COLLAPSIBLE STRUCTURES AND METHODS FOR ERECTING COLLAPSIBLE STRUCTURES

TECHNICAL FIELD

The technical field relates generally to collapsible structures.

BACKGROUND

A structure that can be easily erected and collapsed would be beneficial in many contexts including those where a structure needs to be transported or stored when not in use.

SUMMARY

The various embodiments of the present disclosure provide a structure that is able to be collapsed when tension is not applied to a main tension member. As tension is applied to the main tension member, the tension member aligns and brings tension path components together so as to automatically assemble the tension path components and erect the structure.

General Structure

In embodiments described in further detail below, a structure includes components, assemblies, and/or sub-assemblies. A component, assembly, and/or sub-assembly, can have various embodiments, scales, materials, etc.

The components of the structure can be purely structural features, or can have a feature other than, or in addition to, the structural feature. As an example of a feature other than or in addition to the structural feature, components include parts of a predetermined sculpture (e.g., a wing or foot of a duck sculpture). Here, when the structure comes together, the parts of the predetermined sculpture come together to form the sculpture and the logic and/or form becomes clear. In this way, structural components of the structure can be sculpted or designed for a purpose beyond their self-assembly and/or structural requirements.

For example, a structure includes tension path assemblies, parallel path assemblies, and plug-in components. The parallel path assemblies and plug-in components are stacked onto and/or between tension path assemblies.

The tension path assemblies include components through which a main tension member, such as a cable or wire in embodiments described below, is threaded in series. Each tension path assembly is defined by a unique main tension member and the components through which the tension member is threaded are referred to as tension path components. The tension of the main tension member is simultaneously applied to and released from all the tension path components defined by that tension member. Further described, a component can be considered to be a tension path component if it has the main tension member threaded through it and is, for example, held in place in between other tension path components (or on one side, if positioned at one end of the main tension member).

A tension path tensioner could also be introduced into an existing tension path assembly by attaching directly to an existing tension path member by for example clamping or otherwise locking with a main tension member (e.g. a chain). Extending this strategy also allows for tension path members to be completely split and connected to separate tensioners, thereby subdividing one tension path into two tension paths or more.

A parallel path assembly generally includes components that are connected to the tension path components, but that are not directly tensioned by the main tension member. These components are referred to as parallel path components. A parallel path assembly may have a unique tension member that holds the parallel path components together; but the parallel path tension member generally has a fixed tension and is separate from (e.g., in parallel to) a main tension path tension member.

Further described, parallel path components or assemblies can connect more than two joint blocks, assemblies, and/or sub-assemblies. As suggested above, parallel path assemblies do not need to be substantially linear. In an alternate form (for example a panel shown in FIG. 60), a parallel path assembly can connect multiple joint blocks and/or assemblies together. Also as mentioned above, tension path components and sub-assemblies can also vary in shape, material, size etc.

Plug-in components include surface conditions (e.g., a panel (cladding) or a window), programmatic or functional shapes (e.g., seating or a bar top), framing dedicated to an external system or systems (e.g., placeholders, guides, fasteners for plumbing, wiring), mid-tensioners, end-tensioners, sculpted forms, hinges, ball joints, structural knee bracings, stopper discs, suspension anchors, and the like. Generally, plug-in systems can be placed in and removed from a structure without having to substantially unthread or rethread the main tension member through the tension path components.

In exemplary embodiments, plug-in systems allow tension path and parallel path components and their variations to become part of the structure as tension is applied to the tension member and to be released or to be removed from the structure as tension is released from the tension member. For example, a plug-in system such as a fastener block described in further detail below can be attached and removed through the release and reapplication of tension. Alternatively, a plug-in system can also be attached to the already assembled structure, for example by connecting it to an unused fastener block or through some other means (e.g., clamping around tension path and/or parallel path components. e.g. a secondary isolated tension system over parallel path components). Several variations of plug-in systems and components are described below.

A tension path tensioner can be introduced as a plugin component into an existing tension path assembly by attaching directly to an existing tension path member by for example clamping or otherwise locking with a main tension member (e.g. a chain). Extending this strategy also allows for tension path members to be completely split and connected to separate tensioners, thereby subdividing one tension path into two tension paths or more.

Components of the structure can be connected to and amongst each other by non-rigid connections and joints that allow for predetermined ranges of movement in and out of tension (see FIG. 46). The relationships between a structure's components and joints can be controlled by and brought to an equilibrium by an application of tension and restrictions on the ranges of movement of a complex system. In this way a structure could be modeled and arranged mathematically or topologically without a perfectly clear understanding of the structure's final form which can respond to context specific variations like site or component materials. Once an unassembled structure is tensioned and brought to equilibrium, whether by suspension, modular assembly, and/or other methods, some or all of the components and structure could be further fixed and ranges of movement further limited with plug-in systems.

Further described, parallel path assemblies and components can also be applied over tension path components to lock relationships and positions of tension path components by keeping them in tension while other parts of the tension path assembly are out of tension. Alternatively, parallel path assemblies and components could also be used to temporarily isolate and allow for the release of tension on some tension path components while maintaining tension on the rest of the structure by for example bridging and bypassing certain tension path components. Tension path components can also be designed to for example allow their position to be fixed, automatically as tension is applied or manually after tension is applied, relative to their neighbor or neighbors without the use of parallel path components by for example latching, bucking into, or rotably coupling with each other (see FIGS. 79-86).

Discrete tension paths connected to the same structure can also affect the overall structure as tension is applied and released to different areas of the structure. In this way a structure could, for example, be thought of like a complex puppet that is controlled by main tensioners, external forces, and/or relationships with other components (see FIGS. 75-78). An example of this could be motors that apply and release tension to a structure or part of a structure dynamically based on external data like weather, twitter trends, or even nearby occupancy and movement.

Components can be designed like the exemplary fastener blocks, explained in detail below, such that they can be removed from main tension member, as well as other tension path and/or parallel path components without requiring the complete disassembly of the structural system/network. In other words, all components can be easily designed such that they are, for example, comprised of two halves, have a channel, or other embodied strategy through which they can be removed from the structural network without having to unthread or rethread any tension member through neighboring components.

The members, components, and paths of the tension path assemblies, the parallel path assemblies, and the plug-in systems are not necessarily uniformly shaped, materially constructed, scaled, or hinged at ends. For example, stronger materials might be used where there might be stronger forces; different shapes or profiles might be used for ease of access to the main tensioner; single component-blocks might be constituted of sub-components that come together to make the single block (for example, but not restricted to, fastener blocks); and a member that, as tension is applied and neighboring components are brought together at any point along the length of its tension or parallel path, orients certain components (hinges or plug-in programs) in a predetermined way through for example coupling or nesting with restricted axes of freedom.

Erecting and Collapsing a Structure

The structure is able to be collapsed into minimal space usage when tension is not applied to the main tension member. As tension is applied to the main tension member, the tension member aligns and brings the tension path components together so as to, along with the parallel path components or any other components, automatically assemble the tension path components and erect the structure. The parallel path components are generally preassembled in the exemplary embodiment but may be brought into position by tension applied to the main tension member or members due to connection to the tension path components. As mentioned above, in certain embodiments, cladding and/or other plug-in systems are added to the structure and are held in place by tension path components and/or parallel path components as the tension path components and/or parallel path components are brought into position.

As the scale of the components and structure increases, the force required for automatic assembly increases. A method of suspending (e.g. with cranes, under water, or in outer space) at least some of the unassembled components can help in the assembly of heavier or otherwise difficult to assemble structures (see FIGS. 62-70).

Structural loads are supported and distributed by the tension path components and the parallel path components or other components of the structure. For example, some structural loads are supported and distributed through “socketing” (e.g., nesting tension joint blocks) when the components are brought into alignment. The erected structure can also be fixed by bolting, welding, buckling, or otherwise. In these cases the self-assembly logic and the main tension member is primarily used as a way to pre-fabricate or easily assemble a structure that, for example, intends to be used in a more permanent state. Further described, in these cases, plug-in systems can also be used as more permanent features (e.g. structural knee bracing) as well as temporary and reconfigurable features within a more permanent superstructure.

An already erected structure can be collapsed back into minimal space usage by releasing the tension along the main tension path. An already erected structure can also be reconfigured at any time by partially or releasing the necessary tension along the appropriate tension path and/or parallel path components. As with the assembly of components, the disassembly of structures, especially of larger or more complex structures, can be facilitated through the use of suspension through external forces like cranes, systems, or environments with low gravity.

Tension on a tension member can be applied and released dynamically by external forces as well as by a tensioner. For instance, a structure could be kept partially in tension and only become fully tensioned and rigid once a weight is placed somewhere on the structure. Further described, an example of using an external force as a tensioner could be a water container that collects rain water and is suspended by other tension path and parallel path components in the shape of a funnel or upside down mechanized claw, so that if there is no water weight in the container, counterweights or even the weight of the structure itself opens the top of the structure and as water adds weight to the container, the remaining components come together to close the top of the claw or funnel-like shape (see FIGS. 71-72). As another example, a structure includes a sail or kite to assemble the structure with wind or other natural forces (see FIGS. 65-70). Yet another example of a tensioning strategy by external forces could be a chair that appears unstable until a human sits on it and tensions the structure (see FIGS. 73-74).

Multiple Tension Path Assemblies

According to various embodiments, a structure can include multiple tension path assemblies. The main tension members can be closed loops as shown in the exemplary embodiments or they can be open chains in alternate embodiments. Both of these strategies can be employed as needed independently or together within the same or different structures. Parallel path assemblies can be stacked onto or in between tension path assemblies as well as on top of or in between other parallel path assemblies and any combination therein. For example, two tension path assemblies can comprise a singular structure without sharing a common joint block (e.g., a parallel path assembly straddles and connects two or more different tension path assemblies).

The foregoing has broadly outlined some of the aspects and features of the various embodiments, which should be construed to be merely illustrative of various potential applications of the disclosure. Other beneficial results can be obtained by applying the disclosed information in a different manner or by combining various aspects of the disclosed embodiments. Accordingly, other aspects and a more comprehensive understanding may be obtained by referring to the detailed description of the exemplary embodiments taken in conjunction with the accompanying drawings, in addition to the scope defined by the claims.

DESCRIPTION OF THE FIGURES

FIG. 1 is an axonometric view of a structure 100, according to an exemplary embodiment of the disclosure.

FIG. 2 is an axonometric view of a structure, according to an alternative embodiment of the disclosure.

FIG. 3 is an axonometric view of an end joint assembly of the structure of FIG. 1.

FIG. 4 is an axonometric view of fastener blocks connected by a hinge of the end joint assembly of FIG. 3. FIG. 4 also shows an isolated axonometric view of some of the components of the hinge without the fastener blocks.

FIG. 5 is an axonometric view of a tension path sub-assembly of the structure of FIG. 1.

FIGS. 6-7 are exploded axonometric views of the tension path sub-assembly of FIG. 5.

FIG. 8 is an axonometric view of another tension path sub-assembly of the structure 100 of FIG. 1 including an exemplary tensioner.

FIGS. 9-10 are exploded axonometric views of the tension path sub-assembly of FIG. 8.

FIG. 11 is a section view of the tension path sub-assembly of FIG. 8.

FIG. 12 is an exploded axonometric view of another tension path sub-assembly of the structure of FIG. 1 including another exemplary tensioner.

FIG. 13 is a section view of the tension path sub-assembly of FIG. 12.

FIG. 14 is an elevation view of a tension joint block of the tension path sub-assembly of FIG. 5.

FIG. 15 is a plan view of the tension joint block of FIG. 14.

FIG. 16 is a section view of the tension joint block of FIG. 14.

FIG. 17 is an axonometric view of a parallel path assembly of the structure of FIG. 1.

FIGS. 18-19 are exploded axonometric views of the parallel path assembly of FIG. 17.

FIGS. 20-21 is a section view of the parallel path assembly of FIG. 17, illustrating a method of assembling the parallel path assembly.

FIGS. 22-23 is a partial section view of portions of tension path sub-assemblies of an end joint assembly of the structure of FIG. 1, illustrating a method of assembling the tension path sub-assemblies and the end joint assembly to erect the structure of FIG. 1.

FIG. 24 is a plan view of an alternative structure, according to an exemplary embodiment of the disclosure.

FIG. 25 is a partial plan view of an end joint assembly of the structure of FIG. 24.

FIG. 26 is a partial axonometric view of an alternative end joint assembly of a structure, according to an exemplary embodiment of the disclosure.

FIGS. 27-31 are exploded axonometric views of an alternative tension path sub-assembly, according to an exemplary embodiment of the disclosure.

FIGS. 32-36 are exploded axonometric views of an alternative tension path sub-assembly, according to an exemplary embodiment of the disclosure.

FIGS. 37-41 are axonometric views of alternative tension path sub-assemblies, according to exemplary embodiments of the disclosure.

FIG. 42-43 are exploded axonometric views of an alternative parallel path assemblies, according to exemplary embodiments of the disclosure.

FIG. 44 is an axonometric view of two of the tension path sub-assemblies of FIG. 37 assembled at fastener blocks, according to an exemplary embodiment of the disclosure.

FIG. 45 is an axonometric view of the tension path sub-assembly of FIG. 37 and the parallel path assembly of FIG. 42 assembled at fastener blocks, according to an exemplary embodiment of the disclosure.

FIG. 46 shows examples of joint types with their respective ranges of movement in and out of tension that can be incorporated into a structure as alternative components, for example tension joint blocks 131, 132, hinges 152, or parts of the shafts 200, 300, according to an exemplary embodiments of the disclosure.

FIG. 47 shows examples of variations of components that can nest over other components, for example fastener blocks or second tension joint blocks, according to an exemplary embodiment of the disclosure.

FIG. 48 is a topological diagram that shows the components of each of the end joint assemblies are offset from points at which longitudinal axes of components that are connected at the end joint assemblies substantially intersect.

FIG. 49 is a perspective view of alternative structures, according to exemplary embodiments of the disclosure.

FIG. 50 is a topological diagram showing how the separate structures of FIG. 49 can be combined into a single structure.

FIG. 51 is a schematic illustration of a tension path sub-assembly, according to exemplary embodiments of the disclosure where stopper discs are considered tension path components that can, in alternate embodiments, be inserted and removed when tension is released from main tension member.

FIG. 52 is a schematic illustration of an alternative tension path sub-assembly, according to exemplary embodiments of the disclosure, where stopper discs are considered parallel path components. This would make the stopper discs more easily removable, for example as plug-in components or larger variations of fastener blocks.

FIG. 53 is a schematic illustration of an alternative parallel path sub-assembly, according to an exemplary embodiment of the disclosure.

FIGS. 54-59 is a schematic illustration that shows a variation of tension path assemblies, including tension path components and parallel path components.

FIG. 60 is a schematic illustration of an alternate structure, according to an exemplary embodiment of the disclosure. It shows an example of a non-linear parallel path assembly (e.g. a panel).

FIG. 61A is an image showing how the cable winds around the reel in the exemplary tensioner.

FIG. 61B is an axonometric view of an alternate tensioner that uses a double spool. In this example, as one side of the spool unwinds one cable, the other side winds a different cable. In an alternate embodiment, the extra spool could easily be replaced by an electric motor.

FIGS. 62-64 are schematic illustrations demonstrating how suspension can be used as a method for assembling structures (i.e. through lifting with a crane). This example could, for example, use the tensioner in FIG. 61.

FIGS. 65-66 are schematic illustrations demonstrating how natural forces like wind can be employed as a tensioning force and apply tension to the tension member and thereby assembling or modifying the structure. The structure may not necessarily need to be suspended by the natural forces.

FIGS. 67-70 are schematic illustrations demonstrating how natural forces like gravity and air resistance could be employed as a tensioning force and help assemble the structure.

FIGS. 71-72 are schematic illustrations demonstrating how a structure could be passively modified by external conditions like rainfall. By collecting water in this example the structure uses the weight of the water and the force of gravity to add tension to the structure. Further described, the tension member could be (or contain along its length) a surface condition (i.e. a water tight cloth) to collect the water.

FIGS. 73-74 are schematic illustrations demonstrating an alternate tensioning method where human interaction with the structure provides the tension and rigidity. In this example, a chair is not fully under tension until weight is placed on the seat of the structure (i.e. a person sitting down).

FIGS. 75-78 are schematic illustrations demonstrating how a structure can be changed and manipulated by various tension members.

FIGS. 79-86 are schematic illustrations further demonstrating some of the possible connections between adjacent components partially illustrated in FIG. 46. Further described, these illustrations show how adjacent components could be designed to for example allow their position to be fixed or otherwise constrained.

DETAILED DESCRIPTION

As required, detailed embodiments are disclosed herein. It must be understood that the disclosed embodiments are merely exemplary of various and alternative forms. As used herein, the word “exemplary” is used expansively to refer to embodiments that serve as illustrations, specimens, models, or patterns. The figures are not necessarily to scale and some features may be exaggerated or minimized to show details of particular components. In other instances, well-known components, systems, materials, or methods that are known to those having ordinary skill in the art have not been described in detail in order to avoid obscuring the present disclosure. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art.

Overview

In embodiments described in further detail below, a structure includes tension path assemblies and parallel path assemblies or other plug-in components. Parallel path assemblies are stacked onto and/or between tension path assemblies. The tension path assemblies include components through which a main tension member, such as a cable or wire in embodiments described below, is threaded in series. Each tension path assembly includes a unique main tension member and the components through which the tension member is threaded are referred to as tension path components. The tension of the main tension member is simultaneously applied to and released from all the tension path components associated with that tension member.

The structure includes other components, such as components of a parallel path assembly or plug-in components, that are connected to the tension path components, but that are not directly tensioned by the main tension member. These components may be referred to as parallel path components or plug-in components. For example, a parallel path assembly has a unique tension member that holds the parallel path components together; but the parallel path tension member generally has a fixed tension and is separate from (e.g., in parallel to) a main tension path tension member.

A component can be a purely structural feature, or can have a feature other than, or in addition to, the structural feature. As an example of a feature other than or in addition to the structural feature, components include parts of a predetermined sculpture (e.g., a wing or foot of a duck sculpture). Here, when the structure comes together, the parts of the predetermined sculpture come together to form the sculpture and the logic and/or form becomes clear. In this way, structural components of the structure can be sculpted or designed for a purpose beyond their self-assembly and/or structural requirements.

The erected structure is usually a predetermined and prescribed three-dimensional form suitable to one or more contexts. Once the structure is erect, the tension in the main tension member serves to ensure the components are kept in alignment. Alternatively the tension in the main tension member can be used purely to align the components and instead some other method or system is used to fix the components in place as described below. Structural loads are supported and distributed by the tension path components (and, in some cases parallel path components or other plug-in components). For example, structural loads are generally supported and distributed through “socketing” (e.g., nesting tension joint blocks) when the components are brought into alignment.

The erected structure can also be fixed by bolting, welding, buckling, or otherwise. In these cases, the self-assembly logic and the main tension member is primarily used as a way to pre-fabricate or easily assemble a structure that, for example, intends to be used in a more permanent state. Further described, in these cases, plug-in components can provide more permanent features (e.g. structural knee bracing) as well as temporary and reconfigurable features within a more permanent superstructure.

FIGS. 1-2 Structure

Referring to FIG. 1, according to an exemplary embodiment, a structure 100 includes a tension path assembly 102 (including tension path sub-assemblies 130 that are connected along a main tension path 104) including tension path components and parallel path assemblies 140 including parallel path components. The tension path components include tension path shafts 200, components of a tension joint 202 (here, first tension joint blocks 131 and second tension joint blocks 132), and fastener blocks 134. The parallel path components include parallel path shafts 300, fixed joints 302, and fastener blocks 134, and hinges 152. Referring momentarily to FIG. 2, shafts 200, 300 can be scaled or otherwise have different lengths.

A cable 110 is threaded through the tension path components. A section of the cable 110 is wound around a reel 122 of a tensioner 120. Winding the reel 122 shortens the cable 110, providing tension along the path 104 of the cable 110 through the tension path components. Unwinding or releasing the reel 122 lengthens the cable 110, releasing tension along the path 104 of the cable 110 through the tension path components.

The tension path components (along with the parallel path components or plug-in components) of the structure 100, when assembled, provide structural support once the cable 110 guides the respective components into place. Particularly, the components come together such that the cable 110 is not the only or potentially not a load bearing component of the structure 100 at all. For example, the components include kinematic pairs (e.g., a cylindrical socket and cylindrical insert) and the cable 110 guides the kinematic pairs together to form a load-bearing connection.

End joint assemblies 150 of the structure 100 are assembled when tension is applied to the cable 110. In alternative embodiments, as described in further detail below, joints are formed at other locations on the structure 100. For example, a joint is formed in the middle of a shaft 200. In alternative embodiments, one or more of the joints could be a prescribed rigid angle or a movable joint like a hinge or a ball joint.

Continuing with exemplary end joint assemblies 150, in order to allow for maximum flexibility of a size of an angle between shafts 200, 300, and in order to keep the end joint assemblies 150 as minimal and modular as possible, the components of each of the end joint assemblies 150 are offset from points at which longitudinal axes of components (e.g., of tension path sub-assemblies 130, parallel path assemblies 140) that are connected at the end joint assemblies 150 substantially intersect (see FIG. 48).

For example, longitudinal axes 142, 144, 146 intersect at an intersection point 148. The components of the end joint assembly 150 (e.g., the first tension joint blocks 131 and the second tension joint blocks 132) are offset from the point 148. In alternative embodiments, using a singular ball or disc with sockets centered on point 148 as the joint, the smaller the angle between the longitudinal axes, the bigger the ball would need to be in order to allow space for the sockets.

Hinges 152 (described in further detail below with respect to FIGS. 3-4) connect a fastener block 134 that is connected to components aligned on one longitudinal axis with a fastener block 134 that is connected to components aligned on another longitudinal axis. The hinges 152 are configured to provide an end joint assembly 150 with predetermined angles such that, in the exemplary embodiment, each hinge 152 allows motion in only one plane about a single axis of rotation.

When tension is applied to the main tension member 110, the components and structure 100 are forced into equilibrium. Particularly, the first tension joint blocks 131 and the second tension joint blocks 132 are brought into alignment, each or some of hinges' 152 single axes of rotation are not in alignment, thereby providing that the end joint assembly 150 is rigid. When the main tension member is not under tension, the hinges 152 are not locked in place and can move freely. In other words, the relationships to each other are not fixed such that their axes of freedom do not restrict the relationships of the overall structure and the components can be rearranged for minimal space usage. Alternate embodiments of hinges 152 could, for example, focus on limiting movement ranges or allow multiple axes of freedom between the components such that the end joint assembly is not meant to be rigid.

The hinges 152 space tension path components from other tension path components, as well as from parallel path components, at an end joint assembly 150. In alternate embodiments, the hinges 152 also space parallel path components from other parallel path components. Particularly, second tension joint blocks 132 are offset from intersection point 148. In the exemplary embodiment there may be minimal contact between second tension joint blocks 132 at an end joint assembly 150. However, the second tension joint blocks 132 are configured to guide and offset the cable 110 from the intersection points 148.

In alternative embodiments, the second tension joint blocks can be further offset from intersection points 148 or can be designed with explicit contact in mind such that the second tension joint blocks fit into each other (for example using kinematic pairs) in a manner that strengthens the load-bearing needs of the structure or simply to encourage the proper alignment of components.

When tension is applied, the second tension joint blocks 132 and the fastener blocks 134 connected by hinges 152 work together to arrange the components at predetermined angles. By changing the placements, offsets, sizes, etc. of these two types of components, or by using other joint types, the angles and relationships between the shafts 200, 300 can be controlled in alternate ways. In the exemplary embodiment of FIG. 1, the angles are controlled to be thirty degrees.

Offsetting the components of the end joint assemblies 150 from an associated intersection point (e.g., intersection point 148) minimizes the overall size of the components of the end joint assembly 150 while allowing maximizing modular nature of the system and the functional flexibility of the components. As the angle between a first section of tension path components aligned along a first axis and a second section of tension path components aligned along a second axis gets smaller, the second tension joint blocks 132 are generally positioned farther away from the intersection points 148 in order to create space for the second tension joint blocks 132. To position the second tension joint blocks 132 farther away from the intersection point 148, shafts 200, 300 can be shortened as necessary and the fastener blocks 134 and hinges 152 can be moved.

As described in further detail below, the second tension joint blocks 132 also reduce friction in the tension member 110 and components when the structure 100 is assembled and erected. The second tension joint blocks 132 include a distal end 246 and a cavity 240 (referring to FIGS. 14-16) that guides the tension member 110 into a placement to best reduce friction. Designs could be exaggerated and/or modified to more consistently guide the tension member 110 into position. Moreover as mentioned above, the outer shape of the second tension joint blocks can be manipulated for an additional purpose, for example to fit two second tension joint blocks 132 into one another at a desired angle and reduce the stress on the hinge 152.

FIG. 3 End Joint Assembly

In the structure 100 of FIG. 1, end joint assemblies 150 include two tension joints 202 (e.g., a joint formed by a first tension joint block 131 and a second tension joint block 132) at the ends of tension path sub-assemblies 130 and one fixed joint 302 at ends of parallel path assemblies 140.

In alternative embodiments, tension joints 202 occur at points along the length of shaft 200. In any of these embodiments, a tension joint is at least two components that are brought together under tension to create a connection. Joint assemblies can include two or more tension joints. The joints 202, 302 may serve as connection points for other assemblies or components, for example, to create a joint assembly of two or more joints.

The structure of FIG. 1 includes four end joint assemblies 150. Each of the end joint assemblies 150 includes three hinges 152. Referring to FIG. 3, one of the end joint assemblies 150 is described in further detail and the description is generally applicable to each of the end joint assemblies 150. For purposes of distinguishing similar components from one another, a suffix such as “a,” “b,” or “c,” is attached to the end of a numeral that is assigned to an element.

The components of the end joint assembly 150 include a first tension joint 202a including first tension joint block 131a and a second tension joint block 132a, and fastener blocks 134a, 134b; a second tension joint 202b including a first tension joint block 131b and a second tension joint block 132b, and fastener blocks 134c, 134d; and a fixed joint 302, and fastener blocks 134e, 134f.

The fastener blocks 134 along the tension path are received on respective ones of the first tension joints 202 and can rotate relative to the first tension joints 202. When tension is applied, the fastener blocks 134 are fixed in position between the first tension joint block 131 and the second tension joint block 132. In certain embodiments, the fastener blocks 134 are allowed to rotate around the first tension joint block 131 and the respective longitudinal axis. Particularly, the fastener blocks 134a, 134b are allowed to rotate around the first tension joint block 131a and fastener blocks 134c, 134d are allowed to rotate around the first tension joint block 131b.

When tension is applied to the system, the fastener blocks 134a, 134b are fixed in position along the longitudinal axis of the tension path sub-assembly 130a between a stopper disc 160a of the first tension joint block 131a and the second tension joint block 132a. As tension is increased, the fastener blocks 134a, 134b are compressed together between the second tension joint block 132a, the stopper disc 160a and the other adjacent fastener block 134a, 134b, thereby increasing the friction and limiting the rotational freedom of the fastener blocks 134a, 134b. The stopper disc 160a is fixed in position at a distance from a distal end of the first tension joint block 131a. The distance depends on the number, the size, and the shape of intended fastener blocks 134. The first tension joint block 131a is received in a socket (see FIGS. 6 and 7 and described in further detail below) of the second tension joint block 132a.

Similarly, the fastener blocks 134c, 134d are fixed in position along the longitudinal axis of the tension path sub-assembly 130b between a stopper disc 160b of the first tension joint block 131b and the second tension joint block 132b. As tension is increased, the fastener blocks 134c, 134d are compressed together between the second tension joint block 132b, the stopper disc 160b and the other adjacent fastener block 134c, 134d, thereby increasing the friction and limiting the rotational freedom of the fastener blocks 134c, 134d. The stopper disc 160b is fixed in position at a distance from a distal end of the first tension joint block 131b. The distance depends on the number, the size, and the shape of intended fastener blocks 134. The first tension joint block 131b is received in a socket (see FIGS. 6 and 7 and described in further detail below) of the second tension joint block 132b.

The connection between the first tension joint block 131 and the second tension joint block 132 may be referred to as a cylindrical pair joint, a collinear joint, or a pivot joint. In alternate embodiments, (as is shown in FIGS. 27-36) the tension joint block 131 can be shaped in a way that restricts the orientation of the fastener blocks 134 under tension (e.g., a prismatic pair). Similarly, the first tension joint block 131 and the second tension joint block 132 can be for example, a prismatic pair.

In the structure of FIG. 1, the stopper discs 160, the second tension joint blocks 132, and the fastener blocks 134 all have faces perpendicular to the longitudinal axis (the normal vectors of these faces are all parallel to the longitudinal axis of the tension path sub-assembly 130). In certain embodiments, some of these components 131, 132, 134 are configured to have rotational freedom around the first tension joint block 131 while some others are configured to have a fixed relationship between them. For example, faces of components 131, 132, 134 have a face that is more complex than a perpendicular face such that they fit into each other in predetermined ways. Specifically, the faces can be made more complex by angling the planes, creating saddle joints, and the like. In this way a specific relationship between at least two of the components can be made and their axes of rotational freedom can independently limited with respect to each other and not other components. For example, two fastener blocks 134 can be forced into fixed relative positions to each other, but are able to rotate relative to the stopper disc 160 as well as the second tension joint block 132. Similarly, the relationship between a single fastener block 134 and a second tension joint block 132 could be fixed in a unique way without affecting the other components when compressed under tension (see FIGS. 32-36).

The fixed joint 302 includes a pair of stopper discs 160 at the ends of a fixed joint shaft 310 (see FIGS. 18-19) that is nested (cylindrical pair joint) between both stopper discs. In certain embodiments the fastener blocks 134e, 134f are allowed to rotate around the fixed joint shaft 310. The fastener blocks 134e, 134f are fixed in position (e.g., compressed) along the longitudinal axis of the fixed joint shaft 310 between stopper discs 160c, 160d by applying tension through the local tension member 110. The exemplary embodiment shows a cable 110 threaded through a vented bolt that can be partially unscrewed to increase the tension along the parallel path assembly 140. The stopper discs 160c, 160d are positioned along the longitudinal axis of the parallel path assembly 140 and are separated by a distance that depends on the number, the size, and the shape of intended fastener blocks 134. Importantly, the length of the fixed joint shaft 310 in the exemplary embodiment, should be slightly shorter than the combined longitudinal length of the fastener blocks 134 such that the fastener blocks can be compressed.

As with the tension path components, the stopper discs 160 and the fastener blocks 134 all have faces perpendicular to the longitudinal axis (the normal vectors of these faces are all the longitudinal axis of the tension path sub-assembly 130). However, as with the tension path components, the parallel path components can be shaped in a way that restricts the rotational orientation of the fastener blocks 134 when the main tension member 110 is under tension (e.g., a prismatic pair). As mentioned above, the faces can be made complex such that they fit into each other in predetermined ways. The faces can be made complex by angling the planes, creating saddle joints, and the like. In this way, a specific relationship between at least two of the components can be made and their axes of rotational freedom can be limited independently of the rest.

Referring to FIGS. 6-7, exemplary embodiments of fastener blocks 134 are made up of two separable sections. The exemplary fastener block 134 is composed of two clips that together clamp around the first tension joint block 131 and can be removed without having to unthread the rewire the entire tension path assembly 102. Alternate fastener blocks 134 can vary in shape and size and can clamp, bolt, and clip onto the fixed joint shaft 310, onto other tension path or parallel path components, and onto shaft 300 (see FIGS. 51-53).

In some of these instances, the localized/secondary tension in the parallel path assembly can be left out, the fixed joint shaft 310 can be of equal or greater length to the combined longitudinal length of the fastener blocks 134, etc. so long as there is an alternate method of adequately attaching the fastener blocks or other parallel path components. Variations on fastener blocks can be seen in FIG. 47.

FIGS. 3-4 Hinges

Referring to FIGS. 3-4, the end joint assembly 150 further includes hinges 152a, 152b, 152c. Each hinge 152 positions an end of a first one of the shafts 200, 300 and an end of a second one of the shafts 200, 300 relative to one another. As described above, when tension is applied, the second tension joint block 132 and the fastener blocks 134 connected by hinge 152 work together to arrange the components in a predetermined angle so that the structure 100 reaches equilibrium through tension.

Referring to FIG. 4, the hinge 152 includes a pair of fastener blocks 134, a pair of first links 170a, 170b, and a pair of second links 172a, 172b. Each of the first links 170a, 170b is pivotally connected to a respective one of the second links 172a, 172b by a pin 174a, 174b. The pin 174 connection allows the links 170, 172 to rotate relative to one another about an axis defined by the pin 174. The hinge 152 allows rotation around the pins 174 and resists rotation in other directions.

The lengths of the links 170, 172 depend on the desired geometry of the structure. Particularly, the lengths of the links 170, 172 are determined based on, for example, spacing the components of the end joint assembly 150 from an intersection point 148 and/or controlling the angle between the components of the end joint assembly 150.

Generally, one of the pair of links 170, 172 is connected to a fastener block 134 on one of the first tension joint blocks 131 or the fixed joint shaft 310, and the other of the pair of links 170, 172 is connected to a fastener block 134 on a different one of the first tension joint blocks 131 or the fixed joint shaft 310. For example, the fastener blocks 134 include apertures 176 and the pairs of links 170, 172 include threaded ends. Bolts 180 are inserted through the apertures 176 and tightened into the threaded ends. The pair links 170, 172, could also be used to connect the shafts 200, 300 along any part of their length.

The exemplary hinge 152 includes two smaller stand-off links 170, 172 for structural integrity with variable lengths. Alternatively, the hinge 152 could be a larger single hinge or a custom hinge, so long as it ensures the angle under tension is correct for the larger structure 100. It can assume any shape and have restricted ranges of movement, angles of rotation about the pin 174, have multiple axes of freedom, etc. (see FIG. 46).

Referring again to FIG. 3, the hinge 152a connects fastener blocks 134b, 134c, thereby connecting tension joint 202a to tension joint 202b; the hinge 152b connects fastener blocks 134d, 134e, thereby connecting tension joint 202b to fixed joint 302; and the hinge 152c connects fastener blocks 134a, 134f, thereby connecting tension joint 202a to fixed joint 302. This configuration allows for the same hinge 152 design, with different link lengths 170, 172, to be used modularly on adjacent tension path sub-assemblies 130 and parallel path assemblies 140 that require the same angle (in the exemplary embodiment the relationships between these assemblies are set at 30 degree angles), such that the fastener block 134 positions do not coincide. In alternative embodiments, hinge blocks 152 with varying link-lengths 170, 172 are attached to fastener blocks 134 along any length of the longitudinal axes of each assembly or sub-assembly such that they force the desired relationships between the assemblies and sub-assemblies 130, 140.

Certain of the tension path sub-assemblies 130 are now described in further detail.

FIGS. 5-16 Tension Path Sub-Assemblies

Referring to FIGS. 5-7, a tension path sub-assembly 130 includes a shaft 200 and has a longitudinal axis 201. The length, size, and shape of the shaft 200 depends on purpose and context of the structure 100. Although the illustrated shaft is cylindrical, the shaft can have various shapes, even non-uniform shapes, depending on the design of the structure.

The tension path sub-assembly 130 further includes a tension joint 202. The tension joint 202 includes the tension joint blocks 131, 132, which come together to form the tension joint 202 upon application of tension by the tension member 110.

First Tension Joint Block

First tension joint blocks 131, including stopper discs 160, are positioned at opposite ends of the shaft 200. The first tension joint block 131 includes a joint shaft 210 (e.g., a secondary offset) and a joint end cap 212. The joint end cap 212 has a shape (e.g., a rounded shape) that facilitates inserting the first tension joint block 131 into a socket as described in further detail below.

A channel 220 extends through the tension path sub-assembly 130. Each of the joint end caps 212 includes an open end 222 of the channel 220 through which the cable 110 can be threaded, as described in further detail below.

The first tension joint block 131 and the second tension joint block 132 use an exemplary connection that may be referred to as a cylindrical pair joint, a collinear joint, or a pivot joint. Particularly the first tension joint block 131 has an exemplary cylindrical shape and a socket 230 of the second tension joint block 132 is also cylindrical-shaped such that, when the longitudinal axis of the first tension joint block 131 is aligned with the longitudinal axis of the socket 230, the first tension joint block 131 can move along the longitudinal axis so as to be slidably received in the socket 230.

When the first tension joint block 131 is in the socket 230, the first tension joint block 131 and the second tension joint block 132 can rotate relative to one another about the longitudinal axis (in the exemplary embodiment). The socket 230 restricts other rotation of the first tension joint block 131 relative to the second tension joint block 132 and, the socket 230, in combination with tension in the cable 110, restrict translation of the first tension joint block 131.

Alternate embodiments of the first tension joint block 131 include designs where the first tension joint block 131 can be removed from the assembly or sub-assembly without having to rethread the tension member 110. For example, this could be done by having each component 160, 210, 212 have an open slot or channel along the longitudinal length of the components that allows for the cable 110 to be slid out without having to disassemble the entire or substantial percentage of the tension path assembly. These components 160, 210, 212 could be put together such that their longitudinal slits are misaligned and the cable 110 doesn't unintentionally slip out. Another example could take the same strategy as the fastener blocks, and have the components 160, 210, 212 be made up of two haves that can be connected with clips, fastener, bolts, end caps etc.

Also, as mentioned with the fastener blocks above, alternate embodiments can alter the shape and orientation of the faces of the first tension joint block 131 and/or the second tension joint block 132 that are perpendicular to the longitudinal axis such that the two blocks cannot rotate relative to one another (or the adjacent component) about the longitudinal axis when tension is applied to the cable 110. In this example, the first tension joint block 131 can be slidably and rotably received in the socket 230 as tension is increased and the components are aligned. Once the tension reaches a certain point, the two joint blocks 131, 132 become rotably and slidably fixed relative to one another (see FIGS. 32-36).

Fastener Block

The fastener blocks 134 behave like clasps, shaft collars, or fasteners to which components can be attached. Such components include links that form the hinges 152, other joint types including ball joints and fixed joints, and external systems including cladding and panels, cloth, electrical wiring, lights, piping, motors, etc. Referring again to FIG. 4, the fastener block 134 is ring-shaped. For example, the fastener block includes two roughly semi-circular halves that are secured together to form a ring-shaped structure. This allows for the fastener block 134 to be removed without having to, for example, unthread the cable 110. Alternatively, the fastener block 134 interior and exterior profiles can vary as is shown in FIGS. 27-31. Fastener blocks are a type of socketing component. Some variations are shown in FIG. 47.

The fastener block 134 is configured to be slidably and rotably received on the first tension joint block 131. Particularly, the fastener block 134 includes an aperture 270 (see FIG. 4) that is configured to receive the first tension joint block 131. The fastener block 134 includes a filleted edge adjacent the aperture to better receive the first tension joint block 131. The fastener block 134 can rotate around the joint shaft 210 and move along the longitudinal axis (e.g., longitudinal axis 201) of the joint shaft 210. Moreover, as mentioned above, the shape of fastener blocks 134 in alternative embodiments can vary so that the rotation between adjacent components is fixed relative to one another or their neighbors as shown in FIGS. 32-36. As also mentioned above, the fastener block 134 includes apertures 176 that are configured to receive bolts 180. Each of the apertures 176 has a longitudinal axes that is substantially perpendicular to the longitudinal axis of the joint shaft 210 (e.g., longitudinal axis 201).

Referring momentarily to FIGS. 6-7, a bolt 180 is inserted through each of the apertures 176. The bolt 180 is tightened into the threaded ends 178 (shown in FIG. 4) of the hinge 152 to attach the hinges 152 to the fastener blocks 134. In embodiments where the fastener block 134 includes two halves, the two halves are secured together by this arrangement. In an alternative embodiment, the bolt 180 is tightened into threaded ends of another joint or component to attach the other joint or component to the fastener blocks 134.

In the event that some component or some joint is no longer needed, or might need to be attached to an assembly or sub-assembly in the future, fastener blocks 134 can be included as part of an assembly or sub-assembly without attaching to anything to the fastener blocks 134 other than themselves using the bolts 180 and nuts. Until such a time presents itself that the structure needs to be modified or reconsidered, the bolts 180 and the nuts can be used to hold the two halves of a fastener block 134 together. This allows the design a flexibility to easily change and adapt to potential future needs while limiting the need to reconfigure a part of or the whole structure.

Referring again to FIG. 5, in this illustrated embodiment, a pair of fastener blocks 134 are slidably received around the joint shaft 210. The pair of fastener blocks 134 are fixed in a longitudinal position (e.g., along the longitudinal axis 201) on the joint shaft 210 between a proximal end 280 of the second tension joint block 132 and a stopper disc 160. For example, the length of the first tension joint block 131 is approximately equal (e.g., slightly less) to the height of the socket 230 plus the heights of the (e.g., pair of) fastener blocks 134.

Alternatively, the fastener blocks 134 can be excluded, so long as the stopper disc 160 or first tension joint block 131 is placed in such a way that the second tension joint block 132 can compress shaft 200. In other words if the fastener blocks 134 are excluded from the end of a shaft 200, the length of the first tension joint block 131 at that end is selected to be slightly less than the height of the socket 230. Moreover, if the design requirements were to change and the excluded fastener blocks need to be added in the future, an extension or replacement to the joint block 131 could be added, as explained above, such that the joint block 131 would be of an appropriate length to able to accommodate the fastener blocks 134 and the second tension joint block 132.

FIGS. 14-16 Second Tension Joint Block

The second tension joint block 132 includes a cavity 240 that extends in a radial direction 241 from a longitudinal axis 242 to a sidewall 244 of the second tension joint block 132 and that extends in a longitudinal direction between distal end 246 of the second tension joint block 132 and a distal end 248 of the socket 230. There is an opening 250 between the socket 230 and the cavity 240. The opening 250 and the open end 222 (referring to FIG. 7) align along the longitudinal axis 201 when the first tension joint block 131 is received in the socket 230.

The cavity 240 houses a pulley 260 that rotates around an axle 262. The cavity 240 allows the pulley 260 to slide into position. The axle 262 extends between opposed walls 264, 266 that define the cavity 240 and positions the pulley 260 in the cavity 240. The pulley 260 is configured to guide the cable 110 as it extends through the open end 222, through the opening 250, and into the cavity 240. Particularly, the longitudinal axis 242 is substantially tangential to a point on the circumference of the pulley 260. The pulley 260 rotates around the axle 262 to guide a change in direction of the cable 110 upon exiting the second tension joint block 132, thereby limiting friction on the housing of the second tension joint block 132. A bolt 268 keeps the cable 110 in the pulley groove and prevents pinching and/or wear on the second tension joint block 132.

Alternate embodiments, as mentioned above, have varying interior and exterior shapes of second tension joint blocks 132. These variations can be manifest, for example, as a socket 230 and/or proximal end 280 needing to match an alternate embodiment of a joint shaft 210, joint end cap 212, and/or stopper disc 160 of the corresponding first tension joint block 131 as well as, or rather, potentially adjacent fastener blocks 134.

Moreover, the shape, materiality, etc. of the distal end 246, the cavity 240, and the walls 264, 266 of a second tension joint block 132 can be adapted to best guide the cable into a pulley 260, for example, by shaping these parts of a second tension joint block 132 into a non-symmetrical, conical form with the most proximal end of the conical form near the pulley 260 and the sidewall 244, such that the cable 110 easily slides into the pulley as tension is applied. Depending on the connection between two adjacent sub-assemblies 130, and the ranges of movement allowed and desired relationships forced by the connecting hinge or other joint, different shapes of the second tension joint blocks 132 will yield different results and the shapes, orientations, and/or placements of the second tension joint blocks 132 and their parts (including but not limited to those discussed above, as well as pulleys 260) can be modified accordingly.

The shape of a sidewall 244 of a second tension joint block 132, as also mentioned above, can be made, for example, to fit against or into the sidewall 244 of an adjacent second tension joint block 132 when under tension (e.g., prismatic pair), such that some of the structural loads are lessened on the hinge 152 connecting these adjacent second tension joint blocks.

Similar to other tension path components, the second tension joint block can be made such that it can be removed from the assembly without having to unthread the cable 110. This can be easily done, for example, by splitting the second tension joint block in two halves along the sectional axis. The two axles 262, 268 (e.g., bolts) can serve the additional purpose of holding both halves together thereby not requiring significant modifications to the exemplary design. In this way, and in other ways, all tension path components can be made to be removed and added the main tension member 110, without needing to rethread the entire or part of the assembly.

FIGS. 8-11 and 12-13 Tension Path Sub-Assemblies with Tensioner

Referring to FIGS. 8-11, a tension path sub-assembly 130 with the tensioner 120 includes the reel 122 with a bolt 123, one-way bearings 124, and shaft collars 125 to prevent the cable 110 from unwinding. In the exemplary embodiment, a bolt 123 and a spacer are drilled to create the reel 122 along with two washers. Shaft collars 125 are attached to a housing block 126 that is in turn attached to the tension path shaft 200 of a sub-assembly 130. One-way bearings 124 are nested in the shaft collars 125 such that their one-way rotation axes and direction are aligned to each other and are collinear to the winding axis 127.

As a bolt 123 is placed in the housing block 126, through the shaft collars 125 and the one-way bearings 124, the reel 122 is put in place in the center of the housing block 126, in between the shaft collars 125, and a cable 110 is threaded through the drilled holes of the reel 122 and fixed, clamped, or attached at the cable's ends in a way that prevents the cable 110 from slipping in or out of the reel 122. The reel 122 is able to spin freely in both directions as long as the shaft collars 125 are not tightened. By tightening the shaft collars 125 and thereby clamping the one-way bearings 124 in place within, the reel is allowed to rotate only in one direction and tension is able to be applied to the cable 110. In order to release the tension, the shaft collars 125 have to be loosened thereby allowing the one-way bearings to spin freely within the shaft collars.

Referring to FIGS. 12-13, a tension path sub-assembly with an alternative tensioner 120 includes a ratchet mechanism to prevent the cable 110 from unwinding.

Tensioners can be employed along any point in the longitudinal lengths of the sub-assemblies 130 (i.e., at the ends of tension joints 202) and can apply tension to one or more ends of one or more cables simultaneously. For example, a tensioner is configured to tension a cable 110 from a single end in addition to or instead of both ends of a single cable 110. As another example, a tensioner is configured to tension multiple cables. In other words, tension path assemblies 102 can be considered as loops or chains. By placing a tensioner at the ends of a sub-assembly 130, the second tension joint block(s) 132 can be adapted as housing block(s) for tensioning systems, including but not limited to those detailed above. This example is, in a way, similar to the tensioner of the exemplary parallel path assemblies 140 discussed below, though importantly, the change in length for a cable 110 (between in-tension and not in-tension) in the tension path assembly 102 generally needs to be much greater than the change in length of a tensioning member (e.g., cable 312) in the exemplary parallel path assemblies 140.

FIGS. 17-21 Parallel Path Assembly and Method

Referring to FIGS. 17-21, one of the parallel path assemblies 140 is described in further detail. The parallel path assembly 140 includes the shaft 300 (e.g., a channel or other shape), shaft joints 302, and fastener blocks 134, as described above. The shaft 300 has a longitudinal axis 301 and the length, size, and potential variation of the shaft 300 depends on the structure 100.

The exemplary parallel path assembly 140 includes the shaft joints 302 at opposed ends of the shaft 300. Each fixed joint 302 includes a pair of stopper discs 160 and a joint shaft 310. The joint shaft 310 extends between the pair of stopper discs 160.

The elements of the parallel path assembly 140 can be held together by a tension cable 312 that is tensioned between opposite ends of the parallel path assembly 140. Generally, the tension cable 312 provides a fixed amount of tension whereas the tension applied by the cable 110 is adjustable using the tensioner 120. Moreover, the amount of variation in cable 312 length, between in-tension and out of tension states, can be kept to a minimal amount as compared to the cable 110 which generally needs to be tightened and loosened to a much greater amount. Further described, referring to FIGS. 20-21, the parallel path assembly 140 has two nuts 313 that are attached to both ends, each holding a vented bolt 314 (with a hole along the length of the shaft 300). The cable 312 of fixed length has compression sleeves 316 clamped around it at either end and it runs through the center of the parallel path assembly 140 (including the bolts at each end).

Tension to the parallel path assembly 140 is applied and released by respectively unscrewing and screwing the bolts in the nuts fixed at either end of the parallel path assembly 140. In doing so, the ends of the fixed length cable 312 are brought closer together or farther apart. By releasing the tension, the fastener blocks 134, as well as other components, can be removed, modified, exchanged, or replaced.

In the illustrated embodiment, a pair of fastener blocks 134 are slidably and rotably received on the joint shaft 310 between the stopper discs 160. The pair of fastener blocks 134 are fixed in a longitudinal position (e.g., along the longitudinal axis 301 on the joint shaft 310 by the stopper discs 160. For example, the length of the joint shaft 310 is approximately equal (e.g., slightly less) to the heights of the pair of fastener blocks 134.

In other words, the parallel path assemblies 140 can be held together using the same tension and compression logic as the main tension path 104. However, tension is applied to and released from parallel path assemblies 140 independent of tension that is applied to and released from the tension path assembly 102 (e.g., tension path sub-assemblies 130).

In alternative embodiments, parallel path assemblies do not use tension to assemble, secure, or release the components. For example, a parallel path assembly may be include a shaft (e.g., a wooden dowel) that connects (e.g., by a screw) to one or more other parallel path components. Or, a parallel path attachment may be a single-piece structure rather than an assembled structure.

FIGS. 22-23 Method

A method of erecting the structure 100 from a collapsed condition is now described in further detail. According to an exemplary method, the tensioner 120 shortens the cable 110 until the cable 110 is in tension. As the cable 110 shortens, the cable 110 brings the tension path components together so as to, along with the parallel path components, automatically assemble and erect the structure 100 in a three-dimensional form.

Methods to help in erecting structures 100 include the use of external forces. One example is suspension where at least some of the components can be suspended through lifting, low-gravity, or buoyancy to help with the alignment of components as the tension is added to the main tension member (e.g. in outer space, under water, through lifting components or tension members). For large structures, cranes or other equipment and site conditions could be used to aid the alignment of components (see FIGS. 62-64). Another example is leveraging gravity itself, where weight can apply a force on a tension member and tighten or tension it with respect to the other tension path components. Other natural forces like wind (see FIGS. 65-66), water flow, and centrifugal forces can also aid in both suspending and applying tension to the tension member and assembling the structure. Human forces can also be used to for example move, lock, decouple, or connect tension path components, parallel path components, and/or tension members and thereby altering the tension to the tension member and/or creating new relationships between the tension member and tension path components. Automated forces like motors or engines could also be used to wind the cable 110 within the tensioner in response to certain criteria (see FIG. 61). Hinges or parallel path components as well as tension path components could also dynamically change in length to add tension without changing the length of cable 110 through for example pressurized pistons or hydraulic systems.

Referring to tension path sub-assemblies 130 illustrated in FIGS. 22 and 23, the cable 110 pulls the first tension joint block 131 through the apertures 270 of the fastener blocks 134 and into the socket 230 of the second tension joint block 132. As the first tension joint block 131 is fully received in the socket 230, the stopper disc 160 substantially abuts a first one of the fastener blocks 134, the first one of the fastener blocks 134 abuts a second one of the fastener blocks 134, and the second one of the fastener blocks 134 abuts the second tension joint block 132. The tension in the cable 110 pulls the first tension joint block 131 and the second tension joint block 132 together, which fixes the longitudinal position of the fastener blocks 134 there between, as shown in FIG. 23.

Further, the open end 222 aligns with and is adjacent the opening 250. The cable 110 is threaded through the channel 220 of the tension path sub-assembly 130, exits the tension path sub-assembly 130 at the open end 222, and moves through the opening 250 and into the cavity 240 where it is guided by the pulley 260. The pulley 260 facilitates moving the cable 110 through the cavity 240 and out of the cavity 240 at an angle relative to the longitudinal axis 201 (and to the other tension path sub-assembly 130 in the system) so as to reach an equilibrium of forces and positioning between all the components including, but not limited to, the hinges 152, offsets, fixed connections, ball joints, and parallel path components.

By offsetting the second tension joint blocks 132 from the points 148 the angle of bend in the cable 110 at the end joint assembly 150 is reduced. In a further effort to remove friction, pulleys 260 are used to guide the cables in optimal ways as tension is increased. By employing acute angles between the tension path sub-assemblies 130, the cable 110 pulls back on itself and tightens the tension path components. As the angles increase in size and the cable 110 pulls back on itself less and less, as well as for other reasons, ‘pins’ or ‘functionally stopper discs’ can be pinned to the cable 110 to create the necessary compression of tension path components and to make sure components are properly aligned. Moreover, multiple cables 110 and tensioners 120 can be used as necessary to ensure adequate compression to all the components in the tension path assembly 102 and second tension joint blocks 132 can serve as ends to the tension path by pinning, fixing, or otherwise connecting the end of the cable 110 to a second tension joint block 132.

Alternatively, if the angle of bend in the cable 110 is obtuse, the adjacent second tension joint blocks 132 through which the cable 110 is threaded (tension path) can assume the role of the hinges 152 and fastener blocks 134 such that the first tension joint blocks 131 of adjacent tension path sub-assemblies 130 can still nest within sockets 230 of the second tension joint blocks 132 and allow the compression of all the components of the tension path assembly 102. Adjacent second tension joint blocks 132 could assume a number of different types of joints as described in FIG. 46. This alternate strategy of second tension joint blocks 132 for obtuse angles allows the second tension joint blocks 132 to be modified as detailed above, for example the internal and external shape, scale, and/or materiality. Also as mentioned above, the two adjacent second tension joint blocks 132 can be disconnected and when under tension nest into each other (i.e., prismatic joint).

The distal ends of adjacent second tension joint blocks 132 of the end joint assembly 150 are pulled toward one another by the tension in the cable 110 while the fastener blocks 134 and hinge 152 keeps the tension path sub-assemblies 130 apart and determines the angle or relationship between tension path sub-assemblies 130. The cavities 240 of adjacent second tension joint blocks 132 are oriented towards one another due to the shape of the cavity 240, which guides the cable 110 in a plane from the second tension joint block 132. For example, the cavity 240 from which the cable 110 exits and the adjacent cavity 240 that the cable 110 enters are coplanar.

Referring again to FIG. 3, the parallel path assembly 140, which is connected, in the exemplary embodiment, to the tension path sub-assembly 130 by hinges 152, comes together with the tension path sub-assembly 130 to form the end joint assembly 150. As the hinges' 152 axes of rotation are unaligned and the tension path and parallel path components are simultaneously aligned, the structure reaches equilibrium and becomes rigid. Alternate embodiments allow for the hinges' and/or other joints' axes and/or degrees of freedom to be aligned in which case there may be some freedom movement once the structure 100 is fully assembled. This freedom of movement could be restricted through other structures like plugin systems and connection to other tension path assemblies and parallel path assemblies.

The structure 100 is rigid so long as the tensioner 120 maintains the tension in the cable 110 to keep the joints 202, 302 together. Once under tension, plug in systems could be used to lock the components in place so that the tension member 110, does not have to be load bearing at all. To collapse the structure 100, the tensioner releases the tension in the cable 110 and lengthens the cable 110. The tension path components can then be pulled apart to collapse the structure 100.

Suspending the structures can make the assembly and disassembly process more straightforward (see FIGS. 61-70). Moreover, plugin systems could be used to maintain parts of the structure in tension while other parts are released from tension. Moreover, a complex structure with multiple tension path members can be assembled in parts by discrete tension members and then connected together after the fact by plugin and parallel path components. Moreover, tension path components and/or parallel path components could change shape by for example expanding through telescoping members 200 and 300 (i.e. with pneumatics or hydraulics). Another example is one where components buckle or permanently partially distort in controlled ways under tension so that neighboring components latch together and/or clamp the tension member like compression sleeves.

In alternative embodiments, prior to fully-tensioning the cable 110, or after partially releasing some of the tension, cladding, other parallel or tension components, or some combination, or an external system may be inserted between tension path components of the structure 100 (e.g., between tension joint blocks) such that, as the tension path components come together, the cladding, for example, is fixed in place between the components.

FIGS. 24-26 Alternative Structure

Referring to FIG. 10, a structure 400 includes many of the same elements and features of the structure 100. However, the structure 400 includes six end joint assemblies 150. For example, the structure 400 includes components through which a cable 110 is threaded (e.g., referred to as tension path components, together a tension path assembly including tension path sub-assemblies 130) and components through which a cable 110 is not threaded but that are connected to the tension path components (e.g., parallel path components, which make up parallel path assemblies 140). The structure 400 is able to be collapsed when tension is not applied to the cable 110. When tension is applied to the cable 110, the cable 110 brings the tension path components together so as to, along with the parallel path components, automatically assemble the tension path components and erect the structure 400 in a three-dimensional form.

For simplicity, elements of the structure 400 that are substantially similar to the structure 100 have been labeled using like numerals and are not described again in detail. The tension path components of the structure 400 include tension joints 202 (i.e., tension joint blocks 131, 132) and fastener blocks 134. The parallel path components of the structure 400 include fixed joints 302 and fastener blocks 134.

Referring to FIG. 25, an end joint assembly 150 of the structure 400 includes a tension joint 202a including a first tension joint block 131a and a second tension joint block 132a, and fastener blocks 134a, 134b; a second tension joint 202b including a first tension joint block 131b and a second tension joint block 132b, and fastener blocks 134c, 134d; a third tension joint 202c including a first tension joint block 131c and a second tension joint block 132c, and fastener blocks 134e, 134f; a fourth tension joint 202d including a first tension joint block 131d and a second tension joint block 132d, and fastener blocks 134g, 134h; and a fixed joint 302 and fastener blocks 134i, 134j.

A hinge 152a connects fastener blocks 134b, 134c, thereby connecting tension joint 202a to tension joint 202b; a hinge 152b connects fastener blocks 134d, 134e, thereby connecting tension joint 202b to tension joint 202c; a hinge 152c connects fastener blocks 134f, 134g, thereby connecting tension joint 202c to tension joint 202d; a hinge 152d connects fastener blocks 134h, 134i, thereby connecting tension joint 202d to fixed joint 302; and the hinge 152e connects fastener blocks 134j, 134a, thereby connecting fixed joint 302 to tension joint 202a.

Referring to FIG. 26, another alternative end joint assembly 150 is illustrated, as part of a structure 500, which includes two tension joints 202 and three fixed joints 302. The structure 500 is further illustrated in FIGS. 49 and 50.

FIGS. 27-41 (and 51-53) Alternative Tension Path Sub-Assemblies

FIGS. 27-31 illustrate an alternative tension path sub-assembly 130 including a tension joint block 131 and a fastener block 134. The outside of the tension joint block 131 is tapered and the opening of the fastener block 134 is tapered. The first tension joint block 131 is shaped in a way that restricts the orientation of the fastener block 134 under tension and the fastener block 134 is not able to rotate around the first tension joint block 131 when in tension. Additional alternatives are illustrated in FIG. 46.

FIGS. 32-36 illustrate an alternative tension path sub-assembly 130 including a tension joint block 131, 132 and a fastener block 134. The fastener block 134 and the stopper disc 160 are shaped in a way that restricts the rotation of the fastener block 134 relative to the stopper disc 160. Particularly, the fastener block 134 and stopper disc 160 each have a surface that is not perpendicular to the longitudinal axis of the tension joint block 131. In this case any other components on the other side of the fastener block 134 will still be able to rotate around the first tension joint block 131 without restriction, but the fastener block 134 is forced to rotate together with the neighboring stopper disc 160. This structure can be used to lock relationships between adjacent components.

FIGS. 37-41 illustrate alternative tension path sub-assemblies 130, according to exemplary embodiments of the disclosure. These tension path sub-assemblies 130 demonstrate alternative connections using fastener blocks and other components. FIG. 37 illustrates a tension path sub-assembly 130 with a mid-offset tension joint and fastener blocks; FIGS. 38-39 illustrate a tension path sub-assemblies 130 with a middle hinge; FIG. 40 illustrates a tension path sub-assembly 130 with a middle ball joint; and FIG. 41 illustrates the tension path sub-assembly of FIG. 37 where the fastener blocks are attached to an external system (e.g., cladding or a parallel path assembly) with fixed connection links.

FIGS. 37 and 41 illustrate how tension joints 202 and their variations, fastener blocks 134 and their variations, and parallel path components, assemblies, and their variations (e.g. external systems/cladding) can be inserted and attached at any point along shafts 200. For example, a first tension joint block 131 and a second tension joint block 132 connect at the middle of a shaft 200 when in tension. In general, the tension joint blocks 131, 132 are configured such that tension in the cable 110 causes and/or limits movement of the first tension joint block 131 with respect to second tension joint block 132.

FIG. 51 is a schematic illustration of a tension path sub-assembly 130, according to an exemplary embodiment of the disclosure where stopper discs are considered tension path components. Here, socketing components, shown as fastener blocks 134, can be used at any point along the length of a shaft 200. If there is more space on the shaft between stopper discs 160 or their variations, then socketing components could for example slide along the length of the shaft (e.g., as shown in FIG. 52). Alternate fixing strategies could be used to prevent socketing components from sliding, for example altering the exemplary design of a fastener block 134 to have a smaller aperture 270 so that it can clamp around the shaft 200 like a shaft collar.

FIG. 52 is a schematic illustration of an alternative tension path sub-assembly 130, according to exemplary embodiments of the disclosure. Here there are fastener blocks 134 serving as spacers over a shaft 200 along with alternate stopper discs 160.

Other plug-in systems could also be inserted and removed in this way. Moreover, the differences between tension path and parallel path components with regards to a main tension member 110 are visibly differentiated by hatch patterning. The tighter hatch pattern on the shaft 200 indicates tension path components that directly interact with a tension member 110 with and are responsible for self-assembly as tension is applied and released. The looser hatch pattern on the stopper discs 160 and fastener blocks 134 indicates parallel path components that don't interact directly with a tension member 110.

FIG. 53 is a schematic illustration of an alternative parallel path sub-assembly 140, according to an exemplary embodiment of the disclosure. Similar to FIG. 52, stopper discs 160 and other plug-in systems could be inserted and removed in-between fastener blocks 134 as tension is applied and released from the tension member 312.

FIGS. 42-43 Alternative Parallel Path Assemblies

FIG. 42-43 illustrate alternative parallel path assemblies 140, with additional fixed joints 302. FIG. 42 illustrates a parallel path assembly 140 with a middle fixed joint 302. FIG. 43 illustrates a parallel path assembly 140 with an additional end fixed joint 302. These embodiments illustrate how fastener blocks 134 and external systems can be inserted and attached at any point along shafts 300 and how shafts 300 can be scaled, modified, and/or adapted to make an exemplary parallel path assembly fit the needs of a structure. Any of the joint structure shown in FIGS. 46 and 47 could be employed by parallel path components and assemblies. The exemplary hinge 152 shows how a version of an “Open 180 Hinge” shown in FIG. 46 can be added to the middle of shaft 300 to create a parallel path assembly with prescribes degrees and axes of movement/freedom. In the case of the exemplary hinge 152, a fixed joint 302 is replaced with an “open 180 hinge” joint similar to the one shown in FIG. 46.

FIGS. 44-45 Alternative Connection Between Joints

FIG. 44 illustrates two of the tension path sub-assemblies 130 of FIG. 37 connected by fastener blocks 134 and non-rotating links. Similarly, FIG. 45 illustrates the tension path sub-assembly 130 of FIG. 37 and the parallel path assembly 140 of FIG. 42 connected by fastener blocks and non-rotating links. These embodiments illustrate a straight connection between fastener blocks 134 that connects tension joints 202 and a tension joint 202 and a fixed joint 302. The straight connection is illustrated in contrast to the hinge connection described in earlier embodiments.

FIG. 46 Alternative Structural Joint Strategies

FIG. 46 illustrate alternative types of joints and movement ranges of the same. Each joint type is illustrated above a respective description and range of movement. These examples take tension into consideration such that a joint's ranges of movement and degrees of freedom are variable depending on the amount of tension applied to the structure. For example, Plan/Gliding Saddle joints rely purely on the tensile strength of the tension member and generally only support loads if the force vectors are collinear with the tension member. Socket joints can provide structural support while relying on the tension member to bring components into alignment. Two examples of a socket joint are shown. One socket joint has rotational freedom about the longitudinal axis of the socket and tension member and another socket joint is inserted by matching the profiles of both parts of the joint (as shown in FIGS. 27-31).

The other examples include variations on ball joints and hinge joints. The shapes and profiles of the joints can restrict axes and degrees of freedom as illustrated. Furthermore, tension applied to the tension member can influence preferred angles or positions between the joint components by guiding the cable through different types and placements of openings within the joints. The two ball joint examples illustrate how the same shape and profile with different types of openings can create two different conditions. The Standing Ball Socket joint shows how when under tension the hole on the ball will want to align with the hole in the socket, and since the holes don't provide the tension member much wiggle room with their alignment, the joint will align the holes under tension. In the Open Ball Socket example, the ball joint can still rotate and move in a number of different ways without impacting the length of the cable, and this wiggle room allows the joint to move freely even when under tension.

The hinge examples function similarly and further demonstrate how the placement of the openings can encourage certain angles under tension. The Standing 90 Hinge for example has the hole aligned with the longitudinal axis of the joint while the 90 90 Hinge has the hole placed perpendicular to the longitudinal axis of the joint. Therefore when the Standing 90 Hinge is under tension the openings through which a tension member is threaded align and the longitudinal axes of both joint components are aligned. When the 90 90 Hinge is under tension, the openings, through which a tension member is threaded, align and the joint is brought to a 90 degree angle.

These features can be applied to tension joint blocks 131, 132 as well as other tension path components and parallel path components. As is shown with the exemplary second tension joint block 132, one component can employ more than one of these features simultaneously. The exemplary second tension joint block 132 uses strategies from the Flat Cable Release strategy illustrated as well as the Flat 360 Socket.

Other alternative embodiments include variations on a number of the components illustrated in FIG. 46. For example, alternative embodiments do not use flat connections, but rather use angling components and/or create coupling connections as well as socketing connections. Some of the illustrated hinges use angling components and/or create coupling connections or socketing connections to restrict degrees of rotation, though as shown FIGS. 32-36, angling can also create relationships with other components not part of the first or second tension joint blocks.

FIG. 47 Alternative Socketing Joint Blocks

FIG. 47 illustrate socketing components, for example fastener blocks 134, that can be used as over structural components, according to exemplary embodiments of the disclosure. These socketing components can also be widely adapted, for example to employ hinges or ball joints. The socketing components can be scaled up down to the match the size whatever components they socket over. FIGS. 51, 52, and 53 show how these socketing components can be used as spacers to allow for plug-in components in an alternate way.

FIGS. 49-50 Alternative Structures

FIG. 49 illustrates alternative structures 500, which demonstrate how two individual tension assemblies can be joined together to make a larger structure that can self-assemble and/or reconfigure in parts. FIG. 50 topologically illustrates how the separate tension assemblies composing the structure 500 can be combined into a singular structure.

Discrete tension assemblies can be combined using parallel path components in a similar fashion that parallel path components are connected to tension path components as shown in FIG. 26. The hinges 152 (other joint types/components could also establish a relationship between components) connecting fastener blocks 134 of one tension path sub-assembly 130 and fastener blocks 134 of another tension path sub-assembly 130 determine the angles between the tension path sub-assemblies 130 and/or parallel path assemblies 140 joined by the hinge 152. The hinges 152 and fastener blocks 134 space at least the proximal ends of the second tension joint blocks 132 from one another.

The strategies explained in FIGS. 46 and 47 demonstrate that joints don't have to be rigid. Therefore, if there are multiple tension assemblies combined, as tension is applied and released from one of them, the relationships between components could be affected in the other through changes in applied forces on joints. In other words, manipulating the tension in connected assemblies that have multiple main tension members can allow for example, prescribed or un-prescribed flexibility in certain joint assemblies while restricting angles, movement, etc. in other joint assemblies. To help explain this concept consider the extent of control a single string on a puppet provides, and then consider adding various strings to control specific parts of the puppet (see FIGS. 75-78).

Alternatively, if one tension assembly or part of the structure 500 is under tension and it is rigid, it can be used as scaffolding for and while a different tension assembly or part of the structure 500 is not under tension. In this way components could be added and/or removed and relationships within the structure reconfigured.

FIGS. 54-59 Alternative Structures

Alternatively, these components at the end of each of the end joint assemblies 150 don't have to be offset from the points at which the longitudinal axes of components substantially intersect. They could for example be designed for specific predetermined angles and couple into each other at the point at which the longitudinal axes intersect. In this way the systems provides a framework in which to take advantage of common structural systems/strategies (e.g., structural knee bracing).

FIGS. 54-59 are schematic illustrations that show variations on a tension path assembly, including tension path components, and parallel path components. The examples also show variations on nesting types of components and where tension path component shaft 200 can be segmented into pieces. Through increased modularity, this segmentation allows, for example, the ability to easily add and remove tension path components without having to unthread or rethread neighboring components with a tension member 110.

FIG. 54 illustrates a simple and linear partial tension path assembly where a tensioner is not in the middle of a tension path but at the end of a tension path.

FIG. 55 shows a variation of a shaft tension 200 where it can nest with neighboring components and create specific relationships. For example, FIG. 55 shows alternate ways in which tension joint blocks 131, 132 can interact with each other, as well as neighboring tension joint blocks 131, 132 can interact with each other. A number of these relationships are illustrated by FIG. 46.

FIG. 56 illustrates that any of the tension path components (e.g. shaft 200) can be bent, curved, or shaped in alternate ways. It also shows a mid-tensioner as described in the exemplary embodiment.

FIG. 57 shows two discrete tension path assemblies that are connected by parallel path components. In this case the connection between the tension path component and the parallel path components is through socketing (type B) components (e.g. fastener blocks 134) illustrated in FIG. 47. The parallel path component connecting the socketing components could also be considered like a rigid variation on the hinge 152. In this way, hinge joints behave like parallel path components.

FIG. 58 shows what could be one or two tension path assemblies connected by a parallel path component directly onto tension path components.

FIG. 59 shows a tension path assembly and parallel path components similar to how they are described in the exemplary embodiment. Any of the schematic components shown whether structural (type a) or socketing (type b) can use the joint strategies illustrated in FIGS. 46 and 47.

FIG. 60 Alternative Non-Linear Assemblies

FIG. 60 is a schematic illustration of an alternate structure, according to an exemplary embodiment of the disclosure. It illustrates four linear and simple tension path assemblies that are connected to each other through parallel path components. The tension path assemblies each have two end tensioners. The tension path components are connected by a variation of the tension path components that could be considered as plug-in components. In this example, the parallel path components create a non-linear parallel path assembly (e.g. a panel). Similarly tension path components could be non-linear.

The above-described embodiments are merely exemplary illustrations of implementations that are set forth for a clear understanding of principles. Variations, modifications, and combinations may be made to the above-described embodiments may be made without departing from the scope of the claims. All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims.

COLLAPSIBLE STRUCTURES AND METHODS FOR ERECTING COLLAPSIBLE STRUCTURES

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