Patent Publication Number: US-2011047918-A1

Title: Embedded Height Adjustment Mechanism for Double-Wall Building Panels

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE 
     This application claims priority benefits from U.S. Provisional Patent Application Ser. No. 61/239,062 filed Sep. 2, 2009, entitled “Embedded Height Adjustment Mechanism For Double-Wall Building Panels”. The &#39; 062  provisional application is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to the manufacture of multiple-wall building panels. In particular, the present invention relates to a height-adjustment mechanism for a double-wall building panel such that the distance between the walls can be adjusted to control the distance between the walls during manufacture. 
     BACKGROUND OF THE INVENTION 
     In the manufacture of multiple-wall building panels, it is important to control the distance between the walls. In conventional manufacturing techniques, spacers have been used to control the distances between walls during manufacture. Such spacers are fixed in size and do not provide an adjustment function for variably orienting one wall with respect to the other such that the spacing between the walls is controlled. Uncontrolled spacing between the walls can cause structural and functional defects in the resulting double-wall building panel. 
     SUMMARY OF THE INVENTION 
     Embodiments of the present technology provide mechanisms and systems for adjusting the height between first and second walls of a multiple-wall building panel. 
     In certain embodiments, a mechanism for adjusting the height between first and second walls of a multiple-wall building panel, wherein each of said walls are formed from a slurried material pourable into a frame disposed horizontally and curable therein to solidify said material, includes: (a) a tubular base having an interior threaded surface and at least one arm extending from said base exterior, said at least one arm embedding said base within said first wall when cured; (b) a cap removably attached at a first end to said base and at a second end to said frame interior surface, said cap removable from said base upon curing of said first wall material to expose said base; (c) a cylindrical torpedo screw having a distal end, a proximal end and a threaded exterior surface therebetween, said torpedo screw threads capable of cooperating with said base interior threads such that said torpedo screw is translatable vertically upon rotation of said torpedo screw about its longitudinal axis within said base, said torpedo screw distal end immersible within said second wall material before curing and contacting said frame interior surface, whereby removal of said cap from said base exposes said torpedo screw proximal end such that rotation of said torpedo at its proximal end adjusts vertical orientation of said first wall with respect to said second wall. 
     In certain embodiments, said slurried material is concrete. 
     In certain embodiments, said building panel is double-walled. 
     In certain embodiments, said at least one arm comprises a plurality of arms. 
     In certain embodiments, said torpedo screw proximal end comprises a fitting capable of cooperating with a tool for rotating said torpedo screw about its longitudinal axis. In certain embodiments, said tool is a socket wrench and said fitting is configured to cooperate with said socket interior surface. 
     In certain embodiments, the first end of the cap includes interior threads configured to receive an exterior surface of the tubular base such that the cap is translatable vertically relative to the tubular base upon rotation of the cap about the tubular base. 
     In certain embodiments, the second end of the cap is configured to cooperate with a tool for rotating the cap about the tubular base. In certain embodiments, the tool is a cone wrench and the second end is configured to receive an exterior surface of the cone wrench. 
     In certain embodiments, a method of adjusting the height between first and second walls of a multiple-wall building panel, wherein each of said walls are formed from a slurried material pourable into a frame disposed horizontally and curable therein to solidify said material, includes: (a) attaching a cap at one end to a tubular base and at its other end to said frame interior surface; (b) embedding said tubular base within said first wall material, said base having an interior threaded surface and at least one arm extending from said base exterior, said at least one arm embedding said base within said first wall when cured; (c) inverting said cured first wall such that said cap extends vertically upwardly from said base; (d) removing said cap from said first wall, thereby exposing said base interior threaded surface; (e) inserting a cylindrical torpedo screw within said base, said torpedo screw having a distal end, a proximal end and a threaded exterior surface therebetween, said torpedo screw threads capable of cooperating with said base interior threads such that said torpedo screw is translatable vertically upon rotation of said torpedo screw about its longitudinal axis within said base; (f) immersing said torpedo screw distal end within said second wall material before curing, said torpedo screw distal end contacting said frame interior surface; (g) rotating said torpedo screw at its proximal end to vertically orient said first wall with respect to said second wall. 
     In certain embodiments, said slurried material is concrete. 
     In certain embodiments, said building panel is double-walled. 
     In certain embodiments, said at least one arm comprises a plurality of arms. 
     In certain embodiments, said torpedo screw proximal end comprises a fitting capable of cooperating with a tool for rotating said torpedo screw about its longitudinal axis. In certain embodiments, said tool is a socket wrench and said fitting is configured to cooperate with said socket interior surface. 
     In certain embodiments, the cap includes a first end comprising interior threads configured to receive an exterior surface of the tubular base such that the cap is translatable vertically relative to the tubular base upon rotation of the cap about the tubular base. 
     In certain embodiments, the cap includes a second end configured to cooperate with a tool for rotating the cap about the tubular base. In certain embodiments, the tool is a cone wrench and the second end is configured to receive an exterior surface of the cone wrench. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a perspective view of a height adjustment mechanism for use when fabricating double-wall building panels used in accordance with embodiments of the present technology. 
         FIG. 2  depicts a side-sectional view of the height adjustment mechanism of  FIG. 1 . 
         FIG. 3  depicts a top view of a tubular base used in connection with the height adjustment mechanism of  FIG. 1 . 
         FIG. 4  depicts a side view of a cylindrical torpedo screw used in connection with the height adjustment mechanism of  FIG. 1 . 
         FIG. 5  depicts a top view of the cylindrical torpedo screw of  FIG. 4 . 
         FIG. 6  depicts a side view of the tubular base of  FIG. 3   
         FIG. 7  depicts a side-sectional view of a cap used in connection with the height adjustment mechanism of  FIG. 1 . 
         FIG. 8  depicts a top view of the cap of  FIG. 7 . 
         FIGS. 9-15  depict steps involved in a technique for adjusting the height between first and second walls of a multiple-wall panel used in accordance with an embodiment of the present technology. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT(S) 
     The present invention relates to the manufacture of multiple-wall building panels. In particular, the present invention relates to a height-adjustment mechanism for a double-wall building panel such that the distance between the walls can be adjusted to control the distance between the walls during manufacture. In the figures, like elements have like identifiers. 
       FIG. 1  depicts a perspective view of a height adjustment mechanism  100  for use when fabricating double-wall building panels used in accordance with embodiments of the present technology.  FIG. 2  depicts a side-sectional view of the height adjustment mechanism  100 , which includes tubular base  102 , cap  104  and cylindrical torpedo screw  106 . 
     Tubular base  102  includes an interior threaded surface  108 , an exterior surface  110 , and arms  112  that extend from exterior surface  110 . Tubular base  102  is also depicted in  FIGS. 3 and 6 . In certain embodiments, tubular base can include a single arm rather than two arms. While arms  112  are linear elements, in certain embodiments, an arm can be non-linear. In certain embodiments, each arm  112  can have a length of about 6 inches, tubular base  102  can comprise a 0.75 coil thread insert, and arms  112  can be attached to exterior surface  110  of tubular base  102  about 0.5 inches from the end of tubular base  102  that does not receive cap  104 . 
     Cylindrical torpedo screw  106  includes a distal end  114 , a proximal end  116 , a threaded exterior  118  therebetween, and a fitting  120  disposed at the proximal end  116 . Threaded exterior  118  of torpedo screw  106  is configured to be received by interior threaded surface  108  of tubular base  102  such that torpedo screw  106  is translatable vertically relative to tubular base  102  upon rotation of torpedo screw  106  about its longitudinal axis within tubular base  102 . Fitting  120  is configured to cooperate with a tool for rotating torpedo screw  106  about its longitudinal axis. For example, in certain embodiments, fitting  120  can be configured to cooperate with an interior surface of a socket wrench  1302 , as depicted in  FIGS. 13-14 . Cylindrical torpedo screw  106  is also depicted in  FIGS. 4 and 5 . In certain embodiments, torpedo screw  106  can have an exterior surface diameter of about 0.75 inches and a total length of about 8 inches, 10 inches or 12 inches, and fitting  120  can be a square with 0.5 inch sides. 
     Cap  104  includes a first end  122  and a second end  124  opposite the first end  122 . First end  122  is configured to be removably attached to tubular base  102 . For example, first end  122  can include interior threads  126  configured to receive exterior surface  110  of tubular base  102  such that cap  104  is translatable vertically relative to tubular base  102  upon rotation of cap  104  about tubular base  102 . Second end  124  is configured to cooperate with a tool for rotating cap  104  about tubular base  102 . For example, in certain embodiments, second end  124  can have an interior surface  128  configured to receive an exterior surface of a cone wrench  1202  in order to rotate cap  104  about tubular base  102 , as depicted in  FIG. 12 . Cap  104  is removable from tubular base  102  to expose proximal end  116  of torpedo screw  106  such that fitting  120  can be rotated. Cap  104  is also depicted in  FIGS. 7 and 8 . In certain embodiments, cap  104  comprises a 1.5 inch height plastic cone with 0.75 inch interior coil threads at first end  122  to a 0.5 inch depth configured to receive tubular base  102 , and a 1 inch depth interior opening at the second end  124  configured to receive an exterior portion of a cone wrench. 
     As discussed further in connection with  FIGS. 9-15 , tubular base  102 , cap  104 , and proximal end  116  of torpedo screw  106  (disposed within cap  104  and tubular base  102 ) can be immersed in a first wall formed of a slurried material (such as wet concrete, for example) that has been poured into a horizontally disposed frame. After the first wall has cured, distal end  114  of torpedo screw  106  can be immersed in a second wall formed of a slurried material that has been poured into a horizontally disposed frame to cure, such that the first wall is substantially parallel to the second wall and the two walls are coterminous. Cap  104  can then be removed, thereby exposing fitting  120  of torpedo screw  106 . Separation distance between the first and second wall can then be adjusted by rotating torpedo screw  106  about its longitudinal axis within tubular base  102  such that torpedo screw  106  translates vertically relative to tubular base  102 . Once a desired separation distance is achieved, the second wall can be allowed to cure, for example, in a kiln. After curing, torpedo screw can be removed completely and the separation distance between the walls can be maintained by other spacer elements that were also immersed in the first and second walls. 
       FIGS. 9-15  depict steps involved in such a technique for adjusting the height between first and second walls of a multiple-wall panel used in accordance with an embodiment of the present technology. 
       FIG. 9  depicts a first wall  904  formed of a slurried material (such as wet concrete, for example) that has been poured into a horizontally disposed frame with horizontal interior surface  902 . In certain embodiments, first wall  904  can have a thickness of 2 and ⅜ inches. The end of height adjustment mechanism  100  with tubular base  102 , cap  104 , and proximal end  116  of torpedo screw  106  (disposed within cap  104  and tubular base  102 ) is immersed in first wall  904  such that cap  104  contacts horizontal interior surface  902 . In certain embodiments, cap  104  can be glued to horizontal interior surface  902 . Truss girders  906  are also immersed in the first wall  904 , but do not contact horizontal interior surface  902 . In certain embodiments, truss girders  906  can be held in place using wire strands or supported using plastic chairs, for example. In certain embodiments, any number of height adjustment mechanisms  100  and truss girders  906  can be used depending on the size and shape of a wall. Once the height adjustment mechanism  100  and truss girders  906  are in place, the slurried material of first wall  904  is allowed to cure, for example, in a kiln. 
       FIG. 10  depicts a second wall  1004  formed of a slurried material (such as wet concrete, for example) that has been poured into a horizontally disposed frame with horizontal interior surface  1002 . In certain embodiments, second wall  1004  can have a thickness of 2 and ⅜ inches. First wall  904 , which has been removed from its frame and inverted, for example, using a vacuum turning device, is oriented over second wall  1004  such that first wall  904  and second wall  1004  are substantially parallel and the surfaces areas of both walls are coterminous. 
     Once properly aligned, as depicted in  FIG. 11 , first wall  904  is lowered toward second wall  1004  until distal end  114  of torpedo screw  106  is immersed in second wall  1004  such that distal end  114  of torpedo screw  106  contacts horizontal interior surface  1002  of the frame that the second wall  1004  is provided in. Truss girders  906  are also immersed in the second wall  1004 , but do not contact horizontal interior surface  1002 . 
     At this stage, as depicted in  FIG. 12 , cap  104  can be removed, for example, using a cone wrench  1202 . That is, an exterior portion  1204  of cone wrench  1202  configured to cooperate with interior surface  128  of second end  124  of cap  104  can be inserted into interior surface  128  of second end  124  of cap  104  and rotated, thereby unscrewing interior threads  126  of first end  122  of cap  104  from exterior surface  110  of tubular base  102 . 
     Once cap  104  is removed, as depicted in  FIG. 13 , proximal end  116  of torpedo screw  106  is exposed such that fitting  120  can be rotated. That is, an interior portion  1402  of socket wrench  1302  configured to cooperate with fitting  120  of torpedo screw  106  can be fitted over fitting  120  and rotated about its longitudinal axis within tubular base  102 , thereby translating torpedo screw  106  vertically relative to tubular base  102 . This can allow separation distance x to be increased by rotating torpedo screw  106  in a first direction about its longitudinal axis within base  102 . This can also allow separation distance x to be decreased by rotating torpedo screw  106  in a second direction about its longitudinal axis within base  102  that is opposite the first direction. Thus, separation distance x between first wall  906  and second wall  1006  can be manipulated until a desired double panel wall thickness is achieved. Once the desired separation distance x is achieved, second wall  1006  can be allowed to cure, for example, in a kiln. Once second wall  1006  is cured, torpedo screw  106  can be removed completely by unscrewing torpedo screw  106  from interior surface  108  of tubular base  102 .  FIG. 14  depicts torpedo screw  106  being removed from tubular base  102  in this manner. 
     Once torpedo screw  106  is removed, as depicted in  FIG. 15 , the separation distance x between first wall  904  and second wall  1004  can be maintained by truss girders  906 . All that remains of the height adjustment mechanism  100  within the double wall panel is tubular base  102  with arm  112 . 
     In certain embodiments, operating the mechanisms and/or applying the methods described herein can provide for improved height-adjustment for a double-wall building panel such that the distance between the walls can be adjusted to control the distance between the walls during manufacture. 
     While particular elements, embodiments and applications of the present invention have been shown and described, it will be understood that the invention is not limited thereto since modifications can be made by those skilled in the art without departing from the scope of the present disclosure, particularly in light of the foregoing teachings.