BACKGROUND

1. Technical Field

This disclosure relates generally to construction and in particular to a system and method for forming and securing a wall panel.

2. Description of Related Art

In the field of construction, there is a need to be able to build and install components (for example a wall panel) faster. Many times these components are built on site and fastened to the foundation and then braced while other components are build and assembled. This process of building is sometime sped up by pre-building or partially building components off site and then assembling them and fastening them to the foundation in a modular fashion. The fastening and assembly of these pre-built components can still be time consuming and disruptive.

SUMMARY OF THE DISCLOSURE

According to a first embodiment, there is disclosed a system for securing a wall panel in a vertical configuration to a base comprising a top opening formed in a body secured to a top portion of the wall panel, a bottom coupler secured to the base, a top coupler and a substantially non-elastic tension member extending between the bottom coupler and the top coupler, through the top opening, wherein the top and bottom couplers are adapted to apply a tension to the tension member so as to clamp the wall panel therebetweeen.

The tension member may include a threaded top end adapted to threadably engage on the top coupler. The tension member may include a threaded bottom end adapted to threadably engage on the bottom coupler. The tension member may be substantially flexible. The tension member may be selected from the group consisting of cable, rope or wire. The tension member may be substantially non-elastic. The top connector may include a threaded passage extending vertically thereinto adapted to receive a threaded end of the tension member. The top connector may include at least one tool engagement surface adapted to be gripped and turned by a tool so as to tighten the top connector on the tension member. The at least one tool engagement surface may include horizontal sides adapted to be engaged by a wrench. The bottom connector may include a threaded passage extending vertically thereinto adapted to receive a threaded end of the tension member.

The system may further comprise a base member adapted to be secured to the base under an intended location of the wall member. The bottom coupler may be adapted to be secured to the base member. The base member may be adapted to be embedded within the base. The base member may include protrusions adapted to secure the base member within a poured concrete base.

The system may further comprise an elongate support sized to extend between top and bottom edges of the wall panel. The elongate support comprises a tubular member having a passage therethrough adapted to receive the tension member. The body including the top opening may be formed in the wall panel. The body including the top opening may be secured to the wall panel.

According to a further embodiment, there is disclosed a method for securing a wall pane in a vertical configuration to a base comprising providing a top opening formed in a body secured to a top portion of the wall panel, securing a bottom coupler secured to the base, passing a substantially non-elastic tension member through the top opening to the bottom coupler and securing a top coupler to the tension member so as to apply a tension to the tension member so as to clamp the wall panel therebetweeen.

According to a further embodiment, there is disclosed a kit for forming a wall on a base comprising a wall panel having a passage extending between top and bottom edges thereof and defining a top opening, a bottom coupler secured to the base, a top coupler and a tension member extending between the bottom coupler and the top coupler, through the top opening wherein the top and bottom couplers are adapted to apply a tension to the tension member so as to clamp the wall panel therebetweeen.

Other aspects and features of the present disclosure will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings constitute part of the disclosure. Each drawing illustrates exemplary aspects wherein similar characters of reference denote corresponding parts in each view,

Figure 1 is a perspective view of a wall forming system according to a first embodiment of the present disclosure.

Figure 2 is an exploded view of the system of Figure 1 with the tube.

Figure 3 is an exploded view of the system of Figure 1 without the tube

Figure 4 is a detailed perspective view of the top connector of the system of Figure 1 .

Figure 5 is a cross sectional view of the top connector of Figure 4.

Figure 6 is a perspective view of the bottom connector secured within the base railing of the system of Figure 1.

Figure 7 is a cross sectional view of the bottom connector secured within a foundation of the system of Figure 1 according to a further embodiment of the present disclosure.

Figure 8 is a perspective view of a further embodiment of the present disclosure including more than one floor.

DETAILED DESCRIPTION

Aspects of the present disclosure are now described with reference to exemplary apparatuses, methods and systems. Referring to Figure 1 , an exemplary system for forming a wall according to a first embodiment is shown generally at 10. The system 10 comprises a top connector 12 applied to the top edge of a wall panel 8 and a bottom connector 30 secured to a floor or base 6 below the wall panel 8 with a tension member 70 extending therebetweeen. The top and bottom connector 12 and 30 apply a tensile force to the tension member 70 so as to clamp the wall panel 8 therebetweeen.

Turning now to Figures 4 and 5, the top connector 12 comprises a body extending between top and bottom ends, 14 and 16, respectively, having an outer surface 18 and a threaded bore 28 extending thereinto. Optionally other tightening means, including cable tensioners, turnbuckles, ratchets and cams may also be utilized to apply a tensile load to the tensile member 70 between the top and bottom connectors 12 and 30. The outer surface 18 may include one or more tool engaging surfaces 20 around a periphery thereof at a tool portion 22 adapted to be engaged and gripped by a tool (not shown) and a tapered portion 24 located between the tool portion and the tool portion 22. By way of non-limiting example, as illustrated in Figure 4, the tool engaging surfaces may include a plurality, such as, by way of non-limiting example, 6 surfaces 20 arranged around the periphery so as to be gripped by a hex wrench as are commonly known or 2 surfaces as illustrated. The tapered portion 24 may have a diameter selected to correspond to an opening in the top edge of the wall panel or a tube as will be further described below and may taper in a direction towards the bottom end 16 by a taper angle 26. The taper angle may be selected to be between 1 and 30 degrees. The threaded bore 28 may be a blind bore extending into only the bottom end 16 or may optionally extend through the body from bottom end to top end 16 to 14.

The bottom connector 30 comprises a body extending between top and bottom ends, 32 and 34, respectively, having an outer surface 36 and a threaded bore 48 extending thereinto. The outer surface 36 may optionally include one or more tool engaging surfaces 38 around a periphery thereof at a tool portion 40 adapted to be engaged and gripped by a tool (not shown) similar to the top connector 12 and a tapered portion 42 located between the tool portion and the tool portion 40. The tapered portion 42 may have a diameter selected to correspond to an opening in the bottom edge of the wall panel or a tube as will be further described below and may taper in a direction towards the top end 32 by a taper angle 46. The taper angle may be selected to be between 1 and 30 degrees. The threaded bore 48 may be a blind bore extending into only the top end 32 or may optionally extend through the body from top end to the bottom end 34. The bottom end 34 of the bottom connector 30 may include a threaded portion 50 extending proximate to the bottom end 34. The bottom connector 30 may include a threaded ring 52 having interior threading corresponding to the threaded portion 50 so as to be threadably located thereon. In operation, the threaded portion 42 may be passed through an opening 62 in a base railing or member 60 (as illustrated in Figure 3 and 6), such as, by way of non-limiting example, a square or rectangular hollow tube and the threaded ring 52 threaded thereon so as to clamp a portion of base member 60 therebetweeen thereby forming an attachment to the base member. Optionally, other attachments may also be utilized for securing the bottom connector 30 to the base member, including without limitation, welding, adhesives or bolting. As illustrated in Figure 7, the bottom connector 30 may also be adapted to be cast in place within a floor of the building by the addition of extended rods 54 or other extensions. It will be appreciated that in such embodiments, the bottom member 60 may be omitted or not utilized to secure the bottom connector.

The tension member 70 comprises an elongate non-elastic member having a length corresponding to the height of the wall panel so as to extend between the top and bottom connectors 12 and 30 applied thereto. The tension member 70 may be flexible, such as, by way of non-limiting example, cable, rope, wire or the like and may be formed of any suitable material including metals or the like. The tension member 70 extends between top and bottom ends, 72 and 74, respectively and includes a top end body 76 proximate to the top end 72 and a bottom end body 78 proximate to the bottom end 74. Each of the top and bottom end bodies 76 and 78 may include threading around a periphery thereof sized and selected to correspond to the threading within the threaded bores 28 and 48 of the top and bottom connectors 12 and 30. Optionally one or both of the top and bottom end bodies 76 and 78 may include a tool gripping portion 80 adjacent thereto permitting a tool to engage upon and rotate the tension member so as to tighten the end body into the top or bottom connector.

As illustrated in Figure 1 , the wall panel 8 may include an opening 9 through a top edge thereof corresponding to the tapered portion 24 of the top connector 12. The wall panel 8 may also optionally include a similar opening through the bottom edge. Optionally, the system 10 may include a tube 80 sized to be located within and secured to the wall panel as illustrated in Figure 2. The tube 80 extends between top and bottom ends, 82 and 84 respectively and has a bore corresponding to the tapered portions 24 and 42 of the top and bottom connectors 12 and 30. The tube 80 may be secured to the wall pane 8 by any known means including, without limitation welding, bolting adhesives or the like. All components of the present system may be formed of any suitable material, including without limitation steel or other metals depending on the strength requirements of the wall and design loads.

In operation, a user may secured the base railing 60 to a floor 6 at a desired location for a wall by any known means, including fasteners, casting the railing within the base, adhesives or welding. Thereafter one or more bottom connectors 30 may be secured to the railing. It will be appreciated that where the bottom connector 30 is secured to the railing by passing a threaded portion 50 through an opening 62 in the base 60 that such connection may be completed before securing the base to the floor 6. An optional tube 80 may be located within the wall 8 at a desired location, such as, by way of nonlimiting example along an edge thereof as illustrated. The tube or optionally, an opening in the bottom of the wall panel may then be located over the tapered portion 42 of the bottom coupler 30 and a tension member 70 inserted through the tube 80 or wall opening and secured within the threaded bore 48. Once the wall panel 8 is in the desired location, a top connector 12 may be located on the top end 72 of the tension member such that the top end 72 is located within the threaded bore 28. The top connector 12 may then be tightened on the tension member 70 so as to apply a clamping force to the wall panel thereby creating a connection from the top of the component through the assembly and into the rail and foundation. In particular, with this system, the rails can be laid out on the foundation and installed. Then the components, like a wall panel can be brought in (with the tubes installed) and the whole component drops into place over the bottom couplers and fastened in place from the top. The lower components would get installed in likewise fashion.

Turning now to Figure 8, according to an alternative embodiment, the system may be utilized to form more than one floor by providing a top rail (not shown) into which a top connector and a bottom connector are secured or by coupling a second tension member 70 to the top end of the top coupler 12 above the top edge of the wall through with the top connector 12 is passed. As illustrated in Figure 8, the tubes 80 are abutted against the top and bottom ends of the top coupler 12. Thereafter, additional bottom connectors may also be secured to this top rail thereby forming a bottom connection for a second floor of wall panels with the second floor or roof installed after a previous floor. These components can be installed in modules that use the top couplers to stack another similar section of couple, tube, fastener and top coupler. If this is a floor section then more modular components can be stacked in a similar fashion.

It will be appreciated that a system according to the present disclosure may speed up the installation of pre-built components by offering a modular system for mounting and locating the components to the foundation and each other. Fastening and installing modular components this way would allow the components to be built off-site in a controlled environment that would speed up production. Then installing the module components with this system would decrease the time to set the construction project up, minimizing on site time an disruptions to the surrounding area. While specific embodiments have been described and illustrated, such embodiments should be considered illustrative only and not as limiting the disclosure as construed in accordance with the accompanying claims.