Patent Application
20190136521
The present invention relates to the reinforcement of concrete structures, and more particularly to the reinforcement of concrete wall and floor structures by a metal skeleton made of pre-metal components without the use of conventional rebar.
When constructing a concrete structure, such as the walls and floors of a building, it is common to form the concrete structure by pouring concrete, or sometimes pumping concrete, into a hollow form structure. For the sake of cost reduction, the hollow form structure is typically made from of wood, but may also be made from one or more suitable materials such as steel or other metal materials, or possibly more than one of these materials used together.
In the case of a wall, the hollow form structure is generally defined by opposed generally planar vertical wall forms and side barriers that extend between the opposed generally planar vertical wall forms. In the case of a floor, the hollow form structure is generally defined by a horizontal bottom form and side barriers that extend upwardly from the horizontal bottom form. In any case, the top is open to permit the pouring of concrete into the hollow interior thereof.
Due to the structural characteristics of concrete, it is generally necessary to reinforce the concrete structure in order to maximize the strength and rigidity of the structure. The most common way used in the prior art to provide such reinforcement is to construct a metal skeleton from steel reinforcing rods, also known as re-bar. Re-bar typically comprises cylindrical steel rods having a faceted outer surface that precludes movement of the re-bar with respect to the concrete. Other cross-sectional shapes, such as an “L”-shape are also used.
Numerous problems arise from using re-bar as a reinforcement skeleton for concrete structures. Many of these problems stem from the fact that re-bar is typically shipped (like construction lumber) in bulk to a job site in standardized lengths (or as a continuous roll) that must be cut to size on the job site for subsequent use in assembling the reinforcement skeleton. As such, there substantially no significant pre-engineering that goes into the design or building of such re-enforcement structures, and much happenstance into how they are constructed on site. In short, quality control is substantially hit and miss, and dependent to an unacceptably large extent upon the experience and skill of the construction workers who form the skeleton from bulk materials on site.
Additionally, on-site cutting typically requires the use of cutting torches and/or high-powered metal cutting saws under the less than ideal conditions that typically exist at an open air construction site where structural concrete is being poured. Such tools are expensive to own and dangerous to operate, and are subject to theft, or damage, on construction sites.
Additionally, there is a need for at least semi-skilled labour to carry out the process of constructing the reinforcement structure, as such labour must be able to accurately read plans and to safely operate the cutting tools necessary to accurately cut the re-bar to the various lengths required by the plans for assembly of the reinforcement structure prior to its insertion into the hollow form structures used to retain the concrete. Such labour is expensive and not always readily available when needed.
Furthermore, after cutting to the required lengths, the required number of cut sections of re-bar must be assembled and connected together to form the internal reinforcement skeleton by means of supplemental fastening means, which can include, without limitation, clips, clamps, threaded fasteners, and/or welding. The need for supplemental fastening means not only significantly adds to the cost of producing prior art metal reinforcement skeletons from re-bar, but significantly lengthens the time to produce such skeletons. Moreover, the use of welding equipment to attach re-bar components one to the other is particularly expensive, is subject to explosive mishaps, to damage, and to theft from construction sites.
Even with the proper tools and labour on hand, the cutting and assembly of the components necessary to construct an internal reinforcement skeleton from re-bar at a construction site is slow and difficult, due in large part to the harsh and disruptive working conditions that typically exist at such open-air construction sites where concrete is being poured. These conditions commonly include the lack of cover from rain, wind and cold, and the lack of clear and even work surfaces and spaces for cutting and assembly of the metal skeleton. Such adverse conditions introduce the significant possibility of errors being made and/or shortcuts being taken.
Further, prior art metal skeletons made from re-bar can easily be bent, or otherwise deformed, from their intended shape either during or after assembly, and they lack means for quickly and accurately indicating that a minimum thickness and/or depth of concrete has been evenly and consistently poured therearound during the construction of a concrete floor or wall structure. There is thus a need in the prior art for increased consistency and quality control in the floors or walls produced using metal reinforcement skeletons.
Construction of metal reinforcement skeletons from re-bar also involves significant expense and logistics problems in procuring all of the necessary materials and assembly equipment from various sources and shipping same, in a secure and timely manner, to a construction site. These problems include, without limitation, the nearly inevitable chance of materials or assembly equipment not arriving at, or disappearing from, a construction site, the lack of protection from weather and other agents of metal materials stored at a construction site, the lack of ready access by workers to plans for assembling the metal skeleton.
For at least the above reasons, there exists in the prior art a need for pre-engineered metal reinforcement skeletons that are readily reproducible as full scale test mules for stress and quality control evaluation and testing in controlled environments prior to the skeletons being rolled out for use on a construction site.
Additionally, there exists in the prior art a need for metal reinforcement skeletons that provide enhanced strength and security to the concrete structures formed therearound. Such a need is particularly applicable to wall or floor structures intended for use in a security applications, such as bank vaults, prisons, court houses or other public, governmental or diplomatic buildings and facilities where the walls or floors of such structures may be subjected to destructive attack by vehicles, firearms, explosives, or other destructive devices, weapons or agents. Use of the applicant's internal reinforcement skeleton provides increased strength and security without proportionally increasing the overall thickness of the concrete wall or floor structure formed therearound.
Additionally, there is a need in the prior art for the steel or other metal cladding that serves as wall forms during pouring of the concrete around the reinforcement skeleton to be able to remain permanently attached to the reinforcement structure as an exterior surface of the concrete structure after curing of the concrete, thereby providing significant additional strength and security to the finished structure. In this latter regard, such metal cladding can present a wide variety of different surface treatments, coatings or other finishes on its exposed outer surfaces, thereby providing considerable additional aesthetic and functional utility over that available with prior art poured concrete walls and floors.
More recently, various types of reinforcement skeletons apart from re-bar skeletons have been made available, as can be found in the following prior art documents.
U.S. Patent Application Publication No. 2006/0248832 to Shidler, published Nov. 9, 2006, and is entitled Concrete Wall Form Tie. The disclosed concrete wall form system 10 includes a plurality of wall forms 12 which are arranged to form two series of coplanar walls held in opposing spaced-apart, generally parallel relationship to define a cavity into which concrete is poured and cured to form a concrete wall. The inwardly facing surfaces of the adjacent wall forms 12 are held in a coplanar relationship by connecting pins 14. The two spaced-apart forms 12 are held in the desired spaced-apart relationship by wall ties 16 that are typically fabricated from a strip of metal, such as steel or aluminium, or various other materials or combinations thereof, having a substantially uniform thickness. The wall ties 16 are cut or otherwise configured to define a plurality of notches 28 for positioning reinforcing rods or bars (also known as “re-bar”). Each wall form includes vertical frame members 17 that define a series of vertically spaced-apart apertures 18. The vertical frame members 17 also include a recess 20 adapted to receive an end 22 of wall tie 16. Typically, the depth of recess 20 is about equal to the thickness of wall tie 16 to allow adjacent vertical frame members 17 to about each other with end 22 of wall tie 16 sandwiched between the abutting vertical frame members. A pin 24 passes through a circular aperture 26 defined at each of opposite ends 22 of the wall tie 16 to securely retain wall tie 16 within recess 20 and thereby hold the opposing walls in the desired spaced relationship defining a cavity into which concrete is poured. Although U.S. Published Patent Application No. 2006/0248832 to Shidler may have some advantages over conventional prior art of re-bar skeletons, but does not teach the inventive concepts of the present invention.
U.S. Pat. No. 7,516,589 to Messiqua et al., issued Apr. 14, 2009, and is entitled High-Strength Concrete Wall Formwork. The disclosed concrete wall formwork increases the rigidity of the integrated formworks at the time of their installation.
U.S. Pat. No. 8,621,808 to Sharpe et al., issued Jan. 27, 2014, and is entitled Stud Frame and Formwork Panel Constructed Therefrom. The disclosed stud frame 10 is for constructing a formwork panel unit 12 and comprises a first side member 14 connected to and spaced apart in parallel relation from a second side member 16 by a plurality of interconnecting members 18 formed from a suitable metal such as steel. Each of the side members 14 and 16 comprises an elongate planar member (not numbered) having transversely extending flanges 19 along longitudinal edges thereof. The flanges 19 of the first side member 14 are directed inwardly towards the second side member 16 and the flanges of the second side member 16 are directed inwardly towards the first side member 14. The formwork panel unit 12 is constructed by securing a first side panel 20 to the first side members 14 of a plurality of stud frames 10 and securing a second side panel 22 to the second side members 16 of said plurality of stud frames 10. U.S. Pat. No. 8,621,808 to Sharpe et al. may have some advantages over conventional prior art re-bar skeletons, but does not teach the inventive concepts or advantages of the present invention.
According to one object of the present invention there is provided a metal skeleton for the reinforcement of a concrete structure, such as a wall or a floor of a building, to be formed therearound, which metal skeleton overcomes one or more of the problems associated with the prior art by providing a metal skeleton that is capable of being pre-engineered to exacting standards of rigidity and strength and quality control
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein use of the metal skeleton substantially lessens the need for skilled or semi-skilled labour for construction of the skeleton.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound that is readily reproducible and that is easily and quickly assembled by unskilled labour interlocking together the components thereof, one to the other, without the need for expensive or dangerous tools, such as cutting torches, cutting saws or welding equipment, and without the need for supplemental fastening means, such as, for example, clips, clamps, threaded fasteners or welded connections.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein assembly of the metal skeleton can be carried out relatively quickly and easily at a construction site without the need for measuring and cutting tools, requiring only simple hand tools, such as hammers, U-shaped bending channels, and/or a pair of Vice-Grip™, or the like.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein the metal skeleton is substantially quicker and easier to assembly than prior art metal skeletons and may be substantially self-supporting when assembled, as compared to prior art metal skeletons constructed from re-bar.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein the skeleton may be at least partially pre-assembled by unskilled labour in a factory or other sheltered assembly facility under more controlled conditions as compared to the construction site where the concrete structure will be poured.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete wall or floor structure to be formed therearound which can be manufactured according to very high pre-engineered standards of strength and durability and that is easily reproducible for pre-testing purposes, and for the purposes of building similar concrete structures in the future.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound which can be assembled with greater speed and accuracy than prior art reinforcement skeletons.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound which significantly reduces the likelihood of dimensional errors in the concrete structure formed therearound.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein the metal skeleton provides means indicating that a minimum thickness and/or depth of concrete has been evenly and consistently poured therearound during the construction of a concrete floor or wall structure.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein the components of the metal skeleton can be readily procured and securely shipped from a single source to a construction site in a standard shipping container.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound whose unassembled components are more readily protected from theft, damage and exposure to adverse weather conditions on a construction site than are the components of unassembled re-bar reinforcement skeletons.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein more accurately dimensioned and more complicated concrete structures can be more easily formed therearound than is possible with conventional re-bar reinforcement skeletons.
According to another object of the present invention, there is provided a metal skeleton for the reinforcement of a concrete structure to be formed therearound, wherein weather resistant instructions may be provided with the components of the metal skeleton in a manner in which they are not easily lost or ruined at an open-air construction site.
There is thus disclosed according to one embodiment of the present invention a novel metal skeleton for the reinforcement of a concrete structure to be formed therearound. The metal skeleton comprises a plurality of primary beams, each having a central main body portion with a major axis defining the orientation of the length of the central main body portion and a minor axis defining the orientation of the width of the central main body portion, with the minor axis being transverse to the major axis. Each of the plurality of primary beams is formed from a substantially flat sheet of metal material. There is also a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, the minor axis being transverse to the major axis. The interconnecting members interlock with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means, and with the plurality of interconnecting members have both their major axis and their minor axis oriented substantially transversely to the major axis of the central main body portion of the primary beams.
There is also disclosed according to another embodiment of the present invention a novel metal skeleton for the reinforcement of a concrete structure to be formed therearound. The metal skeleton comprises a plurality of primary beams, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, with the minor axis being transverse to the major axis. There is also a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, with the minor axis being transverse to the major axis. A plurality of major receiving notches is disposed along the length of each of the primary beams, wherein the major receiving notches each have a narrow throat portion and a wide rear portion open to the narrow throat portion. The interconnecting members interlock with the major receiving notches formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means. The plurality of interconnecting members each have both their major axis and their minor axis oriented substantially transversely to the major axis of the primary beams.
There is also disclosed according to another embodiment of the present invention a novel metal skeleton for the reinforcement of a concrete structure to be formed therearound. The metal skeleton comprises a plurality of primary beams, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, and wherein the minor axis is transverse to the major axis. The skeleton also comprises a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, the minor axis being transverse to the major axis. A plurality of major receiving notches is disposed along the length of each of the primary beams. The major receiving notches each have a narrow throat portion defined by first and second facing throat edges. An open space is disposed adjacent the first throat edge of the narrow throat portion of the major receiving notches so as to define a locking clip between the narrow throat portion and the open space. The locking clip is movable between a support passing position and a support locking position. In the support passing position, the interconnecting members can pass through the narrow throat portion and into the wide rear portion. In the support locking position, the interconnecting member is precluded from passing through the narrow throat portion and is thereby retained in place in the wide rear portion. The interconnecting members interlock with the major receiving notches formed on the primary beams, as locked in place by the locking clips, to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means. The plurality of interconnecting members have both their major axis and their minor axis oriented substantially transversely to the major axis of the primary beams.
There is also disclosed according to another embodiment of the present invention a novel metal skeleton for the reinforcement of a concrete structure to be formed therearound, the concrete structure having a thickness defined between first and second opposed surfaces positioned on opposite sides of a medial plane of the metal skeleton. The metal skeleton comprises a plurality of primary beams, each having a central main body portion with a major axis defining the orientation of the length of the central main body portion and a minor axis defining the orientation of the width of the central main body portion, with the minor axis being transverse to the major axis. Each of the plurality of primary beams is formed from a substantially flat sheet of metal material. There is also a plurality of interconnecting members, each having a major axis defining the orientation of its length and a minor axis defining the orientation of its width, with the minor axis being transverse to the major axis. The interconnecting members interlock with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means, and with the plurality of interconnecting members have both their major axis and their minor axis oriented substantially transversely to the major axis of the primary beams, and such that the primary beams are oriented with their major axis arranged substantially parallel one to the next and with their minor axis arranged substantially transverse to the medial plane, with their widths extend between the first and second opposed surfaces.
There is also disclosed according to another embodiment of the present invention a novel method of producing a flat-shippable three-dimensional concrete reinforcement skeleton for assembly at a site remote from the production site without the need of supplemental cutting or fastening means. The method comprises the steps of: a) forming from one or more flat sheets of metal a first plurality of primary beams and a second plurality of interconnecting members substantially pre-cut therein so as to be retained in place within the sheets by frangible connection points left uncut in a remainder of the flat sheets of metal material, with each of the primary beams having a third plurality of mechanical interlocking means integrally formed thereon adjacent lateral edges of the primary beams; b) loading the flat sheets into one or more shipping containers; c) relocating the one or more shipping containers to the assembly site; d) removing the flat sheets of metal material from the one or more shipping containers; e) breaking the frangible connection points; f) separating the primary beams and the interconnecting members from the remainder of the corresponding flat sheets of metal material; g) arranging the second plurality of interconnecting members adjacent the first plurality of primary beams with respective ones of the mechanical interlocking means in operatively close proximity to the second plurality of interconnecting members; and, h) fitting the plurality of interconnecting members within respective ones of the plurality of mechanical interlocking means to secure the primary beams and the interconnecting members one to the other without supplemental fastening means.
There is also disclosed according to another embodiment of the present invention a novel kit for assembling a metal skeleton for the reinforcement of a concrete structure to be formed therearound. The kit comprises a plurality of primary beams, each having a central main body portion with a major axis defining the orientation of the length of the central main body portion and a minor axis defining the orientation of the width of the central main body portion, with the minor axis being transverse to the major axis. Each of the plurality of primary beams is formed from a substantially flat sheet of metal material. A plurality of interconnecting members each have a major axis defining the orientation of its length and a minor axis defining the orientation of its width, with the minor axis being transverse to the major axis. The interconnecting members are dimensioned and otherwise adapted to interlock with co-operating receiving portions integrally formed on the primary beams to secure the primary beams and the interconnecting members one to the other without supplemental fastening means. The plurality of interconnecting members each having both their major axis and their minor axis oriented substantially transversely to the major axis of the central main body portion of the primary beams upon assembly of the metal skeleton.
There is also disclosed according to another embodiment of the present invention a novel kit used for assembling a metal skeleton for the reinforcement of a concrete structure to be formed therearound. The kit comprises a plurality of flat sheets of metal material having a plurality of primary beams and a plurality of interconnecting members substantially pre-cut therein so as to be retained in place by frangible connection points left uncut in the substantially flat sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of the flat sheets of metal material after shipping to an assembly site. The interconnecting members interlock with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means.
There is also disclosed according to another embodiment of the present invention a novel method of providing the components of a flat-shippable three-dimensional concrete reinforcement skeleton for assembly at a site remote from the production site without the need of supplemental cutting or fastening means. The method comprises the steps of a) forming from one or more flat sheets of metal a first plurality of primary beams and a second plurality of interconnecting members substantially pre-cut therein so as to be retained in place within the sheets by frangible connection points left uncut in a remainder of the flat sheets of metal material, with each of the primary beams having a third plurality of mechanical interlocking means integrally formed thereon adjacent lateral edges of the primary beams; b) loading the flat sheets into one or more shipping containers; and c) relocating the one or more shipping containers to the assembly site.
There is also disclosed according to another embodiment of the present invention a novel method of assembling a metal skeleton from a plurality of flat sheets of metal material having a plurality of primary beams and a plurality of interconnecting members substantially pre-cut therein so as to be retained in place by frangible connection points left uncut in the substantially flat sheets of metal material to thereby be subsequently separable from the remainder of the corresponding one of the flat sheets of metal material after shipping to an assembly site, for the reinforcement of a concrete structure to be formed therearound. The method comprises the steps of a) separating the plurality of primary beams and the plurality of interconnecting members from the remainder of the corresponding one of the flat sheets of metal material; and b) interlocking the plurality of interconnecting members with co-operating receiving portions formed on the primary beams to thereby secure the primary beams and the interconnecting members one to the other without supplemental fastening means.
The above and other aspects, objects, advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter of which is briefly described hereinbelow.
The novel features which are believed to be characteristic of the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. In the accompanying drawings:
Referring to
Reference will now be made to
It is contemplated that the metal skeleton 100 according to at least some embodiments enclosed herein could be used with conventional wall forms, which are typically made from wood, or any other suitable type of wall forms, including the specific wall forms disclosed in the present invention. Notwithstanding this flexibility, at least the first illustrated embodiment provides its own metal wall forms 150, that are designed to be left attached to the metal skeleton 100 after the concrete structure 110 is cured, to provide a finished surface of metal material, for added strength and durability (see, for example,
As best seen in
The metal skeleton 100 comprises a plurality of primary beams 120, each having a first side edge 121, a second side edge 122, a first end 123 and a second end 124, a plurality of interconnecting members 130, each having a top edge 131, a bottom edge 132, a first end 133 and a second end 134, metal wall forms 150, each having a top 151, a bottom 152, a first end 153 and a second end 154, and, optional end caps 160 (see, for example,
Reference will now be made to
More specifically,
The metal skeleton 100 can be assembled at either the construction site 104 as shown, or remotely from the construction site 104, at an independent assembly site. It is also possible that the metal skeleton 100 can be assembled at the production site 103, or in other words the factory where the components of the metal skeleton 100 are fabricated. Most commonly, the metal skeleton 100 will be assembled at the construction site 104 in order to minimize transportation costs and transportation effort, and also for the sake of overall convenience. In this case, the construction site 104 and the assembly site would be one and the same.
As seen in the first illustrated embodiment, the plurality of primary beams 120 are preferably, but not necessarily, oriented substantially parallel one to the next and, more specifically, are generally vertically disposed in order to be aligned with the force of gravity. Also, the plurality of interconnecting members 130 are oriented substantially transversely to the primary beams 120 and are generally parallel one to the next. In this manner, any horizontally longitudinal forces, whether compressive or tensile, along the length of the concrete wall structure 110w are transmitted generally along the major axes of the interconnecting members 130.
One of the advantages of the present invention is that its components, such as the primary beams 120, the interconnecting members 130, the metal wall forms 150, and the end caps 160, can all be fabricated from substantially flat sheets of metal material 170, as will be discussed in greater detail subsequently. Once the substantially flat sheets of metal material 170 have had the aforementioned components formed therein, they become formed sheets of metal material 172.
The substantially flat sheets of metal material 170 typically may be made from mild steel sheet or plate, stainless steel sheet or plate, aluminum sheet or plate, copper or brass sheet or plate, and would typically have a relatively thin gauge (e.g. about 0.1 mm to 19.0 mm), but can be made from any other suitable metal material appropriate for the intended application. Accordingly, the metal skeleton 100 may be relatively inexpensive to manufacture and requires only simple manually operable tools to work with. Further, it is relatively easy to cut, or otherwise remove, the components (such as the primary beams 120, the interconnecting members 130, the metal wall forms 150, and the end caps 160) of the metal skeleton 100 from the substantially flat formed sheets of metal material 172, and also relatively easy to bend the various components, as necessary.
It will be appreciated
More particularly, the primary beams 120 and the interconnecting members 130 are substantially pre-cut so as to be retained in place by frangible connection points 127 left uncut in the substantially flat formed sheets of metal material 172, as can be seen in
Also, as can be seen in
Another significant aspect of the present invention is that a relatively large number of the substantially flat formed sheets of metal material 172 can be readily packed into shipping containers, as stacked sheets one atop the other, including conventional shipping containers 108, as shown in
Further, as will be appreciated from
Preferably, but not necessarily, as discussed above, each of the substantially flat formed sheets of metal material 172 may contain a plurality of primary beams 120 and a plurality of interconnecting members 130. The exact number of primary beams 120 and interconnecting members 130 in any given substantially flat formed sheet of metal material 172 can be optimized for a particular job. For instance, in a given wall portion such as is shown in
As illustrated in
The primary beams 120 as illustrated, are elongate and are shown in the first illustrated embodiment, as being vertically oriented to form the metal skeleton 100. The primary beams 120 each have a central main body portion 125 with a major axis as indicated by the reference character “A” and a minor axis as indicated by the reference character “B” (see
The central main body portion 125 defines a plurality of generally circular apertures 126a and a plurality of generally rectangular apertures 126b therein. The plurality of circular apertures 126a and plurality of generally rectangular apertures 126b in the central main body portion 125 are preferably spaced along the major axis “A” at regular intervals one from the next along the length “LP” of the primary beams 120. The apertures are included in the central main body portion 125 purposes of weight reduction, to permit concrete to flow therethrough during pouring thereof as illustrated in
The primary beams 120 also each comprise depth indicators 128 extending horizontally outwardly beyond the first 121 and second 122 side edges of the primary beams 120. Each depth indicator 128 is preferably narrower at its outer end and wider at its base, but could be any other suitable and useful shape. The depth indicators 128 extend outwardly a pre-determined distance from the first side edge 121 and the second side edge 122 of the central main body portion 125 of the primary beam to indicate whether the concrete formed around the metal skeleton 100 has been poured to an appropriate thickness; in other words, if no depth indicators are visible in the finished concrete structure 110, this indicates that it has been formed to an appropriate horizontal thickness in the case of a concrete wall structure 110w, or formed to the appropriate vertical thickness in the case of a concrete floor structure. This is done for the sake of quality control and safety, so as to ensure that the concrete structure 110 formed is of sufficient thickness and strength along the entire length “LP” of the primary beam 120.
As can be readily seen in the Figures, the first side edge 121 and the second side edge 122 of the primary beams 120 are disposed on the central main body portion 125 on opposite sides of the major axis “A”. Preferably, but not necessarily, the first side edge 121 and the second side edge 122 are substantially straight and are substantially parallel one to the other.
Receiving portions 180 are formed in at least one of the first side edge 121 and the second side edge 122 of each of the primary beams 120. In the first illustrated embodiment, but not necessarily, and as can be best seen in
The major receiving notches 180 each have a narrow throat portion 182 defined by first 181a and second 181b facing throat edges and open to the corresponding one of the first side edge 121 and the second side edge 122 of the primary beams 120, and a wide rear portion 184 open to the narrow throat portion 182. The major receiving notches 180 are spaced at regular intervals one from the next along the length of at least one of the first side edge 121 and the second side edge 122, and in the first illustrated embodiment, are spaced at regular intervals one from the next along the length of both the first side edge 121 and the second side edge 122.
The overall shape, size and functionality of the major receiving notches 180 have been shaped, dimensioned and otherwise predetermined to properly receive and retain the interconnecting members 130, and to permit the interconnecting members 130 to be readily inserted firmly and securely into the major receiving notches 180. As best seen in
Further, it has been found that having the ratio of the width “WR” to the length “LR” of the wide rear portion 184 between 10:1 and 5:1 is quite suitable, and that having the ratio of the width “WT” to the length “LT” of the narrow throat portion 182 about 22:5 works very well.
There is also an open space 186 disposed adjacent the first throat edge 181a of the narrow throat portion 182 of the major receiving notch 180 so as to define a locking clip 188 between the narrow throat portion 182 and the open space 186. The locking clip 188 is resiliently movable between a support passing position, as is best seen in
When the locking clip 188 is in the support passing position, the selected interconnecting member 130 can pass through the narrow throat portion 182 and pass by the locking clip 188 and enter into the wide rear portion 184. After the selected interconnecting member 130 fully enters the wide rear portion 184, the locking clip 188 resiliently returns, at least part way, to its support locking position. In the support locking position, the interconnecting member 130 is precluded from passing back through the narrow throat portion 182 and is thereby securely and snugly retained and locked in place in the wide rear portion 184 by the locking clip 188. It has been found that the ratio of the width to the length of the locking clip 188 of about 5:1 works well.
The major receiving notch 180 are disposed along the length of both of the first side edge 121 and the second side edge 122 of each of the primary beams 120 such that the major receiving notch 180 disposed along the length of the first side edge 121 are substantially longitudinally aligned with the major receiving notch 180 disposed along the length of the second side edge 122. Such lateral alignment of the major receiving notch 180 along the first side edge 121 and the second side edge 122 of the primary beams 120 causes the interconnecting members 130 inserted into the laterally aligned pairs of the major receiving notch 180 to be at substantially the same elevation one as the other.
Each of the primary beams 120 further comprises a first side wing portion 129a and a second side wing portion 129b extending transversely outwardly from the central main body portion 125. More specifically, the first side wing portion 129a extends outwardly from the central main body portion 125 at the first side edge 121 thereof and the second side wing portion 129b extends outwardly from the central main body portion 125 at the second side edge 122 thereof. As can be readily seen in the Figures, the first side wing portion 129a and a second side wing portion 129b are substantially transverse to the central main body portion 125. Further, the first side wing portion 129a and a second side wing portion 129b are substantially parallel one to the other and the first side wing portion 129a and the second side wing portion 129b extend outwardly in the same direction one as the other. The first side wing portion 129a and the second side wing portion 129b together serve various purposes including permitting the primary beam 120 to be self standing, especially useful during assembly, which are especially useful during assembly, and increasing the rigidity and strength of the primary beam 120.
Preferably, but not essentially, and as shown in the Figures, the first side wing portion 129a is disposed inwardly from the first side edge 121 of the central main body portion 125 and the second side wing portion 129b is disposed inwardly from the second side edge 122 of the central main body portion 125. This inward disposition of the first side wing portion 129a and the second side wing portion 129b permits the inward movement of the interconnecting members 130 as they are being inserted into the major receiving notch 180 so as to not block such inward movement.
The primary beams 120 further comprise a plurality of connector tabs 190 interconnecting the first side wing portion 129a and the second side wing portion 129b to the central main body portion 125 of the primary beam 120. Also, as is best seen in
As seen in
The interconnecting members 130 are elongate and are shown in the first illustrated embodiment as being horizontally oriented to form the metal skeleton 100. The interconnecting members 130 each have a major axis “C” defining the orientation of its length “LI” and a minor axis “D” defining the orientation of its width “WI” (see
As can be readily seen in
Further, in the first illustrated embodiment, and as best seen in
As discussed briefly above, the present invention also comprises a plurality of metal wall forms 150, as can be best seen in
The metal wall forms 150 are in this manner supported by the primary beams 120 of the metal skeleton 100, and act as wall forms when in place on the upwardly projecting hooks 194, 194a, 194b. The metal wall forms 150 can be removed from the metal skeleton 100 by lifting the metal wall forms 150 off the upwardly projecting hooks 194, 194a, 194b.
Alternatively, the metal wall forms 150 remain in place on the metal skeleton 100 after pouring and curing of the concrete therebetween (as shown in
Reference will now be made to
As illustrated, the primary beams 120 are oriented generally vertically and the interconnecting members 130 are oriented generally horizontally. It has been found that during assembly of the metal skeleton 100, it is useful to arrange a plurality of primary beams 120 on the ground in generally parallel spaced-apart relation, with the spacing being about the same as the distance between adjacent minor notches 138 on the interconnecting members 130. The primary beams 120 can be oriented on the ground or other flat surface such that the first side edge 121 of each of the primary beams 120 is facing upwardly, and therefore is readily accessible, and the second side edge 122 of each of the primary beams 120 is facing downwardly in contacting the ground.
The interconnecting members 130 can then be placed horizontally on the primary beams 120, so as to be oriented perpendicularly to the primary beams 120, and adjacent the co-operating receiving portions 180 formed on the first side edges 121 of the primary beams 120. Next, the interconnecting members 130 can then interlocked with co-operating receiving portions 180 formed on the first side edges 121 the primary beams 120 to secure the primary beams 120 and the interconnecting members 130 one to the other without supplemental fastening means. The partially assembled interlocked primary beams 120 and interconnecting members 130 can then be tilted upwardly as a unit, and the interconnecting members 130 can then be introduced to the co-operating receiving portions 180 along the second side edges of the primary beams 120, and then can be interlocked with the co-operating receiving portions 180 on the second side edge 122 of each of the primary beams 120.
It should also be noted that once the metal skeleton 100 is in an upright orientation, or in other words where the metal skeleton 100 is generally vertically oriented, the metal wall forms 150 can be positioned and supported thereon as previously described.
The above-described method of assembling of the metal skeleton 100 is merely one example of the possible steps used in the assembly of the metal skeleton 100. Other permutations of the assembly steps, or additional assembly steps or alternative assembly steps, can readily be used.
As best seen in
It can therefore readily be seen that once each selected interconnecting member 130 is fully inserted into the wide rear portion 184 of the major receiving notches 180 and is thereafter locked in place by the locking clip 188, that the interconnecting members 130 each interlock with the co-operating receiving portions 180, specifically the major receiving notches 180, formed on the primary beams 120 to thereby secure the primary beams 120 and the interconnecting members 130 one to the other without supplemental fastening means. To this end, and more specifically, as can be seen on an overall basis in
The interconnecting members 130 interlock with co-operating receiving portions 180 formed on the primary beams 120 to secure the primary beams 120 and the interconnecting members 130 one to the other without supplemental fastening means, such as welding or threaded fasteners, and also with the plurality of interconnecting members 130 having both their major axis “C” and their minor axis “D” oriented after assembly substantially transversely to the major axis “A” of the primary beams 120. Further, the interconnecting members 130 interlock with co-operating receiving portions 180, as aforesaid, such that the primary beams 120 are oriented with their major axis “A” arranged after assembly substantially parallel one to the next and with their minor axis “B” arranged substantially transverse to the medial plane “M” (see
It should be understood that the metal skeleton 100 according to the present may be assembled in a sequential manner, or in other words, not all of the primary beams 120 and the interconnecting members 130 are interlocked at the same time. More specifically, the assembly of the metal skeleton 100 may happen as follows. A primary beam 120 is put in place at the assembly site, in a vertical orientation, or lying flat on the ground or other work surface, to be later raised when sections of the metal skeleton 100 are assembled, and an interconnecting member 130 is interlocked to the primary beam 120. Next, another primary beam 120 is put in place in a vertical orientation and the same interconnecting member 130 is interlocked to the second primary beam 120. The second primary beam 120 may be adjacent the first primary beam 120 or alternatively may be interlocked with the interconnecting member 130 at the opposite other end of the interconnecting member 130, or anywhere in between. Typically, once two, or perhaps three or four, primary beams 120 are put in place and interlocked with the interconnecting member 130, whereafter more interconnecting members are interlocked with the selected primary beams 120. This process continues until all of the primary beams 120 and interconnecting members 130 are in place and interlocked together, to thereby assemble a section of the metal skeleton 100. The preferable method of assembling the metal skeleton 100 is to introduce the primary beams 120 and the interconnecting members 130 one to another, and then interlock the primary beams 120 and the interconnecting members 130, as described above, and subsequently raise the metal skeleton 100 in sections, either manually, or with the use of a crane or the like, much as is done in the conventional wood framing of residential home construction. The interconnecting members 130 of one section may then be interconnected to the end ones of the primary beams 120 of the adjacent section to join the previously assembled sections together.
Reference will now be made to
It is contemplated that the second illustrated embodiment metal skeleton 200 according to the present invention could be used with conventional wall forms, which are typically made from wood, or with any other suitable type of wall forms, including the specific metal wall forms disclosed in the present specification and drawings.
Further, the second illustrated embodiment metal skeleton 200 is similar to the first illustrated embodiment metal skeleton 100, except that in the second illustrated embodiment metal skeleton 200, the primary beams 220 (shown separately in
In brief, and as can readily be seen in
The above terms have been selected according to the orientation of the assembled metal skeleton 200 as shown in the Figures, with the primary beams 220 being oriented generally vertically, the first interconnecting members 230 being oriented generally horizontally, the second interconnecting members 240 being oriented generally horizontally, the third interconnecting members 245 being oriented generally horizontally, the metal wall forms 250 being oriented generally vertically. The second illustrated embodiment metal skeleton 200 according to the present invention will now be described in greater detail below.
The metal skeleton 200 comprises a plurality of the primary beams 220, with each of the primary beams 220 having a central main body portion 225 with a major axis “N” (see
The primary beams 220 also each preferably have depth indicators 228 extending horizontally outwardly beyond the first 221 and second 222 side edges of the primary beams 220. Each depth indicator 228 is narrower at its outer end and wider at its base, but could be any other suitable and useful shape. The depth indicators 228 extend outwardly a pre-determined distance from the first side edge 221 and the second side edge 222 of the central main body portion 225 of the primary beam 220 to indicate when the concrete structure has been formed to an appropriate minimum thickness; in other words formed to an appropriate horizontal thickness in the case of a concrete wall structure 110w, or formed to the appropriate vertical thickness in the case of a concrete floor structure that the depth indicators 228 are not visible in the respective exposed surface of the poured/cured concrete. As with the first embodiment, this feature is provided for assuring quality control and safety by ensuring that the concrete structure is of sufficient thickness and strength along the length of each of the primary beams 220.
One of the advantages of the present invention is that all of the components making up the metal skeleton 200, including the primary beams 220, the first interconnecting members 230, the second interconnecting members 240, the third interconnecting members 245, and the metal wall forms 250, are fabricated from substantially flat sheets of metal material 270, as is best seen in
It should be noted that the first interconnecting members 230 are substantially different from the second interconnecting members 240 and the third interconnecting members 245. More particularly, the first interconnecting members 230 are initially cut from the flat sheets of metal material 270 and are bent after removal from said sheets 270 into a “U”-shape, as can be best seen in
The first plurality of interconnecting members 230 each have a major axis “P” defining the orientation of its length and a minor axis “Q” defining the orientation of its width. The minor axis “Q” is transverse to the major axis “P”.
The first interconnecting members 230 interlock with co-operating receiving portions 280 formed on the primary beams 230 to secure the primary beams 220 and the interconnecting members, namely the first interconnecting members 230, the second interconnecting members 240, and the third interconnecting members 245, one to the other without the necessity of supplemental fastening means, and with the plurality of interconnecting members 230, 240, 245 each having both their major axis “P” and their minor axis “Q” oriented substantially transversely to the major axis “N” of the central main body portion 225 of the primary beams 220. As can be readily seen in
The metal skeleton 200 further comprises weight-bearing tabs 290 extending horizontally outwardly beyond the first side edges 221 and the second side edges 222 of the primary beams 220 in parallel relation to the minor axis “G” of the primary beams 220. The weight-bearing tabs 290 are dimensioned and otherwise adapted for retaining the metal wall forms 250 in weight-supported relation thereon during the forming of the concrete structure.
As can be seen in
The outer frangible portion 294 has at least one wedge-receiving aperture 298 therein. Each at least one wedge-receiving aperture 298 is dimensioned and otherwise adapted to receives a securing wedge 299 therein to hold the metal wall forms 250 in place during the pouring and curing of concrete. Subsequent to the pouring and curing of concrete that is poured into and around the metal skeleton 200 and in between the opposed metal wall forms 250, the securing wedges 299 are removable from the at least one wedge-receiving aperture 298. Once the concrete has fully cured, the wall forms 250 can either be removed from the formed concrete wall structure thus leaving a bare concrete surface as the other wall surface, or can remain in place thus leaving the metal wall forms as the outer wall surface.
Optionally, there can be provided on the metal wall forms 250 inwardly oriented projections (not specifically shown, but analogous to the inwardly oriented projections 158′ on the metal wall forms 150 illustrated in
Whether the metal wall forms 250 remain in place or not, the outer frangible portions 294 of the weight-bearing tabs 290 may be broken off at the pair of opposed “V”-notches 296 so as to not to project in a hazardous manner from the finished wall or floor structure, as is shown in dashed lining in
As may readily be seen with reference to
The primary beams 220 and the interconnecting members 230 may optionally be substantially pre-cut, as through use of a CNC laser cutter, so as to be retained in place by small frangible connection points 227 left uncut in the substantially flat formed sheets of metal material 272, as can be seen in
Preferably, the primary beams 220 and the plurality of interconnecting members 230, and any other components that might be formed in the substantially flat sheets of metal material 270 are cut using a CNC laser in order to provide extreme accuracy, and to accommodate the cutting of relatively complicated parts to close tolerances on a commercial scale.
Further, as can readily be seen in
Also, as can readily be seen in
Reference will now be made to
It is contemplated that the third illustrated embodiment metal skeleton 300 according to the present invention could be used with conventional floor forms, which are typically made from wood and typically comprise sheets of plywood or the like disposed below the metal skeleton, or any other suitable type of floor forms. The third illustrated embodiment metal skeleton 300 according to the present invention could be used with conventional wall forms, which are typically made from wood, or any other suitable type of wall forms, including the specific wall forms disclosed in the present specification and drawings.
The third illustrated embodiment metal skeleton 300 is similar to the first illustrated embodiment metal skeleton 100 and the second illustrated embodiment metal skeleton 100 except that in the third illustrated embodiment metal skeleton 300, the primary beams 320 (shown separately in
In brief, as can readily be seen in the Figures, the first illustrated embodiment metal skeleton 300 comprises a plurality of primary beams 320, first and second end-contacting members 360, and a plurality of interconnecting members 330. The plurality of primary beams 320 each have a first side edge 321, a second side edge 322, a first end 323 and a second end 324, and receiving portions 380, and receiving slots 323a,324a. The first and second end-contacting members 360 each have a first side edge 361, a second side edge 362, a first end 363, a second end 364, and securing flanges 365. The plurality of interconnecting members 330 each has a first side edge 331 and a second side edge 332, a first end 333 a second end 334.
The above terms have been selected according to the orientation of the assembled metal skeleton 300 as shown in the Figures, particularly
The metal skeleton 300 comprises a plurality of primary beams 320, with each of the primary beams 320 having a central main body portion 325 with a major axis “R” defining the orientation of the length of the central main body portion 325 and a minor axis “S” defining the orientation of the width of the central main body portion 325. The minor axis “S” is transverse to the major axis “R”. Each of the plurality of primary beams 320 is formed from a substantially flat sheet of metal material, in the same general manner as described above in relation to the sheets of metal material shown for the first and second illustrated embodiments.
The first end-contacting members 360 is secured to the primary beams 320 at the first end 323 thereof by way of insertion of the securing flanges 365 of the first end-contacting members 360 into the receiving slots 323a at the first end 323 of the primary beams 320. Similarly, the second end-contacting member 360 is secured to the primary beams 320 at the second end 324 thereof by way of insertion of the securing flanges 365 into the receiving slots 324a at the second end 324 of the primary beams 320.
The first plurality of interconnecting members 330 each have a major axis “T” defining the orientation of its length and a minor axis “U” defining the orientation of its width. The minor axis “U” is transverse to the major axis “T”.
The interconnecting members 330 interlock with co-operating receiving tab portions 380 formed on the primary beams 320 to secure the primary beams 320 and the interconnecting members 330 one to the other without supplemental fastening means, and with the plurality of interconnecting members 330 having both their major axis “T” and their minor axis “U” oriented substantially transversely to the major axis “R” of the central main body portion 325 of the primary beams 320. As can be readily seen in
According to another aspect of the third illustrated embodiment 300, the metal skeleton 300 can be oriented vertically, so as to form a wall. In this case, metal wall forms 350 can be used, as is shown in
As can be seen in
As with the earlier embodiments describe hereinabove, Optionally, there can be provided on the metal wall forms 250 inwardly oriented projections (not specifically shown, but analogous to the inwardly oriented projections 158′ on the metal wall forms 150 illustrated in
The present invention, with non-limiting reference to the first, second or third illustrated embodiments described above, also teaches a method of producing a flat-shippable three-dimensional concrete reinforcement skeleton 100 for assembly at a site that may be remote from the production site 103 without the need for supplemental fastening means, such as, for example, clips, clamps, threaded fasteners, and/or welding.
More specifically, the metal skeleton 100 may be assembled at either the construction site 104, as shown in
In this regards,
More specifically, the method comprises the following steps.
As indicated by step “M1” in
Also “M1” may further comprise forming an open space 186 that is disposed adjacent the first throat edge 181a of the narrow throat portion 182 of the major receiving notches 180 so as to define a locking clip 188 between the narrow throat portion 182 and the open space 186.
Preferably, but not necessarily, the primary beams 120 and the interconnecting members 130 are each formed using a laser cutter. The laser cutter would typically be a CNC laser cutter, but any other suitable laser cutter could be used. Any other suitable means of forming the primary beams 120 and the interconnecting members 130 in the blank flat sheets of metal material 170 can be used to thereby form the substantially flat formed sheets of metal material 172 may be used.
When such a CNC laser cutter is used, all of the forming actions of step M1 may be carried out with considerable accuracy and dispatch in one pass of the laser cutter over each blank flat sheet of metal material 170.
Optionally, but not essentially, as indicated by step “M2” in
As indicated by step “M3” in
Next, as indicated by step “M4” in
Subsequent to the shipping containers 108 arriving at the assembly site, the next step, as indicated by step “M5” in
As indicated by step “M6” in
Next, as also indicated in step “M6” of
As indicated by step “M7” in
In yet another aspect, the present invention provides a method of providing the components of the flat-shippable three-dimensional concrete reinforcement skeleton 110 for assembly at a site remote from the production site 103, such as the construction site 104, without the need of supplemental cutting or fastening means. The method includes forming from one or more substantially flat sheets of metal material 170 the first plurality of primary beams 120 and the second plurality of interconnecting members 130 substantially pre-cut therein so as to be retained in place within the substantially flat formed sheets of metal material 172 by frangible connection points 127 left uncut in the remainder of the substantially flat formed sheets of metal material 172, with each of the primary beams 120 having a third plurality of mechanical interlocking means integrally formed thereon adjacent lateral edges of the primary beams 120. The third plurality of mechanical interlocking means comprises forming the major receiving notches 180, which are discussed in detail above. Also, the method includes loading the substantially flat formed sheets of metal material 172 into one or more shipping containers 108. Further, the method includes relocating the one or more shipping containers 108 to the assembly site.
In yet another aspect, the present invention provides a method of assembling a metal skeleton 120 from a plurality of substantially flat formed sheets of metal material 172 having a plurality of primary beams 120 and a plurality of interconnecting members 130 substantially pre-cut therein so as to be retained in place by frangible connection points 127 left uncut in the substantially flat formed sheets of metal material 172 to thereby be subsequently separable from the remainder 171 of the corresponding one of the substantially flat formed sheets of metal material 172 after shipping to an assembly site, such as the construction site 104, for the reinforcement of a concrete structure, such as the concrete wall structure 110w, to be formed therearound. The method includes separating the plurality of primary beams 120 and the plurality of interconnecting members 130 from the remainder 171 of the corresponding one of the substantially flat formed sheets of metal material 172. The method further includes interlocking the plurality of interconnecting members 130 with co-operating receiving portions 180, specifically the major receiving notches 180, formed on the primary beams 120, to thereby secure the primary beams 120 and the interconnecting members 130 one to the other without supplemental fastening means, to thereby assemble the metal skeleton 100.
The present invention, with non-limiting reference to the first, second and third illustrated embodiments described above, also teaches, according to another aspect, a kit 107 for assembling a metal skeleton 100 for the reinforcement of a concrete structure, such as the concrete wall structure 110w, to be formed therearound. The kit 107 comprises a plurality of primary beams 120, each having the central main body portion 125 with the major axis “A” defining the orientation of the length of the central main body portion 125 and the minor axis “B” defining the orientation of the width “WC” of the central main body portion 125, the minor axis “B” being transverse to the major axis “A”. Further, each of the plurality of primary beams 120 is formed from a substantially flat sheet of metal material 170 and presented in a correspondingly substantially flat formed sheet of metal material 172.
The plurality of interconnecting members 130 each have a major axis “C” defining the orientation of its length and a minor axis “D” defining the orientation of its width. The minor axis “D” is transverse to the major axis “C”.
The interconnecting members 130 are dimensioned and otherwise adapted to interlock with co-operating receiving portions 180, major receiving notches 180, integrally formed on the primary beams 120 to secure the primary beams 120 and the interconnecting members 130 one to the other without supplemental fastening means, as described above. The plurality of interconnecting members 130 each have both their major axis “C” and their minor axis “D” oriented substantially transversely to the major axis “A” of the central main body portion 125 of the primary beams 120 upon assembly of the metal skeleton 100.
The kit 107 may additionally comprise a container, such as a shipping container 108 (see
It is also possible and within the scope of the present aspect of the invention to produce the primary beams 120, the interconnecting members 130 and any other components of the metal skeleton 100, as separate components completely separated from the metal sheets 170 from which they were formed, and also to store them as separate components in a shipping container, including as a lockable shipping container 108.
According to another aspect of the present invention, the kit 107 is used for assembling a metal skeleton 100 for the reinforcement of a concrete structure, such as, by way of non-limiting example, the previously described concrete wall structure 110w, to be formed therearound. In such case, the kit 107 comprises a plurality of substantially flat formed sheets of metal material 172 having a plurality of primary beams 120 and plurality of interconnecting members 130 substantially pre-cut therein so as to be retained in place by frangible connection points 127 left uncut in the substantially flat formed sheets of metal material 172, so as to be subsequently separable from the remainder 171 of the corresponding one of the substantially flat formed sheets of metal material 172 after shipping to an assembly site. The interconnecting members 130 interlock with co-operating receiving portions 180 formed on the primary beams 120 to thereby secure the primary beams 120 and the interconnecting members 130 one to the other without supplemental fastening means.
Other variations are within the spirit of the present invention. Thus, while the invention is susceptible to various modifications and alternative constructions without departing from the spirit of the inventions disclosed and claimed, only a limited number of embodiments thereof have been illustrated in the drawings and have been described above in detail. It should be understood, however, that there is no intention to limit the invention to the specific form or forms disclosed, but on the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention, as defined in the appended claims.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. The term “connected” is to be construed as partly or wholly contained within, attached to, or joined together, even if there is something intervening. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. The use of any and all examples, or exemplary language (e.g., “such as”, or, “for example”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Various embodiments of this invention are described hereinabove. Routine variations of these embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
| Number | Date | Country | |
|---|---|---|---|
| 62583629 | Nov 2017 | US |
