Explosive blast energy dissipating and carrying building structure

A structural assembly for use in building applications is disclosed. The assembly has spaced inner and outer face sheets, as well as one or more intermediate panels positioned between the inner and outer face sheets. The intermediate panels are parallel to the inner and outer face sheets, and are supported by alternating flanged web members that engage either the inner or outer face sheets. The assembly provides an enhanced ability to dissipate blast or projectile impact forces and to carry the forces throughout the assembly, thus maintaining sufficient structural integrity in the building to enable the occupants to evacuate, to enable contents to be evacuated, and to enable reuse of the building itself.

FIELD OF THE INVENTION

The invention generally relates to an improved building system for use as walls, roofs, floors and also for use in combination with typical building materials for constructing commercial residences and buildings, as well as a retrofit for existing buildings. More particularly, the invention relates to an improved building system that dissipates and carries blasts or projectile impacts throughout the structure and to the foundation of the building of which it is a part.

BACKGROUND

Blast and penetration resistant building structures have been used for many years to protect inhabitants from a variety of natural destructive forces (e.g., tornadoes) as well as man-made destructive forces such as impact loads from projectiles and blasts associated with explosives detonations. These traditional building structures often are constructed of substantial thicknesses of reinforced concrete capable of withstanding the forces associated with the aforementioned loads. An obvious disadvantage of using concrete is its great weight, which makes it difficult to transport and assemble on site. Additionally, although concrete is capable of withstanding large forces or projectile impacts, extreme loading can cause concrete walls to spall, break apart, or be pushed over.

Building modules are known which comprise sheet metal in lieu of concrete and thus are relatively light. These known building modules may easily be prefabricated and transported to the building site for assembly. An example of such modules are those described in U.S. Pat. No. 4,928,468 to Phillips, the entirety of which disclosure is incorporated herein by reference. These building modules may contain thermo/acoustic insulation, or they may contain supplemental internal structures for preventing forcible entry. The structures in these modules may also prevent penetration of the associated building panel by low level ballistic projectiles.

Still some current building modules may be difficult to handle and transport due to their substantial size and weight, making their procurement and installation expensive and costly to heat and cool.

It would, therefore, be desirable to provide a lightweight, low cost building assembly that would resist and dissipate and carry the forces associated with projectiles or blasts to mitigate damage to the overall building structure.

The desired assembly should be versatile enough to be used in a wide variety of structural applications. In addition to the aforementioned blast or projectile resistance, such an assembly should provide substantial structural load-bearing strength to enable its use in any of a variety of building structures.

SUMMARY OF THE INVENTION

The disadvantages heretofore associated with the prior art are overcome by the inventive design for a building assembly that is lightweight, cost effective, and that provides enhanced protection from penetration due to projectiles and blasts.

The inventive assembly is designed to accept multiple local bendings without resulting in structural failure of the building in which the assembly is incorporated. Thus, a wall constructed in accordance with embodiments of the inventive assembly can sustain local bending from an explosive blast, but will retain sufficient structural integrity to remain intact, thus allowing evacuation of the occupants and continued use of the structure. Even where the blast force is sufficient to cause a breach of the inner wall, embodiments of the inventive assembly are still designed to maintain sufficient structural integrity to allow occupants to evacuate and contents to be evacuated, and to enable the building itself to be repaired and returned to full service.

Thus, a structural assembly for use in a building is disclosed, the structural assembly may comprise a building, module, wall, roof, column, beam, or floor. The assembly may comprise a first plate forming a first face sheet of the structural assembly, and a second plate forming a second face sheet of the structural assembly. Third and fourth plates may be positioned between the first and second plates and may be laterally offset with respect to each other, such that an end portion of the third plate may overlap an end portion of the fourth plate. A first flanged web member may connect the first plate to the third plate, and a second flanged web member may connect the second plate to the fourth plate. Further, the first and second flanged web members may be offset by a lateral distance.

A structural assembly is further disclosed, comprising first and second spaced apart plate members, and third and fourth plate members disposed between said first and second plate members. The third and fourth plate members may be laterally offset with respect to each other such that an end portion of the third plate member overlaps with an end portion of the fourth plate member. The structural assembly may comprise a building, module, wall, roof, column, beam, or floor. The assembly may further comprise first and second flanged webs, the first flanged web connecting the first and third plate members, and the second flanged web connecting the second and fourth plate members. The first and second flanged webs may be laterally offset with respect to each other.

A structural assembly is further disclosed, comprising: first and second facing panels; first and second interior panels; and first and second flanged webs. The first and second facing panels may be spaced apart by a distance sufficient to receive the first and second interior panels there-between, with the first facing panel connected to the first interior panel by the first flanged web, and the second facing panel connected to the second interior panel by the second flanged web. The first and second interior panels may be laterally offset with respect to each other such that only a portion of the first interior panel overlaps with a portion of the second panel. Additionally, the first and second flanged webs may be laterally offset with respect to each other.

DETAILED DESCRIPTION

A new structural assembly is disclosed for use in building applications in which a high resistance to large explosive blasts, projectile impact loads, high speed vehicle impacts, forced entry or exit, and the like, is desired. The structural assembly design incorporates a pair of outer face sheets, spaced apart to form a void there between. Within the void is a plurality of particularly situated and oriented structural members configured to resist and mitigate by dissipating explosive blast or projectile loads applied to one of the outer wall faces. The internal structural members are designed and positioned to bend in response to such loads, thereby minimizing the chance that one or both of the external faces will be breached. In addition to breach-prevention, the new structural assembly design also will maintain the structural integrity of the building for sufficient time to enable the occupants to evacuate, to enable the contents to be evacuated, and to allow the building to be repaired and reused.

Thus, embodiments of the present invention provide for inward movement of one of the outer faces (typically the face (e.g., building, module, wall, roof, column, beam, or floor) that is closest to the explosive blast or projectile impact), to thereby dissipate and carry forces rather than to completely withstand it. For cases in which the blast or projectile are of such magnitude that the assembly (wall, roof, floor, etc.) is penetrated, sufficient structural integrity is maintained to allow the occupants to safely evacuate, the contents of the building to be removed, and the building to be repaired and reused.

Before specific embodiments of the present disclosure are described, it should be noted that sheets and structural assemblies of the present disclosure are intended to protect building components (e.g., walls, including both load bearing and non-load bearing), both internal or external, from forced entry or exit by people and/or breach by physical objects such as, for example, cars, trucks, including construction vehicles and the like, military vehicles, projectiles and explosive devices. Any type of building, the walls of which may be subject to breach due to forced entry or exit or natural (e.g., earthquake) or man-made (e.g., explosions, including hostile and accidental) forces, is suitable for use with structures of the present disclosure. Examples of buildings in which structures of the present disclosure may be incorporated include, but are not limited to, schools, residential buildings, commercial buildings, jails, detention centers, prisons, government buildings, and military buildings.

Referring toFIGS. 1 and 2A, an exemplary structural assembly1is shown. The structural assembly1may comprise a wall, module, floor/ceiling, roof, column, beam, or building section. The structural assembly1may be pre-fabricated at the factory in a modular fashion that can then be fully assembled at the installation site. The structural assembly1is shown as having first and second face sheets2,4, and a plurality of internal structural members6configured to provide strength and stability to the assembly1to support the typical vertical and horizontal loads associated with a building structure. In various embodiments, the internal structural members6comprise a plurality of individual vertically positioned sheet elements having portions oriented either substantially parallel to, and/or substantially perpendicular to, the first and second face sheets2,4. It will be appreciated that although the internal structural members6are shown in the figures as being oriented parallel and/or perpendicular to the first and second face sheets2,4, one or more of the members could be oriented so as to be obliquely angled with respect to the face sheets2,4.

As noted, the structural assembly1comprises complete and continuous floors, walls, roofs and buildings having the disclosed arrangement of face sheets2,4and internal structural members6in various embodiments. The structural assembly1is manufactured in at least one of a variety of sizes, depending upon what the installation equipment and site conditions will allow. Thus, for some applications, the structural assembly1is pre-manufactured at the factory to comprise an entire floor, wall, roof or building and then shipped to the site for installation. In other applications, such as for retrofit applications, the assembly is manufactured in discrete modules at the factory, shipped to the installation site, transported into the building and fastened together to form a larger overall assembly1.

In the embodiments depicted inFIGS. 1-2A, the internal structural members6comprise a plurality of opposing intermediate panels8,10oriented substantially parallel to the first and second face sheets2,4, as well as a plurality of flanged web members12,14oriented substantially perpendicular to the first and second face sheets. Each of the intermediate panels8,10is connected to one of the first and second face sheets2,4by an associated flanged web member12,14. As shown, the opposing intermediate panels8,10are alternately positioned along the length “L” of the assembly1so that immediately adjacent panels8,10are connected to different face sheets2,4. The immediately adjacent intermediate panels8,10also are linked to each other by channel shaped members9,11formed at the distal edges of each intermediate panel8,10.

In certain embodiments, the structural assembly1further comprises additional supportive flanged web members16positioned opposite to some of the intermediate panels. In the illustrated embodiment ofFIG. 2A, these additional flanged web members16are positioned opposite to intermediate panels8and are directly connected to the second face sheet4. The additional flanged web members16are positioned so that they are laterally offset along the X axis (by “OD” (FIG. 2A)) from the flanged web members12that connect the intermediate panel8to the first face sheet2. This lateral offset forms a cantilever arrangement in which intermediate panel8is supported by two opposing but offset flanged web members (12,16). Thus, when a load is applied to the second face sheet4(the one to which flanged web member16is attached), the load is carried from the face sheet4, through the flanged web member16, to intermediate panel8, such that panel8bends, but is restrained at each end by the channel shaped members9,11and also by flanged web member12near the center of the structural assembly1(seeFIG. 3B). This bending of intermediate panel8(and also intermediate panel10, as the channel shaped members9,11interlock) dissipates and carries the blast forces throughout the interior structure of the assembly and to the foundation.

It will be appreciated that where the structural assembly1comprises a complete wall, floor, roof, column, beam, or building, that the reaction to an explosive blast will be substantially the same all the way along the length of the assembly, since the arrangement of the flanged web clusters (i.e., those formed by flanged web members12and16) and the interlocking channel shaped members9,11is carried throughout the assembly, as will be described in greater detail. Thus, the flanged web cluster and channel shaped member arrangement serves to effectively dissipate a blast throughout the interior structure to minimize the chance that any of the structural members will fail, at the same time, carrying a substantial portion of the horizontal and vertical blast force to the foundation.

The additional flanged web members16do not directly contact the intermediate panels8in preferred embodiments and during normal use and/or positioning of the assembly1. Rather, members16are offset from the intermediate panels8by a gap such that the additional flanged web members16only contact the intermediate panels8when an explosive blast or projectile impact load is applied to one of the first or second face sheets2,4. This offset enhances the thermal and acoustical efficiency of the structural assembly1by eliminating a direct metal-to-metal contact path between the first and second face sheets2,4. Additionally, insulation material or epoxy may be provided within the gap to further enhance the thermal and acoustical efficiency of the structural assembly1. Thus, the gap is preferably of sufficient size to allow for the installation of a desired thickness of thermal insulation, acoustic insulation or epoxy.

Thus configured, the internal arrangement of the structural assembly1provides for efficient dissipation and carriage of forces in response to a blast or projectile impact load applied to one of the external faces2,4. For example, when an explosive blast or projectile impact load of sufficient force is applied to the first or second face sheets2,4, the portion of the assembly immediately adjacent to the flanged web clusters (12,16) remains substantially rigid, while the intermediate panel8,10associated with the impacted face sheet moves toward the opposing intermediate panel, causing the channel shaped members9,11to engage. The engagement of the channel shapes prevents the face sheet2(with its associated flanged web member12and intermediate panel8) from completely separating from face sheet4(with its associated flanged web member14and intermediate panel10), during a blast or projectile impact. Interlocking also connects the intermediate panels8,10to the immediately adjacent flanged web clusters12,16, thus providing support and facilitating the efficient carriage of force between the face sheets2,4and the intermediate panels8,10. The bending of the intermediate panels8,10and face sheets2,4substantially dissipates the forces from explosive blast and projectile impacts, thus maintaining sufficient structural integrity in the structure to allow occupants to evacuate and contents to be evacuated, and to enable the building itself to be repaired and returned to full service.

An example of how the internal structures of the structural assembly1react in response to an applied blast is shown inFIGS. 3A-3C. Although these figures show only a portion of the structural assembly1, it will be appreciated that the response to a blast will generally be consistent along the entire length, width and height of a full structural assembly1.FIG. 3Ashows the assembly1configuration prior to the blast.FIG. 3Bshows the assembly1configuration during application of a blast to the second face sheet4. As can be seen inFIG. 3B, the second face sheet4is substantially bent inward toward the first face sheet2at a point located between the flanged web clusters12,16. This bending partially dissipates and carries the blast, moving flanged web members14and intermediate panel10inward until the channel shaped members9,11interlock intermediate panels10with intermediate panels8to carry the load throughout the assembly1and to the foundation of the building in which it is incorporated. As noted, the points of maximum movement can be seen to be the mid-points of face sheets2,4between the flanged web clusters12,16. These points may be “designed-in” to the module, for example, by designing the channel shaped members9,11to be less resistant to deflection as compared to the surrounding structural members, by adjusting the length of the flange(s) on the flanged web members16, or by using lighter gauge steel at or near the point at which maximum deflection is desired.FIG. 3Cshows the post-blast configuration in which the first and second face sheets2,4and some of the internal structures (intermediate panels8,10; channel shaped members9,11) have been permanently bent. It can be seen that although these internal structures have been bent, the structural assembly1has not been breached, and none of the interconnections between structural members has completely failed.

The structural assembly1may be oriented to protect the inside as well as the outside of the building. In various embodiments, structures of the present disclosure are arranged to protect the building from internal blasts, such as where the building is an armory, a chemical plant, or the like.

This is in sharp contrast to conventional building module designs, one of which is illustrated inFIGS. 4A and 4B. As can be seen inFIG. 4A, conventional module22has inner and outer face sheets24,26, and an interior panel28supported by a single flanged web member30. In response to an explosive blast force directed at the outer face26, the outer face sheet26, interior panel28and flanged web member30are breached, and substantial deformation (denoted as “DD”) of the inner face sheet24occurs.

As previously noted, the structural assembly1may be used in retrofit applications in which an existing wall, floor, roof or portion of an existing building requires blast or projectile impact protection. In such applications, the confines of the existing building prevents the installation of large assemblies1(i.e., full walls, roofs or floors), and thus the assembly is manufactured in discrete modules, shipped to the installation site, transported into the building and joined together to form a larger overall assembly1.

In various embodiments, adjacent modules are fixed together using any suitable connection method, such as welding, gluing, bolting, and the like. An example of how adjacent modules may be fixed together is shown inFIG. 2B, wherein adjacent modules M1, M2are provided with slightly overlapping face sheets2,4(e.g., the face sheets2,4of one module may overlap the adjacent panel by a distance shown as “OL”). This enables the face sheet of the first module M1to be overlapped and connected to the adjacent module M2. It will be appreciated that where one or more face sheets2,4overlap an adjacent module, the overlapped portion of that adjacent module will be provided without a face sheet. This ensures an even finished external surface configuration for the finished joined modules. Again, this overlapped face sheet approach may only be required for retrofitting applications.

FIGS. 2C and 2Ddepict individual flanged web members12,16formed by the conjunction of a pair of wide-flange channels12a, b;16a, b. Initially, the individual channels are formed from appropriately sized sheets of steel (or other material), which are formed into the channel shapes shown in the figures. The channels12a, b;16a, bare then connected to form the individual flanged web members12,16by welding, gluing or other appropriate technique. Although not shown, it will be appreciated that flanged web member14can be constructed in much the same manner.

As previously noted, the internal arrangement of structural members within the structural assembly1is repeated throughout the assembly, and thus the force dissipating flanged web clusters12,16and interlocking features9,11are carried throughout the entire assembly. This will also be true for retrofit applications, in which individual modules are formed and joined together at the installation site. Thus, the multiple flanged web clusters are formed throughout the assembly when multiple individual modules are joined together, enabling the invention to be applied to buildings of virtually any size.

As previously noted, the end regions18,20(FIG. 2A) of each of the intermediate panels8,10comprise corresponding channel shaped members9,11which allow adjacent internal panels8,10to interlock when the panels8,10bend in response to an explosive blast or projectile impact. As shown inFIG. 2A, these channel shaped members9,11may be separated on all sides from each other by a gap “G,” in order to minimize the transmission of thermal and acoustical energy between the face sheets2,4. These gaps “G” may also be formed between adjacent internal panels8,10, again, to reduce total thermal and acoustical energy transmission between the first and second face sheets2,4of the structural assembly1. Providing these gaps “G” controls the conduction of heat and sound between the first and second face sheets2,4. Such gaps may reduce heating/cooling costs associated with daily operation of a building formed in whole or in part by the structural assembly1. Further improvements are provided wherein one of the face sheets2,4is subjected to fire or source of extreme heat, as the amount of time required to heat up the opposite face sheet is increased, thereby enabling the building to retain sufficient structural integrity to allow occupants to evacuate and contents to be evacuated, and to enable the building itself to be repaired and returned to full service. Such gaps may also reduces the transmission of sound through the structure, which may be desirable in embodiments in which the building comprising the disclosed structures house a large number of people such as, for example, a jail, prison or detention center.

It is noted that the channel shaped members9,11also serve to hold the first and second face sheets2,4together when one of the face sheets is subjected to heat of sufficient magnitude that it weakens a portion of one of the structural assembly and its associated structural members. This is important where building integrity must be maintained for a sufficient time to enable the occupants to evacuate and contents to be evacuated.

In various embodiments, the gaps “G” are filled with one or more insulation material, epoxy or other filler materials to further reduce the conduction, or transfer, of heat or sound across the structural assembly1. Any insulation material can be used to fill the gaps “G”, so long as they have characteristics suitable for reducing, or preventing, transmission of energy (e.g., thermal, acoustic, electronic) while not comprising the functional integrity of the disclosed structure. Examples of useful materials include, but are not limited to, fiberglass, vinyl, mineral wool, polyurethane, foam, aerogel, cellulose, paper and the like. In some embodiments, a single type of insulation material, epoxy or other filler materials may be used. In some embodiments, a single structural panel my include more than one type of insulation material, epoxy or filler materials. Suitable insulation materials, epoxies, filler materials and mixtures thereof for preventing the transmission of particular energies are known to those skilled in the art. It will be appreciated, however, that providing gaps between these structures is not critical, and thus, the structural assembly1may be formed without such gaps.

In further embodiments, the structural assembly1is filled with foamed and/or blown insulation, or precut and formed insulation material or board, to enhance the overall thermal and acoustical efficiency of the building of which it is a part. Other materials also may be provided in the space between face sheets2,4, such as a material appropriate to the specific requirements of the building to provide the assembly with additional mass and resistance to blast or projectile impacts. Additionally, where prevention or inhibition of electronic eavesdropping is desired, the assembly1is partially or completely filled with shredded copper or other appropriate material. Other filler materials include, but are not limited to, copper steel slag filler material (mineral wool and silica), fire resistant insulation, or impact resistant insulation. Additionally, impact resistant insulation such as fiberboard may be applied to one or more surfaces within the assembly. Such impact resistant insulation substantially enhances the assembly's resistance to crushing.

Sheets of the present disclosure may be cut to various user-desired sizes, and bent into the appropriate form to impart desired structural features, and then connected to form site specific structural assemblies1(e.g., walls, roofs, columns, beams, floors) which are ultimately formed into a complete building structure. It should be appreciated that a particular structural assembly may be comprised of sheets of the same size or sheets of various sizes, depending on the application being addressed. Likewise, the sizes of different structural assemblies may vary depending on their intended use, even though multiple structural assemblies of various sizes may use sheets of the same size. Thus, for example, a single floor, wall, etc may contain sheets of various sizes and in fact, may itself be made of several structural assemblies, each of which contains sheets of the same, or different, sizes.

Further, the structural assembly1(e.g., walls, roofs, columns, beams, floors) can be manufactured at the factory in a size as large as the installation equipment and site conditions will allow. When used in a retrofit application, smaller, discrete modules are be manufactured and delivered to the site for assembly with one or more other discrete modules. In one embodiment of the retrofit application, the individual structural elements that form a module are formed and shipped to the installation site as individual pieces or sub-modules where they may be joined together to construct one or more modules. This provides the advantage(s) in that it enables the inventive structural assembly1to be transported and installed anywhere in the world, and minimizes or eliminates problems associated with long-range shipping of oversized loads. Additionally, these features enable unobtrusive installation of the modules for reinforcing all or part of existing buildings. Such unobtrusive installation has the benefit of enabling discreet installation, for example, in protecting classified domestic or foreign building installations or portions thereof.

In various embodiments, structural assemblies of the present disclosure may be formed on-site through the use of one or more portable or semi-portable forming machines. For example, where larger jobs require various structural assemblies in accordance with the present disclosure, the provision of on-site forming machines is contemplated to provide ease of access and rapid construction of the appropriate structural unit.

Any desired fabrication/shipping method may be used, and, as noted, the decision about which method to undertake is based on site-specific requirements, such as the size of the installation equipment and the space available for installation. For example, in new construction applications it may be more cost-effective and efficient to fabricate an entire structural assembly1(walls, roofs, floors, columns, beams, etc.) at the factory and ship them to the installation site. For retrofit applications, however, it may only be practical to fabricate and transport relatively smaller modules that can be hand carried into existing building structures for assembly.

Referring toFIGS. 5A through 5E, exemplary steps are shown for fabricating a portion of the inventive structural assembly1ofFIG. 1. As previously noted, the structural assembly1(here shown as an individual module) may be assembled from a plurality of individual sheet steel sub-units36a,36b,38a,38b, which have been cut and bent to have a desired shape. The individual sub-units may themselves be made of one or more pre-shaped individual pieces which are then joined together (via welding, gluing or the like) to form the desired structural assembly1. As noted, the entire manufacturing process can be performed prior to shipping, or sub-units or modules may be manufactured and shipped and then joined at the installation site.

FIG. 5Ashows the fabrication of a pair of sub-assemblies36a,36bthat comprise the first face sheet2and its associated flanged web members12,12a,12b. In the illustrated embodiment, the individual sheet elements comprise flanged web members12,12a,12bwhich are joined to the panel face sheet2via welding or fastening.FIG. 5Bsimilarly shows the fabrication of a pair of subassemblies38a,38bthat comprise the second face sheet4and its associated flanged web members14, as well as the additional supportive flanged web members16,16a,16b. The individual sheet elements comprising the flanged web members are joined to the face sheet4via welding or fastening. It will be appreciated, however, that joining techniques other than welds may also be used (e.g., gluing, mechanical fasteners, use of double-sided adhesive strips).

FIG. 5Cshows the fit-up of sub-assemblies36a,38aand36b,38b. As can be seen, the respective sub-assemblies (36a,38a;36b,38b) are positioned end-to-end so that their respective channel shaped members9,11align. The sub-assemblies are then placed together in an interlocking position, with sub-assemblies36a,36bmoving with respect to sub-assemblies38a,38bin the direction of arrows “A.” The sub-assemblies36a,38aand36b,38bmay form larger sub-assemblies40a,40b.

Larger sub-assemblies40a,40bare then moved together (along respective arrows “B”) as shown inFIG. 5D.FIG. 5Eshows the sub-assemblies40a,40bin the engaged position, whereupon they may be joined together. Completed flanged web members12,14and16, as well as their sub components12a,12b,16a,16b, can be seen in the engaged assembly.

The completed module shown inFIG. 5Emay then be joined to other such modules to form a completed wall, roof, floor or building, as desired. Alternatively, a single module may be used to protect a discrete portion of a wall, roof, column, beam, or floor.

Referring now toFIG. 6, structural assembly1is shown in a cross-sectional top plan view, the assembly comprising a pair of walls42,44joined at a corner46. As can be seen, the internal arrangement of structural members within the structural assembly1ofFIG. 6is the same as previously described in relation toFIGS. 1 and 2A. Thus, the specified arrangement of flanged webs12,14,16, channel shaped members9,11and intermediate panels8,10, is repeated throughout the assembly1, and thus the force dissipating flanged web clusters12,16and interlocking features9,11are carried throughout the entire assembly1. As before, the flanged web cluster and channel shaped member arrangement shown inFIG. 6serve to effectively dissipate a blast throughout the interior structure of both walls42,44to minimize the chance that any of the structural members will fail. It will be appreciated that this structural scheme can be repeated to obtain a unitized wall, floor, column, beam, panel, roof or building in any of a wide variety of sizes.

Although welding has been described for use in joining the individual elements that make up the finished structural assembly1, other joining techniques may also be used to connect some or all of the sub-units together. For example, one or more of the sub-units may be glued together, such as with an appropriate high-strength epoxy. Alternatively, a combination of epoxy and welding techniques may be used. Thus, in one embodiment, a low-modulus, high-strength epoxy is used in combination with welding to connect the flanged web member subcomponents (12a,12b;14,16a,16b). Epoxy may also be used to strengthen corner members, which may be subjected to extreme loading during an explosive blast or projectile impact.

In addition to its use in fixing individual elements of the structural assembly1together, a layer of epoxy may also be provided over one or more interior surfaces of the assembly1to increase strength and enhance the energy dissipating characteristics of the assembly. Further, a layer of impact resistant insulation may be applied to one or more interior surfaces of the structural assembly1.

The individual structures used to fabricate the structural assembly1may be any of a variety of appropriate materials known for use in structural building applications. In one embodiment, cold drawn sheet steel is provided. Alternatively, some or all of the structural members are made from other metals or a suitable non-metallic material such as PVC, vinyl, etc. Moreover, if a structure contains an insulating material, a single structure can contain a mixture of different types of material (e.g., metal, PVC, etc.) and insulating material (e.g., fiberglass, foam, etc.). Various combinations of such materials are also provided in further embodiments.

The inventive module comprises a modular, lightweight, and cost effective building system that can be used in a variety of applications, including blast walls, safe rooms, hurricane shelters, vandal-resistant garage or storage structures, and the like. It can be applied to existing buildings, as well as new construction, for virtually any structure that requires higher security than can be provided with commercial construction techniques.

Referring now toFIG. 7, a structural assembly50according to one embodiment is shown in a cross-sectional top plan view. The depicted embodiment provides various features and benefits of additional embodiments of the present disclosure, and provides improved blast resistance in part due to structure of channel shaped members52,54,56.

The structural assembly50ofFIG. 7comprises a wall, a floor/ceiling, a column, a panel, a beam, a roof, or a building section, to name a few. The structural assembly50may be pre-fabricated at the factory in a modular fashion that can then be fully assembled at the installation site. The structural assembly50is shown having first and second face sheets60,62, and a plurality of internal structural members configured to provide strength and stability to the assembly50to support the typical vertical and horizontal loads associated with a building structure. In various embodiments, the internal structural members57,58comprise a plurality of individual vertically positioned sheet elements having portions oriented either substantially parallel to, or substantially perpendicular to, the first and second face sheets60,62. It will be appreciated that although the internal structural members are shown in the figures as being oriented parallel or perpendicular to the first and second face sheets60,62, one or more of the members could be oriented so as to be obliquely angled with respect to the face sheets60,62.

In various embodiments, the structural assembly50comprises complete and continuous structures having the disclosed arrangement of face sheets60,62and internal structural members57,58. The structural assembly50is manufactured in at least one of a variety of sizes, depending upon what the installation equipment and site conditions will allow. Thus, for some applications, the structural assembly50is pre-manufactured at the factory to comprise an entire floor, wall, roof or building and then shipped to the site for installation. In certain applications, such as for retrofit applications, the assembly is manufactured in discrete modules at the factory, shipped to the installation site, transported into the building and fastened together to form a larger overall assembly50.

In the embodiment depicted inFIG. 7, the internal structural members comprise a plurality of opposing intermediate panels64,66oriented substantially parallel to the first and second face sheets60,62, as well as a plurality of flanged web members52,54,56oriented substantially perpendicular to the first and second face sheets. As shown, the opposing intermediate panels64,66are positioned along a length of the assembly50so that immediately adjacent panels64,66are connected to different face sheets60,62.

In order to connect adjacent panels, sections are spaced apart and butt welded to each other. For example, a prefabricated assembly50is connected to one or more additional prefabricated sections by providing the assemblies in close proximity and butt welding the assemblies together.

FIG. 8depicts adjacent assemblies50a,50bof the present disclosure. As shown, adjacent assemblies comprise various features as shown and described herein. Adjacent assemblies50a,50bare joined at two or more internal members64,66,70, with opposing face sheets spaced apart and welded together through, for example, one or more butt welds.

An infinite wall can thus be fabricated at almost any desired width or height as may be desired. In various embodiments, a wall is provided with a width of between approximately three inches and approximately eighty inches. In more preferred embodiments, a wall may be provided with a width of between approximately six inches and approximately forty inches.

In certain embodiments, the structural assembly50comprises at least two flanged members52,54extending substantially perpendicularly from internal structural members57and at least one flanged member56extending substantially perpendicularly from internal structural members58. Flanged members52,54extend generally perpendicularly from structural member57toward structural member58and further comprise secondary flanged members52b,54b, respectively. In various embodiments, secondary flanged members52b,54bextend substantially perpendicularly from flanged members52,54and extend toward flanged member56. Flanged member56is disposed generally between additional flanged members52,54and, in one embodiment, is provided approximately at a mid-point between flanged members52,54.

Thus, when a load is applied to the second face sheet62(the one to which internal structural member57is attached), the load is carried from the face sheet62, through structural member57to the flanged members which absorb energy from the load.

Flanged members52b,54band56bprovide a substantially interlocking arrangement for improved blast and fire resistance. At least one of flanged members52b,54band56bare provided to engage at least one other flanged member52b,54band56bregardless of the specific direction and/or vector of force that is applied to the assembly.

It will be appreciated that where the structural assembly50comprises a complete wall, floor, roof, or building, that the reaction to an explosive blast will be substantially the same all the way along the length of the assembly, since the arrangement of the flanged web clusters is carried throughout the assembly. Thus, the flanged web clusters and channel shaped member arrangements serve to effectively dissipate a blast throughout the interior structure to minimize the chance that any of the structural members will fail, at the same time, carrying a substantial portion of the horizontal and vertical blast force to the foundation.

FIG. 9provides yet another embodiment of the present disclosure wherein an assembly is provided comprising two channel shaped members57,58and two respective flanged members80a,80b. The assembly50aof the embodiment provided inFIG. 9comprises various features of the embodiment provided inFIGS. 7-8. As shown inFIG. 9, a plurality of channel shaped members57,58and a plurality of flanged web members80a,80bare provided and oriented substantially perpendicular to the first and second face sheets. The plurality of channel shaped members and flanged members inFIG. 9comprise two flanged web members.

FIG. 10provides yet another embodiment of the present disclosure wherein an assembly50ais provided comprising internal structural members82,84,86,88,88b,90,90bextending from face sheets60,62. As shown, internal structural member82extends generally from face sheet62and is interconnected to laterally extending intermediate panel84. Laterally extending intermediate panel84comprises a terminus, the terminus comprising a first86, second88, and third88binternal structural member. First86, second88, and third88binternal structural members are provided to interact with corresponding members90b,90,92extending from laterally extending intermediate member94. Intermediate member94extends toward additional force-transmitting means98and/or is secured to face sheet60.

In various embodiments, plug welding methods are employed to form and/or join members of a structural assembly in accordance with the present disclosure. Plug welds are provided, for example, to reduce the number of requisite welds to join various portions of the assembly, increase the structural integrity of the assembly, and facilitate manufacturing processes related to forming assemblies of the present disclosure. Plug welds may be provided at various locations including, but not limited to, locations for joining internal structural members57,58to respective first and second face sheets60,62. In alternative embodiments, plug welds are provided at unions of face sheets2,4and respective internal members12,14,16.

Specific weld structures, arrangements, positioning, and type of the present disclosure vary based on usage requirements. In preferred embodiments, full seam welding is provided. In alternative embodiments, such as where cost considerations are present, internal structures can be skip welded to the face and spaced at approximately nine inch centers or less.

FIGS. 11-12depict one embodiment of an assembly50aof the present disclosure, wherein various weld locations100are indicated. It will be expressly recognized, however, thatFIGS. 11-12are merely exemplary embodiments of structures formed with certain weld locations. The present disclosure is not limited to any particular type, arrangement, or positioning of welds and various welding options as will be recognized by one of skill in the art are contemplated as within the scope and spirit of the present disclosure.

FIG. 13depicts another embodiment of an assembly102of the present disclosure wherein C-shaped, galvanized studs are utilized as interlocking channel members108,110. The assembly102comprises a first channel shaped member108and a second channel shaped member110and first and second face sheets104,106. The first channel shaped member108comprises two flanged web members112,114. The second channel shaped member110comprises two flanged web members116,118.

As shown inFIG. 13, a plurality of channel shaped members108,110are provided such that a plurality of flanged web members112,114,116,118are oriented substantially parallel to the first and second face sheets104,106.FIG. 13also depicts the length120of the first face sheet104. In one embodiment the length120is 10 feet, but this is only an example length and should not be viewed as a limitation. In a preferred embodiment, the length120is approximately between 12 feet and 8 feet. In a more preferred embodiment, the length120is approximately between 11 feet and 9 feet. In a most preferred embodiment, the length120is approximately between 10.5 feet and 9.5 feet. In one embodiment, the C-shaped, galvanized studs are commercial off-the-shelf C-shaped, galvanized studs. In a further embodiment, the C-shaped, galvanized studs are commercial off-the-shelf C-shaped, galvanized studs comprising four flanged web members.

In the embodiment depicted inFIG. 13, the channel shaped members108,110further comprise secondary flanged web members124,128, respectively. In various embodiments, secondary flanged web members124,128extend substantially perpendicularly from flanged web members114,116. Thus, when a load is applied to one of the face sheets104,106, the load is carried to the flanged web members112,114,116,118and the secondary flanged web members124,128, which absorb energy from the load.

Secondary flanged web members124,128provide a substantially interlocking arrangement for improved blast and fire resistance. In the event that the assembly102is subject to a shearing force that would displace the channel shaped members108,110away from each other, the secondary flanged web members124,128would contact each other. The secondary flanged web members124,128would limit the distance which the channel shaped members108,110could be displaced, and thus preserve the structural integrity of the assembly102.

FIG. 14depicts another embodiment of the present invention where the structural assembly140comprises C-shaped internal structural members154,170. As described above, different components of the invention may be commercial off-the-shelf materials, such as C-shaped studs or channels. The structural assembly140is shown having a first face sheet176, a second face sheet172, and a plurality of internal structural members154,170configured to provide strength and stability to the structural assembly140.

In one embodiment, the internal structural member154comprises flanged web members148,152and a plate144. Further, the internal structural member170comprises flanged web members160,164,168and a plate156. Flanged web member164may be later interconnected to the plate156to complete the internal structural member170shown inFIG. 14.

In another embodiment, the internal structural member170may comprise multiple C-shaped members. Two C-shaped internal structural members may be interconnected such that a flanged web member from the first C-shaped member is interconnected to a flanged web member from the second C-shaped member to form the single flanged web member164.

The internal structural member154is connected to the first face sheet176, and the internal structural member170is connected to the second face sheet172such that the plates144,156are oriented perpendicular to the face sheets176,172. However, one skilled in the art will appreciate different orientations to offer various advantages.

The flanged web member152is disposed between the flanged web members160,164. Thus, when a load is applied to the second face sheet172(the one to which internal structural member170is attached), the load is carried from the face sheet172and causes displacement of the plate156such that flanged web member164contacts flanged web member152. The subsequent deformation of the internal structural members154,170absorbs energy from the load.

Likewise, when a load is applied to the first face sheet176(the one to which internal structural member154is attached), the load is carried from the fact sheet176and causes displacement of the plate144such that flanged web member152contacts flanged web member164.

The inclusion of flanged web member160limits how far apart the internal structural members154,172can move away from each other. In the event that a force is applied away from a particular pair of internal structural members154,170, buckling of the structural assembly140may cause the internal structural members154,170to move away from one another such that flanged web member160will contact flanged web member152. This limiting features causes the internal structural members154,170remain close to each other along with the face sheets172,176to which they are connected, and the structural assembly140retains structural integrity.

The flanged web members152,160,164overlap each other to provide functionality to the structural assembly140. In one embodiment, the flanged web members152,160,164extend the same length from their respective plates144,156. Thus, the distance between flanged web member160and plate144is the same as the distance between flanged web member152and plate156. This distance may vary between zero to the full length of the flanged web members152,160,164. One skilled in the art will appreciate flanged web members152,160,164may extend different lengths in different embodiments.

In the embodiment depicted inFIG. 14, a plurality of opposing intermediate panels180,184are disposed between the first and second face sheets172,176. As shown, the opposing intermediate panels180,184are positioned such that immediately adjacent panels180,184are connected to different face sheets172,176. The opposing intermediate panels180,184provide an initial distance between internal structural members154,170before any of the above-described forces are applied to the structural assembly140.

It will be understood that the description and drawings presented herein represent an embodiment of the invention, and are therefore merely representative of the subject matter that is broadly contemplated by the invention. Thus, for example, although the drawings do not represent the invention as part of a completed building structure, it will be appreciated by one of ordinary skill in the art that such a completed building structure is contemplated. It will be further understood that the scope of the present invention encompasses other embodiments that may become obvious to those skilled in the art.