Note: Descriptions are shown in the official language in which they were submitted.
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
A NON-STANDARD, REINFORCED LOAD-BEARING CELL FOR A SIMPLIFIED,
INTERCONNECTING CELLULAR CONSTRUCTION SYSTEM
IYAD MOHAMAD ADNAN DAADOUSH
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of US Application No 13/004,856,
filed January 11,
2011, which is hereby incorporated herein by reference in its entirety.
BACKGROUND
Field of the Teachings
[0002] The teachings are directed to a construction system that includes a
three-dimensional,
load-bearing cell that can be modular, releasably connectable with other
construction
components, reinforced with bracing for higher strength, and exceed industry
size limits, for
use in a building or non-building structure.
DESCRIPTION OF THE RELATED ART
[0003] The art of construction is old. Existing systems for the construction
of a building or non-
building structure divide the structure into a number of elements, such as
columns, beams
and slabs connected together. These divisions are considered as the basic
elements of the
structure being constructed and are the status-quo that has been long-
accepted.
[0004] Unfortunately, the art of construction carries many downfalls in the
status-quo, downfalls
that are now built into the long-accepted construction infrastructure. These
downfalls
include, for example, (i) the complexities of design that result in increased
time and budget
requirements, and (ii) the amounts of materials, equipment, and labor that
need to be
involved in a construction project. As such, the status-quo brings in extra
time requirements,
labor requirements, manufacturing requirements, material waste, and, bottom
line,
exorbitant costs. Accordingly, one of skill will appreciate a reduction in
costs, both financial
and environmental. As such, a structure that can be connected using limited
material, time,
and personnel, would be appreciated.
1
CONRRINION COPY
CA 02823585 2013-07-02
WO 2012/095721
PCT/IB2012/000019
[0005] The teachings provided herein offer one of skill (i) an ability to save
on the complexities
and amounts of materials, equipment, and labor needed in a construction
project, (ii) a
reduction in costs, and (iii) a novel, simplified, and bid-winning approach to
the art of
construction. One of skill will appreciate that the systems taught herein
provide a novel-and-
green enhancement that offers a simpler and more cost-effective construction
design and
practice.
SUMMARY
[0006] The teachings are generally directed to a construction system that
includes a load-
bearing, node module for simplifying the connection of a series of load-
bearing bars during
the construction of a building or non-building structure. The load-bearing
bars can be used
to form cells, such as three-dimensional frame structures, that provide
structural support for
a building or non-building structure. In some embodiments, the node module
comprises a
support structure having a top surface and a bottom surface; and, a plurality
of bar
connectors. In these embodiments, the plurality of bar connectors can include
at least one
pair of bar connectors, each pair configured to direct (i) an opposing axial
load into the
support structure, the opposing axial load comprising a first load on the top
surface that is
opposed to a second load on the bottom surface; and, (ii) an opposing shear
load that is
orthogonal to the opposing axial load between each of the at least one pair
through the
support structure, the opposing shear load comprising a tensile force and a
compression
force on the support structure. Each bar connector is configured to mate with
a respective,
complementary portion of a bar, the mating of each of the bar connectors with
their
respective bars forming a node module configured to bear the opposing axial
load and the
opposing shear load within the building or non-building structure.
[0007] In some embodiments, the top surface and the opposing bottom surface of
the support
structure have a compressive strength that is at least as high as a highest
expected axial
load in a location of intended use within the building; and, the connection
between each
respective bar and the node module has a shear strength that is at least as
high as a
highest expected load that is orthogonal to the axial load in the location of
intended use
within the building.
[0008]The node modules taught herein can have one or more connectors for
connecting the
node module to a bar. In some embodiments, the node module can comprise a pair
of
2
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
connectors within the at least one pair of bar connectors that shares a
central axis, or it can
comprise a pair of connectors that do not share a central axis. The node
module can be
used as a component in a shell support structure or a core support structure.
And, in some
embodiments, the mating of each of the bar connectors with their respective
bars comprises
a releasable, slidable connection.
[0009] In some embodiments, the support structure comprises a horizontal base
plate with at
least one pair of bar connectors and a vertical plate, the vertical plate
forming a plane that
intersects a plane formed by the horizontal plate and separating the at least
one pair of bar
connectors. The node module can comprise a cast metal alloy and, in some
embodiments,
the node module can include an elastic coating, for example, where the node
module
contacts a bar.
[0010] The support structure can comprise a first plate having the at least
one pair of bar
connectors and a second plate forming a plane that intersects a plane formed
by the first
plate at an angle 6, the second plate separating the at least one pair of bar
connectors. The
angle 0, for example, can comprise an angle of incline upon which the building
or non-
building structure is constructed. In some embodiments, the angle 0 can
comprise an angle
of assembly formed by a stacking of cellular bar modules within the building
or non-building
structure.
[0011] The teachings are also directed to a system comprising at least two
vertical load-bearing
bars and a node module as described herein. In some embodiments, the load-
bearing,
node module is used for simplifying the connection of a series of load-bearing
bars during
the construction of a building or non-building structure. In these
embodiments, the node
module comprises a first plate comprising a top surface, a bottom surface, and
a base for a
plurality of bar connectors. The first plate forms a first plane, and, a
second plate forms a
second plane that intersects the first plane at an angle 6, the second plate
separating the at
least one pair of bar connectors. The plurality of bar connectors can include
at least one
pair of bar connectors configured to direct (i) an opposing axial load into
the first plate, the
opposing axial load comprising a first axial load on the top surface that is
opposed to a
second axial load on the bottom surface; and, (ii) an opposing shear load that
is orthogonal
to the opposing axial load between each of the at least one pair of connectors
through the
first plate, the opposing shear load comprising a tensile force and a
compression force on
3
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
the first plate. In the present teachings, a load can include, for example, a
dead load, a live
load, an environmental load, or a combination thereof.
10012] Each bar connector can be configured to mate with a respective,
complementary portion
of a bar, the mating of each of the bar connectors with their respective bars
through the
node module configured to bear an axial load and a shear load orthogonal to
the axial load
within the building. The mating can comprise a releasable, slidable
connection, the top
surface and the opposing bottom surface of the support structure can have a
compressive
strength that is at least as high as a highest expected axial load in a
location of intended use
within the building; and, the connection between each respective bar and the
node module
can have a shear strength that is at least as high as a highest expected shear
load
orthogonal to the axial load in the location of intended use within the
building.
[0013] The teachings are also directed to a cellular construction system for
constructing a
building or non-building structure. The system can comprise a node module as
described
herein; a first cell having a first three-dimensional frame structure
comprising a first axial
load bearing bar having a first respective complementary portion for mating
with a first
connector of the node module; and, a second cell having a second three-
dimensional frame
structure comprising a second axial load bearing bar having a second
respective
complementary portion for mating with a second connector of the node module.
The node
module can connect the first three-dimensional frame structure to the second
three-
dimensional frame structure in the creation of a cellular building structure
or a cellular non-
building structure.
[0014] The dimensions of the first or second cellular, three-dimensional frame
structure can
exceeds size standards set for transporting construction materials to a
construction site as
compared to pre-fabricated cellular structures that are required to follow the
size standards.
[0015] in some embodiments, the node module connects the first three-
dimensional
geometrical frame structure to the second three-dimensional geometrical frame
structure in
a face-to-face, edge-to-edge, or vertex-to-vertex arrangement in the creation
of a cellular
building structure.
[0016] The teachings are also directed to a method of creating a cellular
building structure. The
method comprises obtaining a node module described herein, constructing a
first cell having
4
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
a first three-dimensional frame structure comprising a first axial load
bearing bar having a
first respective complementary portion for mating with a first connector of
the node module,
constructing a second cell having a second three-dimensional frame structure
comprising a
second axial load bearing bar having a second respective complementary portion
for mating
with a second connector of the node module, and interconnecting the first
three-dimensional
geometrical frame structure to the second three-dimensional geometrical frame
structure
using the node module in the creation of the cellular building structure. The
interconnecting
can include (i) mating the first connector of the node module to the first
respective
complementary portion and (ii) mating the second connector of the node module
to the
second respective complementary portion.
(0017) The teachings are also directed to a cellular construction system
comprising a single-
unit, node module. The single-unit, node module can be configured with a means
for
interconnecting a series of structural, three-dimensional load-bearing cells,
the series
including a first cell and a second cell. The first cell can comprise a first
axial load bearing
bar having a first respective complementary portion for mating with a first
connector of the
node module. The second cell can comprise a second axial load bearing bar
having a
second respective complementary portion for mating with a second connector of
the node
module. The node module can connect the first cell to the second cell using a
process that
includes (i) mating the first connector of the node module to the first
respective
complementary portion and (ii) mating the second connector of the node module
to the
second respective complementary portion, such that the first cell and the
second cell are
connected in a face-to-face, edge to edge, or vertex to vertex arrangement in
the creation of
a cellular building or non-building structure.
100183 The teachings are also directed to a three-dimensional, load-bearing
cell for use in a
cellular construction system for a building or non-building structure. The
cell comprises a
vertical-load-bearing bar; and, a horizontal-load-bearing bar attached to the
vertical-load-
bearing bar. The load-bearing cell can be constructed on-site and can have a
dimension
that exceeds size standards set for transporting construction materials to a
construction site
as compared to pre-fabricated cellular structures, which one of skill will (i)
readily distinguish
from existing "pre-fabricated structural units" or "pre-fabricated structural
modules" that have
been designed to a size limit that complies with such industry standards; and
(ii) readily see
as a valuable and innovative technical contribution. The load-bearing cell can
also be
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
configured to attach to a second cell using a cell-to-cell connector, the load-
bearing cell and
the second cell being connected through the cell-to-cell connector in a face-
to-face, edge to
edge, or vertex to vertex arrangement in the cellular construction of the
building or non-
building structure.
[0019] The load-bearing cell can be used as a shell support structure or a
core support
structure and, in some embodiments, can be composed of prefabricated assembly
components that are readily transportable to the site. Moreover, the load-
bearing cell can
be more readily assembled and interconnected within the building or non-
building structure
when compared to non-cellular load-bearing structures that are otherwise used
for the shell
support structure or the core support structure of the building or non-
building structure.
[0020] In some embodiments, the load-bearing cell can have an internal cross-
bracing across
the inner volume of the cell that functions to subdivide load-induced stresses
into smaller
distributed force components. And, in some embodiments, the load-bearing cell
can have a
vertical load-bearing bar with a fitting that is complementary to the cell-to-
cell connector. In
these embodiments, the cell-to-cell connector can be a single-unit node having
at least one
pair of connectors for connecting the load-bearing cell to the second cell.
[0021] In some embodiments, the cell-to-cell connector can comprise a first
plate having the at
least one pair of bar connectors and a second plate forming a plane that
intersects a plane
formed by the first plate at an angle 8 ranging from about 0 degrees to about
45 degrees.
The second plate can be positioned between at least two pair of bar connectors
on the first
plate, each pair of bar connectors having a first connector on a first side of
the first plate and
a second connector on a second side of the first plate, the first side
opposing the second
side.
[0022] In some embodiments, the angle 9 can comprise an angle of incline that
ranges from
greater than 0 degrees to about 45 degrees upon which the building or non-
building
structure is constructed on a support surface. In some embodiments, the angle
e can
comprise an angle of assembly formed by a stacking of load-bearing cells
within the building
or non-building structure.
[0023] The teachings are also directed to a frame structure system. The system
can comprise
a series of inter-connected, modular three dimensional geometrical frame
structures
6
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
connected in a face-to-face arrangement, each individual frame structure
comprising a
series of bars connected to define faces of a three dimensional geometrical
frame structure
that includes a base face; and, at least one bar forming a bracing for a face
of the
geometrical frame structure. The geometrical frame structure can comprise a
plurality of
bars that form a cross-bracing for the base face.
[0024] In some embodiments, the geometrical frame structure can comprise bars
forming a
triangular frame structure within a vertical face of the geometrical frame
structure, the
triangular frame structure positioned within the upper part of the face; one
or more diagonal
bars to cross-brace vertical faces of the frame; or one or more diagonal bars
extending
across the interior of the frame. In some embodiments, a geometrical frame
structure can
comprise at least 6 bars and, in some embodiments, a geometrical frame
structure can
comprise cuboid frame structures formed from 14 bars, having twelve bars
forming the
edges of the cuboid frame structure, and two bars forming a cross-bracing for
a base face.
[0025] In some embodiments, the frame structure system can comprise a means
for
interconnecting the geometrical frame structures in a face-to-face, vertex-to-
vertex, or edge-
to-edge configuration, or a means for connecting a structure to a base
surface. And, in
some embodiments, the geometrical frame structures can be connected side-by-
side and/or
stacked, for example, on top of each other. In these embodiments the
structures can be
used to form a core support structure or a shell support structure for a
building or non-
building structure.
[0026] The teachings are also directed to a method of constructing the frame
structure system.
The method comprises delivering a plurality of pre-formed load-bearing bars to
a
construction site, in which each bar in the plurality of load-bearing bars can
have a
dimension that was preselected for forming the geometrical frame structure
without further
resizing of the load-bearing bar. The method also comprises forming the
geometrical frame
structures on-site.
[0027] The teachings are also directed to an apparatus for transporting and
constructing the
frame structure system. The apparatus includes a container for transporting
pre-selected
bars used in forming the geometrical frame, a frame structure configured for
receiving the
pre-selected bars from the containers and holding the pre-selected bars in a
desired position
to define the faces of the geometrical frame, and a configuration to
facilitate connecting, for
7
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
example welding, the bars to form the geometrical frame structure. A budding
or non-
building structure can comprise the frame structure system, in some
embodiments.
BRIEF DESCRIPTION OF THE FIGURES
[0028] FIG. 1 shows a birds eye aspect of a cubical frame, according to some
embodiments.
[0029] FIG. 2 shows a side aspect of a cubical frame, according to some
embodiments.
[0030] FIG. 3 shows a three dimensional aspect of a cubical frame, according
to some
embodiments.
[0031] FIG. 4 shows an expanded view of the corner piece of a cubical frame,
according to
some embodiments.
[0032] FIG. 5 shows a birds eye aspect of cubical frames arranged into a
modular system,
according to some embodiments.
[0033] FIG. 6 shows a side aspect of cubical frames arranged into a modular
system, according
to some embodiments.
[0034] FIG. 7 shows a three dimensional aspect of cubical frames arranged into
a modular
system, according to some embodiments.
[0035] FIG. 8 shows an expanded view of the columns and beams which are
produced from
inter-connecting cubical frames, according to some embodiments.
[0036] FIG. 9 shows a birds eye aspect of a node module, according to some
embodiments.
[0037] FIG. 10 shows a side aspect of a node module, according to some
embodiments.
[0038] FIG. 11 shows a three dimensional aspect of a node module, according to
some
embodiments.
[0039] FIG. 12 shows a node module being inserted into the connection point of
4 cubical
frames, according to some embodiments.
8
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
[0040] FIG. 13 shows a base node module inserted into the connection point of
two cubical
frames, according to some embodiments.
[0041] FIG. 14 shows a three dimensional aspect of cubical frames arranged
into a modular
system with flooring, according to some embodiments.
[0042] FIG. 15 shows a cubical frame structure installation machine, according
to some
embodiments.
[0043] FIG. 16 shows a cubical frame structure installation machine with
cubical frame structure
bars being connected, according to some embodiments.
[0044] FIGs. 17-26 show the three dimensional aspects of geometrical frames,
according to
some embodiments.
[0045] FIG. 27 shows a three dimensional aspect of four sided oblique prism
frame structures
arranged into a modular system, according to some embodiments.
[0046] FIG. 28 shows a three dimensional aspect of geometrical frames arranged
into a
modular system, according to some embodiments.
[0047] FIG. 29 shows a bird's eye aspect of figure 28, showing geometrical
frames arranged
into a modular system, according to some embodiments.
[0048] FIGs. 30-33 show three dimensional aspects of node modules, according
to some
embodiments.
[0049] FIGs. 34 and 35 show three dimensional aspects of plate modules,
according to some
embodiments.
[0050] FIG. 36 shows the three dimensional aspects of cuboid frame structures
and arranged
into a modular system and connected together with plate modules, node modules
and
brackets, according to some embodiments.
[0051] FIG. 37 shows a geometrical frame structural installation machine,
according to some
embodiments.
9
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
[0052] FIG. 38 shows a geometrical frame structural installation machine with
frame structure
bars being connected to form a geometrical frame structure, according to some
embodiments.
[0053] FIG. 39 illustrates a load-bearing node module which can be used as a
connection
means, and which can be inclined at a desired angle, according to some
embodiments.
[0054] FIG. 40 illustrates a clip module that can be used as a connection
means, according to
some embodiments.
[0055] FIG. 41 illustrates a node-to-node arrangement that includes a series
of interconnected
triangular prisms, according to some embodiments.
[0056] FIG. 42 illustrates the flexibility in interconnecting and stacking
that is provided herein,
according to some embodiments.
[0057] FIGs 43A1_5-G1_5 provides a variety of bracing designs contemplated,
according to some
embodiments.
[0058] FIG. 44 illustrates an example of a cell that is built as an inclined
cell, where the node
module has an angle e greater than 0, according to some embodiments.
[0059] FIG. 45 illustrates a side-aspect sketch of an inclined building
structure, where the
structure includes inclined cells and inclined node modules, according to some
embodiments.
[0060] FIG. 46 illustrates the construction of a building or non-building
structure having the cells
as cantilever units, according to some embodiments.
[0061] FIG. 47 illustrates cells placed in face-to-face arrangements and
stacked in an
axial/radial grid-type configuration, according to some embodiments.
[0062] FIG. 48 illustrates an edge-to-edge arrangement of hexagonal-cylinder
shaped cells,
according to some embodiments.
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
DETAILED DESCRIPTION OF THE TEACHINGS HEREIN
[0063] The teachings are generally directed to a construction system that
includes a load
-
bearing, node module for simplifying the connection of a series of load-
bearing bars during
the construction of a building or non-building structure.
[0064] It should be appreciated that a "building" structure can refer to, for
example, any human-
made structure used or intended for supporting or sheltering any use or
continuous
occupancy. A "non-building" structure can refer to, for example, structures
that are not
designed for human occupancy and is used by those of skill to distinctly
identify structures
that are not "building" structures. Examples of non-building structures can
include aerial lift
pylons; boat lifts; bridges and bridge like structures, such as aqueducts,
overpasses,
trestles, viaducts, and the like; building canopies; chimneys and smokestacks;
dams; electric
power transmission towers; ferris wheels and observation wheels; monuments;
parking
structures; offshore oil platforms; piers; roller coasters; retaining walls;
sewers; cranes;
automobiles; structures designed to support, contain, or convey liquid or
gaseous matter,
including cooling towers, pipelines, distillation equipment and structural
supports at chemical
and petrochemical plants and oil refineries, and storage tanks; television and
radio masts
and towers; tunnels; and, wharves; to name just a few. One of skill will
appreciate that the
teachings provided herein are for example only, and that there are a plethora
of applications
of these general teachings.
[0065] The load-bearing bars can be used to form cells, such as three-
dimensional frame
structures, that provide structural support for a building or non-building
structure. The cells
can be interconnected by the node modules. In some embodiments, the "cells"
can be
referred to interchangeably using other terms in the teachings provided
herein, such as
"frame structures," "geometrical frame structures, three-dimensional
geometrical frame
structures, geometrical frames, and the like, and the terms "three-
dimensional," "modular" or
"non-modular" can often sometimes be used to modify the terms for one or more
particular
applications of the teachings provided herein. Likewise, the term "bars" can
be used to refer
to any load-bearing frame component, such as a "beam," or a 'column," in some
embodiments. In some embodiments, the teachings provided herein can sometimes
include
non-load-bearing frame components as well, and such components can also
include "bars."
One of skill will recognize that a non-load-bearing frame component can refer
to a
11,
CA 02823585 2013-07-02
WO 2012/095721
PCT/1132012/000019
component that will occasional bear a load due to, for example, a live load or
an
environment load in some embodiments.
[0066] The teachings are also directed to a system comprising at least two
axial load-bearing
bars and a node module as described herein. The axial load includes, for
example, a load
that is taken by the axis of a bar. The axial load, for example, can be a
vertical load, a
horizontal load, or it can be a component of a vertical or horizontal load.
One of skill will
appreciate that loads placed on a building or non-building structure into
three basic force
components, X, Y, and Z. These three basic components can be used to define
virtually
any load placed on the building or non-building structure in three dimensional
space using,
for example, the force components denoted by X cos 8, X sin A, Y cos 0, Y sin
8, Z cos 0,
and Z sin 0, where 9 can be used to define the angle of the component force,
for example,
from the X, Y, or Z directions. These loads, for example, can be derived from
a dead load, a
live load, an environmental load, or a combination thereof. One of skill will
appreciated that,
in some embodiments, the dead load includes gravitational stresses, the live
load includes
variable stresses that are due to persons, for example, in a building
structure, and the
environmental load includes wind, rain, earthquakes, flood, mechanical
impacts, and the
like. Given the general teachings provided herein, the knowledge of one of
skill can be used
to select and engineer the materials and methods taught herein to be suitable
for a desired
construction.
[0067] FIGs. 1-3 show various aspects of a cubical frame structure 10 that is
connectable to
form a frame structure system, according to some embodiments. The cubical
frame
structure 10 can be constructed from twelve bars 12, corresponding to the
twelve edges
found on a cube. These bars can be connected to define the faces of a cubical
frame
structure 10. One or more further bars 14 can be arranged diagonally to form a
cross
bracing on the lower plane (or lower face) 16 of the cubical frame 10. In some
embodiments, the basic cuboid structure can be formed from a total of fourteen
bars 12,
twelve of the fourteen bars making up the twelve edges and a remaining two
bars 14
forming a cross bracing on the lower plane 16. Diagonal bars 18 may also be
incorporated
on the vertical planes (or vertical faces) 20 of the cubical frame 10 to
counteract horizontal
forces. Such a design can be used to buttress, for example, cubical frames
that are
incorporated at the bottom of a modular system where horizontal forces are
greater. Adding
diagonal bars 18 to counteract horizontal force may also be recommended where
the
12
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
cubical frames are to be used in a modular system carrying large structural
spans, bearing
cantilevers, or forming space frame structures.
[0068] The bars 12, 14 may be constructed from any suitable material known to
one of skill. In
some embodiments, the material can include any form of steel that is strong
enough to
withstand at least the highest expected axial load in the location where the
bar is used in a
building or non-building structure. One of skill will also appreciate that the
bar can be pre-
formed to any desired shape, as long as the interconnectability taught herein
can be
implemented by such desired shape. As such, the cross sectional form of the
bars may be
any desired form that is suitable and provides the necessary strength. In some
embodiments, the desired form may be one that is lightweight, an example being
a
cylindrical cross-section in the form of a square, a circle, or an ellipse;
or, in some
embodiments, an I-beam type of structure.
[0069] The cubical frames 10 may vary in size, corresponding to the length of
the bars 12. The
individual cubical frames 10 may vary in dimensions, and each bar in the
cubical frame may
or may not be of the same size and form. In some embodiments, the frame
structures 10
can be of a standard size such as, for example, a size that works well in a
simple, modular
system. In addition, in some embodiments, each bar may be of the same size in
a frame
structure, further simplifying the selection, transportation, and construction
process. Having
standard sizes can also help to ensure that the individual cubical frames are
correctly
aligned and capable of interconnecting in any such construction system.
[0070] FIG. 4 shows an expanded view of a corner piece 22 of a cubical frame
10, according to
some embodiments. A socket 24 can be provided that is capable of accepting one
of the
four pins on the node module thereby permitting the cubical frame to be
attached to others
in the modular system. Such sockets 24 may be incorporated in all eight corner
pieces 22,
for example, and permit any individual cubical frame to be attachable to
others in all three
dimensions.
[0071] Two or more cubical frames 10 may be inter-connected in a face-to-face
arrangement in
a modular system which may act as infrastructure for the construction of a
building. The
teachings herein provides cubical frame structures 10 which are connectable
side-by-side
and/or on top of each other to form a three dimensional arrangement of cubical
frames
structures. The teachings herein further provide a method of forming a modular
system;
13
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
pre-formed bars 12 can be delivered to a site for installation and are
connected to define the
frame structures 10, which can be further connectable, for example, to form a
modular or
non-modular system.
[0072] FIGs. 5 to 7 show various aspects of cubical frames 10 arranged into a
modular system
26, according to some embodiments. In FIGs. 5 to 7, eight cubical frames 10
have been
connected. One or more cubical frames can be used to form the lower layer 28,
and form
the structure of a ground floor, for example. These can be attached via the
base node
modules to a solid base or foundations on the same level, as described herein.
The node
modules 36,40 (some embodiments are shown in FIGs 9-14) help ensure that the
individual
cubical frames 10 are correctly aligned, for example, both vertically and
horizontally. The
node modules can further be used to help ensure that the weight of the load is
transferred
directly down through the structure to the solid base. The bars of the cubical
frames can be
further fastened together in the same frame, for example, with brackets 105 as
described in
other FIGs, or secondary sub-bars, to provide a stronger frame structure. The
node
modules, the cubical frames, and the solid base, can be further fastened
together, in some
embodiments, with bolts, to provide a stronger interconnected structure.
[0073] The solid base can have a flat surface to ensure the correct alignment
of the cubical
frames 10 and further help ensure that the floors placed on upper levels are
also flat.
Another layer 30 of cubical frames 10 may be connected to the lower layer 28
to form a first
floor and so on until the desired number of floors has been added.
[0074] One or more pre-cast stabs, can be laid upon the lower surface 16a, 16b
of the cubical
frames to provide a floor. Moreover, in some embodiments, the vertical faces
and partitions
which help to form the internal and external walls can be constructed from
lightweight
panels.
[0075] FIG. 8 shows an expanded view of the columns 32 and beams 34 which can
be
produced from inter-connecting structural frames with a node module, according
to some
embodiments. The columns 32 and beams 34 can be used to interconnect
structural frames
using a connector, such as a node module.
14
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
[0076] FIGs. 9-11 show various aspects of a node module, according to some
embodiments.
The node module 36 can comprise plates 37 and pins 38 that are complementary
with
sockets 24 found in the frame structures 10, for example, in the corner pieces
22.
[0077] FIG. 12 shows a node module being inserted into the junction of the
corner pieces of
four cubical frames, according to some embodiments. Each of the four lower
pins 38 can be
inserted, one each, into a corner piece socket 24. Up to eight cubical frames
10, for
example, may converge on a single point. The node module 36 can provide eight
pins 38,
for example, four pointing downwards and four pointing upwards, thereby
permitting these
eight cubical frames 10 to be connected at a single point
[0078] FIGs. 13 and 14 show base node module inserted into the junctions of
the lower corner
pieces of cubical frames that can form the base of the lower layer of the
structure, according
to some embodiments. The base node module 40 comprises pins 42 complementary
with
the sockets found in the cubical frames corner pieces. Up to four cubical
frames 10, for
example, may converge on a single point on the base of the structure. The base
node
module 40 can be used to provide four pins 42 extending upwards from a flat
base, thereby
permitting these four cubical frames to be connected at a single point. In
some
embodiments, one or more pre-cast slabs 44 can be laid upon the lower surface
to form a
floor.
[0079] FIGs. 15 and 16 show an installation machine for use in forming a
cubical frame
structure, according to some embodiments. The cubical frame structure machine
50
arranges the pre-formed bars 12 into the correct position, and connects and
welds the pre-
formed bars 12 together to form the cubical frame structure 10. The machine
can be
transported to, and installed at, the construction site, such that a
production line to produce
the cubical frame structures can be established in the factory or, in some
embodiments,
directly at the site of construction to build frame structures that may exceed
the sizes that
can be transported at all, safely, or as a matter of law. The installation
machine can be
transported by either land, sea, or air to the site of construction. It can be
transported, in
some embodiments, as a one-piece apparatus using any transportation means, for
example,
by helicopter or crane. The machine can comprise containers 52, 54 containing
either
horizontal or vertical pre-formed bars. The containers 52, 54 can be fixed on
the frame
structure of the machine with connections to eight automatically moveable fins
56. The fins
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
56 can be used to hold the pre-formed bars in a desired position to define the
faces of the
desired frame structure. Vertical pre-formed bars 58 can be installed
automatically onto fins
from the vertical pre-formed bars containers 54 and horizontal bars 60 can be
installed
automatically onto the fins 56 from the horizontal pre-formed bars containers
52. Once the
bars are installed in the structure, all the bars can be connected to form a
desired three-
dimensional frame structure. In some embodiments, the bars can be welded to
form the
cubical frame structure 10. The formed structure 10 can then be removed from
the machine
50, at which time it is ready for testing and connecting into a modular or non-
modular
building or non-building structure.
[0080] One of skill will appreciate that there are a plethora of frame
structure shapes possible
for use with the teachings provided herein. FIGs. 17-25 show various
geometrical frame
structures, according to some embodiments.
[0081] FIGs. 17 and 18 show different triangular prism frame structures,
according to some
embodiments. The triangular prism frame structures 70 can be constructed from
nine bars
72 corresponding to the nine edges found on a triangular prism to define the
faces of the
triangular frame structure. Additional diagonal bars 74 and horizontal bars 76
can be
incorporated on the top portion of the triangular prism vertical faces forming
a vertical
triangular frame 77 within the vertical face. The triangular frame 77 can help
support the
middle point of the bars forming the top face of the triangular prism frame.
Further bracing
bars 79, connecting the middle points of the bars forming the base face, can
be arranged as
cross-bracing across the lower plane.
[0082] FIGs 19, 20, and 22 show how diagonal bars may be used to add
structural strength,
according to some embodiments. Diagonal bars 74,80 may be incorporated, for
example,
across the interior of the frame structure from an upper corner of the frame
to a lower corner
to provide further strength to the frame structure.
[0083] FIGs 24 and 25 show how bar length can be varied, according to some
embodiments.
By varying the length of the vertical bars 72 a desired sloping upper plane
for the frame
structure can be formed. Pre-formed bars 82 may be bent, such that the face 83
of the
frame structure is non-planar.
16
CA 02823585 2013-07-02
WO 2012/095721
PC111132012/000019
[0084] FIGs 19 and 20 show frame structures constructed from twelve bars
corresponding to
the twelve edges found on a quadrilateral prism to define the faces of the
quadrilateral prism
frame structure, according to some embodiments. Two cross bracing bars 78 can
be used
in the formation of a base, for example.
[0085] FIG. 21 shows a four sided pyramidal shaped frame structure, where the
frame
structures are constructed from eight bars, according to some embodiments.
Again, cross-
bracing bars 78 can be used in the formation of a base.
[0086] FIG. 22 shows how a hexagonal prism frame structures can be constructed
from
eighteen bars, according to some embodiments. Cross-bracing bars 78 can again
be used,
for example, in the formation of the lower face, and bars 74, 80 in the
vertical planes may
also be used.
[0087] FIG. 23 shows a cuboid frame structure constructed from twelve bars,
according to
some embodiments. Horizontal 76 and diagonal 74 bars can be used in the
vertical faces
forming vertical triangular frames 77 in an effort to help support the middle
of a bar that
defines the top face of the structure. Cross-bracing bars 78 and the bracing
bars 79 can be
used for connecting the middle points of the bars in the lower face.
[0088] FIGs. 26 and 27 show an oblique-sided cuboidal frame structure,
according to some
embodiments. Diagonal cross-bracing bars 74 can be used in the vertical faces.
The frame
structure can be constructed from twelve bars 72 ,73 corresponding to the
twelve edges
found on a oblique four sided prism to define the faces of the oblique four
sided prism frame
structure 82. The structure can include two diagonal bars cross-bracing the
vertical faces
74 and two cross-bracing bars 78 on its base.
[0089] FIGs. 27-29 show an examples of a more complicated structure, according
to some
embodiments. The structure can be formed, for example, from inter-connected
oblique four
sided prism frame structures 82. The modular frame structure system as shown
in Figures
28 and 29 is constructed from cuboid frame structures 84 and triangular prism
frame
structures 86.
[0090] The teachings provided herein also focus on the novelty and
applicability of the node
module itself. The node module provides excellent added utility to any such
construction
17
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
system, for at least the reason that it facilitates a simplification of the
complexity of
components, a substantial reduction in types and quantities of materials, a
substantial
reduction in time, and a substantial reduction in labor required to construct
a building or non-
building structure. These features are in addition to the "green" aspect of
the conservation
of resources through an initial use of less materials, as well as making it
easier to
disassemble and re-use materials.
[0091] FIGs 30-33 illustrate node modules, according to some embodiments. The
node module
is configured according to the number and shape of the frame structures being
connected.
FIG. 30A illustrates the simplest base node module, according to some
embodiments. In
this embodiment, the node module 90 has a single connector 92. FIG. 30B
illustrates a
simple node module with an opposing pair of connectors having different axes,
suitable for
vertex-to-vertex connection, according to some embodiments. In this
embodiment, the node
module 90 has a two opposing connectors 92 that are not on the same axis. FIG.
30C
illustrates a simple node module with an opposing pair of connectors sharing
an axis to
connect cells face-to-face, according to some embodiments. In this embodiment,
the node
module 90 has a two opposing connectors 92 that are on the same axis. FIG. 30D
illustrates a node module having at least two pair of connectors on a first
plate, and a
second plate having a plane that orthogonally intersect the plane of the first
plate. In some
embodiments, the node modules can have support plates and connectors, also
referred to
as "pins" herein, that are complementary with sockets, for example, found in
the corners of
frame structures. In FIG. 30D, for example, the node module has four pins 92,
two
extending upwards and two extending downwards, allowing up to four frames to
be
connected at a single point, in some embodiments. Also, node modules as in
FIG. 30C can
provide additional utility, as they can be used as base nodes to connect the
cellular frames
to the solid base were the downward connecters will be embedded in the
concrete inside
associated sockets. Furthermore, the base node can be fastened to the base
surface with
anchor bolts.
[0092] FIG. 31 shows a node having 4 pair of connectors, according to some
embodiments. In
FIG. 31, the node module has four downward extending pins 92 and four upward
extending
pins 92, allowing up to eight geometrical frames to be connected at a single
point, in some
embodiments.
18
CA 02823585 2013-07-02
WO 2012/095721
PCT/1112012/000019
[0093] FIGs. 32 and 33 show node modules suitable for use with non-cuboid
frame structures,
according to some embodiments. In FIG. 32, the node module has six pins 92,
three
pointing upwards and three pointing downwards, allowing up to six geometrical
frames to be
connected at a single point, in some embodiments. In FIG. 33, the node module
has twelve
pins 92, six pointing upwards and six pointing downwards, allowing up to
twelve geometrical
frames to be connected at a single point, in some embodiments.
[0094] The node module can also comprise apertures 94 in the body of the node
module,
allowing the system to include other fastening means, such as bolts, rivets,
and the like, in
an effort to provide a stronger interconnected structure.
[0095] FIGs 34 and 35 show other connection means that include the use of
plates and bolts,
according to some embodiments. The design of the plates 100,103 can vary to
match the
design of the node modules, wherein location in the building or non-building
structure will be
used by one of skill to determine load-bearing requirements. The plate modules
can also
comprise apertures 94 corresponding with apertures found in the body of the
performed
bars permitting two or more performed bars of different geometrical frames to
be inter-
connected.
[0096] FIG. 36 shows a series of interconnected cuboid frame structures,
according to some
embodiments. Each frame structure can be connected together with node modules
90.
Cross plates 103 can be used, in some embodiments, to connect a plurality of
frame
structures together, and flat plates 100 can be be used to connect adjacent
frame
structures. Brackets 105 can be used between bars in a frame structure, in
some
embodiments.
[0097] The teachings are also directed to an apparatus for transporting and
constructing the
frame structure system. As per the teachings provided herein, the apparatus
can include a
container for transporting pre-selected bars used in forming the geometrical
frame, a frame
structure configured for receiving the pre-selected bars from the containers
and holding the
pre-selected bars in a desired position to define the faces of the geometrical
frame, and a
configuration to facilitate connecting, for example welding, the bars to form
the geometrical
frame structure. A building or non-building structure can comprise the frame
structure
system, in some embodiments.
19
CA 02823585 2013-07-02
WO 2012/095721
PCT/I132012/000019
[0098] FIGs 15 and 16 show such an apparatus, as described above. Likewise,
FIGs 37 and
38 also show an apparatus 150 for use in transporting and forming a
geometrical frame
structure 110. In FIG. 38, a hexagonal frame structure is being built. The
apparatus 150
arranges a configuration of the pre-formed bars 112 and connects the pre-
formed bars 112
to form the frame structure 110. In some embodiments, the pre-formed bars are
welded
together. The apparatus can be transported to site, and installed on-site. As
described
herein, such a machine can be transported by either land, sea, or air to the
site using any
transportation means known to one of skill, and the transportation can include
the use of a
helicopter or a crane in some embodiments. The machine can comprise containers
152,154
containing pre-formed bars 112. The containers 152, 154 can be fixed on the
frame
structure of the machine with connections to moveable fins 156. The frame
structure can
have moveable horizontal bars 160 that are able to move horizontally and
vertically. The
fins 156 can be located on the horizontal bars 160, which are moveable to
position the fins
156 at a desired point within the machine frame structure 150. The fins 156
hold the pre-
formed bars in a desired position to define the faces of the geometrical
frame. The pre-
formed bars 112 are installed onto fins from the pre-formed bars containers
152,154. Once
the bars are installed in the structure all the bars will be connected, for
example welded, to
form the frame structure110. in some embodiments, the frame structure can be
easily
dismantled, if required, for transporting and reinstallation at a different,
or perhaps the same,
construction site.
[0099] In some embodiments, the system can be designed "by-the-numbers". The
bars can be
pre-cut, for example, to a standardized size or sizes and placed in numbered
containers for
ease of transportation to the site for assembly into the cells, where the
cells can be
interconnected as per design. The cells can be lifted by cranes, placed next
to each other
as per the design, and connected using the nodes and other connection means
taught
herein. One of skill will appreciate the ability to design and distribute load
throughout a
building or non-building structure, adding an element of simplicity and safety
to the task of
design and construction.
[00100] Moreover, the teachings provided herein include a computerized
system that
includes a processor, as well as a database operable to store data to assist
in the sizing and
construction of cell components for particular designs and an instruction
module to instruct
the system on a variety of system component configurations to align cell
components as
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
taught herein. The database and instruction module are in a non-transitory
computer
readable storage medium. In some embodiments, the system can include computer-
aided
design (CAD) or computer-aided manufacture (CAM) technology. In some
embodiments,
the system creates cutting lists according to pre-designed engineering
specifications, where
cell components are cut to desired dimensions to facilitate assembly of the
cell or cells. In
some embodiments, the system can provide data that assists in, for example,
any additional
installation considerations, such as the placement of clip modules, bracket
modules, other
fasteners, and the like, such as perhaps welding, which may be desired in the
construction
of a cell or cells. In some embodiments, the computerized system can be
operable to
provide program instructions to an automated construction engine on a non-
transitory
computer readable storage medium, such as a robotic engine, the robotic engine
used in the
robotic assembly of an individual cell, or a series of cells.
[00101] The cells themselves are novel for a variety of reasons. As such,
the teachings
are also directed to a three-dimensional, load-bearing cell for use in a
cellular construction
system for a building or non-building structure. The cell comprises a vertical-
load-bearing
bar; and, a horizontal-load-bearing bar attached to the vertical-load-bearing
bar. It should
be appreciated that, in some embodiments, a vertical-load-bearing bar does not
have to
actually have a vertical axis, as the vertical load borne by the bar's axis
can be a component
of a total vertical load, as described herein, where the bar's axis is at an
angle 8 from the
total vertical load. The same is true of a horizontal-load-bearing bar, as the
horizontal load
borne by the bar's axis can be a component of a total horizontal load, as
described herein,
where the bar's axis is at an angle 0 from the total horizontal load.
[00102] As described herein, the load-bearing cell can be constructed on-
site and, for
that reason, it can have a dimension that exceeds size standards set for
transporting
construction materials to a construction site as compared to pre-fabricated
cellular
structures. In some embodiments, the size standards are established by the
transportation
means, and can differ between jurisdictions. Such transportation can include,
for example,
container ships, railroad cars, cargo planes, and semi-trailer trucks.
Materials are
transported in "unit load devices", in some embodiments. Such devices are
general palates
and containers. The containers are sometimes referred to as cans or pods and
are
designated as LD1, LD2, LD3, LD4, LD6, LD7, LD8, and LD11, in some
embodiments. In
some embodiments, the bars in the cells can range in length from greater than
0 feet to 40
21
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
feet, from about 2 feet to about 20 feet, from about 5 feet to about 30 feet,
from about 3 feet
to about 12 feet, from about 5 feet to about 15 feet, from about 4 feet to
about 8 feet, from
about 2 feet to about 50 feet, from about 3 feet to about 60 feet, from about
4 feet to about
70 feet, from about 5 feet to about 80 feet, from about 6 feet to about 100
feet or any range
or length therein in increments of 1 foot. In some embodiments, the bars in
the cells can
have a length that is about 62, 88, 96, 125, 01 238 inches, or any size
therein. In some
embodiments, a cell built for use in the construction of residential or
commercial buildings,
which may also include parking floors, for example, may be approximately 28' L
x 28' W x
12'-14' H. It should be appreciated that a cell of this size cannot be
considered as
transportable by normal transportation means, as described above.
[00103] The load-bearing cell can also be configured to attach to a second
cell using any
cell-to-cell connector means taught herein. The load-bearing cell and the
second cell being
can be connected through the cell-to-cell connector in a face-to-face, edge to
edge, or
vertex to vertex arrangement in the cellular construction of the building or
non-building
structure.
[00104] The load-bearing cell can be used as a shell support structure or a
core support
structure and, in some embodiments, can be composed of prefabricated assembly
components that are readily transportable to the site. Moreover, the load-
bearing cell can
be more readily assembled and interconnected within the building or non-
building structure
when compared to non-cellular load-bearing structures that are otherwise used
for the shell
Support structure or the core support structure of the building or non-
building structure.
[00105] In some embodiments, the load-bearing cell can have an internal
cross-bracing
across the inner volume of the cell that functions to subdivide load-induced
stresses into
smaller distributed force components. And, in some embodiments, the load-
bearing cell
can have a vertical load-bearing bar with a fitting that is complementary to
the cell-to-cell
connector. In these embodiments, the cell-to-cell connector can be a single-
unit node
having at least one pair of connectors for connecting the load-bearing cell to
the second cell.
[00106] Cell-to-cell connectors can have any of a variety of designs
contemplated by one
of skill, if limited to gist of the teachings provided herein. In some
embodiments, the cell-to-
cell connector can comprise a first plate having the at least one pair of bar
connectors and a
second plate forming a plane that intersects a plane formed by the first plate
at an angle 0
22
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
ranging from about 0 degrees to about 45 degrees. The second plate can be
positioned
between at least two pair of bar connectors on the first plate, each pair of
bar connectors
having a first connector on a first side of the first plate and a second
connector on a second
side of the first plate, the first side opposing the second side.
[00107] As such, in some embodiments, the angle 0 can comprise an angle of
incline that
ranges from greater than 0 degrees to about 45 degrees upon which the building
or non-
building structure is constructed on a support surface. And, in some
embodiments, the
angle 9 can comprise an angle of assembly formed by a stacking of load-bearing
cells within
the building or non-building structure.
[00108] The teachings are also directed to a frame structure system. The
system can
comprise a series of inter-connected, modular three dimensional geometrical
frame
structures connected in a face-to-face arrangement, each individual frame
structure
comprising a series of bars connected to define faces of a three dimensional
geometrical
frame structure that includes a base face; and, at least one bar forming a
bracing for a face
of the geometrical frame structure. And, the geometrical frame structure can
comprise a
plurality of bars that form a cross-bracing for the base face.
[00109] In some embodiments, the geometrical frame structure can comprise
bars
forming a triangular frame structure within a vertical face of the geometrical
frame structure,
the triangular frame structure positioned within the upper part of the face;
one or more
diagonal bars to cross-brace vertical faces of the frame; or one or more
diagonal bars
extending across the interior of the frame. In some embodiments, a geometrical
frame
structure can comprise at least 6 bars and, in some embodiments, a geometrical
frame
structure can comprise cuboid frame structures formed from 14 bars, having
twelve bars
forming the edges of the cuboid frame structure, and two bars forming a cross-
bracing for a
base face.
[00110] In some embodiments, the frame structure system can comprise any
means for
interconnecting the geometrical frame structures in a face-to-face, vertex-to-
vertex, or edge-
to-edge configuration, or any means for connecting a structure to a base
surface. And, in
some embodiments, the geometrical frame structures can be connected side-by-
side and/or
stacked, for example, on top of each other. In these embodiments the
structures can be
23
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
used to form a core support structure or a shell support structure for a
building or non-
building structure.
[00111] The teachings are also directed to a method of constructing the
frame structure
system, or cell, on-site. The method comprises delivering a plurality of pre-
formed load-
bearing bars to a construction site, in which each bar in the plurality of
load-bearing bars can
have a dimension that was preselected for forming the geometrical frame
structure without
further resizing of the load-bearing bar. The method also comprises forming
the geometrical
frame structures on-site.
[00112] The node module is a connection means that is novel in itself, and
it provides a
significant contribution to the art of construction. And, the node modules, or
any of the
variety of connection means (that is, any of the connectors) taught herein,
can be made
using any method known to one of skill. In some embodiments, the node modules
or other
connectors can be cast, for example. In some embodiments, the node modules or
other
connectors can be constructed from individual components that are fastened-
together to
create a node module. One of skill in the art will know how to select the
proper materials for
handling a load in a particular location in a building or non-building
structure. In some
embodiments, the node module or other connectors can comprise any type of
steel selected
by one of skill as suitable for the intended application. In some embodiments,
the node
modules or other connectors can include another metal alloy selected on the
basis of
intended use, cost, and practicality. In some embodiments, the alloy can be an
aluminum
alloy, titanium alloy, stainless steel, or the like. In some embodiments, the
node module can
comprise a synthetic material, such as a polymeric component, for example a
plastic
material, particularly in applications that have limited load requirements. In
some
embodiments, the node module or other connectors can be a natural material,
such as a
material comprising a ceramic or wood component. And, in some embodiments, the
node
module can comprise an elastic material. For example, the elastic material can
serve as a
coating on the node module, as a protective coating or simply as a material
that provides
some elasticity to the system to reduce stresses and noise that may occur from
movements
in the system. Such materials can be placed as a coating where the bars
contact the nodes
to add to seismic resistance, in some embodiments.
24
CA 02823585 2013-07-02
WO 2012/095721
PCT/1132012/000019
[00113] In some embodiments, a three-dimensional printer technology can be
used for
casting the node modules or other connectors. This technology is expanding
rapidly and
can create metal, three-dimensional units like stainless steel having
complicated shapes.
[00114] In some embodiments, the node module comprises a support structure
having a
top surface and a bottom surface; and, a plurality of bar connectors. In these
embodiments,
the plurality of bar connectors can include at least one pair of bar
connectors, each pair
configured to direct (i) an opposing axial load into the support structure,
the opposing axial
load comprising a first load on the top surface that is opposed to a second
load on the
bottom surface; and, (ii) an opposing shear load that is orthogonal to the
opposing axial load
between each of the at least one pair through the support structure, the
opposing shear load
comprising a tensile force and a compression force on the support structure.
Each bar
connector is configured to mate with a respective, complementary portion of a
bar, the
mating of each of the bar connectors with their respective bars forming a node
module
configured to bear the opposing axial load and the opposing shear load within
the building or
non-building structure.
[00115] In some embodiments, the top surface and the opposing bottom
surface of the
support structure have a compressive strength that is at least as high as a
highest expected
axial load in a location of intended use within the building; and, the
connection between
each respective bar and the node module has a shear strength that is at least
as high as a
highest expected load that is orthogonal to the axial load in the location of
intended use
within the building.
[00116] The node modules taught herein can have one or more connectors for
connecting the node module to a bar. In some embodiments, the node module can
comprise a pair of connectors within the at least one pair of bar connectors
that shares a
central axis, or it can comprise a pair of connectors that do not share a
central axis. The
node module can be used as a component in a shell support structure or a core
support
structure. And, in some embodiments, the mating of each of the bar connectors
with their
respective bars comprises a releasable, slidable connection.
[00117] In some embodiments, the support structure comprises a horizontal
base plate
with at least one pair of bar connectors and a vertical plate, the vertical
plate forming a plane
that intersects a plane formed by the horizontal plate and separating the at
least one pair of
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
bar connectors. The node module can comprise a cast metal alloy and, in some
embodiments, the node module can include an elastic coating, for example,
where the node
module contacts a bar.
[001181 The support structure can comprise a first plate having the at
least one pair of
bar connectors and a second plate forming a plane that intersects a plane
formed by the first
plate at an angle 0, the second plate separating the at least one pair of bar
connectors. The
angle e, for example, can comprise an angle of incline upon which the building
or non-
building structure is constructed. In some embodiments, the angle 8 can
comprise an angle
of assembly formed by a stacking of cellular bar modules within the building
or non-building
structure.
[00119] FIG. 39 illustrates a load-bearing node module which can be used as
a
connection means, and which can be inclined at a desired angle, according to
some
embodiments. As described herein, the load-bearing, node module can be used
for
simplifying the connection of a series of load-bearing bars during the
construction of a
building or non-building structure. In these embodiments, the node module 90
comprises a
first plate 1000 comprising a top surface 1010, a bottom surface 1020,
providing a base for
a plurality of bar connectors 92. The first plate 1000 forms a first plane,
and, a second plate
1100 forms a second plane that intersects the first plane at an angle 8 1200,
the second
plate 1100 separating the at least one pair of bar connectors 92a,92b from a
second pair of
bar connectors 92c,92d, where there is at least a second pair of bar
connectors. The angle
0 can also be present, and can even be the same angle, between the axis of a
connector 92
and the first plate 1000, for example. The plurality of bar connectors can
include at least
one pair of bar connectors configured to direct (i) an opposing axial load
1300a,1300b into
the first plate 1000, the opposing axial load 1300a,1300b comprising a first
axial load 1300a
on the top surface that is opposed to a second axial load 1300b on the bottom
surface; and,
(ii) an opposing shear load 1400a,1400b that is orthogonal to the opposing
axial load
1300a,1300b between each of the at least one pair of connectors
92a,92b/92c,92d through
the first plate, the opposing shear load 1400a,1400b creating a tensile force,
a compression
force, or a combination thereof, on the first plate 1000. As described herein,
a load can
include, for example, a dead load, a live load, an environmental load, or a
combination
thereof.
26
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
[00120] A variety of connecting means can be used with the teachings
provided herein.
FIG. 40 illustrates a clip module that can be used as a connection means,
according to
some embodiments. The clip module 2000 can be used to connect bars in the
teachings
provided herein. The clip module 2000 can be pre-formed as a single-unit, or
it can be
provided in component pieces for assembly at the site of construction. In FIG.
40, the clip
module 2000 has four components, to opposing sides 2100,2200, each having an
angle 8
2300 between connecting walls 2100a,2100b, and each having a complementary
mating
means 2400a,2400b,2400c. The complementary mating means 2400a,2400b,2400c is a
hinge/pin connection in FIG. 40, but one of skill will appreciate that any
mating or fastening
means will work, in some embodiments. In some embodiments, the clip module
2000 can
have any number of components, as long as the components can attached to form
a
structural connector. In some embodiments, all of the component walls on the
clip module
2000 can be planar, have a single angle 8, have a plurality of angles 8,, or a
combination
thereof. One of skill will appreciate that the clip module 2000 can be
designed to fit the
design of the bars being connected and can be a single-unit or multi-component
design.
[00121] Each bar connector can be configured to mate with a respective,
complementary
portion of a bar, the mating of each of the bar connectors with their
respective bars through
the node module configured to bear an axial load and a shear load orthogonal
to the axial
load within the building. One of skill can calculate the expected loads and
acceptable risk
factors to use as a multiple in the design and engineering of a building or
non-building
structure, for example. The mating can comprise a releasable, slidable
connection, the top
surface and the opposing bottom surface of the support structure can have a
compressive
strength that is at least as high as a highest expected axial load in a
location of intended use
within the building; and, the connection between each respective bar and the
node module
can have a shear strength that is at least as high as a highest expected shear
load
orthogonal to the axial load in the location of intended use within the
building.
[00122] The teachings provided herein offers considerable flexibility and
ease of
assembly of any of a variety of structures, virtually any structure reasonably
contemplated
by one of skill. FIG. 41 illustrates a node-to-node arrangement that includes
a series of
interconnected triangular prisms, according to some embodiments. Node modules
90 can
be custom-designed and produced to connect this triangular prism arrangement
3000 or
virtually any reasonable bar 3100 arrangement design contemplated by one of
skill.
27
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
[00123] FIG. 42 illustrates the flexibility in interconnecting and stacking
that is provided
herein, according to some embodiments. The structural frames can be built and
interconnected corner-to-corner, as described herein, but FIG. 42 shows that
they can also
be connected horizontally and vertically between the corner of a cell to a
corner of a bracing
bar, for example. FIGs 42A and 426 show top and side cross-sectional views of
an
example structure 4000 interconnected with node modules, and perhaps clip
modules,
plates, fasteners, or other connection means (not shown) in this manner. And,
FIGs 43A1_5-
G1.5 provide a variety of bracing designs contemplated, according to some
embodiments.
[00124] FIG. 44 illustrates an example of a cell that is built as an
inclined cell, where the
node module has an angle 0 greater than 0, according to some embodiments. The
inclined
cell 5000 can include an incline built into the node modules (not shown),
where at least one
type of node module in the structure can, for example, include the angle 0
5100 between a
connector and a plate supporting the connector, as described herein. The
inclined cell 5000
can have additional bracing, as shown, for horizontal and inclined faces. The
bracing can
be suitable, for example, in the core of a building or non-building structure.
In some
embodiments, an opening can be added throughout the system to assist in air
circulation in
the completed structure.
[00125] FIG. 45 illustrates a side-aspect sketch of an inclined building
structure, where
the structure includes inclined cells and inclined node modules, according to
some
embodiments. It should be appreciated that in this or other embodiments, the
cells 6100
can be used at, or below, ground level 6200 in the foundation of a building or
non-building
structure 6000. The below-ground cells 6100 can, in some embodiments, be
filled with a
suitable foundational material 6300, such as concrete, compact soil, or any
other material
used by one of skill as a foundational material, which can include, for
example, an
excavated soil with a special treatment to provide a sustainable solution. In
some
embodiments, the compacted soil can be from the excavated soil from the same
or nearby
plot, for example, having a suitable soil treatment known to one of skill that
would make it
functional for use as a foundational material.
[00126] The teachings are, of course, also directed to a cellular
construction system for
constructing a building or non-building structure. The structures can be
modular or non-
modular. The system can comprise a node module as described herein; a first
cell having a
28
CA 02823585 2013-07-02
WO 2012/095721
PCT/IB2012/000019
first three-dimensional frame structure comprising a first axial load bearing
bar having a first
respective complementary portion for mating with a first connector of the node
module; and,
a second cell having a second three-dimensional frame structure comprising a
second axial
load bearing bar having a second respective complementary portion for mating
with a
second connector of the node module. The node module can connect the first
three-
dimensional frame structure to the second three-dimensional frame structure in
the creation
of a cellular building structure or a cellular non-building structure.
[00127] The term "modular" can include, for example, pre-fabricated cells
that are
transported to the site as modules, or the cells fabricated on-site, in each
case useful as
transportable modules, either to the site or within a site. Due to this
flexibility, the
dimensions of the first or second cellular, three-dimensional frame structure
can exceed size
standards set for transporting construction materials to a construction site
as compared to
pre-fabricated cellular structures that are required to follow the size
standards that are set by
practicality and/or the policies or law of the jurisdiction at which the
building or non-building
structure is being constructed.
[00128] As per the teachings provided, it should be appreciated that the
node module
connects the first three-dimensional geometrical frame structure to the second
three-
dimensional geometrical frame structure in a variety of arrangements. Such
arrangements
include, but are not limited to, a face-to-face, edge-to-edge, or vertex-to-
vertex arrangement
in the creation of a cellular building structure.
[00129] It should be appreciated that any "facade treatment" can be fixed
on the building
structure as a lightweight element on the frame structures, in some
embodiments.
Moreover, the system can be constructed using the methods taught herein to
provide high-
seismic-resistant building or non-building structure. The gaps between the
cells can be
treated as expansion or seismic joints, in some embodiments.
[00130] The teachings are also directed to a method of creating the
cellular building
structure itself, as such buildings are also, per se, novel when constructed
using the
teachings provided herein. The method can comprise obtaining a node module
described
herein, constructing a first cell having a first three-dimensional frame
structure comprising a
first axial load bearing bar having a first respective complementary portion
for mating with a
first connector of the node module, constructing a second cell having a second
three-
29
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
dimensional frame structure comprising a second axial load bearing bar having
a second
respective complementary portion for mating with a second connector of the
node module,
and interconnecting the first three-dimensional geometrical frame structure to
the second
three-dimensional geometrical frame structure using the node module in the
creation of the
cellular building structure. The interconnecting can include (i) mating the
first connector of
the node module to the first respective complementary portion and (ii) mating
the second
connector of the node module to the second respective complementary portion.
[00131] The teachings are also directed to a cellular construction system
comprising a
single-unit, node module. The single-unit, node module can be configured with
a means for
interconnecting a series of structural, three-dimensional load-bearing cells,
the series
including a first cell and a second cell. The first cell can comprise a first
axial load bearing
bar having a first respective complementary portion for mating with a first
connector of the
node module. The second cell can comprise a second axial load bearing bar
having a
second respective complementary portion for mating with a second connector of
the node
module. The node module can connect the first cell to the second cell using a
process that
includes (i) mating the first connector of the node module to the first
respective
complementary portion and (ii) mating the second connector of the node module
to the
second respective complementary portion, such that the first cell and the
second cell are
connected in a face-to-face, edge to edge, or vertex to vertex arrangement in
the creation of
a cellular building or non-building structure.
[00132] FIG. 46 illustrates the construction of a building or non-building
structure having
the cells as cantilever units, according to some embodiments. The cantilevered
structure
7000 uses a combination of node modules 90, clip modules 2000, bracket modules
7100,
cantilevered cells 7200,7300, and other 1-dimensional (linear or non-linear)
7400, or 2-
dimensional load bearing units 7400 fabricated using the methods taught
herein, to help
carry the additional loads provided by the cantilevered cells.
[00133] In embodiments taught herein, cross-bracing can be used for extra
support. And,
it should be appreciated that bracing can include the use of cables to provide
a tension-
based bracing through the tensile strength of the cable alone, rather than the
tensile and
compression strength of an otherwise rigid bracing. Cables can be used, for
example, both
internally and externally with the cells.
CA 02823585 2013-07-02
WO 2012/095721
PCT/1B2012/000019
[00134] Moreover, slabs can be introduced in the cells. Such slab systems
can be cast in
situ, for example, by adding cross bracing and inverted pyramid bracing which
can be filled
with concrete after adding a suitable shutter. In some embodiments, such slab
systems can
simply be adding suitable bracing to the base face of the cell and cast in
situ between these
bars after placing the cell on flat surface. In addition, the bars at the base
face and bracing
bars can also have holes to allow the concrete to fill voids inside the bars
to provide an
additional and strong, composite effect. In some embodiments, the slab systems
can be
created without a need for shuttering using a process that includes (i) adding
suitable
bracing to the base face of the cell; (ii) placing the cell on a flat surface;
and, (iii) casting
lightweight concrete in situ between the bars with a suitable steel mesh
reinforcement
without the need for shuttering.
[00135] As described herein, the system can be non-modular or modular. FIG.
47
illustrates cells placed in face-to-face arrangements and stacked in an
axial/radial grid-type
configuration, according to some embodiments. FIG. 47A shows a side-view of
the overall
structure, and FIGs. 47B-47C show a structural geometrical framing plan and an
architectural zoning plan for the same structure, where the design provides a
novel way to
gain architectural open space within the structure. FIG. 48 illustrates an
edge-to-edge
arrangement of hexagonal-cylinder shaped cells, according to some embodiments.
[00136] While various exemplary embodiments have been described, those
skilled in the
art will realize that there are many alterations, modifications, permutations,
additions,
combinations, and equivalents which fall within the true spirit and scope of
the teachings. It
is therefore intended that the preceding descriptions not be read by way of
limitation but,
rather, as examples with the broader scope of the concepts disclosed herein.
31
