Patent Publication Number: US-9850658-B2

Title: Modular, multiperforated permanent formwork construction system for reinforced concrete

Description:
FIELD OF THE INVENTION 
     The present invention relates to a modular construction molding system with multi-perforated arch centering for concrete or reinforced concrete of direct application to the construction industry, for the construction of all types of real estate properties. More specifically the modular construction system of permanent formwork molding refers to a set of elements including: first polymeric flat structural components, second, corner components; third flat connecting components, fourth: panel-shaped components; each component of the modular system includes longitudinally at the end at least one rail, and at the opposite end of the edge at least one counter rail, the flat components across the width of its longitudinal surface have at least one longitudinal rail for coupling flat connectors, for assembly of the rail system and counter rails of the structural components, which are coupled and locked together slidably to each other, successively until forming a mold structure with permanent arch centering with hollow interconnected interior cavities and multiperforated exposed faces in the hollow cavities where concrete is spread, on the exposed multiperforated faces concrete sprouts and is impregnated, thus covering the permanent arch centering and generating a new texture to the surface. This new surface can receive any type of finish. 
     BACKGROUND OF THE INVENTION 
     Currently in the construction industry there are a variety of materials and processes for construction of buildings. The most developed areas are prefabricated modular systems and materials, as these are useful anywhere where you need to build, whether it is for a small or a large building. These materials and systems offer numerous solutions for businesses and individuals, because the construction can be completed in very short periods of time, with greater control over the work, with cleaner, safe and durable works, furthermore these materials are easy to assemble and the labor used is not specialized or regional. 
     Currently there have been developed various components and modular systems for these purposes, for example there are some panel systems made of rigid PVC as well as foamed PVC panel systems, systems with flat components, systems with angular components, extruded PVC systems, with elements to be continuously assembled together. These systems are complemented by structural reinforcement elements such as metal columns and rods for the construction of all types of outer walls, inner wall partitions, contemplating the formation of walls in corners with all these elements for different types of buildings. 
     For example, the description of U.S. Pat. No. 5,608,999 (MX 202025), describes the use of a series of flat thermoplastic structural components and thermoplastic corner structural components, where some components are locked slidably and releasably together to form continuous wall structure with hollow cells, where these cells receive poured internal concrete and the surface finish is always smooth and plastic. The structural system components of the system of Bernard McNamara as has been disclosed include flat connectors, flat caps and corner angles, prefabricated and extruded in rigid PVC, so they can be assembled on-site, with unskilled labor and short periods of time. 
     A disadvantage of thermoplastic structural system components of the Bernard McNamara system, is that in order to assemble a wall structure a lot of individual elements for assembly of the system are required, consequently any such manipulation of a lot of elements significantly increases the time of assembly and construction, in addition the final surface finish will always be smooth and plastic. 
     The description of U.S. Pat. No. 5,729,944 discloses a building constructed of extruded thermoplastic structural components, these components include hollow panels, hollow connectors, hollow beams and adapters. For the assembly of the system the extruded components are locked over the edge together continuously to form vertical walls and the roof of the building. Each wall to structural component is hollow, is made from PVC plastic material, and formed of spaced inner and outer walls connected by transverse entanglements that form internal cells, this essentially appears as a mold into which concrete is poured to form outer and inner wall faces with smooth finish and plastic. 
     A disadvantage of the system of Vittorio De Zen is that the thermoplastic hollow panel is formed at both ends of the edge for engaging and interlocking with a male member, for assembly between panels to build a continuous flat wall, a connector is always required between panels, without these connectors it is not possible to assemble the panels, in addition the resulting final surface will be smooth and plastic. 
     The Mexican Patent Application PCT/MX2005/000012 with International Publication Number WO 2005/098158 A1 discloses and describes a panel structure with coupling means, for prefabricated buildings, the panel structure of rectangular longitudinal shape with internal individual cavities that are not interconnected, with ease of assembly and engagement with each other, wherein complementary structural elements such as steel columns are inserted and engage only in the cavities formed between the panel structure assemblies against the panel structure, such that concrete or some other material is poured into the internal cavities, forming a wall structure with plastic surface finish for the construction of buildings. 
     A major disadvantage of this panel structure system with coupling means, for prefabricated buildings, is that there is no internal communication between the elements and their internal cavities in the structure of vertical wall, thus reducing the structural capabilities of the system and when the concrete is poured a final continuous monolithic structure is not obtained, to achieve structural stability the system uses steel columns of noncommercial structural shapes, so this greatly increases manufacturing costs and project costs, and furthermore the surface finish will always be smooth and plastic. 
     U.S. Pat. No. 7,628,570 B2 US discloses a modular retaining wall where the wall is at least partially below the surface, where the surface may be land-based or water-based; the walls are composed of polygonal modules with open and closed channels disposed therein, in addition to components such as hollow profiles, flat profiles, module connectors, hollow corner connector profiles and hollow adapters. The wall modules are fastened together by respective coupling and fastening closures so that connectivity is provided between the modules, however the ability for the liquid to pass through is retained, always having a smooth and plastic surface finish. 
     A disadvantage of the modular system of John Davidsaver and Acott Yeany is that in forming intermediate configurations for walls and dividers, nuts and bolts are required, and this increases the time of building and the apparently low costs for these items, but are in fact at a large scale reflected in longer periods of construction and project costs; furthermore, the final surface finish is always smooth and plastic. 
     Due to the above, there is in the market a need for a modular construction system that is more versatile, handy and of a smaller scale, easy to assemble and enabling rapid construction for use in the construction industry, for the building of any kind of construction, which solves the disadvantages mentioned that is more functional over existing systems. The present invention aims to provide a solution to this gap detected, and would be of great relevance in the area of prefabricated construction materials in the construction industry. 
     OBJECTIVES 
     The present invention is generally intended to provide a modular construction system of multi-perforated permanent formwork for reinforced concrete, which is assembled and coupled structurally with panels and components that are easily and quickly constructed. 
     Another objective of the present invention is to provide a permanent construction system with permanent arch centering, multi-perforated for reinforced concrete, with hollow cavities interconnected to function as a mold of permanent arch centering formwork such that the concrete poured into the cavities by the multiperforated surfaces with anterior and posterior concrete “sprout” hiding permanently the formwork and generating a new texture on the surface, which can receive any additional finish. 
     Another object of the invention is to provide a modular building system of permanent formwork for reinforced multi-perforated concrete, where a final specific surface is exposed and can receive any type of finish. 
     Another object of the invention is to provide a modular construction system multi-perforated permanent formwork for reinforced concrete, where one of the exposed end surfaces of the concrete wall is able to receive any type of finish and the remaining wall surface has smooth and plastic finish. 
     Another objective of the invention is to provide a modular molding system of permanent multiperforated formwork for reinforced concrete where panels and hollow components are molds for pouring concrete, which support the weight and the expansion of the concrete. 
     Another important objective is to make available a panel and modular structural multi-perforated components with coupling means easily and stably assembled together, eliminating the use of nuts, bolts, welding, bolts, wedges, and stay bolts. 
     Another object of the invention is to provide a modular panel system with prefabricated structural multi-perforated components for an assisted self construction model where manual labor can be regional and unskilled. 
     Another object of the invention is to make available a modular construction system of permanent formwork multiperforated for reinforced concrete that is resistant, of low molecular weight, thermo acoustic, thereby minimizing energy consumption and build time. 
     Another object of the invention is to make available a modular construction system of permanent formwork multi-perforated for reinforced concrete where doors, windows, electrical, hydraulic, sanitary facilities are compatible with the system. 
     A further object of the present invention is to provide a modular multi-perforated system with prefabricated polymeric components, that can be implemented in all kinds of constructions while maintaining the characteristics of being lightweight, easy to manipulate, easy to transport, and easy to assemble. 
     A further object of the present invention to provide a modular construction system of permanent formwork for reinforced concrete where modules can be trimmed and sectioned according to the requirements and needs of the construction project. 
     Another object of the invention is to provide a modular construction system of permanent multiperforated formwork for reinforced concrete that when assembled acts as an integrated structure yet can be reinforced as needed. 
     Finally another object of the invention is to make available a modular construction system of multi-perforated permanent formwork for reinforced concrete where prefabricated components are extruded from high strength polymeric materials enabling large-scale production. 
     SUMMARY OF THE INVENTION 
     The elements of the modular construction system of permanent formwork multi-perforated for reinforced concrete in all its forms and its plurality of arrays are formed first by modular flat multi-perforated profiles characterized by including a multi-perforated longitudinal surface, featuring at the ends of the edge perpendicular to the longitudinal multi-perforated surface a longitudinal extension having a rail all along the edge of a geometrical form that defined a female element, the remaining end on the longitudinal rail having a male element, as coupling means, interlocking, the width of the multi-perforated longitudinal surface including a plurality of longitudinal rails of T-shape for connecting the flat couplings. 
     Second: a modular multi-perforated hollow corner connector characterized by including two perpendicular longitudinal elongated faces joined together with cut cores distributed longitudinally, these attached to a multi-perforated semicircular longitudinal surface, said multi-perforated modular connector having on one of the perpendicular longitudinal faces integrated thereon two rails of defined geometric shape as a female element and on the remaining face integrated thereon two rails geometrically defined as a male element, such elements provided as engagement and interlocking means. 
     Third: a flat modular connector characterized by comprising a longitudinal surface with sections of cut cores strategically distributed longitudinally, in addition to including at both ends of the edge a U-shaped longitudinal rail with extended inward edges as coupling means. Also a flat modular multi-perforated connector with rectangular profile is characterized by including a multi-perforated front wall, a rear multi-perforated wall and longitudinal ribs with sections of cut cores longitudinally and strategically distributed perpendicular to the multiperforated walls, said modular connectors in a rib having two rails integrated defined geometrically as a female element, on the remaining rib there are two rails integrated, geometrically defined as a male element, as engagement, coupling, and interlocking means. 
     Fourth: One multi-perforated modular panel characterized by comprising a rectangular configuration, a longitudinal multi-perforated front wall, a longitudinal multi-perforated rear wall, a plurality of longitudinal ribs with core cut sections strategically distributed longitudinally, forming between these, interconnected rectangular cavities, at one end of the multi-perforated modular panel on the rib there being integrated two longitudinal rails defined geometrically as the female element, on the remaining rib there being integrated two longitudinal rails defined geometrically as the male element, as engagement interlocking, and crimping means. 
     The assembly of modular construction system of permanent formwork multi-perforated for reinforced concrete consists of the continuous and subsequent coupling of the components of the modular construction system, where each component includes in at least one of its ends a male element and at the remaining end a female element; for the coupling between the elements, the rail with the male element is engaged, is fitted and slides against the rail with the female element performing continuous and subsequent assembly of the components of the building system to form a structural configuration with permanent formwork molds multi-perforated with all interior hollow cavities communicated with each other and whose front and back walls of the permanent formwork mold are multiperforated. 
     In the reception cavities of the mold structure of permanent formwork can be poured concrete or other aggregate, through multiperforated surface the poured concrete will have the effect of “sprouting and impregnating the multiperforated surfaces” thus generating a new texture to the surface covering and hiding to the structure of permanent formwork mold. The permanent formwork covered by the concrete cover on its front and back faces are able to have any additional finishing either smooth, textured, etched or adding another material. 
     Walls obtained by the modular construction system of permanent formwork forming the building can be blind, comprise windows, doors, openings for air conditioning; since the plurality of arrangements between panels and thermoplastic elements forms interconnected internal cavities, these allow you to place sight unseen, electrical, voice, data wiring, water, sanitary facilities, furthermore, you can structurally reinforce the system by installing rods in the cavities or a commercial structural shape vertically or horizontally according to the needs of the construction project. 
     The modular construction system of permanent formwork multiperforated for reinforced concrete is designed for construction and buildings of all kinds, where all components of the modular construction system can be manufactured, cut and sectioned according to the needs of the construction project. 
     The modular construction system of multiperforated permanent formwork for reinforced concrete as configured and described provides structural properties because of being formed as a structural element in itself, includes a solid and reinforced structure, thereby increasing its load capacities, mechanical strength, yet being also easy to manufacture, easy to transport and maneuver, easy to install and useable on any type of construction. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A to 1H  schematically show various views of the modular flat multi-perforated profile with details illustrating the different types and arrangements of multi-perforations and partially enlarged details showing the female and male coupling means. 
         FIGS. 2A to 2B  show top and bottom plan views of the multi-perforated modular profile of  FIG. 1A , with partially enlarged details of the coupling means of female and male type. 
         FIGS. 3A to 3H  show perspective views of multi-perforated modular corner connector profiles with details illustrating the different types and arrangements of multi-perforations, and details showing the male and female coupling types. 
         FIG. 4A to 4B  shows different views of the multi-perforated modular corner connector profile of  FIG. 3A  with details showing the female and male coupling means. 
         FIG. 5  schematically shows a perspective view of a flat profile modular connector of the construction system. 
         FIG. 6  schematically shows the top view of the modular flat profile of  FIG. 5 . 
         FIG. 7A to 7H  show the perspective views of the multi-perforated modular flat profile connector with details showing different types and arrangements of multi-perforations and details of the coupling means of female and male type. 
         FIGS. 8A and 8B  shows a top view of the multi-perforated modular flat profile connector of  FIG. 7A  with details of different female and male coupling means. 
         FIGS. 9A to 9H  show perspective views of the multi-perforated modular panel with partially enlarged details of the type and arrangement of multi-perforations at the anterior and posterior surface, and details showing the female and male coupling means. 
         FIGS. 10A and 10B  show schematically the top view of the modular multi-perforated panel of  FIG. 9A  with details of different female and male couplings. 
         FIG. 11  shows the perspective view of a portion of assembly section of the mold structure multi-perforated permanent formwork, including components of flat profile and flat connecting components with partially enlarged details of the female and male coupling means, also showing the assembly of male-female coupling means, wherein the male type element is engaged, slid and locked against the female type element. 
         FIG. 12  shows the perspective view of a section of the assembly of permanent formwork mold including flat components, flat connectors and components, and panel-shaped components, with details of the female and male coupling means, also showing the assembly of male-female coupling means, wherein the male type element is engaged, slid and locked against the female type element. 
         FIG. 13  is a perspective view of an assembly section of the mold structure of permanent formwork mold and includes flat components, flat connectors, panel shaped components and corner shaped components, with details of male-female type assembly coupling means, wherein the male type element is engaged, slid and locked against the female type element. 
         FIG. 14  shows the perspective view of a section of the modular construction system assembly of permanent mold structure formwork for reinforced concrete, including flat structural components, flat connector components, corners components, panel-shaped components, elements of vertical and horizontal structural reinforcements, wherein concrete is shown having been poured into the hollow cavities, thereby showing the behavior of the permanent concrete hiding the permanent multiperforated formwork in the front and back surfaces of the permanent formwork. 
         FIG. 15  schematically shows the perspective view of a portion of an assembly section of the modular structure of a permanent multiperforated mold for reinforced concrete formwork modular construction system, including: flat structural components, flat connector components corner connector components, panel shaped components, commercial standards structural elements and reinforcements placed vertically and horizontally, poured concrete in the hollow cavities, showing in particular the behavior of the concrete in the rear face that was multiperforated, hides the permanent formwork while the shown multiperforated front face of the permanent formwork is smooth with plastic finish. 
         FIG. 16  shows the perspective view of a section of assembly of a mold structure permanent formwork of the multiperforated modular construction system of permanent formwork for reinforced concrete, including flat structural components, flat connector components, corner shaped connecting components, panel-shaped components, vertical and horizontal elements of structural reinforcements, thermoacoustic insulation cores, poured concrete in the hollow cavities, showing in particular the behavior of concrete in the faces with multiperforation. 
         FIG. 17  shows the perspective view of a portion of assembly mold structure permanent formwork of the multiperforated modular construction system permanent formwork for reinforced concrete including flat structural components, flat connector components, corner connectors components, panel shaped components, vertical and horizontal and structural elements and reinforcements, thermoacoustic insulation cores, poured concrete in the hollow cavities, the new texture generated on the surface and some of the different types of additional finishing that can receive the new texture. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The characteristic details of the modular construction system of permanent formwork perforated for reinforced concrete are shown in the following illustrative description and accompanying drawings, wherein the same reference symbols are used to indicate the same parts. 
     As shown in Figures sets  1  and  2 , a multiperforated flat modular profile  10  includes an elongated longitudinal surface  11 , multiperforations  15  that can be of different types  15   a ,  15   b ,  15   c ,  15   d  strategically distributed on the surface  11 , at an end perpendicular to the surface  11  is provided a longitudinal extension, all along the end is a rail geometrically defined as a female element  13  that may be of the type  13   a  or  13   b , the remaining end in the longitudinal rail a having a male element  12  may be of type  12   a  or  12   b , such rails acting as engaging, coupling, and interlocking means, the width of the multi-longitudinal surface  11  comprises a plurality of longitudinal T-shaped rails  14  to engage the flat connectors. 
     With reference to Figure sets  3  and  4  there is show a multiperforated modular connector with a corner profile  40  with hollow cavity  22  characterized by including two perpendicular interconnected longitudinal elongated faces  23  with sections of cores cut  17  longitudinally distributed, in addition to including two parallel longitudinal lips  31  crossing to the surface  23 , an elongated longitudinal semicircular profile  32  with multiperforations  15  and who&#39;s multiperforations can be of different types of  15   a ,  15   b ,  15   c ,  15   d , said multiperforated modular connector  40  in one of the perpendicular longitudinal sides  23  has integrated thereon on one side two rails geometrically defined as a female element  13  which may be of the type  13   a  or  13   b , and on the remaining side  23  having two rails integrated geometrically defined as male element  12  which may be of the type  12   a  or  12   b , as a means of engaging, coupling, and, interlocking. 
     As shown in  FIGS. 5 and 6 , a flat modular connector profile  20  is characterized by including an elongated longitudinal surface  16  with sections of cores cut  17  longitudinally distributed strategically, parallel longitudinal lips  31  crossing the surface  16 , and at both ends of the edge coupling means, with longitudinal U-shaped rail with edges  18  extended inwards. 
     Referring to Figure sets  7  and  8 , a multiperforated flat modular connector  50  with a rectangular configuration is characterized by including a front wall  11 , a rear wall  11 , each wall multiperforated  15  with multiperforations that can both be of different types  15   a ,  15   b ,  15   c ,  15   d  distributed on the surface  11 , longitudinal ribs (or walls)  21  with core sections cut  17  distributed longitudinally, the walls  11  and ribs  21  forming a hollow cavity  22 , said multiperforated flat modular connector  50  in a rib  21  having integrated thereon two rails geometrically defined as a female element  13  which may be of the type  13   a  or  13   b , the remaining rib having two rails integrated geometrically defined as a male element  12  which may be of the type  12   a  or  12   b , as means of engaging, coupling, and interlocking. 
     Referring to Figure sets  9  and  10 , a multiperforated modular panel  30  is characterized by including a rectangular configuration a front wall  19  with longitudinal multiperforations  15 , a rear wall  19  with longitudinal multiperforations  15 , which may be of the type  15   a ,  15   b ,  15   c ,  15   d  distributed strategically, a plurality of longitudinal ribs (or extruded walls)  21  with core sections cut  17  longitudinally distributed strategically, these also have parallel longitudinal lips  31  crossing the surface  21 , in the configuration of walls  19  and ribs  21  are formed rectangular hollow cavities  22  connected to one another, said modular panel  30  in a rib  21  having two rails integrated geometrically defined as female element  13  which may be of the type  13   a  or  13   b , the remaining two rails integrated in the other rib  21  having geometrically defined thereon a male element  12  which may be of the type  12   a  or  12   b , as means of engaging, coupling, and interlocking. 
     Referring to  FIG. 11 , a section of assembly consists of six multiperforated modular profiles plates  10 , eighteen connector pads  20  and a multiperforated flat modular connector  50 , which when assembled as shown subsequently will form a mold structure of permanent formwork with cavities  22  interconnected with multiperforated surfaces  15 , cut type cores  17  and assembly of the male elements  12  and female elements  13 . 
     Referring to  FIG. 12 , a section formed by modular assembly includes multiperforated profile plates  10 , flat connectors  20 , multiperforated flat modular connectors profiles  50 , panel-shaped components  30  which are subsequently to be assembled to form a mold structure permanent formwork with hollow rectangular cavities  22  interconnected with multiperforated surfaces  15 ,  17  cut type cores and assembly of the male elements  13  and female elements  12 . 
     Referring to  FIG. 13 , a section of an assembly is formed by multiperforated flat modular profiles  10 , multiperforated corner modular connector profiles  40 , flat connectors  20 , multiperforated flat modular connectors profiles  50 , panel-shaped components  30  which when assembled will subsequently form a mold structure with permanent formwork hollow having rectangular cavities  22  interconnected with multiperforated surfaces  15 , having cut type cores  17  and assembly of the male elements  13  and female  12  elements. 
     Referring to  FIGS. 14, 15, 16 and 17  a section of the assembly multiperforated mold structure permanent formwork for reinforced concrete is formed by the multi-perforated plates  10 , flat profiles connectors  20 , multiperforated modular panels  30 , modular connector profiles, multiperforated corner modular connector profiles  40  and  50  multiperforated modular connectors planes, which when assembled subsequently one after another, these system components give form to a mold structure permanent formwork for reinforced concrete with hollow cavities  22  interconnected to each other, where front and back faces of this structure may be multiperforated  15 , this mold structure permanent formwork generated in the assembly being reinforced with structural elements  24  that can be vertically and horizontally situated, in addition with the alternative of adding cores of thermo acoustic insulation  25  in the hollow cavities  22 , then spreads concrete  34  in these mold cavities of the permanent formwork, wherein the concrete surfaces multiperforations  15  spread the concrete  34  “will come out and generate” a new texture to the surface  26 , covering and hiding the permanent mold structure formwork, this structure in its front and rear surfaces, depending on the construction project, can be on one side of the form  26  and the remaining side of the finish surface can be smooth plastic surfaces  27 . Specifically generated surfaces  26  enable the making of any type of finish as in smooth flattened type  26 , or textured surface  29 ; or enable attaching other material  45  shown as additional finishing. 
     This invention has been described in detail with reference to specific embodiments thereof, including the best mode for carrying out embodiments. The illustrations are by way of example only and not a limitation. What is considered as a novelty, and therefore claimed as property, is contained in the appended claims.