Patent Application
20090049762
This invention relates generally to building construction. More specifically the invention relates to systems and methods of creating vertical core structures about which buildings may be built.
Typical slip forming systems known in the art are custom manufactured on site by carpenters per engineering plans for different size building cores. Even after constructed, more materials, besides those actually used to construct the building core, are necessary for the slip form to advance upward to create the building core.
Furthermore, access to the top of the slip forming systems is impeded, making insertion of reinforcement and building-feature components difficult, if not impossible. The systems and methods of the present invention provide solutions to these and other problems.
In one embodiment, a system for slip forming a building core is provided. The system may include a form and a plurality of extendable mechanisms. The form may include an inner frame and an outer frame. The outer frame and the inner frame may at least partially define a space between the inner frame and the outer frame. The form may also be configured to accept a hardenable substance in the space, where the hardenable substance may form at least a portion of the building core. Each of the plurality of extendable mechanisms may include a first end, a second end, and an extendable midsection. The first end may be coupled with the form, the second end may be configured to be supported with a wall of the building core, and the extendable midsection may be configured to change the distance between the first end and the second end such that the form may be moved from a first elevation to a second elevation.
In another embodiment, a method for creating a structure is provided. The method may include providing a form, where the form includes an inner frame and an outer frame which may at least partially define a space between the inner frame and the outer frame. The method may also include depositing a hardenable substance in the space, where the hardenable substance may form at least a portion of the structure. The method may further include providing a plurality of extendable mechanisms, where the plurality of extendable mechanisms may be coupled with the form. The method may additionally include supporting the plurality of extendable mechanisms from one or more walls of the structure. The method may furthermore include extending the extendable mechanism such that the form may be moved from a first elevation to a second elevation.
In another embodiment, a system for creating a structure is provided. The system may include a first means, a second means, and a third means. The first means may be for at least partially defining a space, where the space may be configured to accept a hardenable substance. The hardenable substance may form at least a portion of the structure. The second means may be for providing support from a plurality of locations on at least one wall of the structure. The third means may be for moving the first means away from the second means such that the first means may be moved from a first elevation to a second elevation, where the third means may be coupled with the first means and supported by the second means.
The present invention is described in conjunction with the appended figures:
In the appended figures, similar components and/or features may have the same numerical reference label. Further, various components of the same type may be distinguished by following the reference label by one or more letters which distinguishes among the similar components and/or features. If only the first numerical reference label is used in the specification, the description is applicable to any one of the similar components and/or features having the same first numerical reference label irrespective of the lettered suffix.
The ensuing description provides exemplary embodiments only, and is not intended to limit the scope, applicability or configuration of the disclosure. Rather, the ensuing description of the exemplary embodiments will provide those skilled in the art with an enabling description for implementing one or more exemplary embodiments. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the invention as set forth in the appended claims.
Specific details are given in the following description to provide a thorough understanding of the embodiments. However, it will be understood by one of ordinary skill in the art that the embodiments may be practiced without these specific details. For example, systems, structures, and other components may be shown as components in block diagram form in order not to obscure the embodiments in unnecessary detail. In other instances, well-known processes, procedures and techniques may be shown without unnecessary detail in order to avoid obscuring the embodiments.
Also, it is noted that individual embodiments may be described as a process which is depicted as a flowchart, a flow diagram, a structure diagram, or a block diagram. Although a flowchart may describe the operations as a sequential process, many of the operations can be performed in parallel or concurrently. In addition, the order of the operations may be re-arranged. A process may be terminated when its operations are completed, but could have additional steps not included in a figure. A process may correspond to a method, a process, a procedure, a technique, etc. Furthermore, embodiments may be implemented by manual techniques, automatic techniques, or any combination thereof.
In one embodiment, a system for slip forming a building core is provided. The system may include a form and a plurality of extendable mechanisms. The form may provide a space for accepting a hardenable substance, for example, concrete, and the plurality of extendable mechanisms may move the form to higher elevations once lower elevations of the building core is formed. While building cores will be discussed, the systems disclosed herein may be used to manufacture any number of different structures, especially vertical structures with an at least semi-consistent horizontal cross section. Furthermore, in some embodiments, floors of a building surrounding the building cores produced by the systems and methods of the invention may be supported at least in part by the building core.
Merely by way of example, the types of floors and buildings in which embodiments of the invention may be employed are described in U.S. patent application Ser. No. 11/746,834, filed May 10, 2007 and entitled “Multi-Story Building,” and U.S. patent application Ser. No. 11/757,899 filed Jun. 4, 2007 and entitled “Floor Support Systems and Methods.” The entire contents of both of these applications are hereby incorporated by reference for all purposes. Different types of walls which may be installed on the floors of buildings are described in U.S. patent application Ser. No. 11/766,040, filed Jun. 20, 2007 and entitled “Curtain Wall Systems and Methods,” the entire contents of which are hereby incorporated by reference for all purposes.
In some embodiments, the forms discussed herein may include an inner frame and an outer frame. The outer frame and the inner frame may at least partially define a space between the inner frame and the outer frame. The form may also be configured to accept a hardenable substance in the space, where the hardenable substance may form at least a portion of the building core.
In some embodiments, the inner frame and/or the outer frame of the form may be constructed from a variety of materials, including, but not limited to, metals (i.e. steel), polymers (i.e. plastics), ceramics, composites, and/or cellular materials (i.e. wood). In an exemplary embodiment, fiberglass tubing and sheeting may be molded, fused, or otherwise joined together to create the inner frame and/or the outer frame. In some embodiments, metallic, possibly steel and/or aluminum, reinforcement members may be fiberglassed into the inner frame and/or the outer frame. Additionally, various external features of the inner frame and/or the outer frame may also include metallic elements.
In some embodiments, the inner frame and the outer frame may each, or combined, be a singular piece, or include multiple sub-parts. In an exemplary embodiment, the inner frame and/or the outer frame may include a plurality of sub-frame components. The sub-frame components may be configured to be reversibly assembled and disassembled, thereby easing transportation and assembly at a job site. In some embodiments, either one or both of the inner form and the outer form may include a plurality of end sub-frame components, a plurality of side sub-frame components, and a plurality of corner sub-frame components.
In some embodiments, the inner frame and/or the outer frame may have pre-drilled or otherwise defined apertures for coupling finishing sheeting with the walls of the space where the hardenable substance is to be deposited. Merely by way of example, plywood and/or other composite/cellular sheets may be coupled with the walls of the space where the hardenable substance is to be deposited via screws and/or other fasteners via pre-drilled apertures passing through the walls of the inner form and the outer form.
In some embodiments, the extendable mechanisms may be coupled with the corner sub-frame components of either one or both of the inner frame and the outer frame. Thus, in some of the embodiments discussed, the end sub-frame components and the side end-frame components may be substantially two sided, flat, and light-weight. Meanwhile, the corner end-frame components may carry the more substantial weight of the extendable mechanisms. In an exemplary embodiment, standardized corner sub-frame components may be used with differently dimensioned end sub-frame components and side sub-frame components to allow for the creation of different size building cores merely by altering which side sub-frame components and end sub-frame components are used with the corner sub-frame components having the extendable mechanisms.
In some embodiments, joint members may be inserted into cavities in each adjacent sub-frame component to at least assist in joining such adjacent sub-frame components. Different adjacent sub-frame components may have differing number of cavities for differing number of joint members to be used to connect those adjacent sub-frame components. In some embodiments, flanges on the exterior of the outer frame sub-frame components, as well as flanges on the interior of the inner frame sub-frame components may allow for fasteners or other mechanisms to couple adjacent sub-frame components. Any other mechanism known in the art or otherwise may also be used to couple adjacent sub-frame components.
In some embodiments, at least one bridge member may be coupled with the inner frame and the outer frame such that the inner frame remains substantially stationary relative to the outer frame. Bridge members may be reversibly coupled so that they may be attached/detached with the form as needed during assembly, use, or disassembly. In some embodiments, the bridge member or members may be configured to allow a reinforcement member to be deposited beneath the at least one bridge member in the space. Reinforcement members may, merely by way of example, include rebar, rebar cages, or wire mesh.
In some embodiments, each of the plurality of extendable mechanisms may include a first end, a second end, and an extendable midsection. The first end may be coupled with the form, the second end may be configured to be supported with a wall of the building core, and the extendable midsection may be configured to change the distance between the first end and the second end such that the form may be moved from a first elevation to a second elevation. In this manner, by selective extension and/or retraction of the extendable midsection, the second end of the extendable mechanisms may be pushed away or pulled toward the first end, which may be fixedly coupled with the form.
In an exemplary embodiment, one or more of the extendable mechanisms may be hydraulic cylinders. In other embodiments, one or more of the extendable mechanisms may be pneumatic cylinders and/or mechanical jacking systems (i.e. screw jacks or ratcheting jacks). In some embodiments, the power source for the extendable mechanisms may be provided at ground level, or may be self contained and coupled with the form, for example, on a operator working level coupled with the top, middle and/or bottom of the form.
In some embodiments, the plurality of extendable mechanisms may include two sets of extendable mechanisms. A first set of extendable mechanisms may be coupled with the inner frame of the form, and a second set of extendable mechanisms may be coupled with the outer frame of the form. The two sets of extendable mechanisms may be aligned such that each extendable mechanism in the first set is linearly aligned with an extendable mechanism in the second set.
In some embodiments, the pushing faces of the second end of the extendable mechanisms may be contoured to match a temporary support member that will be used to provide a jacking point on the wall of the building core. In some embodiments, the pushing faces may be flat and/or have a depressed or protruded feature. In these embodiments, the temporary support members may be flat and/or have a protruded or depressed feature, respectively, to match the pushing faces. In an exemplary embodiment, the pushing faces of the second end of the extendable mechanisms may define a cavity having a circular cross section. In these embodiments, the temporary support members may have a circular cross section. In some embodiments, combinations of different pushing faces on different extendable mechanisms may be employed.
In some embodiments, initial push-off from ground level may include providing a concrete pad from which the building core will be supported. The concrete pad may also have foundational elements such as concrete caissons. On the top of the concrete pad, cavities may be defined with features to match the pushing faces of the extendable mechanisms. In these embodiments, the cavities with matching features therein may assist in setting up and assembling the form. In other embodiments, the pushing face of the extendable elements may be retractable into the form such that cavities are not necessary, but rather push off will occur directly off the concrete pad, possibly with interface materials to distribute the loading of the extendable mechanisms to a greater surface area of the concrete pad. Merely by way of example, the interface material may include a plate, possibly made from steel, with a feature on the top face which matches the pushing face of the extendable mechanisms. In embodiments with push-off cavities, the initial push-off cavities in the pad may be filled later to complete the surface of the pad.
In some embodiments, during the initial pouring of hardenable material into the space of the form, temporarily filled receptacles may be deposited into the hardenable material. These temporarily filled receptacles may be coupled with each other so that vertical spacing between them will be proper and/or consistent as desired. Additionally, a coupling member may allow for proper location with reference to the top of the form. Temporarily filled receptacles may continual be deposited as the form works its way upward forming the building core.
The temporarily filled receptacles may define a cavity once the temporary filling is removed. The cavity may have a similar cross section to the temporary support members to be used in a given embodiment. Furthermore, the temporary filled receptacles may have a length substantially similar to the width of the form in the location in which they are deposited. In that manner, after the portion of the building core surrounding the temporarily filled cavity is formed, the temporarily filling may be removed, and the receptacle may define a cavity in which the temporary support member may be supported.
In another embodiment, a method for creating a structure is provided. In some embodiments, the methods disclosed may include any method by which the system embodiments described herein may be used.
In some embodiments, the methods may include providing a form, where the form includes an inner frame and an outer frame which may at least partially define a space between the inner frame and the outer frame. The method may also include depositing a hardenable substance in the space, where the hardenable substance may form at least a portion of the structure. Reinforcement members, as described above may also be deposited in the hardenable substance during at any stage of the method.
The method may further include providing a plurality of extendable mechanisms, where the plurality of extendable mechanisms may be coupled with the form. The method may further include extending the extending the plurality of extendable mechanisms such that the form may be moved from a first elevation, possibly at substantially ground level, to a second elevation, possibly at least some amount above ground level.
The method may additionally include supporting the plurality of extendable mechanisms from one or more walls of the structure. In some embodiments, this may include depositing a plurality of temporary support receptacles in the space where the hardenable material is deposited, where the plurality of temporary support receptacles define a plurality of cavities. Temporary support members may then be supported by the temporary support receptacles. As discussed above, the temporary support receptacles may be temporarily filled with a substance so that hardenable material does not undesirably fill the temporary support receptacle prior to their usage to support temporary support members.
Supporting the plurality of extendable mechanisms may include retracting at least a particular number of the plurality of extendable mechanisms and supporting them from temporary support members. Once these particular number of the plurality of extendable mechanisms are supported by the temporary support members, the remainder of the plurality of extendable mechanisms may be retracted and also supported by the temporary support members.
In one embodiment, the extendable mechanisms coupled with the inner frame may be first retracted in a lifting cycle, with the extendable mechanisms coupled with the outer frame retracted after the inner frame extendable mechanisms are supported at a higher elevation. In other embodiments, the outer frame extendable mechanisms may first be retracted. In yet other embodiments, some combination of inner frame and outer frame extendable mechanisms may first be retracted, with the remainder of extendable mechanisms retracted thereafter. In this or other manners, the form may be moved from one elevation to another higher elevation. The method may be repeated until the proper height of building core is accomplished.
In some embodiments, methods of the invention may also include depositing a first plurality of floor support receptacles in the space during depositing of hardening substance in the space. The first plurality of floor support receptacles may be configured to at least partially support a first plurality of floor support members, and the first plurality of floor support members may be configured to at least partially support a first floor around the structure. In these embodiments, a second plurality of floor support receptacles may also be deposited in the space with the hardenable substance. Similar to the first plurality of floor support receptacles, the second plurality of floor support receptacles may also be used as described above to support another floor. U.S. patent application Ser. No. 11/757,899 filed Jun. 4, 2007 and entitled “Floor Support Systems and Methods,” as incorporated above, discusses some possible systems and methods for implementing floor support receptacles and floor support members.
In another embodiment, a system for creating a structure is provided. The system may include at least portions of the systems for slip forming a building core as described above, systems which implement at least portions of the methods described above, and/or other systems. The system may include at least a first means, a second means, and a third means.
The first means may be for at least partially defining a space, where the space may be configured to accept a hardenable substance. The hardenable substance may form at least a portion of the structure. The first means may, merely by way of example, include the form described above, and/or any other component described herein.
The second means may be for providing support from a plurality of locations on at least one wall of the structure. The second means may, merely by way of example, include the temporary support members described above, the temporary support receptacles described above, and/or any other component described herein.
The third means may be for moving the first means away from the second means such that the first means may be moved from a first elevation to a second elevation, where the third means may be coupled with the first means and supported by the second means. The third means may, merely by way of example, include the extendable mechanisms described above, and/or any other component described herein.
The following figures described just one possible embodiment of the invention and are presented for the purposes of illustrating one possible implementation of the systems and methods of the invention.
To couple components 205, 210, 215, 225, 230, 235 of the slip forming system 200, various mechanisms may be provided. First, matching cavities 240 may be provided at sub-frame interfaces in various numbers and locations to accept joint members 245. Joint members 245 may at least partially assist in properly aligning adjacent sub-frame components. Second, flanges 250 may provide matching surfaces at adjacent sub-frame components to coupled sub-frame components using fastening mechanisms, for example, nuts and bolts. Proper alignment of adjacent sub-frame components may at least partially assist in aligning the walls of the inner space of the form such that smoother, more consistent walls may be slip formed.
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The invention has now been described in detail for the purposes of clarity and understanding. However, it will be appreciated that certain changes and to the exemplary embodiments discussed herein may be practiced within the scope of the appended claims.
