Abstract
A modular structural element (20) which is arranged to be connected to another such element so as to form an assembled structure, wherein the modular structural element is of substantially square outline or of substantially hexagonal or half-hexagonal outline, and the element comprises a principal height dimension and a principle lateral dimension, wherein, a ratio of the two said principal dimensions is no more than 6.
Claims
1. A modular structural element which is arranged to be connected to another such element so as to form an assembled structure, wherein the modular structural element is of substantially square outline or of substantially hexagonal or half-hexagonal outline, and the element comprises a principal height dimension and a principle lateral dimension, wherein, a ratio of the two said principal dimensions is no more than 6.
2. The modular structural element of claim 1 in which the ratio is no more than at least one of 1.5 1.75, 2, 2.25 2.5 2.75, 3, 3.25, 3.5, 3.75, 4, 4.25, 4.5, 4.75, 5, 5.25, 5.5 and 5.75.
3. The modular structural element of claim 1 in which the ratio is between 1.0 and 2.5.
4. The modular structural element of claim 1 in which comprises a half hexagonal modular element, and which is arranged to be attached to a second hexagonal modular element to form a modular structural element of hexagonal outline.
5. The modular structural element as claimed in claim 1 which is a hollow entity comprising an internal void.
6. The modular structural element as claimed in claim 5 in which the distal ends are open distal ends.
7. The modular structural element as claimed in claim 1 which comprises sides which extend from one distal end to an opposite distal end, and any side may be provided with one or more apertures.
8. A modular structural element as claimed in claim 7 in which said sides are of non-solid configuration.
9. A modular structural element as claimed in claim 1 which weighs less than 50 kg.
10. A plurality of the modular structural elements as claimed in claim 1 for realising an assembled structure comprising said elements in a connected configuration.
11. A plurality of modular structural elements as claimed in claim 10 in which an internal space of a hexagonal modular structural element, formed as a unitary entity or by joining two half hexagonal elements, is configured so as to receive a square modular element therein.
12. A plurality of modular structural elements as claimed in claim 10 which comprises at least two different elements from a hexagonal element, a half hexagonal element and a square element, which are of substantially the same principal height dimension.
13. A modular structure which comprises multiple modular elements, assembled together, comprising the plurality of modular elements as claimed in claim 10.
14. A modular structure as claimed in claim 13 which is at least one of an upright structure in which the modular elements are arranged in a vertical formation and a lateral formation in which the modular elements are arranged in a side-by-side formation.
15. A modular structure as claimed in claim 14 in which for the vertical formation, a lower portion of which comprises multiple hexagonal modular elements placed in a vertical direction, and an upper portion comprises multiple square modular elements placed in a vertical direction.
16. A modular structure as claimed in claim 15 in which the lower portion is substantially devoid of square modular elements, and/or the upper portion is substantially devoid of hexagonal modular elements.
17. A modular structure as claimed in claim 16 in which there is an intermediate portion located between the upper portion and lower portion, in which at least one square modular element is received in at least one hexagonal modular element.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0111] Various embodiments of the invention will now be described, by way of example only, with reference to the drawings, in which:
[0112] FIGS. 1A, 1B and 1C show various views of an upright structure in the form of a telecoms mast,
[0113] FIG. 1D is a detailed view of bracing used with the mast of FIGS. 1A, 1B and 1C,
[0114] FIGS. 2A, 2B, 2C and 2D show various views of the cabin which is shown in FIGS. 1A, 1B and 1C, which connects the end of standard ISO containers via the container's TwistLock® system only and forms the structural foundation for the mast,
[0115] FIGS. 3A, 3B and 3C show various views of two HalfHex elements forming a Hex module arrangement,
[0116] FIGS. 4A, 4B and 4C show various views a HalfHex element,
[0117] FIGS. 5A, 5B and 5C show how the Hex elements can be stacked one on top of the other to form the main body of the upright structure, and in the illustrated version with vertical joints between HalfHex modules aligned may also be arranged with such joints misaligned as stacking progresses,
[0118] FIGS. 6 and 7 show two embodiments of basal assemblies,
[0119] FIG. 8 shows a first view of an interpolate,
[0120] FIG. 9 shows a second view of the interplate as shown in FIG. 8,
[0121] FIG. 10 shows three views of a square section element,
[0122] FIG. 11 shows a Hex with a square section element inside and both mounted onto an interplate.
[0123] FIG. 12 shows a square section element and six poles mounted onto an interpolate,
[0124] FIG. 13 shows two interplates separated by three mounting poles, collectively mounted to the top of a stack of two square section elements,
[0125] FIG. 14 shows a complex example of various items of telecommunications equipment mounted to an eight level stack comprised of square section elements, HalfHexs, interplates and poles, in which such a sub-assembly may be lifted to a mast top by crane,
[0126] FIG. 15 shows a perspective view of a square section element which is of sufficient size to contain within a secondary ladder and platform arrangement, as well as a perspective view which shows a number of such elements vertically stacked, and provides an access way for people to pass therein,
[0127] FIG. 16 shows a mast as would be fastened to a pre-prepared foundation which is of Hex form complete with internal ladder way to the top, and which also shows lateral construction in the upper layer, facilitating the installation of greater amounts of the equipment shown in FIG. 14,
[0128] FIG. 17 shows a cutaway view of the upper sections of FIG. 16, in which link plates are seen to join six HalfHexs around a central Hex at three levels, thereby constructing a large, three level platform area with people able to move laterally through cut open panel access holes,
[0129] FIG. 18 shows a Hex complete with secondary ladderway structure,
[0130] FIG. 19 shows a plan of FIG. 16 in which link plates secure an additional ring of HalfHexs, with the central ladderway is shown surrounded by walkways, and wherein gaps down through all structural elements present as cabling routes,
[0131] FIG. 20 shows a derivation of a HalfHex element with a (standard) panel used on both HalfHex and square section element in the variant shown,
[0132] FIG. 21 shows a possible realisation of lateral assembly of modular structural elements,
[0133] FIG. 22 shows a perspective view of various modular structural elements,
[0134] FIG. 23 shows plan views of two of the elements in FIG. 22, and
[0135] FIG. 24 shows an antenna mast structure (in an exploded view) which includes the use of elements shown in FIG. 23.
DETAILED DESCRIPTION
[0136] There are now described various embodiments of a novel modular structural system which comprises modular structural elements which can be connected together to form a modular structure.
[0137] Reference is made initially to FIG. 1 which shows an upright assembled structure 10, which is provided with a base (a cabin plus an ISO-compliant shipping container) 3 and a vertical assembly 5 which is supported on the base. As will be described in detail below, the assembled structure is modular and is formed primarily of square, hexagonal (‘Hex’) or part-hexagonal (‘HalfHex’) modular elements. At a modular scale height (Hm) of one metre, for example, all modular elements may be configured to weigh less than 50 kg, thus allowing for ease of manufacture and of installation.
[0138] FIGS. 1a, 2a and 3a show a sample build of the mast system. Its modular format is comprised substantially entirely of the modular elements weighing less than 50 kg, for facilitating handling and assembly by two people. An aspect of the configuration of the elements in isolation, may not be routinely recognisable as a mast form; being of (un)characteristically low-profile or ‘squat’ aspect ratio for that duty. In fact the system can be seen as a type of assembly scaffold with the unique attribute of assembling to describe highly efficient vertical or horizontal structures.
[0139] Hexagonal (‘Hex’) modular elements (which are described in further detail below) of the mast comprise two connected half hexagon (‘HalfHex’) elements at every layer; the hexagonal modules are twice the strength of square section modular elements (described below) and twice the weight. The Hex and square modules are one metre high in this example, and therefore defining the modular scale Hm as 1 m (one metre), making quantifying components needed to achieve masts of certain heights extremely straightforward.
[0140] The example embodiment shown includes an ISO container 25 to which the cabin 3 is attached. The cabin is sized to couple to the end of standard shipping containers via proprietary Twistlock® compliant connectors bolted to it. The cabin 3 offers a measure of security to the base of the mast whilst allowing access for engineers to climb up and down the inside the mast. Where security is not an issue frames (i.e. cabins without outer paneling) may replace the cabin.
[0141] Modular structures, a mast in this example, need not fix to the cabin, but may be attached to any building structure, vessel, vehicle or structural foundation prepared for it. Or the entirety of a modular construction may act independent of all structural contact, i.e. set down on a surface or launched into space.
[0142] The cabin module 15 provides a (sheltered/protected) connection from the internal space of ISO container into the mast or tower. Note the aperture 15a shown in FIG. 2b, which allows someone to access the internal space of the vertical structure, mast or tower from its base.
[0143] In the example mast shown, the uppermost end of the structure has secured thereto telecoms equipment, such as transceivers, suitable for transmitting and receiving signals over an air interface. In the example this is made possible by the appropriate selection and arrangement of modular elements herein described.
[0144] Although the upright structure has been described as a mast for antennae, it also has numerous other applications, such as to support sensors in an elevated position, and/or to support a visual display or object in an elevated position, and/or be an architectural structure, which may be provided with a decorative cladding. These modular elements are specifically defined structural entities, that may be used in any way calculable.
[0145] Turning to FIGS. 3a, 3b and 3c, the ‘Hex’ modular elements 20 are now described in more detail. As can be seen, each Hex modular element 20 comprises six sides 21. As the illustration shows, this element is an assembly of two HalfHexs 20a shown in FIG. 4, which are connected together. The element 20 has a height equal to the scaling of the overall module system Hm, and the sides (‘panels’) extend from one distal end to the other. Each distal end is an open distal end. The element 20 is a substantially hollow entity. Each panel here comprises a substantially planar face which is provided with a number of through apertures 22. These apertures pattern to present remaining material as a number of ribs or cross members 23, being sometimes referred to in aggregate as a lattice structure.
[0146] Upper and lower distal ends comprise an inwardly facing circular surface 24, the diameter of which is sufficient to allow a square modular element to pass) through.
[0147] As mentioned above, the Hex modular element illustrated 20 comprises two (sub-) half hexagonal modular elements 20a, each being of substantially half hexagonal shape (in plan), which are brought/connected together in use as a full hexagonal assembly. Each module 20a comprises two opposed inwardly directed flanges or interfaces 20b. Each flange 20b is provided with a number of apertures—some for allowing attachment of the two hexagonal halves together in abutting fashion and the others (at this modular scale Hm=1) for handholds to allow an operative to ascend and descend within the internal space of the structure. (It will be appreciated that in a variant the hexagonal module may be provided as a single entity formed as a unitary item, and that at other modular scales alternative means of elevation through the structure may be provided).
[0148] In FIG. 4a it can be seen that the vertical edges of the modular element 20 are formed into what may be termed as structural columns, specifically by the addition of a sloped plate through which bolting tubes are set. This feature is common with the square modular element, though at Hm=1 m the hexagonal form of the column varies additionally with either additional structure between the ends of each column, or the distinct form in way of the joint between adjacent HalfHex's.
[0149] The hexagonal modular element (formed of two connected half-hexagonal elements) and the half-hexagonal elements, have a main lateral dimension, in addition to a height dimension. This main lateral dimension is the distance between opposing corners of the hexagonal shape, as shown in FIG. 3c. This distance also corresponds to the diameter of its circumscribing circle, not illustrated, which is contiguous with all corners/vertices of the hexagonal shape.
[0150] For the Hex module illustrated, its lateral dimension is larger than its height dimension. The lateral dimension (or ‘width’ dimension) being greater than the height dimension results in a low-profile entity. Similarly, for the square element 50, its lateral dimension is close to the height. By definition the greater value of width or height is less than 1.5 times the lesser value. This thereby renders both Hex and square element devoid of ‘slenderness’ or geometrical representation of what they might assemble to become.
[0151] FIGS. 5a, 5b and 5c show how the hexagonal modular elements can be stacked one on top of the other to form the main body of the upright structure (and indeed the major proportion of the height). The illustrated example shows fully aligned stacking. However, in another arrangement the hexagonal elements may be rotated 60 degrees at additional levels to misalign the joints between pairs of HalfHex's to structural advantage.
[0152] At modular scales (Hm) up to 2 m, the vertical paneling/sides of the square modular elements and HalfHex modular elements is achieved by mechanically folding sheets of construction material. This method serves to minimise distortions due to heat during fabrication.
[0153] FIGS. 6 and 7 show various views of two embodiments of assembled base structures, which, in this instance, can be used to support, for example, a vertical stack of hexagonal modular elements (and any equipment attached to the top of the stack). Note how the base structures are primarily and conveniently formed of hexagonal modules or half hexagonal modules. This also includes an interplate (described further below) placed on top thereof, thereby preparing the base to interface with either square- or Hex-based vertical structures.
[0154] It may also be noted that the modular assembly in FIG. 7, presented as a base, demonstrates a versatility in that it may also be introduced higher up in a mast structure, at one or more levels, to generate increased structure for the attachment of increased amounts of equipment. In another instance the upper surface of the base structure can be provided with a suitable covering to serve as a walkway.
[0155] An aspect of the system (i.e. the use of the modules to construct the upright structure) is the relationship between two different column shapes/outlines—that of a hexagon (Hex) and that of a square. Both shapes of modular element can be attached to a foundation/base structure at the same time if need be, and thereby benefitting from the combined strength properties thereof. As can be seen in the Figures, both the hexagonal modular elements and the squared modular elements comprise profiled and formed plate exteriors with plate ends, and sloped plate and tube combinations as strong points for connection together. Advantageously, at smaller modular system scales (Hm), neither module type uses locating dowels or other locating means. This enables sections to slide across each other in the deployment from, or storing into a shipping state.
[0156] FIGS. 8 and 9 show an interplate 40, which is of substantially planar form, and which is arranged to be secured to a distal end of a modular structural element. This is essentially a connection component and/or support component, which comprises multiple attachment or bolting positions to allow for modular structural elements to be connected together to create an assembled structure, and also allows for structural change as the structures develop. The interplate 40 is provided with various apertures as shown. In FIG. 8, it can be appreciated that the aperture pattern provides for the fixture of six poles, each with four bolt flanges, positioned at the corner regions of the hexagon shape of the interplate, whilst, inwardly thereof, there is defined a (central) squared aperture and outlying said central squared aperture are four corner bolt positions are provided that a square modular element attaches to or can extend through. It is then of note that the half-hexagon and hexagon modular elements can attach to or through each of the inner two pole flange holes at each of the six corners of the hexagon shape.
[0157] The interplate 40 is of a thickness equal to that of a link plate (or HexLink). In this way interplates and link plates can be arranged in link layers of the modular structural elements such that they are sandwiched between adjacent square and hexagonal structural layers.
[0158] The square modular element is shown in FIG. 10. It shares some similarity in construction with the HalfHex modular element (e.g. the profiled panels), and is also an open-ended component, however the square modular element is of squared rectilinear transverse sectional shape. The illustrated element may be of module system scale of 1 m. These modular elements may not only be optimised to weigh less than 50 kg each, but the square modular element is especially configured for construction from very high strength steels whilst retaining dimensional stability. Of particular note in this regard, shown generally at 50a, are the folds in the sloped corner plates, that allow the plates to be projected through the panels to be welded from outside the module. The distal end panels too, also feature semi-circular cut-outs 50b which limit weld content to the panel edges; thereby conserving dimensional accuracy.
[0159] The main lateral dimension of the square modular element 50 is measured as the distance between opposing corners of the square outline, as shown in FIG. 10. As will described below, the main lateral dimension of the square modular element 50 is inferior to that of the lateral dimension of hexagonal modular element 20. It will be appreciated that in some instances it may be more suitable or appropriate to determine the main lateral dimension as being the wide of a side of the element.
[0160] FIG. 11 shows how the hexagonal module is dimensioned to fit around the outside of the square modular element 50. By this feature, higher sections of masts that include square modular elements, transition, through the use of interplates 40, at two or three intersections into hexagonal modular elements only, for increased strength lower down. And, as loads build with increasing mast height above a section, even the hexagonal modular elements can become structurally overwhelmed, so that the interplates and square modular elements are introduced again, now at every level, for the maximum strength available within the boundary of the interplate profile.
[0161] With reference to the upright structure shown in FIGS. 1A to 1C this has a lower portion which comprises multiple hexagonal modular elements located one above the other and an uppermost portion which comprises multiple square modular elements arranged one above the other in a vertical direction. Moreover, the lowermost portion has no (i.e. is devoid of) square modular elements, and the uppermost portion has no hexagonal modular elements. However, at a region between the upper portion and the lower portion, one or more of the square modular elements are located inside the hexagonal modular elements, in what may be termed as a transitional portion of the structure.
[0162] FIG. 12 demonstrates a particular modular configuration where modular poles 60 are positionally set by the interplate around the stabilising square modular element core. This arrangement can be set in isolation with the length of a square section mast, where an uppermost interplate would secure the tops of the poles, or continue for many layers. The poles are devised, at the illustrated module scale, for fixture of telecoms equipment, as illustrated here, and similar.
[0163] When, in particular, the configuration set of in FIG. 12 is set down upon a combined hexagonal and square substructure (FIG. 11), structural load bearing on the square modular element(s) bear down on the square element(s) beneath, whereas loads on the poles bear down through to the columns formed of hexagonal modular elements. In this way, also, potentially damaging load concentration developed at sharp changes of section (an engineering constant) are diffused.
[0164] FIGS. 13 and 14 show a configuration in the provision of a single microwave dish (FIG. 13), and a full 5G telecoms installation (FIG. 14). In the latter case, the entire content illustrated in FIG. 14 is demonstration of a complete sub-assembly that can be assembled horizontally on the ground, to be raised to the vertical and up onto the mast in a single, fully tested and operating unit.
[0165] FIG. 15 shows a variant embodiment 50a of a square modular element 50, in which a ladder is provided within the internal space. As is also shown in FIG. 15, a number of such elements are stacked and are relatively orientated so that a person can ascend and descend using the respective ladders within the internal space collectively defined by the elements.
[0166] FIGS. 16 to 19 show a mast structure for cellular network telecommunications equipment 200 which mast structure comprises a vertical stack of hexagonal modular structural elements 21, formed of two connected half hexagonal modules 21a. (The elements 21 may be of Hm=2 m.) The modular elements 21 are variant embodiments of those (hexagonal elements 20) described above, which are formed of two connected halfhex elements, in which one of the halfhex parts comprises a ladder and a platform, and the other halfhex which is attached thereto is devoid of those features. The ladders and platforms advantageously provide access to a service engineer to ascend the internal space of the mast using the steps and perform any necessary work on the telecommunications equipment. FIG. 19 shows a plan view of the mast. As can be seen a number of halfhex elements (i.e. those without the ladder and platform) have been attached to the outer panels of the uppermost hexagonal modular element of the mast head sub-assembly, to provide a support structure for the telecommunications equipment.
[0167] FIG. 20 shows a variant half hexagonal element 300 (which may be combined with another like element) with common sides/panels throughout, thus enabling lateral (side-by-side) connection with another such element by the addition of extra fastening holes 102 and suitable fasteners. Since the panels close with the corner structure but not panel to panel, a recess is formed at the corner into which a utility post 101 is provided. These posts, being similar to the poles 60, conveniently expand opportunities for fitment of equipment and lifting points.
[0168] FIG. 21 shows a lateral arrangement of a number of modular structural elements (which may be of Hm=2 m) which are connected together (and may for example form part of a base structure). The arrangement shown includes several hexagonal elements 300, as well as a square section element 500. The size and shape of the panels/sides of the elements 500 matches those of the sides/panels of the hexagonal elements, allowing the two different varieties of elements to be interfaced together.
[0169] Although for the above described embodiments of the modular structural elements the sides/panels are open (or more precisely, apertured), in other embodiments some or all of these panels/sides of an element may be obfuscated or blocked or covered with material components such as sheets or planar materials (which may be opaque, transparent or translucent). In some embodiments, the modular structural elements may be formed as having closed sides/panels, at the time of manufacture, as compared to retrofitting procedure to cover/close the one or more sides.
[0170] Further in addition to the embodiments disclosed above, the modular structural elements may be of a triangular section. For example, such an element may have three sides/panels which are each of a size and shape which substantially match those of the elements shown in FIG. 21, and are therefore interfaceable therewith.
[0171] Reference is made to FIG. 22 which shows an array of some of the modular elements described above, but also including two further modular structural elements, 600 and 700, which may both be of modular height Hm=2 m. The modular structural element 700 may be termed a fort, and has four orthogonal sides. Three of the sides are solid and not apertured. One of the sides is provided with an opening 701, which allows humans to access the internal space defined by the element. The four corner regions 701 of the element 700 are rounded by virtue of the element containing four corner columns 703. The bolting patterns at the opposite ends of these columns match those described by the square and hexagonal modules when laterally assembled to generate a complete bolting circle (as visible in FIG. 21). These reinforcing elements 703 are hollow and are located internally of the element in the square form. An uppermost surface (or roof structure) of the element 700 is provided with an aperture 702.
[0172] The element 600 which may be termed a castle, is likewise of a reinforced nature, and has access opening 601 in a side, and an uppermost access aperture 602. However, the element 600 matches geometrically the hexagonal cross-section as the hex module 300. A (protruding) corner column 603 is provided along the apexes between adjacent sides, with bolt circles arranged at their ends in positions matching positions in the Hex 300.
[0173] FIG. 23 shows the plan views of the six-sided castle element and the four-sided fort element. For both elements, the distance between one tubular column and an adjacent column is the same. Whilst the interlinking side panels on the castle 600 match the positions of the sides on the Hex 300, the positions of the panels on the fort element do not match the panel positions on the module 500, but instead they align tangentially to the exterior of the corner columns to maximise available internal space.
[0174] FIG. 24 shows one possible embodiment of the way in which the elements 600 can be combined in a mast structure. At the top of the mast structure there is provided an antenna head 1000. Below the antenna head there is provided a vertical stack of hexagonal elements 800. These hexagonal elements may be viewed as variant embodiments to the hexagonal elements 300 in which the sides are provided with solid paneling to cover the apertured open sides. This provides for enhanced security and weather tolerance. Below the elements 800, there is provided a plurality of stacked elements 600.
[0175] A base 1100 is provided which comprises a plurality of solid sided and based versions of hexagonal elements 800 connected laterally, and which contain weight to assist in maintaining the mast in position; for example, poured concrete.
[0176] It will be appreciated that the modular elements may be used to construct a temporary or a permanent structure. For example, the elements with the height of Hm=1 m may be suited to a temporary structure, whereas the elements with the height of Hm=2 may be suited to constructing a permanent structure.
[0177] It will also be appreciated that other modular system heights may be used, other that 1 m and 2 m examples mentioned above. Similarly, variant embodiments have different aspect ratios of lateral dimension and height dimension may be achieved, in which the height dimension is greater than the lateral dimension and in which the lateral dimension is greater than the height dimension.
