U.S. patent application number 11/434815 was filed with the patent office on 2007-11-22 for multi-purpose construction module.
Invention is credited to Antonio Rapaz.
Application Number | 20070266667 11/434815 |
Document ID | / |
Family ID | 38710702 |
Filed Date | 2007-11-22 |
United States Patent
Application |
20070266667 |
Kind Code |
A1 |
Rapaz; Antonio |
November 22, 2007 |
Multi-purpose construction module
Abstract
This application relates to a light-weight, multi-purpose
construction module. The module may be used, for example, as a mold
for settable materials such as concrete. A plurality of modules may
be aligned together in different configurations for use as a
temporary road or support for use on unstable terrain, such as
arctic tundra or wetlands. In yet another application the module
may be deployed as a storage or shelving unit. The module comprises
a deck and a plurality of wall elements projecting from the deck
and defining a plurality of honeycomb-like compartments. The module
may be used in conjunction with a mating cover for sealingly
enclosing the module compartments.
Inventors: |
Rapaz; Antonio; (Chilliwack,
CA) |
Correspondence
Address: |
OYEN, WIGGS, GREEN & MUTALA LLP;480 - THE STATION
601 WEST CORDOVA STREET
VANCOUVER
BC
V6B 1G1
US
|
Family ID: |
38710702 |
Appl. No.: |
11/434815 |
Filed: |
May 17, 2006 |
Current U.S.
Class: |
52/585.1 |
Current CPC
Class: |
E02D 17/20 20130101;
E02D 27/02 20130101; E04G 5/08 20130101; E04C 2/427 20130101; E04G
9/02 20130101; E01C 9/086 20130101; E01C 5/005 20130101; E04C 2/428
20130101 |
Class at
Publication: |
52/585.1 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. A construction module comprising: (a) a planar deck; and (c) a
plurality of wall elements projecting from said deck, wherein said
wall elements define a plurality of compartments, each of said
compartments having a closed end defined by a portion of said deck
and an open end remote from said deck.
2. The construction module as defined in claim 1, wherein at least
some of said wall elements define a plurality of parallel,
spaced-apart partitions extending longitudinally on said deck.
3. The construction module as defined in claim 2, wherein said deck
is a sheet having a first side and a second side, wherein said wall
elements project from said first side in a plane generally
perpendicular to the plane of said sheet.
4. The construction module as defined in claim 3, wherein said wall
elements are arranged such that at least some of said compartments
are diamond-shaped.
5. The construction module as defined in claim 4, further
comprising a plurality of ribs projecting from said second side of
said sheet.
6. The construction module as defined in claim 3, comprising a
plurality of conduits extending transversely through said module at
spaced-intervals for threading cable connectors therethrough.
7. The construction module as defined in claim 6, wherein said
conduits are arranged in parallel and extend in a transverse
direction generally perpendicular to the direction of said
partitions.
8. The construction module as defined in claim 7, wherein said
module comprises lateral cut-outs formed at the locations of end
portions of said conduits to enable access to said end
portions.
9. The construction module as defined in claim 8, comprising at
least one longitudinal slot formed in an end portion of said module
for receiving a locking pin therein.
10. The construction module as defined in claim 7, wherein said
conduits extend through said wall elements at a location
spaced-apart from said deck.
11. The construction module as defined in claim 3, wherein some of
said wall partitions formed a perimeter wall surrounding said
module and enclosing said compartments.
12. The construction module as defined in claim 1, wherein said
module is formed from molded or cast plastic.
13. A construction assembly comprising: (a) a construction module
as defined in any one of claim 1; and (b) a cover connectable to
said module, wherein said cover comprises a plurality of grooves
formed therein for receiving end portions of said wall elements
remote from said deck when said module and said cover are coupled
together.
14. The assembly as defined in claim 13, wherein cover is a sheet
having a first side and a second side, wherein said grooves are
formed on a first side of said cover.
15. The assembly as defined in claim 14, wherein a plurality of
ribs project from said second side of said cover.
16. The assembly as defined in claim 14, further comprising a
gasket located between said perimeter wall and said cover for
sealingly coupling said module and said cover together.
17. The assembly as defined in claim 16, wherein said module
comprises male connectors and wherein said cover comprises female
apertures for receiving said male connectors when said module and
said cover are coupled together.
18. A multi-module construction panel comprising: (a) a plurality
of construction modules as defined in claim 1; and (b) at least one
connector for releasably coupling said modules together.
19. The construction panel as defined in claim 18, wherein each of
said modules comprises a plurality of conduits extending
transversely at spaced-intervals.
20. The construction panel as defined in claim 19, wherein said
modules are arranged so that said conduits are aligned and wherein
said at least one connector comprises a cable threaded through said
aligned connectors.
21. The construction panel as defined in claim 18, wherein said at
least one connector comprises a clip
22. The construction panel as defined in claim 21, wherein said
clip defines a recess for receiving perimeter wall portions of said
modules.
23. The construction panel as defined in claim 18, wherein said
modules are arranged so that said slots in said end portions of
modules are aligned and wherein said at least one connector
comprises a locking pin insertable into said slots.
24. The construction panel as defined in claim 23, wherein pin is
generally U-shaped and comprises to spaced-apart prongs and a
connector joining one end of said prongs together, wherein said
connector is generally flush with said deck when said pin is fully
inserted in said aligned slots.
25. The panel as defined in claim 24, wherein the length of said
prongs exceeds the depth of module, wherein said prongs anchor said
panel in an underlying support surface when said pin is fully
inserted into said aligned slots.
26. A method of constructing a temporary support surface
comprising: (a) providing a plurality of construction assemblies as
defined in claim 13; (b) aligning said plurality of construction
assemblies in a desired configuration; and (c) releasably coupling
said plurality of construction assemblies together.
27. The method as defined in claim 26, wherein said coupling
comprising passing one or more cables through said assemblies.
Description
TECHNICAL FIELD
[0001] This application relates to a multi-purpose construction
module.
BACKGROUND
[0002] Construction forms for containing concrete or other settable
materials are typically fabricated on-site. After the concrete is
poured and set, the forms are removed. These steps are relatively
time-consuming and labor-intensive. Moreover, since the forms are
not designed to be left in place, they do not enhance the
structural integrity or strength of the poured concrete or other
material. While the use of metal reinforcing bars and ribs is known
for stabilizing and strengthening concrete, there is a need for
more light-weight and inexpensive construction solutions.
[0003] Another application where pre-formed construction modules
may be used is to build temporary roads or work pads. This is
particularly important in regions having unstable ground support,
such as arctic tundra during seasons when the ground is not frozen.
Another example of unstable ground support is in wetlands such as
swamps or everglades systems. The unstable ground makes it very
difficult to deploy or move heavy equipment, such as oil drilling
or exploration machinery, at certain times of the year. This
problem is conventionally addressed by laying down a large number
of wood mats on the unstable ground to distribute the machinery
weight over a larger surface area. One problem with this approach
is that protruding nails used to maintain the wood mats together
frequently puncture vehicle tires.
[0004] Interlocking mat systems made from high density polyethylene
are known in the prior art for construction of temporary roads or
other support surfaces. However, such mats are relatively heavy and
require cranes or other specialized equipment to install or remove
the mats. The need has arisen for more light-weight and economical
construction modules which may be quickly and reliably deployed at
remote locations.
SUMMARY OF INVENTION
[0005] In accordance with the invention, a construction module
comprising a planar deck and a plurality of wall elements
projecting from the deck is provided. The wall elements define a
plurality of compartments, each of said compartments having a
closed end defined by a portion of the deck and an open end remote
from the deck. In one embodiment at least some of the wall elements
define a plurality of parallel, spaced-apart partitions extending
longitudinally on the deck. The deck may be a sheet having a first
side and a second side, wherein the wall elements project from the
first side in a plane generally perpendicular to the plane of the
sheet. A plurality of ribs may project from the second side of the
sheet. The module may be economically formed from cast plastic or
other light-weight material.
[0006] In one embodiment of the invention the module may include a
plurality of conduits, such as cylindrical pipes, extending
transversely through the module at spaced-apart intervals for
threading cable connectors therethrough. The connectors may be used
for quickly aligning and securely coupling a plurality of modules
together to form a construction assembly, such as a temporary
roadway. Other means for coupling modules together, such as
removable connecting clips and locking pins may also be
employed.
[0007] A cover may optionally be used in conjunction with the
module for enclosing the module compartments. The cover may include
a plurality of grooves formed therein for receiving end portions of
the wall elements remote from said deck when the module and the
cover are coupled together. Optionally, a sealing gasket may be
interposed between the module and the cover.
BRIEF DESCRIPTION OF DRAWINGS
[0008] In drawings which describe embodiments of the invention but
which should not be construed as restricting the spirit or scope
thereof,
[0009] FIG. 1 is a top plan view of a construction module
configured in accordance with one embodiment of the applicant's
invention.
[0010] FIG. 2 is a side elevational view of the module of FIG.
1.
[0011] FIG. 3 is a bottom plan view of the module of FIG. 1.
[0012] FIG. 4(a) is a bottom perspective, partially exploded view
of a plurality of modules arranged together in an aligned
configuration and showing connecting clips removed from the
modules.
[0013] FIG. 4(b) is a bottom perspective view of a plurality of
modules aligned together and showing the connecting clips fully
inserted for coupling the modules together.
[0014] FIG. 4(c) is an enlarged perspective view of one connecting
clip of FIGS. 4(a) and 4(b).
[0015] FIG. 5 is a top, perspective, partially exploded view of a
plurality of modules aligned together and showing connecting cables
and locking pins for coupling adjacent modules together.
[0016] FIG. 6(a) is an enlarged top perspective view of a plurality
of modules aligned together and showing the locking pins for
coupling end portions of the modules together.
[0017] FIG. 6(b) is an enlarged top perspective view of the modules
of FIG. 6(a) showing the locking pins in their fully inserted
position flush with the top surface of the module decks.
[0018] FIG. 7(a) is an enlarged top perspective view of a plurality
of modules aligned together in an offset pattern and showing the
locking pins removed from the modules.
[0019] FIG. 7(b) is an enlarged top perspective view of the modules
of FIG. 7(a) showing the locking pins in their fully inserted
position for coupling end portions of the modules together.
[0020] FIG. 8(a) is a side elevational view of a plurality of
modules aligned together and showing the locking pins removed from
the modules.
[0021] FIG. 8(b) is a side elevational view of the embodiment of
FIG. 8(a) showing the locking pins fully inserted to couple
adjacent modules together.
[0022] FIG. 9(a) is a side elevational view of a plurality of
modules aligned together and showing locking pins having a length
greater than the pins of FIG. 8(a) removed from the modules.
[0023] FIG. 9(b) is a side elevational view of the embodiment of
FIG. 9(a) showing the locking pins fully inserted to couple
adjacent modules together.
[0024] FIG. 10 is an exploded, isometric view of a construction
assembly comprising a module and a cover which may be coupled
together to sealingly enclose the module compartments.
[0025] FIG. 11 is an enlarged, sectional view of a portion of the
assembly of FIG. 10.
DESCRIPTION
[0026] Throughout the following description, specific details are
set forth in order to provide a more thorough understanding of the
invention. However, the invention may be practiced without these
particulars. In other instances, well known elements have not been
shown or described in detail to avoid unnecessarily obscuring the
invention. Accordingly, the specification and drawings are to be
regarded in an illustrative, rather than a restrictive, sense.
[0027] This application relates to a multi-purpose construction
module 10. In the illustrated embodiment module 10 is generally
rectangular in shape. As described in further detail below, a
plurality of modules 10 may be aligned in a desired configuration
and releasably coupled together. Each module 10 includes a deck 12
and a plurality of wall elements 14 projecting from deck 12. In the
illustrated embodiment deck 12 is a planar sheet having a first
side 16 and a second side 18. Wall elements 14 project from first
side 16 in a direction generally perpendicular thereto. As shown
best in FIGS. 3, 4(a) and 4(b), some of the wall elements 14 define
a plurality of parallel, spaced-apart partitions 19 extending
longitudinally on deck 12 to provide enhanced structural support,
as described below. In the illustrated embodiment, wall elements 14
are arranged to define a plurality of honeycomb-like compartments
20 each having a closed end defined by a portion of deck 12 and an
open end remote from deck 12. Although compartments 20 are shown as
being diamond-shaped or triangular-shaped, other shapes and
arrangements are possible.
[0028] In the embodiment illustrated in FIGS. 1, 5-7 and 11, a
plurality of narrow elongated ribs 22 project a short distance from
second side 18 of deck 12. In this embodiment ribs 22 have the same
diamond-shaped pattern as wall elements 14, although other rib
patterns are also possible.
[0029] A plurality of conduits 24 extend transversely through
module 10 at spaced intervals. In the illustrated embodiment
conduits are cylindrical pipes which extend approximately mid-way
between deck first side 16 and second side 18. As described further
below, conduits 24 are provided for threading cable connectors 26
therethrough. Cable connectors 26 are one means for aligning and
coupling a plurality of modules 10 together lengthwise. Module 10
may include cut-outs 28 at intervals coinciding with conduits 24 to
enable ready access to end portions of conduits 24 and cable
connectors 26.
[0030] As an alternative or additional means for coupling a
plurality of modules together lengthwise, a plurality of connecting
clips 30 may be employed as shown in FIGS. 4(a)-4(c). Each clip 30
is generally U-shaped and includes legs 32 sized to straddle
adjacent sidewalls of modules 10. As best shown in FIG. 4(c),
opposed clip legs 32 may also optionally include an aperture 34 for
receiving a bolt (not shown) which could also pass through matching
holes machined in the sidewalls of modules 10.
[0031] Each module 10 may also include a plurality of spaced slots
or cut-outs 36 formed in end portions thereof. When a pair of slots
36 are aligned, a locking pin 38 may be inserted therein to couple
end portions of adjacent modules 10 together. Modules 10 may either
be arranged in a fully aligned configuration (FIGS. 6(a) and 6(b))
or an offset configuration (FIGS. 7(a) and 7(b)) depending upon how
slots 36 on adjacent modules 10 are matched. When locking pins 38
are fully inserted into modules 10, the outermost surface of pins
38 is flush with the second side 18 of deck 12 (FIGS. 6(b) and
7(b)). As shown in FIGS. 8(a) and 8(b) the size of locking pins 38
may be about the same or less than the depth of modules 10.
Alternatively, locking pins 38 may be longer than the depth of
modules 10 as shown in FIGS. 9(a) and 9(b) to anchor the modules 10
in the ground when the pins 32 are fully inserted (FIG. 9(b)).
[0032] FIG. 10 illustrates an embodiment of the invention
consisting of a construction assembly 40 comprising a module 10 and
a cover 42. As shown best in FIG. 11, cover 42 has a first side 44
and a second side 46. A plurality of narrow slots 48 are formed on
first side 44 for receiving end portions of wall elements 14. When
module 10 and cover 42 are coupled together, compartments 20 are
fully enclosed. A plurality of narrow elongated ribs 50 may be
formed on second side of cover 42 (FIG. 11). Ribs 50 are similar to
ribs 22 formed on second side 18 of deck 12.
[0033] As shown in FIGS. 4(a), 4(b) and 10, module 10 may also
include a plurality of male projections 52 which fit into
corresponding female apertures 54 formed in cover 42. A gasket 56
may be interposed between module 10 and cover 42 to sealingly
couple the components together (FIG. 10). Further, a plurality of
screw fasteners 58 may be used for fastening cover 42 to module
10.
[0034] In one preferred embodiment, both module 10 and cover 42 are
formed from plastic. For example, module 10 and cover 42 may be
manufactured from plastic molds in a mass production process. Since
both module 10 and cover 42 may be formed or substantially formed
from cast plastic, construction assembly 40 is very light-weight in
this embodiment. In one embodiment conduits 24 and cable connectors
26 may be formed from metal.
[0035] As will be apparent to a person skilled in the art, modules
10 may be manufactured in any desired size or shape. By way of
example, modules 10 may be about 3'.times.8' in size and generally
rectangular in shape.
[0036] Module 10 has many possible construction applications. For
example, module 10 may be used separate from cover 42 as a mold for
settable materials such as concrete. In this embodiment, one or
more modules 10 could be deployed as shown in FIGS. 4(a) and 4(b)
with the open ends of compartments 20 facing upward. The settable
material could be introduced into all or some of compartments 20
through the open ends thereof. Partitions 19 provide module 10 with
longitudinal strength and stability to prevent deformation of
module 10 as compartments 20 are being progressively filled.
Depending upon the application, multiple modules may be aligned and
coupled together as described above to form multi-module
construction assemblies. Again, the modules 10 should be coupled
together sufficiently securely to prevent deformation or distortion
of the multi-module assembly as selected modules 10 or module
compartments 20 are filled. If necessary, bolts (not shown) may be
used in conjunction with connecting clips 30. With reference to
FIG. 9(b), multiple modules 10 may also be anchored in the ground
or other underlying support surface using locking pins 38.
[0037] In another application module 10 could be filled with sand
or other granular materials to stabilize roadways and the like and
prevent washout. Depending upon the specific application, module 10
could be deployed with the with the granular material filled within
the module compartments 20 with the open ends of compartments 20
facing either upwards or downwards.
[0038] In yet another application, modules 10 may be used in
conjunction with cover 42 to form a light-weight construction
assembly 40 suitable for making temporary roads and the like. This
embodiment of the invention is particularly suitable for deployment
on unstable ground, such as arctic tundra or wetlands. Assembly 40
is deployed in the orientation shown in FIGS. 10 and 11 with cover
42 placed on the ground surface. A plurality of assemblies 40 may
be assembled lengthwise using cable connectors 26 passed through
conduits 24 of the respective modules 10, as discussed above. Since
assemblies 40 are lightweight and stackable, they may be quickly
deployed at the construction site, even at remote locations. The
sealing connection between respective modules 10 and covers 42
prevents entry of mud and water into compartments 20 which would
otherwise substantially increase the weight of the assemblies 40.
End portions of modules 10 could also be aligned and coupled
together as described above to increase the width of the temporary
roadway or other support. Thus assemblies could be used as supports
to distribute weight over a large surface area while remaining
stable and structurally strong in different weather and ground
conditions. In the orientation shown in FIGS. 1, 5, 6(a)-7(b), 10,
and 11, ribs 22 formed on deck second side 18 project upwardly to
provide traction for vehicles traveling thereover. As shown in the
drawings, deck side 18 may be a continuous sheet to provide a
uniform support surface. Since locking pins 38 are flush with deck
side 18 in their fully inserted position (FIG. 6(b) and 7(b)), they
will not interfere with vehicle traffic or the like on deck 12.
[0039] As will be appreciated by a person skilled in the art,
construction module 10 could be used for many other purposes and
applications. For example, in one further application may be used
as a light-weight storage container or shelving unit. In another
further application module 10 could be used as part of a
scaffolding system.
[0040] As will be apparent to those skilled in the art in the light
of the foregoing disclosure, many alterations and modifications are
possible in the practice of this invention without departing from
the spirit or scope thereof. Accordingly, the scope of the
invention is to be construed in accordance with the substance
defined by the following claims.
* * * * *