Patent Application
20210404183
Not Applicable
Not Applicable
Not Applicable
This invention relates to improvements in building construction. More particularly, the present modular wall sections with electrical, plumbing and structural ground connectors are used to construct a building that is quickly assembled on a foundation.
The construction of buildings has progressed from caves to more modern construction, but the need to construct more efficiently and more rapidly continues to be a high priority. After a foundation is poured and set most methods of construction include cutting and securing 2×4 lumber at 16 inches on-center and then drilling holes in the lumber to accommodate electrical and plumbing connections. The plumbing and electrical wiring is then placed though the holes to make the connections. Both the cutting and nailing of the studs along with the wiring and plumbing is very labor intensive and adds a great deal of cost and time to time to construct a building or house. While some houses are custom built, the majority of houses are similar. There is a need to pre-fab some house walls so they can be quickly connected and secured to both accelerate the construction process and reduce the overall cost of the construction.
A number of patents and or publications have been made to address these issues. Exemplary examples of patents and or publication that try to address this/these problem(s) are identified and discussed below.
U.S. Pat. No. 5,634,315 issued on Jun. 3, 1997 to Kiyomi Toya and is titled Building Method of Construction. This patent discloses constructing a building by forming a foundation on a ground surface, positioning a plurality of upright supports to project upwardly from the foundation and securing cladding panels to said upright supports to extend upwardly from the foundation, positioning a plurality of preformed composite assemblies each having a pair of composite boards and forming a building by utilizing the plurality of preformed composite assemblies disposed adjacent to each other for forming the walls, the floor and the ceiling of the building. This is a typical construction method and does not include pre-fabricated wall section with installed plumbing and electrical conduit.
U.S. Pat. No. 6,256,960 issued on Jul. 10, 2001 to Frank J. Babcock et al., and is titled Modular Building Construction and Components Thereof. This patent discloses a modular building construction and components thereof. A foundation for a building includes anchor bolts extending around its periphery. A metal lower track is installed over the anchor bolts and secured thereto with nuts and rod couplers. Elongated connector rods are threaded onto the upper ends of the couplers. Pre-manufactured modular wall panels, integrally molded with a metal stud along a first lateral edge and a complementary recess along a second lateral edge, are successively installed in the track. A first panel is installed with an open side of the stud surrounding the connector rod. The second, adjacent panel is installed with its second lateral edge facing the stud. The two panels are slid together to surround and enclose the connector rod. In this patent electricity and plumbing is installed by removing the wall skin.
U.S. Pat. No. 7,062,885 issued on Jun. 20, 2006 to George H. Dickenson Jr. and is titled Foundation Wall, Construction Kit and Method. This patent discloses a kit is generally comprised of prefabricated modular components and hardware, which can be used for easily and efficiently constructing a foundation for a moderately sized building such as a house. In another aspect, the present invention kit can be seen as embodying a variety of optional modular components that can be used for constructing steps, landings, and/or decks. While this kit is for home construction, it is limited to exterior walls where there is no electrical or plumbing.
What is needed is a pre-fabricated wall section(s) that can be quickly joined together to build a building or house. The pre-fabricated wall sections should also include plumbing and electrical connections. The proposed modular wall sections with electrical, plumbing and structural ground connectors provide the solution.
It is an object of the modular wall sections to have sides that are tapered and dovetailed. The dovetails are spaced per structural requirements to reduce the height that one section must be lifted to engage in an adjoining wall section. The taper provides a loose fit when the dovetail starts to enter the dovetail slot and a tight secure engagement as the dovetail tapers at the bottom.
It is another object of the modular wall section to provide nearly completely finished two-sided interior and exterior wall structures, this is due to the ability to install at the factory all electrical and mechanical pathways, final electrical devices including but not limited to plug receptacles, wall switches pre-wired circuit panels, transformers and all end of line electrical trim. The exterior and interior finishes can be completed as the labor-intensive field trade work of installing both high and low voltage electrical conduits and pathways will be eliminated, pulling and landing wires will also be virtually eliminated across the world's construction field sites.
It is another object of the modular wall section for plumbing and or electrical connections to use exothermic chemical reactions on the connections between adjoining wall sections for the electrical and or plumbing connection to be instantly, chemically fused and or welded together manually as they are set into place. An instant electrical connection and circuit is instantly and subsequently created by virtue of a push design. The system is designed to accommodate a continuous flow of electricity/electrons through a permanently bonded system, the electro mech connector includes access into the components housing for both welding leads as well as exothermic chemical reactions to bond the internal electrical wires with pre-loaded electrical two-part housing exothermic cylinders.
It is another object of the modular wall sections to have earthquake or hurricane hold-downs in the footer or bottom plate that aligns and can be secured from the foundation to the wall sections. These hold-downs can be spaced according to the building code of the area where the building or house is being constructed.
It is another object of the modular wall sections to have a lock-in-place feature whereby there is no secondary tools to fasten the wall sections together. The locks can be integrated in the side dovetails and be spring loaded or one-way engagement to quickly lock and secure the modular walls. The installation and locking of the modular walls can be performed without tools other than lifting hoists on unwieldy sections.
It is another object of the modular wall sections for the connection of the wall section to the foundation to have counter flashing at the concrete insert. This prevents water intrusion into the wall section or from under the modular wall. The counter flashing can extend slightly up the side of the modular wall and also provides flashing at the vertical intersection of each wall.
It is another object of the modular wall sections to include a global position sensor (GPS) or similar technology connected to the foundation sleeve so the location and position of each modular wall can be quickly located and placed without requiring an installer to refer to plans as they assembly the building.
It is still another object of the modular wall sections for the modular wall section to have integrated electrical wires (creating a circuit pathway) and/or plumbing piping or conduit. This will minimize the installation for secondary manual operations and the location for electrical and plumbing fixtures can be pre-located along a wall. The actuating in-wall electrical circuits mechanism may include an internal release that actuates the mechanism when the machine wall panel locks into place that automatically releases the actuation electrical connectors which create the electrical circuit.
It is still another object of the modular wall sections for the electrical and/or plumbing connections that join modular walls to be connected and sealed with bonding agents, push, spin lock or frictional lock to provide a secure sealed system/pathway for these utilities where the installer can quickly make connections between the modular walls.
Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components.
It will be readily understood that the components of the present invention, as generally described and illustrated in the drawings herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, as represented in the drawings, is not intended to limit the scope of the invention, but is merely representative of various embodiments of the invention. The illustrated embodiments of the invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
While this technology is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the technology and is not intended to limit the technology to the embodiments illustrated. The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the technology. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
It will be further understood that the terms “comprises,” “comprising,” “includes,” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings with like reference characters.
The outside surface would be typically installed, but a finished interior surface that is covered with drywall or sheetrock could equally be covering one-side of the modular wall section(s) 20. The operation(s) to connect the electrical and plumbing lines together is then performed from the outside of the building or house. From the inside surface the drywall or sheetrock can be spackled textured and painted. An advantage of this type of installation is that the openings for the electrical junction boxes and plumbing can be pre-cut into the drywall or sheetrock.
In this preferred embodiment the modular wall section (s) 20 is 96 inches (or 48 inches) in width to accommodate a common width of drywall or sheetrock, but other widths are contemplated from 16 to 96 inches or larger or per industry standards. It should be understood that the width can also be shorter than 16 inches and longer than 96 inches depending upon the design requirements. This embodiment also shows the middle stud(s) 31 with stud spacing 99 at 16 inches on-center, but can also be 12 or 24 inches depending upon the design requirement(s).
The modular wall section (s) 20 can be constructed with 2×4 or 2×6 header 30, middle studs 31 and footer 33, or other dimensions, again as dictated by the design requirements. The stud members can be from wood, metal or other structurally capable material for the studs. Pre-formed concrete and structural steel wall panels are also embedded with interlocking mechanism shows and described herein. The outside vertical studs have a male side stud 40 with a male dovetail 41 and a female side stud 50 with a complementary female dovetail (not shown in this figure). The opposing dovetails allow the modular wall section(s) 20 to be quickly assembled by lifting a (second) new wall section onto a first secured wall section of the modular wall section(s) 20. It is contemplated that the modular walls can include a side vertical slip correction for a wall-to-wall connection system option. Minor labor and lift are required to set the wall system into place as the vertical channel openings are oriented in such a way as to allow for the required structural strength (Typically 16″ on center). The dovetails can be designed with an optional taper at the base of each connection to tighten the connection as it slides into place. Due to the potential lack of ceiling clearance in the system, the base mechanical lock system can also be utilized on the side edge of the system to eliminate the need to lift the panel system when necessary.
The side have dovetail connections that are tapered. The dovetails are spaced to have a gap 42 of between 3 and 18 inches on center to reduce the lift spacing 98 height that one section must be lifted to engage in an adjoining wall section(s), but can be greater than 18 inches or less than 3 inches, the distance between the dovetail connections can be adjusted to meet structural requirements and/or local building code requirements. The taper provides a loose fit when the dovetail starts to enter the dovetail slot and a tight secure engagement as the dovetail tapers at the bottom. The bottom of the modular wall section(s) 20 shows a bottom flashing 70 with hold-down tubes 71 for earthquake or hurricane protection. There can be a mechanical pressure actuating snap lock connection at the base of the wall system which allows for a quick lock in place installation process. The bottom flashing 70 or sill plate and hold-down tubes 71 will be shown and described in other figures herein.
The vertical studs are shown with a cut-out 32 where the plumbing tube 64 passes through the modular wall section(s) 20. While this example shows just a single plumbing tube 64 the modular wall section(s) 20 would have a hot water line a cold-water line and a line for electrical connections. In this figure only one plumbing tube 64 line is shown for clarity and simplicity. There is a first tube 60 and an end coupler 63 that connects to adjacent modular wall section(s) 20 A side tube 61 connects to the plumbing tube 64 for a rough plumbing connection for a sink, toilet, shower, hose bib or the like. An expandable couple 62 allows the plumbing tube 64 to be expanded or contracted to connect to other modular wall section(s) 20.
The electrical conduit(s) 104/105 and/or plumbing connections that join modular walls to be connected and sealed with bonding agents, push, spin lock or frictional lock to provide a secure sealed system where the installer can quickly make connections between the modular walls. This figure shows electrical conduits at both the outlet height 104 and at a switch height 105. The connections are contemplated to be a one-way locking or rotation system as a cam or tab that bends and flexes back into position after the wall section is fully inserted but may also include an access door or hole to release the lock to remove the wall section.
The wall being installed is simply lifted onto the installed machine wall 22 to engage the dovetail surfaces. While only one dovetail connection is shown, multiple dovetail connections can exist along the height of the wall edge to provide multiple securing locations based upon building code. It is also contemplated to include a lateral adjustment track is indicated in image 18. This allow the male stud to be adjustable, if necessary, to line the male and female studs up when needed.
Middle stud(s) 31 are seen in these views inside of the male side stud 40 with the male dovetail 41. The cut-out 32 provides clearance for plumbing tube 64 and/or electrical tubes that can run through the modular wall(s). The end coupler 63 can extend 97 to connect plumbing and/or electrical to multiple modular walls. A detailed view of the electrical connection is shown in other embodiments herein.
An advantage of counter flashing vertical legs that are built into the subsurface or foundation is for a waterproofing process at the base of the wall system, there is a vertical lip built into the subsurface locking channel that allows for a full counter flashed connection when the wall panel that is set in place.
Wall system has built in sensors for unmanned, autonomous or remotely controlled delivery systems, it allows for 2-point fulcrum setting capabilities (wall can be set initially manually). Each panel can have a GPS sensor and/or a RFID tag to identify the panel and where each panel is positioned, located and secured. This will eliminate assembly errors and will allow the building or house to quickly assembled with high precision.
While the panels are shown as solid wall panels it is contemplated that the wall panels can be fabricated and installed with openings for windows and/or doors. It is also contemplated that the window frames or window frame with glass can be installed or pre-installed on the machine walls 20.
When the machine walls are being assembled, the expanding wedge 36 is inserted 95 through the central opening 74 and is expanded 94 to pull and set the machine walls in the foundation. The expanding wedge 36 can be expanded by creating tension 93 as a plug 35 is withdrawn into the expanding wedge 36. It is also contemplated that the expanding wedge 36 can be automatically expanded with internal springs when the plug contacts the bottom of the socket. This does not require any tools for operation and the springs will both pull the expanding wedge 36 into the socket 77 and any downward force on the rod 34 will further secure the expanding wedge 36 within the socket 77. It is contemplated that the machine walls can be assembled with robots or automation.
The male post 120 extends through a hole from the bottom of the footer 33 on the machine wall section(s). A flange 122 holds the footer 33 into the receiver 80. A hole 123 in the flange 122 is the interior of the cylindrical wall 121 of the tube that forms the male post 120. The tube receiver can also be square, rectangular and composed of other practical shapes. The male post 120 has locking teeth 124 that engage in the ledges 86 within the tube 87. The teeth 124 exist on a hinge 126 that allows the teeth 124 to flex and move 88 in and out 89 as the teeth ratch into the ledges 86. While a particular number of teeth 124 and ledges 86 are shown, a different number of teeth 124 and ledges 86 can be used along with locating the teeth 124 and ledges in multiple locations or locating the ledges 86 around the interior of the tube 87. The top of the flange 122 can be “struck” or pressure applied to drive and lock the machine wall onto the receiver 80. The locking teeth 124 components is further shown with a lever 125 that can be rotated or moved 88 to release the teeth 124 from the ledges 86 so the machine wall can be dis-assembled, repositioned or moved.
The male post 120 extends through a hole from the bottom of the footer 33 on the machine wall section(s). A flange 122 holds the footer 33 into the receiver 80. A hole 123 in the flange 122 is the interior of the cylindrical wall 121 of the tube that forms the male post 120. The tube receiver can also be square, rectangular and composed of other practical shapes. The male post 120 has locking teeth 124 that engage in the ledges 86 within the tube 87. The teeth 124 exist on a hinge 126 that allows the teeth 124 to flex and move 88 in and out 89 as the teeth ratch into the ledges 86. While a particular number of teeth 124 and ledges 86 are shown, a different number of teeth 124 and ledges 86 can be used along with locating the teeth 124 and ledges in multiple locations or locating the ledges 86 around the interior of the tube 87. The top of the flange 122 can be “struck” or pressure applied to drive and lock the machine wall onto the receiver 80. The locking teeth 124 components is further shown with a lever 125 that can be rotated or moved 88 to release the teeth 124 from the ledges 86 so the machine wall can be dis-assembled, repositioned or moved.
With the knife blade box 130 the conductors 101 enter a rotatable barrel 133 having an insulator 135 where each conductor 101 connects to a separate blade(s) 134. The barrel 133 rotated 103 to move the blade(s) 134 from a vertical position to a horizontal position. A spring 137 biases the rotation of the blades 134 to maintain the position of the blades 134. In the horizontal position the blades (134) engage into their respective break jaw 112-114. A key 136 or shaft 131 is inserted into the barrel 133 to turn 102 the shaft 131 and or barrel 133 with a key to engage (or disengage) the electrical connection between adjacent machine walls.
This embodiment shows male/female box(s) 150 two rows of connectors with one column of four of male prong posts 152 on one side and one column of four female prong receivers 151. Each wall adjoining section has its own set of male/female box(s) 150 that are configured to mate when the wall sections are vertically slid into position. The male prong posts 152 engage into the female prong receivers 151 to make electrical connection. Insulators 162 are placed between the connectors to isolate power between different conductors 101.
As the male prong post(s) 152 in the electrical housing is guided into place, it makes positive contact to the female prong receiver(s) 151. Electrical components are assured due to the track built into the housing, additionally once it locks into place, it cannot be removed due to one way locking mechanisms, thus creating a permanent installation.
In some contemplated embodiments the male prong posts 152 and female prong receivers 151 are fused together with pre solder packets for preheat and fusion and contact points using an exothermic reactive two part reactive design includes pre-loaded high temperature reactive copper oxide pack located in the base of the heat reaction cylinder and an opposing pre-loaded pack of aluminum power with priming contact igniter on the opposing electrical contact prong (or blade), when they come into contact, the two parts ignite and the exothermic reaction occurs, which fuses the electrical prongs (or blades) together through the exothermic welding reactive process (which creates electrical connections mainly between copper to copper or copper to steel) the heat generated from this reaction is vented through the housing tubes of the assemblies. The electrical housing 150 features sections that are reinforced as needed for high temperature resistant with various materials including but not limited to graphite to withstand the effect of both high temperatures generated from welding but also from generated exothermic reactions.
Heat syncs have been integrated into the design & electrical connection housings 150 to offset the height temperatures and melting characteristics to protect the wire and housing assemblies, they dissipate heat from either the welding, exothermic or chemical bonding process prior to heating the plastic housing surrounding the associated commercial wire feeding into the housing systems. Heat vent tubes 160 provide a path to vent the exhaust gases out of the male/female box(s) 150 and out an exhaust pipe 161 that is later removed from the wall, thereby leaving only a small hole in the wall that is filled when the joint between the wall is plastered. While this is shown on the electrical connections it can also apply to water supply plumbing and the water sewer lines and gas lines.
Thus, specific embodiments of modular walls used to construct a building have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.
Not Applicable.
This application claims the benefit of PCT application PCT/US21/26490 filed Apr. 8, 2021 that claims priority to Utility application Ser. No. 17/168,890 filed Feb. 5, 2021 that claims priority to Provisional Application Ser. No. 62/971,366 filed Feb. 7, 2020 and Provisional Application Ser. No. 62/980,420 filed Feb. 23, 2020 the entire contents of which is hereby expressly incorporated by reference herein.
| Number | Date | Country | |
|---|---|---|---|
| 62980420 | Feb 2020 | US | |
| 62971366 | Feb 2020 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/US21/26490 | Apr 2021 | US |
| Child | 17469121 | US | |
| Parent | 17168890 | Feb 2021 | US |
| Child | PCT/US21/26490 | US |
