Multi-purpose construction module

Abstract

This application relates to a light-weight, multi-purpose construction module. The module may be used, for example, as a mold for settable materials such as concrete. A plurality of modules may be aligned together in different configurations for use as a temporary road or support for use on unstable terrain, such as arctic tundra or wetlands. In yet another application the module may be deployed as a storage or shelving unit. The module comprises a deck and a plurality of wall elements projecting from the deck and defining a plurality of honeycomb-like compartments. The module may be used in conjunction with a mating cover for sealingly enclosing the module compartments.

Description

TECHNICAL FIELD

This application relates to a multi-purpose construction module.

BACKGROUND

Construction forms for containing concrete or other settable materials are typically fabricated on-site. After the concrete is poured and set, the forms are removed. These steps are relatively time-consuming and labor-intensive. Moreover, since the forms are not designed to be left in place, they do not enhance the structural integrity or strength of the poured concrete or other material. While the use of metal reinforcing bars and ribs is known for stabilizing and strengthening concrete, there is a need for more light-weight and inexpensive construction solutions.

Another application where pre-formed construction modules may be used is to build temporary roads or work pads. This is particularly important in regions having unstable ground support, such as arctic tundra during seasons when the ground is not frozen. Another example of unstable ground support is in wetlands such as swamps or everglades systems. The unstable ground makes it very difficult to deploy or move heavy equipment, such as oil drilling or exploration machinery, at certain times of the year. This problem is conventionally addressed by laying down a large number of wood mats on the unstable ground to distribute the machinery weight over a larger surface area. One problem with this approach is that protruding nails used to maintain the wood mats together frequently puncture vehicle tires.

Interlocking mat systems made from high density polyethylene are known in the prior art for construction of temporary roads or other support surfaces. However, such mats are relatively heavy and require cranes or other specialized equipment to install or remove the mats. The need has arisen for more light-weight and economical construction modules which may be quickly and reliably deployed at remote locations.

SUMMARY OF INVENTION

In accordance with the invention, a construction module comprising a planar deck and a plurality of wall elements projecting from the deck is provided. The wall elements define a plurality of compartments, each of said compartments having a closed end defined by a portion of the deck and an open end remote from the deck. In one embodiment at least some of the wall elements define a plurality of parallel, spaced-apart partitions extending longitudinally on the deck. The deck may be a sheet having a first side and a second side, wherein the wall elements project from the first side in a plane generally perpendicular to the plane of the sheet. A plurality of ribs may project from the second side of the sheet. The module may be economically formed from cast plastic or other light-weight material.

In one embodiment of the invention the module may include a plurality of conduits, such as cylindrical pipes, extending transversely through the module at spaced-apart intervals for threading cable connectors therethrough. The connectors may be used for quickly aligning and securely coupling a plurality of modules together to form a construction assembly, such as a temporary roadway. Other means for coupling modules together, such as removable connecting clips and locking pins may also be employed.

A cover may optionally be used in conjunction with the module for enclosing the module compartments. The cover may include a plurality of grooves formed therein for receiving end portions of the wall elements remote from said deck when the module and the cover are coupled together. Optionally, a sealing gasket may be interposed between the module and the cover.

BRIEF DESCRIPTION OF DRAWINGS

In drawings which describe embodiments of the invention but which should not be construed as restricting the spirit or scope thereof,

FIG. 1 is a top plan view of a construction module configured in accordance with one embodiment of the applicant's invention.

FIG. 2 is a side elevational view of the module of FIG. 1.

FIG. 3 is a bottom plan view of the module of FIG. 1.

FIG. 4(a) is a bottom perspective, partially exploded view of a plurality of modules arranged together in an aligned configuration and showing connecting clips removed from the modules.

FIG. 4(b) is a bottom perspective view of a plurality of modules aligned together and showing the connecting clips fully inserted for coupling the modules together.

FIG. 4(c) is an enlarged perspective view of one connecting clip of FIGS. 4(a) and 4(b).

FIG. 5 is a top, perspective, partially exploded view of a plurality of modules aligned together and showing connecting cables and locking pins for coupling adjacent modules together.

FIG. 6(a) is an enlarged top perspective view of a plurality of modules aligned together and showing the locking pins for coupling end portions of the modules together.

FIG. 6(b) is an enlarged top perspective view of the modules of FIG. 6(a) showing the locking pins in their fully inserted position flush with the top surface of the module decks.

FIG. 7(a) is an enlarged top perspective view of a plurality of modules aligned together in an offset pattern and showing the locking pins removed from the modules.

FIG. 7(b) is an enlarged top perspective view of the modules of FIG. 7(a) showing the locking pins in their fully inserted position for coupling end portions of the modules together.

FIG. 8(a) is a side elevational view of a plurality of modules aligned together and showing the locking pins removed from the modules.

FIG. 8(b) is a side elevational view of the embodiment of FIG. 8(a) showing the locking pins fully inserted to couple adjacent modules together.

FIG. 9(a) is a side elevational view of a plurality of modules aligned together and showing locking pins having a length greater than the pins of FIG. 8(a) removed from the modules.

FIG. 9(b) is a side elevational view of the embodiment of FIG. 9(a) showing the locking pins fully inserted to couple adjacent modules together.

FIG. 10 is an exploded, isometric view of a construction assembly comprising a module and a cover which may be coupled together to sealingly enclose the module compartments.

FIG. 11 is an enlarged, sectional view of a portion of the assembly of FIG. 10.

DESCRIPTION

Throughout the following description, specific details are set forth in order to provide a more thorough understanding of the invention. However, the invention may be practiced without these particulars. In other instances, well known elements have not been shown or described in detail to avoid unnecessarily obscuring the invention. Accordingly, the specification and drawings are to be regarded in an illustrative, rather than a restrictive, sense.

This application relates to a multi-purpose construction module 10. In the illustrated embodiment module 10 is generally rectangular in shape. As described in further detail below, a plurality of modules 10 may be aligned in a desired configuration and releasably coupled together. Each module 10 includes a deck 12 and a plurality of wall elements 14 projecting from deck 12. In the illustrated embodiment deck 12 is a planar sheet having a first side 16 and a second side 18. Wall elements 14 project from first side 16 in a direction generally perpendicular thereto. As shown best in FIGS. 3, 4(a) and 4(b), some of the wall elements 14 define a plurality of parallel, spaced-apart partitions 19 extending longitudinally on deck 12 to provide enhanced structural support, as described below. In the illustrated embodiment, wall elements 14 are arranged to define a plurality of honeycomb-like compartments 20 each having a closed end defined by a portion of deck 12 and an open end remote from deck 12. Although compartments 20 are shown as being diamond-shaped or triangular-shaped, other shapes and arrangements are possible.

In the embodiment illustrated in FIGS. 1, 5-7 and 11, a plurality of narrow elongated ribs 22 project a short distance from second side 18 of deck 12. In this embodiment ribs 22 have the same diamond-shaped pattern as wall elements 14, although other rib patterns are also possible.

A plurality of conduits 24 extend transversely through module 10 at spaced intervals. In the illustrated embodiment conduits are cylindrical pipes which extend approximately mid-way between deck first side 16 and second side 18. As described further below, conduits 24 are provided for threading cable connectors 26 therethrough. Cable connectors 26 are one means for aligning and coupling a plurality of modules 10 together lengthwise. Module 10 may include cut-outs 28 at intervals coinciding with conduits 24 to enable ready access to end portions of conduits 24 and cable connectors 26.

As an alternative or additional means for coupling a plurality of modules together lengthwise, a plurality of connecting clips 30 may be employed as shown in FIGS. 4(a)-4(c). Each clip 30 is generally U-shaped and includes legs 32 sized to straddle adjacent sidewalls of modules 10. As best shown in FIG. 4(c), opposed clip legs 32 may also optionally include an aperture 34 for receiving a bolt (not shown) which could also pass through matching holes machined in the sidewalls of modules 10.

Each module 10 may also include a plurality of spaced slots or cut-outs 36 formed in end portions thereof. When a pair of slots 36 are aligned, a locking pin 38 may be inserted therein to couple end portions of adjacent modules 10 together. Modules 10 may either be arranged in a fully aligned configuration (FIGS. 6(a) and 6(b)) or an offset configuration (FIGS. 7(a) and 7(b)) depending upon how slots 36 on adjacent modules 10 are matched. When locking pins 38 are fully inserted into modules 10, the outermost surface of pins 38 is flush with the second side 18 of deck 12 (FIGS. 6(b) and 7(b)). As shown in FIGS. 8(a) and 8(b) the size of locking pins 38 may be about the same or less than the depth of modules 10. Alternatively, locking pins 38 may be longer than the depth of modules 10 as shown in FIGS. 9(a) and 9(b) to anchor the modules 10 in the ground when the pins 32 are fully inserted (FIG. 9(b)).

FIG. 10 illustrates an embodiment of the invention consisting of a construction assembly 40 comprising a module 10 and a cover 42. As shown best in FIG. 11, cover 42 has a first side 44 and a second side 46. A plurality of narrow slots 48 are formed on first side 44 for receiving end portions of wall elements 14. When module 10 and cover 42 are coupled together, compartments 20 are fully enclosed. A plurality of narrow elongated ribs 50 may be formed on second side of cover 42 (FIG. 11). Ribs 50 are similar to ribs 22 formed on second side 18 of deck 12.

As shown in FIGS. 4(a), 4(b) and 10, module 10 may also include a plurality of male projections 52 which fit into corresponding female apertures 54 formed in cover 42. A gasket 56 may be interposed between module 10 and cover 42 to sealingly couple the components together (FIG. 10). Further, a plurality of screw fasteners 58 may be used for fastening cover 42 to module 10.

In one preferred embodiment, both module 10 and cover 42 are formed from plastic. For example, module 10 and cover 42 may be manufactured from plastic molds in a mass production process. Since both module 10 and cover 42 may be formed or substantially formed from cast plastic, construction assembly 40 is very light-weight in this embodiment. In one embodiment conduits 24 and cable connectors 26 may be formed from metal.

As will be apparent to a person skilled in the art, modules 10 may be manufactured in any desired size or shape. By way of example, modules 10 may be about 3′×8′ in size and generally rectangular in shape.

Module 10 has many possible construction applications. For example, module 10 may be used separate from cover 42 as a mold for settable materials such as concrete. In this embodiment, one or more modules 10 could be deployed as shown in FIGS. 4(a) and 4(b) with the open ends of compartments 20 facing upward. The settable material could be introduced into all or some of compartments 20 through the open ends thereof. Partitions 19 provide module 10 with longitudinal strength and stability to prevent deformation of module 10 as compartments 20 are being progressively filled. Depending upon the application, multiple modules may be aligned and coupled together as described above to form multi-module construction assemblies. Again, the modules 10 should be coupled together sufficiently securely to prevent deformation or distortion of the multi-module assembly as selected modules 10 or module compartments 20 are filled. If necessary, bolts (not shown) may be used in conjunction with connecting clips 30. With reference to FIG. 9(b), multiple modules 10 may also be anchored in the ground or other underlying support surface using locking pins 38.

In another application module 10 could be filled with sand or other granular materials to stabilize roadways and the like and prevent washout. Depending upon the specific application, module 10 could be deployed with the with the granular material filled within the module compartments 20 with the open ends of compartments 20 facing either upwards or downwards.

In yet another application, modules 10 may be used in conjunction with cover 42 to form a light-weight construction assembly 40 suitable for making temporary roads and the like. This embodiment of the invention is particularly suitable for deployment on unstable ground, such as arctic tundra or wetlands. Assembly 40 is deployed in the orientation shown in FIGS. 10 and 11 with cover 42 placed on the ground surface. A plurality of assemblies 40 may be assembled lengthwise using cable connectors 26 passed through conduits 24 of the respective modules 10, as discussed above. Since assemblies 40 are lightweight and stackable, they may be quickly deployed at the construction site, even at remote locations. The sealing connection between respective modules 10 and covers 42 prevents entry of mud and water into compartments 20 which would otherwise substantially increase the weight of the assemblies 40. End portions of modules 10 could also be aligned and coupled together as described above to increase the width of the temporary roadway or other support. Thus assemblies could be used as supports to distribute weight over a large surface area while remaining stable and structurally strong in different weather and ground conditions. In the orientation shown in FIGS. 1, 5, 6(a)-7(b), 10, and 11, ribs 22 formed on deck second side 18 project upwardly to provide traction for vehicles traveling thereover. As shown in the drawings, deck side 18 may be a continuous sheet to provide a uniform support surface. Since locking pins 38 are flush with deck side 18 in their fully inserted position (FIG. 6(b) and 7(b)), they will not interfere with vehicle traffic or the like on deck 12.

As will be appreciated by a person skilled in the art, construction module 10 could be used for many other purposes and applications. For example, in one further application may be used as a light-weight storage container or shelving unit. In another further application module 10 could be used as part of a scaffolding system.

As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.

Claims

1. A construction module comprising:

(a) a planar deck; and

(c) a plurality of wall elements projecting from said deck, wherein said wall elements define a plurality of compartments, each of said compartments having a closed end defined by a portion of said deck and an open end remote from said deck.

2. The construction module as defined in claim 1, wherein at least some of said wall elements define a plurality of parallel, spaced-apart partitions extending longitudinally on said deck.

3. The construction module as defined in claim 2, wherein said deck is a sheet having a first side and a second side, wherein said wall elements project from said first side in a plane generally perpendicular to the plane of said sheet.

4. The construction module as defined in claim 3, wherein said wall elements are arranged such that at least some of said compartments are diamond-shaped.

5. The construction module as defined in claim 4, further comprising a plurality of ribs projecting from said second side of said sheet.

6. The construction module as defined in claim 3, comprising a plurality of conduits extending transversely through said module at spaced-intervals for threading cable connectors therethrough.

7. The construction module as defined in claim 6, wherein said conduits are arranged in parallel and extend in a transverse direction generally perpendicular to the direction of said partitions.

8. The construction module as defined in claim 7, wherein said module comprises lateral cut-outs formed at the locations of end portions of said conduits to enable access to said end portions.

9. The construction module as defined in claim 8, comprising at least one longitudinal slot formed in an end portion of said module for receiving a locking pin therein.

10. The construction module as defined in claim 7, wherein said conduits extend through said wall elements at a location spaced-apart from said deck.

11. The construction module as defined in claim 3, wherein some of said wall partitions formed a perimeter wall surrounding said module and enclosing said compartments.

12. The construction module as defined in claim 1, wherein said module is formed from molded or cast plastic.

13. A construction assembly comprising:

(a) a construction module as defined in any one of claim 1; and

(b) a cover connectable to said module, wherein said cover comprises a plurality of grooves formed therein for receiving end portions of said wall elements remote from said deck when said module and said cover are coupled together.

14. The assembly as defined in claim 13, wherein cover is a sheet having a first side and a second side, wherein said grooves are formed on a first side of said cover.

15. The assembly as defined in claim 14, wherein a plurality of ribs project from said second side of said cover.

16. The assembly as defined in claim 14, further comprising a gasket located between said perimeter wall and said cover for sealingly coupling said module and said cover together.

17. The assembly as defined in claim 16, wherein said module comprises male connectors and wherein said cover comprises female apertures for receiving said male connectors when said module and said cover are coupled together.

18. A multi-module construction panel comprising:

(a) a plurality of construction modules as defined in claim 1; and

(b) at least one connector for releasably coupling said modules together.

19. The construction panel as defined in claim 18, wherein each of said modules comprises a plurality of conduits extending transversely at spaced-intervals.

20. The construction panel as defined in claim 19, wherein said modules are arranged so that said conduits are aligned and wherein said at least one connector comprises a cable threaded through said aligned connectors.

21. The construction panel as defined in claim 18, wherein said at least one connector comprises a clip

22. The construction panel as defined in claim 21, wherein said clip defines a recess for receiving perimeter wall portions of said modules.

23. The construction panel as defined in claim 18, wherein said modules are arranged so that said slots in said end portions of modules are aligned and wherein said at least one connector comprises a locking pin insertable into said slots.

24. The construction panel as defined in claim 23, wherein pin is generally U-shaped and comprises to spaced-apart prongs and a connector joining one end of said prongs together, wherein said connector is generally flush with said deck when said pin is fully inserted in said aligned slots.

25. The panel as defined in claim 24, wherein the length of said prongs exceeds the depth of module, wherein said prongs anchor said panel in an underlying support surface when said pin is fully inserted into said aligned slots.

26. A method of constructing a temporary support surface comprising:

(a) providing a plurality of construction assemblies as defined in claim 13;

(b) aligning said plurality of construction assemblies in a desired configuration; and

(c) releasably coupling said plurality of construction assemblies together.

27. The method as defined in claim 26, wherein said coupling comprising passing one or more cables through said assemblies.