Patent Application
20210238843
The present invention is related to a structural horizontal building panel or floor panel. More specifically, it relates to a floor panel with an embedded block that permits connection of the floor panel to wall panels above and below the floor.
Panels that are prepared and fabricated off-site embody a major improvement in the construction field for implementing a high level of standardization for certain building procedures, decreasing costs and facilitating a better quality control of the panels.
The fabrication and the mounting process of floor panels need a high level of accuracy in order to be assembled properly on-site. The assembly must maintain its integrity as the floor panel may be subjected, over time, to wall panel vibrations or movements that can potentially impair a building's structure.
This background is not intended, nor should be construed, to constitute prior art against the present invention.
The present invention is related to a floor panel that has features for connecting it to wall panels. The floor panel has floor connector blocks placed at each corner, for example, integrated in the floor panel. The floor connector blocks also act as anchoring sites where hooks can be mounted in order to lift the floor panel. The floor connector block has projecting anchor pins that provide a mechanical anchor in the cementitious material of the floor panel. The structure of the floor connector block facilitates the fixation of the wall panels to the floor panel using a tapped-head bolt, which has a female threaded head and acts as a double fixation component. Two plates for stabilizing the position of the tapped-head bolt are located inside the floor connector block.
The following drawings illustrate embodiments of the invention, which should not be construed as restricting the scope of the invention in any way.
Referring to
The anchor pins or bolts 14, 18, 22 and 26 are respectively mounted on the two internal rectangular faces 30 and 34, which face inwards to the floor panel in which the floor connector assembly 1 is embedded. The anchor pins 14, 18, 22 and 26 are used as mechanical fixation points for the surrounding cementitious material used in the fabrication of the floor panel. The anchor pins 14, 18, 22 and 26 are embedded in the cured, cementitious material in order to provide a mechanical anchor between the floor connector block 10 and the floor panel. The anchor pins may be bolts, threaded bar, rebar, Nelson™ studs or may have another surface texture, the main requirement being that the anchor pins provide a mechanical attachment to the cementitious material. The anchor pins 14, 18, 22 and 26 of faces 30 and 34 form an angle of 90° between each other in some embodiments.
In some embodiments, the anchor pins 14, 18, 22 and 26 extend from one floor connector block, embedded along the side of the floor panel to another floor connector block in the floor panel. A tapped-head bolt 38 has at its top a ⅝″ (or 16 mm) diameter tapped hole 42 in the head 46. The tapped-head bolt 38 has at its bottom section, at the end opposite the head 46, a threaded part 50 with a diameter of ⅝″ (or 16 mm). Dimensions of the tapped-head bolt are exemplary and are different in other embodiments.
Referring to
At the center of the tapped-head bolt head 46, there is a ⅝″ (or 16 mm) diameter threaded hole 42. The tapped-head bolt head 46 is supported by a top plate 58 fixed in the top section of the floor connector block 10. The floor connector block 10 has rounded corners. In some embodiments, the radius of the rounded corners differs from that shown here.
Referring to
The top plate 58 is welded to the floor connector block inner walls at weld points 76. The dimensions of the top plate 58 ensure that it fits into the top open face of the floor connector block 10 and that it is large enough to be supported by the top shoulder 62. The top plate 58 welded into the floor connector block 10 must support the forces of one quarter of the total dead weight of the floor plus necessary safety margins when the floor panel is being lifted. The lower face 82 of the tapped-head bolt head rests on the upper surface 77 of the top plate 58.
The bottom shoulder 70 supports the bottom plate 66. The bottom plate 66 is ⅜″ (or 10 mm) thick and has a ¾″ (or 19 mm) diameter hole in this embodiment. The bottom shoulder 70 is 3/16″ (or 5 mm) wide and is defined by the difference in thickness between the walls of the bottom section 86 and the middle section 78. The height of the bottom section 86 is ⅜″ (or 10 mm) in this embodiment. In some embodiments, the widths of the top and bottom shoulders 62 and 70 are equal. The lower face 79 of the bottom plate 66 is flush with the bottom edge 90 of the floor connector block 10. The threaded bottom part 50 of the tapped-head bolt 38 passes through the hole 92 located at the center of the bottom plate 66. Hole 92 may also be large enough for a portion of the shank 75 to pass into. The bottom plate 66 is spot welded to inner walls of the bottom section 86 at weld points 88 and ground flat so as to sit flush on top of the wall connector block of the wall panel connected below the floor panel. The purpose of the bottom plate 66 is to guide the location of the tapped-head bolt 38 and the bottom of the floor panel to prevent sway or drift of the floor panel relative to the top of wall panel below.
Referring to
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The bottom plate 66 is similar in appearance to the top plate 58, except that it is optionally thinner.
Referring to
The bottom plate 66 is welded at location 88 to the inner walls of the bottom section 86 of the floor connector block 10. In the same manner, the top plate 58 is welded at location 76 to the inner walls of the top section 74 of the floor connector block. In some embodiments, other ways of fixing the plates 58 and 66 to the floor connector block 10 are used.
The bottom, threaded end 50 of the tapped-head bolt enters a hole 171 in the wall connector block 150 of the lower wall panel 142. The wall connector block 150 has an open face 151 flush with the surface of the wall panel 142, into which the nut 146 can be inserted. The nut 146 mounted on the threaded end 50 of the tapped-head bolt is tightened firmly in order to fix the floor connector block 10, and therefore the floor panel 94, to the wall connector block 150 of the lower wall panel 142.
The wall connector block 162 in the upper wall panel 138 hosts a bolt or screw 166 with a hexagonal head 170 that passes through a hole 172 in the wall connector block 162. The wall connector block 162 has an open face 163 flush with the surface of the wall panel 138, into which the screw 166 can be inserted. The ⅝″ (or 16 mm) diameter threaded part 174 of the bolt is then inserted and screwed into the threaded hole 42 of the tapped-head bolt. The screw 166 is tightened in order to fasten the top wall panel 138 to the floor panel 94.
The floor connector blocks 10 of the floor panel 94 are then fastened to the corresponding wall connector blocks 150 of the lower wall panel 142. The floor connector blocks 10 are first aligned, in step 205, to the floor panel connector blocks 150. Then, in step 206, a tapped-head bolt 38 is provided for each floor connector block and passed through the top plate 58, bottom plate 66 and a hole 171 located on the top face of the wall connector block 150. The nut 146 is inserted, in step 208, in the open face 151 of the wall connector block 150 and then onto the threaded end 50 of the tapped-head bolt 38.
In step 210, the nut 146 on the bottom threaded end 50 of the tapped-head bolt 38 is tightened, in order to fix the wall connector block 150 to the floor connector block 10.
In step 214, an upper wall panel 138 is placed upright on the floor panel 94 with the wall connector blocks 162 being aligned with the floor connector blocks 10. Specifically, the hole 172 of the wall connector block 162 is aligned with the threaded hole 42 of the tapped-head bolt 38.
A screw 166 is passed into the open face 163 of the wall connector 162 in step 216 and through the bottom opening 172 of the wall connector block 162, then screwed into the threaded hole 42 located in the head of the tapped-head bolt 38. In step 218, the wall connector block 162 in the upper wall is tightened to the floor connector block 10 by tightening the screw 166.
While the description has been given largely in terms of a floor panel, it is also applicable to a ceiling panel, or, more generally a horizontal building panel.
It is worth noting that the actual rectangular shape, the proportions and the dimensions shown are simply an embodiment of the present invention and can be subject to modification. For example, in some embodiments, the connector block body may have a rectangular cross-section or may be cylindrical. Additional play may be incorporated into the connector assembly to allow for a greater range of adjustment to the final positions of the connected wall and floor panels.
Other methods of fixing the supporting plates to the connector block body may be used in other embodiments. For example, the plates may be fastened in place by shrink fitting the body to them. In this case, the inner walls may not need to have recessed shoulders, and the wall of the floor connector block may have the same thickness throughout. In some embodiments, retaining pins or screws may be used to fasten the supporting plates (e.g. 58, 66) to the body of the connector block. The pins can be inserted and welded into holes located in the body of the floor connector blocks. Screws or bolts may be used in threaded holes in place of retaining pins.
In some embodiments, the threads of the tapped-head bolt may be located differently.
In some other embodiment, materials other than steel may be used, such as glass-fibre reinforced plastic.
The connector blocks may be positioned or oriented differently than shown is the exemplary embodiments. The anchor pins may be aligned with respect to each other at angles other than 90°, for example at any non-parallel angle including 180°. Anchor pins projecting from the same side of the connector block may not be parallel to each other. The number of anchor pins projecting from the interior faces of the connector block may be other than two.
The bottom plate may be recessed in the connector block rather than flush with the bottom of it. In this case, the bottom section with thinned walls 116 extends upwards more than shown in the figures. Nevertheless, the bottom plate is still located at the open bottom end of the connector body 12.
In some embodiments, the block assembly may be located in the horizontal building panel away from the corner. For example, it may be located part way along a side edge of the panel, or in the central area of the panel.
In general, unless otherwise indicated, singular elements may be in the plural and vice versa with no loss of generality.
Throughout the description, specific details have been set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail and repetitions of steps and features have been omitted to avoid unnecessarily obscuring the invention. Accordingly, the specification is to be regarded in an illustrative, rather than a restrictive, sense.
It will be clear to one having skill in the art that further variations to the specific details disclosed herein can be made, resulting in other embodiments that are within the scope of the invention disclosed. Steps in the flowchart may be performed in a different order, other steps may be added, or one or more may be removed without altering the main function of the invention. All parameters, dimensions, materials, and configurations described herein are examples only and actual ones of such depend on the specific embodiment. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the claims.
Disclosed herein is a connecting assembly for a horizontal building panel, the connecting assembly comprising: a connector block comprising: a body, which is hollow and has an open top end and an open bottom end; a top plate fastened inside the body below the open top end, in a plane perpendicular to a longitudinal axis of the body, the top plate having a hole in its center; and a bottom plate fastened inside the body at the open bottom end, in a plane perpendicular to the longitudinal axis of the body, the bottom plate having a hole in its center; a bolt comprising: a shank that passes through the hole in the top plate; a head that is supported by the top plate and extends not further than the open top end; an internally threaded axial hole in the head; and a threaded end that passes through the hole in the bottom plate and projects below the bottom plate; at least one anchor pin connected to and projecting outward in a first direction from the body; and at least one other anchor pin connected to and projecting outward from the body in a second direction that is non-parallel to the first direction.
In some embodiments, the anchor pins are welded into holes in the connector block. In some embodiments, the top and bottom plates are made from steel and are welded to the connector block. In some embodiments, the body comprises: a first internal shoulder upon which the top plate is located; and a second internal shoulder upon which the bottom plate is located.
In some embodiments, the internally threaded axial hole is ⅝″ in diameter and 1″ deep; the shank is ⅝″ in diameter; the threaded end has a ⅝″ diameter; the first and second internal shoulders are 3/16″ deep; the first internal shoulder is located 1.5″ below the open top end; the top plate is ½″ thick and has a ¾″ threaded hole in its center; the bottom plate is ⅜″ thick and has a ¾″ hole in its center; and the body has a 4″ square section.
In some embodiments, the body has four walls. In some embodiments, the at least one anchor pin projects from a first of the walls; and the at least one other anchor pin projects from a second of the walls adjacent to the first wall. In some embodiments, the bottom plate is flush with the open bottom end of the body. In some embodiments, third and fourth walls of the body define a corner of a horizontal building panel; and the anchor pins are embedded in cementitious material in the horizontal building panel. In some embodiments, the body is made from hollow structural steel with a rounded-corner square cross-section.
Also disclosed is a horizontal building panel comprising: connecting assembly comprising: a connector block comprising: a body, which is hollow and has an open top end and an open bottom end; a top plate fastened inside the body below the open top end, in a plane perpendicular to a longitudinal axis of the body, the top plate having a hole in its center; and a bottom plate fastened inside the body at the open bottom end, in a plane perpendicular to the longitudinal axis of the body, the bottom plate having a hole in its center; a bolt comprising: a shank that passes through the hole in the top plate; a head that is supported by the top plate and extends not further than the open top end; an internally threaded axial hole in the head; and a threaded end that passes through the hole in the bottom plate and projects below the bottom plate; at least one anchor pin connected to and projecting outward in a first direction from the body; and at least one other anchor pin connected to and projecting outward from the body in a second direction that is non-parallel to the first direction; and a volume of cementitious material adjacent to the body, in which the anchor pins are embedded; wherein: the open top end is level with a top surface of the horizontal building panel; and the open bottom end is level with a bottom surface of the horizontal building panel.
Also disclosed herein is a method for connecting building panels comprising: placing a lower wall panel in a required position, the lower wall panel having a first connector block with a top hole on an upper edge of the lower wall panel and a first open face accessible from a side of the lower wall panel; providing a horizontal building panel comprising: a connecting assembly comprising: a connector block comprising: a body, which is hollow and has an open top end and an open bottom end; a top plate fastened inside the body below the open top end, in a plane perpendicular to a longitudinal axis of the body, the top plate having a hole in its center; and a bottom plate fastened inside the body at the open bottom end, in a plane perpendicular to the longitudinal axis of the body, the bottom plate having a hole in its center; a bolt comprising: a shank that passes through the hole in the top plate; a head that is supported by the top plate and extends not further than the open top end; an internally threaded axial hole in the head; and a threaded end that passes through the hole in the bottom plate and projects below the bottom plate; at least one anchor pin connected to and projecting outward in a first direction from the body; and at least one other anchor pin connected to and projecting outward from the body in a second direction that is non-parallel to the first direction; and a volume of cementitious material adjacent to the body, in which the anchor pins are embedded; wherein: the open top end is level with a top surface of the horizontal building panel; and the open bottom end is level with a bottom surface of the horizontal building panel; placing the horizontal building panel so that the bottom open end is over the top hole of the lower wall panel; providing a bolt comprising: a shank that passes through the hole in the top plate; a head that is supported by the top plate and extends not further than the open top end; an internally threaded axial hole in the head; and a threaded end that passes through the hole in the bottom plate and projects below the bottom plate; placing the bolt through the holes in the top and bottom plates; inserting a nut through the first open face and tightening the nut onto the bolt; providing an upper wall panel having a second connector block with a bottom hole on a lower edge of the upper wall panel and a second open face accessible from a side of the upper wall panel; placing the upper wall panel on the horizontal floor panel so that the bottom hole is aligned with the internally threaded axial hole of the bolt; inserting a further bolt through the second open face and tightening the further bolt into the internally threaded axial hole.
