U.S. patent application number 10/646791 was filed with the patent office on 2004-02-26 for modular wall segments and method of making such segments.
Invention is credited to Eliyahu, Maimon, Oren, Dror.
Application Number | 20040035068 10/646791 |
Document ID | / |
Family ID | 31886130 |
Filed Date | 2004-02-26 |
United States Patent
Application |
20040035068 |
Kind Code |
A1 |
Eliyahu, Maimon ; et
al. |
February 26, 2004 |
Modular wall segments and method of making such segments
Abstract
A modular wall segment for constructing a wall includes two
walling sheets of selected size and shape bonded to the opposite
faces of a plurality of contiguously placed aerated concrete
blocks. The segments may be formed with end faces defining slots of
various configurations for receiving various types of fastening
elements to enable a plurality of such segments to be secured
together in a modularized fashion.
Inventors: |
Eliyahu, Maimon; (Kiryat
Ata, IL) ; Oren, Dror; (Raanana, IL) |
Correspondence
Address: |
G.E. EHRLICH (1995) LTD.
c/o ANTHONY CASTORINA
SUITE 207
2001 JEFFERSON DAVIS HIGHWAY
ARLINGTON
VA
22202
US
|
Family ID: |
31886130 |
Appl. No.: |
10/646791 |
Filed: |
August 25, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10646791 |
Aug 25, 2003 |
|
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10032455 |
Jan 2, 2002 |
|
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Current U.S.
Class: |
52/271 ;
52/783.1 |
Current CPC
Class: |
B32B 13/04 20130101;
B32B 13/10 20130101; E04B 1/6145 20130101; E04B 2/7401 20130101;
E04B 1/6162 20130101; E04C 2/041 20130101; E04B 1/14 20130101; B32B
2607/00 20130101; B32B 3/18 20130101 |
Class at
Publication: |
52/271 ;
52/783.1 |
International
Class: |
E04B 001/00; E04B
007/00 |
Claims
What is claimed is:
1. A modular wall segment for constructing a wall, comprising: (a)
a first walling sheet of a selected two-dimensional shape and size;
(b) a second walling sheet of said selected two-dimensional shape
and size; and (c) a plurality of aerated concrete blocks
contiguously located in a plurality of rows and columns between
said first and second walling sheets to form a volume of consistent
thickness of said selected two-dimensional shape and size; said
plurality of aerated concrete blocks being bonded on their opposite
faces to said first and second walling sheets.
2. The modular wall segment according to claim 1, wherein said
plurality of aerated concrete blocks include a quantity of a
bonding material between them to augment their securement together
within the modular wall segment by said walling sheets.
3. The modular wall segment according to claim 1, wherein the
modular wall segment is formed on at least one end face with a slot
for receiving a fastening element to secure the modular wall
segment to other modular wall segments.
4. The modular wall segment according to claim 3, wherein said slot
extends longitudinally through all the aerated concrete blocks at
the respective end of the modular wall segment.
5. The modular wall segment according to claim 3, wherein said slot
is defined by the two walling sheets projecting outwardly past the
plurality of aerated concrete block at the respective end of the
modular wall segment.
6. The modular wall segment according to claim 5, wherein the
modular wall segment includes a U-shaped channel member received in
said slot.
7. The modular wall segment according to claim 3, wherein one end
face of the modular wall segment is formed with said slot, and the
opposite end face of the modular wall segment is formed with a rib
dimensioned to be received in said slot of another like modular
wall segment.
8. The modular wall segment according to claim 3, in combination
with a fastening element dimensioned to be received in said slot to
secure the modular wall segment to another modular wall
segment.
9. The modular wall segment according to claim 8, wherein said
fastening element is a fastening bar dimensioned to be received in
said slot of two aligned modular wall segments to secure them
together.
10. The modular wall segment according to claim 9, wherein said
fastening bar is of a cruciform cross-section.
11. The modular wall segment according to claim 9, wherein said
fastening bar is of a T-cross section.
12. The modular wall segment according to claim 11, wherein said
fastening bar is of a hollow rectangular cross-section.
13. A composite modular wall segment for constructing a wall
constituted of two wall segments each according to claim 1, wherein
said two segments are of the same dimensions, include walling
sheets having planar outer faces, and are joined together at their
planar outer faces to define the composite modular wall segment for
constructing a wall.
14. The composite modular wall segment according to claim 13,
wherein said composite modular wall segment includes an insulating
layer between said two joined segments.
15. The modular wall segment according to claim 1, wherein said
segment includes reinforcement cables passing through said
plurality of aerated concrete blocks.
16. The modular wall segment according to claim 15, wherein said
reinforcement cables are passed through channels formed in said
plurality of aerated concrete blocks and terminate in ends
securable to load-bearing structures to provide protection against
earthquakes.
17. The modular wall segment according to claim 1, wherein at least
one of said walling sheets is of the group consisting of plywood,
gypsum board, cement-board, composition-board, plasterboard and
wallboard.
18. The modular wall segment according to claim 1, wherein said
plurality of aerated concrete blocks are bonded by adhesive layers
to said first and second walling sheets.
19. A building structure including walls made of a plurality of
modular wall segments according to claim 1 secured together.
20. A method of making a wall segment useable for constructing a
wall, comprising: (a) applying a first layer of glue between a
first walling sheet and a first surface of a plurality of
contiguously placed aerated concrete blocks arranged in a plurality
of rows and columns; (b) applying a second layer of glue between a
second walling sheet and a second surface of said plurality of
contiguously placed aerated concrete blocks; and pressing said
first walling sheet against said first surface of said plurality of
aerated concrete blocks and said second walling sheet against said
second surface of said plurality of aerated concrete blocks, while
said first and second layers of glue solidify.
Description
RELATED APPLICATION
[0001] This application is a continuation of U.S. patent
application Ser. No. 10/032,455 filed Jan. 2, 2002, now U.S. Pat.
No. 6,6XX,XXX.
FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to a modular wall segment
construction, to methods of making such segments, and to uses of
such segments in the construction of walls.
[0003] Construction methods currently in popular use in many
locations and climates are typically slow and labor-intensive. In
Israel, for example, most constructions of interior walls rely on
methods substantially unchanged over many years. Interior walls
built in Israel, as well as those built in many similar climates,
are typically constructed of cinderblock or of cement-based blocks
of other types (referred to collectively hereinbelow as
"construction blocks"), built into a wall by masons on the
construction site, then covered by hand with a mixture of cement
and fine sand, and finally finished by paint or plaster. Openings
for doors and windows are measured on site and built into the
block-based construction by hand, and channels for electrical and
plumbing conduits are typically chiseled by hand into the
constructed wall.
[0004] The popular construction process here described is not only
slow and labor intensive, but also requires a high degree of skill
and workmanship. Any failure in the workmanship may result in
unevenness in the wall surface, or inaccurate placement of planned
fixtures.
[0005] Alternative methods for the construction of interior
non-loadbearing walls involve the use of broad prefabricated sheets
of walling material, such as sheetrock, wallboard, gypsum board,
DENSEGLASS, sheetrock, concreteboard or plasterboard. Such
materials, referred to collectively hereinbelow as "walling
sheets", are often used together with a variety of insulating
materials to produce interior walls. To construct a wall using
walling sheets, a worker typically erects a metal or plastic frame
at the desired location of the wall, and then attaches walling
sheets to both sides of the frame, and, optionally, fills the space
between the pair of walling sheets with insulating material.
[0006] Walls constructed of walling sheets are typically built more
rapidly than those built of construction blocks, and have the
advantage that the walling sheets themselves are smooth and
typically present a fairly aesthetic and finished appearance, once
attached to a frame. Therefore, building walls using walling sheets
may be accomplished by workers having less professional skill than
those required to erect a smooth, vertical, and well-finished wall
using construction blocks. Both the greater rapidity of
construction, and the lower skill requirements for the construction
workers, are reflected in substantially lower construction costs
for walls built of walling sheets in modular units. However, walls
built using walling sheets are typically of lower quality than
those built using construction blocks. In particular, walls built
of walling sheets are typically less strong and less solid than
walls built of construction blocks, and their thermal and acoustic
insulating qualities are inferior.
[0007] Thus, there is a widely recognized need for, and it would be
highly advantageous to have, a construction material and method of
construction which provide the relative rapidity, simplicity and
reduced manpower costs of modular construction, as well as the
smooth, aesthetic, and highly finished appearance of walls
constructed with walling sheets, together with the high-quality,
strength, solidity and good acoustic and thermal insulating
properties, of walls constructed with construction blocks.
[0008] Under construction practices typically in use at
construction sites in Israel and in many other locations,
responsibility for implementing the detailed plans provided by
architects and engineers for accurately measuring and accurately
implementing the correct placement of openings for doors and
windows, for communication and electrical conduits, and for pipes
and other conduits, typically falls on the masons constructing the
walls. The fact that primary responsibility for accurate placement
of such features is in the hands of on-site masons or other
construction workers building the walls further reinforces the need
for highly skilled, and consequently relatively expensive,
construction workers on the construction site.
[0009] Thus, there is further a widely recognized need for, and it
would be highly advantageous to have, a construction material and a
method of construction which enable the building of walls having
openings and fixtures which are elegantly finished and accurately
placed according to architects' and engineers' specifications, yet
which do not require highly skilled personnel at the construction
site.
[0010] Prior art methods for building walls further include the use
of pre-fabricated modular wall segments each comprising a pair of
walling sheets sandwiching between them an insulating material of
some sort. Argal, Calcar, and various polyurethane-based
compositions have been used as insulating material in this context.
The modular wall segments thereby produced do allow relatively easy
wall construction, yet they fail to provide the solidity and
acoustic and thermal isolating properties comparable to those
obtained with masonry walls built of construction blocks. Moreover,
many such materials have been found to be flammable, or to emit
poisonous gasses into the surrounding environment when heated. For
this and other reasons, available pre-fabricated modular wall
segments comprising walling sheets surrounding an insulating
material do not meet the minimum acceptable standards required
under the building codes in force in Israel and in various other
localities.
[0011] Thus there is further a widely recognized need for, and it
would be highly advantageous to have, a construction material and a
method of construction providing the advantages of rapidity and
simplicity of modular construction and the solidity and insulating
qualities of construction-block construction, while utilizing
material components which are not flammable and which cause no
harmful emissions to the environment when heated, and which are
already recognized as acceptable building materials according to
common practice and according to the legal requirements of the
building codes in force in many localities.
[0012] In localities which suffer periodic earthquakes, the dangers
and disadvantages of falling masonry construction blocks are well
known. Falling masonry construction blocks comprising the walls of
a building may be responsible for damage to property and injury and
death to people, even in cases where the well-constructed
load-bearing skeleton of the building (e.g., the reinforced
concrete sections) survive an earthquake relatively intact.
[0013] Thus there is further a widely recognized need for, and it
would be highly advantageous to have, a construction material and a
method of construction which minimizes the danger of falling walls
and wall components during earthquakes.
SUMMARY OF THE INVENTION
[0014] According to one aspect of the present invention, there is
provided a modular wall segment for constructing a wall,
comprising: (a) a first walling sheet of a selected two-dimensional
shape and size; (b) a second walling sheet of the selected
two-dimensional shape and size; and (c) a plurality of aerated
concrete blocks contiguously located in a plurality of rows and
columns between said first and second walling sheets to form a
volume of consistent thickness of the selected two-dimensional
shape and size; the plurality of aerated concrete blocks being
bonded on their opposite faces to the first and second walling
sheets.
[0015] According to some described preferred embodiments, the
aerated concrete blocks are contiguously placed in direct contact
with each other and are secured together within the modular wall
segment solely by the external layers. Another embodiment is
described wherein the aerated concrete blocks include a quantity of
a bonding material between them to augment their securement
together within the modular wall segment by the external
layers.
[0016] According to further features in the described preferred
embodiments, the modular wall segment is formed on at least one end
face with a slot for receiving a fastening element to secure the
modular wall segment to other modular wall segments. Various
embodiments described below illustrate various types of
configurations of slots, and of fastening elements to be received
in such slots, for utilizing the segments in a modular manner to
construct a wall or a juncture with a floor or ceiling.
[0017] The present invention thus addresses the shortcomings of the
presently known configurations by providing a construction material
and a method of construction which enable low-cost wall
construction by utilizing the rapidity and simplicity of modular
wall construction techniques, yet which produce high-quality,
strong and solid walls whose acoustic and thermal insulating
properties are comparable to those found in walls built using
constructions blocks.
[0018] The present invention further addresses the shortcomings of
the presently known configurations by providing a construction
material and a method of construction which enable building walls
with highly accurate placement of openings and fixtures, yet which
do not require highly skilled personnel at the construction
site.
[0019] The present invention still further addresses the
shortcomings of the presently known configurations by providing a
construction material and a method of construction providing the
rapidity and simplicity of modular wall construction and the
solidity and insulating qualities of construction-block
construction, while enabling the utilization of materials which
cause no harmful emissions to the environment and which are widely
recognized and accepted as building materials both according to
common practice and according to the building codes in force in a
wide variety of locations.
[0020] The present invention still further addresses the
shortcomings of the presently known configurations by providing a
construction material and a method of construction which minimize
danger of falling walls and wall components during an
earthquake.
[0021] Further features and advantages of the invention will be
apparent from the description below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The invention is herein described, by way of example only,
with reference to the accompanying drawings. With specific
reference now to the drawings in detail, it is stressed that the
particulars shown are by way of example and for purposes of
illustrative discussion of the preferred embodiments of the present
invention only, and are presented in the cause of providing what is
believed to be the most useful and readily understood description
of the principles and conceptual aspects of the invention. In this
regard, no attempt is made to show structural details of the
invention in more detail than is necessary for a fundamental
understanding of the invention, the description taken with the
drawings making apparent to those skilled in the art how the
several forms of the invention may be embodied in practice.
[0023] FIG. 1 is a simplified cross-section of a modular wall
segment according to an embodiment of the present invention;
[0024] FIG. 2 is a simplified isometric illustration of a modular
wall segment according to another embodiment of the present
invention;
[0025] FIG. 3 is a simplified flow chart showing a preferred method
for constructing a modular wall segment according to an embodiment
of the present invention;
[0026] FIGS. 4a and 4b are simplified cross-sectional views of
preferred methods for joining modular wall segments one to another
to make a wall, according to an embodiment of the present
invention;
[0027] FIGS. 5a and 5b are simplified isometric views, and FIG. 5c
is a cross-sectional view of further configurations for joining
modular wall segments longitudinally, according to an embodiment of
the present invention;
[0028] FIG. 6 is a simplified cross-sectional view of a
configuration for joining a modular wall segment to a ceiling or to
a floor, according to an embodiment of the present invention;
[0029] FIGS. 7a and 7b are simplified isometric views of a
configuration for joining a modular wall segment to a floor which
is not horizontal, according to an embodiment of the present
invention;
[0030] FIG. 8 is a simplified isometric view of further
configurations for joining several modular wall segments one to
another to make a wall, according to an embodiment of the present
invention;
[0031] FIG. 9 is a simplified isometric view of a configuration for
joining modular wall segments perpendicularly, according to an
embodiment of the present invention;
[0032] FIG. 10 is a simplified isometric view of a configuration
for joining modular wall segments in parallel, according to an
embodiment of the present invention;
[0033] FIG. 11 is a simplified isometric view of a configuration
for joining a modular wall segment to an exterior wall, according
to an embodiment of the present invention;
[0034] FIG. 12 is a simplified isometric view of a configuration of
walls composed of modular wall segments and including pre-planned
small and large openings, according to an embodiment of the present
invention; and
[0035] FIG. 13 is a simplified cross-sectional view of modular
walls segments in a configuration reducing danger from earthquakes,
according to an embodiment of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0036] The present invention involves a modular wall segment
comprising an inner layer of aerated concrete blocks glued between
two outer layers, methods for constructing same, and uses thereof.
Specifically, the present invention can be used to construct walls
which combine the advantages of modular construction, easy and
rapid installation, and aesthetic appearance, with the solidity and
thermal and acoustic isolating qualities of
construction-blocks.
[0037] To enhance clarity of the following descriptions, the
following phrases will first be defined:
[0038] The phrase "aerated concrete block" is used herein to refer
to a block suitable for use as a building material, containing
cement, sand, and other materials, and having a highly porous
internal structure or a cellularized internal structure. Such
blocks may be produced, for example, by a process of mixing cement,
sand, lime, cement, and a foaming agent with water and pouring into
a mold. The foaming agent causes tiny bubbles to develop within the
cement mixture. The bubbles remain interspersed within the cement
mixture. When the mixture hardens, these tiny bubbles are
permanently fixed within the block structure, resulting in a
cement-based construction block having an internal cellular
structure which includes multiple small spaces formed by the
bubbles created by the foaming process. The block thereby formed is
strong and solid and is a good thermal and acoustic insulator, yet
is significantly less dense than would be a block formed of a
comparable mixture of cement, sand, lime and water without the use
of a foaming agent. In a typical fabrication process, the mixture
is poured into a form, foams up to about double its volume, is kept
moist, and is allowed to set for about 90 minutes, after which it
is hard enough so that it can be moved, or cut to desired
dimensions.
[0039] Construction blocks marketed under the trade name YTONG and
construction blocks marketed under the trade name ESHKOLIT are
examples of aerated concrete blocks. It is noted that it is the
cellularized or highly porous character of the blocks, and their
relatively low density when compared to standard cement-based
blocks, which are their defining characteristics. Aerated concrete
blocks may be produced by the foaming process described
hereinabove, or by any other process.
[0040] The phrase "walling sheets" is used herein to refer to any
member of the general class of objects having a form which combines
a relatively thin dimension, usually between several millimeters
and several centimeters and most typically about one or two
centimeters in thickness, with much larger width and height
dimensions, typically from tens to several hundreds of centimeters
in width and height, whose physical characteristics make them
appropriate for use as partitioning elements in walls. Walling
sheets typically have a generally smooth surface, aesthetically
suitable for use in walls. Wood, for example plywood, wood
composition boards, sheetrock, Gypsum board, cement-board,
plasterboard, wallboard, and DENSEGLASS are examples of "walling
sheets". It is noted that the expression "walling sheets" as used
herein is not intended to be limited to the specific examples here
mentioned. Rather, the expression "walling sheets" is intended to
refer to any objects of size, shape, and physical characteristics
similar to those of plywood, sheetrock, gypsum board, cement-board,
plasterboard, wallboard and DENSEGLASS, making them appropriate for
use as part of a wall structure.
[0041] The principles of the construction and use of wall modules
according to the present invention may be better understood with
reference to the drawings and accompanying descriptions.
[0042] Before explaining at least one embodiment of the invention
in detail, it is to be understood that the invention is not limited
in its application to the details of construction and the
arrangement of the components set forth in the following
description or illustrated in the drawings. The invention is
capable of other embodiments or of being practiced or carried out
in various ways. Also, it is to be understood that the phraseology
and terminology employed herein is for the purpose of description
and should not be regarded as limiting.
[0043] Referring now to the drawings, FIG. 1 is a simplified
cross-section of a modular wall segment according to an embodiment
of the present invention.
[0044] A modular wall segment 101 comprises two external layers,
individually designated as first external layer 105 and second
external layer 107, and an internal layer 111.
[0045] Each external layer 105, 107 is a walling sheet as defined
hereinabove. Commercially available produces such as plywood,
sheetrock, wallboard, plaster-board, cement-board, or DENSEGLASS
may be used. These commercially available produces are, however,
mentioned as illustrative examples only, and are not intended to
limit the scope of the invention. Any object of similar shape and
physical characteristics, whether commercially available or
specifically prepared for the purpose, may be utilized as walling
sheets and incorporated in modular wall segment 101 as external
layers 105, 107.
[0046] Internal layer 111 comprises a plurality of aerated concrete
blocks 113 located in a plurality of rows and columns between the
walling sheets 105, 107, as more particularly seen in FIGS. 2, 4a
and 4b. Blocks 113 are shown as if slightly separated in FIG. 1,
for clarity of the figure, but in practice blocks 113 are
preferably contiguous one to another.
[0047] A first glue layer 116 between internal layer 111 and
external layer 105, and a second glue layer 118 between internal
layer 111 and external layer 107 serves to hold these layers of
modular wall segment 101 together as a unit.
[0048] A slot 114 may be provided in exposed surfaces of certain
blocks 113 at the end faces of the respective segment to facilitate
joining the modular wall segment 101 to floors, ceilings, and to
other modular wall segments. In the construction illustrated in
FIG. 1, slot 114 extends transversely through the block 113 at the
respective end face of the segment.
[0049] Reference is now made to FIG. 2, which is a simplified
isometric illustration of a modular wall segment according to an
embodiment of the present invention. FIG. 2 presents a modular wall
segment 101 similar in structure and identical in purpose to
modular wall segment 101 shown in FIG. 1. As an aid to
understanding, the numbered features of FIG. 1 are reproduced in
FIG. 2 in isometric perspective. Slot 114' in FIG. 2 is presented
as a wide slot, whereas in FIG. 1 slot 114 is narrow. Slot 114 is
formed in the end faces of the line of aerated concrete blocks at
the respective end of the modular wall segment and extends parallel
to the walling sheets 105 and 107. Slot 114' in FIG. 2 is defined
by having the ends of the two walling sheets, 105, 107, project
past the end face of the aerated concrete block 113 at the
respective end of the segment, and a U-shaped channel member 114"
is preferably introduced into that slot for reinforcement purposes.
Both wide and narrow configurations of the slot 114 may be used for
joining modular wall segment 101 to floors, ceilings and other
modular wall segments. The relatively narrow slot 114 presented in
FIG. 1 is a presently preferred configuration.
[0050] Reference is now made to FIG. 3, which is a simplified flow
chart presenting a preferred method for constructing modular wall
segment 101, according to any embodiment of the present
invention.
[0051] A first walling sheet 104 substantially formed in a selected
two-dimensional shape and size is used as a basis for construction.
The selected two-dimensional shape is typically rectangular, but
any selected shape, and any convenient size, may be used.
[0052] At step 121 a first glue layer 116 consisting of a
polyurethane-based glue is placed between a first walling sheet
used as a first external layer 105 and a plurality of aerated
concrete blocks 113 which constitute internal layer 111. KLEIBERIT
glue supplied by BECKER GMBH of Germany is a preferred glue for
this purpose. Glue density of up to 375 gm per square meter, for
each glue layer 116, is preferred.
[0053] A convenient way to place first glue layer 116 between
external layer 105 and blocks 113 is to lay a first walling sheet
on an assembly table, spread glue on the sheet, and then place
aerated concrete blocks 113 on the glue-coated walling sheet.
Blocks 113 are placed contiguously, in contiguous parallel rows, so
that they together constitute a volume of constant thickness
approximating the size and shape of the walling sheet. Blocks 113
are placed in rows in the classical staggered relationship. Neither
glue nor any other binding material is required between contiguous
blocks 113, as blocks 113 are held in place by glue layer 116
between blocks 113 and the walling sheet of external layer 105.
[0054] At step 123, a second glue layer 118 is placed between
aerated concrete blocks 113 and a second walling sheet to serve as
the second external layer 107. The shape and size of the second
walling sheet preferably conforms to the two-dimensional shape and
size of the first walling sheet defining the first external layer
105. The second glue layer 118 can conveniently be applied by
coating the exposed (upper) side of blocks 113 with glue, and then
placing the second walling sheet over the glue-coated blocks 113.
At the conclusion of step 123, first external layer 105, internal
layer 111, and second external layer 107 are placed relative to
each other in the configuration shown as modular wall segment 101
in FIGS. 1 and 2 before the glue layers 116 and 118 intended to
bind them together have solidified.
[0055] In step 125 pressure is applied to the construction in such
a manner as to force both external layer 105 and external layer 107
to be pressed strongly into close contact with blocks 113
constituting inner layer 111, and to be held in close contact until
glue layers 116 and 118 become set. In a preferred mode of
operation pressure is applied by transferring the constructed
layers from the assembly table to a pressure table while preserving
the layers' spatial relationships, and then using the pressure
table to apply pressure vertical pressure which forces layers 105,
111 and 107 to remain strongly pressed together while the glue
dries. In a preferred method, a pressure of approximately 40
atmospheres per square centimeter is applied for approximately 40
minutes. After 40 minutes segment 101 may be moved to a storage
area. In optional step 127, glue layers 116 and 118 are preferably
left to cure for an additional day prior to use of the segment.
[0056] In the method illustrated in FIG. 3, the blocks are placed
in direct contact with each other and are secured together with the
modular wall segment solely by the external layers bonded to the
opposite faces of the blocks. It may be desirable in some cases,
however, to also include a quantity of a bonding material, such as
cement, between the contacting faces of the blocks to augment their
securement together within the modular wall segment by the external
layers.
[0057] In optional step 129, a prepared segment 101 may be sawed to
a desired size and shape, slots 114 may be cut, openings (e.g., for
doors and windows) may be cut, channels (e.g., for electrical
conduits) may be drilled. Slits and other configurations for
joining one module to another, as described hereinbelow with
reference to FIG. 4, may be prepared at this time.
[0058] The process described in FIG. 3 produces a modular wall
segment 101 with desired characteristics. Segment 101 is strong,
provides good thermal and acoustic isolation, yet is lighter and
more easily worked than a wall of comparable shape and size
constructed of cinderblock or construction blocks of other sorts.
Segment 101 has smooth and aesthetically pleasing external surfaces
with a finished appearance, ready for painting. Segment 101 may be
cut to a desired width and shape using a saw. Walls constructed of
modular wall segments 101 may be used for internal
(non-load-bearing) walls. Segments 101 can also be used as an
aesthetic surfacing material (inside or outside) for other types of
walls, such as cast concrete exterior walls of a building.
[0059] Segments 101 can be combined with insulating materials to
constitute exterior walls of a building, as will be shown
hereinbelow, and may be used to construct fences and similar
structures.
[0060] In a preferred embodiment using YTONG blocks as aerated
concrete blocks 113, a segment a square meter in area and seven
centimeters thick weight approximately 42 kg, and meets the Israeli
construction standards for acoustic insulation, for thermal
insulation, and the Israeli mechanical strength standard #268. The
wall segments so constructed are also fairly impervious to water
but in wet environments it is recommended to spread a material
impermeable to water on the module's surface before installation.
HYDROGUM is an example of an appropriate material for this purpose.
In a preferred embodiment, a recommended standard size for a
modular wall segment is 60 cm in width and 260 cm in height, but
modular wall segments can alternatively be constructed in various
other shapes and dimensions.
[0061] Reference is now made to FIGS. 4a and 4b which present
simplified cross-sectional views of two preferred methods for
joining modular wall segments 101 into a continuous surface,
thereby constructing a modularized wall, according to embodiments
of the present invention. FIGS. 4a and 4b present partial views of
a wall 131a, 131b consisting of two modular wall segments 133a,
133b and 135a, 135b, joined together at juncture 137a, 137b.
[0062] In FIG. 4A, glue is used to join a flat end of segment 133a
to a flat end of segment 135a. Additionally, a slot 139 in segment
135a is so positioned that it faces a corresponding slot 141 in
segment 133a when the two segments are to be joined. A connecting
plate 143, which is preferably a metal plate, is coated with glue
and positioned so as to substantially fill both slot 139 and slot
141. Glue thus fixes connecting plate 143 both to slot 139 of
segment 133a and to slot 141 of segment 135a, and consequently
serves to reinforce the joining of the two segments.
[0063] FIG. 4b shows an alternative method for joining the two
segments 133b, 135b. In FIG. 4b an end of segment 135b is shaped as
a rib 155, whereas an end of segment 133 is shaped with a slot or
recess 161, the rib 155 being of a size and position to slide
snugly into the recess 161 during construction of wall 131, where
it is glued in place. Recess 161 is preferably dimensioned as
described above with respect to slot 114 as shown in FIG. 1, or as
described above with respect to slot 114' as shown in FIG. 2.
[0064] FIG. 4b also illustrates the alternative construction
wherein each modular wall segment 101 is formed with a rib 155 at
one end face, and with a slot 161 at the opposite end face, to
enable a plurality of such segments to be assembled together in
modular fashion.
[0065] Reference is now made to FIGS. 5a-5c, which present
simplified isometric and cross-sectional views of additional
configurations for joining modular wall segments longitudinally,
according to embodiments of the present invention. The joining
configurations illustrated are particularly appropriate for the
joining of modular wall segments for external use, for example for
external walls and for fences. The joining configurations
illustrated are appropriate for horizontal configurations, joining
a plurality of modular segments to make a long wall, and are also
appropriate for vertical configurations, joining a plurality of
segments to make a high wall.
[0066] In FIG. 5a, modular wall segment 231 is joined to modular
wall segment 233 by use of an I-shaped joining element 235.
Segments 231 and 233 are constructed with flat ends shaped to fit
into I-shaped joining element 235, where they can be glued or
preferably screwed or bolted into place. I-shaped joining element
235 is preferably of concrete or metallic composition, and
consequently may be a load-bearing element.
[0067] FIG. 5b presents an isometric view of a cruciform joining
element 237, preferably of metallic composition, which may also be
used to join two modular wall segments longitudinally. The position
in which cruciform joining element 237 may be placed is indicated
in isometric presentation in FIG. 5a, and in cross-sectional
presentation in FIG. 5c. In both FIG. 5a and FIG. 5c, cruciform
joining element 237 is shown joining modular wall segments 233 and
234. Use of cruciform joining element 237 requires that slots be
prepared in the ends of segments 233 and 234, similar to slots 141
and 139 of FIG. 4a.
[0068] Reference is now made to FIG. 6, which presents a simplified
cross-sectional view of a configuration for joining a modular wall
segment to a ceiling or to a floor or to both a ceiling and a
floor, according to an embodiment of the present invention. For
connecting to a ceiling 178, modular wall segment 101 is prepared
at its top end with a flat end face 173, in which a longitudinal
slot 175 is prepared, running the length of end face 173. A
T-shaped connecting form 177, preferably of metal, is screwed,
bolted, glued or otherwise connected to ceiling 178 and is used to
position modular wall segment 101 with respect to ceiling 178.
T-shaped connecting form 177, shown in FIG. 6 as being more narrow
than the thickness of modular wall segment 101, may alternatively
be of width equal to the thickness of segment 101, or yet
wider.
[0069] The configuration presented in FIG. 6 also serves for
connecting modular wall segment 101 to a floor. Segment 101 is
prepared also at its bottom end with flat face 174 in which a
longitudinal slot 175 is prepared, running the length of bottom
surface 174. A T-shaped connecting form 177, preferably of metal,
is screwed, bolted, glued or otherwise connected to a floor 179 and
is used to position modular wall segment 101 with respect to floor
179.
[0070] In typical use, an interior wall 131 is erected to partition
an interior space by first attaching T-shaped connecting forms 177
to the floor and ceiling along most of the length along which it is
desired to erect the wall 131, yet leaving a small section of the
intended wall length with at least one form 177 (ceiling or floor)
unattached, to create a staging area. Modular wall segments 101,
constructed to be of an appropriate height and having longitudinal
slots 175 along the top and bottom, are simply moved into the
staging area, slotted onto T-shaped connecting forms 177, and slid
along those forms, one segment 101 after another, until the space
to be partitioned has been nearly filled and most of the wall 131
erected. A final segment, completing the wall 131, is erected in
the staging area by slotting a final section of T-shaped connecting
form 177 into a segment 101 before attaching form 177 to the
ceiling or floor. Final segment 101 is erected in place, and final
section form 177 is then attached to wall or floor as appropriate,
completing construction of wall 131.
[0071] In a recommended mode of operation, a commercially available
sealing agent, impervious to water, is spread on top surface 173,
bottom surface 174, in slits 175, and on T-shaped connecting forms
177 before installing modular wall segments 101 on T-shaped
connecting forms 177.
[0072] The configuration presented in FIG. 6 also serves for
connecting modular wall segment 101 to a wall 172. In this usage
T-shaped connecting form 177 is screwed, bolted, glued or otherwise
connected to a wall 172 of any sort, such as, for example, a
reinforced concrete exterior wall of a building. Form 177 can be
connected to a flat end face of wall 172 to create a linear
horizontal or a vertical extension of wall 172. Alternatively, form
177 can be connected to a side face of wall 172, to join wall 172
and segment 101 in a perpendicular or near-perpendicular
configuration. Segment 101 is prepared with longitudinal slot 175
running the length of a flat end face, and an exposed portion of
form 177, extending outward from wall 172 to which it is attached,
is fitted into slot 175 to form a joint, which joint is then
preferably reinforced using glue, screws, bolts, or similar
materials.
[0073] Similarly, the configuration presented in FIG. 6 may also
serve for connecting modular wall segment 101 to a second, like
modular wall segment. In this usage, element 172 shown in FIG. 6
would also be a modular wall segment of the same construction as
segment 101, and the T-shaped connecting form 177 would be screwed,
bolted, glued or otherwise connected to wall segment 172, either to
a flat end face thereof to create a linear horizontal or a vertical
extension of wall segment 101, or to a side face thereof to join it
to wall segment 101 in a perpendicular or near-perpendicular
configuration. Segment 101 is prepared with longitudinal slot 175
running the length of a flat end face, and an exposed portion of
form 177, extending outward from the other wall segment 172 to
which it is attached, is fitted into slot 175 to form a joint,
which joint is then preferably reinforced using glue, screws,
bolts, or similar materials.
[0074] Reference is now made to FIGS. 7a and 7b, which present
simplified isometric views of a configuration for joining modular
wall segment 101 to a floor that is not horizontal, according to an
embodiment of the present invention. In general, it is desirable to
provide a horizontal floor surface at the point of installation of
modular wall segments 101. This is preferably accomplished by
casting a horizontal concrete strip, preferably about 7 cm in
height and 4 cm thick, on which T-shaped connecting form 177 of
FIG. 6, or other connecting forms or arrangements, or modular wall
segment 101 itself, may be placed.
[0075] A further recommended mode of operation is presented in two
phases in FIGS. 7a and 7b. In a first phase of operation shown at
FIG. 7a, modular wall segment 101 is propped temporarily in a
horizontal position using shims 146. Small sections of walling
board, for example, may be used for this purpose. In a second phase
of operation shown at FIG. 7b, a form is constructed around the
base of modular wall segment 101, and a concrete strip 147 is cast
under segment 101.
[0076] Reference is now made to FIG. 8, which presents a simplified
isometric view of several additional configurations for joining
several modular wall segments one to another to make a wall,
according to an embodiment of the present invention.
[0077] In FIG. 8, elements 201, 203, and 205 are each modular wall
segments (corresponding to segment 101 described earlier) here
shown as joined one to another to make a wall 206. In FIG. 8 a
rectangular connecting form 191a, illustrating an alternate
construction serving the same function as that of T-shaped
connecting form 177 in FIG. 6, is used to connect segment 201 to a
ceiling. Holes 207 may be used to screw or bolt connecting form
191a to a ceiling. Similarly, a second connecting form, marked 191b
is shown as the means by which segments 203 and 205 are connected
to a floor.
[0078] A third connecting form 191c serves a different purpose.
Connecting form 191c fits into a slot 114 at the bottom of segment
201 and into a slot 114b at the tops of segments 203 and 205, and
serves to join segment 201 vertically to segments 203 and 205. This
vertical joining method is useful when it is desired to build a
wall taller than the maximum height of available individual wall
segments 101. In an alternate construction, T-shaped connecting
form 177, shown in FIG. 6, may be used in place of connecting form
191c to join segment 201 vertically to segments 203 and 205. In
this case, T-shaped connecting form 177 in FIG. 6 is glued or
otherwise attached to the bottom of segment 201 and fits into slot
114b, or is attached to the tops of segments 203 and 205 and fits
into slot 114a.
[0079] Reference is now made to FIG. 9, which presents a simplified
isometric view of a configuration for joining modular wall segments
perpendicularly, according to an embodiment of the present
invention. A connecting form 221, screwed, glued, bolted or
otherwise attached to a side of a first modular wall segment 223,
fits into a slot 114 in the end of a second modular wall segment
225. Connecting form 221 is then screwed, glued, bolted or
otherwise attached in slot 114, thereby joining segment 223 to
segment 225 perpendicularly.
[0080] Reference is now made to FIG. 10, which presents a
simplified isometric view of a configuration for joining modular
wall segments in parallel to produce a composite modular wall
segment for constructing a wall and constituted of two of the
above-described segments of the same dimensions joined together at
the planar outer faces of their respective walling sheets. In such
a composite configuration, insulating material 245, such as thermal
insulation or acoustic insulation, is placed between, and may be
attached (e.g. by gluing) to, both first modular wall segment 241
on a first side of said insulating material, and second modular
wall segment 243 on a second side of said insulating material. This
sandwich configuration thereby constructed is particularly
recommended for use as an outside wall.
[0081] Reference is now made to FIG. 11, which presents a
simplified isometric view of a configuration for joining a modular
wall segment to an exterior wall, according to an embodiment of the
present invention.
[0082] Exterior wall 247 is typically not a modular wall segment
101, but rather is constructed by other means. Exterior wall 247
might be, for example, a poured concrete wall. Exterior wall 247
may be a load-bearing wall.
[0083] According to a preferred embodiment, exterior wall 247 is
prepared to include bolts or other fasteners appropriately placed
for use for connecting an interior wall. In a preferred mode of
operation, waterproofing material is applied to exterior wall 247
if appropriate. Insulating material 246 of appropriate thickness is
placed on the inner surface of exterior wall 247. Water pipes,
drain pipes, conduits for electricity, for electronic
communications, and optionally for other installations are
installed at this time. Modular wall segment 241 is then connected
to exterior wall 247 by means of bolts or other connectors provided
for the purpose.
[0084] Reference is now made to FIG. 12, which presents a
simplified isometric view of a configuration of walls composed of
modular wall segments (e.g., 101 described earlier) and including
pre-planned small and large openings, according to an embodiment of
the present invention.
[0085] In a recommended mode of use, when constructing walls of a
building or part of a building utilizing embodiments of the present
invention, detailed plans for the interior construction, based on
architects drawings and engineers specifications, are taken into
account in the planning, design, and construction of appropriately
sized and shaped modular wall segments. Users of the modular wall
segments (typically, the construction crew) provide makers of the
wall segments (typically, a commercial supplier or factory) with
detailed specifications of the sizes and placements of the walls
and the desired positions of openings such as windows and doors,
and desired smaller penetrations in the walls for elements such as
channels for electrical conduits and openings such a for electrical
outlets. The makers of the wall segments can then design segments
of accurately appropriate sizes, and use the manufacturing
facilities of their workshop or factory to cut or drill appropriate
openings in the constructed modules, which process can be
accomplished with ease and accuracy in the factory or industrial
setting.
[0086] In FIG. 12, modular wall segment 253, for example, comprises
a prepared channel 257 for electrical wiring and a prepared opening
259 for an electrical connection. Segments 251 and 253 are shown in
FIG. 12 to have been shaped or cut so as to provide an opening 255
appropriate for a door. Optionally, a wooden door frame base 261 is
provided glued to, or embedded in, segments 251 and 253. Wooden
door frame base 261 is of great utility in providing for elegantly
finished doors within the constructed walls, in that door frame
base 261 can be accurately measured and affixed to the segments
during production of the segments, thus requiring no cutting or
shaping of the segments at the construction site. An aesthetically
pleasing external door frame element (not shown) can easily be
affixed to door frame base 261 at the construction site, for
example using glue and a staple gun.
[0087] In a preferred mode of operation, the makers of the module
carefully number and mark each module, identifying its place in the
installation plan. The construction crew at the building site can
prepare the appropriate connecting forms attached to floors,
ceilings, and exterior walls according to the same plan. On
delivery of the prepared modular wall segments to the building
site, the building crew can easily and rapidly erect the walls on
the prepared connecting forms, and all openings and penetrations
designed by the building's architects and engineers will be
accurately in place and present a finished appearance. If needed,
the builders may apply small amounts of filler to cover any cracks
caused by the installation process, and the walls are finished and
ready for a coat of paint.
[0088] Should it be desired to strengthen modular segment 101
beyond the strength required for normal construction and beyond the
strength requirements of standard building codes, metallic
elements, such as metal reinforcement wires, nettings or cages, may
be added to the sandwich construction during the construction phase
of the modular segments described with reference to FIG. 3, thereby
further strengthening the modular wall segments. It is, however,
generally an advantage of the described modular wall segment (e.g.,
101) that such strengthening elements are usually unnecessary, and
the fact that the segments typically contain no metallic elements
adds convenience, in that no care need be take to locate and to
avoid internal metallic elements when cutting or drilling the
segments.
[0089] Reference is now made to FIG. 13, which is a simplified
isometric view of a configuration for reducing danger from
earthquakes, according to an embodiment of the present invention.
Experience has shown that during seismic disturbances, some or all
of the load-bearing structures of a building may survive intact or
nearly intact, yet people are endangered and property destroyed
because of falling masonry from a building's interior walls. FIG.
13 presents a configuration of modular wall segments 301a, 301b
joined to form a wall in a manner which enhances security of the
wall in the face of seismic disturbances. Modular wall segments
301a and 301b have been prepared with interior channels 381 drilled
or otherwise constructed running lengthwise of the length of the
modular segments. In FIG. 13, three such channels are shown. Each
channel 381 is for accommodating a cable 385, which is made to pass
through channel 381 in segment 301a, and also through channel 381
in segment 301b, thereby linking segments 301a and 301b with a
strong metallic cable. The ends of cable 385 are firmly attached to
load-bearing structures of a building, such as a steel framework,
or a steel-reinforced poured concrete element. In the event of an
earthquake or other major trauma to the building structure, if the
load-bearing structures to which cables 385 are anchored survive
the disturbance, modular wall segments 301a, 301b are held
together, and may largely be prevented from falling and doing
damage, by cables 385. The configuration shown in FIG. 13
substantially reduces risk that segments 301a, 301b will fall from
place and endanger lives and property during a seismic
disturbance.
[0090] It is appreciated that certain features of the invention,
which are, for clarity, described in the context of separate
embodiments, may also be provided in combination in a single
embodiment. Conversely, various features of the invention, which
are, for brevity, described in the context of a single embodiment,
may also be provided separately or in any suitable
subcombination.
[0091] Although the invention has been described in conjunction
with specific embodiments thereof, it is evident that many
alternatives, modifications and variations will be apparent to
those skilled in the art. Accordingly, it is intended to embrace
all such alternatives, modifications and variations that fall
within the spirit and broad scope of the appended claims.
* * * * *