CN112135948A

CN112135948A - PPVC connector

Info

Publication number: CN112135948A
Application number: CN201880093489.8A
Authority: CN
Inventors: 李易兴
Original assignee: Kcl Design Consultants Ltd
Current assignee: Kcl Design Consultants Ltd
Priority date: 2018-05-17
Filing date: 2018-07-06
Publication date: 2020-12-25
Anticipated expiration: 2038-07-06
Also published as: CN112135948B; WO2019221668A1

Abstract

A PPVC connector is provided for joining a first PPVC (pre-fabricated volume structure) module and a second PPVC module. The PPVC connector includes a first anchor for attaching to a first PPVC module and a second anchor for attaching to a second PPVC module. The PPVC connector also includes a frame for joining the first and second anchors together. The frame is configured to prevent separation between the first and second anchors in order to permanently join the first and second PPVC modules together.

Description

PPVC connector

The present application relates to one or more PPVC (prefabricated volume structures) connectors for coupling PPVC modules together. The present application also relates to one or more methods for manufacturing, assembling, disassembling, installing, constructing, maintaining, repairing, and using one or more PPVC connectors to couple PPVC modules.

The present application claims the priority date of singapore patent application nr.10201804186r, filed on 2018, 5, 17 to IPOS (singapore intellectual property office), and entitled connector for PPVC modules. The relevant content and/or subject matter of this prior priority patent application is incorporated herein by this reference where appropriate.

To increase construction productivity and radically improve the design and construction process, singapore construction and construction administration (BCA) encourages the construction industry to accept the concept of design for manufacturing and assembly (DfMA), whereby the construction is designed so that as much work as possible can be done off-site in a controlled manufacturing environment.

PPVC is a game change technology that supports the DfMA concept to significantly accelerate building construction. PPVC can potentially achieve productivity improvements of up to 50% in terms of manpower and time savings, depending on the complexity of the associated project. Furthermore, dust and noise pollution can be minimized as more activities are done off-site (i.e., away from the building construction site). The safety of the building construction site has also been improved as a large amount of installation activity and manpower are moved off-site to the factory controlled environment.

Although important, the connection between PPVC modules is inherently weak because the walls, floors or side panels of the different PPVC modules are individually prefabricated in the factory rather than being built or cured together in series on site. Accordingly, the present application seeks to provide one or more new and useful PPVC connectors for coupling a plurality of PPVC modules, also known as building elements. The present application also seeks to provide one or more new and useful methods for manufacturing, assembling, disassembling, installing, constructing, maintaining, repairing and using PPVC connectors to join building elements or PPVC modules. The essential features of the related invention are provided by one or more of the independent claims, while the advantageous features of these inventions are presented in their respective dependent claims.

According to one aspect, the present application provides a PPVC (pre-fabricated volume structure) connector that is typically manufactured prior to installation to permanently or temporarily couple, join or secure together a first PPVC module and a second PPVC module. The PPVC connector includes a first anchor for attachment to a wall (e.g., ceiling, floor, side wall) or embedding in/on a wall of the first PPVC module. The PPVC connector also includes a second anchor for attaching to or embedding in/on a second PPVC module using shrink-free grout. The PPVC connector also includes a frame (e.g., a metal rod, rebar, or plate) operable to couple the first and second anchors together. The frame is typically a rigid, stiff, tough, strong structural member or structure, although the frame may alternatively be elastic or resilient. Conversely, the rope, cord or soft wire cannot maintain or maintain the predetermined configuration in the absence of an external force. The frame is configured to constrain, limit, inhibit, or prevent separation, misalignment, or relative movement between the first and second PPVC modules, whether in a plane or in more than two cartesian directions (e.g., transverse directions of the PPVC modules). The frame may also be referred to as a restraint, delimiter, coupler, secure connector or link that prevents the two anchors or PPVC modules from disengaging from each other. One or more portions of the PPVC connector can be integrally formed or assembled from several components. For example, the first anchor and frame may optionally be of unitary form or snap fit to facilitate deployment.

PPVC connectors are typically designed for mass production, with all components packaged separately. Since the first and second anchors may be seeded or implanted into a wall or other portion of a PPVC module, respectively, at predetermined locations according to a particular orientation, the frame may be quickly, easily and securely installed at a construction site where two PPVC modules are aligned and adjacent to each other. Indeed, the anchor may even serve as a guide or marker post for positioning the PPVC module. Because the frame or PPVC connectors can connect or fasten the PPVC modules together, the building with the PPVC modules becomes rugged and durable and can withstand earthquakes or other natural disasters for many years.

One or more portions or pieces of the first anchor, the second anchor, and the frame may have dimensions (e.g., height or length) greater than 50 millimeters, 100 millimeters, 150 millimeters, 200 millimeters, 250 millimeters, or extend substantially throughout the height of two PPVC modules. For example, one or more pieces of the first anchor, second anchor, frame or other component of the PPVC connector may comprise one or more plates having a dimension (e.g., height or length) greater than 50 millimeters, 100 millimeters, 150 millimeters, 200 millimeters, 250 millimeters, or extending substantially throughout the height of two PPVC modules. A plate is also effectively considered to be an elongate plate if its dimension or one dimension is substantially larger than the other dimensions of the plate. If one or both edges of the panel are folded, the cavity defined by two adjacent faces of the panel may define a cavity between the two adjacent faces. For example, if two opposing edges of an elongate plate are folded symmetrically towards each other, the elongate plate forms a slot whose cavity is capable of receiving grout or other types of filler. For ease of use or installation, the longitudinal direction of the elongate plate is substantially parallel to the vertical or height direction of the PPVC modules before or after coupling of the PPVC modules.

The first anchor comprises an elongate plate (with a single fold or multiple folds at the edges or middle) (e.g., having a U-shaped profile) that can be folded (in the length and/or width direction, but not in the height direction of the PPVC module or the longitudinal direction of the first anchor) (to provide a cavity through or with the wall of the PPVC module). The cross-section of the first anchor may optionally have a square, circular or any other geometric shape or contour as a projection on a two-dimensional surface (e.g., a plane), such as the contour of a similar pattern block. Illustratively, the hollow conduit formed by the first anchor or anchors is capable of receiving a cylinder having a diameter substantially about 10 millimeters (mm), 15 mm, 23 mm, 38 mm, 50mm, or 60 mm. Similar to the first or simple anchor, the second anchor optionally includes another elongated plate that is folded in a single fold or multiple folds to provide a cavity by the second anchor.

One or more pieces of the first anchor, second anchor, and frame may optionally be corrugated, rough, or lattice-shaped (e.g., having a continuous or repeating square pattern or other regular shape) to capture grout or other types of adhesives. If the components, parts or portions of the PPVC connector (e.g., anchor or frame) are made of a plate, the plate may be pierced, roughened or surface treated (e.g., coated, sandblasted), which can better retain grout or adhesive than a smooth or polished surface.

One example of corrugations includes a regular pattern or repeating configuration on the first anchor, the second anchor, and one or more pieces of the frame. The distance between two adjacent or proximate perforations is substantially about 10, 18, 27, 36, 50, 68 or 72 millimeters. The component, part or portion may optionally be further attached (e.g., welded) to other thin structures, including woven and welded wire mesh, to improve surface adhesion.

One or more components, parts or portions of the first anchor, second anchor and frame are sometimes perforated to allow grout to pass through the perforations in the first anchor, second anchor or frame. Since the one or more adhesives (including grout) is a slurry prior to curing or setting, the one or more adhesives can flow through the perforations to fill the first anchor, the second anchor, both anchors, or the cavity of the PPVC connector, either alone or with one or more PPVC modules. If the perforations are substantially similar, each similar perforation sometimes has an outer diameter of 8 millimeters, 16 millimeters, 20 millimeters, 28 millimeters, or 36 millimeters.

Preferably, one or more of the first anchor, the second anchor and the frame has a thickness or diameter of substantially three (03), four (04), six (06), eight (08) millimeters. The rods or plates of these parts made of steel or steel alloys can be manufactured in large quantities at low cost and with high quality.

In some cases, the frame includes a first coupler having two wings, extensions, or prongs that are spaced apart and possibly facing each other to form a cavity, similar to a "C" or "U" shape, for receiving one or more edges (e.g., two edges) of the first and second anchors, respectively. Two projecting portions (e.g., known as prongs) can retain the projecting portions of the anchors within the cavities, which locks the two anchors and their respective PPVC modules together.

In some cases, the frame further includes a second coupler having two wings, extensions, or prongs spaced apart for receiving edges or extensions of the first and second anchors. The two couplers of the frame are capable of holding two anchors from opposite or multiple sides or directions, thereby increasing the strength of the joint between two PPVC modules. Embodiments of the present application provide that the frame further comprises a rib (e.g., a plate or a rod) that joins the first coupler and the second coupler together.

The first anchor may include a first rod (also referred to as a rod, rebar, or reinforcing rod) and a second rod spaced apart from one another. Similarly, the second anchor comprises a rod and a further rod which are also spaced apart from each other. The first or second rod may be operable to extend along the longitudinal direction of either anchor and/or parallel to the height or vertical direction of either PPVC module. PPVC modules are building units, including living, bathroom, storage room or living room units, that can be joined, assembled or stacked to complete a building or an integral part of a building.

The present application also provides an assembly of PPVC modules (e.g. a multi-storey building) or a building assembly comprising a first PPVC module, a second PPVC module and possibly further PPVC modules. A first anchor of a PPVC connector is attached or embedded to a first PPVC module, while a second anchor of the same PPVC connector is attached or embedded to a second PPVC module. The first and second PPVC modules are sometimes assembled together laterally, adjacent to each other. The assembly or building component is one piece in that the PPVC connector securely fastens the two PPVC modules together, whether temporarily or permanently. One or more of the components can also be stacked, preferably by aligning the stacked PPVC modules along their respective walls. Indeed, the PPVC connector may also protrude above the PPVC module to align the top PPVC module. For example, a PPVC connector has a cavity to receive a rod or dowel rod through two longitudinally aligned PPVC connectors in its cavity.

The assembly of PPVC modules may also include a filler, adhesive, sealant and/or bonding agent that fills the cavity formed by the first anchor, the second anchor, the frame or any combination of these parts or components, whether completely, partially, progressively or instantaneously. The filler, adhesive and/or bonding agent not only evacuates air from the cavity, but also integrally bonds the components (e.g., PPVC connector and PPVC module). It is generally desirable for PPVC connectors, fillers, adhesives, sealants, and/or binders to be water resistant, fire resistant, flame retardant, shock resistant, insect resistant, corrosion resistant, weather resistant, abrasion resistant, or a combination of any of these properties.

The first and second anchors may be aligned (e.g., with the openings of their cavities facing each other) for receiving a frame or an opposing part (e.g., an anchor). Since PPVC connectors can be mass produced, a building builder or worker can easily identify the mating parts of the anchors on different PPVC modules to match.

One or more cavities are optionally formed by the first anchor, the second anchor and the frame, the one or more cavities extending substantially the entire height of any PPVC module. The PPVC connector is optionally configured to extend over the entire height or a portion of the PPVC module. For example, two PPVC connectors extend through the entire height of two adjacent PPVC modules, while the other PPVC connector extends only a portion of the height of the middle of two joined PPVC modules.

The PPVC connector is sometimes completely or partially substantially submerged in or below (e.g., buried within) a surface of a wall of one of the PPVC modules. Thus, one or more components of the PPVC connector (e.g., the first anchor) are integrally joined to the PPVC module, which provides a secure link for coupling the two PPVC modules together. PPVC connectors may provide an indestructible, shatterproof, or rigid connection that ensures the integrity of the building components.

An embodiment of a component of a PPVC module includes a first PPVC connector and a second PPVC connector that are substantially the same as or similar to the PPVC connector. The first and second PPVC connectors are attached to or embedded in the same wall of either of the PPVC modules. Thus, a single PPVC module has multiple pieces for engaging a PPVC connector or anchor of another PPVC module. The multiple pieces of the PPVC connector may limit, reduce, eliminate, or avoid misalignment or separation of two connected PPVC modules.

The first and second PPVC modules are preferably spaced apart from each other with a uniform gap therebetween for filling by grout or filler. Instead of having the hard walls of two adjacent PPVC modules push against each other, the filler or grout provides a "glue" and a "cushion" which can be used to adjust the distance between two adjacent PPVC modules, whether laterally or vertically. Multiple, additional or other types of connectors are optionally mounted between two laterally or vertically adjacent PPVC modules to secure the two PPVC modules together. These PPVC connectors are optionally further connected or interlocked with each other so as to be firmly and elastically secured, for example against earthquakes.

In some cases, the assembly of PPVC modules further includes a third PPVC module stacked on any one of the PPVC modules. Two stacked PPVC modules are optionally vertically aligned by one or more rods or dowel bars, which are sometimes inserted into PPVC connectors or anchors. A single rod or dowel rod is optionally inserted into multiple PPVC connectors or anchors, which are vertically aligned to provide a straight cavity. For example, a rod, rebar, or pin rod is surrounded by the first anchor. Subsequently, a rod, rebar or dowel bar is cast into the anchor or PPVC connector by grouting, cement or any other adhesive, thereby providing an excellent bond between the PPVC modules.

According to another aspect, the present application provides a method of using a PPVC connector. The method comprises the following steps: a first step of attaching a first anchor to a wall of a first PPVC module; a second step of attaching a second anchor to a wall of a second PPVC module; and a third step of coupling the first and second anchors through the frame so as to prevent separation between the first and second PPVC modules. Some of these steps may be combined, divided, or changed in order. For example, the second anchor is first attached to a wall of the second PPVC module. The method provides a simple, reliable and low cost means of securing two PPVC modules together.

The method may further include the step of filling the gap between the first anchor, the second anchor, and the frame with a filler (e.g., adhesive, grout). The filler may not only optionally glue two PPVC modules together, but may also be used to adjust the distance between two adjacent PPVC modules. In some cases, the filler is resistant to water penetration, pests, corrosion, or any other damage.

The method may additionally include the step of joining the first and second PPVC modules together by curing the filler. When applied, the filler is sometimes in the form of a fluid or slurry that flows easily or into the gap. Once cured, whether by air, heat, or automatically cured within a predetermined period of time, the filler is capable of sealing gaps of any shape or size, flexible and reliable for filling. The filler will create a restraining effect between the first and second anchors by using the frame, increasing the binding and restraining forces between the connected PPVC modules.

According to another aspect, the present application provides a method for manufacturing a PPVC connector. The method comprises the following steps: a first step of providing a plate as an anchor for attaching the plate to a wall of a first PPVC module; secondly, the plate is corrugated to improve the surface adhesion of the plate to the wall; and a third step of folding the sheet to form a plurality of sides for more secure attachment to the wall. Some of these steps may be combined, divided, or changed in order. For example, optionally, the third step of folding the sheet precedes the preceding second step of corrugating the sheet. The components of the PPVC connector can be easily manufactured at low cost.

The method may further comprise the step of providing a frame for coupling the plate with another anchor. The frame can be separated by preventing or reducing the motion of two anchors or two adjacent PPVC modules, which typically move in a plane or two dimensions according to a cartesian coordinate system. In other words, under a cylindrical coordinate system, the frame is able to define, limit, constrain or prevent a corresponding movement between two adjacent PPVC modules on their cylindrical axis, in particular to limit the radial movement of the cylindrical coordinate system.

The drawings illustrate embodiments and serve to explain the principles of the disclosed embodiments. It is to be understood, however, that the drawings are presented for purposes of illustration only and not limitation, with respect to the application.

FIG. 1 shows a plan view of two facing walls with components;

FIG. 2 shows a plan view and a perspective view of an assembly for coupling two facing walls;

figure 3 shows a perspective view of the C-channel and the lipped C-channel;

FIG. 4 shows a perspective view of the inner surface of the first wall with five recesses;

FIG. 5 shows a perspective view of two facing walls with the assembly;

FIG. 6 shows a side view of two walls stacked on top of each other; and

figure 7 shows a perspective view of two PPVC modules joined at adjoining long faces.

Exemplary, non-limiting embodiments of the related inventions will now be described with reference to the above-identified figures.

Fig. 1 shows a plan view with two facing walls of the assembly 100. Two similar walls are arranged side-by-side along adjoining long faces 102 in plan view, with a wall width 104 of about one hundred millimeters (100mm), a wall length 106 of about one thousand two hundred millimeters (1,200mm), and a wall height 108 of about three thousand one hundred fifty millimeters (3,150mm) (not shown in FIG. 1). A grid gap 110 of about 20mm separates the two walls.

The assembly includes a PPVC (pre-fabricated volume structure) connector for coupling a first PPVC module 208 and a second PPVC module 210. The

PPVC modules

208, 210 include walls, floors, and ceilings that are built and assembled at a manufacturing facility off-site. The

PPVC modules

208, 210 are then transported and installed in the building under construction. In the following description, the connector for the wall is described in detail; two walls are joined side by side at one face and at the other face by stacking one on top of the other.

For ease of identification, the two similar walls are referred to as a first wall 112 and a second wall 114. The first wall 112 and the second wall 114 each have six faces. The top exterior surfaces of the first wall 112 and the second wall 114 are referred to as a first top surface 116 and a second top surface 117, respectively. The opposite side of the first top surface 116 is a first bottom surface 118, the first bottom surface 118 not being shown in fig. 1. The opposite side of the first adjoining long side 102 is a first relatively long side 120. The first major side surface 122 is a narrow surface that meets the first adjoining long surface 102 with the first opposing long surface 120 and meets the first top surface 116 with the first bottom surface 118. Opposite the first major side 122 is a first minor side 124. The term "opposite" is used to describe a distal side or a distal side that spans a proximal side.

Three components can be seen on the first top surface 116 of the first wall 112, including a first component 126, a second component 128 and a third component 129. The second component 128 is interposed between the first component 126 and the third component 129. Each

assembly

126, 128, 129 includes at least one anchor and a restraint 134. Further details of each

component

126, 128, 129 will be described later. The limiter 134 is also referred to as a delimiter or a frame.

First anchor 130 is secured to first wall 112 and second anchor 132 is secured to second wall 114. The limiter 134 surrounds the first and

second anchors

130, 132, in other words, the limiter 134 brings the two

anchors

130, 132 together, which holds the two

walls

112, 114 together.

The first component 126 proximate the first major side 122 has a first component-to-side distance 136 of two hundred millimeters (200 mm). The first component-to-side distance 136 is measured from the first major side 122 to a center of the first component 126 proximate the first major side 122 or from the first minor side 124 to a center of the third component 129 proximate the first minor side 124. The first to second assembly distance 138 measured from the center of the first assembly 126 to the center of the second assembly 128 is four hundred millimeters (400 mm).

The first wall 112 has three

recesses

140, 142, 144 on the adjoining long face 102, which is clearly shown in fig. 4. The first recess 140 is proximate the first major side 122. The second recess 142 is located at the center of the first wall 112. The third recess 144 is proximate the first minor side 124 of the first wall 112. The first recess 140 has a recess depth 148 of fifty millimeters (50mm) and a recess width 146 of two hundred millimeters (200 mm). The first recess 140 and the third recess 144 have similar dimensions. The second recess 142 has a recess depth 148 of seventy-five millimeters (75mm) and a recess width 146 of two hundred millimeters (200 mm). It is noted that the second recess 142 has a deeper recess, i.e. deeper into the wall.

The first, second and

third assemblies

126, 128, 129 described above include first and

second anchors

130, 132 and a limiter 134. In the case of the first component 126, the first anchor 130 is a C-shaped anchor, referred to as a C-channel 150, while the first anchor 130 of the second component 128 is a shear bar 135 embedded in the first wall 112 in an upright position, exposing a top section at the first top surface 116. Two shear bars 135 are embedded in each second recess 142 of each

wall

112, 114. The anchor is used to describe a device that is secured to a fixed structure, such as a wall.

The restrictor 134 of the first assembly 126 also has a C-shaped profile, referred to as a lipped C-channel 152, which is smaller in size than the

anchors

130, 132 or the C-channel 150. The limiter 134 of the second assembly 128 has a square profile with four rounded corners circumscribing the two first anchors 130 and the two second anchors 132. The limiters 134 used in the second assembly 128 are also referred to as top panel connectors 206. The limiter 134 is used to describe a connector that connects or joins more than one

anchor

130, 132 together.

A black mark is noted in the first component 126. The black marks indicate perforations along the first and

second anchors

130, 132, particularly for the first component 126, which is not shown in fig. 1. The first and

second anchors

130, 132 have perforations at both side wings when viewed in plan. The limiter 134 in the first assembly 126 has perforations at the long side and at both short sides. The two short sides flank the long side. The black marks or perforations have an outer diameter of twenty millimeters (20 mm).

Fig. 2 shows a plan view and a perspective view of a first assembly 126 for coupling two facing walls. The first assembly 126 includes a C-shaped channel 150 (anchor 130) and a lipped C-shaped channel 152 (restrictor 134). The C-shaped channel 150 is also referred to as CC1, and the lip C-shaped channel 152 is also referred to as CC 2. These walls are not shown in fig. 2.

The C-shaped channel 150 includes a base portion 154, a right side portion 156, and a left side portion 158. A right side portion 156 and a left side portion 158 flank each end of the base portion 154. The right and left

side portions

156, 158 also extend over the base portion 154 forming an overhanging extension 166 to form an open portion 160. A bellows 178 is inserted between the opening portions 160 of the two C-shaped passages 150. The corrugated tube has a tube diameter 180 of fifty millimeters (50 mm). Inserted into the bellows 178 at the right opening portion 160 is a dowel bar 182 as shown by the shaded circle.

The base portion 154 has a base width 162 of two hundred millimeters (200 mm). The right and left

side portions

156, 158 have a side depth 164 of fifty millimeters (50 mm). The overhanging extension length 168 above the base portion 154 was measured fifty millimeters (50mm) on each side. The C-channel thickness 170 measures four millimeters (04 mm).

The restraint 134 of fig. 2 is formed by joining two lip C-shaped channels 152 together at the mid-section by rebar 172, as shown in fig. 2. The lip C-shaped channel 152 also has a similar profile to the C-shaped channel 150, but is smaller in size when viewed in plan. Three rebars 172 are used to engage two of the lip C-channels 152, particularly along lip C-channel length 174 of lip C-channel 152. The lip C-shaped channel length 184 measures three thousand one hundred fifty millimeters (3,150mm), which is similar to the wall height 108. Each bar has a bar length 174 of seventy-two millimeters (72mm) and a bar diameter 176 of six millimeters (06 mm).

In the perspective view of the first assembly 127 of fig. 2, three rebars 172 are not visible. Three rebars 172 are positioned along the lip C-channel length 184, specifically at one thousand fifty millimeters (1,050mm) spacing between each of the rebars 172. A partial view of the perforation is seen on the overhanging extension 166 of the C-channel 150. A partial view of the perforations can also be seen on the lipped C-channel 152.

Fig. 3 shows a perspective view of the C-channel 150 and the lip C-channel 152. The C-channel 150 is shown on the left hand side and the lipped C-channel 152 is shown on the right hand side.

A C-shaped channel 150 having a right side portion 156 and a left side portion 158 is flanked on both edges of the base portion 154. Concentric holes 186 are formed in the overhanging extensions 166 on the right side portion 156 and the left side portion 158. Each of the concentric holes 186 has a diameter of twenty millimeters (20 mm). There are nine concentric bores 186 evenly distributed along the C-shaped passage extension length 188 of the overhanging extension 166. The concentric orifice gap 190 between the two concentric orifices 186 is three hundred fifty millimeters (350 mm).

The lip C-channel 152 includes a lip base portion 192, a lip right side portion 194, a lip left side portion 196, and a lip overhang portion 198. Similar to the C-channel 150, the lip C-channel 152 has a similar profile, but is smaller. The lip base portion 192 measures eighty millimeters (80 mm). The right labial and left

labial portions

194 and 196 each measure forty millimeters (40 mm). The lip overhang 198 measures fourteen millimeters (14 mm). The lip C-channel has a lip C-channel thickness of four millimeters (04 mm). There are nine concentric holes 186 in each of the right lip portion 194, left lip portion 196 and base lip portion 192. The concentric bores 186 are equally spaced along the length of the lip C-shaped passage 152.

The C-channel extension length 188, lip C-channel length 184, and wall height 108 all have the same dimensions of three thousand one hundred fifty millimeters (3,150 mm). Concentric holes 186 in the C-channel 150 and the lipped C-channel are shown. There are actually more than nine concentric holes 186.

Fig. 4 shows a perspective view of the first abutment long face 102 of the first wall 112 with five recesses. The first, third and

fifth recesses

140, 144, 204 have a C-shaped channel 150 embedded therein. The first, third, and

fifth recesses

140, 144, 204 extend along the height of the first wall 112, which has a wall height 108 measuring three thousand one hundred fifty millimeters (3,150 mm). The bellows 178 is longitudinally joined to the C-shaped channel 150, particularly at the center of the base portion 154 in the first, third and

fifth recesses

140, 144, 204. Each bellows 178 is eight hundred millimeters (800mm) in length.

The first recess 140 is positioned at a first component-to-side distance 136 of two hundred millimeters (200mm) from the first side 122. The same measurement is applied from the second side 124 to the fifth recess 204.

A first-to-second assembly distance 138 of four hundred millimeters (400mm) is applied between the depressions, i.e., first depression 140 to second depression 142, from second depression 142 to third depression 144, from third depression 144 to fourth depression 202, and from fourth depression 202 to fifth depression 204. The wall length 106 is measured as a total of two thousand millimeters (2,000 mm). The second recess 142 and the fourth recess 202 have two vertical shear bars 135 embedded therein. The second recess 142 and the fourth recess 202 have a recess depth 148 of 75mm, which means that 75mm of the shear bar 135 is exposed.

Fig. 5 shows a perspective view of two facing

walls

112, 114 with

components

126, 128. Two similar walls are positioned with adjoining long faces 102 facing each other. The first recess 140 of the first wall 112 meets the fifth recess 204 of the second wall 114. The second recess 142 of the first wall 112 meets the fourth recess 202 of the second wall 114. The third recess 144 of the first wall 112 meets the third recess 144 of the second wall 114. The fourth recess 202 of the first wall 112 meets the second recess 142 of the second wall 114. The fifth recess 204 of the first wall 112 meets the first recess 140 of the second wall 114.

Two of the lip C-shaped channels 152 are inserted into two adjacent C-shaped channels 150 in the first recess 140, the third recess 144, and the fifth recess 204. The lipped C-channel 152 is positioned orthogonally relative to the C-channel 150 prior to insertion of the two C-channels 150. The overhanging extension 166 of the C-channel 150 and the lipped overhanging portion 198 of the lipped C-channel 152 are communicatively engaged. Above the second recess 142 and the fourth recess 202, the top panel connector 206 is in communicative engagement with the two shear bars 135 of the first wall 112 and the two shear bars 135 of the second wall 114.

The C-shaped channel 152 protrudes above the first top surface 116 and the second top surface 117 of the two

walls

112, 114. The projection measured from the top surfaces 116, 117 to the apex of the lipped C-channel 152 is two hundred forty-five millimeters (245 mm).

Fig. 6 shows a side view of two

walls

112, 114 stacked on top of each other, in particular the second wall 114 on top of the first wall 112. A lip C-shaped channel 152 projecting from the top surface 116 of the first wall 112 extends into the bottom of the C-shaped channel 150 of the second wall 114. The C-shaped channel lip 152 of the second wall 114 projects from the second top surface 117 of the second wall 114. Bellows 178 are between C-shaped channels 150. The dowel bar 182 is within the bellows 178 extending from the second top surface 117 of the second wall 114 to the end of the bellows 178 within the first wall 112.

Fig. 7 shows a perspective view of two PPVC modules 208 joined at adjoining long faces 102. The first PPVC module 208 is a terminating PPVC module having a PPVC connector only on one side thereof. The second PPVC module 210 has PPVC connectors on its two adjoining long sides 102. The PPVC connector comprises: first, a C-channel 150 that serves as an anchor, a lipped C-channel 152 that serves as a coupler; second, shear bar 135 acts as an anchor and top plate connector 206 acts as a connector.

The second PPVC module 210 has an exposed contiguous elongated face 102, exposing eight elongated recesses extending from its top 116 to bottom 118 faces. The exposed abutment long face 102 corresponds to the first wall 112, as shown in fig. 4. Each of the eight recesses has an embedded pair of C-shaped channels 150. Two C-shaped channels 150 are embedded within and along the recess and face each other.

The top panel connector 206 is a bar formed as a square with rounded corners. The first PPVC module 208 and the second PPVC module 210 are coupled by placing the top panel connector 206 into two exposed shear bars 135 of the first PPVC module 208 and the remaining two shear bars 135 of the second PPVC module 210. The top panel connector 206 circumscribes four shear bars 135. There are six short depressions on the exposed adjoining long face 102. Each short recess is interposed between two long recesses. Each short recess has two embedded shear bars 135 exposing a top section of the shear bars 135 for receiving a top panel connector 206. Alternatively, the top panel connector 206 may be a solid piece of metal with four holes drilled at four locations corresponding to the locations of the shear bars 135 embedded in the walls of the

PPVC modules

208, 210.

The

PPVC modules

208, 210 are placed relative to a three-dimensional coordinate system 212 (also referred to as a free-stream coordinate system). The second PPVC module 210 is positioned on the adjoining long face 102 of the first PPVC module 208, the adjoining long face 102 having, in particular, the

PPVC connectors

126, 128, 129 in the x-axis direction. The

PPVC modules

208, 210 may also be placed on top of the first PPVC module 208 and the second PPVC module 210 in the z-axis direction, as shown in FIG. 7. More PPVC modules may also be placed in the x-axis direction as long as there are PPVC connectors available in the PPVC modules in that direction. The x-axis and y-axis both represent the lateral direction of the

PPVC modules

208, 210, while the z-axis represents the vertical direction of the

PPVC modules

208, 210. If a cylindrical coordinate system is used, the x-axis and y-axis are both radial directions, while the z-axis is referred to as the cylinder or longitudinal axis, e.g., the longitudinal axis of the PPVC connector or

assembly

126, 128, 129.

Functionally, the

PPVC connectors

126, 128, 129 provide a coupling means to couple the two walls together. The

PPVC connectors

126, 128, 129 may include a first component 126 and a second component 128. The terms PPVC connector, connector and

assembly

126, 128, 129 are similar coupling devices and are sometimes used interchangeably.

The two

walls

112, 114 that are part of the PPVC module 208 are made of concrete, which is a composite material composed of fine and coarse aggregates that are combined with fluid cement that hardens over a period of time. Aggregates are a wide variety of coarse to medium particle materials used in construction, including sand, gravel, crushed stone, slag, recycled concrete, and geosynthetic aggregates.

The first assembly 126 includes a C-channel 150 and a lip C-channel 152. The first C-shaped channel 150 is embedded in the first wall 112 and the second C-shaped channel 150 is embedded in the second wall 114. Two C-shaped channels 150 embedded in the two walls provide anchors that extend from the top surface 116 to the bottom surface 118 of the walls.

The lip C-channel includes a restrictor 134, which restrictor 134 provides coupling of the two walls by securing two C-channels 150. The lipped C-channel communicatively engages the two C-channels 150 by sliding downward from the top surface 116.

The C-channel 150 and lip C-channel 152 are made of structural steel. Structural steel is used and may be described as 'S275J 2' or 'S355K 2W'. In these examples, 'S' denotes structural steel rather than engineering steel; 275 or 355 represents yield strength in newtons per square millimeter or equivalent megapascals; j2 or K2 represents the toughness of the material, based on the Charpy impact test value; and "W" represents weathering steel. Other letters may be used to denote fine grain steel ('N' or 'NL'); quenched and tempered steel ('Q' or 'QL'); and thermomechanically rolled steel ('M' or 'ML'). Alternatively, steels used in building construction in the united states use standard alloys internationally determined and specified by ASTM (international society for testing and materials, division of america).

In practice, the first PPVC module 208, which includes at least one wall, is mounted on a horizontal plane. The horizontal plane may be a structural strut that supports the first PPVC module 208 from below. The structural uprights have protruding rebars that provide mounting of the first PPVC module 208 thereon. The subsequent PPVC module 208 is mounted either near the first PPVC module 208 or on top of the first PPVC module 208. Thus, the lipped C-channel is inserted through both C-channels 150 from the top surface of the wall. When rebar extends from the structural columns into the bottom of the C-channel 150 of the first PPVC module 208, the lipped C-channel 152 inserted through the top surface 116 will have an exposed partial section extending from the top surface 116. The exposed partial section of the lip C-channel 152 serves to provide a guide for insertion of another C-channel 150 of another PPVC module 208 stacked on top.

The concentric bore 186 in the overhanging extension 166 of the C-shaped channel 150 provides a free flow path for the grout in the cavity. The cavity is a hollow space in the C-shaped channel 150. Grouting to fill the cavity. Concentric holes 186 on the lip base portion 192, lip right side portion 194 and lip left side portion 196 provide free flow of grout in the cavity and in the grid gap 110. The grid gap 110 is formed to have two walls that are in close proximity but not in contact to allow grout to bond the two walls together and also to provide an expansion gap in hot weather. Since the grout has some viscosity, the concentric bore gap 190 between each concentric bore 186 is maintained at 50mm to ensure that the grout is fully immersed without any air bubbles being formed.

The overhanging extension 166 of the C-channel 150 and the lip overhanging portion 198 of the lip C-channel 152 provide clearance and guidance when inserting the lip C-channel 152. The gaps may be slightly closer to each other (referring to the two C-channels 150 and the lip C-channel 152). To ensure a fixed gap between the two lip C-channels 152 and to facilitate ease of installation, the rebar 172 is used to engage the two lip C-channels 152, particularly at the lip base portion 192. The rebar 172 may be selected to be longer so that the lipped C-channel 152 is closer to the C-channel 150 or shorter for further spacing.

The bellows 178 is joined to the inner surface, particularly at the center of the base portion 154 of the C-shaped channel 150. The bellows 178 provides a sleeve and guide for insertion of the pin rod 182. The pin bar 182 provides increased structural strength. The bellows 178 extends partially along the C-shaped channel 150 to allow the lower section end of the pin rod 182 to be covered by grout. The upper section of the pin rod 182 is in the bellows 178. The grout also flows into the bellows 178 which engulfs the pin rod 182. The bellows 178 having an uneven surface provides an additional bond for grout to be applied thereto.

The second assembly 128 provides an alternative to the coupling of the two walls. Two shear bars 135 are embedded in the walls, in particular at the adjoining long faces 102 of each wall. Only a portion of the top end of shear bar 135 is exposed to provide a limiter 134 to attach itself to both shear bars 135. The recess depth 148 of the second component extends partially below the top surface 116 of the wall. The recess depth 148 provides a fixed distance for how far the limiter 134 may travel. The second assembly may provide some sort of locking mechanism to secure the two walls prior to installation of the lip C-channel 152 into the C-channel 150 of the first assembly 126.

The PPVC connector provides a method of manufacture, the method comprising: first, embed a first C-channel 150 into a first wall 112 of a first PPVC module 208; second, embedding the second C-channel 150 into the second wall 114 of the second PPVC module 210; finally, the first C-channel 150 and the second C-channel 150 are coupled by a lip C-channel 152 to prevent separation between the first PPVC module 208 and the second PPVC module 210. The C-shaped channel 150 is pre-cast in the mould together with the concrete.

A method of assembling two

PPVC modules

208, 210, in particular two walls with PPVC connectors. The method includes bringing the first wall 112 of the first PPVC module 208 and the second wall 114 of the second PPVC module 210 into close proximity, which forms the grid gap 110. To secure the two walls, the lipped C-channel 152 is first placed in the second recess 142 and the fourth recess 202. The top panel connector 206 is then placed at the first recess 140, the third recess 144 and the fifth recess 204. A pin rod 182 is inserted into the bellows 178. The non-shrink grout is then poured into the cavity until completely filled.

In this application, unless otherwise indicated, the terms "include," "include," and grammatical variants thereof are intended to mean "open" or "inclusive" language such that they include the recited elements, but also allow inclusion of additional, unrecited elements.

As used herein, the term "about" in the context of concentrations of components of a formulation generally refers to +/-5% of the stated value, more generally refers to +/-4% of the stated value, more generally refers to +/-3% of the stated value, more generally refers to +/-2% of the stated value, even more generally refers to +/-1% of the stated value, and even more generally refers to +/-0.5% of the stated value.

Throughout this disclosure, certain embodiments may be disclosed in a range format. The description of the range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the disclosed ranges. Accordingly, the description of a range should be considered to have specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, description of a range such as 1 to 6 should be considered to have specifically disclosed sub-ranges such as 1 to 3,1 to 4, 1 to 5, 2 to 4, 2 to 6, 3 to 6, etc., as well as individual numbers within that range such as 1,2, 3, 4, 5, and 6. This applies regardless of the width of the range.

It is evident that various other modifications and adaptations of the present application will be apparent to those skilled in the art upon reading the foregoing disclosure without departing from the spirit and scope of the application, and all such modifications and adaptations are within the scope of the appended claims.

Reference numerals

100 plan view of two facing walls with components

102 first adjoining long side

104 wall width

106 wall length

Height of 108 walls

110 grid gap

112 first wall

114 second wall

116 first top surface

117 second top surface

118 first bottom surface

120 first relatively long side

122 first major side surface

124 first minor side

126 first component

127 perspective view of a first component

128 second component

129 third component

130 first anchor

132 second Anchor

134 limiter

135 shear bar

136 first assembly to side distance

138 first to second component distance

140 first recess

142 second recess

144 third recess

146 width of recess

148 recess depth

150C-shaped channel, CC1

152 lipped C channel, CC2

154 base portion

156 right part

158 left part

160 opening part

162 base width

164 lateral depth

166 overhanging extension

168 overhanging extension length

170C channel thickness

172 steel bar

174 length of steel bar

176 diameter of steel bar

178 corrugated pipe

180 pipe diameter

182 pin rod

184 lip C channel length

186 concentric bore

188C channel extension length

190 concentric bore clearance

192 lip base portion

194 right labial part

196 labral left part

198 lipped overhanging portion

200 perspective view of adjoining long faces

202 fourth recess

204 fifth recess

206 Top Panel connector

208 first PPVC module

210 second PPVC module

212 three-dimensional coordinate system

Claims

1. A PPVC connector for coupling a first PPVC module and a second PPVC module, the PPVC connector comprising:

-a first anchor for attaching to the first PPVC module;

-a second anchor for attaching to the second PPVC module;

-a frame coupling the first and second anchors together;

wherein the frame is configured to prevent separation between the first and second anchors.

2. The PPVC connector of claim 1,

at least one of the first anchor, the second anchor, and the frame includes at least one plate.

3. The PPVC connector of claim 2,

the at least one panel is folded laterally to have a plurality of sides to be attached to the first PPVC module.

4. The PPVC connector of any preceding claim,

at least one of the first anchor, the second anchor, and the frame is roughened.

5. The PPVC connector of any preceding claim,

at least one of the first anchor, the second anchor, and the frame is perforated.

6. The PPVC connector of the preceding claim,

the frame includes a first coupler having two wings spaced apart to provide a socket for receiving portions of the first and second anchors.

7. The PPVC connector of claim 6,

the frame also includes a second coupler having two wings spaced apart to receive portions of the first and second anchors.

8. The PPVC connector of claim 7,

the frame further includes a rib that engages the first coupler and the second coupler together.

9. The PPVC connector of the preceding claim,

the frame includes at least one pole for joining the first and second PPVC modules together.

10. A component of a PPVC module, the component of the PPVC module comprising:

-a first PPVC module;

-a second PPVC module; and

-a PPVC connector according to any of the preceding claims;

wherein the first anchor is attached to the first PPVC module and the second anchor is attached to the second PPVC module.

11. A method of using a PPVC connector, the method comprising:

-attaching a first anchor to a first PPVC module;

-attaching a second anchor to a second PPVC module; and

-coupling the first and second anchors by a frame so as to prevent separation between the first and second PPVC modules.

12. The method of claim 11, further comprising:

filling gaps between the first anchor, the second anchor, and the frame with a filler.

13. The method of claim 12, further comprising:

joining the first PPVC module and the second PPVC module together by curing the filler.

14. A method for manufacturing a PPVC connector, the method comprising:

-providing a plate for attachment to a first PPVC module as an anchor;

-corrugating the sheet to improve surface adhesion of the sheet; and

-folding the sheet to create a plurality of sides for attachment to the first PPVC module by the plurality of sides.

15. The method of claim 14, further comprising:

a frame is provided for coupling the plate as an anchor with another anchor.