WO1991003611A1

WO1991003611A1 - Modular construction units and cast-in-place walls and beams employing such units

Info

Publication number: WO1991003611A1
Application number: PCT/US1990/004881
Authority: WO
Inventors: Frank K. Johnson
Original assignee: Johnson Frank K
Priority date: 1989-09-08
Filing date: 1990-08-28
Publication date: 1991-03-21
Also published as: AU6443590A

Abstract

An extrudable modular construction unit for connecting with another modular construction unit, the unit including an elongated member (16) having a first mortise (24, 26) and an adjacent first tenon (22) formed along a side of the member for mating with a similarly shaped tenon (30, 32) and mortise (28) of another unit (20). Also disclosed are a cast-in-place wall (50) including two spaced panels (52, 54) made of interconnected extruded plastic modular units, stringers (60) between the panel (52, 54) and concrete and polygonic beams (70) made of interconnected extruded plastic modular units (12, 68) and concrete.

Description

MODULAR CONSTRUCTION UNITS AND CAST-IN-PLACE WALLS AND BEAMS EMPLOYING SUCH UNITS

Background of the Invention The invention relates to extrudable, modular construction units, in particular, such units that are used in cast-in-place concrete structures. Most commercially available formwork systems used in placing cast-in-place concrete today are made of a sheathing material such as plywood, sheet metal, or wood planking fastened to a structural frame. Metal angles, channels and beams, or wood braces, joined together by assemblies of bolts, nuts, washers, clamps, nails, screws, or one of a variety of other fastening devices, are used as structural members in these formwork systems.

Concrete formwork is designed and constructed as a temporary structure. Once the wet concrete has set, the formwork is broken down into its component parts, or stripped, and removed from the site. Sheathing provides a surface for containing the wet concrete and shaping its outside faces. The structural frame of a wall form holds panelized sheathing in place and prevents hydrostatic forces,, imposed by the wet concrete, from moving the panels.

The over-all strength of a wall or deck form is determined by the dimensions and material strength of each structural member making up the frame, the hardware making up each joint assembly in the frame, and the sheathing.

Sheathing must have sufficient strength to bridge the open distance between structural members without noticeably deflecting under construction conditions. When thin gauged sheathing is used, the structural members must be spaced closer together to reduce the load bearing on each panel. Closer spacing produces more joints in the structural frame. Thicker sheathing can span larger area without deflecting. Structural members and joint assemblies making up the wall or deck structure, as a result, can be spaced further apart, and the number of joint assemblies per wall can be reduced accordingly.

The major expense associated with constructing temporary formwork at the job site is incurred in making up the joint assemblies. The number of joints in these conventional wall forms affects the cost of assembly, handling and disassembly.

Concrete forming systems are described in U.S. Patents Nos. 3,748,806 and 4,223,501 and in the following commercial literature: Richmond Technical Data For Concrete Form Design, Bulletin No. 12, Richmond Screw Anchor Co., Fort Worth, Texas (1977); Burke Hand-Set

Forming System, Burke a subsidiary of Aluma-Systems, San Mateo, CA; Symons Versiform Concrete Forming System, Symons Corporation, Des Plains, IL (1988) ; Symons Steel- Ply Concrete Forming System (1988) ; Symons 30/50 Buy-Back Plan Improved (1989) ; Mod-U-Form Concrete Forming System, Patent Scaffolding Co., Fort Lee, NJ (1981); Patent Scaffolding Co., Instructions and Identification Chart. #314R, (1979).

Systems for making walls of interfitting and/or interconnecting modular units are described in U.S.

Patents Nos. 3,992,834; 4,104,837; 4,144,681; 3,815,311; 4,612,749; 4,688,364; 4,573,296. In U.S. Patent No. 3,992,834, the units are connected to each other by mortise and tenon connections.

Summary of the Invention

In one aspect, the invention features in general an extruded, modular construction unit for connection to other modular construction units. The modular construction unit includes an elongated member having a first mortise and an adjacent first tenon formed along a side of the member for mating with a tenon and a mortise, respectively, of another unit.

In some preferred embodiments, the elongated member has a second tenon on the opposite side of the mortise from the first tenon, and in some other preferred embodiments the elongated member has a second mortise on the other side of the first tenon from the first mortise. Some of the units are stud segments which act as a rigid structural members along their longitudinal axes. Some other units are panel segments that are connected between adjacent stud segments. A panel is made up of a plurality of stud segments and panel segments.

In another aspect, the invention features in general a cast-in-place wall made of two spaced plastic panels that are each made of modular, interconnected extruded units that are connected to adjacent units along longitudinal axes by mortise and tenon connections. The longitudinal axes are arranged vertically. The spaced apart panels are connected together by stringers, and concrete fills the space between the panels.

In another aspect, the invention features in general a beam made of a plurality of interconnected modular units that are connected together to provide a polygon shape to the beam. The individual units provide the sides of the polygon. The units are connected to adjacent units along longitudinal axes by mortise and tenon connections, the longitudinal axes being arranged horizontally or vertically. Other advantages and features of the invention will be apparent from the following description of a preferred embodiment thereof.

Description of the Preferred Embodiment The preferred embodiment will now be described. Drawings

Fig. 1 is a diagrammatic horizontal sectional view of a joint assembly formed of a stud segment and a panel segment according to the invention, the stud and panel segments being modular units.

Fig. 2 is a diagrammatic horizontal sectional view of a cast-in-place wall that includes spaced apart panels employing Fig. 1 joint assemblies.

Fig. 3 is a diagrammatic partial perspective view showing the structure of a polygonic beam made of modular units according to the invention.

Structure

Referring to Fig. 1, there is shown joint assembly 10, including panel segment 12 and stud segment 14. Segments 12 and 14 are plastic (e.g., PVC or another relatively rigid plastic) modular construction units that have been extruded along their longitudinal axes, which are perpendicular to the paper in Fig. 1. Panel segment 12 includes two male connectors 16 at its respective ends along panel axis 18. Each male connector 16 includes a tenon 22 and two mortises 24, 26 on opposite sides of tenon 22. Stud segment 14 includes two female connectors 20, also along panel axis 18. Each female connector 20 includes a mortise 28 and two tenons 30, 32 on opposite sides of mortise 28. Mortises 24, 26 each have a narrow- width opening 33 and larger-width region 34 behind narrow-width opening 33. Each mortise 28 similarly has narrow-width opening 36 and larger-width region 38 behind narrow-width opening 36. Tenon 22 has head 40 that blossoms out from narrow-width connecting portion 42.

Mortises 30, 32 similarly have heads 44 that blossom out from respective narrow-width connecting portions 46. Panel segment 12 has spanning elements 48 that are between the two male connectors 16 and are spaced from panel axis 18 in a transverse direction in order to provide rigidity to panel segment 12. There are voids between the various spanning elements 48. Stud segment 14 similarly has numerous connecting elements 49 and voids, and many of the connecting elements are spaced at a substantial distance from panel axis 18 in order to provide additional rigidity to this member. Panel segment 12 is longer along panel axis 18 than it is along a transverse axis. Stud segment 14 has a dimension along a transverse axis that is longer than the distance between connectors 20 along panel axis 18.

Referring to Fig. 2, cast-in-place wall 50 includes spaced-apart panels 52, 54, 56, 58. Panels 52, 54, 56, 58 are made up of a plurality of joint assemblies 10 that include modified studs 64 after every third panel segment 12 in order to provide a connection for metal stringers 60, used to connect panel segments together and provide proper spacing. Panel 52 is connected to panel 56 by outside corner piece 66, which includes female connectors at a right angle to each other. Panel 54 is connected to panel 58 by an inside corner piece 68, which also has female connectors at right angles to each other. Modified studs 64, outside corner piece 66 and inside corner piece 68 are, like segments 12, 14, made of extruded plastic and have female connectors that are identical to female connectors 20. Diagonal stringer 62 connects outside corner piece 66 to inside corner piece 68. The spaces between panels 52, 54 between panels and 56, 58 are filled with concrete 69 and reinforcing steel members (not shown) , the reinforcing steel members being positioned as necessary to resist tension loads.

Referring to Fig. 3, polygonic beam 70 is shown. It includes six panel segments 12 and six inside corner pieces 68, two of them being connected at adjacent right angle female connectors, and four of them being connected at female connectors making 135° angles with each other. In use, the longitudinal axes of the segments can be directed horizontally (as shown in Fig. 3) or vertically, and the interior space of the polygonic beam is filled with concrete and reinforcing steel members (both not shown) .

Use

In use in a cast-in-place wall, the modular units have lengths corresponding to the height of the wall. The individual units are connected together by sliding the mating male connectors 16 and female connectors 20. Modified studs 64 and stringers 60 are employed at sufficient spacing to hold two panels together and avoid bulging. The bottoms of the panels are secured in anchor channels (not shown) that provide proper spacing for the bottoms of the panels, prevent them from bulging outward when concrete is poured, and prevent leaking of concrete from the bottom. Reinforcing steel is employed as necessary, and concrete is poured into the space between the panels.

Polygonic beams are similarly made by sliding together the male and female connectors to arrive at the desired beam shape prior to or after assembling reinforcing steel in place. After both the module units and steel are in place, the concrete is poured.

Additional polygonic beams can be formed next to each other and can share common modular units (and thus polygon sides and joints) in both the horizontal and vertical orientations. In the horizontal orientation, by continuing the structure horizontally with contiguous polygons, an arch and/or ceiling structure can be obtained with either one or more layers of contiguous polygonic beams, the latter having the general appearance of a honeycomb like structure. In this arch or ceiling application, the cavities within the beams could be hollow, and the concrete and reinforcing shell would be supported by the resulting arch or ceiling structure.

The use of adjacent mortises and tenons provides rigidity to the panels and seals against leaking of water through the tortuous path between the mating parts of the mortise and tenon joint. The use of female connectors having two facing tenons on opposite sides of a mortise and the use of mating male connectors having two mortises on opposite sides of a tenon are particularly effective in providing rigidity and a water-tight seal.

The modular panel and beam approach described herein is quicker and simpler than the use of traditional concrete formwork. In addition, the plastic stud and panel segments remain in place in the wall or polygonic beam structure after the concrete has hardened, providing, e.g., insulation and a moisture and/or other barriers, depending on the plastic used. The spaces within the segments could also be used as ducting and to contain wires etc. The surfaces of the segments could act as the exposed interior or exterior wall surface of a room or could be adapted to support flat esthetic panels that serve as the exposed interior or exterior surface.

Other Embodiments Other embodiments of the invention are within the scope of the following claims. What is claimed is:

Claims

1. An extruded modular construction unit for connecting with another modular construction unit, said unit comprising an elongated member having a longitudinal axis along its length and a constant cross-section profile along said longitudinal axis, said elongated member having an integral connector along a side of said member formed of a first mortise, a first tenon and a second tenon, said first mortise being a cavity having a narrow-width opening to a larger-width region that increases in size behind said narrow-width opening, said first and second tenons being on opposite sides of said first mortise and extending toward each other.

2. An extruded modular construction unit for connecting with another modular construction unit, said unit comprising an elongated member having a longitudinal axis along its length and a constant cross-section profile along said longitudinal axis, said elongated member having an integral connector along a side of said member made of a first tenon, a first mortise and a second mortise, said tenon being a projection that includes a head that blossoms out from a narrow-width connecting portion, said first and second mortises being on opposite sides of said first tenon and extending outward from each other, said mortises being closer together along an axis between them than the width of said head along a parallel axis.

3. The unit of claim 2 wherein said unit is a panel segment that is longer along a panel axis than.it is along a transverse axis,- and wherein said unit has two said connectors on opposite ends along said panel axis.

4. The unit of claim 1 wherein said unit is a stud joint that has two said connectors at opposite ends along a panel axis and has a dimension along a transverse axis that is longer than the distance between connectors along said panel axis.

5. The unit of claim 3 wherein there are a plurality of spaced apart spanning elements between said connectors.

6. The unit of claim 4 wherein there are a plurality of spaced apart connecting elements between said connectors.

7. The unit of claim 4 wherein said unit is a corner unit having two said connectors along axes that make an angle of other than 180° with each other.

8. The unit of claim 7 wherein there are three said connectors.

9. A cast-in-place wall structure comprising two spaced panels each made of interconnected extruded modular units, said units being elongated units having longitudinal axes along their lengths, said lengths corresponding to the height of said wall structure, said units having constant cross-sectional profiles along said longitudinal axes, said units being connected to adjacent units along their longitudinal axes by integral connections having main mortises on some units and mating main tenons on some other units, said longitudinal axes being arranged vertically, each said main mortise being a cavity having a narrow-width opening to a larger-width region that increases in size behind the narrow-width opening, each said main tenon being a projection that includes a head that blossoms out from a narrow-width connecting portion, said mortises and tenons resisting forces tending to pull said units apart, some said units being panel segments having said main tenons on two sides thereof and some said units being stud joints having said main mortises on two sides thereof, each said panel segment being connected to an adjacent panel segment by a said stud joint, said panels providing stay-in-place formwork for retaining and forming concrete poured between them, stringers connected between stud joints in opposite panels to connect said panels to each other, and concrete between said panels.

10. The wall of claim 9 wherein each integral connector of said stud joints is formed of a said main first mortise, a first tenon and a second tenons, said first and second tenons being on opposite sides of said main mortise and extending toward each other.

11. The wall of claim 9 wherein each integral connector of said said panel segments is formed of a said main tenon, a first mortise and a second mortise, said first and second mortises being on opposite sides of said main tenon and extending outward from each other.

12. The wall of claim 11 wherein said panel segments are longer along a panel axis extending between the integral connectors than along a transverse axis.

13. The wall of claim 10 wherein said stud joints each have a panel axis between the connectors and a dimension along a transverse axis that is longer than the distance between connectors along said panel axis.

14. The wall structure of claim 12 wherein there are a plurality of spaced apart spanning elements between said connectors of said panel segments.

15. The wall of claim 13 wherein there are a plurality of spaced apart connecting elements between said connectors of said stud joints.

16. The wall structure of claim 9 wherein some said stud joints are corner units having two said connectors along axes that make an angle of other than 180° with each other.

17. The wall structure of claim 9 wherein some said stud joints have three said integral connectors, two being used to connect to adjacent units and one being used to attach to the end of a said stringer.

18. A polygonic beam assembly comprising a plurality of interconnected, extruded plastic modular units that provide a polygon shape to said beam assembly, individual said units providing the sides of said polygon shape and defining a cavity between them, said units being connected to adjacent units along their longitudinal axes by integral connectors having main mortises and main tenons, each said main mortise being a cavity having a narrow-width opening to a larger-width region that increases in size behind the narrow-width opening, each said main tenon being a projection that includes a head that blossoms out from a narrow-width connecting portion, said mortises and tenons resisting forces tending to pull said units apart, some said units being panel segments having said main tenons on two sides thereof and some said units being stud joints having said main mortises on two sides thereof, each said panel segment being connected to an adjacent panel segment by a said stud joint, said units having constant cross-sectional profiles along said longitudinal axes.

19. The beam assembly of claim 18 wherein said longitudinal axes are arranged horizontally.

20. The beam assembly of claim 18 wherein said longitudinal axes are arranged vertically.

21. The beam assembly of claim 18 wherein each integral connector of said stud joints is formed of a said main first mortise, a first tenon and a second tenons, said first and second tenons being on opposite sides of said main mortise and extending toward each other.

22. The beam assembly of claim 18 wherein each integral connector of said panel segments is formed of a said main tenon, a first mortise and a second mortise, said first and second mortises being on opposite sides of said main tenon and extending outward from each other.

23. The beam assembly of claim 18 wherein said panel segments are longer along a panel axis extending between the integral connectors than along a transverse axis.

24. The beam assembly of claim 18 wherein said stud joints each have a panel axis between the connectors and a dimension along a transverse axis that is longer than the distance between connectors along said panel axis.

25. The beam assembly of claim 18 when there is concrete in said cavity.

26. The unit of claim 1 wherein each said tenon is a projection that includes a head that blossoms out from a narrow-width connecting portion.

27. The unit of claim 2 wherein each said mortise is a cavity having a narrow-width opening to a larger- width region that increases in size behind the narrow- width opening.

28. The beam assembly of claim 18 wherein some said stud joints have more than three connections and more than three panel segments connected to them, and there are plural polygon shapes formed in said beam assembly.