Patent Publication Number: US-2022220733-A1

Title: A modular structural system and construction method thereof

Description:
FIELD OF THE INVENTION 
     The present invention is in the fields of concrete structures construction. More specifically, the invention relates to a modular structural system and construction method thereof, which is utilized for efficient construction of various structures in an economical modular manner. 
     BACKGROUND OF THE INVENTION 
     Current construction methods aim to industrialize the construction process, using frames, advanced techniques and materials for constructing large structures. 
     However, none of these methods has yet solved crucial problems of the construction industry, such as structure failure, disengagement of reinforcement frames from molded structural elements, disintegration and cracking, and loss of workers lives during the construction process. 
     Many of the above failures and risks are due to the numerous manual tasks being performed in inconvenient postures at heights (e.g., pre-casting preparations for concrete structures including molds and reinforcement mesh installation, and post-casting tasks such as uninstalling molds). 
     The costs of construction are currently also still high because of the heavy workload and equipment, which are required and the significant amount of time for completing a construction from the foundation to the finish. 
     It is therefore an object of the present invention, to provide a modular structural system of pre-made elements and coupling means that structurally integrate with the casted concrete structure thereby do not require post-casting disassembly and reducing the pre-casting preparations. 
     It is another object of the present invention, to provide a modular structural system and construction method thereof, which enables simple and modular construction of extended structural elements, thereby enabling reduced construction time. 
     Other objects and advantages of the invention will become apparent as the description proceeds. 
     SUMMARY OF THE INVENTION 
     The invention relates to a modular structural system, comprising: a) one or more building units being comprised of two counter mold partitions, each of which is adapted with one or more anchoring means, into which one or more connecting locks (i.e., which may be of an adjustable length) are engaged to firmly lock and stabilize the two counter mold partitions, wherein each of the two counter mold partitions is peripherally adapted to receive one or more affixing coupling means, b) two or more coupling means for affixing two of the one or more building units, and c) two or more coupling means for affixing the one or more building units to an adjacent building element. 
     The two or more mold partitions are selected from the group consisting of: a solid plate, a multilayered plate (e.g., comprising a thermal isolation layer), or any combination thereof. 
     According to one embodiment of the present invention, the one or more anchoring means are added onto the two or more mold partitions. According to another embodiment of the invention the one or more anchoring means are integrated within the two or more mold partitions. 
     According to an embodiment of the present invention, the one or more anchoring means is integrated with the two or more coupling means. 
     The invention further relates to a modular construction method, comprising: a) providing one or more building units being comprised of two counter mold partitions, being connected by connecting locks, b) affixing each two residing building units by two or more coupling means, c) affixing building units to an adjacent building element, by two or more coupling means, and d) casting a solidifying substance into the one or more building units. 
     According to an embodiment of the present invention, the utility elements are embedded within one or more of the two counter mold partitions before casting a solidifying substance into the one or more building units. 
     According to an embodiment of the present invention, one or more adjustable connecting locks are provided to enable modifying the depth of the one or more building units before casting the solidifying substance into the one or more building units. 
     The solidifying substance may be prepared from a mixture of at least two of the following materials: 
     White cement;
 
Black cement;
 
Sea sand;
 
Quartz sand;
 
Fiberglass fibres;
 
Fiberglass rods construction;
 
Power and fibres of basalt;
 
Mineral wool;
 
Sodium-Chloride power.
 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  schematically illustrate a section view of the proposed system, according to an embodiment of the present invention; 
         FIG. 2  shows another example of anchoring means  101   a , according to an embodiment of the present invention; 
         FIG. 3  shows an integrated anchoring and coupling means, according to an embodiment of the present invention; 
         FIG. 4  shows an integrated of building utilities with the proposed system, according to an embodiment of the present invention; 
         FIGS. 5A-5B  schematically illustrate different designs of coupling profiles, according to an embodiment of the present invention; 
         FIG. 6  schematically illustrate stairs, according to an embodiment of the present invention; and 
         FIG. 7  schematically adjustable connecting locks, according to an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     The present invention relates to a modular structural system, comprising multilayered building units of multiple different types, being engaged to form building elements (e.g., construction wall, gravity wall, piling wall, cantilever wall, anchored wall, staircase, internal walls, etc.) in a fast and modular manner, where each building unit is constructed of two counter partitions being firmly connected by suitable connecting locks, thus forming a mold into which solidifying substance such as concrete is casted. The proposed system further comprises suitable coupling means as well as adhesive materials for affixing two residing building units, or for affixing building units to adjacent building element such as to the floor. 
     In the following detailed description, references are made to the accompanying drawings that form a part hereof, and in which are shown by way of illustrating specific embodiments or examples. These embodiments may be combined, other embodiments may be utilized, and other changes may be made without departing from the spirit or scope of the present invention. 
       FIG. 1  schematically illustrate a section view of the proposed system, according to an embodiment of the present invention, in which system  100  comprises building units  100   a  and  100   b  (e.g., forming a mold for a small wall), where unit  100   a  of the proposed system is essentially constructed of two counter mold partitions  101  and  102  (e.g., two counter faces of a wall unit), each of which is adapted with anchoring means  101   a  and  102   a  correspondingly into which connecting locks  103  are engaged to firmly lock and stabilize the two counter mold partitions. Anchoring means  101   a  and  102   a  can either be add-on brackets added onto mold partitions  101  and  102 , or embedded brackets of mold partitions  101  and  102 . Of course, multiple different designs of connecting locks can be selected by a person skilled in the art, in accordance with specific preferences and requirements in various applications of the proposed system, such as connecting locks  104  of building unit  100   b . For example, the use of connecting locks  103  is preferred when the placement of mold partition  102  is at a later timing, and hence, whereas mold partition  101  is already in place together with connecting locks  103 , mold partition  101  is being threaded from above onto the “U” shaped edges of connecting locks  103 . 
     Furthermore, mold partitions  101  and  102  comprises longitudinal grooves  101   b  and  102   b  correspondingly, into which coupling means such as rectangular profiles  110  are engaged for coupling residing building units (e.g., mold partitions  101  of building units  100   a  and  100   b ), or such as floor affixing unit  120  being anchored to the floor for affixing building unit  100   b  to a floor surface  130 . The width and depth of profiles  110  are selected to be reduced with respect to grooves  101   b  and  102   b , to allow application of suitable portion of adhesive and sealing materials. Of course, multiple different designs of profiles  110  may be selected by one skilled in the art according to specific desirable designs of building units  100   a  and  100   b  as well as its fitness to desirable internal elements (e.g., where a horizontal building unit is utilized for constructing a ceiling with downwardly protruding anchors for lighting fixtures). 
     While mold partitions  101  and  102  of  FIG. 1  are schematically illustrated as solid plates, they can also be multilayered plates, for example, comprising thermal isolation layers. Furthermore, according to different embodiments of the present invention, mold partitions  101  and  102  are of different thicknesses in accordance with expected loading. Moreover, the position of grooves  101   b  and  102   b  with respect to the sectional width of mold partitions  101  and  102  may vary with respect to decorative and structural preferences. 
       FIG. 2  shows another example of anchoring means  101   a , according to an embodiment of the present invention, in which anchoring means  101   a  is an elongated assembly of a round bar  201  attached (e.g., welded) to an elongated profile  202  having a formed portion  202   a  which is suitable for engagement and adhesion into grooves  101   b  of  FIG. 1 , where formed portion  202   a  is adapted to receive coupling means such as rectangular profiles  110  of  FIG. 1 . 
       FIG. 3  shows an integrated anchoring and coupling means, according to an embodiment of the present invention, in which a single anchoring and coupling profile  301  is integrated (e.g., adhered) into groove  101   b  (of  FIG. 1 ) of a mold partition  302 . Further show is a lateral coupling profile  303  which is engaged with mold partition  302  for coupling a laterally residing mold partition. Further shown in  FIG. 3  is a decorative finishing portion  301   a  of profile  301  being highly useful for complementary decoration and sealing inbetween mold partitions  302  of external building surfaces. 
       FIG. 4  shows an integrated of building utilities with the proposed system, according to an embodiment of the present invention, in which various utility elements  401  such as water piping fittings, electrical junction boxes, or other conduit passages, are being integrated with an internal mold partition  402  (e.g., internal surface of a wall), thus enabling a convenient routing of utility piping and wiring. 
       FIGS. 5A-5B  schematically illustrate different designs of profiles  110 , being used with the proposed system for creating corner building units, as well as stairs as shown in  FIG. 6 . 
       FIG. 7  schematically illustrates adjustable connecting locks  701 ,  702  (of a limited extension) and a telescopic  703 , that may be used as an alternative to locks  103  and  104  of  FIG. 1 , where the use of locks  701 - 703  enables to perform last minute modifications (i.e., before casting), as well as constructing vertically or laterally inclined building units (e.g., variating depth of a wall). 
     The proposed structure system enables a highly efficient construction method, according to which an extended mold (i.e., which is stabilized and affixed to adjacent structure elements) is assembled, into which concrete (i.e., or other suitable solidifying material) is casted to form a complete structure element, which does not require pre assembly of wooden/metal mold plates and steel reinforcements, and does not require post-casting disassembly of the mold plates (i.e., mold partitions  101  and  102  are an integral element of building units  101   a    101   b ), thereby enabling a relatively fast construction of structure elements. 
     Upon casting concrete into the mold formed between the two counter mold partitions, static pressure is applied to both partitions due to the weight of the casted concrete. The higher the partitions are, the higher is the pressure. This pressure between counter mold partitions applies opposing lateral forces on the partitions which causes the anchoring means to strongly pull the connecting locks to two opposing directions. These lateral forces has two positive effects. First, the structure is maximally stabilized since the locks are tensioned. Second, the casted concrete is solidified on tensioned metals (in this case, the locks) and thereby causes a similar reinforcement effect to the effect of Prestressed concrete. This strongly increases the of the resulting walls durability against socks, such as during earthquakes. 
     Moreover, utilizing the proposed system and method can reduce (i.e., and possibly eliminate in some cases) the need for scaffoldings, thus requiring fewer scaffoldings at the construction site, hence further reducing construction costs and duration. 
     According to one embodiment of the present invention, the solidifying substance is prepared from a mixture of at least two of the following materials: 
     White cement;
 
Black cement;
 
Sea sand;
 
Quartz sand;
 
Fiberglass fibres;
 
Fiberglass rods construction;
 
Power and fibres of basalt;
 
Mineral wool;
 
Sodium-Chloride power.
 
     Although embodiments of the invention have been described by way of illustration, it will be understood that the invention may be carried out with many variations, modifications, and adaptations, without exceeding the scope of the claims.