Modular structural component

Abstract

A modular component including an elongate hollow body having first and second attaching elements for attaching the modular component to another modular component. The first attaching element is in the form of cylindrical shaped spigot extending along an external surface of a first side wall of the body. The second attaching element is in the form of socket extending along an external surface of a second side wall of the body directly opposite the spigot. The socket has an internal shape that is sized and of a complementary shape of the spigot for receiving a spigot of another modular component. The socket is connected to the spigot by one or more bracing members that extend in a direction from the first side towards the second side between the spigot and the socket.

Claims

1. A modular construction tool for forming curved shapes, comprising: one or more elongate bodies each defining a longitudinal axis and a front shaping face, each elongate body having: first and second attachments extending along the longitudinal axis on directly opposed first and second side walls of the elongate body, on opposite sides of the front shaping face, for successively linking elongate bodies one to another; the first attachment including a cylindrically shaped spigot extending along the longitudinal axis and attached to an external surface of the first side wall of the elongate body by a support, the spigot having a cross sectional shape forming a complete circumference of a cylinder; and the second attachment including a socket extending along the longitudinal axis and forming a partial circumference of a cylinder disposed along an external surface of the second side wall of the elongate body, the socket sized to receive a spigot of another elongate body, the partial circumference forming an opening through which the support is movable to enable pivoting of the spigot within the socket so as to enable successively linked elongate bodies to form an angle relative to each other, wherein the support extends in a direction from the first side wall towards the second side wall between the spigot and socket such that the support connects the spigot and socket, each elongate body has a symmetrical shape about a central plane extending along its length, and each elongate body is substantially uniform along its entire longitudinal length.

2. The tool of claim 1, wherein each elongate body is a structurally rigid hollow body that has two spaced end walls interconnected to the first and second sidewalls.

3. The tool of claim 2, wherein the first and second sidewalls taper towards the two spaced end walls.

4. The tool of claim 1, wherein each elongate body has a shape comprising two isosceles trapezoidal prisms each extending from a side of a longitudinal plane that extends from a center of the spigot to a center of the socket, the two prisms being symmetrical images of one another about the central plane extending along the length of the elongate body.

5. The tool of claim 4, wherein an acute angle of each isosceles trapezoidal prism is between 80? and 89? .

6. The tool of claim 1, wherein each elongate body has a semi-cylindrical portion that is longitudinally joined to the support along its mid-point that defines a concave recess that faces the spigot and extends around an inner side of the spigot and is spaced from the spigot by a distance equal to a thickness of a wall of the socket, the concave recess being continuous along the entire longitudinal length of the elongate body.

7. The tool of claim 1, wherein each elongate body comprises two spigots extending along the first sidewall and two sockets extending along the second sidewall.

8. The tool of claim 1, wherein a width between the first and second side walls is between 50 and 80% of a depth between opposed end walls transverse to the first and second side walls.

9. The tool of claim 1, wherein a ratio of height between a first end wall and a second end wall and width between the first and second side walls is less than or equal to 2.2 to 1.00.

10. The tool of claim 1, wherein each elongate body has first and second spaced end walls interconnected to the first and second sidewalls, and the length of each elongate body is greater than a height between its first and second end walls.

11. A modular construction tool for forming curved shapes, comprising: a plurality of elongate bodies each defining a longitudinal axis, a front shaping face, and a rear face opposite the front shaping face, each elongate body having: first and second attachments extending along the longitudinal axis on directly opposed first and second side walls of the elongate body, on opposite sides of the front shaping face, for successively linking elongate bodies one to another; the first attachment including a longitudinally extending support attached to an external surface of the first side wall, and a shaft extending along the longitudinal axis and attached to the longitudinally extending support, the shaft having a cross sectional shape forming a complete circumference of a cylinder; the second attachment including a socket extending along the longitudinal axis and forming a partial circumference of a cylinder, the socket sized to receive a shaft of another elongate body, the partial circumference forming an opening through which the longitudinally extending support is movable to enable a pivoting of the shaft within the socket so as to enable successively linked elongate bodies to form an angle relative to each other; and a ratio of height between the front shaping and the rear faces and width between the first and second side walls is in a range of between 1.8 to 1.00 and 2.2 to 1.00, wherein a brace extends through an interior of each elongate body and connects the longitudinally extending support and the socket, and each of the elongate bodies has a symmetrical shape about a central plane extending along its length.

12. The tool of claim 11, wherein the tool is a curved mould or former, the curved mould or former being formed by an assembly of the plurality of elongate bodies of the tool, the elongate bodies being interconnected by their shafts engaging one or more sockets of one or more adjacent elongate bodies, and the elongate bodies being fixed to one or more supports.

13. The assembly according to claim 12, further including end plates that are secured to the elongate bodies to hold the elongate bodies in a predetermined curved profile.

14. The tool of claim 11, wherein the brace includes a curved portion.

15. The tool of claim 11, wherein the first and second sidewalls taper towards at least one of the rear faces.

16. The tool of claim 11, wherein each elongate body comprises two shafts extending along the first sidewall and two sockets extending along the second sidewall.

17. A modular tool for forming a template for constructing a curved surface, comprising: a plurality of elongate bodies each defining a longitudinal axis, each having a longitudinally extending front face forming a section of the template of the curved surface, and first and second side walls adjacent the front face on directly opposite sides of the front face, and each having: a first attachment including: a first socket formed as a partial circumference of a cylinder; a longitudinally extending support attached to an external surface of the first side wall within the first socket; and a shaft extending along the longitudinal axis and attached to the longitudinally extending support to extend coaxially with the first socket along the longitudinal axis, the shaft having a cross sectional shape forming a complete circumference of a cylinder; and a second attachment including: a second socket extending along the longitudinal axis and forming a partial circumference of a cylinder disposed partially beneath a surface of the second side wall, wherein a part of the partial circumference extends above the surface of the second side wall to form opposed cylindrical wall sections each having a thickness, an interior of the second socket is sized to receive a shaft of another elongate body, and the partial circumference forms an opening through which the longitudinally extending support is movable to enable pivoting of the shaft within the second socket so as to enable successively linked elongate bodies to form an angle relative to each other, wherein each of the plurality of elongate bodies has a symmetrical shape about a central plane extending along its length, and each of the plurality of elongate bodies is substantially uniform along its entire longitudinal length.

18. The tool of claim 17, wherein the thickness of each of the opposed cylindrical wall sections corresponds to a distance between an exterior surface of the shaft and an interior surface of the first socket.

19. The tool of claim 17, further comprising a brace extending through an interior of each of the plurality of elongate bodies and connecting the longitudinally extending support and the second socket.

20. The tool of claim 17, wherein the first and second side walls taper towards the front face.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will now be described by way of examples and with reference to the accompanying drawings in which

(2) FIG. 1 is an isometric projection of a single modular component according to a preferred embodiment of the present invention;

(3) FIG. 2 is a cross-section through the modular component of FIG. 1;

(4) FIG. 3 is an isometric projection of a plurality of modular components according to the preferred embodiment of the invention joined together;

(5) FIG. 4 is a cross-section through a plurality of modular components according to the preferred embodiment of the present invention that are joined together;

(6) FIGS. 5 to 8 show further modular components constructed in accordance with the present invention; and

(7) FIGS. 9 to 11 show various end plates for holding two or more assembled components in a fixed relationship.

DETAILED DESCRIPTION OF THE INVENTION

(8) A preferred embodiment of a component 1 according to the present invention is shown in FIGS. 1 to 4. The modular component 1 comprises an elongate hollow body 4 having two side walls 17 and 18 and two end walls 10. A first attaching means 2 extends along the first side wall 17 of the body 4, and a second attaching means 3 extends along the second side wall 18 of the body 4 for connecting a first component 1 to an identical second modular component 1 as explained below. The component 1 is preferably made by extruding an extrudable material (but could be cast or moulded) and extends longitudinally, and, as can be seen best in FIGS. 1 and 2, has a symmetrical shape about a central plane 19 (see FIG. 2) extending along its length L.

(9) The first attaching means 2 comprises a longitudinally extending cylindrical spigot 6 and is attached to the body 4 by a mounting portion 7. The mounting portion 7 is substantially planar and is attached to the spigot 6 at a first end and to the body 4 at a second end of the mounting 7.

(10) The second attaching means 3 comprises a longitudinally extending cylindrical socket 8 the internal shape of which is sized and of a complementary shape to the external diameter of the spigot 6 for receiving a spigot 6 of second identical component 1. In other words, the inner diameter of the socket 8 is substantially equal to an outer diameter of the spigot 6 of the first attaching means 2.

(11) The socket 8 has a cutaway section 9 at an outer facing side that faces away from the body of the component. The cutaway section 9 extends approximately 45? around the socket 8 and is centred on the midpoint transverse axis 15 of the component 1 that lies orthogonal to the plane 5. This cutaway section 9 allows the spigot 6 of a first component 1 to be slidably and rotatably mounted within the socket 8 of a second component 1 in the manner shown in FIGS. 3 and 4.

(12) The body 4 comprises two substantially isosceles trapezoidal prisms 11 that together form the side walls 17 and 18 and end walls 10 of the body 4. The two prisms 11 are symmetrical images of one another about the transverse axis 19 of the component 1. Although substantially isosceles trapezoidal prisms, each prism 11 includes two curved sections 12 and 13. The curved sections 12 define part of a wall of the socket 8 whilst the two curved sections 13 define an outwardly facing concave recess that faces towards, and is spaced from, the spigot 6 and therefore each section 13 is an approximately 90? sector of a longitudinally extending tubular cylinder. Each curved section 13 extends around, but is spaced from, approximately 90? of the circumference of the spigot 6 so that the two sections 13 encompass approximately 180? of the circumference of the spigot 6.

(13) The inner radius of each curved section 12 defines a concave second recess that is substantially equal to the outer radius of the wall of the socket 8. As the outer radius of the spigot 6 is substantially equal to the inner radius of the socket 8, the separation of each first curved section 12 from the spigot 6 is substantially equal to the thickness of the wall of the socket 8. This allows the socket 8 to be slidably and rotatably mounted around the spigot 6 of a second component 1 and within the concave recess defined by the curved section 12 as shown in FIGS. 1 and 2.

(14) The mutually common wall of the prisms 11 constitutes a bracing structural member 14 that interconnects the spigot 6 (through the mounting portion 7) to the socket 8.

(15) The acute angle of each isosceles trapezoidal prism 11 is in the range of 81? to 89?, and is preferably 0.85?. This allows approximately 10? of rotation between adjacent connected components 1 about the centroid of area of the spigot 8 when the components 1 are connected together from a straight line position or flat profile, as shown in FIG. 3, to a curved profile, as shown in FIG. 4. As each component 1 can be rotated 10? about the centroid of area of the spigot 6 away from a straight line position in either direction, the maximum degree of rotation of two connected components is 20?. Adjacent components 1 cannot be rotated any more than this, as the bodies 4 of the components 1 are brought into contact with one another and prevent any further rotation. In this manner, it is the acute angle of each prism 11 that defines the maximum degree of rotation about the longitudinal central axis of the spigot 6.

(16) Due to the shape of the body 4, the component 1 has two flat end walls 10. These flat end walls 10 define flat facets of the curved profile shown in FIG. 4 when the component 1 is attached to a plurality of identical components 1 in the manner shown in FIGS. 3 and 4. Although it is preferred that the end walls 10 are flat, if desired they could be formed with an outwardly facing convex or concave curvature (not shown) corresponding to the curvature of the profile defined by an assembly of a plurality of interconnected components 1. The attached components 1 can be easily manually rotated relative to one another to form various profiles with various radii of curvature, as shown in FIG. 4.

(17) The component 1 of the preferred embodiment is formed of extruded metal such as a aluminium, aluminium alloy, or another extrudable metal, but could be made of an extrudable plastics material, and, as such, is suitable for use either as a former for forming curved wooden or plastic panels, or as a structural member in a building. Alternatively, for shorter lengths of component 1 the components 1 could be die cast or possibly moulded, but the preferred manufacturing process is one of extrusion.

(18) The components 1 shown in the FIGS. 1 to 4 are effectively structural hollow beams that have a width W (see FIG. 2) measured in a direction along a transverse plane 18 extending through the structural member 14, and measured from the centre of the spigot 6 to the centre of the socket 8 of approximately 25 mm. The components 1 have a height H measured in a direction perpendicular to the width W of approximately 35 mm. However, as the component 1 is an extruded product, it can be provided in any suitable length L.

(19) Since the components 1 of FIGS. 1 and 2 comprise one or two flat end walls 10 it is preferable that one or both of the end walls 10 have a width perpendicular to the longitudinal direction L of the component 1 that is as large as possible within the constraints of the shape of the body 4. Preferably, the width of one or both end walls 10 will be between 50 and 80% of the width W of the component.

(20) The distance of any flat end wall 10 from the transverse plane extending from the centre of the spigot to the centre of the socket may be substantial and in preferred embodiments of the invention may be greater than, or equal to, half the width W of the component.

(21) Referring to FIGS. 5 to 8 there are shown different shapes of modular components incorporating the present invention. All of the designs of body 4 incorporate an internal bracing structural member 14 extending between each the spigot 6 and each socket 8. As will be seen from FIGS. 5 and 6, the structural member 14a can be positioned at various intermediate locations between the ends 10a of the body 4a.

(22) Referring to FIG. 7 there is shown a further embodiment of the present invention where each body 4b of each component 1b is provided with two spigots 6b on a first side wall of the body 4b and two sockets 8b on an opposite second side wall of the body 4b. In a further embodiment (not shown) of the version of component 1b shown in FIG. 7, the body 4b has one spigot 6b and one socket 8b on a first side wall 18b of the body 4b (instead of two spigots 6b) and one spigot 6band one socket 8b on a second side wall 19b of the body (instead of two sockets 8b). These latter mentioned designs of modular component 1b would not have the same flexibility in defining different shapes of curved surface as those of FIGS. 1 to 7 because it is not possible to rotate the spigots 6b of one component 1b in the sockets 8bof an adjoining component. However, it may be feasible for structures that do not require this flexibility.

(23) A common and important feature of all of components 1, 1a, or 1b of FIGS. 1 to 7 is that they incorporate a structural member 14, 14a, or 14b that acts as a strut or as a tie to keep the side walls of the hollow body 4, 4a, or 4b rigid when the component 1, 1a, or 1b is exposed to external forces on the spigots 6, 6a, or 6b and sockets 8, 8a,or 8b by adjoining components 1, 1a, or 1b.

(24) Referring to FIGS. 1 to 7 the modular components 1, 1a, or 1b can be assembled with identical components 1, 1a, or 1b by sliding their spigots into sockets of adjacent components 1, 1a, or 1b to define a structure that has a curved profile. The structure so formed may be used as a structural component in its own right, or as a temporary, reusable, (or permanent) former, mould, or support, for the manufacture of other articles or materials that are made by laying up laminated materials, or depositing settable materials on the profile defined by the assembled components 1, 1a, or 1b. In the latter instance, curved furniture (for example a chair back and seat) could be made by laying up or forming various laminated pre-glued materials on to a temporary reusable former, mould, or support made up of a plurality of interconnected components 1, 1a, or 1b, and holding the laminated materials in place until the glue is set.

(25) In the above examples, components 1, 1a, or 1b of similar lengths are used to make up a former or structure of even length. It is to be understood that the spigots 6, 6a, or 6b of two or more components 1, 1a, or 1b of various lengths, L, can be laid end to end (so that their end faces 10, 10a, or 10b and confront each other) in rows, then two or more components 1, 1a, or 1b are inserted into a common socket or sockets 8, 8a, or 8b of an adjoining second row of components 1, 1a, or 1b and positioned to overlap the joins between the confronting end faces 10, 10a, or 10b of the adjacent row of components 1, 1a, or 1b. In this way a tessellation of components (very much like the pattern of bricks in a brick wall) can be constructed that extend the overall length and width of the structure formed by the interconnected components 1, 1a, or 1b.

(26) Referring to FIGS. 9 to 11 there is shown a number of end plates 15 which, when used with a plurality of interconnected components 1 hold the assembled components 1 in a desired fixed relationship one with another. The end plates 15 can be a permanent part of the final structure formed by the interconnected components 1, or can be a temporary part of the final structure that is removed from the components 1 to enable the components 1 to be disassembled and reused. The end plates 15 are shaped to define a desired profile such as a cylinder (FIG. 9), or wavy pattern (FIG. 10), or a curved surface (FIG. 11) and have holes 16 at predefined positions that correspond to fixing locations 17 on each of the components 1 that are to be held together by the end plates 15. Screws (not shown) are inserted into the holes 16 and screwed into the fixing locations 17 to hold the components in place.

(27) The fixing locations 17 could be constituted by the ends of the spigots 6 so that the screws are screwed into each spigot 6. However, it is preferred to provide separate fixing locations 17 that are formed on the structural members 14. Referring to FIG. 8 the fixing locations 17 are formed by extruding a cylindrical rib along the length of the structural member 14 of each component 1.

(28) In use of the present invention as a former for making for example a laminated wooden item that has curved shape, a first former is made from a plurality of components 1 that are of the same length connected together as a flat sheet that is then and bent into a curved shape and fixed to on to a suitable support (which may be made of wood, plastics, or metal). Glue is applied to the confronting faces of laminate wood sheets and the laminate layers are laid up on to the first former. A second former made up of a plurality of components 1 connected together as described above is placed on top of the laminated wood layers The second former together with the plywood structure is bent so as to wrap the laminated wood layers and the second former around the outside of the first former by means of tensionable straps that wrap around the outside of the second former so that the laminated layer of unglued wood is sandwiched between the two formers. The whole assembly is then held in place to permit the glue to set to form a wooden curved product. Thereafter the two formers are separated from the wooden structure and can be reused.

(29) In an alternative use of the invention as a former for making curved wooden articles, the end plates 15 can be used as the support for the components 1 that make up the first and second formers. It is possible to make the body 4 of a triangular cross-sectional shape by effectively eliminating one of the end walls 10.