U.S. patent application number 14/208627 was filed with the patent office on 2014-10-16 for modular concrete form panel.
The applicant listed for this patent is Shane Gaddes, Robert Westerlund, Stephen Woolverton. Invention is credited to Shane Gaddes, Robert Westerlund, Stephen Woolverton.
Application Number | 20140308509 14/208627 |
Document ID | / |
Family ID | 51581406 |
Filed Date | 2014-10-16 |
United States Patent
Application |
20140308509 |
Kind Code |
A1 |
Gaddes; Shane ; et
al. |
October 16, 2014 |
MODULAR CONCRETE FORM PANEL
Abstract
A modular form panel for assembling a cast-in-place concrete
structure includes an inner panel section and an outer panel
section. A filling gap is defined between the inner and outer panel
sections. The filling gap is configured to receive concrete poured
on-site to form a concrete wall or roof section. One or more tie
members span the filling gap interconnecting the inner and outer
panel sections. The panel includes an integral side flange in some
embodiments. When multiple panels are positioned adjacent one
another, the adjacent side flanges form an end gap on each lateral
side of the panel. The end gap has a thickness greater than the
filling gap thickness. Concrete disposed in each end gap forms an
integrated support column on each side of the panel. A bond beam
gap is defined along the top edge of the panel having a greater
thickness than the filling gap.
Inventors: |
Gaddes; Shane; (Nashville,
TN) ; Woolverton; Stephen; (Nashville, TN) ;
Westerlund; Robert; (Nashville, TN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Gaddes; Shane
Woolverton; Stephen
Westerlund; Robert |
Nashville
Nashville
Nashville |
TN
TN
TN |
US
US
US |
|
|
Family ID: |
51581406 |
Appl. No.: |
14/208627 |
Filed: |
March 13, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61783057 |
Mar 14, 2013 |
|
|
|
Current U.S.
Class: |
428/223 |
Current CPC
Class: |
E04B 1/161 20130101;
E04B 2/8647 20130101; Y10T 428/249923 20150401; E04B 1/165
20130101 |
Class at
Publication: |
428/223 |
International
Class: |
E04B 5/02 20060101
E04B005/02 |
Claims
1. A modular panel apparatus for forming a concrete structure,
comprising: a first panel section; a second panel section
comprising foam; a filling gap defined between the first and second
panel sections; one or more support ties spanning the filling gap
between the first and second panel sections; and a barrier layer
disposed on the first panel section
2. The apparatus of claim 1, further comprising the second panel
section having an exterior side facing away from the filling gap,
and a cover layer disposed on the exterior side.
3. The apparatus of claim 1, further comprising one or more stud
members disposed on the first panel section, wherein barrier layer
is positioned between the one or more stud members and the filling
gap.
4. The apparatus of claim 3, wherein at least one of the support
ties is secured to at least one of the stud members.
5. The apparatus of claim 4, wherein at least one of the support
ties extends at least partially through the second panel
section.
6. The apparatus of claim 4, further comprising an outer tie
fastener disposed on the second panel section, the outer tie
fastener engaging at least one of the support ties.
7. The apparatus of claim 4, further comprising: the second panel
section including an inner foam layer and an outer foam layer, the
inner foam layer positioned between the outer foam layer and the
filling gap; and a side flange protruding laterally outwardly from
the outer foam layer.
8. The apparatus of claim 7, wherein the outer foam layer has a
greater lateral width than the inner foam layer.
9. The apparatus of claim 2, wherein the cover layer comprises at
least one plastic sheet.
10. A modular panel apparatus for forming a concrete structure, the
concrete structure having a concrete wall and an integral concrete
support column, the apparatus comprising: a first panel section; a
second panel section; a filling gap defined between the first and
second panel sections; and a side flange protruding from the second
panel section in a lateral direction, the side flange having a
distal flange edge extending beyond the first panel section in the
lateral direction, wherein the side flange forms a boundary for the
integral concrete support column.
11. The apparatus of claim 10, wherein the second panel section
comprises an inner foam layer and an outer foam layer, and the side
flange is integrally formed on the outer foam layer.
12. The apparatus of claim 11, wherein the side flange protrudes
laterally beyond the inner panel layer.
13. The apparatus of claim 11, further comprising a cover layer
disposed on the outer foam layer.
14. The apparatus of claim 13, wherein the cover layer comprises
metal wire mesh or a plastic sheet.
15. The apparatus of claim 14, further comprising one or more rigid
support ties spanning the filling gap between the first panel
section and the second panel section.
16. The apparatus of claim 10, further comprising an end gap
defined on at least one lateral edge of the panel apparatus, the
end gap open to the filling gap such that concrete poured into one
of the end gap and filling gap may flow into the other, wherein the
end gap includes a greater thickness dimension than the filling
gap.
17. A modular concrete form panel apparatus, comprising: a first
panel section; a second panel section; a filling gap defined
between the first and second panel sections, the filling gap having
a filling gap thickness; one or more support ties spanning the
filling gap between the first panel section and the second panel
section, each support tie interconnecting the first panel section
and second panel section; one or more stud members disposed on the
first panel section; a barrier layer disposed on the first panel
section between the one or more stud members and the filling gap; a
side flange protruding laterally outwardly from the second panel
section; a first top flange protruding upwardly from the first
panel section; and a second top flange protruding upwardly from the
second panel section, the first and second top flanges defining a
bond beam gap having a bond beam thickness therebetween, wherein
the bond beam thickness is greater than the filling gap
thickness.
18. The apparatus of claim 17, wherein the barrier layer comprises
a vapor barrier material.
19. The apparatus of claim 17, wherein each support tie extends at
least partially through one of the stud members.
20. The apparatus of claim 17, further comprising: an end gap
defined adjacent the filling gap along a vertical edge of the panel
apparatus, the end gap having an end gap thickness greater than the
filling gap thickness, wherein the side flange forms a partial
boundary for an integrated support column.
Description
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] 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.
[0002] 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
[0003] 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.
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] What is needed then are improvements in concrete formwork,
and particularly in modular formwork panels
BRIEF SUMMARY
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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
[0013] FIG. 1 illustrates a perspective view of an embodiment of a
modular form panel in accordance with the present invention.
[0014] 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.
[0015] 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.
[0016] FIG. 4 illustrates a detail cross-sectional view of an
embodiment of modular form panel in accordance with the present
invention.
[0017] FIG. 5 illustrates a detail cross-sectional view of an
embodiment of modular form panel in accordance with the present
invention.
[0018] FIG. 6 illustrates a detail cross-sectional view of an
embodiment of modular form panel in accordance with the present
invention.
[0019] 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.
[0020] 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.
[0021] 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.
[0022] FIG. 10 illustrates a perspective view of an embodiment of
two form panels installed on a footing in accordance with the
present invention.
[0023] 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.
[0024] FIG. 12 illustrates a detail cross-sectional view of a
adjacent modular form panels filled with concrete in accordance
with the present invention.
[0025] FIG. 13 illustrates a detail cross-sectional view of an end
joint between adjacent modular form panels in accordance with the
present invention.
[0026] FIG. 14 illustrates a detail perspective view of an
embodiment of a modular form panel in accordance with the present
invention.
[0027] FIG. 15 illustrates a perspective view of a concrete frame
of a building formed with modular form panels in accordance with
the present invention.
[0028] 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
[0029] 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.
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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.
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] 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.
[0058] 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.
[0059] 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.
[0060] 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.
* * * * *