Patent Publication Number: US-2018030718-A1

Title: Concrete modular element for use in building applications

Description:
CLAIM OF PRIORITY 
     The present application is a Continuation-In-Part application of previously filed, now pending application having Ser. No. 15/230,013 which was filed on Aug. 5, 2016, which claims priority of Argentinian utility patent application number 20110103863 filed Aug. 13, 2015, the contents of which are both incorporated herein by reference in their entireties. 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to the field of structural modules for use in building applications, which may be used alone or in combination to form at least part of an overall larger structure. 
     Description of the Related Art 
     Pre-arranged, pre-assembled, or otherwise pre-fabricated structures are believed to exist which may be used in building applications. Some of these believed to exist products may be used in combination with each other to form a building. Existing products, however, require assembly of different components, such as floors, walls, ceilings, etc. In turn, this generates considerable expense due to the labor required during production. Likewise, the efficacy of the construction or otherwise installation of these products is limited due to the need to assemble different components. 
     The industry would benefit by providing a modular element that would reduce the effort required for its production. Thus, an advantage over existing products would be realized by providing a modular element comprising concrete that may be formed in a continuous casting. Such a modular element would reduce the labor associated with its production, and would permit an efficient and relatively effortless installation. An even further benefit would be realized by providing a plurality of such concrete modular elements that may be cooperatively used to efficiently form at least a part of a building or a structure. 
     SUMMARY OF THE INVENTION 
     The current invention is directed towards a concrete modular element for use in a variety of building applications. It is within the scope of the present invention that the inventive concrete modular element be formed in a continuous casting in order to substantially avoid, limit, or otherwise reduce the formation of cold joints. Cold joints are discontinuities or inconsistencies in the concrete that occur when a portion of the concrete begins to set or harden before the next or adjacent portion is cast. Cold joints are an area of relative weakness within the concrete. The concrete modular element according to the present invention may be provided in a variety of sizes according to preference and/or the specific application. It is also within the scope of the present invention, that the concrete modular element be used by itself to form at least part of a building or structure. Additionally, two or more of the inventive concrete modular elements may be cooperatively used to form at least part of the building or structure. 
     The concrete modular element generally comprises a slab, at least two walls, and a ceiling, all of which should be formed together in a continuous concrete casting. A variety of shapes of the slab and/or ceiling are within the scope of the present invention. However, the slab and the ceiling should have substantially similar shapes and dimensions. For example, if the shape of the slab is substantially square, the shape of the ceiling should also be substantially square, and both the slab and the ceiling should have substantially similar dimensions. If the slab comprises a substantially rectangular shape, so should the ceiling. Thus, the slab and the ceiling each generally comprise a plurality of elongated sides. The length of each one of the plurality of sides of the slab should substantially correspond to the length of a corresponding one of the plurality of sides of the ceiling. Each of the walls are generally disposed between the slab and the ceiling. Each of the walls comprises a proximal end, which is connected to one of the sides of the slab, and a distal end, which is connected to one of the sides of the ceiling. 
     The concrete modular element according to the present invention may comprise at least one open end substantially disposed between said slab and said ceiling, and between said at least two walls. The open end may be substantially disposed next to consecutively disposed walls, or may be disposed in between oppositely disposed walls. For example, if the slab and a ceiling each have four elongated sides, the concrete modular element may generally comprise two or three walls. If the concrete modular element comprises two walls, two open ends may be disposed between oppositely disposed walls. If the concrete modular elements comprises three walls, one open end may be disposed between two of the three sides. If the concrete modular element comprises two adjacently disposed walls, one open end may be disposed adjacent to one of the walls, while a different open end may be disposed adjacent to the other of the two walls. 
     An additional feature of the present invention includes providing a concrete modular element having a plurality of support beams. The plurality of support beams are generally connected to the slab, and are disposed in a spaced apart relation. This spaced apart relation between successive beams, together with the slab and/or the ground surface, may form at least one air chamber. The air chamber(s) is intended to permit natural circulation of air below the concrete modular element. Such circulation of air is advantageous in certain instances where hot air may accumulate below the concrete modular element. Thus, the air chamber(s) may function as a refrigerant by allowing cooler air to circulate and at least partially reduce and/or maintain the temperature of the concrete modular element. If the concrete modular element comprises a plurality of support beams, the slab, the ceiling, the walls, and the support beams should be formed together in a continuous concrete casting. 
     A further feature of the present invention comprises using at least two concrete modular elements to form at least part of a two or more story building or structure. Due to their unitary nature, each concrete modular element may be hoisted or otherwise transported to its intended final location, such as within the building or structure, with relative efficacy. Adjacently disposed concrete modular elements may be secured to each other with a variety of mechanisms that will substantially maintain the structural, and watertight, integrity of the building or structure. 
     These and other objects, features and advantages of the present invention will become clearer when the drawings as well as the detailed description are taken into consideration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which: 
         FIG. 1  is a front perspective view of one embodiment of the concrete modular element according to the present invention. 
         FIG. 2  is a front perspective view of a different embodiment of the concrete modular element according to the present invention. 
         FIG. 3  is a front perspective view of yet a different embodiment of the concrete modular element according to the present invention. 
         FIG. 4  is a front perspective view of even a different embodiment of the concrete modular element according to the present invention. 
         FIG. 5  is a front perspective view of one embodiment of the concrete modular element according to the present invention comprising a plurality of beams. 
         FIG. 6  is a perspective view of one embodiment of the concrete modular element according to the present invention comprising a plurality of beams. 
         FIG. 7  is a perspective view of a different embodiment of the concrete modular element according to the present invention comprising a plurality of beams. 
         FIG. 8  is a front perspective view of one embodiment according to the present invention comprising two concrete modular elements, each comprising a plurality of beams, cooperatively disposed to form at least a portion of a two story building or structure. 
         FIG. 9A  is a side view of the embodiment as represented in  FIG. 8 . 
         FIG. 9B  is a side view of a different embodiment according to the present invention comprising two concrete modular elements, each comprising a plurality of beams, cooperatively disposed to forma at least a portion of a two story building or structure. 
         FIG. 10  is a perspective view of one embodiment according to the present invention comprising two concrete modular elements, one comprising a plurality of beams, cooperatively disposed to form at least a portion of a two story building or structure. 
         FIG. 11  is a perspective view of the embodiment as represented in  FIG. 8 . 
         FIG. 12  is a perspective view of one embodiment according to the present invention comprising two concrete modular elements, each comprising a plurality of beams, cooperatively disposed to form at least a portion of a two story building or structure. 
     
    
    
     Like reference numerals refer to like parts throughout the several views of the drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The current invention is directed towards a modular element  1  for use in a variety of building applications, including, but not necessarily limited to buildings, structures, or components thereof; for use in residential, office, and/or other related settings. Although the inventive modular element  1  may be formed from a variety of materials, concrete is a suitable material given its ability to conform to a variety of different dimensional configurations. It is within the scope of the present invention that the inventive modular element  1  be formed in a continuous concrete casting. As used herein, a concrete casting is referred to as the process of placing a fresh concrete mixture into forms or molds, so that the resulting concrete may conform to the shape of the forms or molds. Thus, care during forming should be taken to ensure that cold joints are avoided. 
     As represented at least in  FIGS. 1-4 , the concrete modular element  1  according to the present invention comprises a slab, generally indicated as  10 . The footprint of the slab  10  may comprise a variety of shapes such as substantially square, or substantially rectangular. Other shapes of the slab  10  comprising an even or an odd number of sides are also possible such as, but not necessarily limited to, pentagonal, hexagonal, heptagonal, octagonal, or other related shapes. With further reference to at least  FIGS. 1-4 , the inventive modular element  1  may comprise four sides, which are indicated as  12 ,  14 ,  16  and  18 . 
     As also represented at least in  FIGS. 1-4 , the concrete modular element  1  of the present invention also comprises a top component or ceiling, indicated as  20 . The ceiling  20  should comprise a shape that substantially corresponds to that of the slab  10 . For example, if the concrete modular element  1  comprises a slab  10  with a substantially square configuration, the ceiling  20  should also comprise a substantially square configuration.  FIGS. 1-4  represent illustrative embodiments of the concrete modular element  1  according to the present invention comprising a ceiling  20  with a substantially square configuration, and a corresponding slab  10  also comprising a square configuration. Thus, for each side  12 ,  14 ,  16 , or  18  of the slab, there should be corresponding sides of the ceiling  20 , which are respectively indicated as  22 ,  24 ,  26 , and  28 . 
     As also represented in  FIGS. 1-4 , the inventive concrete modular element  1  comprises at least two walls, each indicated as  30 . Each wall(s)  30  is generally disposed between the slab  10  and the ceiling  20 . Each wall(s)  30  comprises a proximal end  32  and a distal end  34 . The proximal end  32  generally connects to the slab  10 , while the distal end  34  generally connects to the ceiling  20 . For example, the illustrative embodiment as represented in  FIG. 1  shows a concrete modular element  1  comprising two walls  30 . In  FIG. 1 , one wall  30  connects around its proximal end  32  to the side  14  of the slab  10 , and at the distal end  34  to the corresponding side  24  of the ceiling  20 . Also in  FIG. 1 , a different wall  30  connects around its proximal end  32  to the side  16  of the slab  10  and at the distal end  34  to the corresponding side  24  of the ceiling  26 . As also represented at least in the illustrative embodiment of  FIG. 1 , two consecutive walls  30  connect to each other around a lateral section  36 . 
     Although the inventive concrete modular element  1  may comprise one wall  30 , as may be appreciated in  FIGS. 1-4 , the inventive concrete modular element  1  should comprise at least two walls  30 , which may cooperatively achieve and/or maintain at least partial stability. For example, as represented in the illustrative embodiments of  FIGS. 1 and 4 , the concrete modular element  1  may comprise two walls  30 . An open end, indicated as  30 ′, may be disposed adjacent to at least one of the walls  30 . By way of example only, the illustrative embodiment as represented in  FIG. 1  shows an open end  30 ′ that is disposed between sides  12  and  22 , respectively of the slab  10  and the ceiling  20 . The illustrative embodiment of  FIG. 1  further shows a different open end  30 ′ disposed between the sides  18  and  28 , respectively of the slab  10  and the ceiling  20 . In the illustrative embodiment represented in  FIG. 4 , an open end  30 ′ is disposed between the sides  14  and  24 , respectively of the slab  10  and ceiling  20 , and a different open end  30 ′ disposed between the sides  18  and  28 , respectively of the slab  10  and ceiling  20 . 
     Additional configurations of the open end(s)  30 ′ of the concrete modular element  1  are also possible. For example, the illustrative embodiment as represented in  FIG. 3  shows a concrete modular element  1  comprising at two walls  30 , and one open end  30 ′ disposed between the sides  16  and  26 , respectively of the slab  10  and ceiling  20 . The concrete modular element  1  as represented in  FIG. 3  also comprises a different open end  30 ′ disposed between sides  18  and  28 , respectively of the slab  10  and the ceiling  20 . As an alternative configuration, as shown at least in  FIG. 2 , the concrete modular element  1  may comprise three walls  30  and one open end  30 ′. In  FIG. 2 , the open end  30 ′ is disposed between corresponding sides such as  18  and  28 , respectively of the slab  10  and ceiling  20 . Other configurations of the walls  30  and the open end(s)  30 ′ are also within the scope of the present invention. 
     As represented at least in  FIGS. 5 , the concrete modular element  1  according to the present invention may comprise a plurality of beams, each one of the plurality indicated as  40 . The plurality of beams  40  not only serves as structural support to the modular concrete structure  1 , but as is perhaps best shown in  FIG. 5 , two or more successive beams  40  may be disposed in spaced apart relation. This spaced apart relation at least partially creates a chamber(s), indicated throughout as  42 . The chamber(s)  42 , permit passage of air therebetween. Because hot air may accumulate below a building or other structure, this passage of air through the chamber(s)  42  at least partially permits circulation of currents of cooler air, which may serve as natural ventilation to the modular concrete structure  1 . Thus, the air chambers  42  may at least partially lower the temperature of the modular concrete structure  1 . For example, the illustrative embodiment as represented in  FIG. 5  shows three beams  40  which cooperatively form two different chambers  42 , each of which permits the passage of air. 
     It is within the scope of the present invention that the modular concrete element  1  be formed in different sizes according to the specific intended application. Consequently, the size and/or thickness of each of the above-referenced components of the inventive modular element  1 , namely the slab  10 , ceiling  20 , walls  30 , beams  40 , may vary accordingly. The modular concrete element  1  according to the present invention may be cast on the site of the building or structure  100 . Specifically, the concrete modular element  1  may be directly cast in its final intended location of the building or structure  100 . This is referred to as “cast-in-place concrete”. Alternatively, the concrete modular element  1  may also be cast on a location which is within relative proximity to its final intended location of the building or structure  100 , to permit manageable hoisting of the concrete modular element  1  once it has sufficiently hardened. This is referred to as “pre-cast concrete”. “Pre-cast concrete” also refers to a concrete modular element  1  that is cast in a location not within sufficient proximity to the building or structure  100 , and which would require additional means of transporting the concrete modular element  1  such as trucks or other related ground transportation. 
     With reference now to  FIGS. 8-12 , additional features of the present invention comprise using more than one concrete modular element  1  to form at least a portion of a two, or more, story structure of building  100 . Regardless of whether the inventive concrete modular element  1  comprises a plurality of support beams  40 , the concrete modular element  1  may be placed directly above the ground surface. Alternatively, and also regardless of whether the concrete modular element  1  comprises a plurality of support beams  40 , the inventive concrete modular element  1  may be placed directly on a foundation system which may comprise piles, mat footings, or other related system(s) which can provide adequate support to the concrete modular element  1 . Specifically, the air chamber(s)  42  may be formed between the sides  44  of the beams  40 , the underside  10 ′ of the slab  10 , and/or the ground surface. 
     As will be described in greater detail hereinafter, one, or more, concrete modular element(s)  1  may be disposed on top of a different and corresponding concrete modular element(s)  1 , to form at least part of a two, or more, story structure or building  100 . As shown in the illustrative embodiments represented in  FIGS. 8-12 , one concrete modular element  1  may be disposed above a different and corresponding concrete modular element  1  to form at least a portion of a two story building or structure  100 . In the illustrative embodiment as represented in  FIGS. 8-9B, and 11-12 , air chambers  42  are not only formed between the first or lower concrete modular element  1  and the ground surface, but also between the first or lower concrete modular element  1  and the second or higher concrete modular element  1  disposed directly above. A different configuration comprises a concrete modular element  1 , without a plurality of support beams  40 , disposed on top of a different concrete modular element  1 , with or without a plurality of support beams  40 . For example, the illustrative embodiment as represented in  FIG. 10  comprises a concrete modular element  1 , without a plurality of support beams  40 , disposed directly above a different concrete modular element  1  having a plurality of support beams  40 . In the illustrative embodiment as represented in  FIGS. 8-9B, and 11-12 , air chambers  42  are formed between consecutive ones of the plurality of support beams  40  and the underside  10 ′ of the slab  10  of a top concrete modular element  1 , and the top section  20 ′ of the ceiling  20  of a different, and lower, concrete modular element  1  disposed directly below the top concrete modular element  1 . 
     Yet additional features of the present invention include providing a concrete modular element  1  comprising a ceiling  20  with a substantially inclined or a substantially horizontal orientation. For the purposes of forming a structure or building  100 , or part thereof, a ceiling  20  comprising a substantially inclined orientation may be advantageous for a variety of purposes. Storm water may pond or otherwise accumulate on substantially horizontal surfaces. Therefore, although not strictly necessary, it may be advantageous to provide a concrete modular element  1  with a ceiling  20  having a substantially inclined configuration. For example, a substantially inclined configuration of the ceiling  20  may permit adequate runoff and/or drainage during or after rain events. Conversely, and with reference to at least  FIGS. 8-9A, and 11-12 , a concrete modular element  1  having a ceiling  20  with a substantially horizontal orientation may be provided if a different concrete modular element  1  is to be disposed directly above. 
     With reference to  FIG. 9B , other arrangements are also possible and include combinations of concrete modular elements  1  comprising a ceiling  20  with a substantially horizontal orientation, and other concrete modular elements  1  comprising a ceiling  20  with a substantially inclined orientation. This orientation may be advantageous in buildings or structures  100  comprising more than two stories. For example, as is represented in  FIG. 9B , the top or highest concrete modular element  1  may comprise a ceiling  20  with a substantially inclined orientation to permit drainage and/or runoff, while the lower concrete modular element(s)  1  disposed below may comprise a ceiling  20  with a substantially horizontal orientation that can at least partially provide and/or maintain stability. 
     The use of concrete as a material of the concrete modular element  1  is advantageous because various additives may be included as a part of the concrete mixture that will be eventually cast. Such additives will aid in removing the concrete from its forming components, which may themselves comprise wood, metal, plastic, or even concrete. The additives, also known as admixtures, may be applied to the concrete mixture so that the resulting concrete modular structure  1  comprises different properties according to the specific application or need. For example, some admixtures may permit better control of the concrete during casting or placement. Other admixtures may be advantageous to compensate for relatively high or low ambient temperatures and/or moisture conditions. Other admixtures may be advantageous to facilitate removal of the concrete modular element  1  form the forms. Admixtures may also be used to at least partially achieve a specialized finish such as that of architectural concrete. On the other hand, the concrete modular element  1  may also be provided without architectural or otherwise decorative finishes. Accordingly, the user or owner of the building or structure  100  may eventually customize the outside and/or inside surface(s) of individual concrete modular element(s)  1  according to preference and/or budgetary constraints. 
     Depending on the intended use, the inventive concrete modular element  1  may form a complete structure by itself, or may be used in conjunction with other concrete modular element(s)  1  to form a building or structure  100 , or section thereof. It is contemplated that the entire modular concrete element  1  be continuously cast. That is, the modular concrete element  1  should be fabricated or otherwise constructed in a continuous casting of concrete. As used herein, a continuous casting of concrete refers to placing a fresh concrete mixture into the forms or molds, such that the concrete may conform to the shape of the molds, and such that the resulting concrete modular element  1  is substantially free of any cold joints. Cold joints are those discontinuities or otherwise inconsistencies in the concrete which manifest when a portion of the concrete begins to set or harden before the next and/or adjacent portion of concrete is cast. Cold joints may least partially reduce the effective strength of the concrete as they are an area of relative weakness. 
     The concrete mixture does not necessarily need to be cast or otherwise poured in a single and/or uninterrupted placement. Instead, multiple or otherwise partial placements of the concrete mixture may be made so long as any concrete that has already been placed remains substantially fresh and has not begun to harden or set. The time in which concrete begins to set depends on several factors including the properties of the concrete mixture, ambient conditions, temperature, and other related factors. These factors should be taken into account when coordinating the timing of the placement(s), or portions thereof, so that cold joints are substantially avoided. 
     After sufficient time has elapsed for the concrete to set or otherwise harden, the molds or otherwise forms, may be removed from the resulting concrete modular element  1 . The concrete modular element  1  may comprise attachment structures which will assist hoisting of the concrete modular element  1 . The concrete forms may be configured to at least partially form the shape of or otherwise provide the space for an attachment structure(s). The attachment structure(s) may also be placed inside of the form so that the attachment structure(s) are embedded therein, and form part of the resulting concrete modular element  1 . Alternatively, the attachment structures may be installed on the concrete modular element  1  after the concrete has been cast. 
     Hoisting may be required to transport the concrete modular element(s)  1 . For example, the inventive concrete modular element  1  may have to be transported from the site of manufacture to the site of the building or structure  100 , if these two sites or locations are different. Hoisting may also facilitate positioning of the concrete modular element within different locations of the site of the building or structure  100 . Thus, the unitary or otherwise integral nature of the inventive concrete modular element  1 , permits an at least partially increased efficacy when hoisting or otherwise transporting of all of the components of the concrete modular element  1 . Specifically, given the unitary or otherwise integral nature of the individual components of the inventive modular concrete element  1 , namely the slab  10 , the walls  30 , the ceiling  20 , and/or the plurality of beams  40 , all of these components may be hoisted or otherwise transported together, instead of having to transport them or hoist them individually. 
     A further advantage of using continuously cast concrete is that it at least partially reduces the risk of fracture, breakage, or otherwise detachment of any of the components of the concrete modular element  1 . It is within the scope of the present invention that hoisting or otherwise transporting the concrete modular element  1  may be achieved with cranes, lifts, or other related machinery capable of supporting, lifting and/or transporting the weight of the concrete modular element  1 . Adequate reinforcement should be provided to the inventive concrete modular element  1  in order to further limit cracking or breaking during hoisting or transporting. Such reinforcement may comprise steel, including steel bars of different sizes according to the need. Therefore, structural calculations, such as by a professional engineer, should take into account these considerations. The reinforcement may also comprised different types of mesh, including wire mesh. The reinforcement should be embedded within or otherwise provided inside of the concrete. For example, reinforced concrete may comprise steel bars, which may be provided inside of the forms so that the concrete mix may substantially surround the reinforcement, and so that the concrete may subsequently harden with the embedded reinforcement. Also as an example, a plurality of reinforcement bars may be spread substantially evenly on the inside of the concrete to substantially provide reinforcement throughout the intended section(s) of the concrete. 
     Other features of the present invention include providing a concrete modular element  1  having at least one opening substantially along on the wall(s)  30 . Specifically, such opening may accommodate a building component such as, but not limited to, a window, a door, or a similar building component. The concrete forms may be configured accordingly, such that when the concrete is cast, the resulting wall(s)  30  are formed with the opening(s). The size of the opening may vary according to preference. The door(s) and/or window(s) may be disposed on wall(s)  30 , of the concrete modular element  1  that separate the building or structure  100  from the outside. Alternatively, it may be desirable to have walls, doors, or other similar building components, inside of the building or structure  100 , and between different sections thereof. For example, an opening for a door may be disposed between a wall(s)  30  of the concrete modular element  1  that separates two different rooms or areas inside of the building or structure  100 . It is also possible, depending on the specific purpose, to provide an opening on the slab  10  and/or ceiling  20  of the concrete modular element  1 . Again, the unitary nature of the concrete modular element  1  should be maintained, even when an opening(s) is disposed on the wall(s)  30 . The building component, such as the door or window, may be installed on the opening of the wall(s)  30  either before or after the concrete modular element  1  is cast. Additionally, the building component may be installed on the concrete modular element  1  either before or after it is transported or otherwise hoisted to its intended location within the building or structure  100 . 
     Even further features of the present invention include combining one or more concrete modular elements  1  to form at least a portion of an overall larger building or structure  100 . Each concrete modular element  1  may be hoisted or otherwise transported to its intended location within the building or structure  100 , and with relative ease given its integral nature. Adjacently disposed concrete modular elements  1  may be secured to one another with a variety of mechanisms including, but not limited to, brackets, connectors, rods, membranes, relatively thin supporting elements such as lath, or other compounds suitable for each specific application. For example, elastic and water repellent membranes, sheets of expanded polystyrene, welded meshes and rods, and/or a variety of inner coatings may be used. Other components that may also be used to secure two or more adjacent concrete modular elements  1  include, but are not necessarily limited to concrete, mortar, cement, or other related products. Moreover, polyurethane, and other related products, may be used to achieve and/or maintain, the substantially watertight integrity of the concrete modular element(s)  1  and/or the resulting building or structure  100 . 
     Since many modifications, variations and changes in detail can be made to the described preferred embodiment of the invention, it is intended that all matters in the foregoing description and shown in the accompanying drawings be interpreted as illustrative and not in a limiting sense. Thus, the scope of the invention should be determined by the appended claims and their legal equivalents.