MODULAR STRUCTURAL BUILDING SYSTEM AND DEVICE

Abstract

A modular building system includes a joint for interconnecting a network of struts in a tetrahedral arrangement for forming a structural component supporting a floor, ceiling or post. The interconnected struts have a uniform length and join together with other struts at a predetermined angle defined by the joint. Once connected, the struts and joints form a tensioned network of a load bearing surface or post, where the members are in a tensioned arrangement at an equilibrium. External forces, such as moving loads, winds, and rain tend to spread the loads across the network of tensioned members, temporarily resulting in compression along some of the rigid struts. Panels join the strut network or lattice by load caps secured to the joints for receiving triangular panels matching the joint spacing.

Description

BACKGROUND

Steel and concrete are common in the construction industry because of strength and durability, as well as availability. Concrete exhibits superior integrity against compression forces; similarly steel has superior tensional force properties. These two materials are often integrated as steel reinforced concrete that is able to withstand substantial tensional and compressive loads. Steel reinforced concrete is heavy, energy intensive to produce and requires heavy equipment to manipulate and install.

SUMMARY

A modular building system includes a joint for interconnecting a network of struts in a tetrahedral arrangement for forming a structural component supporting a floor, ceiling or post. The interconnected struts have a uniform length and join together with other struts at a predetermined angle defined by the joint. Once connected, the struts and joints form a tensioned network of a load bearing surface or post, where the members are in a tensioned arrangement at an equilibrium. External forces, such as moving loads, winds, and rain tend to spread the loads across the network of tensioned members, temporarily resulting in compression along some of the rigid struts. Panels join the strut network or lattice by load caps secured to the joints for receiving triangular panels matching the joint spacing.

For floors and roofs, a network of triangular panels each engage a plurality of panel apertures on the load caps attached to the joint. The triangular panels have a vertical pin at each point on the triangle, such that each panel aperture is adapted to receive the vertical pin of a floor panel. Each floor panel engages with panel apertures of adjacent joints, as a plurality of triangular panels forms a network among the joints. The floor panel therefore defines a tensional engagement between the plurality of joints, collectively forming a roof or floor surface in a self-supporting tensional arrangement.

Configurations herein are based, in part, on the observation that concrete is a primary building material employed in construction. Unfortunately, many building materials, and in particular concrete and steel, are typically highly dense and consume substantial energy in fabrication. Portland cement, the chemically active material in concrete, requires extensive drying in a kiln or similar heating approach. Accordingly, configurations herein substantially overcome the shortcoming of conventional building materials by providing a joint and strut system that joins together using tension attachments that are substantially lighter than concrete and more tolerant of external forces such as earthquakes and wind. The result is a lattice system that provides an alternative to concrete floor and ceiling structures, and can also be formed into load bearing columns using the same joint and strut network.

In further detail a modular building device attaches a network of struts connected by a joint, including a flange plate defined by a planar surface, and a plurality of flanges extending perpendicularly from the flange plate. Each of the flanges joins at a common edge, such that the common edge extends perpendicular to the flange plate, and at least one aperture on each of the flanges for attachment to respective strut.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.

FIG. 1 is a diagram of a joint device for interconnecting a plurality of struts forming a structural member;

FIGS. 2A-2C are side and plan views of the joint of FIG. 1;

FIGS. 3A-3D show a strut adapted for connecting to the joint of FIG. 1;

FIG. 4 shows two struts, as in FIGS. 3A-3D engaged with a joint as in FIG. 1;

FIGS. 5A-5C show a load cap adapted for connection to a joint and a sheathing panel (panel) for engaging the load cap;

FIG. 6 shows an exploded view of an interconnected joint, struts and panels as in FIGS. 1-5C;

FIGS. 7A-7D show the joints engaging with a steel I-beam building frame;

FIG. 8 shows a side elevation of interconnected joints and struts forming with panels employed for floor and ceiling surfaces;

FIG. 9 shows a perspective view of the joints and struts engaged with collars around the steel beams as in FIGS. 7A-7D;

FIGS. 10A-10C shows fabrication of the joint of FIGS. 1-2D;

FIG. 11 shows a plan view of a floor structure using the joints and struts; and

FIG. 12 shows results of load bearing span deflection.

DETAILED DESCRIPTION

The joint and struts provide a device a method for constructing structural architectural floors in any multistory building, primarily as an alternative to suspended concrete floors. Configurations herein also describe a system of standardized components for the assembly of the structural floors, providing a commercial means of easily implementing the technology, an a method for fabricating the joints from flat stock. An assembled configuration includes three main layers which work together to create a rigid, stable, fire-resistant, and structurally robust floor with the strength of conventional floors at less than half the dead weight.

FIG. 1 is a diagram of a joint device for interconnecting a plurality of struts forming a structural member. Referring to FIG. 1, the modular building device 100 includes a flange plate 110 defined by a planar surface, and a plurality of flanges 112-1 . . . 112-3 (112 generally) extending perpendicularly from the circular flange plate 110. Each of the flanges 112 join at a common edge 120, also extending perpendicular to the flange plate, The common edge 120 thus forms an axis 122 extending perpendicular from the flange plate 110, and also has a bore 124 through the axis 122. The axis 122 may be implemented as a tubular member, discussed further below. Each flange 112 has at least one aperture 114 for connection to struts, and apertures 116 in the flange plate also engage struts, described further below.

A joint 150 is defined by the flange plate 110 and the plurality of flanges 112 extending therefrom. Each flange 112 of the plurality of flanges has an annular edge 118 for forming a hemispherical shape of the joint 150. Particular configurations may form a compound joint from pair of joints 150, 150′ and a bore 124 defined by the common axis 122 of each joint 150, 150′ of the pair of joints and an elongated fastener extending through the bore 124 of each joint 150.

FIGS. 2A-2C are side and plan views of the joint of FIG. 1. Referring to FIGS. 1-2C, each flange plate 110 has a plurality of apertures 116, also for connecting to struts. As can be seen by FIGS. 1-2C, the flange plate 110 is subdivided into a plurality of angular sections 210-1 . . . 210-3 (210 generally), such that each angular section 210 is defined by the flanges 112 flanking the angular section 210 and extending from the flange plate 110. Each angular section 210 of the flange plate 110 also has at least one aperture 116, Typically, a plurality of apertures 116 are formed on each angular section 210, such that each aperture may engage a strut, where each strut extends in a plane parallel to the planar surface of the flange plate 110.

FIGS. 3A-3D show a strut 260 adapted for connecting to the joint 150 of FIGS. 1 and 2A-2C Referring to FIGS. 1-3D, each aperture 114 and 116 (on the flanges 112 and flange plate 110) is adapted to engage a strut 260. The strut 260 has a proximal portion 266 (end) and a distal portion 268 (end), each formed from a strut end 264-1 . . . 264-2 (264 generally). Each strut 260 also includes a retention bracket 262 having a plurality of slots 272. The retention bracket 272 is adapted to join the proximal end (portion) 266 and the distal portion 268 via at least one through hole 274 on each of the proximal portion and the distal portion. Each strut 260 therefore includes a proximal portion and a distal portion defined by the strut end 264 positioned at a respective end 266, 268.

In the assembled strut 260, the through holes 274 align with a respective slot 272 of the plurality of slots for receiving a connector, such that the connector secures the retention bracket 262 in slidable communication with the proximal portion and the distal portion along a length of the slot 272. As shown, the retention bracket 262 is formed from an elongated body 263 having opposed ends, and a pair of slots 272 at each end of the opposed ends. Each slot 272 of the pair of slots has a width based on a diameter of a fastener or connection peg adapted to extend through the slot 272, and a length greater than the width for accommodating slidable communication of the elongated body with the proximal portion and distal portion 266, 268. The connector may be any suitable threaded bolt, or pin retained by a nut, c-clip, cotter pin, etc. As the slots 272 are slightly elongated in their length, a tolerance along the length of the strut 260 allows for subtle movement for absorbing loads.

Struts ends 264 join via a u-shaped sleeve and an attachment clip, where the attachment clip is adapted to engage opposed strut portions in a butt-fit. In an example configuration, the attachment clip has a plurality of parallel pins attached by a transverse member extending perpendicular to each of the parallel pins, such that the pins are adapted to engage apertures on the respective struts. Slots 272 are oval-shaped apertures to allow axial compression of the strut in response to momentary compression loads. A retainer is pivotally engaged with the parallel pins adjacent the transverse member, and “swings” over the now joined struts to engage an opposed side of each respective pin on an opposed side of the aperture through the strut, forming a secure butt-fit attachment.

In FIG. 3D, the two ends 266, 268 of the strut 260 are aligned and indirectly connected by the two brackets by a set of through pins 270 that allow some compression between them. Each strut end 264 has a small square rubber cap 263 on its interior end such that when pushed in by substantial stresses they compress together, conveying steady loads but absorbing acute stresses and shocks. Each strut end 264 also has flange holes 265 for fastening to the joint 150.

In the example of FIG. 3D, the connector is defined by through pins 270 that form an attachment clip 280 adapted to engage opposed struts ends 264 in a butt-fit, such that the attachment clip 280 has a plurality of parallel pins attached by a transverse member 282 extending perpendicular to each of the parallel pins 270. Each pin 270 is adapted to engage aligned slots 272 and through holes 274 on the respective strut ends 264. A retainer 284 pivotally engages with the parallel pins 270 adjacent the transverse member 282, and is adapted to engage an opposed side of each respective pin on an opposed side of the through hole/slot through the strut 260. An attachment clip 280 with two pins 270 is shown, however differing numbers of pins 270 may be employed in alternate configurations, depending on complexity and load bearing or shear strength desired. Similarly, the length of each slot 272 may be varied to define a tolerance of compression, also buffered by close fitting caps 263. A doubling of the retention bracket 262 may be implemented by a second retention bracket 262′ of a slightly larger “U” channel for encompassing the first retention bracket 262.

Returning to the joint 150, and having described the engageable struts 260, the joint 260 forms a load bearing node consisting of six mount points evenly spaced around the flange plate 110 and three additional mount points projecting perpendicular to the disk on one side at 60 degrees, forming a tetrahedral tripod on one face. A central hole or threaded rod continues through the central axis 122 of the joint allowing other components to be mounted directly to its load center.

The method of connecting the joint 150 to the strut 260 should allow modest movement around the pin 270 or other fasteners. Tight connections are not required as the geometry of the frame provides rigidity regardless of fasteners. A solid pin is recommended but a threaded fastener is suitable.

FIG. 4 shows two struts 260, as in FIGS. 3A-3D engaged with a joint 150 as in FIG. 1. The joint 150/strut 260 connection permits a universal tetrahedral orientation between joints 150-N, such that each joint/strut linkage employs a first flange plate 110 having a plurality of flanges 112, and a second flange plate 110 also having a plurality of flanges, and a strut 260 connecting a flange 112-1 from the first flange plate 110 to a flange 112-N of the second flange plate 110, where the strut 260 has a proximal portion 266 attached to the flange of the first flange plate, and a distal portion 268 attached to the flange of the second flange plate 110, and the retention bracket 262 slidably engaged in linear alignment with the proximal portion 266 and the distal portion 268.

FIGS. 5A-5C show a load cap 300 adapted for connection to a joint 150 and a sheathing panel (panel) 310 for engaging the load cap 300. Referring to FIGS. 1-5C, the load caps 300 attach to the joints 150 through an aperture 324 that aligns with the bore 124 through insertion of a fastener along axis 122. The load caps 300 facilitate attachment of the panels 310 for sheathing surfaces such as floors or ceilings supported by the network of joints 150 and struts 260. Each panel 310 has apertures 314 aligned with apertures 312 in the load caps 300, which also align with the triangular shape formed from the joints 150 have flanges at 120° offsets from 120° angular sections 210.

The load caps 300 are engineered such that they will bear tenant/occupant/industrial load as lateral tension between the panel mount points, but the single bolt holding them to the joint 150 may shear under stress. This means that if the frame pulls down from the floor it will break away and protect the integrity of the floor panels, providing a walkable if less rigid surface in emergencies. Evan absent the structural support from joints 150/struts 260, the load caps 300 and aperture 314/312 attachment form a tensioned surface capable of bearing substantial loads, similar to a trampoline.

In operation, the load cap 300 is a simple component that fixes to the joint 150 with a detachable bolt through the center axis 122 and to as many as six surface panels 310 directly. This allows the load cap 300 to function as a cover and vibration damping cushion on top of the joint 150 and remain fixed to the frame under normal stresses. Floors and ceilings are therefore provided via a load cap 300 having a planar face 315, where the load cap 300 attaches to the joint 150 via the bore 324 such that the planar face 315 extends parallel to the flange plate 110. The bolt or fastener may be designed to shear or break away under extreme stress to allow the joint 150 to separate from the load cap 300 supporting the network of floor panels 310. A top of the load cap 300 may be a steel plate that will maintain the connection between all six panels, ensuring the floor does not open up and the ceiling does not collapse even if the underlying joint 150/strut 260 frame shifts.

The height 306 of the load cap 300 is variable depending upon function and choice. They can be relatively flat, acting as little more than a connecting plate fixed to the joint face to deep spacers of 9 inches in height. The composition and specific height is less important than the function of vibration damping and layer isolation,

The panels 310 used for floors are load bearing equilateral triangles engineered to handle at least 160 lbs./sq ft. One composition is to manufacture the panels 310 as single form injection molded panels two inches thick and 36 inches on a side. They may have ¼ inch holes at each corner allowing fastening directly to the load caps 300.

FIG. 6 shows an exploded view of an interconnected joint, struts and panels as in FIGS. 1-5C. Referring to FIGS. 1-6, FIG. 6 aggregates the joint 150, strut 260, load cap 300 and panels 310 discussed above. In FIG. 6, a matrix of sheathing panels 310 engages respective load caps 300 having at least one aperture for receiving a fastener securing the sheathing panel 310. The panel 310 has a shape based on uniform distances between a plurality of load caps (36″ equilateral triangles in the disclosed approach), and an aperture 314 aligned with a plurality of load caps 300 aligned with the shape. When aligned with axis 122 on top of the load caps 300, a spacing to other load caps is defined by equilateral triangle shape having apertures aligned with three of the load caps.

FIGS. 7A-7D show the joints engaging with a steel I-beam building frame 340. The disclosed joint 150 and strut 260 may form a structural column for multi-story structures, or may be engaged with steel I-beam construction to form a tensioned floor structure within an I-beam perimeter. Referring to FIGS. 1-7D, A mount collar 350 is composed of two steel saddles 351 and 352 spanning the width of a steel joist I-beam 360. Mount collar 350 sizes correspond to the width of the respective beams 360 for attachment. These saddles 351, 352 fasten together around the beam 360, one up the other down, using one-inch bolts or similar fastener. These will bear the full load of the floor frame and translate it to the building steel members 362 evenly and without the need for through holes or welded fixtures.

Mount collars 350 include at least a portion of the flange plates 110 and flanges 210, shown in FIGS. 7B and 7C. FIG. 7D shows a strut attachment 370 directly to the beam 360 for struts 260 extending to a joint 150 or compound joint 150/150′

FIG. 8 shows a side elevation of interconnected joints and struts forming with panels employed for finished floor 310′ and ceiling 318 surfaces. Referring to FIGS. 1-8, a structural building system according to configurations herein includes comprising: a plurality of joints 150, each including a plurality of flanges 112 joined at predetermined angles, such that each flange 210 is defined by a planar surface and having at least one apertures 114. A plurality of struts 260 each has a pair of opposed strut ends 264 such that each end of the opposed ends are adapted to join with the aperture 114 on one of the flanges 110 of a respective joint 150 of the plurality of joints. Utilities are accommodated by pipe hangers 330, wire chases 332 and electrical fixtures 334.

Overall strength is retained by the plurality of struts and the plurality of joints being engaged in a tensioned tetrahedral arrangement. The tetrahedral arrangement results from the plurality of struts 260 that engage the apertures 116 on the flange plate 110 form a planar arrangement of struts, such that each strut 260 extending in a plane defined by the plurality of flange plates 110 and forming an equilateral triangle with adjacent struts, generally forming a horizontal arrangement defining a floor or ceiling. The struts are typically 32 inches long, where a two inch offset from the center axis 122 results in a 36 inch on center between the joints 150. Depending on the height 306 of the load cap, a total distance of the floor 310′ to ceiling 318 may be about 28-40 inches, consistent with typical voids in a drop ceiling arrangement.

FIG. 9 shows a perspective view of the joints 150 and struts 260 engaged with mount collars 350 around the steel I-beams 360 as in FIGS. 7A-7D, forming a tetrahedral structure from a polyhedron shape formed by the struts 260.

FIGS. 10A-10C shows fabrication of the joint of FIGS. 1-2D. Referring to FIGS. 1-2C and 10A-10C, the joints 150 may be formed from flat stock cut in an open circle or “C” pattern, The method for forming the structural joint 150 device includes cutting a sheet of planer stock 400 in a partial circle 410 having a width, and forming a plurality of apertures through the sheet of planer stock corresponding to apertures 114 and 116 on the flange sections 210 and flanges 112. The partial circle 410 is marked (dotted lines 412) for designating an angular section 210, 120° in the disclosed approach. With an angular section of 120°, and to form 90° perpendicular flanges, the partial circle 410 is 120°+90°+90°=300°, 60° less than a full 360° circle. Folds are made to the partial circle on the markings to form perpendicular flanges 112 on each side of the angular section 210, such that the flanges 112 bend upwards and perpendicular from the angular section 210. The angular section 210 now occupies a 120° “wedge” shape with the flanges 112 extending vertically. In FIG. 10C, 3 angular sections 210-1 . . . 210-3 are joined and welded or attached joining the angular sections with at joining the flanges 112 in a parallel double wall and maintaining the angular sections 210 in a coplanar arrangement, thus forming the flange plate 110 as a complete planar circle perpendicular to three double-wall flanges 112.

FIG. 11 shows a plan view of a floor structure using the joints 150 and struts 260 attached and engaged with perimeter I-beams 360, forming a square shaped load bearing lattice or matrix.

FIG. 12 shows results of load bearing span deflection resulting from finite element (FE) analysis for various spans with computed deflection.

While the system and methods defined herein have been particularly shown and described with references to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.

Claims

1. A modular building device, comprising: a flange plate defined by a planar surface;a plurality of flanges extending perpendicularly from the flange plate; each of the flanges joined at a common edge, the common edge extending perpendicular to the flange plate; andat least one aperture on each of the flanges.

2. The device of claim 1 further comprising a plurality of apertures on the flange plate.

3. The device of claim 1 wherein the flange plate is subdivided into a plurality of angular sections, each angular section defined by the flanges extending from the flange plate, further comprising at least one aperture on each angular section of the flange plate.

4. The device of claim 3 further comprising a plurality of apertures on each angular section, each aperture adapted for engaging a strut, each strut extending in a plane parallel to the planar surface.

5. The device of claim 1 wherein the common edge has an axis extending perpendicular from the flange plate, and a bore through the axis.

6. The device of claim 5 further comprising a load cap having a planar face, the load cap attached via the bore,the planar face extending parallel to the flange plate.

7. The device of claim 1 further comprising: a joint defined by the flange plate and the plurality of flanges extending therefrom,each flange of the plurality of flanges having an annular edge for forming a hemispherical shape.

8. The device of claim 7 further comprising a compound joint formed from: a pair of joints;a bore defined by the common axis of each joint of the pair of joints; andan elongated fastener extending through the bore of each joint.

9. The device of claim 1 wherein each aperture is adapted to engage a strut; the strut having a proximal end and a distal end,the aperture engaging the proximal end, the distal end adapted to engage an aperture of a distal end.

10. The device of claim 9 wherein each strut includes: a proximal portion and a distal portion,a retention bracket having a plurality of slots;the retention bracket adapted to join the proximal portion and the distal portion via at least one through hole on each of the proximal portion and the distal portion; the through holes aligned with a respective slot of the plurality of slots for receiving a connector, the connector securing the retention bracket in slidable communication with the proximal portion and the distal portion along a length of the slot.

11. The device of claim 9 further comprising: a first flange plate having a plurality of flanges;a second flange plate having a plurality of flanges;a strut connecting a flange from the first flange plate to a flange of the second flange plate, the strut having: a proximal portion attached to the flange of the first flange platea distal portion attached to the flange of the second flange plate; anda retention bracket slidably engaged in linear alignment with the proximal portion and the distal portion.

12. The device of claim 9 wherein the retention bracket further comprises: an elongated body having opposed ends;a pair of slots at each end of the opposed ends;each slot of the pair of slots having a width based on a diameter of a connection peg adapted to extend through the slot, anda length greater than the width for accommodating slidable communication of the elongated body with the proximal portion and distal portion.

13. The device of claim 6 further comprising a sheathing panel, the load cap having at least one aperture for receiving a fastener securing the sheathing panel, the sheathing panel having: a shape based on uniform distances between a plurality of load caps; andan aperture aligned with a plurality of load caps aligned with the shape.

14. The device of claim 13 wherein the load caps for a spacing to other load caps defined by an equilateral triangle, and the shape is an equilateral triangle having apertures aligned with three of the load caps.

15. A structural building system, comprising: a plurality of joints, each of the joints including a plurality of flanges joined at predetermined angles, each flange defined by a planar surface and having at least one aperture, anda plurality of struts, each strut having a pair of opposed ends, each end of the opposed ends adapted to join with an aperture on one of the flanges of a respective joint of the plurality of joints,the plurality of struts and the plurality of joints engaged in a tensioned tetrahedral arrangement.

16. The system of claim 15 wherein each of the joints further comprises a flange plate, the flanges extending perpendicularly from the flange plate; anda plurality of apertures on the flange plate for receiving a strut of the plurality of struts,the plurality of struts forming equilateral triangles.

17. The system of claim 16, wherein: the plurality of struts that engage the apertures on the flange plate form a planar arrangement of struts, each strut extending in a plane defined by the plurality of flange plates and forming an equilateral triangle with adjacent struts.

18. The system of claim 16, further comprising: a load cap attached to each joint, the load cap having a face extending parallel to the flange plate,each load cap having a plurality of apertures for engaging a plurality sheathing panels; anda plurality of pegs, the apertures of the load cap adapted for receiving the pegs, each peg for engaging a respective sheathing panel of the plurality of sheathing panels, the plurality of sheathing panels forming a tensioned arrangement with the others of the plurality of sheathing panels.

19. A method for forming a structural joint device, comprising: cutting a sheet of planer stock in a partial circle having a width;forming a plurality of apertures through the sheet of planer stock;dividing the partial circle for designating an angular section;folding the partial circle to form perpendicular flanges on each side of the angular sections, the flanges perpendicular from the angular section;joining the angular sections with at least one other angular section by joining the flanges in parallel and maintaining the angular sections coplanar.

20. The method of claim 19 wherein the angular sections are 120 degrees, further comprising joining three angular sections for forming a flange plate with joined flanges extending perpendicularly from the flange plate.