four square grid.

Preferably, the array comprises, preferably consists of, a repeating sub-array of apertures, the repeating sub-array comprising four apertures arranged with aligned or parallel orientations.

Preferably, the four apertures are arranged in a two-by-two square grid.

Preferably, the array comprises, preferably consists of, an integer number of the sub-arrays.

Preferably, within each row and/or within each column of the array, every aperture, except the end-most apertures in each row or column, is located between one aperture with the same orientation and another aperture with a different orientation.

Preferably, the orientation difference is approximately 90 degrees.

Preferably, the module comprises multiple faces, and wherein at least one aperture arranged to receive a connector is provided on at least two of the faces, preferably on every face.

Preferably, the module is a cuboid shape, preferably a rectangular cuboid, preferably wherein the module consists of repeating cubic voxels and/or wherein the width of the module is equal to the distance between the centres of adjacent apertures of the module.

Preferably, the module is comprised of substantially rectangular panels coupled together to form the module.

Preferably, the rectangular panels are coupled via: dowel and hole joints and/or tongue and groove joints, preferably wherein the joints are glued and/or nailed.

Preferably, the module is formed of timber.

Accordingly another aspect disclosed herein, there is provided a kit of parts comprising: at least one module for use in a modular structure; and a connector for connecting the module to another module, wherein: the module comprises at least one aperture; and the at least one aperture is arranged to receive at least a part of the connector when the connector is oriented in a first orientation relative to the aperture, and to engage the module when the connector is oriented in a second orientation relative to the aperture, thereby to connect the module to the other module.

Preferably, the at least one aperture is a slot, and wherein the part of the connector received through the aperture comprises an elongate body.

Preferably, in the first orientation the longitudinal axis of the elongate body is aligned with the longitudinal axis of the slot.

Preferably, in the second orientation the longitudinal axis of the elongate body is perpendicular to the longitudinal axis of the slot.

Preferably, the length of the part of the connector received through the aperture is less than the length of the aperture, preferably less than 50% less than the length of the aperture, more preferably less than 10% less than the length of the aperture, yet more preferably less than 5% less than the length of the aperture; the width of the part of the connector received through the aperture is less than the width of the aperture, preferably less than 50% less than the width of the aperture, 10% less than the width of the aperture, more preferably less than 5% less than the width of the aperture; and the length of the part of the connector received through the aperture is longer than the width of the aperture, preferably at least double the width of the aperture.

Preferably, the connector is a connector as aforementioned and the part of the connector arranged to be received through the at least one aperture is one of the first and second jaws, and/or wherein the module is a module as aforementioned.

Preferably, the connector is a connector as aforementioned, and wherein the formation for engaging at least one of the apertures has a width fitting within, and preferably providing a clearance fit with, the aperture.

Preferably, the connector is a connector as aforementioned, and wherein the formation for engaging at least one of the apertures has a length that less than or equal to the thickness of panels of the module, preferably less than 10% less than the thickness of the panels, more preferably less than 5% less than the thickness of the panels.

According to another aspect disclosed herein, there is provided a structure comprising the kit of parts as aforementioned, comprising at least two modules, wherein the modules are connected to other modules in the structure by the connector, preferably wherein the structure comprises a shear key for securing the modules against shear movement, more preferably wherein the shear key is: part of the connector; co-operating parts of the modules; and/or a separate inserted receiving at least one aperture of the module.

Preferably, the structure comprises a cladding panel, wherein the cladding panel is connected to an exterior face of the module with at least one connector as aforementioned.

Preferably, the cladding panel is connected to the exterior face of the module spaced apart from the exterior face of the module.

Preferably, the structure comprises a waterproofing layer between the cladding panel and the exterior face of the module.

Preferably, the waterproofing layer is secured to exterior face of the module by the first jaw of the connector.

Preferably, the structure is a habitable structure such as a cabin or house.

Preferably, at least two of, preferably all of: the walls, the floors, and the roof of the structure are formed of the modules connected by the connectors.

Preferably, at least the walls and the roof of the structure are formed of the modules and wherein the modules forming the walls and the roof being substantially planar, the structure further comprising at least one angled module connected between modules of a wall and modules of the roof.

According to another aspect disclosed herein, there is provided a method of constructing a module as aforementioned, the module being formed of at least first and second panels, and the at least one aperture arranged to receive a connector being provided on at least the first panel, the method comprising using a robotic arm to: engage the at least one aperture of the first panel thereby to pick up the first panel; position the first panel against the second panel so as to align cooperating joint elements on the panels; and release the first panel to connect the first panel to the second panel via the cooperating joint elements.

Preferably, the cooperating joint elements are: dowels and holes and/or tongues and grooves.

Accordingly to another aspect disclosed herein, there is provided a method of constructing a structure from the kit of parts as aforementioned, the kit of parts comprising first and second modules, the method comprising: using a robotic arm to: engage the at least one aperture of the first module thereby to pick up the first module; position the first module against the second module so as to align at least one aperture of the first module with at least one aperture of the second module; and connecting the first and second modules by the connector through the apertures.

Preferably, the connector is a connector as aforementioned, and wherein connecting the first and second modules comprises: inserting one of the jaws of the connector through the apertures of each of the first and second modules; rotating the inserted jaw relative to the modules; and moving at least one of the jaws along the longitudinal axis of the shank such that the at least one the formation for engaging at least one of the apertures is received within at least one of the apertures.

Preferably, the one of the jaws is inserted through the apertures of each of the first and second modules from within an internal cavity of one of the modules.

Preferably, the robotic arm comprises a tool for engaging the at least one aperture.

Preferably, the tool comprises a gripper tool.

Preferably, the gripper tool comprises first and second elements, wherein at least the first element is movable relative to the second element, preferably wherein both the first and second elements are movable relative to the tool.

Preferably, the first and second elements are arranged to be inserted into the at least one aperture and at least the first element is arranged to move apart from the second element thereby to engage walls of the at least one aperture.

Preferably, the first and second elements are arranged to be inserted into separate apertures and at least the first element is arranged to move towards or apart from the second element such that the elements engage walls of the respective apertures.

Preferably, both the first and second elements are movable, and arranged to move apart or together to engage the walls.

Preferably, the engagement is a friction engagement between the first and/or second elements and the walls.

Preferably, the robotic arm is arranged to carry out the inserting, rotating, and moving steps while using the gripper tool to grip the connector by at least one of the jaws.

Preferably, the connector is a connector as a forementioned; and the tool of the robotic arm further comprises a nut driver tool arranged to engage the nut of the connector. Preferably, the rotating of the connector comprises using the nut driver tool to rotate the shank of the connector by turning the nut.

Preferably, the connecting of the first and second modules by the connector comprises using the nut driver tool to tighten the nut.

According to another aspect disclosed herein, there is provided a robotic arm having a tool programmed to carry out the method as aforementioned.

Any apparatus feature as described herein may also be provided as a method feature, and vice versa. As used herein, means plus function features may be expressed alternatively in terms of their corresponding structure.

Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa. Furthermore, any, some and/or all features in one aspect can be applied to any, some and/or all features in any other aspect, in any appropriate combination. It should also be appreciated that particular combinations of the various features described and defined in any aspects of the invention can be implemented and/or supplied and/or used independently.

The invention also provides a computer program or a computer program product for carrying out any of the methods described herein, and/or for embodying any of the apparatus features described herein, and a computer readable medium having stored thereon a program for carrying out any of the methods described herein and/or for embodying any of the apparatus features described herein.

The invention also provides a signal embodying a computer program or a computer program product for carrying out any of the methods described herein, and/or for embodying any of the apparatus features described herein, a method of transmitting such a signal, and a computer product having an operating system which supports a computer program for carrying out the methods described herein and/or for embodying any of the apparatus features described herein.

Any feature in one aspect of the invention may be applied to other aspects of the invention, in any appropriate combination. In particular, method aspects may be applied to apparatus aspects, and vice versa. As used herein, means plus function features may be expressed alternatively in terms of their corresponding structure, such as a suitably programmed processor and associated memory. Furthermore, features implemented in hardware may generally be implemented in software, and vice versa. Any reference to software and hardware features herein should be construed accordingly.

The invention extends to methods, system and apparatus substantially as herein described and/or as illustrated with reference to the accompanying figures.

One or more aspects will now be described, by way of example only and with reference to the accompanying drawings having like-reference numerals, in which:

Figures 1a, 1 b, and 1 c are perspective views of an exemplary module according to the present disclosure;

Figures 1d and 1e are perspective views of another exemplary module according to the present disclosure;

Figures 1f, and 1g are perspective views of another exemplary module according to the present disclosure;

Figures 2a and 2b are perspective views, from above and below respectively, of a connector for connecting modules as shown in Figures 1a to 1e to form a modular structure;

Figure 2c is a front, side, and top view of the connector of Figures 2a and 2b showing dimensions of various parts of the connector;

Figures 2d and 2e are perspective views of a different embodiment of a connector for connecting modules as shown in Figures 1f and 1g.

Figure 3a is a perspective view of a connector for connecting a cladding panel to a module as shown in Figures 1a to 1g;

Figure 3b and 3c are perspective and plan views of an alternative connector for connecting a cladding panel to a module as shown in Figures 1a to 1g;

Figure 4a is a perspective view of the module of Figure 1a, showing the connectors of Figures 2a and 3a being connected to the module;

Figure 4b is a perspective view of two modules connected end-to-end;

Figure 4c is a plan view of the connected modules of Figure 4b;

Figure 4d is a cross-section view along line A-A in Figure 4c;

Figure 4e is a close up part of Figure 4d as indicated; Figure 5 is a photograph showing the connector of Figure 3a connecting a cladding panel to a module as shown in Figures 1a to 1g;

Figure 6a is a schematic view of a tool for a robotic arm for interfacing with the module and/or the connectors;

Figures 6b and 6c are plan and perspective views of a particular exemplary implementation of the tool of Figure 6a;

Figure 6d is a plan view of another implementation of the tool of Figure 6a;

Figure 7 is a perspective view of the module of Figures 1a to 1g, showing the tool of Figures 6a to 6c interfacing with the module;

Figure 8 is a cutaway view of a structure constructed from the modules and connectors;

Figure 9a is a bottom perspective view of another structure constructed from the modules and connectors;

Figure 9b is a close up view of a part of the structure shown in Figure 9a;

Figure 10 is a block diagram of a manufacturing system for manufacturing the modules;

Figure 11 is a flow diagram illustrating a process for manufacturing the modules; and

Figure 12 is a flow diagram illustrating a process for assembling structures from the modules.

Detailed description

The modular construction system disclosed herein employs discrete modules, also referred to as cassettes, which are connected together to form structures. The discrete modules are described before with reference to Figures 1a to 1g. The discrete modules are connected together with connectors, which are described below with reference to Figures 2a and 2b. Cladding panels may be attached to an exterior face of the modules, and a connector for doing so is described below with reference to Figures 3a and 3b. The coupling of the module-to- module connector of Figures 2a and 2b and the module-to-cladding connector of Figures 3a is described below with reference to Figures 4a to 4e and 5.

The modular construction system disclosed herein is adapted for automated assembly of modular structures. In this regard, a tool for interfacing with the cassette modules and the connectors is described with reference to Figure 6a to 6d. The tool is arranged to engage the modules for the purposes of automated assembly, as is described with reference to Figure 7. By assembling the cassette modules using the connectors, modular structures can be constructed, such as those described with reference to Figures 8, 9a and 9b.

Discrete modules

Figures 1a to 1g are perspective views of exemplary modules 100 for use in modular construction. The module is a discrete building block from which modular structures can be constructed. The module in this example is formed as a cassette, and the terms “module” and “cassette” can be used interchangeably to refer to the module 100 shown in Figures 1a to 1e. The module 100 shown in Figures 1a to 1g has a three dimensional cuboidal shape, specifically a rectangular cuboidal shape, however in other examples the module may be shaped differently, for example as a cube. The module 100 in Figures 1 a to 1 g is substantially planar; in other examples the module may have an angled shape where it forms a joint between parts of a structure. The module 100 shown in Figures 1a to 1g is formed of timber, in particular laminated engineered timber sheet materials. However, in other examples the module may be formed of a different material. Exemplary materials for the modules include plywood and sterling board.

The cuboidal module 100 comprises six or more face panels: and front face panel 102; a rear face panel 104 opposing the front face panel 102; two opposing side face panels 106 along the longer edges of the module 100; and two opposing end face panels 108 along the shorter edges of the module 100. There may be any number of internal bracing panels similar or identical to the side panels or opposing end face panels distributed inside the module The front face panel 102 is typically arranged such that, when the module 100 is assembled in a modular structure, such as a house, the front panel 102 is accessible from within that structure (e.g. a wall panel for a room, accessible from within the room). The rear panel 104 is typically arranged such that, when the module 100 is assembled in a modular structure, such as a house, the panel 104 forms part of an external face of that structure. In other examples, such as when the module 100 is assembled as part of a structure that is not intended to be inhabited, the module may comprise a second rear face panel 104 in place of the front face panel 102.

Each of these six panels is generally rectangular in shape. These six panels are fitted together to form the module 100. In this example, the side face panels 106 and the end face panels 108 comprises one or more dowels (not shown) distributed along their longer edges, and the front face panel 102 and rear face panel 104 comprise blind holes corresponding to the positions of the dowels. To connect the panels together to form the modules, the panels are positioned to align the dowels of the side and end face panels with the blind holes of the front and rear face panels, and the panels are pushed together to insert the dowels into the blind holes to join the panels. Similarly, the side face panels 106 may comprise at least one dowel distributed along their shorter edges, and the side face panels may comprise blind holes on their interior faces to receive the dowels to connect the end face panels between the side face panels.

The joints between the panels may also be glued before being joined by the dowel and hole joints. The joints may additionally or alternatively be nailed to increase the security of the joints. In the examples of Figures 1a to 1e, the joints are nailed by nails 109. The dowels may be integral to the side and/or end face panels, or the side and/or end face panels may comprise blind holes corresponding to the blind holes of the front and rear face panels, and the dowel is a separate part having one end inserted in each of the corresponding blind holes of the panels being joined together. It should be understood that in other examples, the locations of the dowels and holes may be reversed, in that the front and rear face panels may comprise the dowels and the side and end face panels may comprise the blind holes.

In other examples, the panels may be joined by tongue and groove joints between the panels, where some panels comprise tongues and other panels comprise grooves arranged to receive those tongues. The dowel and hole joint described above is preferred for three main reasons. First, it is simpler to manufacture than the tongue and groove joints because it required only holes to be drilled in the panels to accommodate the dowels. Second, it results in the loss of less material because less material needs to be removed to form the blind holes as compared to forming the grooves. Third, the dowel and hole joints enable the panels to be precisely aligned with one another, with the positions of the holes being carefully drilled to ensure that the panels are flush with one another when connected. This eliminates the need for additional finishing of the panel faces as the faces have already been accurately finished in their original manufacture and their relative positions are controlled by the dowels. This third advantage means that the modules 100 can be finished during off-site fabrication and are provided to a construction site in a finished and usable form, not needing to be finished on site. This provides for more efficient construction.

In a different embodiment, dowels are not used, and the six panels are nailed together to form the module 100. Optionally an adhesive may also be used with the nails to increase the strength of the joints. This method of attachment simplifies the manufacturing process as the panels are not required to be clamped together whilst the glue cures.

The module 100 comprises at least one cavity 110. Thus, the module 100 is hollow, with the cavity 100 provided in the hollow interior of the module 100. The module 100 comprises at least one opening 112a, 112b arranged to provide access to the cavity. The opening may have a stepped edge around some or all of its perimeter to allow a capping piece to be inserted and supported. In this example, the module 100 the cavity 110 is divided into two roughly equal sized cavities by a slat or bracing member (not shown) across the interior of the module 100, between the opposing side face panels 106. The slat also advantageously provides structural reinforcement to the module 100. In this example, the module 100 comprise two openings 112a, 112b, each opening corresponding to one of the two cavities and providing access to the respective cavity.

In other examples, the module may comprise multiple slats dividing the hollow interior of the module 100 into multiple cavities; for example two equidistant slats dividing the interior of the module 100 into three equal sized cavities. In such examples, the module may comprise multiple openings each opening corresponding to one of the multiple cavities. In yet other examples, the cavities may not be equally sized, but instead unequally sized, and accordingly the openings corresponding to the cavities may also be unequally sized to provide access to each respective cavity.

The cavity or cavities provide a space which can be filled with insulation material (not shown), particularly when the module 100 is used to construct a modular structure, such as a house, that is intended to be inhabited. Alternatively or additionally, the cavity or cavities may provide a space for mechanical and/or electrical devices or connections, wiring or plumbing, for example, for the modular structure. Preferably, only components that will only rarely need to be accessed for maintenance or replacement are run through the cavities to avoid the need to repeatedly remove the insulation for such access. The modules may also be provided with one or more removable caps to cover the openings when the openings are not in use to access the cavity.

It may be advantageous to have differently sized cavities within the module. For example, the hollow interior of the module may advantageously be divided into three cavities: two wider cavities and one narrower cavity between the wider cavities. In this case, the wider cavities may be filled with insulation, while the narrow cavity may provide a conduit for pipes and/or wiring to run through the module, and not filled with insulation so as to provide easy access to those pipes and wiring. It is preferable for the insulation material to be sheep’s wool or hemp fibre, as these are more sustainable insulation material, but other insulation materials would also be suitable.

The six panels of the module (the front face panel 102, rear face panel 104, side face panels 106, and end face panels 108) each themselves have interior and exterior faces. The interior face of each panel is the face which, when the panels are assembled to form the module, faces inwards towards the cavity 110 in the hollow interior of the module 100. The exterior face of each panel is the face which, when the panels are assembled to form the module, faces outwards away from the module.

The module 100 further comprises at least one aperture arranged to receive a connector for connecting the module to another module to form a modular structure. In the simplest case the apertures may simply be circular holes to accept a threaded rod or bolted connection. The apertures in this example are formed as slots 114a, 114b, and the terms “slots” is used interchangeably with the term “apertures” herein. Each of the slots has a length longer than its width, and references to the longitudinal axis of the slots are used to mean the direction along the length of the slot. Use of a slot rather than a circular hole allows a connection to be made accessing only one side of the assembly. This is advantageous because the connections can be more easily be made in a variety of structure formations and modules can be added in any order. For example, adding one module may block access to the interior of another module. It may also be that the opening of the module is oriented away from the site of the new block and is therefore inaccessible. If a standard bolted connection were used, access to the interior would be required to add a nut, washer or other mechanical fastener. Thus once if the opening to a module is blocked, no more bolted connections can be made to it. With a slotted connection however, a bolted connection can be achieved through at least the opening of the module being added to the structure

At least one slot is provided on each of at least two of the faces (i.e. face panels) of the module 100, and ideally at least one slot is provided on every face of the module 100. In the examples shown in Figures 1a to 1g, multiple slots are provided on every face of the module 100. The panels themselves and the apertures in the panels may be formed by CNC or robotically controlled routing. Alternatively, the panels and apertures may be formed by a stamping process. The panels may also be cut using a straight, rail or table saw, followed by CNC or robotically controlled routing of the apertures after the module has been assembled..

In this example, the module 100 is provided with a plurality of slots, which are distributed around the face panels of the module. The slots in this example are arranged in an array, that is, in an ordered arrangement. In particular, on the side face panels 106 the slots are arranged in a linear array of eight slots arranged end-to-end and spaced apart equidistantly. Similarly, on the end face panels 108 the slots are arranged in a linear array of four slots arranged end- to-end and spaced apart equidistantly. On the front face panel 102 and rear face panel 104 (partly occluded), the slots are arranged in a rectangular array. On the front face panel 102, there is a gap in the array where the openings 112a, 112b are located.

The array of slots on the module 100 comprises adjacent slots with the same orientation. By this, it is meant that the array comprises at least two slots located adjacent one another in the array where the orientations of the two slots (i.e. the directions of the longitudinal axis of the slots) are parallel to or aligned with one another. For example, on the front face panel 102 and the rear face panel 104, there are adjacent slots 114a with aligned (i.e. the same) orientations, the aligned orientation being parallel to the longitudinal axes of the side face panels 106. Also in the front face panel 102 and the rear face panel 104, there are adjacent slots 114b with parallel (i.e. the same) orientations, the parallel slot orientations also being parallel to the longitudinal axes of the end face panels 108.

In addition, the array of slots on the module 100 comprises adjacent slots with different orientations. By this, it is meant that the array comprises at least two slots located adjacent one another on the array, where the orientations of the slots (i.e. the directions of the longitudinal axis of the slots) are offset from one another. For example, on the front face panel 102 and the rear face panel 104, there are adjacent slots (see adjacent slots 114a and 114b) with different orientations. In particular, in this example the difference in the orientations of the adjacent slots is 90 degrees, such that the orientations of the adjacent slots are perpendicular. More particularly, the orientation of slot 114a is parallel to the longitudinal axes of the side face panels 106, while the orientation of slot 114b is parallel to the longitudinal axes of the end face panels 108.

Thus, on the front face panel 102 and rear face panel 104, the slots are arranged in two subarrays: a first sub-array of slots 114a having a first orientation; and a second sub-array of slots 114b having a second orientation different from the first orientation. In this example, the difference in the orientation of the first and second sub-arrays is 90 degrees. The first and second sub-arrays of slots are interleaved, in that the first and second sub-arrays are arranged among one another, with the slots in one sub-array being located in gaps in the other subarray. The exemplary modules shown in Figures 1d and 1e differ from the modules of Figures 1a to 1c in that each slot of the modules in Figures 1d and 1e is rotated by 90 degrees relative to the corresponding slot of the modules in Figures 1a to 1e. Nonetheless, in all modules shown in Figures 1a to 1g the plurality of slots are arranged in two sub-arrays as described above.

In this example, the array of apertures comprises a repeating pattern of apertures, the repeating pattern forming a sub array. In particular, two repeating patterns can be seen:

1. The array of apertures on the front 102 and rear 104 face panels comprise (more specifically consist of) two repeated four-by-four square sub-arrays of slots (albeit that, on the front face panel 102, the central four apertures of the sub-array are missing due to the openings 112a, 112b). In other examples the panels may comprise another integer number of these sub-arrays. This repeated four-by-four square sub-array comprises at least two adjacent slots arranged with different orientations (in this example, perpendicular orientations) and at least two adjacent slots arranged with aligned or parallel orientations. See, for example, the column of four slots on the left of the front face panel 102, which is part of the left hand repeating sub-array, which comprises two pairs of perpendicular apertures and one pair of parallel apertures.

2. The array of apertures on the front 102 and rear 104 face panels also comprise repeated two-by-two square sub-arrays, the sub-arrays each consisting of slots arranged with aligned or parallel orientations. See, for example, the group of four slots between the two openings 112a, 112b which comprises two parallel pairs of aligned apertures.

Arranging the apertures of the array on the front and rear face panels of the module in this way means that every aperture in each row and/or column (except for the end-most apertures in each row or column) is located between one aperture with the same orientation and another aperture with a different orientation.

The arrangement of apertures on the module described above gives rise to a number of advantages. First, providing a plurality of apertures on the module 100 for receiving a connector is advantageous because it provides a number of options for the position of connections between from the module 100 to another module. Second, and similarly, providing apertures on every face of the module 100 enables the module to be connected to other modules by each face of either module. For example, any of the front, rear, side, or end face panels of one module may be connected with any of the front, rear, side, or end face panels of another module. In this way, a wider variety of structures can be constructed from the modules. Third, providing apertures with orientations that differ from one another provides more options for connecting the module 100 to another module. For example, if one wished to connect two such modules 100 between the end face panel 108 of the first module and the front face panel 102 of the second module (such that the modules were connected perpendicularly), the end face panel 108 of the first module could be arranged to abut the front face panel 102 of the second module across the width or along the length of the second module. And, in either case, there would be at least two slots on the front face panel of the second module 102 with orientations that align with the orientations of the slots on the end face panel 108 of the first panel by which the two modules could be connected by a connector.

Furthermore, the use of repeating sub-arrays to make up the array of slots means that further patterns of slots are formed when the modules are connected together. In particular, when modules are connected side-by-side of end-to-end the arrangement of apertures is mirrored across the joint. For example, when two of the modules 100 are connected side-by-side (i.e. between their side face panels 106) the three pairs of parallel or aligned slots on the front face panel running the long edge of the panel match up with the three pairs of corresponding slots on the other module, thus forming two-by-two grid sub-arrays consisting of slots arranged with aligned or parallel orientations (as mentioned in point 2. above). A similar two-by-two subarray of slots of formed by the slots located at the corner of the front and rear face panels when four of the modules are connected in a two-by-two arrangement of modules.

Another embodiment of module 100 is shown in Figures 1f and 1g. In this embodiment, the module 100 comprises a different aperture arranged to receive a connector for connecting the module to another module to form a modular structure, as compared to the previously described embodiments. In the embodiment shown in Figures 1f and 1g, the apertures 114c comprise a circular recess, or cut-out, 111 , a slotted through-hole 113 and partially blind slotted hole 115 which acts as a seat for a connecting member.

The slotted through-hole 113 and partially blind slotted hole 115 have lengths longer than their widths, and references to the longitudinal axis of the slots are used to mean the direction along the length of the slot. The longitudinal axes of these two slotted holes are perpendicular to each other thereby forming a cross or plus shape with just the singular slotted through-hole 113 extending through the thickness of the module 100. The partially blind slotted hole 115 is blind except where it intersects the through-hole 113.

The circular cut-out, or recess, 111 is located on a first surface of the module 100 which is preferably an interior surface of the module 100. The circular cut-out 111 has a diameter equal to or exceeding the longitudinal axis length of the slotted through-hole 113 or partially blind slotted hole 115. The circular cut-out 111 extends from the surface of the module 100 partially through the thickness of a panel of the module 100 such that it finishes blind in the panel of the module 100.

The partially blind slotted hole 115 extends from the terminal surface of the circular cut-out 111 through the thickness of the panel of the module 100, again finishing blind in the panel of the module 100.

The slotted through-hole 113 also extends from the terminal surface of the circular cut-out 111 and continues through the entire remaining thickness of the panel of the module 100 such that it opens onto the opposing surface of the panel. The slotted through-hole 113 is preferably constant in cross-section which takes the form of a rectangular centre section with rounded ends. The longitudinal axis of the slotted through-hole 113 is perpendicular to the longitudinal axis of the blind slotted hole 115. In other embodiments, the axes may be offset differently, such as by a 45 degree offset rather than a perpendicular (90 degree) offset.

From the exterior of the module 100, only the slotted through-hole 113 is therefore visible. From the interior surface, the circular cut-out 111 , slotted through-hole 113 and blind slotted hole 115 may all be seen extending through the thickness of the module 100 (for example as shown in Figures 1f and 1g). The apertures 114c may be arranged throughout the module 100 as previously described for the other slot embodiments 114a and 114b.

Whilst not shown, a circular blanking plug may be used on conjunction with the circular cutout 111. The circular blanking plug may be inserted with an interference fit into the circular cut-out recess 111 to cover the hole and provide a smooth surface finish to the interior of the module.

The wall thickness of the module 100 panels is larger in the embodiment shown in Figures 1f and 1g. As there are three levels of removed material in the apertures114c (i.e. the cut-out circular recess 111 , the partially blind slot 115, and the through-hole slot 113). The increased wall thickness ensures the depth of each individual apertures114c subcomponent (the circular cut-out 111 , the slotted through-hole 113 and the blind slotted hole 115) is sufficient to provide enough strength to the apertures114c to hold the modules 100 together.

In the embodiment shown, the module 100 has an open face opposite the rear face panel 104 thus the module 100 is formed only of five panels. This improves access for insertion of insulation into the module 100 and also allows for the insulation to be formed from solid sheets. In comparison to the embodiments shown in Figures 1a-e, the aperture for inserting insulation is much larger. This is advantageous as the insulation can be made from solid panels rather than flexible panels, given that there is no need to feed the insulation through an opening in the front face panel. In other embodiments, a front face panel is provided similar to the front face panel 102 of the embodiment of Figure 1a-1e.

A recess 116 is formed in an exterior surface of the module 100. The recess 116 is formed into the outer perimeter of the rear face panel 104 such that it forms a continuous recess that traverses both long and short edges of the rear face panel 104. The recess is preferably rectilinear in cross section, preferably with a recess width of 6mm although it will be appreciated that other dimensions may be chosen as deemed necessary. The recess 116 is narrower than the thickness of the rear face panel 104 such that it forms a step in the outer perimeter of the rear face panel 104. When the rear face panel 104 is assembled to the side face panels 106 and end face panels 108, the recess 116 is formed on two sides by the rear face panel 104 and on one side by the side face panels 106 and end face panels 108. The recess 116 is thus defined in the assembled module 100 and opens outwards away from the centre of the rear face panel 104.

A rubber seal may be inserted into the recess 116. The rubber seal has a depth greater than the depth of the recess 116 such that when the rubber seal is inserted into the recess 116 it protrudes slightly. The rubber seal is D-shaped in cross section, with the straight edge of the ‘D’ sitting against the bottom of the recess 116 and the curved edge protruding outwards. The rubber seal may be a closed loop stretched around the rear face panel 104 or may instead be formed from a continuous strip which is cut and placed into the recess 116.

When two modules 100 are assembled, the rubber seals in the recesses 116 are compressed together thus forming a seal. This improves insulation characteristics of the modules 100. It may also provide an airtight seal between the blocks, removing the need for a vapour barrier layer. It will be understood that sealing materials other than rubber may be used to achieve the same effect.

It is to be understood that a module 100 may use a combination of slot embodiments as described herein. In particular, a module 100 may use a combination of the slots described with reference to Figures 1a-1e and those described with reference to Figures 1f and 1g.

In any embodiment described previously, the face of the block may be pre-finished (sanded and painted or varnished) so no additional finishing such as plasterboard is required. The block surface may be coated with additional products to increase its performance in terms of fire and vapour resistance.

To allow the block to be the finished surface, it may not have connection points (i.e. apertures 114a, 114b, 114c) over the whole surface. Instead, they may be added only where necessary to connect in other intended configurations. Thus, there is a typical library of modules with predetermined connection points. Alternatively, blocks may be manufactured with few connection points and then more may be added at a later stage by an additional machining process.

The partially blind slot 115 may have additional chamfers to allow easy seating of a connector heat in the slot 115. The circular recess allow the whole connecting member to be seated in the aperture 114c and end up below the internal plane of the module. This is useful in allowing a piece of solid insulation to be inserted from the outside without interfering with the connector. The slots of the aperture may have filleted or curved corners to allow the connectors (as described below) to be used more easily, and also to facilitate machining process. Router bits are circular in profile, meaning it is efficient to leave internal corners of the slots and recess in a rounded profile. The partially blind slot 115 is curved where it meets the intersecting through- hole slot 113. Adding curves into the toolpath often results in a faster machining time as there are fewer stops and starts.

It should be understood that while the modules described herein are two-by-one rectangular modules, other position dimensions are possible. For example, the module could equally be formed as a one-by-one square, comprising just one of the repeated sub-arrays of apertures, or, or generally, as an M-by-N module, with M*N repeated sub-arrays of apertures. It should also be understood that the entire modules could be scaled up to suit a particular structure. For example, when building a habitable dwelling, it may be convenient to provide modules that are 1 metre by 0.5 metres, however for larger structures the modules could be formed as 2 metres by 1 metre modules such that fewer modules are needed to compete the structure. In the latter case, the sizes of the slots and connectors are scaled accordingly.

As well as joining the modules, the slots may also be used for the purpose of computer vision. Cameras of various types such as Infra-Red, Visual Light, LiDAR sensors and so on may be used in conjunction with edge detection (insert other methods too) algorithms to detect the positions and orientations of the slots relative to the camera. In the simplest case, the face of the block is easily categorised as “light” or “near” and the slots categorised as “dark” or “far”. This is advantageous when programming a robot arm to interface with these slots as part of the assembly process. The position of an end effector seeking to interface with the slots can be guided in real time using information derived from a camera. This function of the slots may be improved with additional markers on or around the faces of the module. Similarly, when positioning blocks relative to one another, the slots can be used to accurately judge relative distances and orientations.

The cavity 110 is arranged to provide access to the apertures from within the interior of the module, so that a connector that is received within one of the apertures (for connecting the module to another module) can be accessed and tightened from within the cavity thereby to secure the connector to the module (for example by engaging the interior face of one of the panels of the module, as is described below with reference to Figures 4a to 4d). Advantageously, this allows the modules to be connected together without the need for any other fasteners to be applied to the outside of the modules to connect them together; instead, the connections between the modules are hidden internally within the cavities of the modules. The module 100 also comprises at least one formation arranged to interface with a tool of a robotic arm. This formation enables the module to be handled by the robotic arm (via the tool) thereby to assemble the module with another module into a structure. In the example of Figures 1a to 1e, the formation is provided by any one of the slotted apertures 114a, 114b, through which a tool, preferably a gripper tool, is inserted to grip the module. In this way, the apertures provide a dual function of receiving connectors to connect the module to another module, and of receiving the tool of the robotic arm in order to interface with that tool. Therefore, each of the panels which make up the module can also be individually gripped by the tool of the robotic arm - as each panel includes at least one aperture - which enables the robotic arm to be used not only to handle and assemble entire module, but also to handle assemble the individual panels and assemble them into a module 100. This mechanical interface is advantageous compared to other handling methods such as vacuum suction because it does not rely on either the porosity of the material or smoothness or cleanliness of the material surface to give a good seal around the vacuum. With a mechanical interface, the gripper can be locked in place so that even if power is cut to the gripper, the module stays firmly gripped by the robotic arm. These factors are particularly important when considering the reliability of the assembly system and the potential proximity to human workers. Furthermore, as the scale of the module increases or many modules are joined together, the vacuum force required would become impractically large.

Rather than interfacing with a single aperture, the robotic arm may instead interface with a group of apertures. For example, with reference to the sub-arrays of apertures described above, a gripper end effector of a robotic arm (the gripper itself having two fingers) may be arranged to interface with two adjacent modules which have parallel or aligned orientations, by inserting a finger through each of the two apertures and grasping the part of the panel between the apertures. Analogously, a gripper end effector having four fingers may be arranged to interface with a two-by-two square sub-array of four apertures having parallel or aligned orientations, by inserting one finger of the gripper through each of the four apertures and grasping the part of the panel between the apertures.

In other examples, the formation arranged to interface with a tool of a robotic arm may be different from the apertures arranged to receive the connectors. For example, the formation might be a protrusion on one, some, or all of the panels of the module, the protrusion(s) arranged to be gripped by the tool of the robotic arm.

The interface between the module 100 and the tool of the robotic arm is described in more detail below with reference to Figures 6 and 7. Connectors

Figure 2a and 2b are perspective views, from above and below respectively, of a connector 200 for connecting together modules 100, as described with reference to Figures 1a to 1e, to form a modular structure. The connector 200 comprises a first jaw 202a and a second jaw 202b. The jaws may be referred to alternatively as ‘connecting members’. The first and second jaws 202a, 202b are joined along a shank 204, the shank having a longitudinal axis along its length. The shank passes through openings on each of the first and second jaws 202a, 202b. The first jaw 202a is arranged to be movable along the shank in the axial direction towards and away from the second jaw 202b. The first jaw 202a is also arranged to be rotatable on the shank about the longitudinal axis of the shank.

The second jaw 202b in this example is not movable on the shank 204, instead it is fixed in place on the shank against axial movement along the shank and against rotational movement on the shank (i.e. relative to the shank). The second jaw 202b is fixed in place against rotational movement on the shank by a keyed interface between the second jaw and shank, wherein the shank comprises a keyed portion (e.g. a part of the shank with a square cross section) which corresponds to a keyed (e.g. square) opening through the second jaw. In other examples the second jaw 202b may be glued of welded to the shank. The keyed parts of the shank and jaw prevent rotation of the second jaw on (i.e. relative to) the shank. The second jaw 202b is fixed in place against rotational movement on the shank by a friction engagement between the second jaw and the shank. Thus, the second jaw 202b rotates with the shank, when the shank itself is rotated, but not independently of the shank. The second jaw can be released from being fixed against axial movement by applying a force to overcome the friction engagement and moving the jaw along the shank clear of the keyed part of the shank, after which the second jaw can also rotate on the shank. Preferably, the engagement between the second jaw and the shank is a location or interference fit. Structurally, the jaws 202a, 202b are identical, and any description of one jaw, or any reference numerals used in respect of one jaw, should be understood to apply equally to the other jaw. To improve the friction engagement of the second jaw with the shank, the shank and/or the second jaw may be heat treated during or after the second haw is assembled with the shank.

The connector 200 comprises a head 205 at one end of the shank corresponding to the second jaw, and the friction engagement between the second jaw and the shank is located adjacent the head 205. The head 205 prevents the jaws moving off the shank and that end. In this example, the shank 204 of the connector is threaded and the connector also comprises a threaded nut 206 on the shank. The nut 206 can be threaded along the shank in the axial direction. The nut 206 provides a backstop behind the first jaw 202a to restrict axial movement of the jaw 202a and, when the nut is tightened along the shank, to force the first jaw 202a along the shank towards to the second jaw 202b. The nut 206 is a lock nut, and in this example a nyloc nut (i.e. a nylon insert lock nut). Other combinations of nuts and washers may be used to achieve the same desired effect, for example a standard nut and spring washer.

Each jaw 202a, 202b comprises an elongate body 208 which extends perpendicular to the longitudinal axis of the shank. The elongate body 208 comprises a central collar portion 209 which surrounds the shank 204. The collar portion 209 is formed as a single piece with the body 208. The collar portion 209 comprises the opening through which the shank passes thus the collar portions acts as a guide for movement of the jaw along the shank 204.

Each jaw 202a, 202b in this example further comprises a formation for engaging at least one of aperture of a module (e.g. the of the module 100) to prevent rotation of the jaw in the aperture. This formation in this example is a pair of tongues 210 which extend from the elongate body 208 parallel to the axis of the shank 204, that is, perpendicular to the longitudinal axis of the elongate body 208. Each tongue has a tapered portion 211 comprising chamfers which assists the tongue fitting within an aperture of the module 100, as is described below. In another embodiment these tongues may be lengthened and formed with grooves or folds so they interlock when moved towards each other. This may be advantageous to transmit shear forces between the modules when connected.

The elongate body 208 and the tongues 210 are formed as a single T-shaped piece of malleable material, such as a malleable metal. Strips 212 of the elongate body 208 running along the long edge of the body 202 are upturned (i.e. folded) with respect to the elongate body 208. The tongues 210 extend from the upturned (i.e. folded) strips 212 of the elongate body, one from each side of the body 208, parallel to the axis of the shank 204. Thus, each jaw 202a, 202b is initially formed as a cross-shaped net before the strips 212 and the tongues 210, which extend from the strips 212, are upturned to create the T-shaped jaws. Cut-out portions 214 are provided between the collar portion 209 and the tongues 210. These cut-out portions separate the collar portion 209 from the tongues 210 so that during formation of the jaw the collar portion 209 of the elongate body 208 is not deformed from the folding of the tongues.

The strips 212 of the elongate body may comprise relatively indented portions 213 proximal to the tongue and shank and relatively protruded portions 215 (also referred to as teeth) distal from the shank. Thus, the relatively indented portions (which in this example are cut-out notches) and located between the tongue and the relatively protruded portions. In this way, when the jaws engage a face of a module 100 to connect the modules, the relatively intended portions do not contact the face, while the relatively protruded portions do contact the face. Thus, the contact points of the jaws with the face are spaced apart from the shank, which provides more stability of the engagement between the jaw and the face of the module.

Figures 2d and 2e are perspective views of a different embodiment of the connector 200 for connecting together modules 100 described with reference to Figures 1f and 1g, to form a modular structure.

The connector 200 comprises a first jaw 202c and a second jaw 202d. The first and second jaws 202c, 202d are joined along a shank 204, the shank having a longitudinal axis along its length. The shank passes through openings on each of the first and second jaws 202c, 202d. The first jaw 202c is arranged to be movable along the shank in the axial direction towards and away from the second jaw 202d. The first jaw 202c is also arranged to be rotatable on the shank about the longitudinal axis of the shank.

The second jaw 202d in this embodiment is not movable on the shank 204, instead it is fixed in place on the shank against axial movement along the shank and against rotational movement on the shank (i.e. relative to the shank). The second jaw 202d is fixed in place against rotational movement on the shank by a keyed interface between the second jaw and shank, wherein the shank comprises a keyed portion (e.g. a part of the shank with a square cross section) which corresponds to a keyed (e.g. square) opening through the second jaw. In other examples the second jaw 202d may be glued or welded to the shank. The keyed parts of the shank and jaw prevent rotation of the second jaw on (i.e. relative to) the shank. The second jaw 202d is fixed in place against rotational movement on the shank by a friction engagement between the second jaw and the shank. Thus, the second jaw 202d rotates with the shank, when the shank itself is rotated, but not independently of the shank. The second jaw 202d can be released from being fixed against axial movement by applying a force to overcome the friction engagement and moving the jaw along the shank clear of the keyed part of the shank, after which the second jaw 202d can also rotate on the shank. Preferably, the engagement between the second jaw and the shank is a location or interference fit. Structurally, the jaws 202c, 202d in this example are identical to one another, and any description of one jaw, or any reference numerals used in respect of one jaw, should be understood to apply equally to the other jaw. To improve the friction engagement of the second jaw with the shank, the shank and/or the second jaw may be heat treated during or after the second haw is assembled with the shank.

The connector 200 comprises a head 205 at one end of the shank 204 corresponding to the second jaw 202d, and the friction engagement between the second jaw 202d and the shank is located adjacent the head 205. The head 205 prevents the jaws moving off the shank at that end. In this example, the shank 204 of the connector is threaded and the connector also comprises a threaded nut 206 on the shank. The nut 206 can be threaded along the shank in the axial direction. The nut 206 provides a backstop behind the first jaw 202c to restrict axial movement of the jaw 202c and, when the nut is tightened along the shank, to force the first jaw 202c along the shank towards to the second jaw 202d. The nut 206 is a lock nut, and in this example a nyloc nut. Other combinations of nuts and washers may be used to achieve the same desired effect, for example a standard nut and spring washer.

Each jaw 202c, 202d comprises an elongate body 208a which extends perpendicular to the longitudinal axis of the shank 204. The elongate body 208a comprises an opening through which the shank passes and acts as a guide for movement of the jaw along the shank 204.

In this embodiment, the elongate body 208a acts as a formation for engaging with the partially blind slotted hole 115 to prevent rotation of the jaw in the aperture. The shape and size of the elongate body 208a is configured to pass through the slotted through-hole 113 in a first orientation and to engage the partially blind slotted hole 115in a second, different orientation. In the embodiment shown, the elongate body 208a is a plate

Optionally, the first jaw 202c may also have at least one smaller aperture 216 drilled through its thickness. In the embodiment shown in Figures 1f and 1g, the first jaw 202c has two apertures 216 located on its longitudinal axis.

This embodiment of connector 200 uses a simpler manufacturing method (single cut rather than cut and fold). There is also potentially more fire resistance in this embodiment due to being a larger solid mass of material as compared to the embodiment shown in Figures 2a-c. There is also more contact surface with the module, meaning splitting the module material is less likely.

The connector may also have a shear key which locks and prevents the module faces from sliding past one another.

The smaller holes 116 can be used to pre-fasten the connector in position e.g. with screws without needing to tighten it in place. This is helpful when lifting a large prefabricated module composed of panels into position on top of another prefabricated module. In an example, a shear key helps guide the upper block in to position and then the other side of the connector can be added later.

Connectors may also have one side substituted to a lifting ring or similar attachment to allow it to be used to easily lift a large panel or module. It is easy to create a multitude of connection points to safely lift a large structure that may otherwise require additional lifting apparatus. The connector may be inserted and tightened by hand with the aid of an electric socket spanner. Alternatively, the connector may be picked, inserted and tightened by a robot with specialised end effector. This end effector may consist of gripper jaws sized to grasp the jaw of one side of the connector, in conjunction with a socket spanner device. Thus, the end effector can control the orientation of both connector plates, as well as tighten the nut to the required torque.

It is to be understood that connectors 200 described with reference to Figures 2a-c and Figure 2d-e may be used in combination. In particular, a module 100 may use a combination of the two connector embodiments, in addition to a combination of the two aperture embodiments.

Figure 3a is a perspective view of a different connector 300 for connecting a cladding panel to a module 100 as described with reference to Figures 1a to 1e. The connector 300 comprises a jaw 302 located on a shank 304. The jaw 302 is structurally identical to the jaws 202a, 202b described above with reference to Figures 2a and 2b. The connector 300 also comprises a head 305 at one end of the shank corresponding to the jaw 302 which prevents the jaw 302 moving off of the shank 304. The jaw 302 in this example is not movable on the shank 204, instead it is fixed in place on the shank against axial movement along the shank and against rotational movement on the shank (i.e. relative to the shank), in the same way as the second jaw 202b described above with reference to Figures 2a and 2b. Thus, the jaw 302 cannot rotate on the shank 304, but rotates with the shank when the shank itself is rotated.

The connector 300 also comprises a further jaw on the shank, which in this example is formed as a stopper 308, meaning that it is sized and shaped to be unable to pass through the apertures of the module 100 in any orientation, such that it stops against the module face. In this example, the stopper jaw is formed as a timber block. In other examples, it may be formed as a flat plate. The stopper jaw 308 is arranged to be movable on the shank 304. The stopper has an elongate body which is oriented substantially perpendicular to the jaw 302, such that when the connector is rotated such that the jaw is perpendicular to the slot, the stopper is aligned with and covers the slot.

In this example, the shank 304 of the connector is threaded and the connector also comprises a threaded nut 306 on the shank. The nut 306 can be threaded along the shank in the axial direction. The nut 306 provides a backstop behind the stopper jaw 308 to restrict axial movement of the stopper jaw 308 and, when the nut is tightened along the shank, to force the stopper jaw 308 along the shank towards to the jaw 302. The nut 306 is a lock nut, and in this example a nyloc nut. The connector 300 comprises a clasp portion 310 arranged to clasp the stopper jaw 308 between two arms. The arms may be biased together to clasp the stopper jaw 308 between the arms. In this example, the clasp portion is a metallic U-shaped element, where the stopper jaw 308 is wedged in the crook of the U-shaped element. The shank 304 passes through the arms of the clasp element 310 and the stopper 308 and clasp element 310 are retained on the shank 304 by the nut 306.

The connector 300 also comprises attachment means 312 for connecting the connector 300 to the cladding panel. In this example, the attachment means 312 is formed as a single piece with the clasp element 310. A spacing element 314 is located between, and formed as a single piece with, the attachment means 312 and the clasp element 310. In this way, the attachment means 312 is spaced apart from the stopper jaw 308 by the spacing element 314, meaning that when the connector 300 is attached to a module 100, and the attachment means 312 is attached to a cladding panel, the cladding panel is spaced apart from the module 100. The attachment means is therefore coupled to the stopper jaw 308 via the shank 304, because the stopper jaw is mounted on the shank and the attachment means is coupled to the shank via the clasp element 310. The attachment means 312 comprises a plate having at least one aperture 316 arranged to receive one leg of an R-clip for securing the connector 300 to a cooperating piece on the cladding panel. The cladding panel to be attached to the module may be, for example, a timber sheet or a gypsum board.

Figures 3b and 3c show an alternative implementation of the cladding connector. In this alternative example, the connector comprises a right angled bracket 320 comprising a first plate 322 arranged to be connected via screws through apertures of the second plate to the cladding panel, and a second plate 324 arranged to be connected via screws through apertures of the second plate to a module (e.g. module 100 described above). The connector comprises a tongue 326 resiliently attached to the second plate 324. In use, a waterproofing layer is added to the external face of the module, and the second plate is then attached to the external face of the module by screws through apertures. The screws pierce through the waterproofing layer and fix the connector to the module. The holes in the waterproofing layer are sealed by the second plate when connected. The tongue 326 is arranged to help locate the second plate in place the module by protruding slightly from the second plate and entering an aperture on the external face of the module. The tongue 326 enters the aperture typically by only approximately 1 or 2 millimetres. The first plate 322 is then connected to a cladding panel in the same way as the attachment means 312 of connector 300 described above. Figure 4a is a perspective view of the module of Figure 1a, showing the connectors 200, 300 of Figures 2a-c and 3 respectively being connected to the module. Figure 4b shows two modules connected end-to-end using connectors 200.

The connector 200 is attached to the module by the following procedure:

• First and second modules 100 are arranged to abut one another, with the slot apertures intended to be used for connection of the modules being aligned with one another.

• From the cavity of the first module, the fixed jaw (i.e. the second jaw 202b of the connector 200) is passed through the aligned slots of the modules 100 into the cavity of the second module. This is possible when the connectors 200 are oriented in a first orientation with respect to the slots, in which the fixed jaw is aligned with the orientation of the slots so that it can pass through the slots. The jaw 202b is passed all the way through the slot, in the sense that no part of the jaw is within the slots; only the shank is located within the slots.

• The shank 204 and the fixed jaw are then rotated together by 90 degrees (as the shank and the fixed jaw are rotationally fixed together) such that the fixed jaw is oriented perpendicular to the slot. The shank may be rotated by gripping and turning the locknut while it is locked with the shank. In this perpendicular orientation, the jaw 202b is unable to pass back through the slot.

• From within the cavity of the first module, the shank is then pulled from the end opposite the fixed jaw, so that the tongues of the fixed jaw are pulled into the slot of the second module, and the elongate body of the jaw engages an internal face of the second module. When the tongues are received within the slot, the fixed jaw is prevented from rotating relative to the module.

• The movable jaw (i.e. the first jaw 202a of the connector 200) is then moved along the shank in the axial direction towards the fixed jaw, so that the tongues of the movable jaw are received within the slot of the first module, and the elongate body of the movable jaw engages the internal face of the first module. When the tongues are received within the slot, the movable jaw is prevented from rotating relative to the module.

• Finally, from within the cavity of the first module, the nut 206 is tightened along the shank to meet the movable jaw and to secure the movable jaw in engagement with the internal face of the first module. In particular, the connector 200 shown in Figures 2d and 2e is configured to interact with the module 100 shown in Figure 1f and 1g, and is attached to the module 100 by the following procedure:

• First and second modules 100 are arranged to abut one another, with the slot apertures 114c intended to be used for connection of the modules being aligned with one another.

• From the cavity of the first module, the fixed jaw (i.e. the second jaw 202d of the connector 200) is passed through the slotted through-hole 113 of the aperture 114c into the cavity of the second module. This is possible when the connectors 200 are oriented in a first orientation with respect to the slot, in which the orientation of the fixed jaw is aligned with the orientation of the slotted through-hole 113 so that it can pass through the slot.

• The shank 204 and the fixed jaw are then rotated together by 90 degrees (as the shank and the fixed jaw are rotationally fixed together) such that the fixed jaw is oriented perpendicular to the slotted through-hole 113 and aligned with the partially blind slotted hole 115. The shank may be rotated by gripping and turning the locknut while it is locked with the shank. In this perpendicular orientation, the jaw 202d is unable to pass back through the through-hole 113. The jaw 202d may be rotated within the circular recess 111.

• From within the cavity of the first module, the shank is then pulled from the end opposite the fixed jaw, so that jaw 202d is seated in the blind slotted hole 115 of the aperture 114c of the second module, and the elongate body of the jaw engages against the walls of the blind slotted hole 115 of the second module. In this position, the fixed jaw is prevented from rotating relative to the module.

• The movable jaw (i.e. the first jaw 202c of the connector 200) is then moved along the shank in the axial direction towards the fixed jaw, so that the first jaw moves into the blind slotted hole 115 of the aperture 114c of the first module, and the elongate body of the movable jaw engages the internal face of the blind slotted hole 115. In this position, the movable jaw is prevented from rotating relative to the module.

• Finally, from within the cavity of the first module, the nut 206 is tightened along the shank to meet the movable jaw and to secure the movable jaw in engagement with the internal face of the first module.

• Optionally screws may be inserted through the apertures 216 and into the module 100 to secure the connector 200 to the module. Following this connection procedure, the first and second modules are secured together by the connector 200. Figures 4b and 4c show an example of two modules 100 fixed together between their end face panels by connectors 200. Figure 4d is a cross-sectional view through the modules along the line A-A in Figure 4c, and Figure 4e is a close up view of part of the cross-sectional view as indicated by the circular dashed line. Figures 4d and 4e show how the opposing jaws 202a, 202b of the connector 200 are moved together such that the tongues 210 of the jaws enter respective slots of the end face panels 108 of the modules and engage the interior sides of the end face panels 108 via the teeth 215 to connect the modules together under the force of the nut 206.

By screwing the connector 200 to the module 100 through the apertures 216, the connector 200 is more securely attached to the module 100. The connector 200 (or a jaw of the connector, separated from the connector) may then serve as an attachment point for moving the module or several connectors 200 may be used to distribute the weight of the module 100. Of course, several modules 100 may be assembled using the connectors 200 with the connectors 200 acting as attachment points for the assembly. The process of lifting heavy and awkward modules 100 and assemblies of modules 100 is thereby improved by using the connectors 200 as attachment points for lifting and handling devices.

The friction engagement between the jaws 202a, 202b of the connector 200 is sufficient to retain modules 100 together against shear forces (i.e. forces parallel to or aligned with the longitudinal axis of the slots). However, to increase the security of the connection, particularly in the case where the axis of the is aligned vertically in a structure, a shear key is provided at the interface between connected modules. In one example, the shear key may be a part of the connector 200, for example an extension of the tongues of the connector along the axis of the slots, which engage the interior of the slot to prevent movement of the connector along the axis of the slot. In another example, the shear key may be a separate insert to be inserted into the slot along with the connector to engage the interior of the slot to prevent movement of the connector along the axis of the slot. In yet another example, the shear key may be provided on the panels of the modules, for example cooperating protrusions and holes on the panels of the modules to fix the panels together against shear forces. In yet another example, the shear key may be an insert for being received through slots not being used to receive the connector 200; for example, where the end face panel 108 of one module is connected to a front face panel 102 of another module, two slots on each panel will align with one another and are used to receive connectors 200, while two other slots will be perpendicular to one another and could be used to receive a shear key insert (which would be substantially square in cross section). This square cross section may have chamfers on its edges to assist with its insertion and correct any misalignment of modules. In a further embodiment the shear key may be asymmetrical to prevent movement in a particular direction whilst allowing movement in another. This is advantageous when considering expansion and contraction of modules and related structures in a building.

The connector 300 is used to attach a cladding panel to the module by the following procedure:

• From outside the cavity of the module, the fixed jaw (i.e. the jaw 302 of the connector 300) is passed through a slot of the module 100 into the cavity of the module. This is possible when the jaw 302 is oriented in a first orientation with respect to the slot, in which the jaw is aligned with the orientation of the slot so that it can pass through the slot. The jaw 302 is passed all the way through the slot, in the sense that no part of the jaw is within the slot; only the shank is located within the slot.

• The shank 304 and the fixed jaw 302 are then rotated together by 90 degrees (as the shank and the fixed jaw are rotationally fixed together) such that the fixed jaw is oriented perpendicular to the slot. The shank may be rotated by gripping and turning the locknut while it is locked with the shank. In this perpendicular orientation, the jaw 302 is unable to pass back through the slot.

• From outside module, the shank is then pulled from the end opposite the fixed jaw, so that the tongues of the fixed jaw are pulled into the slot of the module, and the elongate body of the jaw engages an internal face of the module. When the tongues are received within the slot, the fixed jaw is prevented from rotating relative to the module.

• The movable jaw (i.e. the stopper jaw 308 of the connector 300) is then moved along the shank in the axial direction towards the fixed jaw to engage the external face of the first module.

• From outside module, the nut 306 is tightened along the shank to meet the movable stopper jaw 308 and to secure the movable jaw in engagement with the external face of the first module.

• Finally, the cladding panel is attached to the connector 300 via the attachment means 312 by the R-clip, to secure the cladding panel to the connector 300 spaced apart from the module 100.

Following this connection procedure, the cladding panel modules are attached to the module 100 by the connector 300.

The dimensions of the connector 200 are shown in Figure 2c and set out in the following table:

These dimensions are chosen to promote the functions described above (and also chosen relative to the dimensions of the slotted apertures of the modules 100, as follows:

The length of the jaw body (A) is as large as possible while being less than the length of the aperture to leave an assembly clearance (e.g. 2.75mm) to insert the jaw through the slot on the module, but at least twice the width of the aperture to ensure it cannot pass through the aperture when oriented perpendicular to it. In this way, the jaws are able to pass through the apertures of the module when the jaws are oriented in alignment with the apertures.

The length of the jaw body (A) is also smaller than half of the distance between adjacent slots such that there can be a line of connectors with jaws all aligned in the same direction when attached (e.g. for side-to-side connections of the modules in Figures 1d and 1 e) whilst also maintaining structural integrity of the timber.

The width of the jaw (B) is as wide as possible while also being smaller than the width of the slot with an assembly clearance (e.g. 2mm). In this way, the jaws are unable to pass through the apertures of the module when oriented perpendicular to the apertures.

The height of the jaws excluding the teeth (C/D) is as long as necessary to obtain sufficient structural performance of the connection. If the jaw is not long enough, the connector can bend and flex. This length can be varied according to the material of the connector and the expected loading conditions of the module. The teeth of the jaws extended slightly further to ensure that most pressure is exerted near the ends of the jaw to have most mechanical advantage. If the connector flexes, it keeps the jaw ends in contact with the timber via the teeth, rather than concentrating compression force to the open centre of the slot.

The length of the tongues (E) is less than thickness of the module panels so that the tongues of the jaws don’t come into contact when being tightened together. By this, it is meant that there is an air gap or clearance between the tongue and the aperture when the tongue is inserted in the aperture. Thus, no force is required to insert or withdraw the tongues into or out of the aperture, but the tongues substantially span the width of the aperture, thus preventing rotation of the connector jaws within the apertures. The chamfer on the tongues allows the position of the jaw to self-correct when it is tightened and inserted into the slot. The size of chamfer must be larger than the expected tolerance in the positioning of the bracket.

The length of the non-tapered (i.e. straight) portion of tongues is length enough to ensure a good contact with the interior of the slot to prevent the jaw turning. If the module material is softer (like timber) this can’t be too small otherwise it will just round out a bit of the timber slot, allowing the jaw to turn.

The widths of the tongues (G) are of a similar dimension to the width of the slot on the module, but with a degree of clearance tolerance (e.g. 2mm) to allow it to enter into the slot. The tongues are tapered with chamfers on the front edges to correct for error when it is being inserted. Once inserted, the tongues grip inside the slot and prevents the jaw from turning.

The bolt length (H) is long enough to allow at least one jaw to turn when it is being placed into the slot, in the state where the nut is fully loosened. The bolt has a diameter sufficient to withstand the maximum loading on the connection.

The width of the shank head (J) is smaller than the width of the slot with an assembly tolerance (e.g. 2mm).

These dimensions apply also to the jaw 302 of the connector 300 shown in Figure 3a.

These dimensions may be scaled up or down in proportion to the size of the slot and module. It will also be apparent that, depending on the size and/or strength of the structure, any or each of the dimensions described above may differ. For example, any or each dimension may be an integer multiple of the exemplary dimensions provided above or may be a fraction of the exemplary dimensions provided above (e.g. 75%, 66%, 50%, 40%, 30%, 20%, or 10% smaller than the exemplary dimensions provided above). The ratios of certain dimensions may be kept constant as the dimensions are scaled, or the ratios may vary accordingly to the scaling. It should also be understood that Figure 4a is provided for example only to show how the connectors interact with the slots; in practice, the connectors may be inserted into different slots on the modules, in particular the connector 300 may be inserted into slots on the rear face 104 of the module.

Figure 5 is a photograph showing the connector 300 of Figure 3a connecting a cladding panel 500 to a module 100 as described above with reference to Figures 1a to 1e. The connector 300 has been inserted into the rear face panel 104 of the module 100 from the outside of the module, and the rear face panel 104 is engaged between the fixed jaw 302 and the stopper jaw 308 and of the connector 300, secured in place by the lock nut 306. The stopper 308 therefore engages the exterior face of the rear face plate 104 under the force of the lock nut (not shown). Between the stopper 308 and the exterior face of the rear face panel 104 is a weatherproofing layer 502. The weatherproofing layer 502 is secured by to the module 100 by the engagement of the stopper 308 to the module 100.

The connector 300 is attached to the cladding panel 500 by attachment means 312, specifically by an R-clip 318 passing through an aperture 316 in the attachment means 312, which attaches the attachment means to a cooperating piece 504 on the cladding panel 500. The attachment means 312 is spaced apart from the stopper by spacing element 314. Thus, the cladding panel 500 is attached to the module 100 with a gap between. This gap can be used to accommodate electrical wiring or plumbing, for example, between the cladding panel 500 and the module 100, and also accommodates the weatherproofing layer 502 and ventilation cavity.

Robotic assembly

Figure 6a is a schematic of a tool 600 for a robotic arm for interfacing with the module 100 and/or the connectors 200, 300. Figures 6b and 6c are plan and perspective views of a particular exemplary implementation of the tool 600. The tool 600 is an end effector for a robotic arm. The tool comprises a base block 602 onto which the other components of the tool are mounted, and which is attached to the end of a robotic arm (not shown). The robotic arm (not shown) comprises various motors and joints which enable the end effector tool 600, when attached to the robotic arm, to move in all directions and to rotate. The tool may also be attached to a 3 axis manipulator such as a crane, palletising robot or SCARA robot.

The tool 600 in this example comprises a gripper tool 604 for engaging parts of the modules and optionally parts of the connectors, so as to assemble the panels to form the modules and to assemble modules together with connectors. In particular, the gripper tool 604 is configured to engage the apertures of the module and the jaws of the connectors. The gripper tool 604 comprises a pair of fingers 606a, 606b which in this example are angled plates, specifically right angled plate. Each right angled plates comprise a first portion extending parallel to the face of the block 602 and a second portion extended perpendicular to the face of the block 602. The first and second portions are formed as a single piece, with a right angle between them.

The two right angled plates are arranged to move relative to one another, together and apart, thereby to grip a part of the module or a part of the connectors with the plates. The relative movement of the plates in this example is achieved by mounting the plates 606a, 606b slidably in a track 210 on the block 602. The first, parallel portion of each angled plate comprises a runner 610 that is received within the track 608 and runs along the track 608, for example being driven by a motor within the block 602. In this example, both of the plates 606a, 606b are movable towards and away from one another along the track 608 relative to the block 602. In other examples, one of the plates may be fixed, and the other plate may be movable along the track 608 towards and away from the fixed plate. In yet other examples, the fingers may not be formed of plates, but may instead be formed as part of a claw-type gripper, the finger of the claw being configured to move together and apart to grip the parts of the modules or connectors; however, the right angled plates of the example shown in Figure 6 are particularly well suited for engaging the modules and connectors disclosed herein as is described below with reference to Figure 7.

Figure 7 is a perspective view of the module of Figure 1a, showing the tool 600 of Figure 6 interfacing with the module. In particular, the tool 600 is shown interfacing with an aperture 114b of the front face panel of the module 100. To engage the aperture, the fingers 606ab 606b are moved together along the track 608, such that they will both fit within the slot 114b of the module. The tool 600 is then moved towards the module 100, as indicated by the downward arrow in Figure 7, such that fingers 606a, 606b are received within the slot 114b. The fingers 606a, 606b are then moved apart, as indicated by the pair of opposing arrows in Figure 7, until the fingers contact the walls of the slot to create a friction engagement against the walls of the slot. The tool 600 comprises a sensor arranged to measure the force of the engagement of the fingers against the walls of the slot, and the motor which drives the fingers apart is controlled so as to maintain an outward force against the walls of the slot which will provide a friction engagement stronger than the weight of the item being lifted (which in this example is the module 100). In this way, the robotic arm can lift the module 100 for assembly with another module to form a modular structure. To release the module, the fingers 606a, 606b are moved together to disengage the slot, and are withdrawn from within the slot. In this way, the tool 600 can be used to assemble multiple modules 100 into modular structures. To construct a structure of modules 100, the robotic arm and tool 600 are used to engage one of the apertures 114b of the module, as shown in Figure 7 and described above. Via this engagement, the robotic arm can pick up the module and move it into position against another module, with at least one other aperture of the module aligned with at least one aperture of the other module. The modules can then be connected together, for example by inserting part of a connector (such as the fixed jaw 202b of connector 200 described above with reference to Figures 3 and 4) through the aligned apertures from within the cavity of one of the modules, rotating the connector such that it cannot be withdrawn back through the aperture, and tightening the nut 206 on the connector such that the jaws 202a, 202b engage the internal faces of the module panels to connect the modules together.

In other examples, the tool fingers 606a, 606b of the tool 600 may be inserted into separate slots of the module 100. For example, one of the fingers may be inserted in a first slot 114b and the other finger may be inserted in an adjacent parallel aperture. To achieve this, the fingers must be moved sufficiently far apart to correspond to the positions of the adjacent parallel slots. To engage the slots, the fingers are then moved together to as to engage the inner walls of the respective slots, either side of the part of the panel between the slots. Alternatively, the fingers may be moved apart to as to engage the opposite, outer walls of the respective slots.

In yet other examples, the tool 600 may comprise a claw-style gripper rather than the right angle plates of the gripper shown in Figures 6 and 7. In this case, fingers of the gripper may be inserted into the same slot and moved apart, or in adjacent slots and moved together, to engage the slots of the module 100. However, the right angled plates described above are preferred because the elongate plates extending perpendicular to the block 602 correspond to the shape of the slots, meaning that the plates generate a face-to-face engagement between the contact faces of perpendicular portions of the plates and the walls of the slots. This may provide an improved friction engagement as compared to the engagement generated between the relatively small area of a finger of a claw-style gripper.

Figure 6d shows an alternative implementation of the gripper tool 604. In this example, the fingers 606a, 606b have respective hooks 612a, 612b. In use, the hooks are inserted through the aperture of the modules to engage the modules to provide a reliable mechanical connection rather than relying on friction alone. The gripper tool shown in Figure 6d is preferred for lifting and moving whole modules, as the hooks provide a backup securement to the modules in the event that the friction grip is insufficient to hold the weight of the module, or in the event of a sudden power loss to the robotic arm which cases the friction grip to loosen. The robotic arm on which the tool 600 is mounted is configured to move the tool 600 in any directions and to rotate the tool. Therefore, the tool 600 can be rotated so as to orient the gripper tool 604 as needed to engage slots of different orientations. For example, the gripper tool shown in Figure 7 could be rotated by 90 degrees about an axis perpendicular to the block 602 so that it can engage one the slots having an orientation perpendicular to the slot 114b shown.

The robotic arm and the tool 600 can also be used to construct the modules 100 from the panels described above with reference to Figures 1a to 1e. In this case, when handling certain panels, the gripper tool 604 may grasp the panels between the fingers 606a, 606b instead of interfacing with the apertures of the panels as described above. To construct a module 100 from the panels:

The rear face panel 104 is first positioned on a flat surface, for example a floor. The rear face panel 104 comprises one part of a dowel and hole joint, for example holes distributed around the edge of the inner face of the rear face panel 104.

The robotic arm is then used to lift a side face panel 606, either by interfacing with one of the apertures of the panel as described above, or by simply grasping the panel, and to position the side face panel against the rear face panel so as to align the holes on the rear face panel with dowels inserted in holes along a long edge of the side face panel.

When in position, the side face panel is lowered and released such that the side face panel is joined to the rear face panel by the cooperating dowels and holes.

This process is repeated for the other side face panel, and for the two end face panels 108.

Finally, the robotic arm is used to lift the front face panel 102 by interfacing with one of the apertures of the panel as described above. This arm is then moved to position the front face panel such that holes on the inner face of the panel are aligned with dowels extended from the side and end face panels. When in position, the front face panel is lowered and released such that the panel is joined to the side and end face panels by the cooperating dowels and holes.

Optionally, after being picked up by the robotic arm but before being joined to the module being constructed, the robotic arm may hold and move the panel under a glue dispenser such that a line of glue is dispensed along the edge of the panel which will be joined to the module. For example, when the first side panel is picked up, the arm may move the panel under the glue dispenser to deposit a line of glue along the bottom long edge of the panel. Also optionally, after the module is constructed, the joints between panels may be further reinforced with nails.

The tool 600 may also comprise additional tools beyond the gripper 604. In particular, the tool 600 may comprise a nut driver tool (not shown) for tightening a connector 200, 300 into engagement with the module. The nut driver tool comprises an opening on the block 602 between the fingers 604a, 604b arranged to receive and engage the nut 206, 306 of a connector. In use, the gripper tool 604 is used to clamp the rotatable jaw 202a, 308 between the fingers 604a, 604b as described above, with the nut 206, 306 at the end of the shank being receive within the nut driver tool opening. While holding the connector 200, 300 by the jaw, the robotic arm is moved to insert the fixed jaw 202b, 302 through the aperture of a module panel or through align apertures of adjacent modules being connected together. Once the fixed jaw 202b, 302 has been inserted through the aperture(s), the shank 204, 304 of the connector can be rotated (e.g. by 90 degrees about the axis of the shank) by the nut driver tool turning the locknut 206, 306, which thus rotates the shank. Once the fixed jaw 202b, 302 is perpendicular to the aperture, the robotic arm is configured to pull the connector until the tongues of the jaw are received through the aperture to prevent rotation of the jaw and thus the shank to which it is fixed. The nut driver tool then turns the nut 206, 306 which (now that the shank is fixed against rotation by the tongues of the fixed jaw in the aperture) screws the nut along the shank to move the rotatable, movable jaw 202a, 308 along the shank to engage the module panels between the opposing jaws. In an alternative embodiment the nut driver tool may use one or multiple magnets in combination with passive features to allow the connector without an additional gripping element. The nut driver tool has a hollow slot of the same width as the width of the jaw of the connector with magnets placed along or around the slot. The tool has a driving element with the rotational axis in the centre of this hollow slot, such that when the nut driver tool is held over a static connector, the connector is automatically gripped and held by the nut driver tool.

Advantageously, the methods described above for constructing modules from panels, and for constructing modular structures from the modules, involve exclusively a single robotic arm with a small number of tools or end effectors. In a minimal configuration there may be a first gripper for assembling module faces into modules themselves, with the same gripper used for assembling modules into assemblies of modules, combined with a second nut driving end effector for attaching the connectors single tool or end effector. The nut driver tool may also be embedded into the first gripper end effector, meaning only one end effector is required for all operations.. This is in direct contrast to existing modular constructions system which are characterised by the use of a linear sequence of highly specialised, single-purpose machines engineered to fulfil a single task. With the present disclosure, multiple such robotic arms can be used to construct modules and structure in parallel rather than forming part of a series of machines each performing one step in a sequence. This improves the efficiency of the construct process, and also the reliability of the process, as a breakdown of one machine does not affect the other parallel construction processes of the other machines.

Modular structures

Using the modules, connectors, and construction methods described above, various modular structures can be realised. One exemplary structure 800 is shown in Figure 8, which is a cutaway view of a habitable dwelling, specifically a house, constructed from the modules and connectors described above. The house comprises a ground floor having a bathroom (in which a shower is shown) and a first floor having a bedroom.

The structure 800 comprises a plurality of modules 100 as described above. In particular, the structure comprises a first 100a, second 100b, and third 100c groups of modules. The first group of modules 100a form the floors of the structure, including the floor of the ground floor and the floor of the first floor, which also forms the ceiling of the ground floor. The second group of modules 100b form the walls of the structure, including external walls of the structure and internal walls between rooms of the structure. The third group of modules 100c forms the roof of the structure and these modules are arranged at a 45 degree angle to walls.

The structure 800 is supported on a foundation comprising helical screw piles 802 screwed into the ground beneath the structure. The heads of the helical piles 802 form platforms upon which the floor modules 802a are placed. The heads of the helical piles 802 may comprise apertures corresponding to the apertures of the modules to enable connection of the modules with the helical piles using the connectors 200 described above. Gravels beds 804 are provided in the ground underneath the walls of the structure to provided rainwater drainage. The gravel beds 804 are positioned in the ground around the perimeter of the base of the structure to catch rainwater running off of the structure down the walls. Drainage pipes are provided at the bottom of the gravel beds to collect rainwater filtering through the gravel bed. The drainage pipes are preferably arranged to direct rainwater to a tank in which the water is stored for use in the structure.

The first group of modules 100a are connected together using the connectors 200 as described above to form a flat floor area. The internal surface of floor, intended to be inhabited, may be covered by a rubber floor covering, such as a noraplan® rubber or ethylene propylene diene monomer (EPDM) rubber floor covering for comfort. The floor may also comprise other layers between the modules 100a and the floor covering, in particular an underfloor layer such as Oriented Strand Board (OSB) subflooring layer, and vapour barrier layer to prevent water vapour from inside the house passing into the timber floor modules 100a. The modules 100a, specifically the cavity within the modules, are filled with insulating material such as sheep wool, mineral wool or hemp fibre.

The second group of modules 100b are also connected together using the connectors 200 as described above to form walls. The lowermost module in each wall is connected perpendicularly to the floor modules 100a. Similarly, the modules 100a forming the ceiling of the ground floor and the floor of the first floor are connected perpendicularly between opposing walls. The wall modules 100b are also filled with insulating material. Cladding panels 500 are attached to the external faces of the wall modules 100b using the cladding connectors 300 described above. The cladding panels 500 fit together to form a continuous external face of the structure 800 to weatherproof the structure. A separate weatherproofing layer may also be provided in the gap between the cladding panels and the external faces of the modules.

The third group of modules 100c are also connected together using the connectors 200 as described above to form a roof for the structure 800. The roof modules 100c are joined at the ridge of the roof perpendicular to one another. The roof modules 100c are joined to the wall modules 100b by special angled modules 806. The angled modules are single modules each having 45 degree kink to join the upright wall modules 100b with the 45 degree roof modules 100c. The angled modules 806 have end face panels connected to panels of the wall modules 100b and roof modules 100c. The roof modules 100c are filled with insulating material. Cladding panels 500 are attached to the external faces of the roof modules 100c using the cladding connectors 300 described above. The cladding panels 500 fit together to form a continuous external face of the structure 800 to weatherproof the structure. A separate weatherproofing layer may also be provided in the gap between the cladding panels and the external faces of the modules. A window 808 is provided in the roof by way of a gap between roof modules 100c. A window frame may be screwed of nailed onto the panels of the modules facing the window gap, and a window panel (such as a pane of glass, of a clear acrylic sheet) may be fixed to the frame

The internal faces (i.e. the surfaces facing the interior of the rooms of the structure) of the floor panels 100a, the wall modules 100b, the roof modules 100c, and the angled modules 806 may also be cladded, for example using cladding panels connected via the connectors 300 described above, or by nailing or screwing cladding panels (e.g. plywood panels) onto the modules. Other layers may also be provided between the modules and the internal cladding panels, such as vapour barrier layer to prevent water vapour from inside the house passing into the timber modules. The structure 800 shown in Figure 8, having floors, walls and a roof formed of connected modules 100a, 100b, 100c, forms a skeleton which can accommodate prefabricated room units, such as bathroom, bedroom, or kitchen units. In this example show in Figure 8, a prefabricated bathroom unit 810 is installed in the ground floor and a prefabricated bedroom unit 812 is installed in the first floor. The bathroom unit in this example comprises a shower and a sunken shower tray (not shown) along with waterproof interior cladding. The bedroom unit 812 comprises a bed. Both units also comprise means for connecting to utilities, such as electrical plugs and plumbing to connect the unit to electricity and/or water outlets provided in the skeleton of the structure 800. Other similar prefabricated units, such as kitchen units, could be installed in place of the bathroom and bathroom units shown in Figure 8. To access the first floor, a hatch is provided between the ground and first floors by way of a gap in the modules 100a that make of the floor of the first floor and ceiling of the ground floor. A ladder may be used to climb between the floors through the hatch. Alternatively, a flight of stairs could be connected to the hatch, or a flight of stairs could be connected outside the structure to access the first floor from outside the structure. In either case, the stairs may comprise a set of apertures similar to the apertures of the modules to enable the stairs to be connected to the modules with the connectors 200 described above.

Figure 9a is a bottom perspective view of another exemplary structure 900 constructed from the modules and connectors described above. Figure 9b is a close up view of a part of the structure as indicated by the dashed box in Figure 9a. The structure 900 in Figures 9a and 9b is a decorative outdoor shelter structure. In this structure 900, the modules are connector together to form aesthetic elements, such as beams 902 and pillar 904, which depend from a planar roof structure 906. The roof structure 906 is comprised of a plurality of modules connected together using the connectors 200 described above. The modules are connected in the same plane to create a wide flat structure extending over a larger area. The beams 902 are constructed from multiple modules connected together using the connectors 200 described above. The modules of the beams are connected end-to-end (i.e. between their end face panels) to produce an elongate structure. The beam structure 902 is then connected to the roof structure 906, using the connectors 200, between side face panels of the beam modules and front or rear face panels of the roof modules.

The pillar structures 904 comprise multiple modules connected together using the connectors 200 described above. In the example shown in Figure 9b, the beam comprises three modules 100d, 100e, 100f depending from a beam structure, which itself depends from the roof structure. Two of the modules 100d, 100e are oriented in a portrait orientation, and connected together side-by-side, and with their end faces connected to the beam structure. The third module 10Of is oriented in a landscape orientation and connected along its side face to the opposite end faces of the portrait modules. Each pillar of the structure 900 is of the same length, such that these pillars act as legs for the entire structure, and the roof 906 is supported on the pillars when the structure 900 is put down on the ground. Different arrangements of the modules in each pillar are possible, such as three modules in landscape orientation connected side-by-side, however including modules with different orientations (such as in pillar 904) may provide improved structural reinforcement.

Each module in the beam comprises cladding to cover the faces of the modules. For the front and rear face panels, a natural coloured timber cladding panel is used, whereas on the side and end faces black battens (preferably also timber) are attached to the modules to provide a black accent along the edges of the module, as shown in Figures 9a and 9b. Other configuration of colours may be used to emphasise the underlying structure in a similar manner.

Manufacturing modules

Manufacture of the aforementioned modules may be carried out using a process 1100 as shown in Figure 11 , with an exemplary layout of the manufacturing system shown in Figure 10. Structures may be assembled from the modules using a process shown in Figure 12.

As show in Figure 10, the manufacturing system 1000 comprises two parallel rows 1010, 1020 of adjacent manufacturing machines 1040 with an intermediate storage 1030 between the rows. Each row comprises at least one machine 1040 and may have a plurality of machines 1040 arranged in a line such that the output of one machine 1040 faces the input of another.

The first row 1010 of machines 1040 is configured to receive raw materials and apply machining stages to yield semi-processed material. The second row 1020 of machines 1040 is configured to receive semi-processed materials and assemble them into modules for a modular construction system.

The manufacturing system 1000 is configured to receive raw materials at a first end 1012 of the first row 1010 of machines 1040. A transport means is used to bring the raw materials from storage to the input of the manufacturing system 1000. The raw materials are transferred to the first machine 1040 by a handling means 1050. A conveyor system may be located at the input to the first machine 1040. The conveyor system moves raw material into the first machine 1040.

As used herein, a transport means is used to describe a device or process for transporting material. This may for instance refer to a transport vehicle, wheelable carrier or carrying by a person. The first machine 1040 is configured to receive the raw materials from the transport means and is also configured to process the raw materials into semi-processed materials. The semiprocessed materials are then passed to the next stage of the manufacturing system 1000. This may occur in the same machine 1040, or the semi-processed materials may be passed to a different machine 1040.

If the semi-processed materials are required to be passed to another machine 1040 for further processing, the semi-processed materials are output from the first machine 1040. A handling means 1050 is then used to transfer the semi-processed materials to a second machine 1040 in the first row 1010 of machines 1040.

The second and further machines 1040 if required are arranged sequentially in the first row 1010 of machines 1040 such that the output of the first and sequential machines 1040 face the input of the next machine 1040. This allows for easier handling of materials by reducing the distance between the machines 1040. The semi-processed materials may then be processed as appropriate in any number of stages. The output of the first row 1010 of machines 1040 is at a second end 1014 of the row 1010.

Adjacent to the first row 1010 of machines 1040, there is located an intermediate storage 1030. The intermediate storage 1030 is closely located to the first row 1010 of machines 1040 to allow for easier handling of materials. The intermediate storage 1030 may comprise shelving or other simple means of storing the materials being processed or may further comprise an automated storing system configured to separate the materials appropriately. Either configuration allows for easy access to the semi-processed material for later stages in the manufacturing process.

The second row 1020 of machines 1040 is located adjacent to the intermediate storage 1030; thus the intermediate storage 1030 is sandwiched between the two rows 1010, 1020 of machines 1040. The size of the intermediate storage 1030 is dependent on the requirements of the manufacturing system 1000 but may be chosen to minimise the floor area occupied by the manufacturing system 1000.

A handling means is located near the intermediate storage 1030 to move semi-processed materials from the first row 1010 of machines 1040 to the intermediate storage 1030. The same handling means 1050 may also be used to move semi-processed material from the intermediate storage 1030 to the second row 1020 of machines, or this may be achieved by a separate handling means 1050. The second row 1020 of machines 1040 receive semi-processed materials at a first end 1022 of the second row 1022. The semi-processed materials are received into the first machine 1040 on the second row 1020 and are further processed.

The second row 1020 of machines 1040 comprises at least an assembly machine 1040 configured to process semi-processed materials into assembled modules. The second row 1020 of machines 1040 may also optionally comprise additional machines 1040 applying further processing to the semi-processed material. The second row 1020 of machines 1040 may further comprise an additional machine 1040 applying processing to the assembled modules.

The semi-processed materials and assembled modules are passed between machines 1040 on the second row 1020 of machines 1040 by handling means 1050. The machines 1040 on the second row 1020 are arranged sequentially such that the input of each machine 1040 on the row faces the output of the previous machine 1040 on the row. This minimises the distance between the machines 1040 to ease the handling of semi-processed materials and modules.

The second row 1020 of machines 1040 outputs assembled modules at a second end 1024 of the second row 1020 of machines 1040. The assembled modules are then transferred by a handling means 1050 either into storage or to a transport means.

The arrangement of two rows 1010, 1020 of machines 1040 separated by an intermediate storage 1030 minimises the footprint of the manufacturing system 1000 and reduces the distance required to move the raw materials, semi-processed materials and modules.

The first end 1012 of the first row 1010 of machines 1040, and the first end 1022 of the second row 1020 of machines 1040 may be located opposite to each other. As such, the material follows a U-shaped path in which the raw materials are input to the manufacturing system 1000 at the same end as the modules are output. This layout allows the input and output to the manufacturing system 1000 to be located on the same side of the manufacturing system 1000 and may ease handling of the materials.

In the embodiment shown in Figure 10, the first end 1012 of the first row 1010 and the first end 1022 of the second row 1020 of machines are located at the same end of the manufacturing system 1000. In this embodiment, the material follows a Z-shaped path such that the input and output to the manufacturing system 1000 are located opposite to each other. As such, the handling of raw materials and assembled modules is separated by the manufacturing system 1000 which may simplify the flow of materials. Reference is now made to Figure 11 to explain an exemplary process using the aforementioned manufacturing system.

In the first step 1110 of the process, raw material is fed into the beginning of the manufacturing process. The raw material may be in the form of sheets or planar material which are unloaded from a transport means by a handling means. Other forms of raw material may be used depending on the desired modules to be manufactured.

In a second step 1120, the raw materials undergo a first machining process. Depending on the requirements of the finished modules, the first machining process may be a singular stage or may consist of numerous stages of machining. The machining process may comprise a Computer Numerically Controlled (CNC) machine working under instruction from a computing device. The CNC machine may be a router or similar cutting device configured to remove material from the raw materials fed into the machine.

The first machining process may also comprise additional stages, for instance a sanding stage in which the surface finish of the materials being processed is improved or a coating stage in which a coating is applied to the materials. The additional machining processes may be achieved by a single machine or by a plurality of machines. In the latter configuration, the materials being processed are moved between the discrete machines by a handling means.

The machining step by way of example may produce apertures 114a, 114b, and 114c, size the module sheets appropriately and form openings 112a and 112b.

In a third step 1130, the first machining process has been completed and the now semiprocessed materials are moved to the intermediate storage. The first machining process may comprise all the machining stages required for the raw materials, or further machining may be applied in later stages if required for the finished modules. The semi-processed materials are preferably moved to the intermediate storage by a robotic arm configured to handle the materials without damaging them, or a different handling means may be used.

The intermediate storage acts in part as a buffer to allow the upstream and downstream manufacturing processes to work at optimal rates and increase the overall throughput of the manufacturing process. The intermediate storage also acts to separate the upstream and downstream manufacturing processes which is desirable when manufacturing modules of differing sizes. The upstream machines and processes may be configured to handle only sheet materials, and thus are capable of manufacturing a variety of different sheet sizes sequentially. Advantageously this can reduce wastage of the raw material as multiple smaller sheets can be cut from a larger sheet. Sheets for the competed modules can therefore be manufactured from the raw material that don’t necessarily correspond to a single module. The intermediate storage allows for separating these sheets by type thereby allowing only the immediately required sheets to be picked at a later time for assembly in the downstream manufacturing processes.

In a fourth step 1140, the stored semi-processed material is removed from the intermediate storage. This allows for the semi-processed material to be finished in further machining and assembly stages of the manufacturing process to yield completed modules. The material is removed from the intermediate storage by a handling means and transferred to the input of another manufacturing process. The same handling means used to store the semi-processed material may also be used to retrieve the material.

It should be noted that the second step 1120 of the process may be split across the intermediate storage and retrieval of the semi-processed material if required. In this instance, the semi-processed material is retrieved from storage and returned to the machining process to undergo further machining before passing to a fifth step 1150 of the process.

In the fifth step 1150 the semi-processed material is assembled into modules. The semiprocessed material is fed into a handling means and then assembled into modules by joining the materials together. The joining method used depends on the specification of the finished modules but may comprise gluing and nailing the edges of the semi-processed material together or inserting dowels into pre-formed holes and gluing the semi-processed materials together.

As part of the assembly process, the modules may pass through a coating machine in which a varnish or similar coating is applied to the modules. If a coating is applied, the assembled modules then undergo a drying or curing process as part of the assembly to finish the coating.

During assembly the modules may also have additional components added to them as required by the final specification of the modules. As an example, these may include insulation, the aforementioned connectors or seals/membranes.

In a sixth step 1160, the modules may undergo an optional final machining process. This may for instance involve removing any excess material or residue from the assembly and curing process. The final machining may occur in the same machine as assembly or previous machining stages or may have a dedicated machine to fully finish the assembled modules.

In a seventh and final step 1170, the assembled modules are optionally moved to final storage by a handling means. The assembled modules may otherwise be exported directly from the final machining or assembly process by a handling means. The separation of the machining and assembly stages by the intermediate storage advantageously allows for a plurality of different modules to be assembled on a single manufacturing line. Raw material is handled prior to the intermediate storage and is preferably in the form of sheets of material. These can be handled and processed into a plurality of different forms as semi-processed material by the same machine, thus reducing costs.

The intermediate storage then allows for storage of the semi-processed material until needed. To maximise throughput, minimise wastage or minimise cost it may be beneficial to manufacture parts of different modules which are not immediately required. The intermediate storage allows for storage of material until required and thus also acts as a buffer to maximise manufacturing throughput.

The machining and assembly stages after the intermediate storage are configured to produce one module at a time, and thus are to be fed with only the material they immediately require. The intermediate storage allows for this as only the material required can be retrieved from the intermediate storage.

A quality control step may be added into the process in which properties of the raw or semiprocessed materials, and assembled modules are checked against reference values. This process may be performed manually, or by an automated inspection machine to ensure quality of the components.

A structure according to Figures 8 or 9 may be assembled using the following method, as shown in Figure 12.

The assembled modules are first retrieved from the store having been manufactured using the aforementioned process. The assembled modules are retrieved using a handling means and assembled further into panels or modules comprising at least one module.

Fittings and finishes are then applied to the panel or volumetric module. This step may be manually applied or automated using a robotic device. The fittings may for instance comprise brackets and hardware for a later final fitting, electrical, or plumbing fittings. This reduces the assembly required on-site thereby minimising cost of the completed structure. Finishes may also be applied to the panel or volumetric module at this stage to improve the longevity or aesthetic appearance of the component.

A quality control process may then be optionally applied at this stage in which parameters of the assembled panel or volumetric module are checked against reference values to ensure quality of the component. The completed components are then moved by a handling means to storage for eventual transportation to a building site. The components may then be loaded onto a transport means using a handling means, transported to the building site and assembled onsite into the final structure, for instance the structure as shown in Figures 8 or 9.

Further aspects of the present disclosure are set out in the following numbered clauses:

1. A connector for connecting modules of a modular structure by being received through apertures of the modules, wherein the connector comprises first and second connecting members, preferably elongate connecting members, more preferably elongate plates, yet more preferably jaws, positioned on a shank, preferably wherein; the first and second jaws are arranged to be rotatable on or with the shank about a longitudinal axis of the shank; and/or at least one of the first and second jaws is arranged to be movable along the longitudinal axis of the shank; and/or at least one, preferably each, of the first and second jaws comprises a formation for engaging at least one of the apertures to prevent rotation of the jaw in the aperture.

2. A connector according to Clause 1 , wherein the first jaw is arranged to be movable along the longitudinal axis of the shank, and wherein the second jaw is arranged to be fixed, preferably releasably fixed, in position along the longitudinal axis of the shank.

3. A connector according to Clause 1 or 2, wherein the one of the first and second jaws is arranged to be rotatable on the shank about the longitudinal axis of the shank, and wherein the other of the first and second jaws is arranged to be fixed, preferably releasably fixed, against rotation with respect to the shank.

4. A connector according to any preceding clause, wherein the jaws have bodies, said bodies preferably extending, in use, perpendicular to the longitudinal axis of the shank.

5. A connector according to Clause 4, wherein the jaw bodies are arranged to engage faces of the modules, and wherein preferably at least one of the first and second jaw bodies is arranged to engage an interior face of one of the modules.

6. A connector according to Clause 4 or 5, wherein at least one, preferably both, of the jaw bodies comprises at least one, preferably elongate, tooth for contacting a face of the modules. 7. A connector according to Clause 6, wherein the at least one tooth is spaced apart from the shank.

8. A connector according to Clause 6 or 7, wherein the at least one tooth is a portion of the jaw body protruding from the at least one of the jaw bodies.

9. A connector according to any of Clauses 6 to 8, wherein the at least one of the jaw bodies comprises an indented portion between the shank and the at least one tooth.

10. A connector according to any of Clauses 6 to 9, wherein the at least one of the jaw bodies comprises two teeth spaced apart, the shank passing through the at least one of the jaw bodies between the teeth.

11. A connector according to any of Clauses 4 to 10, wherein the formation for engaging at least one of the apertures comprises at least one tongue extending from the body of the at least one of the first and second jaws, preferably along or parallel to the longitudinal axis of the shank.

12. A connector according to Clause 11 , wherein the at least one tongue comprises a pair of parallel tongues extending from the body of the at least one of the first and second jaws, preferably along or parallel to the longitudinal axis of the shank.

13. A connector according to Clause 11 or 12, wherein the at least one tongue comprises a tapered portion, said tapered portion preferably tapering towards the tip of the at least one tongue.

14. A connector according to any of Clause 11 to 13, wherein the body of the at least one of the first and second jaws comprising the formation is formed as a single piece with the tongue(s).

15. A connector according to any of Clauses 4 to 14, wherein the body of the at least one of the first and second jaws comprising the formation has a collar portion.

16. A connector according to Clause 15, wherein the body of the at least one of the first and second jaws comprising the formation is formed as a single piece with the collar portion. 17. A connector according to Clause 14 and 16, wherein the connector comprises one or more cut out portions positioned between the collar portion and the tongue(s).

18. A connector according to any preceding clause, wherein the formation for engaging at least one of the apertures is arranged to engage the interior of the aperture, preferably to engage walls around the aperture.

19. A connector according to any preceding clause, wherein the shank is threaded.

20. A connector according to Clause 19, wherein the connector comprises a nut on the threaded shank, the nut being arranged to restrict axial movement of the at least one of the first and second jaws that is arranged to be movable along the longitudinal axis of the shank.

21 . A connector according to Clause 20, wherein the nut is a lock nut, preferably a Nyloc nut.

22. A connector according to any preceding clause, wherein: the connector comprises a head at an end of the shank; the first jaw is arranged to be rotatable on the shank about the longitudinal axis of the shank, and movable along the longitudinal axis of the shank; and the head comprises a keyed portion at the end of the shank arranged to interface with a keyed portion of the second jaw so as to fix, preferably releasably fix, the second jaw against rotation relative to the shank about the longitudinal axis of the shank and against axial movement along the longitudinal axis of the shank.

23. A connector according to any preceding clauses, wherein the first jaw comprises an attachment for attaching the connector to a cladding panel.

24. A connector according to Clause 23, wherein the connector comprises a spacing element arranged to space the attachment from the first jaw.

25. A connector according to Clauses 23 or 24, wherein the attachment comprises a plate having at least one aperture arranged to receive a leg of an R-clip to attach the connector to a corresponding piece on the cladding panel. A connector according to any of Clauses 23 to 25, wherein the attachment is coupled to the first jaw. A connector according to Clause 26, wherein the attachment is coupled to the stopper by the shank. A connector according to any preceding clause, wherein the first jaw is formed as a stopper extending perpendicular to the longitudinal axis of the shank. A module for use in modular construction comprising: at least one aperture arranged to receive a connector for connecting the module to another module; a cavity; and an opening, wherein the opening is arranged to provide access to the aperture via the cavity to secure the connector to the module from within the cavity. A module according to Clause 29, comprising multiple cavities divided by one or more slats across the interior of the module. A module according to Clause 30, comprising a plurality of openings, each opening corresponding to one of the cavities. A module according to any of Clauses 29 to 31 , further comprising at least one formation arranged to interface with a tool of a robotic arm. A module according to Clause 32, wherein the at least one formation arranged to interface with a tool of a robotic arm is at least one of the apertures arranged to receive a connector for connecting the module to another module. A module according to any of Clauses 29 to 33, wherein the at least one aperture is a slot. A module according to any of Clauses 29 to 34, comprising a plurality of apertures arranged to receive a connector for connecting the module to another module, the plurality of apertures being arranged in an array. 36. A module according to Clause 35, wherein the array of apertures includes adjacent slots arranged with different orientations.

37. A module according to Clause 35 or 36, wherein the array of apertures comprises a first sub-array of slots having a first orientation and a second sub-array of slots having a second orientation different from the first orientation.

38. A module according to Clause 37, wherein the first and second sub-arrays are interleaved.

39. A module according to any of Clauses 29 to 38, wherein the array comprises, preferably consists of, a repeating sub-array of apertures, the repeating sub-array comprising at least: two adjacent slots arranged with different orientations; and two adjacent slots arranged with aligned or parallel orientations.

40. A module according to Clause 39, wherein the repeating sub-array of apertures is arranged in a four-by-four square grid.

41. A module according to any of Clauses 29 to 38, wherein the array comprises, preferably consists of, a repeating sub-array of apertures, the repeating sub-array comprising four apertures arranged with aligned or parallel orientations.

42. A module according to Clause 41, wherein the four apertures are arranged in a two- by-two square grid.

43. A module according to any of Clauses 37 to 42, wherein the array comprises, preferably consists of, an integer number of the sub-arrays.

44. A module according to any of Clauses 29 to 43, wherein within each row and/or within each column of the array, every aperture, except the end-most apertures in each row or column, is located between one aperture with the same orientation and another aperture with a different orientation.

45. A module according to any of Clauses 36 to 40, or 44, wherein the orientation difference is approximately 90 degrees. 46. A module according to any of Clauses 29 to 45, wherein the module comprises multiple faces, and wherein at least one aperture arranged to receive a connector is provided on at least two of the faces, preferably on every face.

47. A module according to any of Clauses 29 to 46, wherein the module is a cuboid shape, preferably a rectangular cuboid.

48. A module according to Clause 47, wherein the module is comprised of substantially rectangular panels coupled together to form the module.

49. A module according to Clause 48, wherein the rectangular panels are coupled via: dowel and hole joints and/or tongue and groove joints, preferably wherein the joints are glued and/or nailed.

50. A module according to any of Clauses 29 to 49, wherein the module is formed of timber.

51 . A kit of parts comprising: at least one module for use in a modular structure; and a connector for connecting the module to another module, wherein: the module comprises at least one aperture; and the at least one aperture is arranged to receive at least a part of the connector when the connector is oriented in a first orientation relative to the aperture, and to engage the module when the connector is oriented in a second orientation relative to the aperture, thereby to connect the module to the other module.

52. A kit of parts according to Clause 51 , wherein the at least one aperture is a slot, and wherein the part of the connector received through the aperture comprises an elongate body.

53. A kit of parts according to Clause 52, wherein in the first orientation the longitudinal axis of the elongate body is aligned with the longitudinal axis of the slot.

54. A kit of parts according to Clause 52 or 53, wherein in the second orientation the longitudinal axis of the elongate body is perpendicular to the longitudinal axis of the slot. A kit of parts according to any of Clauses 51 to 54, wherein: the length of the part of the connector received through the aperture is less than the length of the aperture, preferably less than 50% less than the length of the aperture, more preferably less than 10% less than the length of the aperture, yet more preferably less than 5% less than the length of the aperture; the width of the part of the connector received through the aperture is less than the width of the aperture, preferably less than 50% less than the width of the aperture, 10% less than the width of the aperture, more preferably less than 5% less than the width of the aperture; and the length of the part of the connector received through the aperture is longer than the width of the aperture, preferably at least double the width of the aperture. A kit of parts according to any of Clauses 51 to 55, wherein the connector is a connector according to any of Clauses 1 to 28 and the part of the connector arranged to be received through the at least one aperture is one of the first and second jaws, and/or wherein the module is a module according to any of Clauses 29 to 50. A kit of parts according to Clause 56, wherein the connector is a connector according to any of Clauses 1 to 28, and wherein the formation for engaging at least one of the apertures has a width fitting within, and preferably providing a clearance fit with, the aperture. A kit of parts according to Clause 56 or 57, wherein the connector is a connector according to any of Clauses 1 to 28, and wherein the formation for engaging at least one of the apertures has a length that less than or equal to the thickness of panels of the module, preferably less than 10% less than the thickness of the panels, more preferably less than 5% less than the thickness of the panels. A structure comprising the kit of parts according to any of Clauses 51 to 58, comprising at least two modules, wherein the modules are connected to other modules in the structure by the connector. A structure comprising the kit of parts according to any of Clauses 51 to 58 and a cladding panel, wherein the cladding panel is connected to an exterior face of the module with at least one connector according to any of Clauses 1 to 28, preferably according to any of Clauses 23 to 28. A structure according to Clause 60, wherein the cladding panel is connected to the exterior face of the module spaced apart from the exterior face of the module. A structure according to Clause 60 or 61 , comprising a waterproofing layer between the cladding panel and the exterior face of the module. A structure according to Clause 62, wherein the waterproofing layer is secured to exterior face of the module by the first jaw of the connector. A structure according to any of Clauses 59 to 63, the structure being a habitable structure such as a cabin or house. A structure according to Clause 64, wherein at least two of, preferably all of: the walls, the floors, and the roof of the structure are formed of the modules connected by the connectors. A structure according to Clause 64 or 65, wherein at least the walls and the roof of the structure are formed of the modules and wherein the modules forming the walls and the roof being substantially planar, the structure further comprising at least one angled module connected between modules of a wall and modules of the roof. A method of constructing a module according to any of Clauses 29 to 50, the module being formed of at least first and second panels, and the at least one aperture arranged to receive a connector being provided on at least the first panel, the method comprising using a robotic arm to: engage the at least one aperture of the first panel thereby to pick up the first panel; position the first panel against the second panel so as to align cooperating joint elements on the panels; and release the first panel to connect the first panel to the second panel via the cooperating joint elements. A method according to Clause 67, wherein the cooperating joint elements are: dowels and holes and/or tongues and grooves. A method of constructing a structure according to any of Clauses 59 to 66, the kit of parts comprising first and second modules, the method comprising: using a robotic arm to: engage the at least one aperture of the first module thereby to pick up the first module; position the first module against the second module so as to align at least one aperture of the first module with at least one aperture of the second module; and connecting the first and second modules by the connector through the apertures.

70. A method according to Clause 69, wherein the connector is a connector according to any of Clause 1 to 28, and wherein connecting the first and second modules comprises: inserting one of the jaws of the connector through the apertures of each of the first and second modules; rotating the inserted jaw relative to the modules; and moving at least one of the jaws along the longitudinal axis of the shank such that the at least one the formation for engaging at least one of the apertures is received within at least one of the apertures.

71 . A method according to Clause 70, wherein the one of the jaws is inserted through the apertures of each of the first and second modules from within an internal cavity of one of the modules.

72. A method according to any of Clauses 67 to 71 , wherein the robotic arm comprises a tool for engaging the at least one aperture.

73. A method according to Clause 72, wherein the tool comprises a gripper tool.

74. A method according to Clause 73, wherein the gripper tool comprises first and second elements, wherein at least the first element is movable relative to the second element, preferably wherein both the first and second elements are movable relative to the tool.

75. A method according to Clause 73 or 74, wherein the first and second elements are arranged to be inserted into the at least one aperture and at least the first element is arranged to move apart from the second element thereby to engage walls of the at least one aperture. 76. A method according to Clause 73 or 74, wherein the first and second elements are arranged to be inserted into separate apertures and at least the first element is arranged to move towards or apart from the second element such that the elements engage walls of the respective apertures.

77. A method according to Clause 75 or 76, wherein both the first and second elements are movable, and arranged to move apart or together to engage the walls.

78. A method according to any of Clauses 75 to 77, wherein the engagement is a friction engagement between the first and/or second elements and the walls.

79. A method according to any of Clauses 73 to 78, and Clause 70 or 71 , wherein the robotic arm is arranged to carry out the inserting, rotating, and moving steps while using the gripper tool to grip the connector by at least one of the jaws.

80. A method according to Clause 79, wherein: the connector is a connector according to Clause 20 or 21 ; and the tool of the robotic arm further comprises a nut driver tool arranged to engage the nut of the connector.

81. A method according to Clause 80, wherein the rotating of the connector comprises using the nut driver tool to rotate the shank of the connector by turning the nut.

82. A method according to Clause 80 or 81 , wherein the connecting of the first and second modules by the connector comprises using the nut driver tool to tighten the nut.

83. A robotic arm having a tool programmed to carry out the method of any of Clauses 67 to 82.

84. A manufacturing system for manufacturing a module for use in modular construction, the system comprising: a first series of machines arranged to process raw material to form panels, the panels comprising at least two panels having different dimensions; a second series of machines arranged to assemble the panels to form modules for use in modular construction; and a storage area arranged between the first series of machines and the second series of machines. 85. A system according to Clause 84, wherein the first series of machines comprises handling means for moving materials to the storage.

86. A system according to Clause 84 or 85, wherein the second series of machines comprises handling means for retrieving materials from the storage.

87. A system according to Clause 85 or 86, wherein the handling means is a robotic arm.

88. A system according to any of Clauses 84 to 87, wherein the first series of machines is configured to process sheet material.

89. A connector for connecting modules of a modular structure by being received through apertures of the modules, wherein the connector comprises first and second elongate connecting members arranged on a shank, preferably a bolt.

90. A connector according to Clause 89, wherein the first and second connecting members are arranged to be rotatable on or with the shank about a longitudinal axis of the shank.

91 . A connector according to Clause 89 or 90, wherein at least one of the first and second connecting members is arranged to be movable along the longitudinal axis of the shank.

92. A connector according to any of Clauses 89 to 91 wherein at least one, preferably each, of the first and second connecting members comprises a formation for engaging at least one of the apertures to prevent rotation of the connecting member in the aperture.

It will be understood that the invention has been described above purely by way of example, and modifications of detail can be made within the scope of the invention.

Each feature disclosed in the description, and (where appropriate) the claims and drawings may be provided independently or in any appropriate combination.

Reference numerals appearing in the claims are by way of illustration only and shall have no limiting effect on the scope of the claims.