Patent Grant
10597881
The present invention is directed to a wall system that incorporates a series of panel assemblies, which may be quickly and easily constructed into structural (multi-story) walls. Specifically, the present invention is directed to a less expensive and more efficient system of exterior panel assemblies, which may be constructed into exterior walls of a structure without the need for additional exterior surfacing.
Construction of exterior structural walls is often a very labor intensive, time consuming and complex process, requiring a series of construction phases. For example, in most traditional construction settings, a jobsite must be prepared with footings and appropriate reinforcements, then a series of ply-wood molds or forms are positioned to receive concrete. These ply-wood molds define a shape of the concrete and require extensive amounts of additional support beams and reinforcements to keep the molds in place under the pressure and weight of the concrete that is introduced into the molded area. As can be appreciated, these reinforcement posts are typically angled and take up a significant amount of additional space and require significant amounts of added lumber and lumber costs. Thereafter, once the concrete has hardened, these wooden molds and supports must be removed, and due to the porous and breakable nature of the wood and the inability to clean the wood, they are discarded the expenditure being attributed to a sunk cost of the molding process. Thereafter, once the molds are removed, the normal setting of the concrete invariably results in the formation of air pockets or deformations which, while in most cases not impacting the structural integrity of the wall, do provide an unappealing aesthetic for most applications. As a result, additional surfacing such as stucco or the addition of siding is required, adding yet another cost and phase to the process. Further, because it is solely the molded concrete and interior reinforcements that make up the structural integrity of the wall, these structural walls are typically made up of a larger thickness to meet the needed demands, thereby requiring more concrete and reducing interior space.
Conversely, prefabricated construction techniques often include the assembly of components of a structure in a controlled plant and the transportation of the assembled components to a jobsite to be constructed. As opposed to traditional construction techniques, prefabrication provides a host of benefits such as shorter construction times, cost effectiveness, etc. A problem that exists with traditional prefabricated molded wall panels, however, involves the heavy weight that makes it expensive and difficult to transport, manipulate and tie in the panels without the use of heavy equipment. Further, transport can introduce flaws or cracks and results in points of potential weakness as seams are formed between the wall panels and vertical structural elements such as corner posts.
Accordingly, it would be beneficial to develop a system that builds upon the benefits of an efficient wall system by eliminating the need for complex, costly and wasteful wood molding and reinforcement, while also addressing other needs felt in the art, by providing generally lightweight panel assemblies that may be prefabricated, or that may be assembled quickly and efficiently at the jobsite, and used to act as concrete forms which substantially remain in place as integral parts of structural walls. The panel assemblies may be integrally formed with columns, tie beams, base tracks, etc. in a manner that provides added strength in a smaller form factor and provides a finished appearance that does not require additional surfacing. Other benefits of the present invention will be illuminated in the sections below.
The present invention is directed toward a wall system that incorporates the use of panel assemblies which may be quickly and easily assembled into structural interior walls. Each panel assembly may be constructed from two panel members disposed in spaced relation to each other and connected via a plurality of connecting members which can be assembled at the jobsite or pre-assembled in the factory. As discussed in further detail below, the connecting members may be roll-formed steel “U” shaped structural channels or steel plates. In addition, the present invention may include a base member which comprises an elongated structural channel acting as a template that can be disposed along and affixed to, for example, a concrete slab of which the present invention is to be erected. The base member may be a “U” shaped steel track channel deployed longitudinally along a concrete slab including apertures that act as a template for unskilled laborers to set steel dowels, reinforcing steel, etc. through the apertures to the concrete slab.
End-users may include reinforcing steel rebar, steel dowels, etc. for enhanced strength to the invention. Thus, steel rebar may extend the length of the panel assembly and into an aperture of the base member. The reinforcing steel rebar may be placed between interconnected panel members and extend the length thereof and extend through the base member aperture to allow concrete to be poured after this pre-set construction is completed. As such, steel rebar, etc., may be connected to the concrete slab for additional support to the structure. In another embodiment, a steel dowel (e.g., #5 dowel) may be connected and extend up from the concrete slab through an aperture of the base member and be tied to steel rebar for additional support to the structure.
Furthermore, this assembly is less expensive and less time consuming relative to traditional construction methods. The present invention provides a superior wall construction in several ways. For example, in traditional construction methods, wood forms are generally used at jobsites to cast concrete, but are usually thrown away after just one time when the concrete dries. In addition, when the wood forms are removed they rip away pieces of concrete with them, and as such take additional time and concrete to re-patch such areas. However, the interconnected panel assemblies of the present invention are capable of acting as permanent concrete forms which remain in place and serve as an integral part of the structure. Thus, the present invention is less expensive and more efficient than a traditional exterior wall construction. Further, the edges of the permanent concrete forms may be covered with compound without the need to apply stucco thereon.
In addition, the panel assemblies of the present invention are capable of being manufactured in a controlled environment. This dispenses with the need to perform inspections on-site, which can cause delays. Thus, the present invention is much quicker and less expensive than a traditional exterior wall construction. Furthermore, the factory construction is particularly amenable to template-based construction lending to more uniformity between panel assemblies relative to traditional construction methods.
Further, the panel members are capable of being made from lightweight and less expensive materials, such as fiber cement, magnesium sulfate, magnesium oxide, lightweight cement, wall paneling, etc. which also provide for lightweight walls which are easy to handle and assemble, but also provide strength to prevent shearing and/or cracking as is the case of walls constructed of concrete blocks, and other materials. These panels are also intended to remain in place and provide a finished appearance to the completed wall structure.
One or more panel assemblies may be deployed as exterior wall segments as desired. The above-mentioned plurality of connecting members also serve as interconnecting means to panel assemblies which facilitate the quick and easy erection process of the exterior walls. The base member which comprises an elongated “U” shaped structural channel acting as a template can be disposed along and affixed to, for example, a concrete slab of which the present invention is to be erected. The connecting U-shaped channels and steel plate members may extend the length of the panel member to rest on the foundation concrete slab or be disposed on or within the channel of the base member. The base member can facilitate erection of a plurality of panel assemblies into an exterior wall structure. Further, the base member and connecting members act to hold the panel assemblies in place, preventing the panel assemblies from moving.
The base member may include one or more operative features to facilitate a secure retention to the concrete slab. For example, the base member may include a plurality of apertures or pre-punched holes or slots running longitudinally on the surface which abuts the concrete slab. Thus, a structural reinforcement, such as pre-set steel dowels (e.g., 1½ inch) and/or reinforcing bars (“rebar”) may be effectively utilized to pass through the apertures and be secured directly to the concrete slab.
As mentioned above, the panel assembly may be constructed from two panel members disposed in spaced relation and connected via a plurality of connecting members. The panel members are substantially planar, being much larger in length and width than in thickness, and also substantially rigid and moisture resistant so as to not deform under their own weight or the buckling effect of a variety of filler (e.g. concrete) therebetween. In addition, snap ties may be used, but are not required. However, the thickness of the panel members may be increased or decreased, depending upon the desired use and deployment of the system.
Another operative feature of the present invention is the spaced relation of the assembled panel members. The spaced relation may provide an air gap in between the correspondingly disposed panel members in which, for example, concrete or other filler may be disposed in order to further enhance the added strength of the panel assemblies. However, the air gap may also be filled with slate, clay, or other suitable materials readily found at the jobsite. In addition, pre-set wire mesh may be installed on the inner walls of the panel members for added tension and strength. Further, the air gap may also include conduits for electric wiring and/or pre-set plumbing stacks.
It may be desirable to allow users of the present invention to dispose their own desired filler material within the air gap at the jobsite. Connecting members may be disposed at the ends of abutting panel members in order to increase the structural strength of the panel assembly. For example, two panel assemblies may be interconnected, such as by a typical ‘tongue and groove’ connection of two corresponding “U” shaped connecting members which may form a structural channel therebetween, as described in greater detail below.
A connecting member of the present invention is generally an elongate and rigid structure which includes facilities for the secure attachment of panel members thereto. In at least one embodiment, a connecting member may comprise a structural channel such as in the form of a “U” shaped channel mentioned above. Such a “U” shaped channel can be made of strong but flexible material such as steel. As mentioned above, each panel member of a panel assembly may be securely attached to each other via a connecting member, creating spacing or an “air gap” therebetween.
Aside from enhancing the structural strength and/or rigidity of a panel assembly, the U-shaped channels with apertures or steel plate connecting members may also be used to allow the flow of liquid fillers between different sections, and may also be utilized to facilitate erection of a plurality of panel assemblies by providing a relatively easy connection means between adjacent panel assemblies. A connecting member may comprise two adjacently disposed L-shaped angles that may be disposed on at least one end of a panel assembly and extending therefrom. Two panel assemblies may be disposed in interconnecting relation via corresponding “U” shaped connecting members and forming columns therebetween. This interconnection of two “U” shaped connecting members comprises a double wall along the length of the panel members for additional bending strength. In a further embodiment, two different panel assemblies may be disposed in interconnecting relation via L-shaped angles structured to allow insertion of reinforcement bars, e.g., angle bars, at corner columns.
An easy erection method may be performed whereby the connecting member of one panel assembly may be disposed within the connecting member of an adjoining panel assembly and so forth until a desired length of wall or partition is accomplished. The panel members and panel assemblies may be securely retained by inserting screws, bolts, etc. to secure the panel members and panel assemblies to the connecting members.
In embodiments where the connecting members comprise structural channels, or “U” shaped channels, the interconnected connecting members may be correspondingly oriented and disposed such that upon insertion of a connecting member of one panel assembly within a connecting member of another panel assembly, the corresponding connecting members are disposed in a ‘tongue and groove’ connection or substantially telescopically interconnected. Thusly, disposed, the joints of each adjoining panel assembly are strengthened twofold. Further, at least some of the elongate connecting members may extend the length of the panel members such that the lowermost portion thereof is disposed on or within the channel of the base member, as described in greater detail below, and this region can also be filled with concrete or an appropriate fill to add further structural integrity.
It will be appreciated that in use of the present invention a plurality of panel assemblies will generally be required in order to construct an exterior wall of a desired length. As desired, each panel assembly may be the same or of differing sizes, but generally each panel assembly will include both a connecting member at each end.
As used herein, the term “exterior wall” refers to walls which define the exterior boundary of a structure, in distinction to an “interior wall” (that can also be structural or of conventional drywall) which can define interior boundaries within a structure. For ease of reference, the panel members of the exterior panel assembly may be defined as including an exterior panel member and an interior panel member. The exterior panel member being the panel member which faces the exterior of the structure, the interior panel member (which can also be a structural wall) being the panel member which faces the interior of the structure.
The exterior panel assembly system may also include a corner assembly, whereby exterior panel assemblies are adjoined at an angle via L-shaped sections disposed to allow setting of reinforcing steel bars to enhance structural characteristics of corner columns. As such, a corner may be created. Accordingly, additional hardware and fasteners may be utilized in order to provide for an angled interconnection including structural integrity wind load. In describing a corner assembly, an end panel assembly may be defined for ease of reference, with an end panel assembly comprising an exterior panel assembly that at least partially comprises the corner assembly. In a preferred embodiment, a vertical support structure may be included to enhance structural stability and may comprise steel rebar and/or steel dowels (e.g., “L” shaped rebar corner bars).
The present invention is also directed to a wall system that can employ a reduced thickness that may be used as a portion of a building structure, generally as an exterior or interior structural wall. The inventive wall system generally comprises two panel members disposed in interconnecting relation, for example via retainers, which collectively define a panel assembly. The panel members collectively define an air gap that is generally filled with a filler material, such as for example, concrete. It is within the scope of the present invention that the panel members themselves be moisture resistant so that they do not decompose or deflect when coming into contact with a liquid(s), e.g. moisture content of the concrete or in the case of an exterior wall, environmental moisture. That is, the material of the panel members should be such that the panels should at least partially resist absorption to moisture from the filler material, e.g., concrete, or from the environment, i.e., humidity, rain, etc. The wall system may also comprise removable support member(s) disposed on an outside face of a corresponding panel member of the panel assembly. The removable support members are intended to provide enhanced structural support to the filler materials to at least partially reduce bowing, buckling, and/or deflection of the panel members during filling and hardening. As such, the removable support members may comprise corrugated steel panels. The removable support members also eliminate the need to incorporate panel members having an increased thickness, and as they do not act as a mold and/or come into contact with the fill material, can be easily removed and re-used. The retainers may be used to interconnect, not only the panel members, but also the removable support members. Wire mesh may be disposed within the air gap to further enhance the structural integrity of the panel assembly, and also to enable a reduced thickness of the panel assembly.
One or more panel assemblies may be interconnected via a connecting assembly, which may comprise a U-shaped channel with one or more apertures formed thereon. The apertures are intended to allow a filler, such as concrete, to freely flow between adjacent air gaps of adjacently connected panel assemblies, reducing the need to incorporate concrete vibrators, but more importantly to provided effective interconnecting or tying together of the hardened adjacent structures. More specifically, a filler is intended to flow through the apertures between adjacent structural components of a building, such as for example, columns, beams, and/or walls. The apertures may also be used as templates for reinforcement members, which may go through the aperture between different air gaps of connected panel assemblies.
These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration.
For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
Like reference numerals refer to like parts throughout the several views of the drawings.
As illustrated in the Figures, the present invention is directed towards a wall system 10 that incorporates the use of one or more panel assemblies 100. The wall system 10 may be prefabricated, although this is not always required as it may also be quickly assembled on a job site. As seen in
As illustrated in
In at least one embodiment, such as may be appreciated in
The connecting members 200 may comprise “U” shaped roll-formed structural channels including a web 210 and two flanges 220, oppositely disposed on each end of the web 210. A connecting member 200 may be disposed on a male connecting end 150 of a panel assembly 100 with the web 210 projecting a predetermined distance therefrom in order to form a male connector 230. Accordingly, another connecting member 200 may be disposed on a female connecting end 160 of a panel assembly 100 with the web 210 recessed inwardly therefrom a predetermined distance in order to form a female connector 240. In one embodiment, at least one connecting member 200 may be disposed on the middle portion 235 of a panel assembly 100, between the male connecting end 150 and the female connecting end 160 of the panel assembly 100.
Further, as illustrated in
The type of connecting member fastener 501 and/or panel assembly adjoining fastener 502 may vary depending upon the preferred or intended construction application. For example, connecting member fasteners 501, which may be configured for quick and/or automated installation, may be preferred such that the prefabrication of individual panel assemblies 100 may be facilitated. Accordingly, the two panel members 110 of a panel assembly 100 may be interconnected to a connecting member 200 via the connecting member fasteners 501 by the end-user prior to arriving at the construction site. As such, it may not be necessary that the connecting member fasteners 501 be removable, thus they can be configured to be permanently installed, which may enhance the strength of the panel assembly 100. Conversely, the panel assembly adjoining fasteners 502, which are configured for hand installation, may be preferred to facilitate connection by the end-user at the construction site. As such, it may be preferable to use removable panel assembly adjoining fasteners 502 such that the plurality of panel assemblies 100 may be connected and/or disconnected locally at the construction site.
As mentioned above, the two panel members 110 of a panel assembly 100 may be interconnected with a plurality of connecting members 200. In addition, the panel assemblies 100 may act as permanent “forms” that allow end-users to fill at least a portion of the panel assembly 100 with material at the construction site for added structural integrity. These “forms” may allow the end-user to quickly connect and fill the panel assemblies 100. As such, the panel assembly 100 includes an air gap 120 disposed between the two panel members 110, which filler material 140, such as, but not limited to concrete, fiber concreate, clay, slate, pellets, waste materials, may be disposed therein as desired for added strength. The panel assembly 100 may also comprise a variety of structural features that lend themselves to use in an exterior partition. For example, the panel members 110, specifically the exterior panel member 111, may be comprised of magnesium oxide board, phenolic fiberglass board, or wood strand board for increased strength and weather resistance.
As illustrated in
An additional feature of the present invention comprises at least one air conduit disposed within the “formed” air column 125 that may allow end-users to include filler material 140 such as pre-set reinforcing steel rebar or the like therein at the construction site for enhanced strength. Thus, steel rebar may extend the width of the panel assembly and into an aperture of the base member 300. The reinforcing steel rebar are placed into an air conduit 125 and extend through the base member 300 aperture to allow concrete to be placed after this pre-set construction is completed. As such, the steel rebar may be connected to the concrete slab 1000 for additional support to the structure. In another embodiment, the steel rebar may extend and be disposed within the structural channel of the base member 300, but not necessarily through an aperture thereof. For example, a steel dowel may (e.g., #5 dowel) be connected and extend up from the concrete slab 1000 through an aperture of the base member 300 and be tied to a steel rebar for additional support to the structure.
As illustrated in
As such, the corresponding flanges 220 of the male connector 230 may be inserted into the corresponding female connector 240. As such, the air column 125 is formed between the two adjoined connecting members 200. This may enhance the strength of the panel assemblies 100 twofold. Moreover, the strength of at least the exterior panel member 111, which may be the critical side of exterior panel assemblies 100 exposed to the wind, is increased by double.
As mentioned above, and illustrated in
In certain embodiments, it may be desirable to cooperatively dimension the depth of the recess 161 of the female connector 240 with the length of projection of the corresponding flanges 220 of the male connector 230 such that the male connector 230 and female connector 240 effectively connect when corresponding panel assemblies 100 are adjoined. Thusly disposed, the interconnected male connector 230 and female connector 240 comprise the air column 125, which serves to increase the overall strength of the present invention, and specifically increases the bending stiffness at the joint portion 190 of the interconnected panel assemblies 100. For example, the female connector 240 being disposed substantially across the joint portion 190, provides added strength and a measure of resistance to fluid flow therethrough.
Further, in one embodiment, the exterior panel member 111 of a panel assembly 100 may be intended to face an exterior of the structure; the interior panel member 112 of the panel assembly 100 may be intended to face an interior of the structure. As such, drywall or the like may be affixed where desired on the interior panel member 112, and an exterior treatment, such as stucco or another finish, may be applied where desired to the exterior panel member 111. Such an exterior treatment may increase the strength and weather resistance of the panel assembly 100.
As illustrated in
As illustrated in
More specifically, the male and female connectors 230, 240 of the end panel assemblies 100′ may comprise a plurality of corresponding apertures along an exterior surface thereof. Such apertures may be drilled, cut, or otherwise formed at the jobsite, or alternatively may be provided with pre-punched apertures. Such apertures may provide a recess into which angled rebar can be passed therethrough allowing for additional support to the structure.
With reference now to
The base member 300 may comprise a plurality of apertures along an exterior surface of the base member 300 and particularly along an exterior surface to be disposed adjoining the concrete slab 1000 upon which the present invention is to be deployed. Such apertures may be drilled, cut, or otherwise formed at the jobsite, or alternatively, a base member 300 may be provided with pre-punched apertures. Such apertures may provide a recess into which filler, such as a steel dowel or rebar can be passed therethrough to the concrete slab 100 allowing for additional support to the structure. As depicted
In another embodiment, not shown for clarity, a plurality of panel assemblies 100 may be disposed in interconnected relation to a ceiling of the structure. More specifically, the plurality of panel assemblies 100 may include a support member to which trusses and/or roof beams may be fastened. Further, a horizontal support beam may be disposed coextensively with the support member to reinforce the attachment point of the roof beams and/or trusses. The horizontal support beam may comprise pressure treated lumber or the like.
With reference to
As is shown at least in
The inside faces 114 of the two panel members 110′ will generally face towards one another, and will later be in contact with, and will provide support to the filler 140′. The filler 140′ may comprise a combination of different materials, such as for example suitable concrete mixtures. For example, the filler 140′ may comprise lighter or lightweight concrete, or a related material, or traditional concrete formulas. For example, the filler 140′ may comprise lightweight concrete, slate, volcano compounds, and other suitable materials. Lighter concrete, if used, is advantageous when used in connected with an air gap 120′ having a reduced thickness 122 as it may flow more effectively through different areas of the air gap(s) 120′, and with lesser air bubbles, which may otherwise develop during casting operations. As used herein, the term “casting” refers to the process of placing a filler 140′, e.g., concrete, within the air gap(s) 120′ defined by the two panel members 110′ of the inventive panel assembly 100′. Lighter concrete provides the advantage of filling certain areas of the air gap(s) 120′ more efficiently, for example, at the corners, and or at lower portions of the air gap(s) 120′. Lighter concrete also reduces the need to use vibrators during casting operations. Of course, it is nevertheless understood that standard concrete can be equivalently used with the novel structure of the present system, and may in fact be desirable in certain applications.
It is also within the scope of the present invention that the panel member 110′ comprise other advantageous features that may contribute to a reduced overall thickness, added strength, faster construction and pre-finished exterior of an intended component of a building structure. For example, the panel member 110′ may comprise a material that provides added structural support and/or that may reduce longitudinal deflections of the panel members 110′, such as along their width W1. The material of the panel members 110′ may also be at least partially resistant to a liquid filler 140′, such as, but not limited to, concrete. That is, the panel members 110′ should reduce absorption of moisture from the filler 140′ to effectively function as permanent forms that will be a part of the building structure. This provides enhanced structural properties, including of portions of the building which act as shear walls once the filler material 140′ dries and gains sufficient structural strength. Such shear walls may be used to protect the building structure from lateral loads such as may be associated with wind, hurricanes, or earthquakes. When used as a shear wall, the panel assembly 110′ may be provided with suitable structural components, such as wire mesh, and may be interconnected to roof trusses, concrete slabs, or to foundation dowels, including, but not limited to, No. 5 structural steel dowel bars.
As a non-limiting example, the material of at least one of the panel members 110′ may include fiber cement. In a preferred embodiment the material of both panel members 110′ of a panel assembly 100′ may also comprise fiber cement. The panel members 110′ may include, but are not necessarily limited to one or more of the following: magnesium sulfate, magnesium oxide, wall panels, sandwich panels, and other materials with a suitable modulus of elasticity, bending and/or tensile properties, and/or compressive strength, which may at least partially reduce bowing, buckling, or deflecting. The material of the panel members 110′ may further allow for a reduced panel thickness 118. Such a reduced thickness 118 may vary, but in at least one embodiment is about 6 millimeters. Additionally, and as mentioned above, each panel member 110′ comprises an inside face 114, as well as an outside face 116. The outside face 116 of at least one panel member 110′ of an assembly 100′ may be disposed on an outside of a building structure, such that it is in direct contact with the outside environment. Accordingly, the outside face 116 of one or more panel members 110′ may comprise a coating or other material that may protect the panel assemblies, and consequently the inside of the building, from ambient conditions. Such coating or other suitable material may be provided as a substitute to stucco, which is a commonly used product to protect the inside of the building structure from ambient conditions, for example, moisture. Further, because of the uniform, finished appearance of the outside face 116, additional surfacing may not be required.
As mentioned above, and with reference to at least
The removable support member(s) 170 may comprise a variety of structural components. For example, at least one, and in some embodiments both, removable support member(s) 170 of a panel assembly 100′ may comprise corrugated steel panels. Illustrative examples of various removable support members 170 are shown in
As is generally shown at least in
As is perhaps best shown in
As shown in
With reference now to
The present application is a continuation-in-part application of previously filed, pending application having Ser. No. 16/053,267, filed on Aug. 2, 2018.
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| Child | 16506165 | US |
