Note: Descriptions are shown in the official language in which they were submitted.
MODULAR ~CONSTRUCTIO~
~a~3~
The present invention relates to the modular
construction of structures which comprise a network of
interconnected struts and may be conveniently built up from
a plurality of modular components. Such structures have
become increasingly popular for roofing large areas such
as warehouses, stadiums, public open space, shopping halls
and the like as they may be fashioned to span large areas
without central supporting columns. Such structures may be
either load bearing or primarily decorative and have the
capacity to form space frames which clear span in two
directions.
Typically such structures are huilt up using a
pluralit~v of standard or modular components. The components
may comprise a plurality of elongated struts held in spaced
relationship to one another by a plurality of connectors
whereby to form a network of interconnected struts.
Numerous means of joining the connectors and struts to
one another have been proposed but none have proved entirely
satisfactory.
The connecting means should proviae for a secure connec-
tion of adequate strength which is easy to assemble. For
this reason it would be preferable for power tools to be
usable for connecting the elements to form the network.
In addition the connection should preferably facilitate
erection of an array in situ and thus be self aligning and
self supporting.
Previously proposed modular building methods have not
proved entirely satisfactory in all of these respects.
It is an object of the present invention to provide, in
one embodiment, a structure formed from a plurality of
modular components. It is also an object of the invention
to provide in another embodiment a method of forming a
structure from a plurality of modular components.
Still further o~jects of the invention will become
apparent from the following description of the invention.
In one embodiment the present invention provides a
structure comprising a plurality of elbngated strut members ,
extending between a plurality of connectors and affixed
thereto by threaded bolts extending longitudinally outwardly
from said struts and threadedly engaging the connectors.
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The strut members according to the invention may each
comprise an elongated rod-like member. The rod-like member
preferably includes a sleeve portion extending into the
hollow section with the tapered portion extending longitudi-
nally beyond the hollow portion. The rod-like member is
preferably substantially annular in transverse cross-section
along the majority of its length although other configurations
are also envisaged as falling within the scope of the present
invention.
A strut member according to the present invention
may have a tapered end~piece at each of its ends. The
end-piece may be integral with the remainder of the strut
member or a separable portion thereof. The external surface
of the end-piece may be of a substantially conical, domed
or other substantially smooth external surface which tapers
toward an outer extremity or nose.
The tapered ènd-piece may be formed in a variety of
ways. For example, the strut member may comprise a pipe or
other hollow section and the end-piece may include a sleeve
portion extending into the hollow section with the tapered
portion extending longitudinally beyond the hollow section.
The end-piece and hollow section may be secured to one another
such as by welding, screw threads, adhesives or other means
suitable for the securement and consistent with the materials
Gf which the respective pieces are composed. The end-piece
is preferably machined from a solid block.
The end-piece may have a bore for receiving a bolt
or other pin-type ~astener so that the fastener may extend
longitudinally outwardly from the strut member.
Preferably the inner face of the end-piece is funnel-
like and an~led toward the bore. By this means the end
of a bolt being fed through the bore from within the strut
member is directed toward the bore opening thereby facilita-
ting the insertion of a bolt into the bore. MoreovPr, the
funne]-like inner face of the end-piece allows a powered wrench
or like tool to be used in the assembly of the structure.
Preferably the bore comprises a first portion adapted
to receive the head of the threaded fastener and a second
portion of a reduced size relative to the first portion and
~0 adapted to receive the shank but not the head of the fastener;
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the second portion being positioned outwardly of said first
portion, i.e. closer to the outer extremity or nose of the
end-piece. Thus the head of a bolt may be at least partly
housed within the first portion with the shank extending
through the second portion and longitudinally outwardly of
the strut member for threadedly engaging a connector according
to the invention.
The outer surface o~ an end-piece according to the
invention may be in the form of a cone. Conveniently the
outer face is in the form of a truncated cone whereby the
nose terminates in an annular mating face. The surface of
the mating face may be substantially planar with the plane
extending substantially normally of the longitudinal a~is
of the strut member.
Preferably each elongated strut member further
includes an access port positioned adjacent each end of
the strut member whereby in use a threaded fastener may be
passed through the access port into the interior of the strut
member and positioned to extend through the bore. The access
port may be substantially circular, oval or other convenient
shape. Conveniently the access port is of a teardrop like
shape with its longer axis extending along the strut member.
The broader end of the tear-drop may face toward the nearer
end-piece of the strut.
To minimize the reduction in strength o~ the strut
member the a~ess port should be of the smalles'~ practicab~e
size. The radius of curvature of the broader end of a tear-
drop shaped access port may accordingly be only marginally
larger than that of the bolt head to be projected through the
bore.
The access port may be provided with a cover. The
cover preferably seals the port to minimize moisture access.
The cover may take the form of a grommett conveniently formed
from metal, rubber or plastics materials.
The strut members provided by the invention may be
formed from a variety of materials including steel, stain-
less steel, plastics and aluminium. T~e choice of material
will depend upon a number of factors including the function
of the structures and the desired strength characteristics.
~0 When steel components are employed they may be
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protected against corrosion by galvanising, painting, po~der
coating and other coatings.
A connector according to the present invention
comprises an enclosed body having a plurality of threaded
passages. The longitudinal axis of the threaded passa~es
of each body all intersect at a single point. Preferably
the body is substantially symmetrical in shape.
Substantially spherical bodies are preferred although
faceted spheroids such as platonic and semi-platonic
bodies and all shaped bodies are all considered as falling
within the scope of the invention. The size of the body
with respect to that of the strut members may be varied
considerably. The extent of variation may be influenced by
such factors as the number, angle, length, and diameter of
the threaded passageways and the weight cost and structure
of the body.
The angles between the passageways in any one
connector may be varied to suit the geometry of the desired
structure.
The connector body may be hollow or substantially
solid and may be conveniently formed ~rom steel, aluminium,
stainless steel or plastics materials. The selection of
material for any particular application is dependent upon a
number of factors including the desired structural strength
indoor/outdoor applications, compatability with other
components, and the like.
The outer surface of the body may be facetted in the
region of the passagewa~s to provide a substantially planar
mating surface about each passageway. A counter-bore or
counter-sink may be provided at the entrance to each
passageway to facilitate mating ~etween the connector and a
strut member. The mating surface may be conveniently
provided ~ithin the counter bore i.e. the mating surface may
be below the outPr surface of the body.
In a structure according to the invention the nose of
the strut may abut the connector. In an alternative
arrangement a spacer may be interposed between the strut
and the connector. Preferably the spacer is in the form of
a sleeve having an internal diameter sufficient to allow
free passage of a bolt therethrough. The external surface
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of the sleeve may be of the same cross sectional shape as
tha-t of the strut. Preferably -the sleeve is subs-tantially
cylindrical.
The end Eaces of -the sleeve may form a complemen-tary
angle with the faces of the connector and stru-t with which they
are to abut.
The nose of the strut member may be substantially
planar with the plane being substantially normal -to the longi-
tudinal axis. The end faces of the sleeve are preferably also
substantially planar, with the plane being substantially normal
to the longitudinal axis whereby to nes-t against the nose. In
one arrangement a counter-bore or counter-sink may be pro-
vided in the nose of the end--piece for receiving one end of a
sleeve in accordance with the invention.
The optional counter-bore or counter-sink in the
connector and/or nose may each be dimensioned to receive a
separate end face of the sleeve.
The use of counter-bores or counter-sinks may serve
to alleviate the bending and shear forces on the bolts in an
erected structure according to the invention.
The rims of intersection between the end faces and
longitudinal wall of the sleeve may each be chamfered.
The sleeve may be a separate component as described
above. In an alternative arrangement the sleeve may be affixed
to the end of the strut such as by welding or adhesives. In
yet another embodiment the sleeve ma~ be formed as an integral
part of -the strut end piece. In this arrangement the sleeve
may appear as an extension of the nose of the end
piece.
The bolt provided in accordance with the lnvention
may have a partly or fully threaded shank. The head of the
bolt may be shaped to receive a spanner or similar tool.
Preferably the head is substantially cylindrical with a
socket provided in its top face. Such an arrangement facili-
ta-tes tightening of the bolt using a wrench with a complemen-
tary stud and a universal joint, the shank of the wrench
projecting out of the strut through the access port. The
shank of the wrench may be fitted with a handle for manual
operation or may be coupled to an impact drill or similar
power tool for rotation of the bolt.
A Eirst sealing member may also be provided in
accordance with the invention. The member is preferably in
the form of an O-ring which may be formed from elastomeric,
polyurethane, rubber, neoprene or other resiliently deformable
material. In use, the sealing member may surround -the shank
of the bolt adjacent the nose of the strut. The inner rim
of the nose and the abutting inner rim of the sleeve or
other connector are preferably chamfered and the sealing
member may conveniently be situated within the void so
formed.
The sealing member may firstly serve the purpose
of sealing the strut by acting as a barrier to moisture
migrating along the bolt to the interior of a hollow strut.
The sealing member may secondly serve the puxpose of holding
the bolt in place in the end of the strut prior to engagement
with the connector.
A second sealing member may optionally be provided
between the connector and the sleeve. Preferably a void is
created to receive the sealing member in this location by
chamfering the neighbouring rims. Where the sleeve is
integral with the strut a single sealing member may be provided
between the connector and the sleeve.
A seat or washer may be provided for the bolt in
accordance with the present invention. The seat or washer
may be adapted to receive the shank of the bolt or in-ternal
diameter of the washer may be sufficient to allow passage of
the shank or the bolt but retain its head. The washer may
be positioned between the head of the bolt and the inner face
of the end piece. The washer or seat may be of greater
diameter than -the bolt head. The washer may be of a hardy
material to reduce wear. For example the washer may be
manufactured in a high tensile steel.
In use, the assembly of -the elements provided by the
invention may be effected simply and positively as will now
be described in rela-tion to one preferred embodimen-t.
The bol-t is inserted head firs-t through the access
port with the head being directed up the tube away from the
adjacent end-piece. When the bolt is wholly within the tube
the tube is angled for the bolt -to fall by gravity -through
the bore.
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The washer or seat when presen-t may be positioned within -the
end piece prior to insertion of the bolt. Alternatively, -the
washer may be placed around -the shank of the bolt prior to
its insertion into the end piece.
An O-ring is placed over the protruding shank of -the
bolt~ The bolt is -thereby captured wi-thin the bore. The
sleeve is then placed over the protruding shank and a wrench
engages the socket in the head. The other end of the wrench
is coupled to an impact drill. The shank of the bolt is
entered into the desired passageway of the connector and
the bolt rotated by the impact wrench to engage the threads
of the passageway. The strut is thereby affixed to -the
connector. A network of interconnected struts may be
built up following the above described procedure by affixing
a plurality of struts to each connector.
The present invention will now be more fully described
with reference to the accompanying drawings. It should be
unders-tood, however, that the following description is
illustrative only and should not be taken in any way as
superceding the generality of the preceding description.
In the accompanying drawings Figure 1 is a cut-away
view of one possible form of elements according to the present
invention.
Figure 2 is a schematic representation of one
possible form of network incorporating an embodiment of a
structure according to the present invention.
Figure 3 is a perspective view of an embodiment of
the structure according to the present invention.
In more detail Figures 1 to 3 illustrate a structure
according to the present invention comprising a plurality of
connector~ 1 f~om which extend a plurality of elongated strut
members 2 in a variety of networks. An example of such a
ne-twork is illustrated in Figure 2.
The elongated strut members 2 include an access port
3 to assist in the assembly of the elements provided by the
invention~. The elongated strut mernber 2 includes a tapered
end piece 4 at each of its ends. the end piece may be secured
to a hollow section of the elongated strut member in any suit--
able manner. The end piece 4 includes a stepped bore 5 adap-ted
to receive a bolt 6 and which commences in a countersunk end face 5A.
The bolt 6 thus extends longitudinally outwardly from the
elongated s-trut member 2.
The bol-t 6 passes through a passage 7 in the form of
a sleeve. The bolt -then is threadably connec-ted to a threaded
passage 8 in the connector 1. As best illustrated in Figure
3 the outer surface of the connec-tor is faceted around -the
threaded passage to provide a substantially planar mating
surface for the passage 7 or elongated strut member 2. A
sealing member 10 in the form of an O-ring is provided on
the shank of -the bolt 6 and is positioned between the nose
of the end piece 4 and the passage sleeve 7. The inner rim
of the nose and the abutting inner rim of the sleeve 7 are
camphered to provide a void for the O-ring 10.
A washer 11 is provided between the head of the
bolt 6 and the base of the bore 5.
Finally it is to be understood that various altera-
tions, modifications and/or additions may be introduced into
the constructions and arrangements of parts previously
described without departing from the spirit or ambit of the
invention-
