US20160069101A1

US20160069101A1 - Wall and pillar system for building modular structures

Info

Publication number: US20160069101A1
Application number: US14/849,252
Authority: US
Inventors: Jurgen Willi Pooch
Original assignee: Individual
Current assignee: Individual
Priority date: 2014-09-09
Filing date: 2015-09-09
Publication date: 2016-03-10

Abstract

An example system for building a modular wall structure includes at least one wall unit and at least one pillar. Each wall unit has top and bottom surfaces, opposed first and second side surfaces, first and second ends, and a projection disposed on each end extending outwardly from the first and second side surfaces. Each pillar has a top and bottom surface configured to be vertically stackable, and at least one vertical groove comprising, in section, a wall unit accepting opening open to an outer vertical surface of the pillar and continuous with a wider projection accepting opening disposed inwardly of the wall unit accepting opening When the projection is inserted into the vertical groove, the projection can rotate within the projection accepting opening.

Description

PRIORITY CLAIM AND REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application Ser. No. 62/047,938, filed Sep. 9, 2014. U.S. Provisional Application Ser. No. 62/047,938 is incorporated by reference herein.

FIELD

Examples of the invention relate generally to systems for building structures, and more particularly to modular structures.

BACKGROUND OF THE INVENTION

Putting out or retaining uncontrolled fires has been a problem throughout history. There are many ways to go about this problem. For example, wildfires have been fought with water and sand from the ground and from the air. However, such methods have not always been successful in preventing fires from spreading, resulting in the loss of life and property, and having detrimental environmental effects.

SUMMARY

An example system for building a modular wall structure includes at least one wall unit and at least one pillar. Each wall unit has top and bottom surfaces, opposed first and second side surfaces, first and second ends, and a projection disposed on each end extending outwardly from the first and second side surfaces. Each pillar has a top and bottom surface configured to be vertically stackable, and at least one vertical groove. The vertical groove comprises, in section, a wall unit accepting opening open to an outer vertical surface of the pillar and continuous with a wider projection accepting opening disposed inwardly of the wall unit accepting opening, the wall unit accepting opening having a width that is greater than a width of the wall unit between the first and second side surfaces and smaller than a width of the wall unit at the projection, the width of the projection accepting opening being greater than the width of the wall unit at the projection.
When the projection is inserted into the vertical groove, the projection can rotate within the projection accepting opening to angle the wall unit vertically and horizontally. Further, each wall unit is configured to be vertically stacked with another wall unit so that vertically stacked wall units move together when rotated.
An example modular structure includes a plurality of wall units and a plurality of pillars. Each wall unit comprises top and bottom surfaces, opposed first and second side surfaces, first and second ends, and a projection disposed on each end extending outwardly from the first and second side surfaces. Each pillar comprises a top and bottom surface configured to be vertically stackable, and at least one vertical groove. The vertical groove comprises, in section, a wall unit accepting opening open to an outer vertical surface of the pillar and continuous with a wider projection accepting opening disposed inwardly of the wall unit accepting opening The wall unit accepting opening has a width that is greater than a width of the wall unit between the first and second side surfaces and smaller than a width of the wall unit at the projection. The width of the projection accepting opening is greater than the width of the wall unit at the projection. At least one wall unit is inserted into the vertical groove of one of the pillars such that the projection is disposed within the projection accepting opening and such that a portion of the length of the wall unit extends through the wall unit accepting opening
A method for constructing a modular structure includes providing a plurality of wall units and a plurality of pillars. Each wall unit comprises top and bottom surfaces, opposed first and second side surfaces, first and second ends, and a projection disposed on each end extending outwardly from the first and second side surfaces. Each pillar comprises a top and bottom surface configured to be vertically stackable, and at least one vertical groove. The vertical groove comprises, in section, a wall unit accepting opening open to an outer vertical surface of the pillar and continuous with a wider projection accepting opening disposed inwardly of the wall unit accepting opening. The wall unit accepting opening has a width that is greater than a width of the wall unit between the first and second side surfaces and smaller than a width of the wall unit at the projection. The width of the projection accepting opening is greater than the width of the wall unit at the projection. The plurality of pillars are arranged on a surface. Pillars can be vertically stacked. At least one wall unit is vertically loaded into the vertical groove of at least one of the pillars such that the projection of the at least one wall unit is disposed within the projection accepting opening A portion of the length of the wall unit extends through the wall unit accepting opening.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a side elevation view of a vertically stackable wall unit for an example system.

FIG. 1B is an end elevation view of the vertically stackable wall unit of FIG. 1A.

FIG. 1C is a top plan view of the vertically stackable wall unit of FIG. 1A.

FIG. 2A is a side elevation view of another vertically stackable wall unit.

FIG. 2B is an end elevation view of the vertically stackable wall unit of FIG. 2A.

FIG. 2C is a top plan view of the vertically stackable wall unit of FIG. 2A.

FIGS. 3A-3G are top elevation views of pillars.

FIG. 4 is a top elevation view of a wall unit connected to an example pillar and positioned at three respective horizontal angles to provide three respective example walls. The central projection of each wall unit is omitted for clarity.

FIG. 5 is a side elevation view of a set of three vertically stacked wall units connected to an example pillar and positioned at two respective vertical angles to provide two respective example walls.

FIG. 6 is a perspective view of a portion of an example wall constructed using an example system.

FIG. 7 is a top perspective view of the example wall of FIG. 6.

FIG. 8 is a front perspective view of a portion of another example wall constructed using an example system.

FIG. 9 is a rear perspective view of the example wall of FIG. 8.

FIG. 10 is a perspective view of another example wall constructed using an example system including a branched wall portion.

FIG. 11 is a perspective view of a portion of another example wall constructed using an example system.

FIG. 12 is a perspective view of an end of another example wall constructed using an example system.

DETAILED DESCRIPTION

An embodiment of the present invention provides, among other things, a system for building a modular structure, and modular structures built using the system. Modular structures as used herein refer to structures that are built from one or more modular units.
The modular structure includes two different modular units: a preferably stackable wall unit and a preferably stackable pillar. The wall units and pillars may be provided in various numbers and/or configurations depending on a particular desired use. An example system for building a modular structure also includes at least one wall unit and at least one pillar. It is possible to provide many different modular structures using only these two units (e.g., without the need for other types of units), in various numbers and arrangements. Requiring only two principal types of units, or requiring only two types of units entirely, simplifies storage, transport, and modular structure construction. Additional walls and pillars, in any quantity, can be incorporated into the system and structure as necessary. Individual wall units and pillars can each be substantially identical, or can vary.
The system, including one or more wall units and one or more pillars, can be transported, in whole or in part, to a location where a modular structure is desired to be built, or provided or manufactured onsite, and then quickly and easily assembled in any of various configurations to provide the modular structure. The modular structure can then be disassembled, reconfigured, expanded, transported, etc. as needed or desired, used temporarily once or many times, or remain as a permanent structure.
Modular structures formed by example systems are also provided herein. Methods of constructing modular structures are further provided herein.
One particular example modular structure, among many that can be provided by example embodiments, is a temporary wall for use in fighting fires. An example wall can provide a temporary barrier that can be placed at any selected distance away from a blaze and in the direction of a suspected path. Due to the flexibility of an example system, a wall can be constructed from a multitude of combinations of shapes, lengths, and heights to contain the fire within its realm until the fire burns out. Walls can be configured to cover various terrains. If the wind shifts, the wall can easily be moved or added onto, and example walls can be made as long and as high as necessary.
Preferred embodiments will now be discussed with respect to the drawings. It will be appreciated that the drawings may not be to scale, which will be fully understood by skilled artisans with reference to the accompanying description. Features may be exaggerated for purposes of illustration. From the preferred embodiments, artisans will recognize additional features and broader aspects of the invention.
FIGS. 1A-1C show an example wall unit 20 according to an embodiment of the invention. The example wall unit 20 is a generally rectangular unit (e.g., a rectangular prism), having generally rectangular first and second ends 24, 26. However, it is also contemplated that the wall units could have a different shape. Another example wall unit 30, shown in FIGS. 2A-2C, includes a general rectangular wall, but with first and second ends 34, 36 that are slightly V-shaped or chevron shaped. Each of the example wall units 20, 30 preferably has opposed side surfaces 37 a, 37 b extending along a length that is substantially greater than its height to provide a generally large aspect ratio, though such an aspect ratio is only exemplary and can vary as needed or desired. Preferably, the wall unit 20, 30 is relatively thin for reducing overall weight and providing a larger degree of wall unit movement for forming modular structures. Varying lengths, widths (thickness), heights, shapes, scales, etc. of wall units 20, 30 can be provided in a particular system or modular structure for further flexibility in constructing the modular structures, though it is also contemplated to construct modular structures using only a single configuration of wall unit.
In an example embodiment, top and bottom surfaces 38, 40 of the wall unit 20, 30 are configured in a way that allows them to nest with one another, so that the wall units are vertically stackable. As best viewed in FIGS. 1B and 2B, in a non-limiting example embodiment the top surface 38 of the wall unit 20, 30 has or is formed in a first connecting shape or configuration, such as a positive V-shape (e.g., a shape or other projection extending in a positive normal direction from the top surface), and the bottom surface 40 of the wall unit has or is formed in a second, complementary connecting shape or configuration, such as a negative V-shape (e.g., a shape or recess extending in a negative normal direction from the top surface). Alternatively, the top surface 38 can have a negative shape and the bottom surface 40 a positive, complementary shape in an alternative embodiment. With such example configurations, the bottom surface 40 of the example wall unit 20, 30 fits onto, and is at least partially received by, the top surface 38 of another wall unit, or vice versa, when the wall units are vertically stacked. This in turn keeps the stacked wall units 20, 30 in place, at which time the wall units lock automatically for stability.
As shown by example in FIG. 1A-1B and 2A-2B, the example wall unit 20, 30 further includes an outward projection, such as but not limited to an outwardly extending rod or bar 42, at or near at least a first end 24, 34 or a second end 26, 36, and preferably at or near both first and second ends of the wall unit. Preferably, one or more additional projections such as rods or bars 44 are more centrally disposed on the sides of the wall unit 20, 30. For example, in the wall units 20, 30, the rod 42 is disposed in the middle of the wall unit, and is horizontally and vertically centered on each side of the wall unit. A non-limiting example projection 42, 44 is a steel bar. Each of the projections 42, 44 extends outwardly (i.e., in a normal direction) from the first and second side surfaces 37 a, 37 b.
The projections 42, 44 can be coupled to the wall units 20, 30, e.g., inserted through a corresponding throughhole 46 formed in the wall unit and affixed to the wall unit using methods that will be appreciated by those of ordinary skill in the art. Alternatively, the projections 42, 44 may be formed as a unitary piece with the wall units. It is also contemplated that the projections 42, 44 can be embodied in a pair of projections extending in opposing directions outwardly from the side surfaces of the wall unit 20, 30, e.g., inserted partially in a hole (not shown) extending partially or entirely through the wall unit. As a non-limiting example, the projections 42, 44 are made from steel, though they can instead be made from other metals, or from any of the other materials described herein. The projections 42, 44 can be used to lift the wall units 20, 30 into pillars, or to load and unload the wall units, particularly if the wall units are large. In some embodiments, the central projections 44 are omitted.
FIGS. 3A-3G show example pillars 50 a-50 g for engaging the wall units 20, 30 to provide the modular structure. The pillars 50 a-50 g can vary in shape, e.g., sectional shape. For example, pillars 50 a, 50 c, and 50 g each have a generally square shape in horizontal section (and in plan view), while pillar 50 b has a generally square shape but with a triangular portion removed. Pillar 50 d is generally triangular. Pillar 50 e is generally trapezoidal. Pillar 50 f is generally diamond-shaped. FIGS. 4 and 5 show another example pillar 50 h, which is generally square in horizontal section, engaged with one or more wall units 30 for providing a modular structure. The pillars 50 a-50 h can be, but need not be, made of similar materials to the wall units 20, 30. The pillars 50 a-50 h can be of any height, an example of which is shown in FIG. 5.
Preferably, the pillars 50 a-50 h are also configured to be vertically stackable with one another. In an example embodiment, the pillars 50 a-50 h have substantially flat planar top surfaces 52 and bottom surfaces 54 for allowing even vertical stacking. For connecting the vertically stacked pillars 50 a-50 h, a preferably centrally disposed cavity 56 extends vertically into the bottom surface 54 of the pillars. As shown in FIG. 5, the cavity 56 in an example embodiment is square tapered in section to receive and retain a vertically extending counterpart connector, such as a pin or projection 58 at, e.g., in or on, the top surface 52 and extending at least partially from the top surface 52. This connector 58 can be shaped (e.g., square tapered) in section to define an insertion depth with the cavity 56, or can include an additional projection (e.g., a rod or pin) coupled to or formed therewith to engage the bottom surface 54 and thus define the insertion depth. However, it is also contemplated that the cavities can have other shapes, or that the pillars 50 a-50 h can be vertically connected in other ways. The connector 58 can be formed from a separate piece from the pillars 50 a-50 h that is inserted into an opening on the top surface 52, or alternatively can be formed, e.g., molded or extruded, as a unitary piece with the pillars 50 a-50 h.
For connecting to the wall units 20, 30 the pillars 50 a-50 h include one or more vertical grooves 60 preferably extending from the top surface 52 to the bottom surface 54 (i.e., into the paper in FIGS. 3A-3G) and defining an opening at, and in, respective outer surfaces of the pillars 50 a-50 h. The number of vertical grooves 60 can vary. For example, pillars 50 a, 50 d each have three vertical grooves 60, while pillars 50 b, 50 c, 50 e, 50 f, and 50 g each have two vertical grooves at respective outer surfaces. Pillar 50 h (FIGS. 4 and 5) has four vertical grooves 60.
The vertical grooves 60 are configured, e.g., sized and preferably shaped, for receiving either the first end 24, 34 or the second end 26, 36 of the wall units 20, 30. In this way, the wall units 20, 30 can slide vertically along the vertical grooves 60 to change their relative position to the pillars 50 a-50 h. Further, to retain the wall units 20, 30, the vertical grooves 60 are also configured, e.g., shaped, for receiving the projection 42 at or near the first end 24, 26 or the second end 34, 36 when the wall unit is vertically loaded, but inhibiting removal of the projection from the vertical groove along a horizontal direction (e.g., in FIGS. 3A-3G and FIG. 4, along the plane of the paper).
For example, referring to FIGS. 3A and 4, the vertical groove 60 in horizontal section (and in plan view, as shown in FIGS. 3A-3G and 4) includes a wall unit accepting opening 62 that is open to an outer vertical surface 65 of the pillar 50 a-50 h, so that the end 24, 34, 26, 36 of the wall unit 20, 30 can be inserted into the vertical groove 60 from the outer vertical surface. The wall unit accepting opening 62 has a width W₁that is greater than the width (thickness) of the wall unit 20, 30 defined between the first and second side surfaces 37 a, 37 b (e.g., the width of either the top surface 38 or the bottom surface 40). The wall unit accepting opening 62 is continuous with, and widens to (e.g., tapers outwardly or otherwise widens to) a projection accepting opening 64, which is disposed inwardly of the wall unit accepting opening, that is, farther away from the outer vertical surface 65. Preferably, the projection accepting opening 64 is generally circular in section.
The projection accepting opening 64 has a greater width (e.g., diameter for a circular opening) W₂than the width W₁of the wall unit accepting opening 62, to accommodate the full width of the wall unit at the projection 42 when the wall unit 20, 30 is within the vertical groove 60. For example, for a single projection extending through the wall unit, the width W₂is sufficient to accommodate the full end-to-end length of the projection 42, or if a pair of opposing projections is used, it is sufficient to accommodate the combined lengths of the opposing projections extending outwardly from the first and second side surfaces 37 a, 37 b and the thickness of the wall unit 20, 30.
However, the width W₁of the (outer) wall unit accepting opening 62 is smaller than the width of the wall unit at the projection 42, providing a bottleneck for the vertical groove 60. Due to the smaller width of the wall unit accepting opening 62, the projection 42 cannot be inserted into, or removed from, the vertical groove 60, without raising or lowering the wall units 20, 30 such that the projection exits either at the top surface 52 or the bottom surface 54 of the pillar 50 a-50 h. Preferably, the width of the wall unit accepting opening 62 and/or the projection accepting opening 64 are also smaller than the height of the wall unit 20, 30 to inhibit a full vertical rotation of the wall unit within the vertical groove 60.
For example, as best viewed in FIGS. 3A and 4, the projection accepting opening 64 of the pillar 50 h can be defined by, in horizontal cross section, an open portion of a circle significantly greater than 180 degrees. The wall unit accepting opening 62 forms the remainder of this circle at an outer portion (that is, a portion closer to the outer vertical surface 65 of the pillar 50 h). Further, the width W₂, which can be defined by the diameter of the circle, is greater than an overall length of the projection 42 at the end 26 of the wall unit 30. The width W₁of the wall unit accepting opening 62 at the outer portion of the circle is smaller than the width of the projection accepting opening 64, and smaller than the length of the projection 42, but is large enough to accommodate several times the thickness of the wall unit 30 between the first and second side surfaces 37 a, 37 b. This example configuration inhibits removal of the wall unit 30 from the vertical groove 60 along the horizontal plane, but permits rotation of the projection 42 within the projection accepting opening 64, and thus rotation of the wall unit along the horizontal plane, to selectively position the wall unit with respect to the pillar 50 h.
As shown in FIG. 5, this example configuration also allows the projections 42 of multiple wall units 20, 30 to be vertically placed, e.g., stacked, within the projection accepting opening 64 so that stacked wall units extend outwardly from the vertical groove 60 and through the wall unit accepting opening Individual wall units 20, 30, or groups of stacked wall units, can be rotated along a vertical plane to raise or lower the wall units and vary the height of a portion of the structure. For example, FIG. 5 shows a set 66 of three vertically stacked wall units 30, rotated in two distinct positions, an upper position and a lower position. In an example configuration, the wall units 20, 30 interlock with each other as well as with the pillars 50 a-50 h.
As shown in FIG. 5, the interlocked stacked wall units (e.g., wall unit 30) can move together as a single unit for positioning Each projection 42 within the projection accepting opening 64 rotates vertically within the opening Such interlocked stacked wall units can also move together as a single unit when rotating horizontally in the manner shown in FIG. 4. Providing a V-shape for the top and bottom surfaces 38, 40 of the wall unit 20, 30 as disclosed above allows the wall units to interlock with each other to ensure stability, while also permitting the stacked wall units 20, 30 to slide horizontally with respect to one another as the stacked units are raised or lowered, as shown in FIG. 5.
Referring again to FIGS. 3A and 4, the wall unit accepting opening 62 preferably also tapers outwardly or otherwise widens to a larger width outer opening 68 disposed at the outer vertical surfaces 66 of the pillars 50 a-50 h. In an example embodiment, the width W₃of the outer opening 68 is substantially equal to the width (e.g., diameter) W₂of the projection accepting opening 64 to allow for maximum range of movement of the wall unit 20, 30 within the vertical groove 66. This is illustrated by the three distinct positions of the wall unit 30 provided by rotating the wall unit along the horizontal direction in FIG. 4.
Providing the cavity 56 on the bottom surface 54 and the counterpart connector 58 on the top surface 52 allows the pillars 50 a-50 h to be stacked and remain in place, while permitting the pillars to be rotated with respect to one another. For example, the pillars 50 a-50 h can be vertically lined up with one another if desired to allow the vertical grooves 60 of the stacked pillars to align, forming a single vertical groove. The wall units 20, 30 can engage the pillars to slide vertically from the top of the stacked pillars to the bottom, and vice versa. Alternatively, the stacked pillars 50 a-50 h can be respectively rotated so that the vertical grooves are misaligned. In this way, upper and lower wall units 20, 30 can project in respectively different directions.
Example modular structures can be provided from any combination of single or stacked pillars 50 a-50 h, having any combination of single or stacked wall units 20, 30 engaged with the pillars via the vertical grooves 60. Wall units 20, 30 can be interlocked with a single pillar 50 a-50 h, a single stack of pillars, or between two pillars or two stacks of pillars to provide any of a multitude of configurations. For instance, wall units 20, 30 can be disposed between and bridge two laterally opposed pillars 50 a-50 h (or laterally opposed stacks of pillars), so that the first end 24, 34 with corresponding projection 42 is accommodated in the vertical groove 60 of one pillar, and the second end 36, 36 with corresponding projection 42 is accommodated in the vertical groove of the laterally opposed pillar. The wall units 20, 30 can be positioned at any of various horizontal (e.g., as shown in FIG. 4) or vertical (e.g., as shown in FIG. 5) angles to customize the overall modular structure.
The projections 42 of the wall units 20, 30 are retained within the vertical grooves 60, and the wall units are thus coupled to the pillars 50 a-50 h. The projections 42 prevent the wall units 20, 30 from being dislodged from the pillars 50 a-50 h and at the same time serve as a hinge for horizontal or vertical rotation of the wall units. With the pillars 50 a-50 h standing vertically the wall units 20, 30 can be moved (e.g., angled) horizontally (e.g., left & right) and vertically (e.g., up & down) in any direction, as shown by various example modular structures herein, to contour the modular structure to any terrain.
As a non-limiting example, positioning the wall units 20, 30 and pillars 50 a-50 h in this way allows for an overall modular structure, such as a wall, to be constructed onto an uneven terrain. As the wall gets higher, the wall units 20, 30 can also be used as braces on the front and/or back of the wall if needed. The example configuration of the wall units 20, 30 and the pillars 50 a-50 h allows the wall units to be moved in any vertical or horizontal direction so that the wall can contour to almost any terrain. As one rotates the wall units 20, 30 left to right (FIG. 4), the wall units remain together. As one rotates the wall units 20, 30 up and down (FIG. 5), the projections 42 keep the wall units locked into the pillars 50 a-50 h, but respective wall units can slide in place due to the V-shaped configurations of the top surface 38 and bottom surface 40. While changing the angles of the wall units 20, 30 up or down the vertical groove 60 acts as a track and allows the wall units to slide back and forth. The central projection(s) in example wall units 20, 30 can be used to load and unload the wall units and further help to move the wall units into place.
Example materials for the wall units 20, 30, pillars 50 a-50 h, projections 42, 44, and resulting modular structures include plastic, concrete, metal, metal alloys, wood, or any other material that can be casted, poured, pressed, extruded, or formed. The materials can be customized for particular uses if desired (e.g., fire resistant materials for a firewall, sturdy materials for permanent structures, light and non-toxic material for toys, etc.). The wall unit 20, 30 surfaces and/or the pillar surfaces 50 a-50 h can be smooth or textured.
In an example method for forming a modular structure, the system, including one or more wall units 20, 30 and one or more pillars 50 a-50 h, can be transported, in whole or in part, to a location where a modular structure is desired to be built. Alternatively or additionally, one or more wall units 20, 30 or pillars 50 a-50 h can be provided or even manufactured onsite. The pillars 50 a-50 h are selectively arranged over a surface. Particular pillars 50 a-50 h may be vertically stacked to provide higher modular structures, and such pillars may be respectively rotated to align (or misalign) one or more of the vertical grooves 60. It is also contemplated that higher unitary pillars may be used instead of plural stacked pillars 50 a-50 h, though it can be advantageous to reduce the number of types of individual units.
The wall units 20, 30 are then loaded and interlocked into the pillars 50 a-50 h by vertically inserting the first end 24, 34 or the second end 26, 36 of the wall units into the vertical grooves 60 of selected ones of the arranged pillars, such that the wall unit extends through the wall unit accepting opening 64, and the projection 42 at or near the respective end is placed within the projection accepting opening The projections 42 and/or the central projections 44 can be engaged to help raise or lower the wall units 20, 30 if desired. Alternatively, it may be possible to load some or all of the wall units 20, 30 by raising or lower the pillars 50 a-50 h themselves around the wall units, particularly if the wall units 20, 30 and pillars 50 a-50 h are relatively small (e.g., used as toys or for smaller-scale modular structures).
The loaded wall units 20, 30 can be positioned, e.g., angled horizontally and/or vertically, within the vertical groove 60 to accommodate various wall configurations and/or terrains or to otherwise configure the modular structure. Wall units 20, 30 can be loaded between two laterally opposed pillars 50 a-50 h by inserting the projections 42 at first 24, 34 and second ends 26, 36 of the laterally opposed pillars to connect the pillars. Example pillars 50 a-50 h can be stacked and connected as needed to provide higher walls. Pillars having multiple vertical grooves 60 can be used to connect walls of different orientations, or to provide branching walls.
To disassemble the modular structure, the above steps for constructing the modular structure can be reversed. However, it is not required to completely disassemble the modular structure. For example, a portion of the modular structure, e.g., one or more wall units 20, 30 and/or pillars 50 a-50 h, can be selectively removed to modify the structure, or to be transported to be used for a different modular structure, and then quickly and easily assembled in any of various configurations to provide the modular structure. Modular structures can be disassembled, reconfigured, expanded, transported, etc. as needed or desired, used temporarily once or many times, or remain as a permanent structure.
FIGS. 6-12 show example modular structures 80 a-80 e. It will further be appreciated that the modular structures shown are merely examples. As shown in FIGS. 6-12, many configurations of modular structures can be made using the example wall units 20, 30 and pillars 50 a-50 e. Modular structures 80 a-80 e can be varied to suit many different terrains, different shapes, sizes, heights, etc. In FIG. 6-12, for example, footers 90 are disposed underneath certain pillars 50 a-50 e or stacks of pillars to selectively raise the pillars or stacks and vary a lower surface. This also illustrates how vertically angling the wall units 20, 30 can accommodate varying surface heights.
Modular structures 80 a-80 e can be generally open, or partially or fully closed. FIGS. 6 and 7 show a partially closed modular structure 80 a. FIGS. 8-9 show portions of a modular structure 80 b having footers 90 and vertically angled wall units extending from raised pillars 50 a-50 h (e.g., simulating higher terrain) to a lower surface. FIG. 10 shows a modular structure 80 c having a branched portion 92. FIG. 11 shows a modular structure 80 d having a plurality of walls 94 of various heights. FIG. 12 shows a modular structure 80 e having a single, downwardly angled wall unit and a wall unit disposed generally parallel to a lower surface.
The wall units 20, 30 and pillars 50 a-50 h (and any separate connectors, if used) can be scaled to essentially any size depending on the usage. Smaller-scale modular structures, for instance, can include smaller- scale wall units 20, 30 or pillars 50 a-50 h. Modular structures can be supplemented with other components as desired to complement the structure. Ornamentation can be provided on the modular structure. Resulting modular structures can be either a temporary or a permanent structure.
One non-limiting example use for modular structures is as a barrier wall to limit the spreading of fires. The wall units 20, 30 and pillars 50 a-50 h (and any separate connectors, if used) can be transported to a site for building a modular barrier wall, and/or individual units can be formed on site. Since example wall units 20, 30 and pillars 50 a-50 h are portable, they can be easily moved or transported (e.g., borrowed) if needed, from any existing location to another location, such as a location of an emergency (fire, flood, etc.). As another non-limiting example, wall units 20, 30 currently being used for a dividing wall on a freeway can be easily accessible for partial or complete disassembly, so that wall units and pillars can be transported to any emergency location temporarily. This reduces or even removes the need for a special storage area.
Example modular structures and applications include, but are not limited to: fire retainer walls, which can be mobile or permanent, and stackable to any length and any height contouring any terrain; sound barrier walls that can contour any terrain without steps; dividing walls on freeways, which dividing walls can be stackable to any height to prevent being blinded by oncoming traffic; retaining walls for creeks, rivers, oceans, sand dunes, snow drifts, mud slides, floods and other disasters that can contour any terrain; repairing or reinforcing dams and other barriers; onsite reusable portable molding forms for concrete structures (e.g., in plastic, aluminum, or other material); partitions for farms or ranches; instant building structures; temporary or permanent enclosures for properties, yards, gardens, etc.; dividing walls of any kind, e.g. events, shows, fairs, markets, concerts, factories, warehouses, etc.; or building blocks for children's toys, e.g., in plastic or wood. Further, individual components, e.g., wall units 20, 30 and/or pillars 50 a-50 h, can be removed from any one of these structures, by partially or completely disassembling the structure, and used for a different structure of similar scale.
Such modular structures and system components can be made of plastic, concrete, wood, metal, or any other material that can be casted, poured, pressed or formed. Modular structures, pillars 50 a-50 h, and wall units 20, 30 can be used temporarily, repeatedly, or permanently. Pillars 50 a-50 h, wall units 20, 30 (including projections 42, 44), and/or any separate connectors can be formed of multiple pieces suitably connected together or formed together as unitary pieces.
While various embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions, and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions, and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.
Various features of the invention are set forth in the appended claims.

Claims

What is claimed is:

1. A system for building a modular wall structure comprising:

at least one wall unit having top and bottom surfaces, opposed first and second side surfaces, first and second ends, and a projection disposed on each end extending outwardly from the first and second side surfaces; and

at least one pillar, the pillars having a top and bottom surface configured to be vertically stackable;

each pillar including at least one vertical groove, the vertical groove comprising, in section, a wall unit accepting opening open to an outer vertical surface of the pillar and continuous with a wider projection accepting opening disposed inwardly of the wall unit accepting opening, the wall unit accepting opening having a width that is greater than a width of the wall unit between the first and second side surfaces and smaller than a width of the wall unit at the projection, the width of the projection accepting opening being greater than the width of the wall unit at the projection;

wherein, when the projection is inserted into the vertical groove, the projection can rotate within the projection accepting opening to angle the wall unit vertically and horizontally;

wherein each wall unit is configured to be vertically stacked with another wall unit so that the vertically stacked wall units move together when rotated.

2. The system of claim 1, wherein said pillar further comprises:

a vertical cavity disposed on the bottom surface and extending into the bottom surface; and

a vertically extending connector disposed at and extending at least partially from the top surface, said connector being configured to fit at least partially within the vertical cavity to connect vertically stacked pillars.

3. The system of claim 1, wherein said connector is centrally disposed along the top surface; and

wherein said vertical cavity is centrally disposed along the bottom surface.

4. The system of claim 1, wherein the top and bottom surface of said pillar are substantially flat.

5. The system of claim 1, wherein the top surface of the wall unit is configured to nest with the bottom surface of a like wall unit.

6. The system of claim 5, wherein the top surface of the wall unit defines a first connecting shape, and the bottom surface of the wall unit defines a second connecting shape that is complementary to the first connecting shape.

7. The system of claim 6, wherein the first connecting shape comprises a positive V-shape, and wherein the second connecting shape comprises a negative V-shape.

8. The system of claim 1, wherein each pillar comprises a plurality of vertical grooves, each vertical groove disposed at a respective vertical outer surface of the pillar.

9. The system of claim 1, wherein the vertical groove extends from the top surface of the pillar to the bottom surface of the pillar.

10. The system of claim 1, wherein the vertical groove further comprises an outer opening continuous with the wall unit accepting opening and disposed at the outer surface of the pillar;

wherein the outer opening has a width greater than a width of the wall unit accepting opening.

11. The system of claim 1 further comprising:

a plurality of wall units; and

a plurality of pillars.

12. The system of claim 11, wherein each of the plurality of wall units has a substantially identical configuration, and wherein each of the plurality of pillars has a substantially identical configuration.

13. A modular structure comprising:

a plurality of wall units, each wall unit comprising:

top and bottom surfaces, opposed first and second side surfaces, first and second ends, and a projection disposed on each end extending outwardly from the first and second side surfaces; and

a plurality of pillars, each pillar comprising:

a top and bottom surface configured to be vertically stackable; and

at least one vertical groove, the vertical groove comprising, in section, a wall unit accepting opening open to an outer vertical surface of the pillar and continuous with a wider projection accepting opening disposed inwardly of the wall unit accepting opening, the wall unit accepting opening having a width that is greater than a width of the wall unit between the first and second side surfaces and smaller than a width of the wall unit at the projection, the width of the projection accepting opening being greater than the width of the wall unit at the projection;

wherein at least one wall unit is inserted into the vertical groove of one of the pillars such that the projection is disposed within the projection accepting opening and wherein a portion of the length of the wall unit extends through the wall unit accepting opening.

14. The modular structure of claim 13, wherein the projection can rotate horizontally and vertically within the projection accepting opening to angle the wall unit horizontally and vertically.

15. The modular structure of claim 13, wherein a plurality of stacked wall units are inserted into the vertical groove of one of the pillars such that the projection of each of the plurality of stacked wall units is disposed within the projection accepting opening and wherein a portion of the length of each wall unit extends through the wall unit accepting opening.

16. The modular structure of claim 15, wherein the plurality of stacked wall units vertically interlock with one another so that they move together when horizontally or vertically rotated.

17. The modular structure of claim 16, wherein the plurality of stacked wall units slide horizontally with respect to one another when vertically rotated.

18. The modular structure of claim 13, wherein the modular structure comprises one or more of a fire retainer wall, a sound barrier wall, a dividing wall, a retaining wall, a dam, an onsite reusable portable molding forms, a partition for farms or ranches, a building structure, or an enclosure.

19. A method for constructing a modular structure comprising:

providing a plurality of wall units, each wall unit comprising:

top and bottom surfaces, opposed first and second side surfaces, first and second ends, and a projection disposed on each end extending outwardly from the first and second side surfaces;

providing a plurality of pillars, each pillar comprising:

a top and bottom surface configured to be vertically stackable; and

arranging the plurality of pillars on a surface; and

vertically loading at least one wall unit into the vertical groove of at least one of the pillars such that the projection of the at least one wall unit is disposed within the projection accepting opening, wherein a portion of the length of the wall unit extends through the wall unit accepting opening.

20. The method of claim 19, further comprising:

positioning the loaded at least one wall unit by rotating the wall unit horizontally or vertically while the wall unit is inserted into the vertical groove.