U.S. patent application number 15/790079 was filed with the patent office on 2018-02-15 for pre-fabricated structures and methods.
The applicant listed for this patent is Tai Dung Nguyen, Trung Quoc Tran. Invention is credited to Tai Dung Nguyen, Trung Quoc Tran.
Application Number | 20180044918 15/790079 |
Document ID | / |
Family ID | 55267016 |
Filed Date | 2018-02-15 |
United States Patent
Application |
20180044918 |
Kind Code |
A1 |
Nguyen; Tai Dung ; et
al. |
February 15, 2018 |
Pre-fabricated structures and methods
Abstract
Building structures can be fabricated at an offsite, and then
assembled at the construction site. The building structures can
include beams and wall panels having metal attachments. The beams
and wall panels can be assembled by coupling the metal attachments,
for example, by welding.
Inventors: |
Nguyen; Tai Dung; (Fremont,
CA) ; Tran; Trung Quoc; (Fremont, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nguyen; Tai Dung
Tran; Trung Quoc |
Fremont
Fremont |
CA
CA |
US
US |
|
|
Family ID: |
55267016 |
Appl. No.: |
15/790079 |
Filed: |
October 23, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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14819419 |
Aug 5, 2015 |
9797135 |
|
|
15790079 |
|
|
|
|
62033115 |
Aug 5, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04C 2/06 20130101; E04C
2/521 20130101; E04C 2/044 20130101; E04B 2001/2463 20130101; E04B
2103/02 20130101; E04C 2/52 20130101; E04C 2/46 20130101; E04B
2103/06 20130101; E04B 1/24 20130101; E04B 2001/2472 20130101; E04B
2001/2481 20130101 |
International
Class: |
E04C 2/52 20060101
E04C002/52; E04B 1/24 20060101 E04B001/24; E04B 2/00 20060101
E04B002/00; E04C 2/04 20060101 E04C002/04; E04C 2/06 20060101
E04C002/06 |
Claims
1. A prefab house comprising multiple beams, wherein the multiple
beams are secured to a foundation to form a frame of the prefab
house; one or more wall panels, wherein at least a wall panel of
the one or more wall panels is disposed between two beams of the
multiple beams, wherein the at least a wall panel is disposed
between the two beams in such as way so that the at least a wall
panel is movable in a direction along a length of the two beams,
wherein the at least a wall panel is disposed between the two beams
in such as way so that the at least a wall panel is constrained in
directions perpendicular to the length of the two beams.
2. A prefab house as in claim 1 wherein each of the two beams
comprises a channel running along from one end to an apposite end
of the beam, wherein the at least a wall panel comprises a
structure that fits in the channel.
3. A prefab house as in claim 1 wherein the at least a wall panel
comprises a channel running along from one end to an apposite end
of the wall panel, wherein each of the two beams comprises a
structure that fits in the channel.
4. A prefab house as in claim 1 wherein each beam of at least two
beams of the multiple beams comprises at least a first mating
element along a length of the each beam, wherein at least a wall
panel of the one or more wall panels comprises a cement material,
wherein the at least a wall panel comprises two second mating
elements at two ends of the at least a wall panel, wherein the
first and second mating elements are configured for mating with
each other, wherein the at least a wall panel is disposed between
the at least two beams with the second mating elements fitted into
the first mating elements of the at least two beams.
5. A prefab house as in claim 1 wherein the multiple beams, the one
or more wall panels, a floor panel, and a ceiling panel are
pre-fabricated in a factory before being brought to a construction
site for assembling the prefab house.
6. A prefab house as in claim 1 wherein the at least a wall panel
comprises a cement or concrete material coupled to meal
connectors.
7. A prefab house as in claim 1 wherein the multiple beams and at
least a frame of a floor panel or a ceiling panel comprises a metal
material.
8. A method to form a prefab house, the method comprising securing
multiple beams to a foundation to form a frame of the prefab house;
bringing a wall panel to a position above the multiple beams,
wherein the wall panel comprises a cement material; sliding the
wall panel between two beams of the multiple beams, wherein the
wall panel is constrained in directions perpendicular to the length
of the two beams.
9. A method as in claim 8 wherein each of the two beams comprises a
channel running along from one end to an apposite end of the beam,
wherein the wall panel comprises a structure that fits in the
channel.
10. A method as in claim 8 wherein the wall panel comprises a
channel running along from one end to an apposite end of the wall
panel, wherein each of the two beams comprises a structure that
fits in the channel.
11. A method as in claim 8 wherein the multiple beams, the wall
panel, a floor panel, and a ceiling panel are pre-fabricated in a
factory before being brought to a construction site for assembling
the prefab house.
12. A method as in claim 8 wherein each beam of at least two beams
of the multiple beams comprises at least a first mating element
along a length of the each beam, wherein the wall panel comprises a
cement or concrete material, wherein the wall panel comprises two
second mating elements at two ends of the wall panel, wherein the
first and second mating elements are configured for mating with
each other, wherein the wall panel is disposed between the at least
two beams with the second mating elements fitted into the first
mating elements of the at least two beams.
13. A method as in claim 8 wherein the wall panel comprises a
cement or concrete material coupled to metal connectors.
14. A method as in claim 8 wherein the multiple beams and at least
a frame of a floor panel or a ceiling panel comprises a metal
material.
15. A prefab house comprising multiple beams, wherein each of the
multiple beams comprises first and second couplers at two ends; a
floor panel, wherein the floor panel comprises third couplers for
coupling with foundation poles protruded from a ground, wherein the
floor panel comprises fourth couplers for coupling with first
couplers of the multiple beams; a ceiling panel, wherein the floor
panel comprises fifth couplers for coupling with second couplers of
the multiple beams; one or more wall panels, wherein the wall
panels are configured to be coupled to each other or to the
multiple beams, wherein the multiple beams, the floor panel, the
ceiling panel, and the one or more wall panels are configured to be
assembled in a secured package configuration comprising the floor
panel and the ceiling panel sandwiching an inner package comprising
the one or more wall panels and the multiple beams.
16. A prefab house as in claim 15 wherein the multiple beams, the
one or more wall panels, the floor panel, and the ceiling panel are
pre-fabricated in a factory before being brought to a construction
site for assembling the prefab house.
17. A prefab house as in claim 15 wherein at least a wall panel of
the one or more wall panels comprises a door, a windows, or
electrical outlets.
18. A prefab house as in claim 15 wherein at least a wall panel of
the one or more wall panels comprises a cement or concrete material
coupled to metal connectors.
19. A prefab house as in claim 15 wherein the multiple beams and at
least a frame of the floor panel or the ceiling panel comprises a
metal material.
20. A prefab house as in claim 15 wherein the prefab house is
constructed by bringing the secured package configuration to a
construction site, placing the secured package configuration on the
foundation poles, so that the third couplers coupled with the
foundation poles, unsecuring the secured package configuration,
lifting the ceiling panel from the unsecured package configuration,
removing the multiple beams from the inner package, coupling the
multiple beams with the floor panel, so that the first couplers
coupled with the fourth couplers, lowering the ceiling panel, so
that the second couplers coupled with the fifth couplers, removing
the one or more wall panels from the inner package, assembling the
one or more wall panels with the multiple beams and with each
other.
Description
[0001] The present application is a continuation-in-part of
application Ser. No. 14/819,419, filed on Aug. 5, 2015, now U.S.
Pat. No. 9,797,135, which claims priority from U.S. Provisional
Patent Application Ser. No. 62/033,115, filed on Aug. 5, 2014
entitled: "Pre fabricated structures and methods" which are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] Portable structures have been used by people, including soft
walls structures such as tents and teepee and portable building
having rigid or semi-rigid walls. Some portable buildings can be
transported assembled, e.g., the structure is complete and
transported by truck or rail to the site. Some portable buildings
can be transported in components, e.g., the complete structure is
disassembled and transported as components to be assembled at the
site.
[0003] There is a need for construction designs that can use
available and inexpensive materials, together with ease of
fabrication, construction, and assembling.
SUMMARY OF THE EMBODIMENTS
[0004] In some embodiments, the present invention discloses
pre-fabricated houses and methods to construct pre-fabricated
houses. The pre-fabricated houses can include beams, such as
vertical pillars and horizontal joists, together with wall
panels.
[0005] In some embodiments, the present invention discloses pillars
and wall panels having attachments or mating components for ease of
construction. The attachments or mating components can include a
metal material for ease of coupling, such as welding or bolting,
e.g., securing with nuts and bolts.
[0006] In some embodiments, the pillars can include a metal
material, such as the pillars are made from steel. The attachments
can be fabricated from the pillars, for example, the attachments
can include a component from the pillars, or a hole in the pillars
for coupling with a foundation of the house or for coupling with a
wall panel. The attachments can be a part of the pillars, e.g., the
hole can be made in the pillars, or the component can be a portion
of the pillars.
[0007] In some embodiments, the pillars can include a cement
material, such as the pillars are made from concrete, e.g., a
mixture of cement, sand and water. The concrete pillars can have
metal-based attachments, e.g., attachments having a metal material
such as steel. The metal-based attachments can be secured to the
concrete, or can be secured to a metal-based reinforced element in
the concrete.
[0008] In some embodiments, the wall panels can include metal-based
attachments, e.g., attachments having a metal material such as
steel. The metal-based attachments can be secured to the wall
panels. The attachments can be configured to se coupled to the
pillars or to the attachments of the pillars, for example, by
welding or bolting.
[0009] In some embodiments, the wall panels can include a cement
material, e.g., forming a concrete wall panel. The wall panels can
have metal-based attachments secured to the cement material. The
metal-based attachments can facilitate the coupling of the wall
panels with other wall panels or with beams (vertical pillars or
horizontal joists), e.g., through the coupling of metal to
metal.
[0010] In some embodiments, the present invention discloses methods
for constructing pre-fabricated houses. The methods can include
forming a foundation for a house. The foundation can have
metal-based attachments, which can be configured to be coupled to
the pillars of the house. The methods can include coupling multiple
beams to the foundation. The beams can include metal-based
attachments, which can be configured to be coupled to the
foundation. The beams can include other metal-based attachments,
which can be configured to be coupled to the wall panels. The
methods can include coupling the wall panels to the beams. The wall
panels can include metal-based attachments, which can be configured
to be coupled to the beams. In some embodiments, the wall panels
can be concrete wall panels, e.g., wall panels having a cement
material.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIGS. 1A-1B illustrate a portable house according to some
embodiments.
[0012] FIGS. 2A-2E illustrate pillars and wall panels according to
some embodiments.
[0013] FIG. 3 illustrates a flow chart for forming components of a
house according to some embodiments.
[0014] FIGS. 4A-4E illustrate configuration for concrete wall
panels according to some embodiments.
[0015] FIGS. 5A-5E illustrate configurations for wall panels having
meshes according to some embodiments.
[0016] FIGS. 6A-6E illustrate configurations for end portions of
wall panels according to some embodiments.
[0017] FIGS. 7A-7D illustrate configurations of attachments for
wall panels according to some embodiments.
[0018] FIGS. 8A-8F illustrate configurations of attachments for
wall panels according to some embodiments.
[0019] FIGS. 9A-9F illustrate configurations of attachments for
wall panels according to some embodiments.
[0020] FIG. 10 illustrates a wall panel according to some
embodiments.
[0021] FIG. 11 illustrates a flow chart for fabricating a concrete
wall panel according to some embodiments.
[0022] FIGS. 12A-12E illustrate configurations for assembling wall
panels according to some embodiments.
[0023] FIG. 13 illustrates a flow chart for assembling wall panels
according to some embodiments.
[0024] FIGS. 14A-14G illustrate configurations for assembling a
wall panel with a beam according to some embodiments.
[0025] FIG. 15 illustrates a flow chart for assembling wall panels
according to some embodiments.
[0026] FIGS. 17A-17F illustrate configurations for assembling
pre-fabricated houses according to some embodiments.
[0027] FIGS. 16A-16G illustrate configurations for assembling
pre-fabricated houses according to some embodiments.
[0028] FIG. 18 illustrates a flow chart for assembling wall panels
according to some embodiments.
[0029] FIGS. 19A-19D illustrate various configurations for
assembling pre-fabricated houses according to some embodiments.
[0030] FIGS. 20A-20C illustrate various configurations for
assembling pre-fabricated houses according to some embodiments.
[0031] FIG. 21 illustrates a configuration for assembling
pre-fabricated houses according to some embodiments.
[0032] FIGS. 22A-22C illustrate a process for constructing a house
according to some embodiments.
[0033] FIG. 23 illustrates a configuration of wall panel and pillar
attachments according to some embodiments.
[0034] FIGS. 24A-24B illustrate a process for forming a two story
house according to some embodiments.
[0035] FIG. 25 illustrates a flow chart for constructing a
pre-fabricated house according to some embodiments.
[0036] FIGS. 26A-26G illustrate wall panels according to some
embodiments.
[0037] FIGS. 27A-27C illustrate a process for alignment improvement
according to some embodiments.
[0038] FIG. 28 illustrates a flow chart for alignment improvement
according to some embodiments.
[0039] FIGS. 29A-29B illustrate a process for installing wall
panels according to some embodiments.
[0040] FIGS. 30A-30B illustrate a process for installing wall
panels according to some embodiments.
[0041] FIG. 31 illustrates a flow chart for constructing a portable
house according to some embodiments.
[0042] FIGS. 32A-32F illustrate a process for assembling a prefab
house according to some embodiments.
[0043] FIG. 33 illustrates a coupling configuration between a floor
or ceiling panel 3310 with a wall panel or the beams 3320.
[0044] FIGS. 34A-34G illustrate coupling configurations between
wall panels according to some embodiments.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0045] In some embodiments, the present invention discloses
portable houses and methods to fabricate portable houses. The
portable houses can be transported in a vehicle such as a truck to
a construction site, and then assembled at the construction site.
The term houses can include any dwelling structures, e.g.,
buildings for living, storage structures, e.g., buildings for
storing, or office buildings, e.g., buildings for working. The term
portable can include movable, such as moving by components and then
assembling at the construction site.
[0046] The portable houses can include wall panels, beams such as
vertical pillars or horizontal joists, floor panels and roof
panels. A foundation can be built at the construction site, then
the floor panels can be installed. Pillars can be attached to the
floor panels, such as at 4 corners of the floor panels.
Alternatively, the pillars can be attached to the foundation before
the installation of the floor panel. The wall panels can be
attached to the beams or pillars. The roof panels, or second floor
panels, can be attached to the beams or pillars and/or to the wall
panels. Optional components can be included, such as floor support
members, truss members, and upright studs.
[0047] FIGS. 1A-1B illustrate a portable house according to some
embodiments. In FIG. 1A, multiple panels 110, such as floor panels,
wall panels, and roof panels can be transported to a building site.
The panels can have different sizes, pre-fabricated according to
the design of the house. Windows and doors can also be
prefabricated on the panels, such as sky doors on roof panels,
basement door on floor panels, and doors and windows on wall
panels. Electrical components, such as wall outlets or wall
connectors for lighting or for internet cables, can be
prefabricated on the wall panels or ceiling panels. Other
components can be included, such as pillars and support structures.
The components can include attachments, for example, to couple or
attach to other components.
[0048] Support structures can be included either as a separate
component or a component pre-attached to the panels, beams, or
pillars. For example, rim joists can be coupled to bottom of the
wall panels, upright posts or studs can be embedded in wall panels,
for example, to increase the structural integrity of the wall
panels, floor joints and floor support members can be embedded in
floor panels to increase the structural integrity, rafters can be
embedded in roof panels, and fasteners for securing the panels
together.
[0049] In FIG. 1B, the panels 110 can be assembled to form a
complete house. In some embodiments, the wall panels 120 can be
fabricated and transported as complete wall panels, e.g., large
wall panels that can be used to form the house walls with one or
two wall panels. The wall panels 120 can have multiple wall pieces
122, 124, and 126 assembled together, with the separation between
the wall pieces along a direction 130 of the vertical pillars. The
wall pieces can be one large piece, from a ceiling 140 to a floor
145 of the house.
[0050] In some embodiments, the present invention discloses
pre-fabricated housing and methods to construct pre-fabricated
housing. The pre-fabricated houses, e.g., structures for dwelling
or for storing, can include major support vertical pillars, such as
pillars at four corners of the houses (for example, for houses
having dimensions of 5 m.times.5 m or less, or for houses having
lateral wall dimensions of 5 m or less), and middle pillars (for
example, for houses having dimensions larger than, or for houses
having lateral wall dimensions greater than 5 m, such as a middle
pillar for 5 m.times.10 m houses at the middle of the 10 m walls).
The pre-fabricated houses can include large panels, such as
complete wall panels, roof panels, or floor panels, such as
complete panels between the pillars. For example, a 5 m.times.5 m
house can have 4 pillars at four corners of the house, together
with 4 wall panels having 5 m lateral dimensions. A 5 m.times.10 m
house can have 6 pillars, 4 at four corners and 2 at the middles of
the 10 m length of the house, together with 6 wall panels having 5
m lateral dimensions.
[0051] The pillars and complete wall panels can simplify the
construction of the houses, since after forming a foundation of the
house at the construction site, a minimum number of floor panels,
roof panels, walls panels, and pillars can be transported to the
construction site for assembling.
[0052] In some embodiments, the pillars can be made of a metal
material, e.g., an metal alloy such as steel. The wall panels can
be made of a cement material, e.g., a large piece of cement can be
formed as a wall panel. Steel reinforced mesh can be included in
the cement-based wall panels, for example, to increase the
structure integrity of the cement-based wall panels. Other elements
can be incorporated in the fabrication of the large cement wall
panels, such as openings for electrical components, metal-based
attachments for coupling with the metal-based beams such as
vertical pillars or horizontal joists. The wall panels can have
hollow pockets for weight reduction, such as hollow passages from
one end to an opposite end of the wall panels. The hollow passages
can be horizontal passages, vertical passages, or a combination of
horizontal and vertical passages.
[0053] In some embodiments, the present invention discloses pillars
and wall panels having mating components for ease of construction.
The pillars, wall panels, and mating components can include
available, low cost elements such as C shape or L shape beams.
[0054] FIGS. 2A-2E illustrate pillars and wall panels according to
some embodiments. In FIG. 2A, a pillar 210 can include 2 C shape
beams 212 and 214 secured together, for example, by welding 220 or
by nuts and bolts. For example, a C shape beam can have a first
width 214A of 12 cm, a second width 214B of 4.8 cm, and a thickness
214C of 0.6 cm. The pillar 210 can also include a bottom and a top
flanges for securing to the bottom panels (such as floor panels)
and to the top panels (such as a top floor or a roof). Other
dimensions can also be used.
[0055] The two C shape beams 212 and 214 can be welded back to
back, with an offset amount, for example, about half the first
width 214A of the C shape beam. Holes can be drilled into C shape
beams for attaching with nuts and bolts. Alternatively, nuts or
bolts can be welded to the C shape beams.
[0056] In FIG. 2B, a panel, such as a wall panel 230, can include a
wall 250 having end beams 260, 262 and attachments 240, 242 at two
end of the wall 250. The wall 250 can be constructed of cement, or
some light weight materials. A solid wall 250 is shown, but other
configurations can be used, such as two thin walls at outer
surfaces.
[0057] At the ends of the walls 250, end beams 260 and 262 can be
attached. The end beams can surround the wall, e.g., at 4 end sides
of a rectangular wall. The end beams can be attached to 2 opposite
end sides of the wall. The end beams can include C shape beams.
Attachment beams 240 and 242 can be coupled to the end beams 260
and 262 respectively. The attachment beams can include L shape
beams. Holes can be drilled into L shape beams for attaching with
nuts and bolts. Alternatively, nuts or bolts can be welded to the L
shape beams. The holes, nuts, and bolts in the L shape beams of the
wall panels can be mated to the holes, nuts and bolts in the C
shape beams of the pillars. The L shape beams 240 and 242 can be
attached so that the flat side 270 can be at a center line of the
wall panel 230. This can allow the wall panel to couple to another
beam (such as the pillar) with a center disposed between the two
beams. The two L shape beams 240 and 242 can be disposed at
opposite sides.
[0058] In some embodiments, the wall 250 can include a cement
material, for example, to form a concrete wall. In addition, cement
additives can be included, to modify the properties of the concrete
wall. For example, a latex resin, such as Polyvinyl Acetate (PVA),
Ethylene Vinyl Acetate (EVA), Styrene Butadiene Rubber (SBR), and
Acrylic, can be used for increasing the compressive strength (such
as tensile, flexural, compression, and modulus), reducing the
weight, reducing water permeability and absorption, increasing
abrasion resistance, dampening vibration, color retention, and
resistance to aggressive and corrosive environments such as rain
water, freeze-thaw cycles, or seawater. The concrete can be
impregnated with a liquid monomer that is polymerized in situ.
Additives can also include plastic materials, such as thermoset
polyester, phenolic, epoxy, and poly ethylene.
[0059] The concrete, e.g., the wall having a cement material, can
be a lightweight concrete, which can include an additive for
reducing the weight of the concrete. The additives can include a
foam additive, which can generate bubbles in the concrete, forming
porous concrete.
[0060] In FIG. 2C, the L shape beams 244 and 246 can be attached at
a different configuration as compared to the L shape beams 240 and
242 in FIG. 2B. For example, the two L shape beams 244 and 246 can
be disposed at a same side.
[0061] In FIG. 2D, a side view of the panel 235 is shown. The wall
panel 250 can be surrounded at all sides by end beams 260, 262,
264, and 266. The end beams 260 and 262 can have attachment beams
240 and 242, which are configured to be attached to pillars, e.g.,
C shape beams of the pillar. The end beams 264 and 266 can be
configured to be attached to the bottom and/or top floor
panels.
[0062] FIG. 2E shows another configuration of a wall panel 237. End
beams 260 (and 262, 264, 266 as shown in FIG. 2D) can be secured
together, e.g., by welding, to form a frame. Middle beams 252 can
be attached to the frame to increase the structural integrity. Thin
walls 258 can be attached to the frame to form the wall panel 237.
The thin wall 258 can have a plastic-concrete composition, e.g.,
concrete having a plastic additive (such as a latex additive such
as acrylic resisn), for example, to increase compressive strength
for forming thin wall.
[0063] FIG. 3 illustrates a flow chart for forming components of a
house according to some embodiments. Operation 300 attaches two
first C-shape beams to form a pillar. The first C-shape beams can
be attached back to back with an offset. The side portions of the C
shape beams can be used as attachment points for the wall panels.
The two C shape beams thus can include 4 side portions, two at one
side, and two at the opposite side. The side portions can be
offset, e.g., positioned at different planes.
[0064] Operation 310 forms a wall panel having one or more second C
shape beams as frame. For example, a wall panel can be provided,
and C shape beams can be attached to two edge sides or to 4 edge
sides of the wall panel. Alternatively, two or four C shape beams
can be coupled together, for example, by welding or by bolting, for
form a frame. Additional beams can be used, for example, as middle
beams or as edge beams (in the case of 2 C shape beam frame). The
additional beams can be smaller, lighter, or can be of different
materials. Wall plates can be coupled to the frame, for example, at
both flat sides of the frame, to form a wall panel.
[0065] Operation 320 attaches a L-shape beam to a second C-shape
beam. Two L shape beams can be used, attached to two opposite C
shape beam of the wall panel. The L shape beam can be formed after
forming the frame, and before attaching the wall plates. The L
shape beams can be formed after forming the wall panel.
[0066] Operation 330 transports the pillars and the wall panels to
a construction site. Operation 340 couples the wall panels to the
pillars to form a pre-fabricated house. A foundation can be first
constructed at the construction site. A floor can be formed on the
foundation. The floor can include one or more floor panels,
depending on the size of the house. For example, the floor panels
can have dimensions of 5 m or less. The floor panels can include
attaching components for attaching the pillars. For example, the
floor panels can have protruded bolts at corners and/or middles of
edges of the floor panels, which can be used to attach to the
pillar, since the pillars can have mated holes at the ends.
[0067] The pillars can be coupled to the floor panels, for example,
by bolting the pillars to the protruded bolts from the floor
panels. Alternatively, the floor panels can have metal plates at
corners and the pillars can be welded to the metal plates.
Afterward, the wall panels can be coupled to the pillars, for
example, by bolting or welding the pillars with the end beams of
the wall panels. For one story houses, roof panels can be attached
to the pillars. For two or more story houses, upper floor panels
can be attached to the pillars.
[0068] In some embodiments, the present invention discloses
cement-based wall panels for a pre-fabricated house. The
cement-based wall panels can include a cement material. For
example, the cement-based wall panels can include concrete, which
is a harden mixture of cement, sand, and water, together with
optional gravels or crushed stones. The wall panels can be large,
such as having a length from the ceiling to the floor, e.g., the
wall panels form one piece wall along a vertical direction of the
house. The width of the wall panels can be from a pillar to another
pillar, or can be a fraction of the pillar-to-pillar distance. For
example, the width of the wall panels can be 1.2 m, thus multiple
wall panels (or wall pieces) can be put together side by side to
form a complete wall panel.
[0069] In some embodiments, the thickness of the wall panels can be
larger than 10 mm, such as larger than 100 mm, or larger than 200
mm. The wall panels can be hollow, e.g., having hollow pockets such
as hollow passages from one end of the panel to an opposite end.
The hollow passages can lighten the wall panels, and at a same
time, allowing electrical wires to pass through the wall
panels.
[0070] In some embodiments, the cement-based wall panels can have
additives for changing the properties of the concrete wall panels.
For example, a plastic additive can be added to the cement mixture
to increase the compressive strength of the concrete, allowing the
formation of thin wall concrete. The plastic additives can include
a latex resin, such as an acrylic resin. Other additives can be
included, such as foam additives, which can form air bubbles in the
concrete, for forming lightweight concrete.
[0071] In some embodiments, the wall panels can have attachments
for coupling to other components of the house, such as coupling to
the beams (e.g., vertical pillars or horizontal joists) or to each
other. The attachments can include a metal material, such as the
attachment can be made of metals or alloys such as steel or
iron-based alloys. Metal-based attachments can simplify coupling,
for example, by welding or by bolting with bolts and nuts. Thus the
wall panels and beams can have metal-based attachments.
[0072] In some embodiments, the metal-based attachments can be
bonded to concrete, e.g., the cement-based wall panels. An
interlocked feature can be included to secure the attachment to the
concrete.
[0073] In some embodiments, the wall panels can have a step at an
end of the wall panels. The step can simplify the coupling of the
wall panels, e.g., to a pillar or to another wall panel.
Metal-based attachments can be coupled to the step.
[0074] In some embodiments, the present invention discloses a
pre-fabricated house using one-piece vertical concrete wall panels.
The one-piece vertical concrete wall panels can have a length
similar to a height of the house, such as a distance from the floor
to the ceiling. Multiple one-piece vertical wall panels can be
assembled together, along the length, to form a complete wall
panel. The coupling of the one-piece vertical wall panels can be
through the metal-based attachments, e.g., by welding or
bolting.
[0075] In some embodiments, the pre-fabricated house can include
metal-based beams, such as vertical pillars and/or horizontal
joists. The beams can include steel or other iron-based alloys. The
beams can be fabricated with attachments for coupling directly with
the wall panels or with the metal-based attachments of the wall
panels. The attachments can be formed from the beams, e.g., holes
can be drilled in the beams to form the attachments. The
attachments can be externally formed, and then coupled to the
beams, e.g., a protrusion with a hole can be welded to the beams to
form the attachment.
[0076] In some embodiments, the pre-fabricated house can include
cement-based or concrete-based beams, such as vertical pillars. The
beams can be fabricated with metal-based attachments for coupling
directly with the wall panels or with the metal-based attachments
of the wall panels. The attachments can be coupled to the cement or
concrete portion of the beams, optionally with interlocked feature
for securing the attachments to the concrete or cement beams. The
attachments can be coupled to a metal-based reinforced portion of
the beams, for example, by welding or bolting.
[0077] FIGS. 4A-4E illustrate configuration for concrete wall
panels according to some embodiments. The concrete wall panels can
include a cement material, for example, a mixture of cement, sand,
water, and other optional elements. The concrete wall panels can be
porous, e.g., having hollow void inside the wall panels, for
example, to reduce the weight of the wall panels.
[0078] In FIG. 4A, a concrete wall panel 400 can include a concrete
material 410, e.g., a mixture of a cement material with other
elements, together with hollow passages 420. The hollow passages
420 can be through passages, e.g., running from one end of the wall
panel to an opposite end of the wall panel. As shown, the hollow
passages can have an oval profile 427, e.g., a cross section of the
hollow passage can show an oval shape. Other shapes can be used,
such as a rectangular shape or a polygon shape.
[0079] The wall panel 400 can have a length 414, which can be long
enough to cover the vertical length of the house, such as from the
floor to the ceiling of one story. The length 414 can be longer
than 2 m, longer than 3 m, or longer than 4 m. The wall panel 400
can have a width 412, which can cover the horizontal length of the
house, such as from a pillar to another pillar. The wall panel 400
can be a wall piece, e.g., multiple wall pieces can be assembled to
form a wall panel, spanning the horizontal length of the house
between two pillars. The wall piece can have a width of longer than
1 m, shorter than 2 m, or can be about 1.2 m. The wall panel 400
can have a thickness 416, which can be longer than 10 mm, or can be
longer than 100 mm or 200 mm.
[0080] FIG. 4B shows a configuration of a wall panel 401, including
horizontal passages 421 and vertical passages 431 embedded in a
concrete material 411. The horizontal passages 421 can pass
substantially horizontal to the floor or to the ceiling plane. The
vertical passages 431 can pass substantially vertical to the floor
or to the ceiling plane.
[0081] FIG. 4C shows a configuration of a wall panel 401, including
horizontal passages 422 and hollow voids 442 embedded in a concrete
material 412. The horizontal passages 422 can pass substantially
horizontal to the floor or to the ceiling plane. The hollow voids
442 can be distributed in the concrete material of the wall
panel.
[0082] FIG. 4D shows a configuration of a wall panel 403, in which
the hollow passages 423 extend to a surface of the wall panel 403.
The wall panels 403 can include a concrete material 413 forming a
wall surface 463 and multiple horizontal ridges 473 forming the
hollow passages 423.
[0083] FIG. 4E shows a configuration of a wall panel 404, in which
the hollow voids 424 extend to a surface of the wall panel 404. The
wall panels 404 can include a concrete material 414 forming a wall
surface 464 and a protrusion mesh 474 forming the hollow voids
424.
[0084] In some embodiments, the concrete wall panels can be
reinforced with a mesh, such as a steel mesh. The mesh can be a net
from steel wire, or multiple steel wires interlacing or
interlocking to form a grid. The mesh can be used to strengthen the
wall panels, such as preventing the wall panels from shattering.
The mesh can be placed inside and along a surface of the wall
panels.
[0085] FIGS. 5A-5E illustrate configurations for wall panels having
meshes according to some embodiments. In FIG. 5A, a wall panel 500
can include a concrete material or a cement material 510. The wall
panel can include hollow passages 520, passing from one end of the
wall panel to an opposite end of the wall panel. A mesh 550 can be
disposed along a surface of the wall panel, and can be placed
inside the wall panel. The mesh can be placed at a distance greater
than 10 mm, 20 mm, 30 mm, or 50 mm from a surface of the wall
panel. The mesh can be placed at a middle of an outer surface 561
and inner surfaces, such as surfaces 562 made from the hollow
passages 520, hollow pockets or voids in the wall panel.
[0086] Different configurations for the mesh can be used. The mesh
can be configured to surround the hollow passages, or additional
mesh surrounding the hollow passages can be added, in addition to a
mesh along an outer surface of the wall panel. The additional mesh
can be used to constructing the hollow passages, for example,
tube-like meshes can be placed in a mold, and concrete paste (e.g.,
a mixture of cement, sand and water before hardened) can be poured
on to the mold. The tube-like meshes can block all or a portion of
the concrete paste to enter the volume inside the meshes, thus
forming hollow passages within the concrete wall panel.
[0087] FIG. 5B shows a mesh 551 with some bending portions 571. The
bending portions 571 can be used to form a part of hollow passages
521. For example, concrete material 511 can be disposed immediately
under the bending portions 571 (and maybe a little above the
bending portions to cover the bending portions). The concrete
material 511 can be disposed separated from the bending portions at
an opposite direction to form hollow passages.
[0088] FIG. 5C shows a mesh 552 together with some tube-like meshes
572. The tube-like meshes 572 can be used to form hollow passages
522, or a part of the hollow passages. For example, concrete
material 512 can be disposed on a surface to form a thin layer of
concrete, such as less than 100 mm thickness, or less than 50 mm,
30 mm, 20 mm, or 10 mm thickness. Before the concrete is hardened,
a mesh 552 can be placed on the concrete layer. Another thin layer
of concrete can be placed on the mesh 552. Multiple tube-like
meshes 572 can be placed on the another thin layer of concrete, and
then additional concrete can be poured surrounded the tube-like
meshes and covering the tube-like meshes.
[0089] FIG. 5D shows a mesh 553 with some bending portions 573. The
bending portions 573 can be somewhat conformed to a shape of hollow
passages 523. Tube-like meshes or conduits 563 having the outer
shape of hollow passages 523 can be placed near the bending
portions. Concrete material 513 can be disposed. The tube-like
meshes or conduits can prevent the concrete material from filling
in the hollow passages. The tube-like meshes or conduits can be
removed after the concrete is hardened. Alternatively, the
tube-like meshes or conduits can be left inside the concrete wall
panel. In this case, the conduits can be hollow conduits, and the
hollow passages can be the hollow portion inside the hollow
conduits.
[0090] FIG. 5E shows a mesh 554 together with some conduits 564.
The conduits 564 can be used to form hollow passages 524, or a part
of the hollow passages. For example, concrete material can be
disposed, followed by the mesh, and then additional concrete
material. The conduits can be placed on the concrete material,
followed by more concrete material. The conduits can be removed
after the concrete is hardened. Alternatively, the conduits can be
left inside the concrete wall panel. In this case, the conduits can
be hollow conduits, and the hollow passages can be the hollow
portion inside the hollow conduits.
[0091] As shown, the bending portions and the tube-like meshes have
a curve cross section, such as circular or oval tubes. Other
configurations of bending portions and the tube-like meshes can be
used, such as bending portions or the tube-like meshes having
rectangular or polygon cross section shapes.
[0092] In some embodiments, the concrete wall panels can have end
portions configured for ease of assembling with other wall panels
or with the construction beams (vertical pillars or horizontal
joists for the house). The end portions can include configurations
for the concrete, such as a straight end portion or a step end
portion. The straight end portions can allow the wall panels to
have uniform shapes. The step end portions can allow the wall
panels to be adjusted, e.g., the wall panels can be moved relative
to the step end portions without any shown gaps.
[0093] FIGS. 6A-6E illustrate configurations for end portions of
wall panels according to some embodiments. FIG. 6A shows a straight
end portion 670 for a wall panel 600. The straight end portion can
be a flat and perpendicular to the large wall panel surfaces. In
general, the straight end portion can be slightly curved and can
make a small angle with the wall panel surfaces. The wall panel 600
can include a cement material 610, forming a concrete wall panel.
The wall panel 600 can include a mesh 650, disposed along the wall
panel surface, for example, to strengthen the structural integrity
of the wall panel. The wall panel 600 can include hollow passages
620, running from the end portion 670 to an opposite end portion.
The straight end portion can allow two wall panel to be placed next
to each other, to form a larger wall panel. In the present
specification, the term wall panel and wall piece can be used
interchangeably. A wall piece can be a portion of a wall panel, if
the wall panel has multiple wall pieces. A wall piece can be a wall
panel, if the wall panel has only one wall piece.
[0094] FIG. 6B shows a step end portion 671 for a wall panel 601.
The step end portion can have a protrusion or a recess at the end
portion of the wall panel. In general, the step end portion can
have different sizes and shapes, which can allow two step end
portions of two adjacent wall panels to mate to each other with a
tolerance. For example, a step end portion of a wall panel can have
a protrusion at an inner surface of the wall panel (e.g., the
surface facing the inside of the house when the wall panels are
assembled into the house). A step end portion of another wall panel
can have a protrusion at an outer surface of the wall panel (e.g.,
the surface facing the outside of the house when the wall panels
are assembled into the house). The two wall panels can be
assembled, with the step end portions mated to each other, e.g.,
the step end portions overlap each other. The step end portions can
increase the tolerance of the width of the wall panels, since the
distance 675 between two wall panels can be adjusted without any
gap between the two wall panels. The wall panels can have a width
smaller than a nominal width, and with straight end portions, the
small width wall panels can have a gap between the wall panels.
With the step end portions, the small width wall panels can be
assembled without any exposed gaps.
[0095] The wall panel 601 can include a cement material 611,
forming a concrete wall panel. The wall panel 601 can include a
mesh 651, disposed along the wall panel surface, for example, to
strengthen the structural integrity of the wall panel. The wall
panel 601 can include hollow passages 621, running from the end
portion 671 to an opposite end portion.
[0096] Other end portions can be used for the wall panels, such as
curved end portions, zigzag end portions (which is a variation of
the step end portions, with the end surface making an angle with
the middle surface instead of a right angle), middle pin end
portions (which includes a protrusion at a middle of the wall panel
thickness), and middle recess end portions (which includes a recess
at a middle of the wall panel thickness).
[0097] The wall panels can have different configurations of end
portions. For example, a wall panel can have straight end portions
at both ends of the wall panels. The wall panels can have different
end portions at the ends, such as a straight end portion at one end
and a step end portion at another end. The wall panels can have
both step end portions at both ends. Different step end portions
can be used at different ends of the wall panels.
[0098] FIG. 6C shows a configuration in which a wall panel have
step end portions at two ends, and the protrusion of the end
portions are located at different surfaces of the wall panel, e.g.,
a protrusion at an inner wall surface and a protrusion at an outer
wall surface. A wall panel 602 can have two step end portions, for
example, at a left end and at a right end of the wall panel. At the
left end, the step end portion can include a protrusion 680, for
example, at a wall surface 640, such as an inner wall of the house;
or a recess 660 at a wall surface 641, such as an outer wall of the
house. At the right end, the step end portion can include a
protrusion 681, for example, at the outer wall 641 of the house; or
a recess 661, for example, at an inner wall 640 of the house. The
wall panel 602 can include a cement material 612, forming a
concrete wall panel. The wall panel 602 can include meshes 652,
disposed along the two wall panel surfaces, for example, to
strengthen the structural integrity of the wall panel. The wall
panel 602 can include hollow passages 622, running from the end
portion to an opposite end portion.
[0099] FIG. 6D shows a configuration in which a wall panel have
step end portions at two ends, and the protrusion of the end
portions are located at a same surface of the wall panel, e.g.,
both protrusions at an inner wall surface or at an outer wall
surface. A wall panel 603 can have two step end portions, for
example, at a left end and at a right end of the wall panel. At the
left end, the step end portion can include a protrusion 682, for
example, at a wall surface 642, such as an inner wall of the house;
or a recess 662 at a wall surface 643, such as an outer wall of the
house. At the right end, the step end portion can include a
protrusion 683, for example, at the inner wall 642 of the house; or
a recess 663, for example, at an outer wall 643 of the house. The
wall panel 603 can include a cement material 613, forming a
concrete wall panel. The wall panel 603 can include a mesh 653,
disposed along a wall panel surface. The wall panel 603 can include
hollow passages 622, running from the end portion to an opposite
end portion.
[0100] In some embodiments, the present invention discloses wall
panels having metal-based attachments, thus can facilitate the
coupling of the wall panels with other wall panels or with beams
(vertical pillars or horizontal joists), e.g., through the coupling
of metal to metal. For example, two wall panels can have
metal-based attachments, e.g., attachments having a metal material,
such as attachments made of steel or other alloys. The two wall
panels can be coupled to each other through the attachments, for
example, by welding, by bolting with bolts (the attachments can
function as nuts), or by bolting with bolts and nuts.
[0101] The wall panels with metal-based attachments can be used to
coupled to metal beams, such as beams having a metal material or
beam having a metal-based attachment. For example, a pillar can be
made of a metal material, such as steel or other metal alloys
(e.g., alloy having metal as an element in the material
composition). The pillar can be coupled to the wall panels through
the metal-based attachments, for example, by welding, by bolting
with bolts (the attachments can function as nuts), or by bolting
with bolts and nuts.
[0102] In some embodiments, the present invention discloses a
pre-fabricated house and construction methods to form the
pre-fabricated house. The pre-fabricated house can include
metal-based beams (e.g., vertical or horizontal joists) and wall
panels having metal-based attachments. The beams and the wall
panels can be coupled through the metal-base portions, e.g.,
between the metal based beams and the metal-based attachments of
the wall panels. The wall panels can be formed of various
materials, such as sheet rock, wood, brick, cement, concrete, and
any other construction materials.
[0103] In some embodiments, the present invention discloses
pre-fabricated houses having concrete wall panels, e.g., wall
panels having a cement material. The concrete wall panels can have
attachment elements, or attachments, for ease of coupling. For
example, the attachments can include a metal material, such as an
iron based material like steel, which can be used for welding or
accepting a bolt, thus allowing easier coupling as compared to a
concrete material. The attachments can be formed at an end portion
of the wall panel, for example, to allow coupling of two wall
panels, or to allow coupling of a wall panel with a beam, such as a
vertical pillar or a horizontal joist.
[0104] The following description describes concrete wall panels
having metal-based attachments for coupling with other wall panels
or with beams of the house. The invention is not so limited, and
the description can be applied to wall panels made of other
materials with metal-based attachments.
[0105] FIGS. 7A-7D illustrate configurations of attachments for
wall panels according to some embodiments. In FIG. 7A, a wall panel
can have a straight end portion with protruded attachments 760,
extended from the straight end portion. The attachments can have
multiple pieces, separated from each other. The wall panel can
include a cement or concrete material 710, with hollow passages
720. As shown, the hollow passages 720 have an oval shape, but
other shapes can be used. The attachments can be placed near the
hollow passages.
[0106] In FIG. 7B, a wall panel can have a straight end portion
with protruded attachments 761, extended from the straight end
portion. The attachments can have multiple pieces, separated from
each other. The wall panel can include a cement or concrete
material 711, with hollow passages 721. As shown, the hollow
passages 721 have a rectangular shape, but other shapes can be
used. The attachments can be placed in a middle of the wall panel
thickness, between the hollow passages.
[0107] In FIG. 7C, a wall panel can have a step end portion with an
attachment 762, coupled to the step of the step end portion. The
attachment can be placed at the step portion, such as at a face
parallel to a wall panel surface. The attachment can run along a
length of the wall panel, for example, from a top portion to a
bottom portion of the wall panel. The wall panel can include a
cement or concrete material 712, with hollow passages 722. The
attachments can have bent configurations, for example, to run
around the hollow passages. Other attachment configurations can
also be used, such as straight attachments running near and along a
surface of the wall panel.
[0108] In FIG. 7D, a wall panel can have a step end portion with
one or more attachments 763, coupled to the step of the step end
portion. The attachment can be placed at the step portion, such as
at a face parallel to a wall panel surface. The attachment can run
along a portion of a length of the wall panel, for example, between
two hollow passages of the wall panel. The wall panel can include a
cement or concrete material 713, with hollow passages 723. The
attachments can have bent configurations, for example, to run from
a middle of a hollow passage to a middle of a portion of the wall
panel not having the hollow passages. Other attachment
configurations can also be used, such as straight attachments
running along an exposed surface of the wall panel.
[0109] In some embodiments, the attachments can be interlocked or
secured with the wall panel material. For example, the attachments
can be placed at an exposed surface of the wall panel, together
with a locking element embedded within the wall panel. As shown,
the attachment 763 can be disposed at an exposed surface of the
wall panel, and the attachment 763 can be coupled to locking
elements 773, which are embedded in the wall panel. The locking
elements 773 can have an inverse T shape, which can secure the
attachment 763. Other configurations for the locking elements can
be used, such as star shapes, hook shapes, inverse triangular
shapes, and any shapes that can present a physical action which can
prevent the attachment from being loosened from the wall panel
surface.
[0110] FIGS. 8A-8F illustrate configurations of attachments for
wall panels according to some embodiments. In FIG. 8A, a wall panel
can have a straight end portion with protruded attachments 860,
extended from the straight end portion. The attachments can be
coupled to a surface of the wall panel, such as the surface of the
straight end portion. The attachments can have multiple pieces,
separated from each other. The wall panel can include a cement or
concrete material 810, with hollow passages 820.
[0111] In FIG. 8B, the protruded attachments 861 can have a portion
871 embedded in the wall panel. The attachments can have multiple
pieces, separated from each other. The wall panel can include a
cement or concrete material 811, with hollow passages 821.
[0112] In FIG. 8C, the protruded attachments 862 can have a portion
872 embedded in the wall panel in a locking configuration, such as
the embedded portion near the wall panel surface has a smaller
volume than the embedded portion farther from the wall panel
surface. The locking configurations can include a star shape, a
inverse triangle shape, or a T shape. The attachments can have
multiple pieces, separated from each other. The wall panel can
include a cement or concrete material 812, with hollow passages
822.
[0113] In FIG. 8D, a wall panel can have a straight end portion
with an attachment 863, coupled to the straight wall of the
straight end portion. The attachment can be protruded from the
straight wall. The attachment can run along a length of the wall
panel, for example, from a top portion to a bottom portion of the
wall panel. The wall panel can include a cement or concrete
material 813, with hollow passages 823. The attachments can have
bent configurations, for example, to run around the hollow
passages. Other attachment configurations can also be used, such as
straight attachments running near and along a surface of the wall
panel.
[0114] In FIG. 8E, a wall panel can have a straight end portion
with an attachment 864, coupled to the straight wall of the
straight end portion. The attachment can be coupled to the straight
wall, such as running along and covering a length of the wall
panel, for example, from a top portion to a bottom portion of the
wall panel. The wall panel can include a cement or concrete
material 814, with hollow passages 824. The attachment 864 can be
attached to an outer surface of the straight wall, or can be
embedded inside the straight wall.
[0115] In FIG. 8F, a wall panel can have a straight end portion
with an attachment 865, coupled to the straight wall of the
straight end portion. The attachment can include a coupling element
875, such as a hole or a tap 875 made in the attachment 865. The
wall panel can include a cement or concrete material 815, with
hollow passages 825. The attachment 865 can be attached to an outer
surface of the straight wall, or can be embedded inside the
straight wall.
[0116] FIGS. 9A-9F illustrate configurations of attachments for
wall panels according to some embodiments. In FIG. 9A, a wall panel
can have a step end portion with attachments 960 coupled to a wall
portion of the step end portion. The attachments can have multiple
pieces, separated from each other. The wall panel can include a
cement or concrete material 910, with hollow passages 920.
[0117] In FIG. 9B, a wall panel can have a step end portion with
attachments 962 coupled to two surfaces 972 of the step end
portion. In FIG. 9C, a wall panel can have a step end portion with
attachments 961 coupled to two surfaces of the step end portion,
together with attachments 972 coupled to another surface of the
wall panel.
[0118] In FIG. 9D, a wall panel can have a step end portion with
attachments 963 coupled to a all portion of the step end portion.
The attachment can have a coupling element 973, such as a hole or a
tap in the attachment 963. In FIG. 9E, a wall panel can have a step
end portion with attachments 964 coupled to a all portion of the
step end portion. The attachment can have a coupling element 974,
such as a hole or a tap in the attachment 964. The hole or tap 974
can be extended to the wall panel, for example, the wall panel can
have a hole passing through, from the attachment to the other
surface of the wall panel. In FIG. 9F, a wall panel can have a step
end portion with attachments 965 coupled to two surfaces of the
step end portion, together with attachments 966 coupled to another
surface of the wall panel. The attachment can have a coupling
element 975, such as a hole or a tap in the attachments 965 and
966. The hole or tap 975 can be extended to the wall panel, for
example, the wall panel can have a hole passing through, from the
attachment 965 to the attachment 966.
[0119] In some embodiments, the concrete wall panels can be formed
with electrical or mechanical couplings, such as electrical outlets
or electric connections for electrical devices (lights, fans, etc),
or mechanical hooks for attaching fixtures such as clocks,
pictures, etc. The wall panels can have hollow passages connecting
the electrical couplings, so that electrical wires can pass to
these couplings. For example, horizontal hollow passages can be
used for coupling between wall panels, and vertical hollow passages
can be used for coupling between the horizontal hollow
passages.
[0120] FIG. 10 illustrates a wall panel according to some
embodiments. A wall panel 1000 can include a concrete or cement
material 1010, horizontal hollow passages 1020, and reinforced mesh
1050. Electrical outlets 1025 can be provided, for example, at a
horizontal hollow passage so that electrical wire can reach the
electrical outlets. Electric connections 1070 can be provided, for
example, at a horizontal hollow passage so that electrical wire can
reach the electrical connections. Vertical hollow passages can be
included (not shown), to connect the horizontal passages. Other
coupling can be included, such as opening 1027. Mechanical 1077
coupling can be included.
[0121] FIG. 11 illustrates a flow chart for fabricating a concrete
wall panel according to some embodiments. Operation 1100 provides a
mold, wherein the mold optionally comprises a wall coupling section
at an end portion, wherein the mold optionally comprises a fixture
coupling for fixture attachment, wherein the mold optionally
comprises hollow elements for weight reduction.
[0122] Operation 1110 places a first portion of a cement-based
compound into the mold. Operation 1120 places a reinforced mesh
into the mold. Operation 1130 places a second portion of a
cement-based compound into the mold, wherein the first and second
portions cover the reinforced mesh. Operation 1140 couples
attachment elements to the cement-based compound.
[0123] In some embodiments, the present invention discloses
pre-fabricated houses, and methods to assemble pre-fabricated
houses, which include multiple wall panels or wall pieces assembled
together to form a large wall panel. The assembling process can
include metal-based elements, such as using metal-based conduits to
connect the wall panels or using welding or bolting for connecting
metal-based attachments in the wall panels. In the specification,
the term "wall panel" and "wall piece" can be used interchangeably,
in the sense that multiple wall panels or multiple wall pieces can
be assembled to form a wall panel. For example, multiple wall
panels can be assembled to form a larger wall panel, or multiple
wall pieces can be assembled to form a wall panel.
[0124] FIGS. 12A-12E illustrate configurations for assembling wall
panels according to some embodiments. FIGS. 12A and 12B show that
two wall panels can be assembled using conduits passing through
hollow passages in the wall panels. The conduits can be metal-based
conduits, e.g., conduits having composition including a metal
material such as steel or an alloy. The conduits can be hollow
tubes, such as hollow square or rectangular tubes, hollow oval or
circular tubes, or hollow tubes having any cross section shapes. In
FIG. 12A, two wall panels 1200 and 1201 each having a straight end
portion are assembled together. The wall panels can be concrete
wall panels, including a concrete or cement material 1210. The wall
panels can have hollow passages 1220, such as hollow passages
running from one end to an opposite end of the wall panels. Hollow
conduits 1270 can be inserted in the hollow passages, securing the
two wall panels together. There can be a gap 1280 between the two
straight end portions of the two wall panels. As shown, the hollow
conduits 1270 have a rectangular shelf cross section, but other
shapes can be used, such as oval shelf, or even solid rectangular
or solid oval cross sections. In FIG. 12B, two wall panels 1202 and
1203 each having a step end portion are assembled together. The
wall panels can be concrete wall panels, including a concrete or
cement material 1211. The wall panels can have hollow passages
1221, such as hollow passages running from one end to an opposite
end of the wall panels. Hollow conduits 1271 can be inserted in the
hollow passages, securing the two wall panels together. There can
be a gap 1281 between the two step end portions of the two wall
panels, however, there is no exposure or communication between the
inside of the wall and the outside of the wall due to the step end
portions.
[0125] FIGS. 12C-12E show that two wall panels can be assembled
using attachments that are coupled or formed in the wall panels.
The attachments can be metal-based attachments, e.g., attachments
having composition including a metal material such as steel or an
alloy. The attachments can be straight plates, angle plates, or
curved plates. The attachments can also have coupling elements,
such as drilled holes or tap holes. In FIG. 12C, two wall panels
1204 and 1205 each having a straight end portion are assembled
together. The wall panels can be concrete wall panels, including a
concrete or cement material 1212. The wall panels can have hollow
passages 1222, such as hollow passages running from one end to an
opposite end of the wall panels. The wall panels can have
metal-based attachments 1262 coupled to the straight portion of the
straight end portions. The attachments can be coupled together, for
example, by welding 1272. There can be a gap between the two
straight end portions of the two wall panels, which can be covered
by the weld.
[0126] In FIG. 12D, two wall panels each having a step end portion
are assembled together. The wall panels can be concrete wall
panels, including a concrete or cement material 1213. The wall
panels can have hollow passages 1223, such as hollow passages
running from one end to an opposite end of the wall panels. The
wall panels can have metal-based attachments 1263 coupled to the
step end portions. The attachments can be coupled together, for
example, by welding 1273. There can be a gap between the two step
end portions of the two wall panels, however, there is no exposure
or communication between the inside of the wall and the outside of
the wall due to the step end portions. Thus the weld can be spot
weld, e.g., at locations for securing the wall panels together,
without concerning about covering the gap.
[0127] In FIG. 12E, two wall panels each having a step end portion
are assembled together. The wall panels can be concrete wall
panels, including a concrete or cement material 1214. The wall
panels can have hollow passages 1224, such as hollow passages
running from one end to an opposite end of the wall panels. The
wall panels can have metal-based attachments 1264 coupled to a
portion of the step end portion. The attachments can be coupled
together, for example, by a bolt 1274 securing the attachments
together. There can be a gap between the two step end portions of
the two wall panels, however, there is no exposure or communication
between the inside of the wall and the outside of the wall due to
the step end portions.
[0128] FIG. 13 illustrates a flow chart for assembling wall panels
according to some embodiments. Operation 1300 provides two wall
panels, wherein the two wall panels comprise a cement-based
compound, wherein the two wall panels optionally comprise a
metal-based attachment, wherein the two wall panels optionally
comprise a through straight hole from one end to an opposite end of
the wall panels. Operation 1310 couples the two wall panels,
wherein the coupling comprises at least one of welding the
metal-based attachments of the two wall panels together, inserting
a metal conduit through the through straight holes of the two wall
panels, bolting the two wall panels together, optionally through
the metal-based attachments, and bolting one wall panel to a
metal-based attachment of another wall panel.
[0129] In some embodiments, the present invention discloses
pre-fabricated houses, and methods to assemble pre-fabricated
houses, which include wall panels assembled to beams such as
vertical pillars or horizontal joists. The assembling process can
include welding or bolting for connecting metal-based attachments
in the wall panels with metal-based attachments in beams or with
metal-based beams.
[0130] FIGS. 14A-14G illustrate configurations for assembling a
wall panel with a beam according to some embodiments. FIG. 14A
shows that a wall panel 1400 can be assembled to a beam 1480 by
welding the metal components. For example, the beam 1480 can
include a metal material, such as steel or a metal alloy. The wall
panel 1400 can include a metal-based attachment 1460, which can be
used for welding 1470 to the metal-based beam 1480. In some
embodiments, the wall panel 1400 can include a cement or concrete
material 1410, together with hollow passages 1420. As shown, the
wall panel includes a straight end portion for welding to the
metal-based beam. Other configuration can be used, such as wall
panels having step end portions or different types of
attachments.
[0131] FIG. 14B shows that a wall panel 1401 can be assembled to a
beam 1481 by passing a metal-based conduit 1461 through a hollow
passages 1421 of the wall panel. The beam 1481 can include a metal
material, such as steel or a metal alloy, which can be welded 1471
to the conduit 1461. In some embodiments, the wall panel 1401 can
include a cement or concrete material 1411. As shown, the wall
panel includes a straight end portion for welding to the
metal-based beam. Other configuration can be used, such as wall
panels having step end portions or different types of
attachments.
[0132] FIG. 14C shows that a wall panel 1402 can be assembled to a
beam 1482 by welding the metal components. For example, the beam
1482 can include a metal material, such as two C shape beams
secured together by welding. The wall panel 1402 can include a
metal-based attachment 1462, which can be used for welding 1472 to
the metal-based beam 1482. In some embodiments, the wall panel can
include a cement or concrete material, together with hollow
passages.
[0133] FIG. 14D shows that a wall panel 1403 can be assembled to a
beam 1483 by bolting the metal components. For example, the beam
1483 can include a metal material, such as two C shape beams
secured together by welding. The wall panel 1403 can include a
metal-based attachment 1463, which can be used for attaching a bolt
1473 to the metal-based beam 1483.
[0134] FIG. 14E shows that a wall panel 1404 can be assembled to a
beam 1484 by welding the metal components. For example, the beam
1484 can include a metal material, such as two C shape beams
secured together by welding. The wall panel 1404 can include a
metal-based attachment 1464, which can be used for welding 1474 to
the metal-based beam 1484.
[0135] FIG. 14F shows that a wall panel 1405 can be assembled to a
beam 1485 by bolting the metal components. For example, the beam
1485 can include a metal material, such as two C shape beams
secured together by welding. The wall panel 1405 can include a
metal-based attachment 1465, which can be used for attaching a bolt
1475 to the metal-based beam 1485.
[0136] FIG. 14G shows that a wall panel 1406 can be assembled to a
beam 1486 by passing a metal-based conduit 1466 through a hollow
passages 1426 of the wall panel. The beam 1486 can include a metal
material, such as two C shape beams secured together by welding,
which can be welded 1476 to the conduit 1466.
[0137] FIG. 15 illustrates a flow chart for assembling wall panels
according to some embodiments. Operation 1500 a beam, wherein the
beam optionally comprises a metal-based attachment. Operation 1510
provides a wall panels, wherein the wall panel comprises a
cement-based compound, wherein the wall panel optionally comprises
a metal-based attachment, wherein the wall panel optionally
comprises a through straight hole from one end to an opposite end
of the wall panel. Operation 1520 couples the wall panel to the
beam, wherein the coupling comprises at least one of welding the
metal-based attachments of the wall panel to the beam or to the
metal-based attachment of the beam, inserting a metal conduit
through the through straight hole of the wall panel passing through
the beam, bolting the wall panel or the metal-based attachment of
the wall panel to the beam or to the metal-based attachment of the
beam, and bolting the beam or the metal-based attachment of the
beam to the wall panel or to the metal-based attachment of the wall
panel.
[0138] In some embodiments, the present invention discloses
pre-fabricated houses, and methods to assemble pre-fabricated
houses, which include beams, such as vertical pillars or horizontal
joists, that have metal-based elements for coupling with a wall
panel of the houses. The beams can include a metal-based
attachment, which can be configured to be coupled with the wall
panel, such as another metal-based attachment in the wall panel.
The two metal-based attachments can be coupled by welding, or by
bolting. The beams can be made of a metal material, such as steel
or other alloys, and can be fabricated to include an attachment
feature, which can be configured to be coupled with the wall panel,
such as another metal-based attachment in the wall panel. The
attachment feature and the metal-based attachment can be coupled by
welding, or by bolting.
[0139] FIGS. 16A-16G illustrate configurations for assembling
pre-fabricated houses according to some embodiments. FIG. 16A shows
a wall panel 1600 assembled with beams 1670 and 1680 (vertical
pillars 1680 and/or horizontal joists 1670) through metal-based
attachments 1660. The attachment can be built in the wall panel
1600, and then coupled to the beams 1670 and 1680 through, for
example, welding or bolting. In some embodiments, the wall panel
1600 can include a cement or concrete material 1610, and can have
hollow passages 1620 within the wall panel.
[0140] FIG. 16B shows a wall panel 1601 assembled with beams 1671
and 1681 (vertical pillars 1681 and/or horizontal joists 1671)
through metal-based attachments 1661. The attachment can be built
in the beams 1671 and 1681, and then coupled to the wall panel 1601
through, for example, welding or bolting.
[0141] FIG. 16C shows a wall panel 1602 assembled with beams 1672
and 1682 (vertical pillars 1682 and/or horizontal joists 1672)
through metal-based attachments 1662. The attachment can be built
in the wall panel 1602, and then coupled to the wall panel 1602
through bolt 1652.
[0142] FIG. 16D shows a wall panel 1603 including multiple wall
pieces (or smaller wall panels) 1603A, 1603B and 1603C. The wall
pieces 1603A, 1603B and 1603C can include a cement or concrete
material 1613, and can have hollow passages 1623 within the wall
pieces. The wall pieces can be assembled together by conduits 1653
passing through the hollow passages 1623. The wall panel 1603 can
be assembled with beams 1673 and 1683 (vertical pillars 1683 and/or
horizontal joists 1673) through metal-based attachments 1663. The
attachment can be built in some of the wall pieces, for example, in
wall pieces 1603A and 1603C, and then coupled to the beams 1673 and
1683 through, for example, welding or bolting.
[0143] FIG. 16E shows a wall panel 1604 including multiple wall
pieces (or smaller wall panels) 1604A, 1604B and 1604C. The wall
pieces 1604A, 1604B and 1604C can include a cement or concrete
material 1614, and can have hollow passages 1624 within the wall
pieces. The wall pieces can be assembled together by conduits 1654
passing through the hollow passages 1624. The wall panel 1604 can
be assembled with beams 1674 and 1684 (vertical pillars 1684 and/or
horizontal joists 1674) through the conduits 1654, e.g., the
conduits can be extended outside of the wall panel, and can be
welded to the beams 1674 and 1684.
[0144] FIG. 16F shows a wall panel 1605 including multiple wall
pieces (or smaller wall panels) 1605A, 1605B and 1605C. The wall
pieces 1605A, 1605B and 1605C can include a cement or concrete
material 1615, and can have hollow passages 1625 within the wall
pieces. Each wall piece can be placed between beams, such as
between vertical pillars 1685 and dividing beams (or studs) 1655
and horizontal joists 1645. The wall pieces can be assembled
together by conduits 1655 passing through the hollow passages 1625
and the dividing beams (or studs) 1655. The wall panel 1605 can be
assembled with beams 1675 and 1685, (vertical pillars 1685 and/or
horizontal joists 1675) through metal-based attachments 1665. The
attachment can be built in some of the wall pieces, for example, in
wall pieces 1605A and 1605C, and then coupled to the beams 1675 and
1685 through, for example, welding or bolting.
[0145] FIG. 16G shows a wall panel 1606 including multiple wall
pieces (or smaller wall panels) 1606A, 1606B and 1606C. The wall
pieces 1606A, 1606B and 1606C can include a cement or concrete
material 1616, and can have hollow passages 1626 within the wall
pieces. Each wall piece can be placed between beams, such as
between vertical pillars 1686 and dividing beams (or studs) 1656
and horizontal joists 1646. The wall pieces can be assembled
together by conduits 1656 passing through the hollow passages 1626
and the dividing beams (or studs) 1656. The wall panel 1606 can be
assembled with beams 1676 and 1686 (vertical pillars 1686 and/or
horizontal joists 1676) through the conduits 1656, e.g., the
conduits can be extended outside of the wall panel, and can be
welded to the beams 1676 and 1686.
[0146] In some embodiments, the present invention discloses
pre-fabricated houses, and methods to assemble pre-fabricated
houses, which include beams, such as vertical pillars that have
metal-based elements for coupling with a foundation of the houses.
The beams can include a metal-based attachment, which can be
configured to be coupled with the foundation, such as another
metal-based attachment in the foundation. The two metal-based
attachments can be coupled by welding, or by bolting. The beams can
be made of a metal material, such as steel or other alloys, and can
be fabricated to include an attachment feature, which can be
configured to be coupled with the wall foundation, such as another
metal-based attachment in the foundation. The attachment feature
and the metal-based attachment can be coupled by welding, or by
bolting.
[0147] FIGS. 17A-17F illustrate configurations for assembling
pre-fabricated houses according to some embodiments. FIG. 17A shows
a metal pillar 1700, e.g., a pillar having a metal material 1710,
such as made of steel or other alloys. The metal pillar 1700 can
have a metal-based attachment 1720, which can be secured to the
metal pillar, for example, by welding 1730. Other configurations
can also be used, such as the metal pillar having an attachment
feature which is machined from the pillar material, or a
metal-based attachment secured to the pillar by bolting.
[0148] The metal based attachment 1720 can be secured to a
foundation 1750, e.g., coupled to a metal-based attachment 1740 of
the foundation. For example, the foundation can include a cement or
concrete material, with metal reinforced elements. The foundation
can include metal-based poles 1740, which are secured to the
foundation, and which are configured to form an attachment to a
vertical pillar. The vertical pillar 1700 can be placed on the
foundation 1750, with the metal-based attachment 1720 of the pillar
coupled to the metal-based attachment 1740 of the foundation. For
example, the attachment 1720 can include through holes, and the
attachment 1740 can include bolts, which can pass through the
through holes of the attachment 1720. The pillar can be secured to
the foundation, for example, by nuts bolting on the bolts, or by
welding the bolts to the holes.
[0149] FIGS. 17B and 17C show a metal pillar 1701/1702, e.g., a
pillar having a metal material 1711/1712, such as made of steel or
other alloys. For example, the metal pillar 1701 can be two C shape
beams secured together by welding. The metal pillar 1701/1702 can
have an attachment feature 1721/1722 which is machined from the
pillar material. The metal based attachment 1721/1722 can be
secured to a foundation 1751/1752, e.g., coupled to a metal-based
attachment 1741/1742 of the foundation, respectively.
[0150] FIG. 17D shows a concrete pillar 1703, e.g., a pillar having
a cement material 1713, such as a mixture of cement, sand and
water. The concrete pillar 1703 can have a metal-based attachment
1723, which can be secured to metal-based reinforced elements 1763
of the pillar, for example, by welding 1733. The metal based
attachment 1723 can be secured to a foundation 1753, e.g., coupled
to a metal-based attachment 1743 of the foundation. For example,
the foundation can include a cement or concrete material with metal
reinforced elements 1763. The foundation can include metal-based
poles 1743, which are secured to the foundation, and which are
configured to form an attachment to a vertical pillar. The vertical
pillar 1703 can be placed on the foundation 1753, with the
metal-based attachment 1723 of the pillar coupled to the
metal-based attachment 1743 of the foundation.
[0151] FIGS. 17E and 17F show different configurations of concrete
pillars attaching to foundations. Metal-based attachment 1724 can
include coupling elements 1734 which are coupled to the reinforced
elements 1764 of the concrete pillar 1704. Alternatively,
metal-based attachment 1725 can be bolted by a coupling element
1735 to secure the attachment 1725 to the concrete pillar 1705.
[0152] FIG. 18 illustrates a flow chart for assembling wall panels
according to some embodiments. Operation 1800 provides a beam,
wherein the beam optionally comprises a metal-based attachment.
Operation 1810 provides a wall panels, wherein the wall panel
comprises a cement-based compound, wherein the wall panel
optionally comprises a metal-based attachment, wherein the wall
panel optionally comprises a through straight hole from one end to
an opposite end of the wall panel. Operation 1820 couples the wall
panel to the beam, wherein the coupling comprises at least one of
welding the metal-based attachments of the wall panel to the beam
or to the metal-based attachment of the beam, inserting a metal
conduit through the through straight hole of the wall panel passing
through the beam, bolting the wall panel or the metal-based
attachment of the wall panel to the beam or to the metal-based
attachment of the beam, and bolting the beam or the metal-based
attachment of the beam to the wall panel or to the metal-based
attachment of the wall panel.
[0153] In some embodiments, the present invention discloses a
pillar structure that can allow construction of houses having
various sizes and shapes.
[0154] FIGS. 19A-19D illustrate various configurations for
assembling pre-fabricated houses according to some embodiments. The
pillars can include two C shape beams secured together, for
example, by welding. The C shape beams can be attached with an
offset amount, thus providing multiple surfaces for coupling with a
L shape beam of the wall panel. For example, a pillar can have 6
external surfaces for connection, two (1961 and 1962) at the middle
portion of the C pattern, and four (1971, 1972, 1973, and 1974) at
the outer portions of the C pattern. The pillar can have 4 internal
surfaces for connection at each inner protruding portion (1981,
1982, 1983, and 1984) of the C shape beams.
[0155] For example, as shown in FIG. 19A, wall panel 1931 can have
a L shape end beam 1941 coupled to an outer C portion 1911. Wall
panel 1932 can have a L shape end beam 1942 coupled to a middle C
portion 1912. Thus the pillars can allow construction of different
housing configurations depending on the rotation and attachment
point of the pillars.
[0156] FIGS. 20A-20C illustrate various configurations for
assembling pre-fabricated houses according to some embodiments. The
houses can have middle wall panels.
[0157] FIG. 21 illustrates a configuration for assembling
pre-fabricated houses according to some embodiments. The house can
have multiple rooms, divided by middle wall panels.
[0158] FIGS. 22A-22C illustrate a process for constructing a house
according to some embodiments. In FIG. 22A, pillars 2210 and wall
panels 2230 and 2237 can be transported to a construction site. The
wall panels can be pre-fabricated according to the house, for
example, having proper length and attachment beam connections, such
as wall panels 2230 and 2237 having different attachment beam
connections.
[0159] In FIG. 22B, a foundation can be first constructed at the
construction site. A floor 2200 can be formed on the foundation.
Pillars 2210 can be attached to the floor, or to the foundation. In
FIG. 22C, wall panels 2230 and 2237 can be attached to the pillars
2210, such as by bolting 2270, and/or by welding.
[0160] FIG. 23 illustrates a configuration of wall panel and pillar
attachments according to some embodiments. House 800 can include
multiple wall panels 830, which can attach to pillar 810 in
different configurations to form a house having a desired size and
shape.
[0161] FIGS. 24A-24B illustrate a process for forming a two story
house according to some embodiments. In FIG. 24A, a floor panel
2490 can be installed, for example, on a foundation 2495. Pillars
2410, 2415, and 2417 can be attached to the floor panel 2490, or
alternatively, attached to the foundation through the floor panel.
For example, pillar 2410 can be welded 2485 to the floor panel,
e.g., to a metal frame of the floor panel. Pillar 2415 can be
bolted 2470 to the foundation through the floor panel, e.g., to
bolts secured to the foundation and protruded to the floor panel.
Alternatively, the pillar can be bolted to the floor panel, e.g.,
to bolts that are secured to the frame of the floor panel. The
foundation can be protruded through the floor panel, and the pillar
can be welded 2486 or bolted 2471 directly to the foundation.
[0162] Top floor panels 2497 can be secured to the pillars 2410,
2415, and 2417. New pillars can be secured to the top floor panels,
or to the existing pillars under the top floor panels.
[0163] In FIG. 24B, wall panels 2430 and 2435 can be secured to the
pillars. The wall panels can be pre-fabricated to include all
necessities, such as window 2420, or doors, or other elements such
as electrical connections or outlets. Alternatively, the wall
panels can include outer wall plates that are pre-fabricated. The
inner wall plates can be installed after the house structure is
completed. The electrical connections such as wiring and outlets
can be installed at the interior of the wall panels, and then the
inner wall plates can be installed.
[0164] In some embodiments, the wall panels can be installed before
forming the new pillars for the top floor. Alternatively, the wall
panels can be installed before forming the top floor panels.
[0165] FIG. 25 illustrates a flow chart for constructing a
pre-fabricated house according to some embodiments. Operation 2500
prepares a foundation for a house. Operation 2510 couples first
multiple pillars to the foundation, wherein the pillars comprise
two C-shape beams offsetly attached back to back. Operation 2520
attaches multiple walls to the multiple pillars, wherein the
multiple walls comprise L-shape beams coupled to C-shape beams
coupled to ends of the multiple walls. Operation 2530 couples a
second floor on the multiple pillars. Operation 2540 couples second
multiple pillars to the second floor.
[0166] FIGS. 26A-26G illustrate wall panels according to some
embodiments. In FIG. 26A, an attachment beam 2640 is shown, which
can be used for attaching to a pillar. The attachment beam 2640 can
have a L shape cross section, with one part of the L shape attached
to an end beam of a wall panel, and the other part of the L shape
attached to a pillar.
[0167] In FIG. 26B-26D, various wall panels without an attachment
beam are shown. A wall panel 2630 can have end beams 2660 disposed
at edges of a wall plate 2650. The end beams can be at two opposite
edges or at all four edges of the wall plate. The end beams can
have a C shape cross section. The attachment beams, for example
attachment beams 2640, can be coupled to the end beams 2660. The
coupling can be by bolting or by welding. The coupling can be
pre-fabricated, e.g., welded according to the design of the house.
The coupling can be performed at the construction site, e.g., tack
welded during assembling with the pillar, and then removed for
final weld before re-assembled with the pillar.
[0168] A wall panel 2631 can have a frame attached together. For
example, end beams 2661 and middle beams 2691 can be welded
together to form a frame for the wall panel. Wall plates 2651 can
be coupled to the surfaces of the frame to form a wall panel.
[0169] Alternatively, a wall panel 2632 can have a frame with end
beams 2662 and middle beams 2692. One wall plate 2652 can be
coupled to a surface, such as an external surface, of the wall
panel. After complete the structural construction for the house,
e.g., the floor panels, the pillars, the wall panels, and the roof
panels have been assembled, electrical wiring and/or gas line
running can be installed. The other wall plate of the wall panel
2632 can be installed to cover the electrical wiring.
[0170] In FIG. 26E-26G, various wall panels with attachment beams
are shown. An attachment beam 2643 can have a T shape cross
section, and can be attached, e.g., welded, to end beam 2663 of
wall panel 2633. The attachment beam 2643 can be symmetric, e.g.,
the attachment portion can be symmetric with respect to a center
line of the wall panel. The attachment beams 2643 and 2673 at two
end of the wall panel 2633 can be symmetric, e.g., both attachment
portions can be symmetric with respect to a center line of the wall
panel.
[0171] The attachment beam 2644 of wall panel 2634 can be
asymmetric, e.g., the attachment portion can be asymmetric with
respect to a center line of the wall panel. The attachment portion
of attachment beam 2644 can be attached to a mated attachment
portion of a pillar 2614, with the center line disposed between the
two attachment portions, thus providing a symmetrical configuration
after coupling. In wall panel 2634, the attachment portions of two
opposite attachment beams 2644 and 2674 can be a rotating image,
e.g., one attachment portion can be obtained by rotating the other
attachment portion. In wall panel 2635, the attachment portions of
two opposite attachment beams 2645 and 2675 can be a mirror image,
e.g., one attachment portion can be obtained by reflecting the
other attachment portion.
[0172] In some embodiments, the present invention discloses methods
and systems for improved alignments between components in
pre-fabricated houses. The components can be pre-attached for
proper matching, and then disassembled for secured attachment
before re-assembling.
[0173] FIGS. 27A-27C illustrate a process for alignment improvement
according to some embodiments. In FIG. 27A, attachment beams 2740
and 2741 can be attached to pillars 2710 and 2711, respectively,
through bolts such as 2770. A wall panel 2730 can be brought to
couple with the attachment beams 2740 and 2741. Tack weld 2780 can
be used to attach the attachment beams 2740 and 2741 to the wall
panel 2730.
[0174] Alternatively, an attachment beam 2740 can be attached to
the wall panel 2730, either temporarily (e.g., by tack weld) or
permanently (e.g., by secured weld). The wall panel 2730 with the
attachment beam 2740 can be attached to pillar 2710. Other
attachment beam 2741 can be coupled to pillar 2711 and tack welded
to the wall panel 2730. Thus the attachment of the attachment beams
to the wall panel can occur after performing an alignment, thus
allowing proper alignment of the wall panel with pillars.
[0175] In FIG. 27B, the attachment beams can be secured to the wall
panel, for example, by a permanent weld 2785. The permanent weld by
be performed when the wall panel is attached to the pillars, or can
be performed after the wall panel is removed from the pillars.
[0176] In FIG. 27C, the wall panel can be re-installed after
securing the attachment beams. The re-installation can be performed
with nuts and bolts 2770, or with welding. Since the positions of
the attachment beams have been proven to be mated properly with the
pillars, the re-installation of the wall panel should fit
perfectly.
[0177] FIG. 28 illustrates a flow chart for alignment improvement
according to some embodiments. Operation 2800 prepares a foundation
for a house. Operation 2810 couples first multiple pillars to the
foundation, wherein the pillars comprise two C-shape beams offsetly
attached back to back. Operation 2820 puts multiple walls to the
multiple pillars, wherein the multiple walls comprise C-shape beams
coupled to ends of the multiple walls. Operation 2830 loosely
couples L-shape beams to the pillars and the walls. Operation 2840
removes the coupling between the L-shape beams and the pillars to
obtain the walls having L-shape beams loosely attached. Operation
2850 securely attaches the L-shape beams to the walls. Operation
2860 attaches the walls to the pillars, wherein the walls are
attached to the pillars through the L-shape beams.
[0178] In some embodiments, the present invention discloses methods
and systems for constructing portable houses. Pillars can be
installed, for example, on floor panels. The pillars can have
channels along the length of the pillars. Wall panels can have
mating elements that fit in the channels of the pillars. The wall
panels can be raised to a position above the pillars and then
dropped to the channels of the pillars, so that the mating element
fit in the channels. Additional attachment process can be added,
for example, by welding or bolting the wall panels to the pillars,
to secure the wall panels to the pillars.
[0179] FIGS. 29A-29B illustrate a process for installing wall
panels according to some embodiments. Pillars 2910 can be installed
on floor panels 2900. The pillars 2910 can have channels 2912 along
the length of the pillars, e.g., parallel to the pillars. Wall
panels 2930 can have end beams 2940, which have mating elements
2942 that can fit in the channels 2912. The wall panels 2930 can be
raised and then slide along the channels 2912 so that the mating
element 2942 is within the channels 2912. The channels thus can
secure the wall panels in place, even without any additional
attachment means. Alternatively, the wall panels can be welded or
bolted to the pillars, e.g., the end beams 2940 can be welded to
the pillars 2910, or the mating element 2942 can be bolted to the
pillars 2910. The pillars 2910 can have a middle channel 2912.
[0180] FIGS. 30A-30B illustrate a process for installing wall
panels according to some embodiments. Pillars 3010 can be installed
on floor panels 3000. Wall panels 3030 can have end beams 3040,
which have channels 3042 that can fit the pillars 3010. The wall
panels 3030 can be raised and then slide along the pillars 3010 so
that the channels 3042 covers the pillars 3010. The channels thus
can secure the wall panels in place, even without any additional
attachment means. Alternatively, the wall panels can be welded or
bolted to the pillars, e.g., the end beams 3040 can be welded or
bolted to the pillars 3010.
[0181] In some embodiments, the prefab house can include multiple
beams, with the multiple beams configured to be secured to a
foundation to form a frame of the prefab house. The prefab house
can include one or more wall panels. At least a wall panel can be
disposed between two beams of the multiple beams. The wall panel is
disposed between the two beams in such as way so that the at least
a wall panel can be movable in a direction along a length of the
two beams. The wall panel can be disposed between the two beams in
such as way so that the wall panel is constrained in directions
perpendicular to the length of the two beams.
[0182] In some embodiments, the beams can include a channel running
along from one end to an apposite end of the beam, with the wall
panel having a structure that fits in the channel.
[0183] The wall panel can include a channel running along from one
end to an apposite end of the wall panel. The beams can include a
structure that fits in the channel.
[0184] The beams of the multiple beams can include at least a first
mating element along a length of the each beam. The wall panel can
include a cement material. The wall panel can include two second
mating elements at two ends of the at least a wall panel. The first
and second mating elements are configured for mating with each
other. The wall panel can be disposed between the at least two
beams with the second mating elements fitted into the first mating
elements of the at least two beams.
[0185] The multiple beams, the wall panels, and floor panels and
ceiling panels can be pre-fabricated in a factory before being
brought to a construction site for assembling the prefab house. The
wall panel can include a cement or concrete material coupled to
metal connectors, such as a metal coupler. The multiple beams and
at least a frame of the floor panels or the ceiling panels can
include a metal material.
[0186] FIG. 31 illustrates a flow chart for constructing a portable
house according to some embodiments. Operation 3100 prepares a
foundation for a house. Operation 3110 couples multiple poles to
the foundation, wherein the poles comprise C-shape or box shape
beams. Operation 3120 lifts multiple walls above the multiple
poles, wherein the multiple walls comprise an attachment for
coupling to the multiple poles. Operation 3130 optionally secures
the walls to the pillars.
[0187] In some embodiments, the prefab house can be formed by
securing multiple beams to a foundation to form a frame of the
prefab house, A wall panel can be brought to a position above the
multiple beams, wherein the wall panel comprises a cement material
coupled to metal connectors. The wall panel can be slide between
two beams of the multiple beams, wherein the wall panel is
constrained in directions perpendicular to the length of the two
beams.
[0188] In some embodiments, the beams can include a channel running
along from one end to an apposite end of the beam, with the wall
panel having a structure that fits in the channel.
[0189] The wall panel can include a channel running along from one
end to an apposite end of the wall panel. The beams can include a
structure that fits in the channel.
[0190] The multiple beams, the wall panels, and floor panels and
ceiling panels can be pre-fabricated in a factory before being
brought to a construction site for assembling the prefab house. The
wall panel can include a cement or concrete material coupled to
metal connectors, such as a metal coupler. The multiple beams and
at least a frame of the floor panels or the ceiling panels can
include a metal material.
[0191] The beams can include a first mating element along a length
of the each beam. The wall panel can include two second mating
elements at two ends of the at least a wall panel. The first and
second mating elements can be configured for mating with each
other. The wall panel can be disposed between the at least two
beams with the second mating elements fitted into the first mating
elements of the at least two beams.
[0192] In some embodiments, the present invention discloses a
prefab house and its construction and assembly. A floor panel and a
ceiling panel can be fabricated, for example, using a metal frame.
Multiple beams, such as 4 beams at four corners of the floor and
ceiling panels, can be fabricated with a metal material. Wall
panels, including doors, windows, and optionally wall outlets can
be fabricated.
[0193] The beams can include couplers at two ends. The floor panel
can include bottom couplers for coupling with foundation poles. The
floor panel can include top couplers for coupling with the couplers
of the beams. The ceiling panel can include couplers for coupling
with the couplers of the beams. The beams can include corner beams,
e.g., beams at 4 corners of the prefab house. The beams can include
middle beams, e.g., beams between the 4 corner beams, for
supporting the wall panels. The wall panels can be configured to be
coupled to each other, or to the beams, e.g., the corner beams or
the middle beams. The wall panels can include a cement or concrete
material, with optionally metal connectors.
[0194] The components can be packaged in a secured package
configuration, having the floor panel at a bottom, the ceiling
panel at a top, and the wall panels and the beams are packaged and
placed in a middle, so that the floor and ceiling panels
sandwiching the package of beams and wall panels. The complete
package configuration is secured, such as by cables or straps.
[0195] For construction, foundation poles can be prepared at the
construction side. For example, foundation poles at 4 corners of
the prefab house can be prepared. In addition, the foundation poles
can be formed in between the corner poles, for supporting the
prefab house.
[0196] The secured package can be brought to the construction site,
and placed on the foundation poles, for example, by a hoist. The
secured package can be packaged in such as way to expose the
couplers of the floor panel. Thus the couplers of the floor panel
can be secured to the foundation poles.
[0197] The secured package can be unsecured, e.g., the cables or
straps can be removed. The removal of the secured cables or straps
can occur while the hoist is still coupled to the package. Thus,
the hoist can lift up again, lifting the ceiling panel from the
remaining of the package, exposing the inner package of wall panels
and beams. The beams can be packed so that they are at the top of
the inner package, so can be easily removed first.
[0198] The inner package can be unsecured, e.g., unwrapped. The
beams are removed from the inner package. The beams can be coupled
to the floor panel. The ceiling panel can be lowered, so that the
ceiling panel can be coupled to the beams.
[0199] The wall panels can be removed from the inner package, and
assembled between the beams and the floor and ceiling panels. The
wall panels can include multiple panels coupling together. The
prefab house can include middle beams, e.g., beams between the 4
corner beams, to support and secure the wall panels.
[0200] FIGS. 32A-32F illustrate a process for assembling a prefab
house according to some embodiments. In FIG. 32A, a secured package
3220 is hoist to a construction site, aligned to foundation poles
3210. The secured package 3230 can include a floor panel 3221 and a
ceiling panel 3222, sandwiching an inner package 3223.
[0201] In FIG. 32B, after placing the secured package on the
foundation poles, and optionally securing the floor panel to the
foundation poles, the secured package is unsecured, and the hoist
lifted up, separating the ceiling panel from the package. The inner
package is exposed, and unwrapped.
[0202] In FIG. 32C, the corner beams 3241 are removed from the
inner package and coupled to the floor panel. The ceiling panel can
be lowered, so that the ceiling panel is coupled 3231 to the corner
beams.
[0203] In FIG. 32D, the coupling between the floor panel, the
ceiling panel, and the corner beams are secured. The wall panels
3240 are removed from the inner package.
[0204] In FIG. 32E, the wall panels are assembled between the
corner beams. The wall panels can include multiple panels, with the
panels optionally mating with each other. Inner beams can also be
used for supporting the wall panels. For example, a corner panel
can be installed, coupling to a corner beam. A middle beam can be
coupled to the free side of the panel, e.g., to the side of the
panel that is not already coupled to the beam. A second panel can
be installed, coupling to the corner panel through the middle beam.
A second middle beam can be coupled to the corner and second
panels, securing the two panels together. Subsequent panels can be
repeated.
[0205] FIG. 32F shows an assembled prefab house.
[0206] FIG. 33 illustrates a coupling configuration between a floor
or ceiling panel 3310 with a wall panel or the beams 3320. The
floor or ceiling panel can include a hook configuration 3330 and
3331 for hooking with slits in the beam 3320. The floor or ceiling
panel can include a support 3332 for connecting to another floor or
ceiling panel.
[0207] FIGS. 34A-34G illustrate coupling configurations between
wall panels according to some embodiments. In FIG. 34A, a wall
panel 3410 can include one or more plates 3411. Two plates are
shown. Attachments 3412 in a form of a cross can be coupled to the
plates, having a protrusion extended from the panel, which can be
used for coupling with other wall panel or with a beam. The
protrusion can have different sizes, such as a longer size at one
end of the wall panel and a shorter size at an opposite end of the
wall panel.
[0208] FIG. 34B shows a straight coupling configuration between two
wall panels. A beam 3420 having a box cross section can be used to
couple the two attachments of two panels. Two beams can be used,
one for each side of the attachments.
[0209] FIG. 34C shows another straight coupling configuration
between two wall panels. A beam 3421 having a C-shape cross section
can be used to couple the two attachments of two panels. Two beams
can be used, one for each side of the attachments.
[0210] FIG. 34D shows an angle coupling configuration between two
wall panels. A beam 3422 having an angle cross section, such as a
square beam, can be used to couple the two attachments of two
panels. Two beams can be used, one for each side of the
attachments.
[0211] FIG. 34E shows another angle coupling configuration between
two wall panels. A beam 3423 having a box cross section, similar to
the box beam used for a straight coupling discussed above, can be
used to couple the two attachments of two panels. A box beam and an
angle beam can be used, one for each side of the attachments.
[0212] FIGS. 34F-34G show a configuration for coupling a floor or
ceiling panel to the beam. The beam 3425, such as a box beam or a
square beam, can have a slit 3426. The floor or ceiling panel 3430
can include an attachment having a hook configuration 3431. The
attachment can be slide to the slit 3426 in the beam, and the hook
configuration can be used to secure the floor or ceiling panel to
the beam.
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