SYSTEMS AND METHODS FOR COUPLING PREFABRICATED PANELS TO STRUCTURES

Example embodiments provide systems and methods for coupling prefabricated panels to a structure. One example system provides a system for coupling a prefabricated panel to a structure. The system may comprise a first member. The first member may be couplable to a framing structure of the prefabricated panel. The system may also comprise a second member. The second member may pivot relative to the first member. The system may also comprise a fastener. The fastener may be configured to bias the first and second members together such that a component of the structure is at least partially receivable between the first and second members and tightening the fastener reduces a distance between the first and second members.

FIELD

This invention relates to systems and methods for coupling prefabricated panels to structures. Example embodiments provide coupling mechanisms and methods for clamping prefabricated panels onto or to structures.

BACKGROUND

Constructing a building is typically an extensive project involving significant amounts of time and/or resources (labour, energy, materials, etc.). Moreover, the carbon footprint of a building built using existing systems and methods can be large.

Reducing the amount of time and/or resources required to construct a building can be desirable. Reducing the carbon footprint of a building can also be desirable. With more environmentally stringent building codes being passed regularly, reducing the amount of resources used to construct a building and the carbon footprint of the building is increasingly becoming a requirement to be in compliance with new building codes.

One way the amount of time and/or resources required can be reduced is by constructing the building using prefabricated panels. However, such prefabricated panels typically need to be coupled to a structure once the prefabricated panels are delivered to the installation site. Coupling the prefabricated panels to the structure typically requires precise alignment of corresponding coupling bores, connectors, etc. For such precise alignment to be possible, individual components may need to be manufactured with extreme precision. Additionally, or alternatively, weld connections may not be sufficiently precise. Misalignments that occur may significantly delay a project.

There remains a need for practical and cost effective ways to couple prefabricated building panels to structures.

SUMMARY

This invention has a number of aspects. These include, without limitation:coupling systems;systems and methods for coupling prefabricated panels to structures.

Further aspects and example embodiments are illustrated in the accompanying drawings and/or described in the following description.

DETAILED DESCRIPTION

Aspects of the technology described herein provide systems and methods for coupling prefabricated panels to structures.

FIG.1Ais a perspective view illustrating an example coupling mechanism10. Coupling mechanism10may, for example, couple a prefabricated panel to a component of a structure. The structural component may, for example, comprise an I-beam, an anchor plate, a flange (e.g. a flange of a steel profile), an angle bar, a plate extending from a structure, a lip and/or the like.

Coupling mechanism10comprises a first member12and a second member13.

First member12may be coupled to a framing structure of a prefabricated panel such as a Structural Insulated Panel (SIP). First member12may, for example, be welded, adhered, fastened, etc. to the framing structure of the prefabricated panel. In some embodiments first member12is machined, formed, etc. into an existing member of the framing structure of the prefabricated panel. In some embodiments first member12is embedded within the prefabricated panel. In some embodiments first member12is at least partially embedded into concrete, a cementitious material and/or the like. In some such embodiments one or more reinforcing members (e.g. reinforcing mesh, reinforcing fibers, re-bar, etc.) may at least partially secure first member12within the concrete, cementitious material, etc.

Second member13is typically separate from first member12.

First and second members12,13may be biased together with a fastener14. In some such embodiments second member13may pivot relative to first member12. Fastener14may pass through a bore13A extending through second member13and be inserted into a bore12A which at least partially extends through first member12. Bore12A may comprise threads which correspond to threads of fastener14. Bore13A may optionally also at least partially comprise threads which correspond to threads of fastener14; however, in currently preferred embodiments bore13does not comprise threads. In some embodiments fastener14is a self-tapping fastener (e.g. may at least partially tap its own threads and/or bore). Additionally, or alternatively, bore13A may optionally have a larger diameter than fastener14to facilitate vertical (“vertical” as oriented inFIG.1B) pivoting of second member13relative to first member12.

In some embodiments bore13A comprises plural diameters. For example, a first portion13A-1of bore13A may comprise a first diameter. The first diameter may be similar to the diameter of fastener14. Bore13A may also comprise a second portion13A-2having a second diameter that is larger than the first diameter (see e.g.FIG.1B). Bore13A having plural diameters may facilitate vertical (“vertical” as oriented inFIG.1B) pivoting of second member13relative to first member12. In some embodiments at least one diameter of bore13A is at least about 10-25% larger than the diameter of fastener14.

In some embodiments a plurality of fasteners14bias first and second members12,13together.

In some embodiments one or more spacers or washers15are positioned between a head of fastener14and second member13. If plural spacers or washers15are used, some of spacers or washers15may be different than other ones of spacers or washers15. In some embodiments spacers or washers15comprise at least one split washer. The split washer may distribute a load from a head of faster14onto second member13. Additionally, or alternatively, the split washer may at least partially lock (e.g. frictionally lock) fastener14relative to first and/or second members12,13or other spacers or washers15. Locking fastener14relative to first and/or second members12,13or other spacers or washer15may, for example, at least partially prevent inadvertent unwinding or loosening of fastener14once coupling mechanism10is installed.

FIG.1Bis a front view of the example coupling mechanism10illustrating first and second members12,13biased together with fastener14.

A component of a structure (e.g. an I-beam, an anchor plate, etc. as described elsewhere herein) may at least partially be positioned in a cavity16between first member12and second member13. Tightening fastener14reduces a distance d between first member12and second member13. Fastener14may be sufficiently tightened such that the component of the structure is effectively clamped between first and second members12,13and cannot move relative to first and second members12,13thereby coupling the prefabricated panel that first member12is coupled to (or is a part of) to the component of the structure (and the structure generally). In some embodiments tightening fastener14reduces a distance d between first member12and an end13B of second member13.

In some embodiments the clamping force exerted on the structural component coupled between first member12and second member13is about 5 to about 35 kN. In some embodiments the clamping force exerted on the structural component coupled between first member12and second member13is about 25 kN.

Having first and second members12and13clamp onto the component of a structure advantageously facilitates rapid coupling of prefabricated panels to one or more structures. Advantageously, precise alignment of components of prefabricated panels with corresponding components of the structure (e.g. precise alignment of corresponding bores, connectors, etc.) is not required. First and second members12,13may easily and rapidly squeeze or clamp a component of a structure which is placed between first and second members12,13. In some embodiments first and second members12,13frictionally engage the component of the structure.

In some embodiments about 15-45% of one or both of an upper surface of first member12(e.g. surface12B) and a lower surface of second member13(e.g. surface13F) engage a component of a structure.

It may be desirable to permit movement of a clamped component of a structure relative to one or both of first and second members12,13. For example, it may be desirable to permit movement of a prefabricated panel relative to the structure during seismic activity. In some embodiments first and second members12and13may at least partially slipingly engage (or clamp) the component of the structure permitting movement of the component of the structure relative to one or both of first and second members12,13up to a threshold amount (e.g. an amount that safely dissipates seismic forces, shear forces and/or the like).

In some embodiments one or both surfaces of first and second members12,13which engage a component of a structure (e.g. surfaces12B,13F) may comprise lower friction elements (e.g. a slip sheet, a slip plate, low friction tape or membrane, etc.) which facilitate at least a partial slip engagement with the component of the structure without coupling mechanism10becoming uncoupled from the structural component. For example, one or both of the surfaces of first and second members12,13may comprise a Teflon™ liner or the like. In some embodiments end13B of second member13comprises a Teflon™ liner or the like. Surfaces12B,13F may be configured to have a length L that is sufficiently large to allow movement or slipping of surfaces12B and/or13F relative to the structural component without surfaces12B and/or13F becoming uncoupled from the structural component.

FIG.2Ais a perspective view of an example second member13.FIG.2Bis a front view of the example second member13.

In some embodiments second member13may pivot relative to first member12about end13C of second member13.

In some embodiments second member13comprises one or more sloped surfaces (e.g. surfaces13D and13E). Such sloped surfaces may reduce a spatial footprint of second member13thereby enabling use of second member13within smaller spaces, reducing expense (e.g. reducing amount of material required) and/or the like.

In some embodiments second member13is talon-like. The talon-like shape may, for example, facilitate use of coupling mechanism10with a number of different structural components (e.g. the talon-like shape can sufficiently extend over a number of different sized structural components). Additionally, or alternatively, the talon-like shape may ensure that second member13is large enough to sufficiently extend over a structural component to ensure a proper coupling.

In some embodiments a lower surface13F of second member13at least partially slopes downwards towards end13B.

In some embodiments end13B comprises a plurality of faceted surfaces. The faceted surfaces may assist end13B with forming an engagement with (or gripping) a component of a structure.

In some embodiments end13B and/or end13C may be at least partially rounded or curved. Having ends13B and/or13C be rounded or curved may advantageously disperse forces exerted on ends13B and/or13C.

FIG.3Ais a perspective view of an example first member12.FIG.3Bis a front view of the example first member12.

As shown inFIGS.3A and3B, first member12may comprise a slot12C. Slot12C may extend at least partially across an upper surface12B of first member12. End13C of second member13may, for example, be received within slot12C. Receiving end13C of second member13within slot12C may align second member13relative to first member12. Additionally, or alternatively, slot12C may prevent lateral pivoting or rotation (e.g. as illustrated inFIGS.1A and1B) of second member13about end13C relative to first member12. Additionally, or alternatively, slot12C may prevent longer term lateral pivoting or rotation of second member13about end13C relative to first member12once coupling mechanism10is installed due to, for example, vibrations or movement of the structure, forces exerted on the prefabricated panel and/or structure, etc. In some embodiments end13C of second member13slipingly engages one or more walls of slot12C.

In some embodiments first member12comprises a plurality of bores12A. For example, a plurality of bores12A may be aligned linearly along slot12C. Having a plurality of bores12A may accommodate a larger number of structural components. In some such cases, a technician may select which bore12A to run fastener14through depending on a size of the structural component that is received within cavity16.

In some embodiments first and/or second members12,13are made of steel, aluminum, cast iron, a forged metal or another similar metal. In some embodiments first and/or second members12,13are made of a material other than metal (e.g. fiberglass, carbon fiber, etc.).

Although second member13may be talon-like, second member13need not be talon-like and may have any profile. Non talon-like second members13may comprise any features described herein with respect to second member13. For example, second member13may have a generally flat plate-like profile. A portion of the generally flat plate-like second member13may be configured to fit within slot12C of first member12.

A prefabricated panel may comprise plural coupling points at which the prefabricated panel is to be coupled to a structure. The prefabricated panel may comprise a first member12at each one of the coupling points. The prefabricated panel may be coupled to the structure by sufficiently tightening corresponding fasteners14such that components of the structure are clamped between first members12and corresponding second members13at the coupling points. The prefabricated panel may be uncoupled from the structure by untightening or releasing fasteners14thereby releasing second members13relative to first members12.

Second members13and fasteners14may be pre-coupled to first members12of a prefabricated panel or may be shipped as separate components.

In some embodiments surface12B of first member12is flush with a surface of a prefabricated panel to which the first member12is coupled to.

FIG.4Aillustrates an example coupling of a prefabricated panel20to a structural component22(an I-Beam in the illustrated example case) using coupling mechanism10described herein. As shown inFIG.4Astructural component22is engaged (e.g. clamped) between first and second members12and13. Advantageously, first and second members12and13may engage inward portions of structural component22. First and second members12and13are not limited to engaging edges (or edge portions) of structural component22. In the example illustrated inFIG.4A, first member12comprises plural bores12A (e.g. bores12A-1,12A-2) as described elsewhere herein.

FIGS.4B to4Eillustrate additional example couplings of prefabricated panels20to structural components22. As shown inFIGS.4B to4Epositioning of coupling mechanisms10may match the structural components22to which panels20will be coupled to. In the example shown inFIGS.4B and4C, coupling mechanisms10extend around a periphery of panel20. In the example shown inFIGS.4D and4E, coupling mechanisms10are positioned vertically to match the vertical structural components22panel20will be coupled to. As shown inFIGS.4D and4Ecoupling mechanism10need not be positioned proximate to a peripheral edge of panel20.

In the example cases illustrated byFIGS.4B to4Estructural components22comprise flanges23coupled to structural beams24.

Although coupling mechanisms10have been illustrated as being coupled to inner surfaces of panels20inFIGS.4A to4E, coupling mechanisms10may be coupled to any surface of a panel20.

FIGS.5A to5Dschematically illustrate example couplings of first and second members12,13of coupling mechanism10to structural components22having various profiles.FIG.5Aillustrates structural component22comprising an example flange or angle bar component25.FIG.5Billustrates structural component22comprising an example plate26.FIG.5Cillustrates structural component22comprising an example lip27.FIG.5Dillustrates structural component22comprising an example I-beam28.

In some embodiments fastener14is designed to break and release second member13from first member12if a force exerted on a prefabricated panel exceeds a threshold amount to protect a structure the panel was coupled to from being damaged.

INTERPRETATION OF TERMS

In addition, while elements are at times shown as being performed sequentially, they may instead be performed simultaneously or in different sequences. It is therefore intended that the following claims are interpreted to include all such variations as are within their intended scope.