CROSS-REFERENCES TO RELATED APPLICATIONS This application claims domestic priority to U.S. Provisional patent application No. 61/783,057 filed Mar. 14, 2013, all of which is hereby incorporated by reference in its entirety.
A portion of the disclosure of this patent document contains material that is subject to copyright protection. The copyright owner has no objection to the reproduction of the patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever.
BACKGROUND The present invention relates generally to concrete forms for building structures and more particularly to cast-in-place construction form panels and associated structures, devices and methods.
Removable form work devices are generally known in the art for casting concrete structures. When erecting structures made of concrete using conventional methods, workers typically assemble a form or mold for casting wet concrete. The amorphous wet concrete fills the mold and takes the shape defined by the mold. When the concrete has dried, or cured, the mold may be removed and a rigid concrete structure having the same shape as the mold remains. Removable concrete formwork of this nature is generally known to include materials such as plywood or metal.
One problem associated with such conventional removable formwork concrete building devices and methods includes the amount of labor and time required to assemble the initial concrete formwork. For example, using conventional plywood or metal formwork devices, workers must work on a jobsite for several days to prepare the formwork in place before concrete is poured. Great care must be taken to ensure that proper spacing is achieved between formwork panels to provide concrete walls, beams and columns having the proper dimensions. This is especially burdensome for forming complex architecture and curved members. Additionally, reinforcing members such as rebar, wire mesh, or other materials must be precisely placed in the interior vacancy of the formwork before the concrete is poured. These tasks are time-consuming, costly, and very labor-intensive. The problems associated with conventional removable formwork concrete construction methods and devices are even more pronounced on smaller scale construction projects, such as residential home construction, where overall project budgets generally do not accommodate the labor and cost intensive procedures associated with formwork assembly.
Others have attempted to overcome the problems associated with removable concrete formwork construction by providing modular forms that can be pre-assembled in a remote location and then interconnected at a construction site to form a building. A simple example of this is the standard concrete masonry block. Concrete masonry blocks generally include a rectangular shell having an interior vacancy. The blocks are dimensioned such that they may be easily handled by a single worker. The blocks are stacked to form a building wall section, and then concrete is poured vertically into the overlapping vacancies in the centers of the blocks. Conventional masonry blocks of this nature, however, are also very time-consuming and require significant labor to construct at a building site. Additionally, the generally standardized shape of the blocks limits the variety of building architecture that can be assembled using the blocks.
Another alternative to conventional removable formwork and concrete masonry blocks includes pre-cast concrete walls. In these systems, building components such as wall sections or floors are pre-cast at a remote location and are shipped to a construction site for assembly. The pre-cast structures are very heavy and must be installed using heavy machinery such as overhead cranes. These types of concrete construction systems are also very labor intensive and expensive to implement. Additionally, others have developed tilt-up concrete construction systems. In these systems, concrete building sections are poured into a horizontal mold at a construction site. Once the concrete is cured, the building sections are lifted up to a vertical orientation using heavy machinery such as cranes or lifts. Like pre-cast systems, tilt-up systems are very labor intensive and expensive to implement.
What is needed then are improvements in concrete formwork, and particularly in modular formwork panels
BRIEF SUMMARY In some embodiments, the present invention provides a modular form panel for assembling concrete structures. The modular form panels of the present invention include inner and outer panel sections separated by a filling gap. One or more support ties span the filling gap and provide a load-bearing function to prevent the panel sections from separating when concrete is poured into the filling gap. Concrete poured into the filling gap provides a concrete wall or roof section. The outer panel section includes the side of the panel that is oriented toward the exterior of the structure, and the inner panel section includes the side of the panel that is oriented toward the interior of the structure. In some embodiments, the outer panel section includes a foam material such as but not limited to expanded polystyrene foam (EPS). The outer panel section serves both a thermally insulative function as well as provides a protective sheathing covering the concrete wall or roof portions of the structure.
In some embodiments, the outer panel section includes at least two discrete layers of foam, including an inner foam layer and an outer foam layer. An integral side flange extends from the vertical lateral edges of the outer foam layer in some embodiments. Each side flange provides a portion of an exterior boundary for an integrated support column defined at the lateral intersection of adjacent form panels. Integrated support columns are formed in corresponding end gaps between adjacent panels when concrete is poured into the spacing between inner and outer panel sections. Integrated support columns include a thickness greater than the filling gap thickness. As such, integrated support columns provide load-bearing vertical supports integrally combined with concrete wall or roof sections.
In some additional embodiments, a bond beam gap is also defined horizontally along the top edge of the panel. The bond beam gap defines a bond beam gap thickness greater than the filling gap thickness. As such, a horizontal concrete support is formed at the top edge of the panel when concrete is poured into the panel. The concrete bond beam is integrally formed as a continuous concrete structure with vertical concrete support columns on either side of the panel and the concrete wall or roof section between inner and outer panel sections.
Numerous other objects, features and advantages of the present invention will be readily apparent to those of skill in the art, upon a reading of the following disclosure, when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 illustrates a perspective view of an embodiment of a modular form panel in accordance with the present invention.
FIG. 2 illustrates a partial cross-sectional view of Section 2-2 of FIG. 1 showing an embodiment of a modular form panel in accordance with the present invention.
FIG. 3 illustrates a detail cross-sectional view of Section 3 of FIG. 2 showing an embodiment of a modular form panel in accordance with the present invention.
FIG. 4 illustrates a detail cross-sectional view of an embodiment of modular form panel in accordance with the present invention.
FIG. 5 illustrates a detail cross-sectional view of an embodiment of modular form panel in accordance with the present invention.
FIG. 6 illustrates a detail cross-sectional view of an embodiment of modular form panel in accordance with the present invention.
FIG. 7 illustrates a partially exploded detail cross-sectional view of an embodiment of an end joint between two modular form panels in accordance with the present invention.
FIG. 8 illustrates a detail cross-sectional view of an embodiment of an end joint between two modular form panels filled with concrete in accordance with the present invention.
FIG. 9 illustrates a detail cross-sectional view of an embodiment foundation, or footing, and a reinforcement member configured to accept one or more modular form panels in accordance with the present invention.
FIG. 10 illustrates a perspective view of an embodiment of two form panels installed on a footing in accordance with the present invention.
FIG. 11 illustrates a detail cross-sectional view of Section 11-11 of FIG. 10 showing adjacent modular form panels in accordance with the present invention.
FIG. 12 illustrates a detail cross-sectional view of a adjacent modular form panels filled with concrete in accordance with the present invention.
FIG. 13 illustrates a detail cross-sectional view of an end joint between adjacent modular form panels in accordance with the present invention.
FIG. 14 illustrates a detail perspective view of an embodiment of a modular form panel in accordance with the present invention.
FIG. 15 illustrates a perspective view of a concrete frame of a building formed with modular form panels in accordance with the present invention.
FIG. 16 illustrates a side view of an embodiment of a top portion of a modular panel including vertical reinforcement members a bond beam gap in accordance with the present invention.
DETAILED DESCRIPTION Referring now to the drawings, an embodiment of a modular form panel is generally illustrated in FIG. 1 and is designated by the numeral 10. Modular form panel 10 includes an inner side 12 and an outer side 14. Inner side 12 may be referred to as an inner panel section 12. Outer side 14 may also be referred to as an outer panel section 14. Panel 10 provides a modular component that can be combined with additional panels to form a form for pouring concrete at a construction location. A filling gap 26 is defined between the inner and outer sides 12, 14. Filling gap 26 defines a void between inner and outer sides 12, 14 into which concrete may be poured. Inner and outer sides 12, 14 provide containment for concrete that is poured into filling gap 26. Filling gap 26 defines a filling gap width 26a, seen in FIG. 2. Filling gap width 26a may vary in different embodiments of modular form panel 10 to provide desired concrete thicknesses between inner and outer sides 12, 14.
Modular building panel 10 can be used to form an exterior wall or roof portion of a building. Multiple modular building panels 10 can be assembled adjacent each other to form a wall, as seen in FIG. 10. Referring further to FIG. 1 and FIG. 2, outer side 14 is generally configured to be oriented toward the exterior of the building. Outer side 14 in some embodiments includes lightweight insulating material such as but not limited to a foam material. In some embodiments, outer side 14 includes a polystyrene material such as expanded polystyrene (EPS) foam. Outer side 14 can include only one layer of foam in some embodiments. In alternative embodiments, as seen in FIG. 2, outer layer 14 includes two layers of foam—an inner foam, or first foam layer 28 and an outer foam, or second foam layer 30. When a building is constructed using one or more modular foam panels 10 having a foam outer layer 14, the outer side 14 may provide enhanced thermal insulation. Additionally, outer side 14 may absorb impacts from wind-driven projectiles such as flying debris resulting from high-wind conditions, tornados or hurricanes. When flying debris impacts the exterior outer side 14, the foam material one or more foam layers may be compressed. Compression of the foam material absorbs and dissipates impact energy. As such, the foam material in outer side 14 in some embodiments prevents damage to the concrete structure filled in filling gap 26 by partially or fully dissipating the kinetic energy of the projectile. Additionally, outer side 14 may be compressed by a projectile to form a compressed pad between the projectile and the concrete structure housed in filling gap 26. As such, in many applications, outer side 14 prevents the projectile from contacting the concrete structure directly.
Inner and outer foam layer thicknesses may be selected to provide optimal impact characteristics. Referring to FIG. 3, Inner foam layer 28 has an inner foam layer thickness 29, and outer foam layer 30 has an outer foam layer thickness 31. Outer side 14 includes a total outer side thickness 27. In some embodiments, inner foam layer thickness 29 is greater than outer foam layer thickness 31. In alternative embodiments, outer foam layer thickness 31 is greater than inner foam layer thickness 29. Different combinations of various foam layers in outer side 14 provide enhanced mechanical, impact, and thermal performance.
Outer side 14 additionally provides a protective shield over the concrete structure housed in filling gap 26. For example, outer side 14 blocks the concrete surface from direct exposure to the weather elements such as wind, sun, snow and rain. This protection afforded by outer side 14 prolongs the life of the concrete structure housed in filling gap 26 and prevents deterioration or damage to the concrete surface and the overall concrete structure.
Referring further to FIG. 1 and FIG. 2, inner side 12 includes an interior mold wall for forming a concrete structure housed in filling gap 26. Inner side 12 can take many various forms in different embodiments. In some embodiments, inner side 12 includes an inner barrier 16 configured to contain the flow of concrete poured into filling gap 26 and to hold firm against the hydrostatic pressure associated with concrete poured in filling gap 26 until the concrete has cured. Inner barrier 16 may include a single or multi-layer construction in various embodiments. Referring to FIG. 3, in some embodiments, inner barrier 16 includes a first inner barrier layer 52 and a second inner barrier layer 56. First inner barrier layer 52 is positioned on the side of inner barrier 16 away from filling gap 26, and second inner barrier layer 56 is positioned between first inner barrier layer 52 and filling gap 26. In some embodiments, first inner barrier layer 52 includes a reinforcement member such as a metal wire lathe or metal wire screen. Second inner barrier layer 56 in some embodiments includes a vapor or liquid barrier material such as a plastic or polymer sheet. While first inner barrier layer 52 may include a permeable mesh in some embodiments, second inner barrier layer 56 provides an impermeable layer to prevent the flow of concrete through inner barrier 16.
Referring further to FIGS. 1-3, one or more support ties 32 are positioned between inner side 12 and outer side 14. Each support tie 32 provides a tensile support between inner and outer sides 12, 14 when concrete is poured into filling gap 26. The flow of concrete into filling gap 26 exerts an outwardly-directed hydrostatic force against the inner and outer sides 12, 14. Support ties 32 bear this tensile load and prevent the inner and outer sides 12, 14 from pushing too far away from each other or undesirably bulging outwardly when filling gap 26 is filled with concrete. As such, in some embodiments, each support tie 32 may include a tensile support member such as a cord or a cable. As seen in FIG. 14, multiple support ties 32a, 32b, 32c, 32d, etc. span filling gap 26 between inner side 12 and outer side 14. When concrete is poured into or otherwise enters filling gap 26, the exposed portion of each support tie 32 is encapsulated with concrete.
It is generally desirable to assemble modular form panel 10 at a location other than a construction site and then to ship the pre-fabricated panels to the construction location. In some embodiments, support ties 32 include rigid tie members that can support not only the tensile stress associated with pouring concrete in filling gap 26, but also the compression and shear stresses associated with shipping and handling of modular form panels 10. As such, support ties 32 in some embodiments include a rigid material such as fiberglass, metal, wood, composite, or any other suitable rigid material for spanning between inner and outer sides 12, 14 and withstanding both tensile and compressive loads.
As seen in FIGS. 3-6, in some embodiments, support tie 32 extends at least partially through outer side 14. For example, as seen in FIG. 3, support tie 32 extends through inner foam layer 28 and also through outer foam layer 30. Support tie 32 passes through holes defined in inner foam layer 28 and outer foam layer 30. An inner foam layer tie hole 33 is defined in inner foam layer 28, and an outer foam layer tie hole 35 is defined in outer foam layer 35. Each tie hole may be defined by any suitable means, such as by drilling, punching, etc. In some embodiments, each tie hole is integrally formed in its corresponding foam layer during the foam production process, wherein the foam is expanded or extruded around a blank or post installed where the tie hole is to be located, and then the blank or post is removed after the foam layer is formed. In additional embodiments, each tie hole is formed by passing a heated member through the foam layer such that the foam material is melted away. This may be done with a heated insert or a gravity-fed heated object such as a heated ball bearing in some embodiments. By passing a heated object through the foam layer to produce a tie hole, the interior of the hole may be advantageously sealed or locally heat-treated, providing a passage wall that prevents undesirable flaking of the foam material when tie rod 32 is installed into the passage.
As seen in FIG. 3, an outer tie fastener 48 may be attached to support tie 32 to secure support tie 32 to outer side 14. In some embodiments, outer tie fastener 48 includes a mechanical fastener such as a screw, bolt or rivet inserted axially into the end of support tie 32. An outer retainer 84 may be positioned between outer tie fastener 48 and outer foam layer 30 in some embodiments. Outer retainer 84 provides a larger surface than outer retainer 84 for applying a force against outer side 14. Outer retainer 84 may be integrally formed on outer tie fastener 48 in some embodiments. In additional embodiments, outer retainer 84 is a separate component such as a washer or strip of material positioned against outer side 14. In alternative embodiments, a small portion of support tie 32 extends outwardly from outer side 14, as seen in FIG. 4, and outer tie fastener 48 includes a circular friction clip positioned axially over the portion of support tie 32 protruding beyond outer side 14. Outer tie fastener 48 may take many other suitable forms, such as a retainer pin or clip installed transversely through support tie 32 or an adhesive installed along support tie 32 inside a tie hole on outer layer 14. As seen in FIG. 14, a plurality of support ties 32a, 32b, 32c, 32d, etc. span filling gap 26 between inner side 12 and outer side 14. Each support tie includes a corresponding outer retainer 84a, 84b, 84c, 84d in some embodiments.
Referring further to FIGS. 1 and 3, a cover layer 54 is disposed on the exterior portion of outer side 14 in some embodiments. Cover layer 54 provides a reinforcement layer for outer side 14. In some embodiments, cover layer 54 includes a metal wire lathe layer. The metal wire lathe material provides an exterior surface suitable for applying stucco or other surface finishes for the exterior of a building in some embodiments. Cover layer 54 may include any suitable material for covering outer foam layer 30 in various embodiments. For example, cover layer 54 includes metal wire mesh or metal lathe in some embodiments. Alternatively, cover layer 54 includes at least one plastic sheet covering outer foam layer 30. The plastic sheet may include any suitable thickness ranging from 0.5 mm to 5 mm in some embodiments. In some embodiments, cover layer 54 includes a plastic sheet having a thickness of about 3 mm. Additionally, cover layer 54 includes a corrugated metal or non-metal material in some embodiments.
Referring to FIG. 2 and FIG. 5, in some embodiments, outer side 14 includes a side flange 58 protruding laterally from one or both sides of outer side 14. Side flange 58 protrudes integrally from outer foam layer 30 in some embodiments. As such, outer foam layer 30 includes a larger width dimension than inner foam layer 28 such that a portion of outer foam layer 30 extends beyond inner foam layer 28 along one or both vertical side edges of modular panel 10. Side flange 58 on outer foam layer 30 extends a flange width 60 beyond the vertical edge of inner foam layer 28 in some embodiments. Side flange 58 includes a distal flange edge 68 protruding away from panel 10. As seen in FIG. 5, in some embodiments, cover layer 54 is folded around side flange 58 and around distal flange edge 68, forming an cover layer flap 64 wrapped around to the interior side of side flange 58. Cover layer 54 may be secured to outer side 14, or outer foam layer 30 using any suitable fastening means such as using mechanical fasteners or an adhesive material. In alternative embodiments, cover layer 54 may be integrally formed or attached to outer foam layer 30 during to foam layer manufacturing process. As seen in FIGS. 3-5, in some embodiments, cover layer 54 is sandwiched between outer retainer 84 and outer foam layer 30. As such, cover layer 54 is mechanically affixed to outer side 14 indirectly using outer tie fastener 48. Referring further to FIG. 5, in some embodiments, cover layer flap 64 may extend inwardly beyond inner foam layer distal end 66 such that the cover layer flap 64 is sandwiched between inner foam layer 28 and outer foam layer 30. Additionally, support tie 32 extends through a hole in cover layer flap 64 such that support tie 32 mechanically secures cover layer flap 64 to outer side 14.
During transport or assembly of modular panel 10, outer side 14 may have a tendency to slide inwardly toward filling gap 26. To prevent this from happening, outer side 14 further includes an inner retainer 86 in some embodiments. Inner retainer 86, seen in FIGS. 4-6, provides a support to the interior surface of outer side 14. In some embodiments, support tie 32 passes through a corresponding opening or hole in inner retainer 86. Inner retainer 86 may include one or more bars or straps of material oriented in any suitable direction to provide support to inner foam layer 28. Inner retainer 86 in some embodiments includes a horizontal metal strip extending between adjacent support ties 32. Multiple support ties 32 extend through inner retainer 86. An inner retainer fastener 88 is disposed on each support tie 32 at or near the local position where the support tie 32 passes through inner retainer 86. Each inner retainer fastener 88 provides a stopping function that keeps inner retainer 86 from sliding away from the outer side 14. Inner retainer fasteners 88 can include any suitable fastener for providing an axial stop along the axial length of support tie 32 to keep inner retainer 86 from sliding away from outer side 14. For example, in some embodiments, inner retainer fastener 88 includes a round friction clip disposed around the circumference of support tie 32. In various other embodiments, inner retainer fastener 88 includes a pin or clip inserted transversely through support tie 32. In alternative embodiments, inner retainer fastener 88 includes a retainer structure integrally formed on support tie 32 protruding radially outwardly from support tie 32 for providing an axial stop against inner retainer 86. In some embodiments, inner retainer 86 is locally positioned on only one support tie 32, and in other embodiments inner retainer 86 may span between two or more support ties 32.
Referring further to FIGS. 1-6, in some embodiments, modular panel 10 includes an integrated stud member 40 on inner side 12 of panel 10. Stud member 40 can include any conventional wall or ceiling stud, such as an aluminum, steel, or wood stud. Each stud member 40 can include a solid or hollow-body or U-shaped channel construction. Each stud member 40 in some embodiments is positioned with a minor vertical edge located against inner barrier 16. Each stud member 40 is generally configured to readily receive an interior finish panel such as drywall on the interior of a building. As such, the inclusion of stud members 40 on modular panel 10 eliminates the need for workers to install studs after the walls and ceiling panels have been finished. Additionally, stud members 40 provide space for running electrical wires and plumbing between the concrete wall portion and the interior finish panels such as drywall.
In some embodiments, each stud member 40 includes an inner stud flange 42 and an outer stud flange 44. Inner stud flanges 42 are positioned on the interior side of inner panel 12 and are configured to receive finishing panels such as drywall. Outer stud flanges 44 are located against inner barrier 16 in some embodiments. As seen in FIG. 3, stud member 40 is mechanically attached to one or more support ties 32 in some embodiments. For example, as seen in FIG. 3, inner stud flange 44 defines a passage hole through which support tie 32 extends in some embodiments. Support tie 32 abuts the inner side of inner stud flange 42 in some embodiments, and an inner tie fastener 46 engages support tie 32 and inner stud flange 42 on stud member 40. Inner tie fastener 46 can include any suitable fastener for providing a mechanical attachment between stud member 40 and an axial end of support tie 32. For example, in some embodiments, inner tie fastener 46 includes a screw, rivet, nail, bolt, etc. inserted through inner stud flange 42 and axially into support tie 32. Alternatively, in other embodiments, inner tie fastener 46 includes a friction clip ring installed over the axial end of support tie 32, as seen in FIG. 4. In other embodiments, inner tie fastener 46 includes a pin, clip or other suitable retaining member inserted transversely through support tie 32 engaging any portion of stud member 40.
Referring further to FIGS. 4-6, in some embodiments, inner barrier 16 may have a tendency to move relative to support tie 32 such as during handling or shipment. It is generally desirable to keep inner barrier 16 positioned at a uniform distance from outer layer 14 to provide a desired width of filling gap 26. As such, in some embodiments, one or more inner barrier fasteners 90 may be positioned on support tie 32 adjacent inner barrier 16. Each inner barrier fastener 90 may be located on the interior side of inner barrier 16 against second inner barrier layer 56. Inner barrier fastener 90 can include any suitable fastener such as a clip fitting around support tie 32 or a pin or clip extending transversely through support tie 32.
Additionally, in some embodiments, a stud fastener 92 is located on the interior side of outer stud flange 44, such that outer stud flange 44 and inner barrier 16 are both sandwiched between stud fastener 92 and inner barrier fastener 90. The use of these fasteners in some embodiments provides enhanced rigidity and stability to inner side 12 and prevents inner side 12 from inadvertently sliding toward outer side 14 during handling, shipment or installation.
Referring further to FIG. 5, an embodiment of a cross-sectional view of a vertical edge of a modular panel 10 is generally illustrated. Inner barrier 16 in some embodiments includes an inner barrier flap 62 extending beyond the outermost vertical stud member 40. Inner barrier flap 62 is folded against the side of stud member 40. Inner barrier flap 62 may be secured to the side of stud member 40 using any suitable attachment means such as a mechanical fastener or an adhesive in various embodiments.
Modular panel 10 in some embodiments is constructed with integrated concrete support material positioned in filling gap 26. Concrete structures are generally built with internal support materials for absorbing and transferring tensile stresses in the concrete material. Steel rebar or steel wire is typically used for these types of applications. In some embodiments, modular panel 10 includes one or more horizontal reinforcing members 94 extending through filling gap 26. Each horizontal reinforcing member 94 includes metal rebar material in some embodiments. In various other embodiments, each horizontal reinforcing member 94 can include any suitable material known in the art such as a metal, composite, fiberglass or polymer rods, bars or cables. Each horizontal reinforcing member 94 may be secured in place in filling gap 26 by fastening directly to one or more support ties 32. For example, in some embodiments, a horizontal reinforcing member 94 spans the width of modular panel 10 in filling gap 26, and the horizontal reinforcing member 94 is fastened to one or more, or all, support ties 32 in the same horizontal plane. Each horizontal reinforcing member 94 may be secured to a support tie 32 using any suitable attachment means such as a wire tie or a polymer rebar clip.
Referring further to FIG. 6, in some embodiments, one or more vertical reinforcement members 96 may also be disposed in filling gap 26. Each vertical reinforcement member 96 can include any suitable reinforcement member known in the art such as metal, composite, fiberglass or polymer rods, bars or cables. Each vertical reinforcement member 96 in some embodiments includes a metal rebar rod. Each vertical reinforcement member 96 in some embodiments is positioned adjacent both a horizontal reinforcement member 94 and a support tie 32, as seen in FIG. 6. As such, one fastener may be used to join all three members at the intersection of the tie member 32, horizontal reinforcement member 94 and vertical reinforcement member 96. By using only one fastener to combine these three members at a common intersection, labor and material costs may be reduced. Additionally, by combining these three members at common intersections, modular panel 10 includes enhanced strength as all three members may provide stress distribution throughout the concrete structure.
Another feature of the modular panels 10 of the present invention provides an integrated concrete support column between panels. Referring to FIGS. 5, 7 and 8, in some embodiments, each side flange 58 protrudes from inner foam layer 28 a side flange distance 66. In some embodiments, as seen in FIG. 2, a side flange 58 protrudes from each vertical edge of modular panel 10. Side flange 58 may be integrated into outer side 14 when only one foam layer is provided. In other embodiments, where outer side 14 includes inner foam layer 28 and outer foam layer 30, side flange includes a portion of outer foam layer 30 protruding laterally beyond the inner foam layer side edge 66. As seen in FIG. 7, when two modular panels 10a, 10b are positioned with vertical edges adjacent one another, a first side flange 58a on first modular panel 10a abuts second side flange 58b on second modular panel 10b. Because first and second side flanges 58a, 58b both protrude beyond the other components on each of first and second modular panels 10a, 10b, an end gap 70 is formed between the remainder of first and second panels 10a, 10b. End gap 70 defines an end gap width 72, as seen in FIG. 7. End gap width 72 may be controlled by choosing a pre-determined side flange width 60, seen in FIG. 5 for each modular panel 10a, 10b.
When adjacent modular panels 10a, 10b are positioned against one another as seen in FIG. 7, end gap 70 includes a larger dimension that first filling gap 26 in first panel 10a and second filling gap 26b in second panel 10b. End gap 70 is generally dimensioned to correspond to an integral concrete support column or support post that is formed when concrete is poured into the filling gaps between the modular panels. As seen in FIG. 7, a blocking channel 74 may be disposed in the gap between opposing inner sides 14a, 14b before concrete is poured into the end gap 70. Blocking channel 74 may include a vertical U or C shaped member that fits between first stud member 40a on first panel 10a and second stud member 40b on second stud member 10b. Blocking channel 74 may be secured in place using any suitable fastening means such as mechanical fasteners, adhesives, or a friction fit. When installed in the end gap 70, blocking channel 74 provides an inner boundary for concrete poured into end gap 70. Referring to FIG. 8, when concrete is poured into end gap 70, the concrete may flow continuously into first filling gap 26a and also into second filling gap 26b. The concrete creates a first concrete wall section 78a in first filling gap 26a on first panel 10a as well as a second concrete wall section 78b in second filling gap 26b on second panel 10b. The concrete also creates an integrated support column 76 defined in the filling gap between first and second panels 10a, 10b.
Integrated support column 76 is made possible by the unique geometry of the vertical edges of each panel, including side flange 58. Each integrated support column 76 is characterized by a support column thickness 73 and a support column width 75, seen in FIG. 8. Although integrated support column 76 seen in FIG. 8 includes a generally rectangular cross-sectional profile, various other embodiments may include one or more integrated support columns 76 having cross-sectional profiles with other polygonal or curvilinear shapes. Support column thickness 73 is generally larger than first wall thickness 77a on first panel 10a, and support column thickness 73 is also generally larger than second wall thickness 77b on second panel 10b. Additionally, in some embodiments, support column width 75 is also larger than both first wall thickness 77a and second wall thickness 77b.
In some embodiments, an integrated support column 76 is formed at each intersection between adjacent modular panels 10. For example, during building construction, multiple modular panels 10a, 10b, etc. are assembled adjacent each other on a footing 112, as seen in FIG. 10. A cross-sectional view in FIG. 11 shows vacant first end gap 70a, second end gap 70b, and third end gap 70c, as well as vacant first filling gap 26a and second filling gap 26b. Once panels are positioned on footing 112 and blocking channels 74 are installed, concrete may poured into any vacant section on either panel. In some embodiments, it is preferable to pour concrete from overhead into at least one end gap 70 and to allow the poured concrete to flow laterally outwardly into the adjacent filling gaps 26. In other embodiments, concrete may be poured into filling gaps 26 and flow outwardly toward end gaps 70. Referring to FIG. 12, concrete is allowed to flow into adjacent gaps forming an integrated concrete structure. As seen in FIG. 12, a wall or roof section may include a first integrated support column 76a, then a first wall section 78a, then a second integrated support column 76b, then a second wall section 78b, then a third integrated support column 76c, and so on.
Multiple modular panels may be positioned beside each other to form a large building structure having numerous integrated support columns. For example, an embodiment of a concrete frame, or skeleton, of a building is generally illustrated with outer foam layers removed. The building 100 includes a plurality of vertical integrated support columns 76a, 76b, etc. A roof formed using panels 10 also includes integrated roof columns 77a, 77b. One aspect of some embodiments of the present invention provides a building 100 having integrated vertical support columns 76a, 76b, etc. formed end-to-end with integrated concrete roof columns 77a, 77b, etc. As such, vertical integrated support columns 76 provide load-bearing members to support the weight of a concrete roof. This provides a significant advantage over conventional concrete buildings which typically include non-concrete roof structures.
By providing integrated vertical support columns 76 aligned with corresponding roof columns 77 in some embodiments, the present invention provides a roof system having a variable pitch angle. In some embodiments, the present invention provides a concrete roof having a pitch (rise over run) ranging between 3:12 all the way up to 12:12. The building system of the some embodiments of the present invention allows low-pitch roofs because the integrated vertical support columns 76 provide a significant load-bearing function. Further, because the roof is integrally poured with the side walls and vertical support columns as one integral concrete structure in some embodiments, the entire building 100 includes a continuous concrete frame that includes internal supports in both tension and compression. This further allows for lower pitch angle roofs as compared to conventional concrete roof structures.
Referring now to FIG. 9 and FIG. 10, in some embodiments, it is generally desirable to include one or more column reinforcements 104 in end gap 70 before pouring concrete to form integrated support column 76. Each column reinforcement 104 is generally dimensioned to fit in end gap 70. As seen in FIG. 9, each column reinforcement 104 corresponds to a pre-determined location on footing 112 in some embodiments. Footing 112 includes a concrete structure forming a base for installing modular panels 10. Footing 112 in some embodiments includes a plurality of mounting post groups 114a, 114b, 114c, etc. located at pre-defined intervals. Each mounting post group 114 is positioned to correspond to a location of an end gap 70 between adjacent modular panels 10. Each mounting post group 114 provides a mounting location for affixing column reinforcement 112. As such, once concrete is poured to form integrated support column 76, stress may be transferred through the column reinforcement 104 and into footing 112 via post group 114. Post group 114 in some embodiments includes a plurality of rebar posts protruding upwardly from footing 112. Post group 114 includes a spacing pattern such that each post will generally be located an adjacent member on column reinforcement 104. During installation, each column reinforcement 104 may be placed into end gap 70 from the interior side of the panels. For example, referring to FIG. 7 and FIG. 13, in some embodiments, a column reinforcement 104 may be installed into end gap 70 from the same direction as blocking channel 74. Column reinforcement 104 is positioned in end gap 70 prior to placement of blocking channel 74 between panels. Once column reinforcement 104 is in place, blocking channel 74 may be installed and concrete may be poured to fill end gap 70.
In some embodiments, column reinforcement 104 includes a pre-formed rebar cage having a plurality of vertical supports 106a, 106b, 106c, 106d and a plurality of horizontal supports 108a, 108b, 108c, 108d, 108e, 108f. Column reinforcement 104 in some embodiments, as seen in FIGS. 11 and 12, is dimensioned to allow concrete to completely surround the individual reinforcement members on column reinforcement 104. Various construction standards require a specified amount of concrete surrounding reinforcing elements, and column reinforcement 104 is generally dimensioned to comply with such standards. In some embodiments, as seen in FIG. 13, each vertical support 106 is positioned to fit on the outside of a corresponding footing post 102. For example, a first footing post 102a protrudes from footing 112 at a fixed location, and a first vertical support 106a in column reinforcement 104 fits adjacent to and on the outside of first footing post 102a. Additionally, a first horizontal reinforcing member 94a and a first vertical reinforcing member 96a are positioned on a first side of column reinforcement 104 in first modular panel 10a. To provide further support, in some embodiments, a second horizontal reinforcing member 94b and a second vertical reinforcing member 96b are positioned on a second side of column reinforcement 104 in second modular panel 10b. First support tie 32a and second support tie 32b also provide additional support to the region forming the integrated support column.
Referring further to the drawings, FIG. 14 illustrates an embodiment of an upper edge of a modular panel 10. Panel 10 includes a bond beam tray 50 horizontally positioned along the upper edge of inner side 12 in some embodiments. Bond beam tray 50 provides a barrier for preventing concrete from falling into the spacing between stud members 40. As seen in FIG. 14 and FIG. 16, panel 10 in some embodiments includes an upper bond beam gap 110 having a bond beam gap thickness 111 than the thickness of filling gap 26. Additionally, in some embodiments, an outer top flange 97 protrudes upwardly from outer side 14. Upper flange 97 extends integrally from outer foam layer 30 in some embodiments. Outer foam layer 30 has a larger height than the top edge of inner foam layer 28, forming an integral outer top flange 97 extending above the top edge of inner foam layer 28.
Additionally, an inner top flange 80 protrudes upwardly from inner side 12 in some embodiments. Inner top flange 80 may extend upwardly from stud members 40, or may be formed from a separate member attached to the upper portion of each stud member. Each inner top flange 80 has a smaller thickness than the stud member 40 above which it extends. Bond beam gap 110 is defined at the top of panel 10 above filling gap 26. Bond beam gap 110 has a bond beam gap thickness 111 defined as the distance between inner top flange 80 and outer top flange 97. Bond beam thickness 111 is larger than filling gap thickness 77. When concrete is poured into the filling gap 26 or end gap 70, the concrete will fill bond beam gap 110 and form an integral bond beam 116, seen in FIG. 15. Each bond beam gap 110 has the same thickness as support column thickness 73 in some embodiments. In alternative embodiments, bond beam gap 110 has a different thickness than support column thickness 73. One advantage of the present invention is the formation of a horizontal bond beam 116, seen in FIG. 15, integrally formed with support columns 76c, 76d. In some embodiments, outer side 14 includes a first side flange on a first side flange 58a protruding laterally from a first side of panel 10 and a second side flange 58b protruding laterally from a second side of panel 10. Panel 10 also includes an outer top flange 97 protruding upwardly from outer side 14 and an inner top flange 80 protruding upwardly from inner side 12. The outer and inner top flanges 80, 97 define a bond beam gap having a width greater than filling gap 26, and each side flange 58a, 58b defines a boundary for an integrated support column 76 having a thickness greater than filling gap 26.
Referring further to FIG. 16, another feature of some embodiments of modular panel 10 includes an outer top flange 97 having an outer top flange offset 126. In some embodiments, outer top flange 97 extends a vertical distance above the upper end of inner top flange 80. That vertical distance is described as an outer top flange offset 126. In some applications, the modular panels of the present invention may be used to form both walls and a roof. For example, a concrete roof 128, seen in FIG. 15, can be formed by placing panels 10 over a wall structure and filling the filling gap with concrete such that the concrete flows through the filling gap in the roof panels and extends downwardly to the walls. When a wall panel is positioned vertically to form a portion of a wall, a corresponding roof panel will be placed above and at an angle to the wall panel. The roof panel may be at any desirable pitch angle relative to the vertical wall panel. Outer top flange offset 126 protrudes upwardly to close the gap between the lower edge of the adjacent roof panel and the upper edge of the wall panel. Outer top flange 97 may also include a beveled top edge 98 defining a top edge angle 120. Top edge angle 120 is the angle of beveled top edge 98 with reference to a horizontal reference axis 118.
Referring further to FIG. 16, in some embodiments vertical reinforcement members 96 terminate at an upper end providing bond beam reinforcement members. Concrete bond beam 116, seen in FIG. 15, requires internal reinforcement to distribute tensile loads within the bond beam. Bond beam reinforcement members 124a, 124b, etc. are positioned inside the internal structure of bond beam 116 in some embodiments. Bond beam reinforcement members 124a, 124b can include any suitable reinforcement structure for use with concrete, such as wire mesh or metal, composite, fiberglass or polymer rods, bars or cables. In some embodiments, a first bond beam reinforcement member 124a extends upwardly from first vertical reinforcement member 96a. First bond beam reinforcement member 124a may include an angle bracket integrally formed on first vertical reinforcement member 96a. A second bond beam reinforcement member 124b protrudes upwardly into bond beam gap 110 from an adjacent vertical reinforcement member. In some embodiments, adjacent bond beam reinforcement embers 124a, 124b extend either toward inner side 12 or outer side 14 in an alternating fashion. In additional embodiments, one or more horizontal bond beam supports 128 spans horizontally between bond beam reinforcement members within bond beam gap 110 to provide additional reinforcement to concrete bond beam 116.
Thus, although there have been described particular embodiments of the present invention of a new and useful modular concrete form panel apparatus it is not intended that such references be construed as limitations upon the scope of this invention except as set forth in the following claims.
