Assembly Module for Composite Wall and Method of Assembly

Abstract

Systems and methods for constructing composite wall structures are described in which opposing faceplates are provided that define a transverse void. A plurality of through connector assemblies, which span the transverse void between the faceplates, are attached with the opposing faceplate. A connecting mechanism is applied to the through connector assemblies from an outside of at least one of the faceplates and attaches with portions of the through connector assemblies in the transverse void. The transverse void may be filled with a fill material after attaching the opposing faceplates with the plurality of through connector assemblies.

1 . An assembly module for a composite wall, the assembly module comprising:
 opposing faceplates with a transverse void between said faceplates;   a plurality of through connector assemblies at least partially spanning the transverse void and connected with at least one of the opposing faceplates, said through connector assemblies including a securing mechanism that is configured to attach a portion of the connector assembly in the transverse void with the at least one faceplate from an outside of the at least one faceplate.   
     
     
         2 . The assembly module of  claim 1 , further comprising at least one intermediate plate positioned between said opposing faceplates and connected with at least one of said through connector assemblies. 
     
     
         3 . The assembly module of  claim 1 , wherein said securing mechanism is mechanical. 
     
     
         4 . The assembly module of  claim 1 , wherein:
 a threaded portion of the connector assembly protrudes through holes in each of the opposing faceplates; and   said securing mechanism includes a nut configured to be attached to the threaded portion of the connector assembly.   
     
     
         5 . The assembly module of  claim 4 , said securing mechanism further comprising a second nut configured to be attached to the threaded portion of the through connector. 
     
     
         6 . The assembly module of  claim 1 , wherein:
 a male threaded portion of at least one of the connector assemblies is engaged with a female threaded portion of a hole in at least one of the faceplates.   
     
     
         7 . The assembly module of  claim 1 , wherein at least one of the through connector assemblies comprises a sleeve between the opposing face plates. 
     
     
         8 . The assembly module of  claim 7 , wherein said sleeve defines a distance between the opposing faceplates. 
     
     
         9 . The assembly module of  claim 7 , wherein said sleeve defines a distance between one of the faceplates and an intermediate plate. 
     
     
         10 . The assembly module of  claim 1 , wherein:
 at least one of the through connector assemblies penetrates at least one of the faceplates; and   the at least one through connector assembly includes a stopping mechanism at an end of the through connector assembly that positions the connector assembly with respect the at least one faceplate.   
     
     
         11 . The assembly module of  claim 10 , wherein said stopping mechanism includes a nut attached to a threaded portion of the through connector assembly. 
     
     
         12 . The assembly module of  claim 1 , wherein:
 at least one of the through connector assemblies includes a sleeve with a female threaded portion;   at least one of the opposing faceplates includes a hole substantially where the at least one through connector assembly connects with the at least one faceplate; and   the securing mechanism includes a bolt configured to be inserted through the hole in the at least one faceplate and engaged with the female threaded portion of the sleeve.   
     
     
         13 . The assembly module of  claim 1 , wherein the through connector assemblies include at least partially threaded rods that traverse the transverse void. 
     
     
         14 . The assembly module of  claim 1 , wherein the through connector assemblies include at least partially threaded sleeves that traverse the transverse void. 
     
     
         15 . The assembly module of  claim 1 , wherein the securing mechanism is adjustable from an outside of the assembly module after the securing mechanism is secured. 
     
     
         16 . The assembly module of  claim 1 , wherein the faceplates comprise sheets of material including through holes, and said securing mechanism is configured to attach with said through connectors through said through holes. 
     
     
         17 . The assembly module of  claim 1 , wherein said through connectors are mechanically attached with the faceplates substantially without welding of said through connectors to the faceplates. 
     
     
         18 . The assembly module of  claim 1 , wherein the transverse void has a width greater than 29 inches. 
     
     
         19 . The assembly module of  claim 1 , further comprising a concrete fill material that substantially fills the transverse void,
 wherein, said faceplates consist essentially of steel plate material.   
     
     
         20 . An assembly module for composite wall comprising:
 opposing faceplates with a transverse void between said faceplates;   means for connecting said faceplates across the transverse void; and   means for adjusting a tension of said means for connecting after the transverse void is filled with a fill material.   
     
     
         21 . The assembly of  claim 20 , further comprising:
 means for adjusting a tension of said means for connecting before the transverse void is filled with the fill material.   
     
     
         22 . The assembly of  claim 20 , further comprising:
 means for transmitting an attachment load from an exterior portion of one faceplate to an exterior portion of an opposite faceplate.   
     
     
         23 . The assembly of  claim 20 , further comprising:
 means for reducing a stress concentration of an attachment load from an exterior portion of one faceplate.   
     
     
         24 . A method of constructing a composite wall comprising:
 providing opposing faceplates;   attaching the opposing faceplates with a plurality of through connector assemblies that span a transverse void between the faceplates including applying a connecting mechanism from an outside of at least one of the faceplates to attach with portions of the through connector assemblies in the transverse void; and   filling the transverse void with a fill material after attaching the opposing faceplates with the plurality of through connector assemblies.   
     
     
         25 . The method of  claim 24 , wherein the connecting mechanisms is adjustably connected with the through connectors. 
     
     
         26 . The method of  claim 24 , further comprising:
 after filling at least a portion of the transverse void with the fill material, adjusting the connecting mechanism such that a tension of at least one of the through connectors is changed.   
     
     
         27 . The method of  claim 24 , further comprising:
 before filling the transverse void with the fill material, adjusting the connecting mechanism such that a tension of at least one of the through connectors is set to a desired tension.   
     
     
         28 . The method of  claim 24 , further comprising:
 attaching an external connector with at least one of the through connectors via the connecting mechanism.   
     
     
         29 . The method of  claim 24 , wherein attaching the opposing faceplates with a plurality of through connector assemblies includes:
 placing a plurality of sleeves between the opposing faceplates;   for each of the plurality of sleeves, inserting a rod through a hole in one of the opposing faceplates, through the respective sleeve, and out of a hole in the other of the opposing faceplates; and   securing the rods from an outside of at least one of the opposing faceplates.   
     
     
         30 . The method of  claim 24 , wherein attaching the opposing faceplates with a plurality of through connector assemblies includes engaging a male threaded portion of at least one of the connector assemblies with a female threaded portion of a hole in at least one of the faceplates. 
     
     
         31 . A method of constructing a composite wall in a building comprising:
 providing a pre-assembled wall assembly module including at least two opposing faceplates, and a plurality of through connector assemblies attached with said faceplates;   placing the pre-assembled wall assembly module in a position that the wall assembly module will occupy in the building;   after the pre-assembled wall assembly module occupies the position, filling a transverse void between said faceplates with a fill material;   adjusting a tension of at least one of said through connector assemblies after the transverse void is filled with the fill material at least to a height of the at least one through connector assembly.   
     
     
         32 . The method of  claim 31 , wherein said adjusting the tension of the at least one through connector assembly includes adjusting a threaded portion of a connecting device engaged with a sleeve of the at least one through connector assembly. 
     
     
         33 . The method of  claim 31 , further comprising:
 attaching an external connector with at least one of the through connectors via a connecting mechanism on one side of the composite wall; and   attaching the external connector with at least one load distributing device on an opposite exterior side of the composite wall via the at least one through connector.