Connector for precast concrete structures

Abstract

An apparatus, system, and method is provided to connect precast concrete panels to a structural member. The connector can have a receiving member embedded in a precast concrete panel and can further have an attachment member that selectively interconnects to the receiving member. This attachment member can have a surface that is oriented substantially perpendicular to the precast concrete panel and that receives or supports a structural member such as a floor joist or a second precast concrete panel. The configuration of a protrusion of the attachment member allows for a rapid and secure interconnection with an aperture in the receiving member. A builder can use the connector system described herein to rapidly and securely assemble multiple precast concrete panels to structural members in the construction of, for example, a parking garage or other similar structure.

Claims

1. A precast concrete panel with integral connector mechanism, comprising: said precast concrete panel with an outer surface, an inner surface, and sidewalls extending around a perimeter edge; a receiving member having a body extending in a first plane that is configured to be substantially parallel with at least one of said outer surface and said inner surface of said precast concrete panel, said receiving member having at least one aperture, wherein each of said at least one aperture has a longitudinal dimension, and at least one anchor extends into said precast concrete panel from an interior surface of said body; a partially enclosed volume positioned adjacent to each of said at least one aperture; and an attachment member having at least one protrusion and having a horizontal member extending between lower ends of two side plates, wherein each of the at least one protrusion has an arcuate transition surface extending between a top surface and a bearing surface; wherein, in an assembled state, an arcuate surface of the partially enclosed volume is configured to receive each arcuate transition surface to allow said at least one protrusion to extend through said at least one aperture and rotate into said partially enclosed volume, and said horizontal member is oriented in a second plane that is substantially perpendicular to said first plane, wherein said side plates and said horizontal member are made from a single continuous material.

2. The precast concrete panel of claim 1, wherein each of the at least one protrusion further comprises: a retention surface oriented substantially perpendicular to said second plane and positioned adjacent said top surface; wherein said bearing surface is oriented substantially parallel to said second plane, and a distance between said top surface and said bearing surface is greater than said longitudinal dimension of each of said at least one aperture; and wherein, in said assembled state, said retention surface contacts said interior surface of said body, and said bearing surface contacts an inner surface of said at least one aperture.

3. The precast concrete panel of claim 1, further comprising: a second protrusion of said attachment member and a second aperture of said receiving member, wherein a bearing surface of said second protrusion is configured to contact an inner surface of said second aperture in said assembled state.

4. The precast concrete panel of claim 1, wherein said two side plates are substantially perpendicular to said horizontal member, and said horizontal member defines a bottom surface of said attachment member.

5. The precast concrete panel of claim 1, wherein said at least one aperture is two apertures, and said longitudinal dimension of each aperture is oriented in a vertical direction of said receiving member.

6. A precast concrete structure with a connector system, comprising: a precast concrete panel with a front surface, a rear surface, and sidewalls extending around a perimeter edge; a receiving member having a pair of vertical apertures and an additional aperture positioned below said pair of vertical apertures, and said receiving member having at least one anchor extending from a back surface of said receiving member into said precast concrete panel to secure said receiving member in said precast concrete structure; an attachment member having a pair of opposing side plates and having a horizontal member extending between lower ends of said pair of opposing side plates, each side plate having a protrusion that has a retention surface oriented substantially perpendicular to a bearing surface of said protrusion and a top surface that is adjacent to said retention surface, wherein a distance between said top surface and said bearing surface of each protrusion of each side plate is greater than a vertical dimension of each vertical aperture, said horizontal member also having an additional protrusion positioned below said protrusions of said opposing side plates in a vertical direction, wherein said additional protrusion has a bearing surface; wherein said attachment member is configured to engage said receiving member such that said protrusions of said opposing side plates extend through said vertical apertures, and said retention surface of each protrusion of each side plate contacts said back surface of said receiving member, and said bearing surface of each protrusion of each side plate resides within one of said vertical apertures, and said bearing surface of said additional protrusion resides within said additional aperture of said receiving member.

7. The precast concrete structure of claim 6, wherein said opposing side plates are arranged substantially parallel to each other and oriented in a substantially vertical direction.

8. The precast concrete structure of claim 6, wherein a distance between a lower end of said retention surface and said bearing surface of each protrusion of each side plate is substantially equal to said vertical dimension of each aperture.

9. The precast concrete structure of claim 6, wherein said additional protrusion extends horizontally between said pair of opposing side plates.

10. The precast concrete structure of claim 6, wherein said pair of opposing side plates and said horizontal member are made from a single material structure that is shaped to form said pair of opposing side plates and said horizontal member.

11. The precast concrete structure of claim 6, wherein a vertical dimension of said additional protrusion is substantially equal to a vertical dimension of said additional aperture.

12. A precast concrete panel connector system, comprising: a receiving member having a body with a pair of vertical apertures and a horizontal aperture, wherein said receiving member has at least one anchor extending from a back surface of said body to secure said receiving member to said precast concrete panel; an attachment member having: a pair of side plates arranged substantially parallel to each other and oriented in a substantially vertical direction; a horizontal member extending between lower ends of said pair of side plates, wherein said pair of side plates and said horizontal member define a volume configured to receive a structure; and a protrusion extending from each of said side plates, wherein each protrusion comprises a retention surface, a top surface adjacent to said retention surface, a bearing surface oriented substantially perpendicular to said retention surface, and a transition surface extending from said top surface to said bearing surface, wherein a distance between said top surface and said bearing surface of each protrusion is greater than a vertical dimension of each vertical aperture; an additional protrusion extending from said horizontal member in a horizontal direction; wherein said attachment member engages said receiving member where said protrusions of said side plates extend through said vertical apertures such that said retention surface of each protrusion contacts said back surface of said receiving member, said bearing surface of each protrusion rests on said body of said receiving member within one of said vertical apertures, and said additional protrusion extends into said horizontal aperture.

13. The precast concrete panel connector system of claim 12, further comprising: a backplate extending between said pair of side plates of said attachment member.

14. The precast concrete panel connector system of claim 12, wherein, when said attachment member engages said receiving member, said horizontal member of said attachment member is substantially perpendicular to said body of said receiving member.

15. The precast concrete panel connector system of claim 12, wherein said transition surface comprises at least one flat edge and at least one curved edge.

16. The precast concrete panel connector system of claim 12, wherein a distance between a lower end of said retention surface and said bearing surface of each protrusion is substantially equal to a vertical dimension of each aperture.

17. The precast concrete panel connector system of claim 12, wherein said pair of side plates and said horizontal member are made from a single continuous material that is shaped to form said pair of said plates and said horizontal member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the Summary of the Invention given above and the Detailed Description of the drawings given below, serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. Additionally, it should be understood that the drawings are not necessarily to scale.

(2) FIG. 1 is a front perspective view of a connector system with an attachment member and a receiving member in accordance with one embodiment of the present invention;

(3) FIG. 2 is a partial cross-sectional, side elevation view of a connector system with an attachment member in a first position in accordance with the embodiment of FIG. 1;

(4) FIG. 3 is a partial cross-sectional, side elevation view of a connector system with an attachment member in a second position and a floor joist on a horizontal member of the attachment member in accordance with the embodiment of FIG. 1;

(5) FIG. 4 is a front perspective view of another connector system with an attachment member and a receiving member in accordance with one embodiment of the present invention;

(6) FIG. 5 is a rear perspective view of the connector system in accordance with the embodiment in FIG. 4;

(7) FIG. 6A is a partial cross-sectional, side elevation view of a connector system with an attachment member in a first position in accordance with the embodiment of FIG. 4;

(8) FIG. 6B is a partial cross-sectional, side elevation view of a connector system with an attachment member in a second position in accordance with the embodiment of FIG. 4;

(9) FIG. 7 is a front perspective view of a connector system in an assembled state in accordance with the embodiment in FIG. 4;

(10) FIG. 8 is a perspective view of a connector system in an assembled state with the receiving member embedded in a precast concrete panel in accordance with one embodiment of the present invention; and

(11) FIG. 9 is a perspective view of the connector system with a T-beam positioned on a horizontal member in accordance with the embodiment in FIG. 8.

(12) Similar components and/or features may have the same reference label. Further, various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components. If only the first reference label is used, the description is applicable to any one of the similar components having the same first reference label irrespective of the second reference label.

(13) A list of the various components shown in the drawings and associated numbering is provided herein:

(14) TABLE-US-00001 Number Component 10 Connector System 12 Receiving Member 14 Attachment Member 16 Body 18 Anchor 20 First Aperture 22 Second Aperture 24 Horizontal Member 26 Vertical Member 28 First Protrusion 30 Retention Surface 32 Top Surface 34 Arcuate Surface 36 Bearing Surface 38 Second Protrusion 40 Precast Concrete Panel 42 Volume 44 Arcuate Surface 46 Second Structural Member 48 Transition Surface 50 Side Plate

DETAILED DESCRIPTION

(15) The present invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, may be modified in numerous ways within the scope and spirit of the invention.

(16) Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.

(17) Various embodiments of the present invention are described herein and as depicted in the drawings. It is expressly understood that although the figures depict connectors, members, protrusions, apertures, and methods and systems for using the same, the present invention is not limited to these embodiments.

(18) Now referring to FIG. 1, a perspective view of the connector system 10 is provided. Generally, the system 10 comprises an attachment member 14 that selectively interconnects to the receiving member 12. The receiving member 12 can be embedded in a precast concrete panel such that a body 16 of the receiving member 12 is substantially parallel to a side wall or surface of the precast concrete panel. At least one anchor 18 extends from the body 16 of the receiving member 12 and into the precast concrete panel to secure and embed the receiving member 12 in the precast panel. The at least one anchor 18 can extend into the panel in a first direction that is substantially perpendicular to the body 16. FIG. 1 depicts an anchor 18 extending from each corner of a rectangular-shaped body 16, however, it will be appreciated that the present invention may include any number of anchors 18 extending in other directions from the body 16.

(19) The receiving member 12 also has a series of apertures 20, 22 to aid in the selective interconnection with the attachment member 14. Specifically in FIG. 1, the receiving member 12 has two first apertures 20 and two second apertures 22. The first apertures 20 are elongated and each aperture has a longitudinal dimension that is oriented in a vertical direction. The second apertures 22 are substantially square or rectangular in shape and positioned below the first apertures 20. As discussed in greater detail below with respect to FIGS. 2-3, the first apertures 20 can have adjacent cavities that are formed using a void former that extends into the precast concrete panel to establish a partially enclosed volume. In the depicted embodiment, the first and second apertures 20, 22 are aligned with each other in the horizontal dimension of the body 16. However, it will be appreciated the apertures 20, 22 may be offset, and/or there may be greater or fewer than two first apertures 20 and two second apertures 22.

(20) The attachment member 14 has several features that allow the attachment member 14 to rapidly and securely interconnect to the receiving member 12 and bear a second precast concrete panel, floor joist, or I-beam. The attachment member 14 in FIG. 1 has a horizontal member 24 on which a second precast concrete panel can rest, and two vertical members 26 extend downward from the horizontal member 24 in a substantially parallel manner. The vertical members 26 taper from a proximal end to a distal end of the attachment member 14. The proximal end of the attachment member 14 also has first protrusions 28 and second protrusions 38. The first protrusions 28 extend into the first apertures 20 of the receiving member 12 and the second protrusions 38 extend into the second apertures 22 to selectively interconnect the attachment member 14 to the receiving member 12. It will be appreciated that, like the variety of apertures, the protrusions may have a corresponding variety in position, numbers, shape, etc.

(21) The first protrusion 28 has a series of surfaces to aid in the selective interconnection with the corresponding first aperture 20. A retention surface 30 extends downward from a top surface 32 of the protrusion 28. An arcuate surface 34 also extends downward from the top surface 32, and the arcuate surface 34 terminates at a bearing surface 36, which in this embodiment is substantially perpendicular to the retention surface 30. The retention surface 30 and the bearing surface 36 bear the forces generated by a second precast concrete panel, or other object, resting on the attachment member 14. The arcuate surface 34 provides a guiding and rotation function as the attachment member 14 selectively interconnects to the receiving member 12. How these surfaces 30, 32, 34, 36 work together to achieve these functions is described in greater detail below with respect to FIGS. 2 and 3.

(22) The attachment member 14 optionally comprises second protrusions 38 that extend into the second aperture 22 of the receiving member 12 as the attachment member 14 is rotated into the receiving member 12. The second protrusions 38 also have a bearing surface 36 that can bear at least some of the forces generated by a second precast concrete panel or other object resting on the attachment member 14. Although the second protrusions 38 are shown as having a square shape, it will be appreciated that the second protrusions 38 may be cylindrically or rod shaped, or may not exist in some embodiments of the present invention.

(23) Now referring to FIGS. 2 and 3, partial cross-sectional views of the connector system 10 are provided. The attachment member 14 is in a first position in FIG. 2 and engages the receiving member 12 at an acute angle. Then, the attachment member 14 is in a second position in FIG. 3 where the attachment member 14 has rotated into a selective interconnection with the receiving member 12. The first protrusion 28 extends into a volume 42 defined by a void former, and together the volume 42 and the adjacent first aperture define a partially enclosed volume. In addition, the volume 42 can also refer to the partially enclosed volume.

(24) For the retention surface 30 of the attachment member 14 to bear a force, at least a portion of the retention surface 30 extends above the first aperture 20 and contacts a back surface of the body 16 as shown in FIG. 3. As a result, the distance between the top surface 32 of the first protrusion 28, alternatively the distal end or edge of the retention surface 30, and the bearing surface 36 is larger than the longitudinal distance of the first aperture 20. Therefore, the first protrusion 28 of the attachment member 14 cannot translate laterally into the first aperture 20 of the receiving member 12, but instead may rotate into place.

(25) The arcuate surface 34 facilitates the selective interconnection between members 12, 14 by allowing the first protrusion 28 to enter the first aperture at an acute angle in a first position, and then rotate to a second position. The acute angle is formed between the planar body 16 of the receiving member 12 and the direction that the protrusions 28, 38 extend from the attachment member 14. Alternatively, the acute angle is formed between the planar body 16 of the receiving member 12 and a planar surface of the horizontal member 24 of the attachment member 14. In some embodiments, the acute angle ranges between approximate 5 and 45 degrees. In various embodiments, the acute angle is approximately 20 degrees. These acute angles reduce to substantially zero degrees as the planar body 16 of the receiving member 12 and either the direction of the protrusions 28, 38 or the planar surface of the horizontal member 24 establish a substantially perpendicular orientation relative to each other in the second position.

(26) The acute angle allows the larger distance between the top surface 32 and the bearing surface 36 of the first protrusion 28 to pass into the first aperture 20 and adjacent volume 42. As the first protrusion 28 moves into the first aperture 20 and volume 42, the arcuate surface 34 of the first protrusion 28 contacts an arcuate surface 44 of the volume 42. The contact between arcuate surfaces 34, 44 allows the attachment member 14 to rotate relative to the receiving member 12. The arcuate surface 34 is depicted as having a constant radius of curvature with the attachment member 14 rotating about a center of curvature of the arcuate surfaces, but it will be appreciated that other embodiments may have an arcuate surface 34 that has a variable curvature, a surface defined by n-order polynomials, a surface defined by disjointed shapes, a surface that facilitates both rotation and translational movement such that the attachment member 14 does not rotate about a single point, etc.

(27) Once the attachment member 14 rotates into a second position relative to the receiving member 12, the bearing surface 36 of the first protrusion 28 rests on an inner surface of the first aperture 20, and the first protrusion at least partially extends into the volume 42 defined by the void former adjacent the first aperture 20. Also, once the attachment member 14 rotates into place, the retention surface 30 extends above the first aperture 20 and contacts the back surface of the body 16 to transmit at least some of the force generated by a floor joist 46 or other object that rests on the horizontal member 24 of the attachment member 14 to the precast concrete panel 40.

(28) It will be further appreciated that the components discussed herein may comprise a depression and detent combination to promote the selective interconnection between the attachment member and the receiving member. For example, after the attachment member is in a second position, a shaking or jostling could shake the attachment member out of the second position. A detent positioned on the side of the protrusion and a depression positioned on the inner surface of the aperture or associated volume could allow a more secure selective, or even permanent, interconnection between the attachment member and the receiving member.

(29) Now referring to FIGS. 4 and 5, front and rear perspective views of another connector system 10 are provided, respectively. The receiving member 12 for this embodiment also has two first apertures 20 that have a longitudinal dimension oriented in a vertical direction. The receiving member 12 also has a single second aperture 22 that is oriented in a horizontal direction. The first protrusion 28 of the attachment member 14 has a retention surface 30 configured to contact a back surface of the receiving member 12, and the first protrusion 28 has a bearing surface 36 that is substantially perpendicular to the retention surface 30 and is configured to transfer at least a portion of the load on the attachment member 14 to the receiving member 12 and the precast concrete panel. A top surface or edge 32 is positioned adjacent the retention surface 30, and a distance between the top surface 32 and the bearing surface 36 is larger than the longitudinal dimension of the first apertures 20. A transition surface 48 extends between the top surface 32 and the bearing surface 36, and the transition surface 48 has a non-arcuate shape can promote the rotation of the first protrusion 28 from a first position to a second position as described elsewhere herein.

(30) A horizontal member 24 is positioned on a lower end of the attachment member 14, and the horizontal member 24 receives a second structural member such as, for example, a beam or joist to connect the second structural member to the precast concrete panel in which the receiving member 12 is embedded. The lower position of the horizontal member 24 allows for the bottom surface of the second structural member to be closer to the bottom surface of the precast concrete panel, which can minimize the exposure of the connector system 10 below the second structural member and precast concrete panel and provide better positioning of the second structural member relative to an opening in, for instance, a parking garage.

(31) Side plates 40 can extend from the horizontal member 24 and transition into the first protrusion 28. The side plates 40 partially define the volume that receives a second structural member, and the side plates 40 provide lateral stability for the second structural member such that the second structural member does not slide off of the horizontal member 40. This additional functionality can improve the integrity of the structure in which the connector system 10 is used, and can help maintain a connection between a precast concrete panel and a second structural member during a catastrophic event such as an earthquake. As depicted, the horizontal member 40, the side plates 50, and the first protrusions 28 are made from the same continuous material, but it will be appreciated that other configurations of these components are encompassed by the present invention.

(32) Now referring to FIGS. 6A and 6B, cross-sectional side elevation views of the connector system 10 are provided where the attachment member 14 is in a first position and a second position, respectively. As described elsewhere herein, the attachment member 14 in the first position forms an acute angle with the receiving member 12 such that a first protrusion 28 can extend through a first aperture in the receiving member 12. Once the first protrusion 28 is in place, the attachment member 14 can be rotated into the second position where a second protrusion 38 extends into a second aperture. In the second position, the attachment member 14 is ready to receive a second structural member, and the connector system 10 transfers the load of the second structural member to the precast concrete panel in which the receiving member 12 is embedded.

(33) Now referring to FIG. 7, a perspective view of an assembled connector system 10 is provided. In this embodiment, the protrusions of the attachment member 14 are positioned in the apertures of the receiving member 12. The horizontal member 24 of the attachment member 14 is configured to receive a second structural member, and the connector system 10 transfers the load of the second structural member into the precast concrete panel in which the receiving member 12 is embedded.

(34) Now referring to FIGS. 8 and 9, perspective views of a connector system 10 embedded in a precast concrete panel 40 with and without another structural member 46 are provided, respectively. In FIG. 8, the receiving member 12 is embedded into a precast concrete panel 40, the attachment member 14 is selectively interconnected to the receiving member 12. In FIG. 9, another structural member 46 is positioned on the attachment member 14, and the connector system 10 transfers the load of the second structural member 46 to the precast concrete panel 40. The construction of the connector system 10, in particular the low positioning of the horizontal member of the attachment member 14, allows the second structural member 46 to rest in a lower and more stable position.

(35) It will also be appreciated that a shim or plurality of shims can be positioned between the attachment member and the receiving member to modify the relative orientation of the two members. For instance, in some embodiments, the receiving member may be embedded in a precast concrete panel that is not oriented vertically with respect to a ground surface. Therefore, at least one shim can be positioned between the members such that a planar surface of the attachment member is oriented substantially parallel to the ground surface.

(36) The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described and shown in the figures were chosen and described in order to best explain the principles of the invention, the practical application, and to enable those of ordinary skill in the art to understand the invention.

(37) While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims.