The present invention relates to a structural apparatus for connecting beams.
Domed structures provide certain advantages over other more traditionally shaped structures. Geodesic domes are one kind of domed structures. A geodesic dome is a portion of a geodesic sphere with a structural frame composed of a network of triangles wherein the vertices of the triangles are at points on the sphere and the sides of the triangles are along cords between the points. Geodesic domes may be simplified so that the vertices lie approximately on the sphere. The triangles create a self-bracing framework that gives structural strength while using a minimum of material. The design allows enclosure of large interior space, free from columns or other supports.
Geodesic sphere structures may comprise hubs and struts, wherein the struts are straight members that radiate from the hubs, and the hubs connect the struts together in a network of triangles. A single geodesic structure may comprise many different triangle patterns and varying triangle sizes. For example a three-frequency geodesic dome requires struts of three different lengths, 5-way hubs (connecting five struts) and 6-way hubs (connecting six struts). Unless otherwise indicated, the description herein will be based on a three-phase geodesic structure.
Five triangles share a vertex at a 5-way hub, and the triangle sides opposite the hub form a pentagon. Likewise, six triangles share a vertex at a 6-way hub, and the triangle sides opposite the hub form a hexagon. A three-phase geodesic sphere comprises a pattern of adjacent pentagons and hexagons having coincidental sides.
Struts are typically tubular construction and hubs are configured to receive the tubes, which results in a structure that has undesirable limitations with respect to supporting other components, such as exterior paneling, interior paneling, studs, insulation and utilities such as plumbing, wiring and HVAC.
Geodesic structures may also comprise wooden beams that have compound angles at their ends so that the ends of five or six beams mate together to form a snug hub joint, without a separate hub component. Such a joint is typically reinforced with additional construction materials such as metal straps and screws. This type of structure requires three different beam lengths with complex beam shapes. It also requires precision machining of complex, compound angles. Due to the various combinations of beam lengths and end shapes for different joints, construction can be very difficult and time consuming, requiring much care to provide the correct inventory of beams for a project, to select the right beams for each joint, to align the beams, and to assemble them into a joint.
There is a need for a beam connector that combines the benefits of a separate hub in a geodesic beam structure and simplifies the construction process, while providing a strong and easy to assemble joint.
The present invention is directed to an improved beam connector for connecting beams to form a geodesic structure. It provides a stronger joint and reduces material needs, manpower needs, and construction time. Due in part to the strength of the beam connector of the present invention, some of the beams in the geodesic pattern may be omitted from the structure. The remaining beams in the structure are disposed along the edges of adjacent hexagons and pentagons. Each beam connection comprises three beams instead of five or six. Therefore, the present invention provides even more material savings and even fewer beam joints to construct.
In a first aspect, the present invention provides a beam connector comprising a middle portion 41 (
In a second aspect, the present invention provides a beam connector comprising a middle portion and three legs extending radially outward from the middle portion at a downward longitudinal pitch of 11.64° from a horizontal plane, wherein the second leg is disposed at a 124.31° angle counterclockwise from the first leg, the third leg is disposed at a 111.38° angle counterclockwise from the second leg, and the first leg is disposed at a 124.31° angle counterclockwise from the third leg, and wherein at least one of the first, second and third legs is adapted for connection to a beam disposed longitudinally along the pitch of the leg.
In a third aspect, the present invention provides a beam and connector assembly comprising: a beam connector comprising a middle portion and three legs extending radially outward from the middle portion at a downward longitudinal pitch of 11.64° from a horizontal plane wherein the second leg is disposed at a 124.31° angle counterclockwise from the first leg, the third leg is disposed at a 111.38° angle counterclockwise from the second leg, and the first leg is disposed at a 124.31° angle counterclockwise from the third leg; and a beam connected at one end to and disposed longitudinally along the pitch of one of the first, second and third legs.
In a fourth aspect, the present invention provides a beam and connector assembly comprising: a plurality of beam connectors, each beam connector comprising a middle portion and three legs extending radially outward from the middle portion at a downward longitudinal pitch of 11.64° from a horizontal plane wherein the second leg is disposed at a 124.31° angle counterclockwise from the first leg, the third leg is disposed at a 111.38° angle counterclockwise from the second leg, and the first leg is disposed at a 124.31° angle counterclockwise from the third leg; and a plurality of beams, each connected at one end to a leg of a beam connector and at the other end to a leg of another beam connector, wherein the on-center spacing between adjacently connected beam connectors is the same.
In a fifth aspect, the present invention provides a beam connector kit for connecting beams in a hexagonal and pentagonal pattern, comprising: at least one beam connector that comprises a middle portion; three legs extending radially outward from the middle portion at a downward longitudinal pitch of 11.64° from a horizontal plane, wherein the second leg is disposed at a 124.31° angle counterclockwise from the first leg, the third leg is disposed at a 111.38° angle counterclockwise from the second leg, and the first leg is disposed at a 124.31° angle counterclockwise from the third leg; and a plurality of beams having the same length for connecting to said beam connectors.
The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, may be best understood by reference to the following detailed description of various embodiments and the accompanying drawings in which:
For the purposes of this description, references to the angle between two intersecting planes, or angle between two flat surfaces refers to the dihedral angle unless expressly indicated otherwise. Similarly, an angle of a plane or surface relative to vertical or horizontal refers to the dihedral angle to a reference vertical or horizontal plane. The dihedral angle is measured in a plane that is perpendicular to the line of intersection of the planes (also referred to herein as the “dihedral line”). As used herein, the term “dihedral angle” infers that there are two intersecting planes or two surfaces disposed at an angle to one another. A dihedral angle may be formed by surfaces of separate objects or by two surfaces of the same object.
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With further reference to
A line running in the same angular direction as a leg, through the center axis of the beam connector, and at the same pitch angle α of a leg may be referred to herein as the “pitch line” of the leg.
The legs divide space around the center into three “sectors.” In a completed structure such as a dome, the sectors will be covered by panels attached to the connector. Two hexagonal panels and one pentagonal panel may be assembled to each connector (see
The two hexagonal panels and the pentagonal panel assembled to a connector are each oriented in a different plane from one another and their respective planes form a dihedral angle at their lines of intersection (also referred to herein as “dihedral lines”). In a preferred embodiment, the three panels form three dihedral angles on three dihedral lines that radiate outward from the center of the connector at the same pitch angle as the legs and same angular direction as the legs.
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In an alternate embodiment, beams may be provided without tenons, in which case leg extensions 18, 19, 28, 29, 30 and 39 and openings 101, 201 and 301 provide for ease of assembly as beams may be slid into place between the leg extensions into the openings through the end of the openings or the top or bottom sides of the openings. A combination of beams with and without tenons may also be used. For example, tenons on the final beam of a geodesic sphere frame may interfere with assembly, and the beam may be provided without tenons so that each end of the beam may be slid sideways into connector openings.
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Beam length of
The spacing between beam connectors may be defined herein as the distance from the center of one connector to the center of the adjacent connector along the beam connecting them (referred to herein as the “on-center” spacing). It is understood that the center axes of adjacent beam connectors are not parallel to one another and that on-center distance is dependent upon the location along the center axes at which the distance is measured. Comparison of on-center distances assumes a consistent standard.
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Panels 60, 70, 80 and 90 may comprise fastener holes for accepting fasteners for fastening the panels to beam connectors and/or beams.
The space between interior and exterior panels in geodesic structures of the present invention may accept studs, insulation, plumbing, wiring, HVAC and other things.
The legs of the beam connector may be widened as necessary to provide a broader seating surfaces 11, 12, 21, 22, 31 and 33 for the panels to accommodate location of panel fasteners further away from the panel edges. Additionally or in the alternative, in order to provide broader seating surface and accommodate more widely spaced panel fastener locations, beam connectors may be provided with flanges extending laterally outward from each leg along the slope of the respective top surfaces 11, 12, 21, 22, 31 and 33.
Geodesic structures of the present invention may further comprise parallel studs spanning the hexagonal and pentagonal spaces between beams. Structures may further comprise horizontal floors and vertical walls of tradition construction in the interior of the sphere.
The expression of linear and angular dimensions herein to the second decimal place or otherwise do not imply or impose greater precision or tighter tolerances than are generally accepted with conventional manufacturing methods for structural frame components or generally accepted for framing in the construction trade. Clearances in the joints allowing for finite adjustment before tightening may be desirable for ease of assembly and may be required to accommodate typical dimensional variances in individual parts.
While the invention has been particularly shown and described with reference to certain embodiments, it will be understood by those skilled in the art that various changes in form and details may be made to the invention without departing from the spirit and scope of the invention as described in the following claims.
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