Patent Publication Number: US-11643803-B2

Title: Composite construction for secure compartmentalized enclosure

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to Provisional Patent Application Ser. No. 63/028,152, filed on May 21, 2020, entitled “Composite Construction for Secure Compartmentalized Enclosure,” the contents of which is fully incorporated herein for all purposes. 
    
    
     TECHNICAL FIELD 
     This disclosure relates to an enclosure formed from a composite construction. More particularly, the present disclosure relates to a secure enclosure of the type used for jails, prisons, or containment cells and that is formed from composite construction techniques. 
     BACKGROUND OF THE INVENTION 
     Over the last several decades, the rate of incarceration in the United States has sharply increased. With this increase comes an increasing demand for prisons, jails, and similar containment facilities. Federal, state and local government agencies, as well as private entities, are faced with the task of building these secure facilities. In each case, building these secure facilities involves many often competing demands. One the one hand, the facilities must house inmates in a manner that prevents escape and that allows inmates to be compartmentalized within certain defined locations within the facility. On the other hand, these facilities must be scalable and capable of inexpensive and quick construction. 
     The background art contains several examples of construction techniques for secure facilities. U.S. Pat. No. 7,178,297 to Seavy discloses various steel structures made from interlocking steel modules. The wall modules are formed from plate steel and are assembled together using C-channel connectors. The interlocking tongue and grove construction allows for quick and cost-effective construction. Similarly, U.S. Pat. No. 8,833,002 to Lack, Jr. discloses a design and method for constructing and installing a cell front panel. The design allows for the construction and installation of cell fronts to occur at any time during the construction of the facility using only small hand tools and non-specialized workers. 
     Although the background art discloses various secure construction methods, all of the background art suffers from one or more drawbacks. For example, the background art fails to fully employ composite construction methods, and therefore, fails to allow facilities to be secure, quickly assembled, and cost effective. The secure compartmentalized enclosure of the present disclosure is designed to fulfill these and other shortcomings present within the art. 
     SUMMARY OF THE INVENTION 
     This disclosure relates to a secure enclosure that employs a composite construction. 
     The disclosed enclosure has several important advantages. For example, the enclosure can have some components manufactured from pre-fabricated concrete and other components manufactured from metal. 
     The present enclosure also benefits from interconnecting the concrete components and the metal components in a secure and tamper proof manner. 
     A further advantage is attained by allowing a metal divider or wall to be quickly and easily fitted into a pre-fabricated concrete structure, thereby greatly reducing manufacturing times and costs. 
     Yet another advantage is realized by allowing a metal divider to be secured to a pre-fabricated concrete structure via a secure and tamper proof connection. 
     Still yet another benefit is achieved by allowing a metal divider to be placed within an outer concrete shell, whereby the size and configuration of individual cells can be adjusted and modified during the manufacturing process. 
     Another benefit is realized by securing the metal divider in a fully encapsulated manner such that the edges of the divider are inaccessible. 
     The enclosure disclosed herein benefits from being quickly erected, cost effective, scalable, and secure. 
     It is another advantage to reduce manufacturing costs by reducing the need for specialized tooling. 
     Various embodiments of the invention may have none, some, or all of these advantages. Other technical advantages of the present invention will be readily apparent to one skilled in the art. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present disclosure and its advantages, reference is now made to the following descriptions, taken in conjunction with the accompanying drawings, in which: 
         FIG.  1 A  is perspective view of a metal partition being fitted into a pre-fabricated concrete structure. 
         FIG.  1 B  is a perspective view of the metal partition fitted into the pre-fabricated concrete structure. 
         FIG.  1 C  is a perspective view of a multistory building constructed in accordance with the present disclosure. 
         FIG.  2    is a sectional view of a building taken along line  2 - 2  of  FIG.  1 B  and constructed in accordance with the present disclosure. 
         FIG.  3 A  is a detailed view taken from  3 A of  FIG.  2   . 
         FIG.  3 B  is a detailed view taken from  3 B of  FIG.  2     
         FIG.  4    is a detailed view of an alternative construction to that depicted in  FIG.  3 B . 
         FIG.  5    is a detailed view of the upper edge of the metal partition fitting into a ceiling mounted C-shaped channel. 
         FIG.  6    is a perspective view of an alternative embodiment of the secure enclosure made in accordance with the present disclosure. 
         FIG.  7    is a perspective view of an alternative embodiment of the secure enclosure made in accordance with the present disclosure. 
     
    
    
     Similar reference numerals refer to similar parts throughout the several views of the drawings. 
     
       
         
           
               
             
               
                   
               
               
                 Parts List 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                   
                 18 Secure Facility 
               
               
                   
                 20 Concrete Structure 
               
               
                   
                 21 Open Bottom of Structure 
               
               
                   
                 22 Concrete Walls 
               
               
                   
                 22a Far Wall/22b Near Wall 
               
               
                   
                 24 Door and Door Frame 
               
               
                   
                 26 Window Frames 
               
               
                   
                 28 Toilet/Sink Unit 
               
               
                   
                 32 Desk 
               
               
                   
                 34 Bed 
               
               
                   
                 36 Metal Panel 
               
               
                   
                 38 Main Divider 
               
               
                   
                 40 Individual Cell 
               
               
                   
                 42 Chase (Two Legs) 
               
               
                   
                 44 Hollow Opening Main Divider 
               
               
                   
                 46 Hollow Opening in Chase 
               
               
                   
                 48 Sub-Compartment between Legs 
               
               
                   
                 50 Recess in Concrete Wall 
               
               
                   
                 52 Recessed Concrete Anchor (Far Wall) 
               
               
                   
                 53 Bolt for Concrete Anchor 52 
               
               
                   
                 54 Metal Channel for Main Divider 
               
               
                   
                 55 Lower Edge of Metal Channel 
               
               
                   
                 56 Recessed Concrete Anchor(Near Wall) 
               
               
                   
                 57 Bolt for Concrete Anchor 56 
               
               
                   
                 58 Angle Iron for Leg 
               
               
                   
                 59 Lower Edge of Leg 
               
               
                   
                 60 Recess in Concrete Ceiling 
               
               
                   
                 62 Recessed Concrete Anchor (Ceiling) 
               
               
                   
                 63 Bolt for Concrete Anchor 62 
               
               
                   
                 64 Ceiling 
               
               
                   
                 66 Ceiling Channel 
               
               
                   
                 67 Lower Edge of Ceiling Channel 
               
               
                   
               
            
           
         
       
     
     DETAILED DESCRIPTION OF THE DRAWINGS 
     The present invention relates to secure enclosures and to composite construction methods for assembling such enclosures. The described enclosures preferably utilize a prefabricated concrete structure that is mated to one or more metal panels. The metal panels include hollow ends that are connected to anchors formed within the walls of the prefabricated concrete structure. A further connection can be made between an upper edge of the metal panel and the ceiling. These connections join the metal panel to the concrete structure in a secure and tamper proof manner. The disclosed methods allow enclosures to be quickly constructed and easily configured to meet the needs of the particular facility. The enclosures are cost effective, scalable, and easy to assemble. The various details of the present disclosure, and a manner in which they interrelate, are described in greater detail hereinafter. 
     With reference to  FIG.  1   , the primary component of the facility  18  is a pre-fabricated concrete structure  20 . As used herein, “pre-fabricated” means that one or more elements of the concrete structure  20  are constructed at a plant that may be remote from the location at which the ultimate facility  18  is being erected. In the depicted embodiment, the pre-fabricated concrete structure  20  includes four concrete walls  22  ( FIG.  1 A ) and a ceiling  64  (note  FIG.  5   ) that are erected in a rectangular configuration using any of a variety of known concrete construction techniques. Structure  20  includes an opened bottom  21 . Although four walls are depicted, structure  20  can be formed from fewer than four walls may not include a ceiling and can generally be formed into any of a wide variety of shapes and sizes depending upon the needs of the facility being built. 
     Structure  20  is preferably formed without a floor to enable panel  36  to slid into structure  20  as depicted. The bottom of structure  20  can be anchored to a slab-on-grade foundation. In multistory structures ( FIG.  1 C  and  FIG.  5   ), the ceiling  64  of the lower structure  20  forms the floor of the upper structure  20 . As is known in the art, the precast structure  20  may be made utilizing rebar or rebar cages that are initially held within a concrete form. In this regard, the walls and ceiling can be monolithically cast using known techniques. The concrete may be pre or post tensioned. The pre-fabricated concrete structure  20  may have one or more door frames and doors  24  to provide access to the interior of the structure  20 . In the event structure  20  is intended for use as a prison or jail cell, fixtures can be provided within the walls for affixing toilet/sink combinations  28 , desks  32 , or beds  34 . 
     The depicted precast concrete structure  20  is divided into two individual cells  40  by way of a centrally located metal panel  36 . In the preferred embodiment, this metal panel  36  bisects the concrete enclosure  20  to create two equally sized cells  40 . However, panel  36  can be configured and secured to create individual cells  40  of varying shapes and sizes. The use of multiple, smaller panels  36  is also within the scope of the present disclosure. Metal panel  36  can be fitted into the concrete structure  20  by sliding the panel  36  upwardly from the bottom of structure  20  as noted by the dotted arrows in  FIG.  1 A . Panel  36  is preferably secured in this fashion after the concrete structure  20  is formed. The manner in which panel  36  connects to structure  20  is described in greater detail hereinafter. Panel  36  and concrete structure  20  are preferably joined together at an offsite facility and thereafter delivered to a jobsite (i.e. the ultimate location of the secure facility  18 ) using a tractor trailer or similar conveyance. Alternatively, structure  20  and panel  36  can be joined together at the location of the facility  18 . In a preferred but non-limiting example, panel  36  is formed from 12 Ga (0.093 inches or 2.3 mm) thick metal with a Zinc coating that is applied using a hot-dip process and that conforms to ASTM A 653/A 653M Commercial Steel (CS) coating designation A60 (Z180). 
     The metal panel  36  in the embodiment of  FIG.  1 A  includes both a main divider  38  and a chase  42  with two opposing legs. In a non-limiting example, main divider  38  is anchored to the far wall  22 ( a ) of the enclosure  20  (the wall containing widow frames  26 ), and the two opposing legs  42  are anchored to the near wall  22 ( b ) of the enclosure  20  (the wall housing the door frames  24 ). In the preferred embodiment metal panel  36  is hollow with both the far and near ends including hollow openings ( 44  and  46 ) ( FIGS.  3 A and  3 B ). The two legs  42  of the metal panel  36  create a triangular shaped sub-compartment  48  that is positioned between the two individuals cells  40 . This triangular sub-compartment  48  may be used to house the plumbing and/or electrical conduits needed by the associated cells  40 . 
     As noted in  FIG.  3 A , the far wall  22 ( a ) of the concrete structure  20  includes a metal channel  54  that runs the entire height of far wall  22 ( a ). Metal channel  54  is secured in place by a series of concrete U-shaped anchors  52  that are cast in place during the manufacture of structure  20 . Each anchor  52  includes a threaded aperture into which a bolt  53  can be secured. Channel  54  includes corresponding apertures that receive bolts  53 . In this manner, bolts  53  are used to secure channel  54  to the corresponding anchors  52  within far wall  22 ( a ). Channel  54  includes a lower edge  55 . The result is a metal channel  54  that is securely fastened within the far concrete wall  22 ( a ) and that protrudes a distance from the surface of the wall. As noted in  FIG.  3 A , in the preferred embodiment, wall  22  includes a recess  50  for receiving channel  54 . Recess  50  can be, for example, between ¼″ to ½″ deep. The hollow opening  44  of the main divider  38  is thereafter secured over top of this exposed channel  54 . In order to prevent tampering with the connection, the edges of the main divider  38  are completely received within recess  50  the concrete wall  22 . This results in the ends of divider  38  being recessed into wall  22  and inaccessible to the occupant of the cell. Spot welding may be used to weld main divider  38  to metal channel  54  and thereby increase the security of the connection. 
     As noted in  FIG.  3 B , each of the opposite legs  42  of panel  36  are secured in place by similar U-shaped anchors  56  and associated bolts  57 . Again, these anchors  56  are cast into wall  22  as it is formed. Each of these anchors  56  secures an associated bolt  57 . Bolts  57 , in turn, are used to secure a length of an L-shaped angle iron  58 . Angle iron  58  includes a lower edge  59 . This is preferably one long length of angle iron  58  extending the length of the wall  22 . Alternatively, a series of shorter, individual angle irons can be employed. In either event, the angle iron(s)  58  are secured in place adjacent to one of the door frames  24 . The exposed leg of each angle iron  58  is then securely fastened within the hollow opening  46  of a corresponding leg  42 . As noted in  FIG.  3 B , angle iron  58  is recessed into wall  22  and the end of each leg  42  is flush against angle iron  58  when installed. This prevents the edges of divider  36  from being exposed. Again, spot welding may be employed to permanently secure each leg  42  to one or more associated angle irons  58 .  FIG.  4    illustrates an angle iron  58  secured to wall  22  but at a location remote from a door and frame  24 . 
     As a result of the channel  54  and angle iron  58 , metal panel  36  is securely anchored between the near and far walls ( 22 ( a ) and  22 ( b )) of concrete structure  20 . Notably, divider  36  is secured and fully encapsulated in a way to prevent the ends of the divider  36  from being accessed or tampered with. In one embodiment, appropriate cut-outs may be provided at the top of panel  36  to permit it to be slide into place from the bottom of concrete structure  20  as noted in  FIG.  1 A . 
     Panel  36  is further secured in place by attaching the upper edge of panel  36  to the ceiling  64  of concrete structure  20 . To accomplish this, and as noted in  FIG.  5   , ceiling  64  of structure  20  includes additional U-shaped anchors  62  and associated bolts  63 . As described above, anchors  62  are cast in place during the formation of structure  20 . These anchors/bolts ( 62  and  63 ) are used to secure a U-shaped channel  66  that runs the length of the ceiling  64  and the length of structure  20 . U-shaped channel  66  includes a lower edge  67 . Into this channel, the upper extent of panel  36  is secured. Again, this can be accomplished by sliding divider  36  upwardly from the bottom of structure  20 . Notably, the top extent of divider  36  is received within the U-shaped divider  66 ; this prevents the upper end of divider  36  from being exposed. Additionally, a recess  60  is preferably provided within ceiling  64  for receiving channel  66 . Spot welding can be used as needed to provide a more secure connection. The depicted anchors/bolts can be used to secure the compartment to a foundation at the site of the facility. They may likewise provide a connection between adjacent floors of a multistory structure ( FIG.  1 C ). 
       FIGS.  6  and  7    illustrate various alternative configurations for the secure enclosure. In  FIG.  6   , panel  36  takes the form of a flat wall, eliminating the two legs  42  and the associated sub-compartment  48 . In  FIG.  7   , compartment  20  is formed from two physically separate units ( 20 ( a ) and  20 ( b )) that are secured together to form a single unit. Additional panel  36  arrangements can be provided depending upon the size and shape of the room that are desired within the facility. Although the depicted facility is a prison cell, the present disclosure can be used with a variety of other types of facilities; this includes, but is not limited to, telecommunications structures, work camps, storm shelters, and hurricane preparedness housing units. 
     Although this disclosure has been described in terms of certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure.