Note: Descriptions are shown in the official language in which they were submitted.
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BEAM AND BOLTING CONSTRUCTION SYSTEM AND METHOD
[0001] This non-provisional application claims priority as a
continuation-in-
part of U.S. Patent Application Ser. No. 17/095,181, filed on November 11,
2020, the
contents of which are incorporated herein by reference. This non-provisional
also
claims priority of U.S. Patent Application Ser. No. 15/986,605, filed on May
22, 2018,
the contents of which are incorporated herein by reference. This non-
provisional
application claims priority of Serial No. 65/539,556, by the same inventor,
filed
August 1, 2017, the contents of which are incorporated herein by reference.
BACKGROUND
[0002] Like nearly all other areas of knowledge and commerce,
the field of
dwelling construction is subject to continual improvements in techniques, use
of
materials, and related structural designs. This is certainly the case in the
construction of dwellings such as cabins and small houses.
[0003] Although the concept of wooden dwellings goes back into
prehistory,
these have always been subject to problems, both in the construction methods
and in
the resulting products. For example, there are problems with traditional "log
cabins"
with respect to finding sufficiently uniform logs and requiring caulking
materials
(often requiring frequent renewal) to protect the inhabitants from the
elements.
[0004] Wood constructions have many advantages, particularly
since natural
woods, with the exceptions of some hardwoods, have at least some degree of
flexibility
and compressibility. This allows for better weather sealing, and for better
resistance
to earthquake and wind damage. Better methods of improving these aspects are
highly desirable.
[0005] Accordingly, there is significant room for improvement
and a need for
stronger and more easily constructed walls and frames for buildings.
SUMMARY
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SUMMARY
[0006] In view of the above, a combined beam structure includes a
plurality of
beam segments, each beam segment having a top surface and a bottom surface and
made of a material that is at least slightly compressible. The plurality of
beam
segments is arranged with the top surface of each beam segment substantially
in
contact with the bottom surface of a next beam segment between a first beam
segment
and a last beam segment. A plurality of bolt bores extends between the top and
bottom
surfaces of each of the plurality of beam segments in substantial alignment
through
each of the plurality of beam segments. A plurality of bolt segments extends
through
corresponding bolt bores, and a plurality of tightening fasteners fasten to
the bolt
segments to apply compression between the first beam segment and the last beam
segment.
[0007] In one aspect, the combined beam structure includes a
joint side
corresponding with a joint end portion of each of the plurality of beam
segments. The
joint end portion of each beam segment in a first subset of beam segments
extend a
distance from the joint end portion of each beam segment in a second subset of
beam
segments. The beam segments in the first subset of beam segments are arranged
as
alternating layers with the second subset of beam segments forming a staggered
pattern of joint end portions at the joint side of the combined beam
structure.
[0008] In another aspect, the combined beam structure is a first
combined beam
structure configured to couple with a second combined beam structure. The
joint side
is a first joint side of the first combined beam structure. The second
combined beam
structure is formed of another plurality of beam segments having a second
joint side
corresponding with joint end portions of the other plurality of beam segments
arranged to form a staggered pattern on the second joint side of the second
combined
beam structure. The staggered pattern of the first joint side of the first
combined
beam structure interlocks with the staggered pattern of the second joint side
of the
second combined beam structure to form a wall structure junction between the
first
combined beam structure and the second combined beam structure.
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[0009] In one example, the wall structure junction forms a wall
corner between
the first combined beam structure and the second combined beam structure
extending at an angle with the first combined beam structure.
[0010] In an example wall corner, the first combined beam
structure and the
second combined beam structure form a substantially 90-degree angle.
[0011] In another example, the wall corner is formed with the
joint end portions
of the first combined beam structure extending to interlock with the joint end
portions
of the second combined beam such that the joint end portions of the first
combined
beam structure are flush with a planar surface of a wall structure formed by
the
second combined beam structure.
[0012] In another example, the wall corner is formed with the
joint end portions
of the second combined beam structure extending to interlock with the joint
end
portions of the first combined beam such that the joint end portions of the
second
combined beam structure are flush with a planar surface of a wall structure
formed
by the first combined beam structure.
[0013] In another example, the wall corner is formed with the
joint end portions
of the first combined beam structure extending to interlock with the joint end
portions
of the second combined beam such that the joint end portions of the first
combined
beam structure extend beyond a planar surface of a wall structure formed by
the
second combined beam structure.
[0014] In another example, the wall corner is formed with the
joint end portions
of the second combined beam structure extend to interlock with the joint end
portions
of the first combined beam such that the joint end portions of the second
combined
beam structure extend beyond a planar surface of a wall structure formed by
the
second combined beam structure.
[0015] In another aspect, the plurality of bolt bores in each of
the plurality of
beam segments includes a junction bolt bore in the joint end portion of each
of the
plurality of beam segments where the junction bolt bore aligns with a junction
bolt
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bore at a joint end portion of the second combined beam structure at the wall
structure junction.
[0016] In another aspect, the plurality of bolt bores in each of
the plurality of
beam segments includes an inner junction bolt bore disposed an inner junction
distance from the junction bolt bore. The inner junction bolt bores of beam
segments
that extend to form the staggered pattern align with the junction bolt bores
of non-
extending beam segments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The purposes and advantages of example implementations
will be
apparent from the following detailed description in conjunction with the
appended
drawings in which:
[0018] Fig. 1 is a front plan view of an example dwelling
constructed using
examples of combined beam structures.
[0019] Fig. 2 is a perspective view of a construction site at an
early stage, prior
to installation of any beams, showing a typical bolting array.
[0020] Fig. 3 is a plan view of the left side/end of the example
dwelling.
[0021] Fig. 4 is a rear plan view of the example dwelling.
[0022] Fig. 5A is a truncated perspective view of an example beam
for use in an
example of a combined beam structure.
[0023] Fig. 5B is a cross sectional view of the beam of Fig 5A,
taken along line
B-B.
[0024] Fig. 6 is a plan view of the right side of the example
dwelling, showing
a roof mounting approach.
[0025] Fig. 7 is cutaway side view of an alternate dwelling,
showing another
roof mounting approach.
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[0026] Fig. 8 is a fanciful cross-sectional illustration of a
segment of a wall
showing an interstitial bolt anchored in the foundation slab and extending
upward to
pass through the bolt holes in the beams.
[0027] Fig. 9 is a fanciful cross-sectional view of a section of
the foundation slab,
an elongated bolt anchored in the slab and extending through bolt holes, and
an
alternate washer plate providing an external spacing and securing bracket.
[0028] Fig. 10 is a side view of a prototype partial corner
section of two very
short exterior walls, showing the layering and bolting techniques.
[0029] Fig. 11A shows a system for precise anchoring of an
elongated
threaded bolt in the foundation slab.
[0030] Fig. 11B is a top plan view of a top (or bottom) mounting
bracket for the
system of Fig. 11A; and
[0031] Fig. 12 shows in examples A B C and D four envisioned
corner
bracing configurations.
[0032] Fig. 13A is a front plan view and a side section view of
an example
implementation of a combined beam structure.
[0033] Fig. 13B is a front plan view and a side section view of
another example
implementation of a combined beam structure.
[0034] Fig. 14 is an isometric view of an example of a wall
junction structure
formed as a wall corner.
[0035] Fig. 15 illustrates an example of a bolt segment.
[0036] Fig. 16 is an isometric view of an example building
structure.
[0037] Fig. 17 illustrates another example building structure and
a top view of
an example combined beam structure used as a floor.
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[0038] Fig. 17A is a top cross-sectional view of the building
structure in Fig. 17
at cross-section 17A.
[0039] Fig. 18 illustrates example mechanisms for attaching a
bolt segment to
a combined beam structure configured to function as a floor.
[0040] Fig. 19 illustrates another example implementation of a
combined beam
structure and an alternative mechanism for providing a foundation for the
combined
beam structure in a building structure.
[0041] Figs. 19A and 19B are cross-sectional views of portions of
the alternative
mechanism for providing a foundation shown in Fig. 19 at cross-sections 19A
and
19B, respectively.
DETAILED DESCRIPTION
[0042] Described below are examples of implementations of
combined beam
structures and methods of construction (M) for dwellings and other buildings
utilizing
beam and bolting and of the structures resulting therefrom. A front view of an
example dwelling 10, in this case a cedar or redwood beam cabin, is
illustrated in Fig.
1. The structure is defined in terms of the spatial relationships (shown in
phantom)
including a primary vertical plane 11 (in Fig. 3), a transverse vertical plane
12
perpendicular to the primary plane 11, and a horizontal plane 13 perpendicular
to
the vertical planes.
[0043] An example process (M) involves a series of steps in
constructing and
maintaining a beam and bolting building/dwelling. A brief summary of the steps
is
set forth below:
1. Select site and prepare layout, including bolting array positioning.
2. Locate corners for bolting on foundation slab.
3. Precisely locate bolt anchor locations for foundation slab.
4. Determine height of walls.
5. Select locations for gaps in walls (doors, windows, etc.).
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6. Determine whether corners will have extended beam segments and
sequential order of beam vertical overlap at corners.
7. Select materials.
8. Choose gauge and length of vertical bolts and choose nuts and washer
plates.
9. Choose materials for beams (e.g., cedar, redwood, composite, etc.).
10. Determine cross-sectional structure of beams.
11. Determine default beam length.
12. Prepare foundation slab.
13. Situate and secure vertical bolts in predetermined bolt anchor
locations
defined by the bolting array.
14. Construct foundation slab to provide a flat upper surface and secure
vertical bolt in precise vertical orientation.
15. Prepare beams.
16. Provide bolt bores through each beam in accordance with spacing of the
predetermined vertical bolt locations.
17. Cut beam segments (truncated beam segments) to accommodate corners
and wall gaps according to plans.
18. Vertically lower first beam in corner overlap sequence (cross beam)
onto
respective vertical bolts, including the selected corner bolt and at least
one interstitial bolt, through respective bolt bores until it rests upon the
foundation slab, and, if selected, extending beyond the corner bolt.
19. Vertically lower second beam in the corner overlap sequence (truncated
transverse beam) onto respective interstitial vertical bolts such that it
rests upon the foundation slab with a beam end abutting against the
cross beam at the corner.
20. Repeat steps set forth in the two immediately preceding paragraphs,
inserting bolt couplings and additional bolt segments as required, until
all corners are completed.
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21. If necessary, lay clown beam segments on interstitial bolts to fill in
any
gaps not corresponding to doors, or the like in the layer.
22. Lay down additional layers until the desired wall heights are achieved,
alternating the functions of the cross beam and the transverse beam in
each successive layer such that the corner bolts alternatively pass
through cross and transverse beams.
23. Upon achieving desired wall height:
a_ Lay down washer plates (pressure distribution plates) encompassing
each of the vertical bolts on top of the beams; and
b. Apply and tighten nuts to each of the treaded bolts to force all of the
beams together to a desired pressure in order to achieve a desired "seal"
and a secure structure.
24. Install a desired roof above the walls, maintaining an access gap above
all bolts and nuts to allow subsequent pressure adjustment.
[0044] Other steps, which are not critical to the present
invention, may also be
performed. In addition, some of these steps may be omitted.
[0045] Considering a product (in this case a building or
dwelling) constructed
in accordance with the above-described method (M) the example dwelling 10 is
further explained below. For the purposes of simplified description, and since
these
are a matter of choice not critical to the invention, most architectural
details and all
interior details are omitted from the description. The example dwelling
(cabin) 10
illustrated in Figs. 1-4 includes a foundation slab 14, which is carefully
aligned to be
parallel to the horizontal plane 13. The initial actual construction step
(after site and
layout and materials selection) in the method (NI) is to provide the flat
(level) and
horizontal (perpendicular to gravitational force) foundation slab 14 with bolt
anchor
locations 16 in which elongated vertical threaded bolt segments (vertical
bolts) 18 are
countersunk and secured in precise vertical orientation (see Figs. 2, 7-9 and
11). The
foundation slab 14 is typically poured concrete but other sturdy structural
approaches
may be used. The vertical bolts 18 are threaded (at least at the ends), are
held in the
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bolt anchor locations 16 and are situated in a precise bolt array 19
corresponding to
the dwelling design (an example array - not congruent to the example dwelling
10) is
shown in Fig. 2). The array 19 includes corner bolts 20 and interstitial bolts
21
situated between corner bolts 20.
[0046] A further step in the construction method (M) relates to
completing
vertical walls mounted upon the vertical bolts 18. For simplicity of
explanation, the
example cabin 10 is rectangular, but a myriad of other configurations is
possible. In
the example dwelling 10 illustrated in Figs. 1, 3, 4, and 6, a set of four
exterior vertical
walls 22 are provided. A front wall 23 and a rear wall 24 are aligned parallel
to the
primary vertical plane 11, and consequently with each other. Similarly, a left
wall 26
and a right wall 28 are aligned parallel to the transverse vertical plane 12,
and to
each other. Each of the walls 22 will overlap at opposing ends with the
respective
perpendicular transverse walls at a corner 29, as described below. Each of the
exterior
walls 22 is constructed in accordance with the construction method (M).
[0047] A roof 30, of generally conventional construction, is
mounted on and
above the exterior walls 22 as described below. For at least a significant
amount of
the expanse, an access gap 32 separates the top of each exterior wall 22 from
the roof
30 and any other overhead components, as explained below. Various other
exterior
details, not pertinent to the primary inventive concepts, are also shown and
provided.
These details include a fireplace 34 with an associated chimney 36, and doors
38 and
windows 40 as desired.
[0048] The exterior walls 22 of the present invention are
constructed with
beams 42 as illustrated in more detail in Fig. 5A and 5B. Fig. 5A is a
perspective view
of an example beam 42 while Fig. 5B is a cross sectional view taken along line
B-B.
The beams 42 are selected to have a beam top 44 and a beam bottom 46 which are
flat and parallel to each other, and a pair of beam ends 48. The beams 42 also
have
beam edges 50 which may also be flat and parallel so that the beam has a
rectangular
cross section (square, as illustrated in Fig. 5B) but may also be beveled or
otherwise
shaped for aesthetic purposes as these surfaces are not critical to the
effectiveness of
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the construction. In the example dwelling 10 the beams 42 are uniform in cross
sectional dimensions but may vary in thickness as breadth as desired for
particular
purposes.
[0049] Each beam 42 includes series of bolt bores 52 vertically
passing
therethrough between the beam top 44 and beam bottom 46 surfaces. These bolt
bores
52 are strategically spaced and located so as to correspond and mate with the
specific
bolt array 19. Each bolt bore 52 has a diameter slightly greater than the
diameter of
the selected vertical bolt segments 18.
[0050] Although all of the beams 42 in the example dwelling 10
are
substantially similar for the purposes of construction method (M) it is
convenient to
refer to them separately for the purposes of description. Thus, some beams,
which are
aligned with the primary vertical plane 11 (e.g., front wall 23 and rear wall
24) are
referred to as cross beams 54 while those aligned with the transverse vertical
plane
12 (e.g., left wall 26 and right wall 28) are designated as transverse beams
56. An
unmodified beam 42 such as is illustrated in Fig. 5A is referred to as a full
beam 58,
while a beam that is cut short so as to abut against a full beam 58 at a
corner 29 is
designated as a truncated beam 60. A beam segment 62 is defined as a section
of a
beam used to fill in gaps in the structure.
[0051] As described above with respect to the steps of the method
(M), the
exterior walls 22 are constructed in a vertically ascending series of layers,
as the
beams are fitted onto the respective vertical bolts 18. The layers are
designated as an
odd layer 64 (the lowest of which abuts against the foundation slab 14) and an
even
layer 66 which rests on top of an odd layer 64 to create a vertical overlap 68
of beams
in adjacent layers at each corner 29. The discussion below with regard to Fig.
12
shows four envisioned corner overlap schemes for suitable stable corners 29.
[0052] For the purposes of description of an example embodiment
(Fig. 12,
depiction D), and referring to the left end of the front wall 23 (and the rear
wall 24),
the cross beam 54 in an odd layer 64, will be mounted to include a corner bolt
20, as
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illustrated in Figs. 3 and 4. Referring to the corner 29 in the example
dwelling 10 as
shown in Fig. 10, the cross beam 54 includes an integral extended segment 70
which
extends outward beyond the corner 29.
[0053] For the odd layers 64 the transverse beams 56 are
truncated beams 60
which are mounted only on interstitial bolts 22 and have one beam end 48 which
abuts against a cross beam 54 at each corner 29. For even layers 66, the roles
are
reversed (see Figs. 4, 5, and 10) and the transverse beams 56 include extended
segments 70 and are mounted to include a corner bolt 20, while the cross beams
are
truncated beams 60, and are mounted only on interstitial bolts 21.
[0054] In order to facilitate construction, it is ordinarily
necessary to insert bolt
couplings 71 at a convenient working height above the foundation slab 14.
Workers
can usually only effectively lift and position beams 42 on and over the
vertical bolt
segments 18 to a certain height which is usually consistent with the height of
the bolt
segment above the foundation slab 14. As the typical threaded bolt segment 18
is
about six feet long in US constructions, and since bottom of the lowermost
bolt
segments is typically embedded about one foot into the foundation slab 14, the
most
common location to insert a coupling 71, with another bolt segment 18' in the
same
vertical alignment, will be at a height of about five feet above the
foundation slab 14.
The upper bolt segment 18' will then extend to slightly above the typical ten-
foot
height of each wall 22, and placement of the beams 14 will then be
accomplished with
the aid of scaffolding or mechanical lifts. The alternating layers continue
until the
desired wall height is reached. At this stage rigid washer plates 72 are
placed over
the elongated bolt 18' and against the top layer of the beams 42. Right angle
corner
plates 74 are situated on corner bolts 20 to lay against both abutting beams
while
elongated plates 76 are placed over interstitial bolts 21, preferably
extending between
two or more interstitial bolts. Nuts 78 are then threaded onto the respective
elongated
bolts 18' and tightened to the desired pressure levels, forcing the beams
against the
foundation slab 14 and each other to form a bolt laminated structure.
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[0055] A prototype shortened corner segment of intersecting walls
is shown in
Fig. 10. This shows the alternating levels, with extended segments 70 at
appropriate
levels of the cross beam 54 and transverse beam 56, as well as the
corresponding
abutment of a truncated beam 60 of the respective beam type for each level.
Although
shown without an elongated vertical bolt 18 anchored in a foundation slab 14
this
also shows the washer plate 72 and nut 78 attached to be tightened to force
the beams
in adjacent layers together.
[0056] This prototype (Fig. 10) has been wind-tunnel tested and
was shown to
successfully withstand gale and hurricane force winds (from many angles and
with
winds of 50 to 150 mph) without any compromise of integrity.
[0057] Figs. 8 and 9 illustrate, in fanciful cross-sectional
views, the anchoring
of elongated bolts 18 in the foundation slab 14 and extending upward through
the
bolt holes 52 of each beam in the layer. In Fig. 9 a spacing/securing bracket
80 is
illustrated providing spacing between the foundation slab 14 and the bottom
beam
42' and also engaging the bottom beam 42' to hold it securely in position.
[0058] Figs. 6 and 7 illustrate potential methods/arrangements
for mounting a
roof 30 onto a dwelling. It is emphasized in method (M) that any roof or
ceiling
structure requires that an access gap 82 is provided such that each nut 78 may
be
accessed from inside the structure in order to adjust the pressure level and
compensate for the slight material deformations over time. It is also
necessary that
the roof 30 be secured to the wall structures. In order to typically
accomplish this a
series of roof spacer blocks 84 (beam segments including bolt bores 52) are
placed on
top of the wall 28 intermediate the access gaps 82. These roof spacer blocks
84 and
rafters 86 and other connective portions of the roof 30 are then secured to
the top and
potentially lower beams. The securing method includes roof bolting 88 having
threaded bolt segments 18' with an additional coupling 71 to extend through
the
upper beams 42 to beyond and through and above the spacer blocks 84 and
rafters 86
and provided with washer plates 72 and nuts 78 to tighten the wall and roof
elements
together in a stable and secure fashion. Depending on the nature of the roof
30, the
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rafter bolting 88 and. roof spacer blocks 84 may only be needed on some of the
exterior
walls 22.
[0059] As other roof construction details are not strictly
pertinent to the
invention or method (M) these are not addressed herein.
[0060] Figs 11 (A & B) and 12 (A, B, C, and D) show examples of
helpful
construction details and alternate corner bolting configuration in accordance
with the
present invention.
[0061] Fig 11 illustrates, both in cut away view (11A) and top
view (11B), an
alignment system 90 for placing and aligning each bottom vertical bolt 18 in
the
desired bolt anchor location 16 in the foundation slab 14. Prior to pouring
the
foundation slab 14, a foundation frame 92 is placed around the desired border.
This
is typically in the form of a wooden border, in the illustration a 4x8 board.
The
foundation frame rests outside a foundation cavity 94, into which the concrete
or
other solid filler will be poured once the bolt array 19 is prepared. A nut 78
is threaded
onto the vertical bolt segment above the level of the foundation frame 92,
while a
further nut 78 and washer plate 72 are situated well below, near the nether
end of
the bolt segment 18.
[0062] A top bracket 96 and a bottom bracket 98 are adapted to
fit about the
upper and lower surfaces of the foundation frame 92 and extend into the
foundation
cavity 94. The top bracket 96 and lower bracket 98 each include a right-angle
flange
100 to abut against the outside of the foundation frame to form a horizontal
plate
102, with a centering notch 104 at its interior end in order to receive the
bolt segment
18. When the brackets 96 and 98 are properly placed and aligned, the bolt
segment
18 is placed to vertically fit into the centering notches 104 of both
brackets, with the
exterior nut 78 tightened to secure the bolt segment 18 into position and
alignment.
When all necessary alignment systems 90 are set up around the perimeter (and
in
portions of the interior when interior walls or the like are included in the
plan), the
foundation slab 14 may be poured to set each bolt segment into the bolt anchor
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locations 16 of the array 19. The top bracket 96 and bottom bracket 98 may
either be
left in place or laterally slid out as the foundation slab hardens.
[0063] Fig. 12 shows (in sub-Figures A, B, C, and D) four
possible desirable
corner 29 structures, each including one or more "L" brackets 106 situated on
the
interior or exterior angle, or both. In three of the example corners 29 (B, C,
and D),
the corner bolt 20 extends through the actual corner location and through the
alternating layers 64 and 66 of the beams. In the upper right example (Fig.
12A) there
are two offset corner bolts 20' passing through respective cross beams 54 and
transverse beams 56, each of which is trimmed at a forty-five degree angle so
as to
abut each other at the apex of the corner 29. The lower left example (Fig.
12D) is the
top view of a corner 29 as described above for the example dwelling 10 (Fig.
7) .
[0064] The materials selected for the components of the building
constructed
according to the Method (M) are structurally strong. In one example
implementation,
the foundation slab 14 is poured concrete, but other materials may also
suffice. The
elongated threaded bolts 18 may be formed of construction steel and have
dimensions
as described above. The beams 42 may be selected from stable, yet slightly
deformable
woods, such as cedar or redwood, while other types of slightly compressible
materials,
such as synthetic and composite materials, all having compatible upper and
lower
surfaces, may also be suitable. The beams 42 may be elongated and have square
cross
sections. The beams 42 may be of a uniform thickness for alternating layers,
however,
beams of differing heights (thicknesses) may be used, so long as each layer
has a
uniform thickness. Bolt hole 52 separation and locations in the beams 42 may
be
standardized and prefabricated beams 42' may be provided such that onsite
drilling
is avoided and time is saved.
[0065] It is noted that the bolt array 19 defines an exterior
frame 108 for the
dwelling 10 and the exterior frame 108 defines an interior 110 for the
dwelling 10.
[0066] Example implementations of systems and methods for
constructing
dwellings and other building structures using beams and bolting arrays
incorporated
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in a foundation slab are described above. Examples of systems and methods for
construction of building structures are described below with reference to
Figs. 13A,
13B, and 14-23 in which a foundation slab is not used. In accordance with
examples
described below, combined beam structures may be assembled and used as wall or
floor or ceiling sections at a building site. The combined beam structures may
be
delivered to a building site in a prefabricated or assembled state for
assembly at the
building site.
[0067] Fig. 13A is a front plan view and a side section view of
an example
implementation of a combined beam structure 150 comprising a plurality of beam
segments 152 each having a top surface 153 and a bottom surface 155 and made
of a
material that is at least slightly compressible. The plurality of beam
segments 152
may be arranged with the top surface 153 of each beam segment 152
substantially in
contact with the bottom surface 155 of a next beam segment between a first
beam
segment 158 and a last beam segment 160 in the combined beam structure 152.
Each
beam segment 152 in the example beam segments 152 in Fig. 13A includes a
plurality
of bolt bores 162 extending between the top surface 153 and bottom surface 155
of
each of the plurality of beam segments 152. The bolt bores 162 may be formed
as
described above with reference to bolt bores 56 in Figs. 5A and 5B. The bolt
bores 162
may be formed so as to substantially align through each of the plurality of
beam
segments 152 in the combined beam structure 150 in a spaced apart arrangement
A.
[0068] The combined beam structure 150 includes a plurality of
bolt segments
166 extending through corresponding bolt bores 162. A plurality of tightening
fasteners 168 may be attached to the bolt segments 166 to apply a compression
force
between the first beam segment 158 and the last beam segment 160 in the
combined
beam structure 150. In an example implementation, the tightening fasteners 168
include nuts 78 and washers 72 of the type described above with reference to
Fig. 11A
having threads matching the bolt segments 166.
[0069] Each beam segment 152 in the combined beam structure 150
includes a
joint end portion 170 disposed in a joint side 167 of the combined beam
structure 150.
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The joint end portion 170 of each beam segment 152 in a first subset of beam
segments 172 extends a distance d from the joint end portion of each beam
segment
in a second subset of beam segments 174. The beam segments 152 in the first
subset
of beam segments 172 are arranged in alternating layers with the second subset
of
beam segments 174 to form a staggered pattern at 167 of joint end portions 170
at
the joint side 167 of the combined beam structure 150.
[0070] The combined beam structure 150 shown in Fig. 13A may be
used as a
construction unit for constructing a building structure. The combined beam
structure
150 may for example be used to form walls of a building structure by joining
the
combined beam structure with other combined beam structures. The combined beam
structure 150 may for example be implemented as a prefabricated wall unit. The
tightening fasteners 168 may be tightened when installed at the building site
to form
a substantially solid wall unit as illustrated in the side section view 150'
of Fig. 13A.
In some implementations, the wall unit may form a sufficiently solid structure
that
may be used as a wall of a large fluid containing vessel. An adhesive may be
added
between the top and bottom surfaces 153 and 155 to enhance the impermeability
of
such a vessel.
[0071] It is noted that the combined beam structure 150 in Fig_
13A has a joint
side with a staggered pattern on one side of the combined beam structure. In
another
example, the combined beam structure 150 may have joint sides with staggered
patterns on both sides. In another example, the combined beam structure may
include joint sides without staggered patterns and use a separate joining
structure to
provide attachment between two combined beam structures.
[0072] In one example implementation, the staggered pattern
formed at the
joint side 167 of a first combined beam structure 150 may be interlocked with
a
complementary staggered pattern at the joint side of a second combined beam
structure. Fig. 13B is a front plan view and a side section view of another
example
implementation of a combined beam structure 180 comprising the plurality of
beam
segments 152 arranged as described with reference to Fig. 13A. The combined
beam
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structure 180 in Fig.13B includes a plurality of bracket structures 184 on a
top side
and on a bottom side of the combined beam structure 180. The bracket
structures 184
on the top side of the combined beam structure 180 may be attached in one
plane to
the combined beam structure 180 and in the other plane to a top cross beam
186. The
bracket structures 184 on the bottom side of the combined beam structure 180
may
be attached in one plane to the combined beam structure 180 and in the other
plane
to several bottom cross beams 188. A floor 185 implemented as, for example, a
sheet
of plywood, or another solid material, may be mounted on top of the cross
beams 188
and under the combined beam structure 180. The top cross beams 186 may form a
part of a ceiling structure of a building structure, such as a dwelling, or a
room in a
building structure. The bottom cross beams 188 may form a part of a foundation
of
the building structure.
[0073] The combined beam structure 180 in FIG. 13B is shown
attached to a
second combined beam structure 182 at the joint side 167 of the combined beam
structure 180. The second combined beam structure 182 includes a plurality of
beam
segments 152 of the type used for the plurality of segments in the first
combined beam
structure 180. The plurality of beam segments in the second combined beam
structure
182 include a first subset of beam segments 192 arranged in a complementary
fashion
with the first subset of beam segments 172 of the first combined beam segment
180.
The first subset of beam segments 172 with extending portions relative to the
second
subset of beam segments 174 alternate with the extending portions of the first
subset
of beam segments 192 of the second combined beam structure 182. In this
manner,
the staggered pattern of the joint side 167 of the first combined beam
structure 180
interlocks with the joint side of the second combined beam structure 182.
[0074] Fig. 14 is an isometric view of an example of a wall
junction structure
200 formed as a wall corner. The wall junction structure 200 is formed by a
first
combined beam structure 202 and a second combined beam structure 204. The
first
and second combined beam structures 202 and 204 include a plurality of beam
segments 152 arranged as described with reference to Fig. 13A. The staggered
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pattern formed at a joint side 207 of the first combined beam structure 202
interlocks
with the staggered pattern formed by a joint side 209 of the second combined
beam
structure 204. The wall junction structure shown in Fig. 14 forms a junction
at an
angle a, of substantially 90 degrees to form a wall corner. The angle a may be
any
angle up to 180 degrees. The angle a may be varied as described below with
reference
to Fig. 17 to form structures of different shapes.
[0075] The wall junction structure 200 in Fig. 14 forms a wall
corner using a
junction bolt bore 216 in the joint end portion of each of the plurality of
beam
segments 152. The junction bolt bore 216 in the joint end portion of the first
subset of
the beam segments 212 in the first combined beam structure 202 aligns with the
junction bolt bore 216 in the joint end portion of the first subset of beam
segments
212 in the second combined beam structure 204 at the wall structure junction
204.
[0076] The plurality of beam segments 152 in each combined beam
structure
202, 204 includes an inner junction bolt bore 218 disposed an inner junction
distance
/from the junction bolt bore 216. The inner junction bolt bores 218 in the
first subset
of beam segments 212 in the first combined beam structure 202 are configured
to
align with the junction bolt bores 216 in the second subset 214 of the beam
segments
in the first combined beam structure 202. Similarly, the inner junction bolt
bores 218
in the first subset of beam segments 212 in the second combined beam structure
204
are configured to align with the junction bolt bores 216 in the second subset
214 of
the beam segments in the second combined beam structure 204.
[0077] The junction bolt bores 216 and inner junction bolt bores
218 in the beam
segments 152 that form the wall junction structure 200 in Fig. 14 may be
configured
to receive bolt segments 166 in a manner similar to the bolt bores 168
arranged in
the beam segments 152. The inner junction bolt bores 218 may be disposed the
distance I from the junction bolt bores 216 and a distance A from the next
bolt bore
168 in each beam segment 152. In example implementations, the distance I
between
the corner bolt bores and the distance A between the remaining bolt bores 166
may
be the same. In other examples, the distance I may be less than the distance A
to
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impart enhanced compression forces in the region of the structure corner
thereby
strengthening the integrity of the overall structure.
[0078] The wall junction structure 200 in Fig. 14 is formed with
the joint end
portions of the first combined beam structure 202 that extend to interlock
with the
joint end portions of the second combined beam structure 204 having a cross-
sectional
surface being flush with a planar surface of a wall structure formed by the
second
combined beam structure 204. In addition, the joint end portions of the second
combined beam structure 204 that extend to interlock with the joint end
portions of
the first combined beam structure 202 are flush with a planar surface of a
wall
structure formed by the first combined beam structure 202.
[0079] In alternative embodiments, the joint end portions of the
beam
segments of either combined beam structures may extend beyond the planar
surface
formed by either combined beam structure. In an example implementation, the
joint
end portions of the beam segments may extend beyond the corner formed by the
combined beam structures in a manner similar to that illustrated in Fig. 10.
[0080] The plurality of beam segments 152 in the combined beam
segments in
Figs. 13A, 13B, and 14 may be made of any suitable compressible material such
as,
for example, natural wood, cedar, redwood, wood composites, and synthetic
materials.
Thee beam segments 152 may be of any suitable size. In one example
implementation,
beam segments are 6x6 wooden beams, but 4x4, 8x8, or any other beam size may
be
used. Illustrated examples use substantially square cross-sectional beam
segments.
However, bean segments having other rectangular, or non-rectangular cross-
sections
may be used as well. The bolt segments 166 may be any suitable rod-shaped
member
adapted to receive a tightening fastener. Fig. 15 illustrates an example of a
bolt
segment 250 having a thread 252 configured to receive a nut 254 and a washer
256.
[0081] In an example implementation, the first combined beam
structure 202
and the second combined beam structure 204 in Fig. 14 may be arranged over a
foundation, which may be gravel prepared to support a building structure. The
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foundation may also be a deck, or a set of beams mounted on posts inserted
into the
ground. The first combined beam structure 202 and the second combined beam
structure 204 may be provided with the bolt segments 166 and tightening
fasteners
168 inserted into the bolt bores 162, but not into the junction bolt bores 216
or the
inner junction bolt bores 218. The staggered pattern of the joint side 207 of
the first
combined beam segment 202 may be interlocked with the staggered pattern 209 of
the second combined beam segment 204 with the junction bolt bores 216 and the
inner
junction bolt bores 218 are aligned as described above. A bolt segment 166 may
be
inserted into each of the junction bolt bores 216 and inner junction bolt
bores 218 as
described above to integrate the joint ends of the first combined beam
structure 202
and the second combined beam structure 204. The tightening fasteners 168 may
then
be tightened to strengthen the wall junction structure 200.
[0082] In example implementations, the combined beam structures
described
above with reference to Figs. 13A, 13B, and 14 may be used to assemble a
building
structure. Fig. 16 is an isometric view of an example building structure 300
formed
by a first combined beam structure 302, a second combined beam structure 304,
a
third combined beam structure 306 and a fourth combined beam structure 308.
The
combined beam structures 302, 304, 306, 308 are arranged and joined at wall
corners
310a, 310b, 310c, and 310d to form a substantially rectangular structure. The
wall
corners 310 may be formed, as described above with reference to Fig. 14. In
particular,
the junction bolt bores, the inner junction bolt bores, the corresponding bolt
segments,
and the interlocking of the joint sides of the combined beam structures
cooperate to
strengthen the building structure 300 at the junctions between the combined
beam
structures. By tightening the tightening fasteners at each bolt segment, the
attached
combined beam structures are joined to form a unitary building structure. In
addition, each bolt segment or selected bolt segments may be extended above or
below
the building structure at 305. The extended bolt segments 305 may be used to
attached to rafters above the building structure 300 or to a floor or
foundation below
the building structure at 305.
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[0083] In example implementations, a combined beam structure may
be part of
the building structure as a floor. Fig. 17 is a front plan view of another
example
building structure 320 and a top view of an example combined beam structure
used
as a floor 322. The building structure 320 in Fig. 17 comprises 8 combined
beam
structures attached to form a structure having an octagonal shape from a top
view.
Fig. 17A depicts a top view cross-section 17A of a portion of the front
section of the
building structure 320 illustrating a first combined beam structure 320a
joined to a
second combined beam structure 320b, which is further attached to a third
combined
beam structure 320c. The combined beam structures 320a-c are joined at an
angle
sufficient to form the octagonal shape with five other combined beam
structures. The
combined beam structures 320a-c are joined using a three-bolt segment wall
junction
structure that includes two inner junction bolts 326 and a junction bolt 324
as
described above with reference to Fig. 14.
[0084] The floor 322 includes a plurality of beam segments 340
arranged
horizontally and joined with horizontal bolt segments 321 in a manner similar
to that
described above with reference to Fig. 13A. The combined beam structures 320
may
be mounted on the floor 322 as shown in Fig. 17. The integrated building
structure
may then be mounted on a plurality of posts 335 or on another foundation
structure.
In an example implementation, the bolt segments and tightening fasteners
forming
the beam composite structures of the building structure and of the floor 322
may be
tightened sufficiently to form an integrated structure. The tightening of the
bolt
segments, which may be performed using an impact driver, for example, combined
with the compressibility of the beam segments may allow for the building
structure
320 to function as a water container. The building structure 320 in Fig. 17
includes a
water spigot 325 to allow water to exit and a water inlet 327 to allow water
or any
other liquid to flow into the building structure 320.
[0085] Fig. 18 illustrates example mechanisms for attaching a
bolt segment 382
to a combined beam structure 380 configured to function as a floor. The
horizontal
combined beam structure 380 formed using horizontal bolt segments 388 may be
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mounted on posts 392 or beams supported by the ground, or by other structures
such
as a deck. The horizontally disposed combined beam structure 380 may include a
cross bolt bore 385 to receive a vertically disposed bolt segment 382, which
may be
secured to the floor combined beam structure 380 using a nut and washer 384
combination. The vertical bolt segment 382 may be one of a plurality of bolt
segments
that are part of vertically disposed combined beam structures forming walls
for the
building structure.
[0086] Fig. 19 is front plan view 400, a side section view 402,
and a top view
404 of another example implementation of a wall junction structure 420 for
joining a
first combined beam structure 410 and a second combined beam structure 412.
The
wall junction structure 420 uses an alternative mechanism for joining the
combined
beam structures 410 and 412, and for providing a foundation for a wall formed
by the
multiple combined beam structures. The first combined beam structure 410 and
the
second combined beam structure 412 may be constructed as described above with
reference to Fig. 13A, but with an even, not staggered pattern, on each side
of the
combined beam structures 410, 412. The sides of each combined beam structure
410,
412 may be inserted into I-beams 422. The combined beam structures 410, 412
may
extend from opposite sides of the I-beams 422 to form an extended wall. The I-
beams
422 may also be buried into postholes 421 to secure building structure to the
ground.
In this manner, the postholes 421 may be said to provide a foundation for the
building
structure.
[0087] Many modifications to the above embodiment may be made
without
altering the nature of the invention. The dimensions and shapes of the
components
and the construction materials may be moclified for particular circumstances.
While
various embodiments have been described above, it should be understood that
they
have been presented by way of example only, and not as limitations.
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