U.S. patent application number 10/257483 was filed with the patent office on 2004-11-11 for modular building structure.
Invention is credited to Zornes, David A..
Application Number | 20040221529 10/257483 |
Document ID | / |
Family ID | 33415607 |
Filed Date | 2004-11-11 |
United States Patent
Application |
20040221529 |
Kind Code |
A1 |
Zornes, David A. |
November 11, 2004 |
Modular building structure
Abstract
A hexagon building structure offset layering system uses hexagon
structures assembled in an offset layering architecture to
construct building walls, floors, roofs, and other structures.
Hexagon building structures (7) include interior panels (1) and (2)
that are adhered to both sides of a foam core (3). The structures
(7) also include radial cutouts (6) at each corner for offset
layering assembly with another structure (7). Peg retainers (5)
selectively secure the hexagon building structures (7) to one
another. Six alignments fastening holes (4) are equidistantly
spaced and located on interior panels (1) and (2). The holes (4)
provide fastener locations for screwing or bolting through the
layers of the hexagon. The holes (4) align with an offset layer of
hexagons when assembled in the axial direction. Conduct holes (12)
are selectively located depending on the fastening technique
selected. The hexagon system includes five derivatives of hexagon
building structures (7) and a door or window header, providing
square, triangular, and curved geometries when assembled. Since
hexagon buildings are built from hexagon building structures (7)
without customization, hexagon buildings can be rebuilt, modified,
or recycled onto a like building using the same materials.
Inventors: |
Zornes, David A.;
(Sammamish, WA) |
Correspondence
Address: |
David A Zornes
HexaBlocks Inc
4348 202nd Avenue NE
Sammamish
WA
98074-6112
US
|
Family ID: |
33415607 |
Appl. No.: |
10/257483 |
Filed: |
October 4, 2002 |
PCT Filed: |
April 3, 2001 |
PCT NO: |
PCT/US01/10904 |
Current U.S.
Class: |
52/311.1 |
Current CPC
Class: |
E04B 1/14 20130101; E04B
2001/0069 20130101; E04F 15/00 20130101; E04F 13/00 20130101; E04F
19/00 20130101 |
Class at
Publication: |
052/311.1 |
International
Class: |
E04F 013/00; E04F
015/00; E04F 019/00 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A building structure configured to be utilized in an offset
layering building technique, the building structure comprising: a
first hexagon member having a central point and six corner points;
and a second hexagon member having a center point and six corner
points, said second hexagon member corresponding in size and shape
to the first hexagon member; wherein the first hexagon member is
selectively mountable to the second hexagon member in an offset
layering configuration, such that one of the six corner points of
the first hexagon member, aligns with the center point of the
second hexagon member and the fist layer of hexagons are positioned
parallel to a mounting surface, providing a beam load and the
second layer of hexagons are rotated at a 30 degree angle relative
to the first hexagon layer converting beam loads to distributed
loads through all second layer hexagons members at a 60 degree
angle under a beam load source.
2. The building structure of claim 1, wherein the first and second
hexagon members each contain an array of equally spaced locating
holes, or fastener means, and at least two of the equally spaced
locating holes of the first hexagon member align with at least two
of the equally spaced locating holes of the second hexagon member
when the first and second hexagon members are selectively mounted
in an offset layering configuration.
3. The building structure of claim 1, wherein the hexagon members
each include a first and second panel.
4. The building structure of claim 1, wherein the hexagon members
each include a core that is sandwiched between first and second
panels.
5. The building structure of claim 4, wherein the hexagon member
core is a foam core.
6. The building structure of claim 1, wherein a central aperture is
located at the center point of each hexagon member, and wherein a
radial cutout is located at each corner point of each hexagon
member.
7. The building structure of claim 6, wherein a peg member is
selectively securable to the central aperture of each hexagon
member, and wherein the peg member is selectively securable to the
radial cutouts located at each corner point of each hexagon
member.
8. The building structure of claim 1, further comprising additional
hexagon members that are configured to be selectively mountable to
first and second hexagon members in an offset layering
configuration.
9. The building structure of claim 1, wherein each hexagon member
contains conduits holes oriented in the plane of each hexagon
member.
10. The building structure of claim 1, wherein the hexagon members
contain foam tubes.
11. The building structure of claim 1, wherein the hexagon members
are selectively mountable each other in an offset layering
configuration to produce a multi-layered wall assembly.
12. The building structure of claim 1, wherein the hexagon members
are selectively mountable to each other in an offset layering
configuration to produce housing structures.
13. The building structure of claim 12, wherein the hexagon members
are selectively mountable to each other in an offset layering
configuration to produce housing structures using only hexagon
members and five hexagon derivative shaped members.
14. The building structure of claim 12, wherein hexagon members of
different sizes are incorporated together to produce housing
structures.
15. The building structure of claim 12, wherein the hexagon members
are non-destructively, non-customizedly secured to each other to
produce housing structures, such that the hexagon members are
readily recyclable for use in another structure due to the
non-destructive, non-customized securement.
16. The building structure of claim 1, wherein hexagon members are
buoyant, and are selectively mountable to each other to produce
buoyant structures.
17. The building structure of claim 1, wherein hexagon members and
two hexagon derivative shaped members are selectively mountable to
each other in an offset layering configuration to produce
substantially round assemblies.
18. The building structure of claim 1, wherein the hexagon members
comprise non-paneled hexagon frames.
19. The building structure of claim 18, wherein the hexagon frames
are selectively mountable to each other in an offset layering
configuration that allows reinforcement material to be interspersed
between the hexagon frames.
20. The building structure of claim 18, wherein the hexagon frames
contain cavities.
21. The building structure of claim 20, wherein the hexagon frame
cavities contain insulative material.
22. The building structure of claim 20, wherein the hexagon frame
cavities contain phase change materials.
23. The building structure of claim 18, wherein hexagon members
having first and second panels are selectively mountable to hexagon
frames in an offset layering configuration.
24. A building assembly employing an offset layering architecture,
the building assembly comprising: a plurality of hexagon members,
each hexagon member including a central protrusion and six corner
receptacles; wherein the central protrusion of each hexagon member
is configured to align with a corner receptacle of another hexagon
member; and wherein each hexagon member includes an array of
equally spaced connecting holes in the plane of the hexagon member
for selectively securing hexagon members to one another in an
offset layering architecture,
25. The building assembly of claim 24, wherein at least two of the
equally spaced connecting holes of a first hexagon member align
with at least two of the equally spaced connecting holes of a
second hexagon member when a first and second hexagon member are
selectively mounted in an offset layering configuration.
26. The building assembly of claim 24, wherein the central
protrusions are selectively connectable to the hexagon members.
27. The building assembly of claim 24, wherein each hexagon member
contains conduits holes oriented in the plane of each hexagon
member.
28. The building assembly of claim 24, wherein the hexagon members
are selectively mountable to each other in an offset layering
configuration to produce housing structures.
29. The building assembly of claim 24, wherein the hexagon members
are selectively mountable to each other in an offset layering
configuration to produce housing structures using only hexagon
members and five hexagon derivative shaped members.
30. The building assembly of claim 24, wherein the hexagon members
are non-destructively, non-customizedly secured to each other to
produce housing structures, such that the hexagon members are
readily recyclable for use in another structure due to the
non-destructive, non-customized securement.
31. The building assembly of claim 24, wherein the hexagon members
are a helium filled closed foam.
32. The building assembly of claim 24, wherein the hexagon members
are a reticulated foam that is coated, sealed, and filled with
helium.
33. The building assembly of claim 24, wherein the hexagon members
are a compartmentalized helium filled closed foam.
34. The building assembly of claim 24, wherein the hexagon members
are a polymide foam.
35. The building assembly of claim 24, wherein the hexagon members
are a aluminum foam.
36. A building structure configured to be utilized in an offset
layering building technique, the building structure comprising: a
first tessellation member having a central point and corner points;
and a second tessellation member having a center point and corner
points, said second tessellation member corresponding in size and
shape to the first tessellation member; wherein the first
tessellation member is selectively mountable to the second
tessellation member in an offset layering configuration, such that
one of the corner points of the first tessellation member aligns
with the center point of the second tessellation member.
37. A display system configured utilizing an offset layering
architecture, the display system comprising: a plurality of hexagon
members having central points and corner points; wherein the
plurality of hexagon members are selectively securable in a
juxapositioned offset layering configuration, such that at least
one of the six corner points of each hexagon member aligns with the
center point of another hexagon member, thereby constructing the
display system.
38. The display system of claim 37, wherein the hexagon members are
selectively securable to each other in an offset layering
configuration to produce a readily scaleable display system.
39. The display system of claim 37, wherein the hexagon members are
light emitting polymers.
40. The display system of claim 37, wherein the hexagon members are
selectively securable to each other to produce a cold cathode
emitter display systems.
41. The display system of claim 37, wherein the hexagon members are
selectively mountable to each other to produce thin CRT display
systems.
42. The display system of claim 37, wherein the hexagon members are
microprism films.
43. The display system of claim 37, wherein the hexagon members are
retroreflective sheeting.
44. A method of converting low-density stable polyimide foam into a
low density stable carbon foam or fiber composite, the method
comprising: heating a polyimide resin at substantially atmospheric
pressure; and applying microwave energy to control polyimide
density; whereby carbon foam is produced has a density
substantially close to the original polyimide foam density.
45. A method of claim 44, wherein the polyimide is heated within an
aluminum mold.
46. A heat exchanger configured utilizing an offset layering
architecture, the heat exchanger comprising: a plurality of hexagon
members having central points and corner points; wherein the
plurality of hexagon members are selectively mountable to each
other in an offset layering configuration, such that at least one
of the corner points of each hexagon member aligns with the center
point of another hexagon member, thereby constructing the heat
exchanger.
47. The heat exchanger of claim 46, wherein the hexagon members
contain with tubular members for containing heat exchanging
fluids.
48. The heat exchanger of claim 46, wherein the hexagon members are
carbon foam.
49. The heat exchanger of claim 46, wherein the hexagon members are
unidirectional conducting carbon foam.
50. The heat exchanger of claim 46, wherein the hexagon members
contain phase change materials.
51. The heat exchanger of claim 46, wherein the hexagon members are
secured in a spaced apart relationship to facilitate movement of
heat exchange fluid between the hexagon members.
52. The building structure of claim 2, wherein the hexagon members
equally spaced locating holes, or fastener means, are hexagonal in
shape and oriented at the same angle relative to the hexagon
member.
53. The building structure of claim 2, wherein the hexagon members
equally spaced locating holes, or fastener means, are hexagonal in
shape and oriented such that one of the six hexagonal holes, or
fastener means, sides of each hole is parallel to each of the
closest flat sides of the hexagon member.
55. The building structure of claim 2, wherein the hexagon members
equally spaced locating holes, or fastener means, are hexagonal in
shape and oriented at the same angle relative to the hexagon
member.
56. The building structure of claim 52, wherein the hexagon members
equally spaced locating holes, or fastener means, are hexagonal in
shape and are all oriented at the same angle relative to the
hexagon member.
57. The building structure of claim 52, wherein the hexagon members
equally spaced locating holes, or hexagonal fastener means, are
hexagonal shafts for insertion into the hexagonal holes.
56. The building structure of claim 52, wherein the hexagon members
equally spaced locating holes, or hexagonal fastener means, are
hexagonal shafts for insertion into the hexagonal holes with screw
threads.
57. The building structure of claim 52, wherein the hexagon members
equally spaced locating holes, or hexagonal fastener means, are
hexagonal shaft for insertion into the hexagonal holes with screw
threads and threaded nuts.
58. The building structure of claim 52, wherein the hexagon members
equally spaced locating holes, or hexagonal fastener means, are
hexagonal shaft for insertion into the hexagonal holes with screw
threads and ratchet locking threaded nut.
59. The building structure of claim 52, wherein the hexagon members
equally spaced locating holes, or hexagonal fastener means, are
hexagonal shaft for insertion into the hexagonal holes with a
pressure locking means.
60. The building assembly of claim 1, wherein each hexagon member
contains six conduits holes oriented in the plane of each hexagon
member and in the shape of a six pointed star where each point
location is in the middle of each hexagon such that a rhombus forms
at each hexagon member point and a hexagon shape forms from the
conduit centrally in the hexagon member.
61. A method of injecting a super critical fluid filled polymer
into a uniform stable molded low density stable foam comprising:
heating a polymer resin within an injection machine; and pumping in
super critical fluid into the heated polymer; and venting air out
of the mold in areas where controlled leak rates will increase flow
rate of the super critical filled polymer and provide uniform
density. whereby polymer foam is produced when released for
injection into a mold and has a low density closed cell foam is
produced from the original polyimide foam density such that.
62. A method of claim 61, wherein the centrally injected hexagons
with leak rates increased controlled leak rates at the edges and
points of the hexagon increases uniformity of the closed cell foam
polymer.
63. A method of claim 61, wherein helium is the base gas of the
super critical fluid.
64. A process of computer analyzing building blocks by reducing the
three dimensional model of points to a program formula called a
super element and locating these superelement building blocks by
referencing coordinate points only: two dimensional objects with
coordinate points on a snap grid; and user requirements are entered
for end use of structure; coordinate points are processed through a
superelement formula that analysis and optimizes results; and
whereby materials and thicknesses and coordinate points are
returned by the superelement formula such that the physical
structure will function under the original user requirements.
65. A process of claim 64, wherein the superelement formula
represents a hexagon building block.
66. A process of claim 64, wherein the superelement formula
coordinate points are sent over the world wide web (Internet) such
that user input points are transferred to the computer node where
the superelement analysis processed and the new analyzed coordinate
points are returned to the user specified Internet address.
Description
FIELD OF THE INVENTION
[0001] The present invention is generally directed to building
block apparatus, and more specifically to tessellation building
block apparatus that can be arrayed as tessellation shapes and
their derivatives, into geometric forms that construct various
types of structures.
BACKGROUND OF THE INVENTION
[0002] Currently, building lumber boards, layered insulated panel
structures, and composite materials are engineered products that
must be custom manufactured for every job, requiring manual cuts to
achieve the geometry's desired in a building. It would be far
superior to use a building structure that does not require
customization in-order to assemble the geometric shapes required to
construct a building or other structure. Further, many materials
are either not easy to cut, or are unhealthy to fashion on the job.
It would be highly desirable to have a-building structure that can
tolerate high stress loads and does not require numerous amounts of
customization.
[0003] Accordingly, there is a continuing need in the art for a
type of building structure that can be used to produce most
geometry desired in the construction of a building or other
structure. It is also desirable for a building structure to
recyclable, allowing building occupants to be able to change a
building's geometry in relatively short time without cutting any
panels to achieve the new geometry. This is useful since in the
field of buildings materials, many composite materials are very
difficult to cut, and many concrete fiber-type materials produce
carcinogens when cut.
SUMMARY OF THE INVENTION
[0004] In brief, this invention is directed to a building block
that does not need to be cut to assemble geometric shapes required
to build a building or other structure. For the purpose of this
invention tessellation will mean any shape that can be tiled
together along the edges. Materials can be selected for building
blocks automatically by a superelement formula that are not easy to
cut or healthy to cut on the job, but are good environmental
material like concrete fiber sheeting. The skill level needed to
produce or design a building is reduced by allowing the computer to
process the common shapes in a superelement formula analysis.
Structures are recyclable to other like buildings in the normal
course of remodeling and can be retrieved for new buildings, after
natural disasters like tornado, hurricane, flooding, earthquakes,
and tidal waves randomly scatter building parts. The present
invention is recyclable directly to another building using the same
dimension of hexagon, or a hexagon twice the size and half the
size. Hexagons can be clustered providing construction of smaller
hexagons with larger hexagons In one embodiment of the present
invention, the apparatus is a hexagon panel assembly, which
includes geometric derivatives of hexagons and a header for door
and window openings to assemble single or double hexagon panel
walls including a pitched roof. A floor base plate is designed to
mount to the floor and establish the wall locations. Steel wire can
make the independent hexagon components all one strong assembly.
Contractors could pick the building off the ground as one unit.
[0005] In still a further embodiment of the present invention,
square-shaped panel assemblies and their derivatives are utilized
for the offset layering building structures. Square shapes,
however, do not assemble into 30 degree pitched roofs, circular
geometry, or provide the maximum equally spaced fasteners per
square foot of buildings. Stresses are lower in hexagons than in
squares. Concrete squares layered, provides a high performance
foundation floor. Walls made from squares and square derivatives in
the shape of rectangles and triangles form walls and 45.degree.
pitch roofs. Window and door openings can also be assembled from
square tessellations and their derivatives. Square and hexagon
tessellation walls and floors, or other structures can be assembled
into one structure. Other types of tessellation panel assemblies
are also contemplated, and can be utilized without departing from
the scope of the present invention.
[0006] In still a further embodiment of the invention a hexagon
tessellation frame is provided to replace dimensional lumber for
the construction of ceilings, roofs, wall and other structure.
These tessellation frames also can be a variety of shapes, but
hexagons are a preferred embodiment for offset layering and common
fastening points.
[0007] In still a further embodiment of the invention, closed cell
spheres are cast into foam from aluminum, ceramic, glass, polymers,
polyimides, and other materials as spheres or closed cell materials
become available. Further these closed cell foam spheres can have
the gases or air replaced with fluids like perilites that are phase
change materials or gases like helium. Some spheres are coatings
providing spheres within spheres.
[0008] Utilizing the present invention, a structurally sound
building can be assembled in harsh climatic regions. The building
can be assembled on snow, ice fields, desert sand, and flood
plains. When panels contain foam materials the building will float
on water and will rise from the ground during flooding of the
grounds around the building. This building could be used as a
houseboat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The foregoing aspects and many of the attendant advantages
of this invention will become more readily appreciated as the same
become better understood by reference to the following detailed
description, when taken in conjunction with the accompanying
drawings, wherein:
[0010] FIG. 1 illustrates a perspective view of the hexagon and
peg;
[0011] FIG. 2 illustrates a perspective view of the peg dowel;
[0012] FIG. 3 illustrates a perspective view of two hexagons
assembled;
[0013] FIG. 4 illustrates a perspective view of three hexagons
assembled;
[0014] FIG. 5 illustrates a perspective view of four hexagons
assembled;
[0015] FIG. 6 illustrates a perspective view of the opposite side
of FIG. 5;
[0016] FIG. 7 illustrates a perspective view of the FIG. 6 showing
foam tubes;
[0017] FIG. 8 illustrates a sectional view of the center of a
hexagon assembly showing the detail of the peg dowel system;
[0018] FIG. 9 illustrates an exploded view of the hexagon panel
assembly;
[0019] FIG. 10 illustrates a perspective view of the foam hexagon
core;
[0020] FIG. 11 illustrates a plan view of the six shapes used to
build geometric patterns from hexagons;
[0021] FIG. 12 illustrates a perspective view of the hexagon split
on points;
[0022] FIG. 13 illustrates a perspective view of the hexagon split
across flats;
[0023] FIG. 14 illustrates a perspective view of the hexagon cut
long across points;
[0024] FIG. 15 illustrates a perspective view of FIG. 14 split
left;
[0025] FIG. 16 illustrates a perspective view of FIG. 14 split
right;
[0026] FIG. 17 illustrates a perspective view of door and window
header;
[0027] FIG. 18 illustrates a plan view of hexagon wall
sections;
[0028] FIG. 19 illustrates a plan view of hexagon wall sections
assembled into a wall;
[0029] FIG. 19A illustrates a cross-sectional view of the hexagon
wall section of FIG. 19;
[0030] FIG. 20 illustrates a perspective view of building walls,
door and window openings, and floor double hexagon panel wall
assembly;
[0031] FIG. 21 illustrates a sectional view of hexagon assemblies
showing how mechanical fasteners penetrate the full layer of
hexagons;
[0032] FIG. 22 illustrates a perspective top view of a
substantially round hexagon assembly;
[0033] FIG. 23 illustrates a perspective bottom view of the
substantially round hexagon assembly in FIG. 22;
[0034] FIG. 24 illustrates a perspective inside wall view of
hexagons partially assembled around a door;
[0035] FIG. 25 illustrates a perspective view of a home assembly of
one-meter wide hexagons;
[0036] FIG. 26 illustrates a plan view of all the shapes in FIG.
25;
[0037] FIG. 27 illustrates a perspective view of the door and
window header;
[0038] FIG. 27A illustrates a side view of the door and window
header;
[0039] FIG. 28 illustrates sectional view A-A of FIG. 27A;
[0040] FIG. 29 illustrates sectional view B-B of FIG. 27A;
[0041] FIG. 30 illustrates a perspective view of the top and bottom
plate of a wall or floor;
[0042] FIG. 31 illustrates a side view of the top and bottom plate
assembly in FIG. 30;
[0043] FIG. 32 illustrates a sectional view A-A of FIG. 31;
[0044] FIG. 33 illustrates a perspective view of a hexagon
frame;
[0045] FIG. 34 illustrates a side view of the hexagon frame of FIG.
33;
[0046] FIG. 35 illustrates an end view of the hexagon frame of FIG.
33;
[0047] FIG. 36 illustrates a perspective view of a hexagon frame
split on the flats;
[0048] FIG. 37 illustrates a side view of the split hexagon frame
of FIG. 36;
[0049] FIG. 38 illustrates an end view of the split hexagon frame
of FIG. 36;
[0050] FIG. 39 illustrates a perspective view of a hexagon frame
split on points;
[0051] FIG. 40 illustrates a side view of the split hexagon frame
of FIG. 39;
[0052] FIG. 41 illustrates an end view of the split hexagon frame
of FIG. 39;
[0053] FIG. 42 illustrates a side view of a partial wall assembly
of the hexagon frames of FIGS. 33, 36, and 39;
[0054] FIG. 43 illustrates an end view of hexagon frame assembly of
FIG. 42;
[0055] FIG. 44 illustrates a perspective view of the six common
fastening holes between four hexagons;
[0056] FIG. 45 illustrates the top view of the six common points
displayed in FIG. 44;
[0057] FIG. 45A illustrates a sectional view C-C of FIG. 45;
[0058] FIG. 46 illustrates a perspective view of "A" frame building
end walls;
[0059] FIG. 47 illustrates an end view of the "A" frame building
end walls of FIG. 46 showing the hidden lines of the hexagons
offset in the second layer;
[0060] FIG. 48 illustrates a perspective view of square layered
offset tessellations showing the common fastener locations;
[0061] FIG. 49 illustrates a front perspective view of a layered
offset square tessellation-building wall with a 45-degree roof
pitch and square derivatives;
[0062] FIG. 49A illustrates a rear perspective view of the layered
offset square tessellation building wall of FIG. 49;
[0063] FIG. 50 illustrates a front perspective view of a layered
offset square tessellation building wall with 45-degree roof pitch
and square derivatives forming doors openings;
[0064] FIG. 50A illustrates a rear perspective view of the layered
offset square tessellation-building wall of FIG. 50;
[0065] FIG. 50B illustrates an end view of the building wall of
FIG. 50 showing the hidden lines of offset squares and derivatives
of squares point-to-center locations;
[0066] FIG. 51 illustrates a perspective view of a square
tessellation panel;
[0067] FIG. 52 illustrates a perspective view of a rectangle
derivative that is one half of the square panel of FIG. 51 split
along flats;
[0068] FIG. 53 illustrates a perspective view of a triangle
derivative that is one half of the square panel of FIG. 51 split
along points;
[0069] FIG. 54 illustrates a perspective view of a trapezoid
derivative of the square panel of FIG. 51;
[0070] FIG. 55 illustrates a perspective view of a triangle
derivative of the square panel of FIG. 51;
[0071] FIG. 56 illustrates a side view of a TV screen;
[0072] FIG. 57 illustrates a perspective view of a tessellation TV
screen cathode/backplate circuits and faceplates aligned by
point-to-center offset layering;
[0073] FIG. 58 illustrates a perspective view of an optically
transparent multi-color film for TV screen or large optical
projectors;
[0074] FIG. 59 illustrates a perspective view of a hexagon carbon
foam heat exchanger assembly formed from offset hexagons integrated
and held together by tubes;
[0075] FIG. 60 illustrates a perspective view of a hexagon carbon
foam beat exchanges assembly formed from closely tiled hexagons and
tubes;
[0076] FIG. 61 illustrates a side view of a hexagon bridge
assembly; and
[0077] FIG. 62 illustrates a top view of the hexagon bridge
assembly of FIG. 61;
[0078] FIG. 63 illustrates a hexagonal shaft fastener with a
threaded ratchet head;
[0079] FIG. 64 illustrates a seat for the assembly of fastener FIG.
63;
[0080] FIG. 65 illustrates a perspective close exploded view of a
hexagon with the hexagonal shaft fastener of FIG. 63 aligned with
the hexagonal molded hole of FIG. 64;
[0081] FIG. 66 illustrates a perspective view of all six hexagonal
ratchet fastener seat.
[0082] FIG. 67 illustrates an alternate tamper resistant bouquet
fastener;
[0083] FIG. 68 illustrates a fastener that provides a male press
fit fastener;
[0084] FIG. 69 illustrates a hexagon the fastener in FIG. 68 mates
to;
[0085] FIG. 70 is a side view of a preferred fastening means when
walls are spaced and filled with straw bales or cast with
concrete;
[0086] FIG. 71 is a section view of a fastener head with an insert
for wall coverings.
[0087] FIG. 72 illustrates a perspective view of a preferred
hexagon conduit pattern.
[0088] FIG. 73 illustrates a perspective view of an assembly of
preferred hexagon conduit pattern in FIG. 72 and FIGS. 63, 64, 66,
and 67.
[0089] FIG. 74 illustrates a cross sectional view of fasteners
configured for multiple layers.
[0090] FIG. 75 illustrates a set of hexagon panels glued to hexagon
assemblies to make a single structurally insulated panel.
[0091] FIG. 76 illustrates the process of analyzing by superelement
formulas.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENT
[0092] FIG. 1 illustrates a preferred embodiment hexagon building
structure 7 and peg retainer 5 constructed in accordance with the
present invention. Preferably, six alignments fastening holes 4 are
equidistantly spaced and located on interior panels 1 and 2. The
panels 1 and 2 are adhered to a foam core 3. Preferably, the
hexagon building structure 7 includes radial cutouts 6 for assembly
to another peg retainer (not shown). Preferably, the holes 4 are
the primary fastener location for screwing or bolting through the
layers of the hexagon. The holes 4 align with an offset layer of
hexagons when assembled in the axial direction (as shown in the
assembly of FIG. 3). In one preferred embodiment of the present
invention, the set of six holes 4 are the only fastening technique
necessary for joining an offset layering assembly of hexagon
building structures 7. Conduit holes 12 are selectively located
depending on the fastening technique selected.
[0093] A preferred embodiment of the present invention includes a
hexagon building structure 7 system for constructing buildings and
other structures, including but not limited to, complex geometries
such as door openings, window openings, roof pitches, and curved
archways. Tessellations are seamless tileable patterns created from
a basic geometric grid. Variations of tessellations can be formed
from squares, triangles, stars shapes, hexagons, and curved shapes.
Hexagons in particular, are easy to produce, and provide the
benefits of forming desirable geometric shapes, lowering stresses,
and increasing leverage when tile hexagons are used in an offset
layering configuration. The hexagon building structure 7 is
symmetrical and provides seven fastening points (at the six corner
points and the center point) when layered and offset equally
against three other hexagon-building) structures 7 of the same
size. When offset equally, the center point of a first six corner
points aligns with a corner point three other hexagon building
structures 7, in a corner point-to-center alignment. Thus, three
hexagon-building structures 7 assemble symmetrically in the same
plane and connect centrally to one offset hexagon building
structure 7 in another plane.
[0094] In order to layer and offset a tessellation into a composite
structure that is useful, symmetrical equal fastening points are
desirable for calculating and predicting structural stress. An
additional structural benefit of hexagon building structures 7 is
the alignment of six additional common alignment points (alignments
fastening holes 4 in this preferred embodiment) that result when
hexagon building structures 7 are stacked or layered in the axial
direction at an equal symmetrical offset distance. The six
alignments fastening holes 4 are located between the six flat edges
and center. These six alignments fastening holes 4 are found by
drawing lines between each corner-point and the two closest
non-adjacent, corner-points (forming two isosceles triangles). The
intersecting points of these lines define the location of the
alignments fastening holes 4, which are equally spaced. This
additional set of six fastening points provides the most
substantial fastening points for maximum strength. These six
alignments fastening holes 4 align in stacked offset layers of
hexagons to provide common predictable fastening locations.
[0095] In a preferred embodiment of the present invention, thirteen
common fastening points (the six alignments fastening holes 4, six
corner points, and one center point) align in stacked offset
hexagons. Other common fastening points can also be derived without
departing from the scope of the present invention. Bolt, wire, or
other suitable fasteners penetrate through the panels 1 and 2 to
mechanically compress the panels at the fastener points. In some
embodiments the walls at right angles are compressed together for
building integrity. This is desirable over panel systems dependent
on adhesives.
[0096] In another aspect of the present invention, adhesives or
caulking sealant are added between the panels during assembly. A
void or a full sheet of insulation can also be sandwiched between
the hexagon building structures 7 depending upon the particular
application. Further, in some embodiments an adhesive closed cell
tape seal, similar to automotive weather stripping, is wrapped
around the hexagon building structures 7 prior to assembly for
additional compression sealing. Preferably, joint fasteners with
flat heads fasten hexagon-building structures 7 together. Screws
can either partially or fully penetrate through the full set of
layered hexagon building structures 7 and are also adaptable.
[0097] In other embodiments of the present invention, the peg
retainer 5 is replaced with a small bolt (not shown), depending
upon the strength of the materials utilized. Fasteners can be
inserted through the alignments fastening holes 4 either manually
or by CNC automation. The number of fasteners applied is an issue
typically specified by the builder. In some embodiments, steel
cables (not shown) are threaded through the wiring holes 12. The
steel cable can be configured to run in all directions, as required
by the builder. Further, in high wind and/or flood areas, the steel
cables and wiring holes 12 can be used as a cabling system in order
to anchor a building to the ground.
[0098] As further illustrated in FIG. 2, the peg retainer 5
includes a peg portion 5a and a retainer portion 5b (see also FIG.
9). The peg portion 5a and the retaining portion 5b fasten the
panels 1 and 2, and the core 3, together during the manufacturing
of the hexagon building structures 7. Further, the retaining
portion 5b provides dowel panel assembly registration during the
manufacturing of the hexagon building structures 7. FIG. 2 shows
the peg portion 5a and the retainer portion 5b joined together,
while FIG. 9 shows the peg portion 5a and the retainer portion 5b
separated apart. In one preferred embodiment, a polyvinyl chloride
adhesive is utilized to adhere the peg portion 5a to the retainer
portion 5b.
[0099] Referring now to FIG. 3, two hexagon-building structures 7
can be correspondingly configured to assemble around a peg retainer
5. Similarly, three hexagon-building structures 7, 8, and 9 can
also be correspondingly configured to assemble around peg retainer
5, as shown in FIG. 4. The panels of the hexagon building
structures 8 and 9 act to conceal the peg retainer 5. This
concealment feature is of intrinsic cosmetic value to many
builders. The peg retainer can penetrate though the panel and be
slanted on its face as well as on the points of the hexagons. The
central peg hole can be much larger than the point slants providing
a full peg with two slanted ends. This slanted peg would be easy to
install and aid in building a building. However, for other
builders, other embodiments of the present invention employ bolts
fasteners that penetrate completely through the panels,
mechanically compressing and fixing the panels in location.
Standard metal stamped cleats or metal earthquake straps can also
be inserted between the hexagon building structures during
assembly. These earthquake type straps can be sandwiched between
hexagons and fastened to fasteners 4, extending out of the hexagon
to be a corner fastener strap or an insertion into a concrete
foundation. This has value when using superelement stress analysis,
which is designed to use common fastening points and symmetry.
[0100] When four hexagon building structures 7, 8, 9, and 10, are
assembled together, as shown in FIG. 5, the peg retainer 5 cannot
be seen. Alternatively, a joint fastener, barbed press fit plastic
fastener, screw or metal cleats is placed in the center of hexagon
building structure 7 and the joining points of hexagon building
structures 8, 9, and 10 (instead of a peg retainer 5). Referring
now to FIG. 6, the alignments fastening holes 4 and II of hexagon
building structure 7 align with the alignments fastening holes of
hexagon building structures 8, 9, and 10.
[0101] As shown in FIG. 7, foam tubes align to form wiring and
plumbing conduit holes 12. Referring now to FIG. 19, conduit holes
25, 26, and 27 can be seen. Wire cable conduit hole 25 provides a
connection path from corner 28 to base plate 19 at location 19a.
Conduit holes 26 and 27 provide a steel wire hole to compress the
wall together from one end to the other. The steel wire cable 29
and 30 can be extended through the adjoining wall forming corners
31 (shown in FIG. 20). These steel wire cables or ropes can be used
to anchor the building to the ground. Cable can also be connected
across the interior of the walls through common hole 4. These
cables will be exposed when applied in buildings for food storage
of grains, fluids, and other biomass. These interior cables
strength additions can easily be calculated with accuracy, because
of the superelement modeling.
[0102] Referring again to FIG. 7, graphite rod 32 and rod flange 33
are inserted into conduit holes 12. The rod 32 is centered and
fixed in location by the rod flange 33. Rod 32 can be constructed
of tubing, wood or other materials, without departing from the
scope of the present invention. In one embodiment, rods are placed
in multiple locations between every hexagon building structure 7,
in order to connect the hexagon building structure 7 during
assembly. Preferably, one side of the rod is attached to a hexagon
building structure 7 prior to assembly. In low stress construction
designs, rods 32 are sized in length and diameter to replace the
need for offset double walls. In some climates and wind conditions,
conduit holes 12 are not produced. This is particularly true when
higher strength structures are required, or when replacing concrete
block buildings where wiring and plumbing is run in an external
conduit as a standard practice.
[0103] Although conduit holes 12 are convenient, the holes do
result in some weakening of the panel. Wiring, water plumbing,
toilet pea-traps, alarm systems, fans, sensors, refrigeration
components, heat exchangers, heating sources, and air-ducting
systems can be packaged into hexagons. In some embodiments, the
conduit holes 12 have hoses inserted for radiated liquid heating or
liquid circulation for absorption cooling. Any amount of foam can
be removed and replaced by thermal storage and/or release
materials. These materials change phase forming liquid when heated
and solidifying releasing stored heat when cooled. Hexagon panels
provide a building structure for packaging these types of phase
change materials and containing them within a building environment
for safety.
[0104] Referring now to FIG. 8, a peg retainer 5 is shown in the
center of an offset layering hexagon building structure assembly.
In one embodiment of the present invention, a peg retainer 5 is
constructed from an assembly of PVC pipes adhered together with
glue. Injection molding is one suitable technique for this purpose.
Conduit holes 12 are formed in the foam core 3.
[0105] As shown in FIG. 9, the peg portion 5a and the retainer
portion 5b can be separated. The retainer portion 5b provides the
dowel function during glue assembly of exterior panel 7b and
interior panel 7a. The peg portion 5a is inserted and glued into
the retainer portion 5b. The hexagon foam core 3 and conduit holes
12 are shown in greater detail in FIG. 10.
[0106] Referring now to FIG. 11, a hexagon building structure 7 and
five-hexagon derivative building structures 13, 14, 15, 16, and 17
are shown. These six structures are assembled into the geometric
shapes that make walls, floors, window, and door openings. Hexagon
derivative building structure 13 is a hexagon split on points, and
is shown in FIG. 12. Hexagon derivative building structure 14 is a
hexagon split on flats, and is shown in FIG. 13. Hexagon derivative
building structure 15 is a hexagon cut long across points, and is
shown in FIG. 14. Hexagon derivative building structure 16 is a
hexagon cut long across points and split left, and is shown in FIG.
15. Hexagon derivative building structure 17 is a hexagon cut long
across points and split right 17, and is shown in FIG. 16. Finally,
hexagon derivative building structure 18 is a hexagon door and
window header 18, and is shown in FIG. 17.
[0107] Referring now to FIG. 18, hexagon wall sections door 20,
window 21, and the finished ends assemble into corners of a
building. Hexagon wall sections can be computer numeric control
(CNC) machined out of a single solid panel. All of the
above-described hexagon and hexagon derivative building structures
are utilized in this embodiment. In this embodiment of the present
invention, partial hexagons extend out of the wall sections. Corner
sections can also be prefabricated as a single part. Accordingly,
corner sections are prefabricated out of a single part or by
joining smaller corner sections in order to strengthen the corners
of the structures. These prefabricated corner sections can be
applied on the interior or exterior of the house to join the main
walls to a room wall or partitions wall. Prefabricated hexagons can
take the form of a cross with extensions off the front and back of
the hexagons for locations where the interior and exterior walls
are on the same locations, and a top cross sectional view would
form a cross. A corner is also a monolith and can represent a
stepped portion of hexagons, where other full hexagons fasten and
become a full surface without steps. These corners have the
appearance of missing a hexagon when first put up, because they are
stepped and integrate to the wall. The preferred corner is a molded
corner that can be flipped upside down and fit onto a like corner
providing an infinite height potential.
[0108] Builders can use these hexagon computer aided design
sections to rapidly build wall sections. Super-elements are
computer models that the computer processes stress calculations
around. Hexagons make desirable super-elements that process as one
math node in the computer. This reduces computer time dramatically
to optimize building designs. Super-elements are possible from
common symmetrical shapes, which is why hexagons, hexagon
derivatives, or tessellation shapes are useful in building design.
One of the advantages of tessellation symmetrical shapes, and
specifically hexagons, is that accurate optimized designs are
produced when calculating super-elements computer design
assemblies. Prior art buildings structures have proved to be near
impossible to use in calculating stress. Current dimensional lumber
homes have random fastener locations and random tetrahedral element
meshes resulting in billions of nodes to calculate to obtain the
same accuracy of several hundred-hexagon nodes. Online World Wide
Web Internet services can be provided to builders, because results
can be obtained in minutes. Even the most unskilled builder will
have data on the building structure using superelement efficiencies
across networks. FIG. 76 is a drawing of the superelement analysis
of tessellating structures that have common fasteners. Customers
enter a design environment, process 1, which would appear to the
customer as a finished rendered wall or the hexagons patterns would
show up on the computer display. After a geometry is selected the
x, y, and z coordinates are sent to the superelement process 502,
which is the a formula of the superelement providing uniform
symmetrical hexagons or other tesselations. The superelement
formula in process 502 provides very fast analysis of the design
for stress, thermal behavior, and other common structural
engineering questions. Process 502 is very fast because of the
symmetrical common shapes and common fasteners. A variety of
materials are in the materials library and the superelement formula
optimizes the design by selecting various materials and thickness,
as well as special composites of shapes to meet engineering
requirements. Process 503 is the post results, which can be viewed
in the analysis program as "raw" data, only most professional
engineers would understand or the customer can view their data in
the rendering program they started in. Process 504 is the bill of
materials providing the list of parts needed to build a building or
other structure. Process 504 includes the different materials that
the analysis automatically selects when optimizing the Process 501
image.
[0109] Referring now to FIG. 19, hexagon wall sections are
assembled into a wall. Cable locations are provided by conduit
holes 25, 26, 27, 27a. Cables 29, 30, and 30a are inserted in a
preferred embodiment of the present invention. It is to be
understood that any one of the many conduits holes can be used in
the wire cable compression.
[0110] In further embodiment of the invention, shown in FIG. 19A,
the hexagon building structures 7 and 37 are spaced apart by beam
35 in a spaced apart, double wall assembly. Location dowel
fasteners 38 and 39 are placed along the beam 35 to join the
hexagon building structures together. Preferably, the beam 35 is
substantial vertical and is arrayed along the building for
increased strength. In another embodiment the beam 35 runs
horizontally as well, is divided into segments providing a fluid
path for concrete or cast in place foams, or at other angles.
Hexagon frame building structures 70, 71, and 72 (shown in FIGS.
33, 36, and 39, and described in further detail below) are used
between solid panels in order to make the panels on the outside and
inside walls symmetrical. These panels can be cut for the wiring,
water or plumbing pipes, or other building requirements.
[0111] As shown in FIG. 20, hexagon building structures 7 and their
hexagon derivative building structures 13, 14, 15, 16, and 17 are
used to simply and efficiently build walls, door openings, window
openings, and a floor double hexagon panel wall assembly. A header
18, hexagon building structures 7 (50-centimeter structures in this
preferred embodiment), and hexagon panel derivatives 13, 14, 15,
16, and 17, assemble into a double wall system. Preferably, a
hexagon beam 50 is utilized as a crossbeam, which has a foam core
3, along with air ducts and wiring, integrated into the beam. In
one embodiment of the present invention, the wall hexagons are
50-centimeter flat to flat, and the floor hexagons are 1-meter flat
to flat.
[0112] Hexagon building structures 7 of different sizes can be
assembled into a single building. Referring to FIG. 20, one-meter
hexagon building structures 7c, and hexagon derivative building
structures 13c, 14c, 15c, 16c, and 17c, assemble into a double
floor system. One-meter hexagon building structures 7c exhibit
substantial strength, and thus, are preferable for many floor
applications. Conduit holes 12 in these floor panels are large
enough to use as heating and air-conditioning air ducts. One-meter
hexagon building structures 7c are also a good selection for roof
cover. Using smaller hexagon building structures 7c (such as
50-centimeter hexagons) allows an increased amount of possibilities
for changes. The roofline on the preferred embodiment hexagon
building of FIG. 20 is 30 degrees. In another embodiment, "A" frame
steep roof alpine building is produced when the hexagon building
structures are rotated 90 degrees and assembled. The thickness of
the hexagon building structures can be adjusted to meet climate
conditions. Any size hexagon can be made. Other tessellation made
from squares and square derivatives have a 45 degree pitched
roofline. These multiple tessellation can be combined for a desired
shape.
[0113] In some embodiments of the present invention, mechanical
fasteners penetrate the full layer of hexagon building structures
7, as shown in FIG. 21. A larger number of layers of hexagon
building structures 7 can also be layered in this alternating
offset layering structure, without departing from the scope of the
present invention. The hexagon building structure center hole and
alignments fastening holes 4 alien with the bolt 63 and holes 60
and 61, respectively. Preferably, T-NUTs are utilized for fastening
the bolts.
[0114] Substantially round hexagon assemblies 34 are also produced
using hexagon building structures 7 and hexagon derivative building
structures 13 and 15, as shown in FIGS. 22 and 23. These
substantially round hexagon assemblies 34 are assembled without
requiring cutting or other customization of hexagon building
structures 7. These shapes can form substantially round hexagon
assemblies 34, or circular openings for windows, door arches, and
other builder-specified needs. For regional specific designs, such
as in Japan and China, these round hexagon assemblies 34 can be
assembled to poles in multiple floor levels to make religious or
cultural buildings similar to those of ancient construction. It is
to be understood that hexagons can be stacked as high as necessary
in order to make big beams. Tessellation can also be curved on the
surfaces and assemble around the circular shape. Hexagons can be
uniformly curved on the plain surfaces and assemble into a
tube.
[0115] Further, in some embodiments, long graphite poles are
inserted into high stacks of offset layered hexagon building
structures 7. For example, a 20-foot beam could be assembled from
20 hexagons a foot thick and assembled in the substantially round
hexagon assembly 34 configuration. The hexagon building structures
7 can be joined together by inserting rods into the set of six
alignments fastening holes 4. Alternatively, tubes can be used
instead of rods. In another embodiment of the present invention,
these type of multiple stack arrangements form complex shapes like
boat hauls and airplane fuselage, or wings. Only the exterior
hexagon building structures 7 need to be shaped to match a desired
design. Preferably, the rods act to fasten the hexagon building
structures 7 together. These types of three-dimensional shapes can
be fiber-glassed on the surface, including fiber-resin winding of
the whole structure. Other surfaces can also be used without
departing from the scope of the present invention.
[0116] Referring now to FIG. 24, hexagon-building structures 7, 8,
9, and 10 are partially assembled around a door. Specifically, the
offset layering of the hexagon building structures 7, 8, 9, and 10
is shown in this house wall assembly. A hexagon building structure
home assembly is illustrated in FIG. 25. This particular embodiment
utilizes one-meter wide hexagons. When larger hexagon building
structures 7 are utilized, fewer of the hexagons building
structures 7 are needed. However, as shown in FIG. 26, a larger
number of hexagon derivative building structures are then required
(items 4, 5, 7, 8, 9, and 10). These additional hexagon derivative
building structures are constructed with optional plates 67a, and
68a.
[0117] One interesting hexagon derivative building structure is the
door and window header 67, as shown in FIGS. 27 and 27A. Optional
plates 67a, 67b, and 67c are integrated into the panel 67 for
strengthening and providing a platform for bolting the wall to the
floor and joining corners, as shown in FIGS. 28 and 29. Another
interesting hexagon derivative building structure is the top and
bottom plate for a wall or floor, as shown in FIGS. 30 and 31.
Similarly, optional plates 68a, 68b, and 68c are integrated to the
panel 68 for strengthening and providing a platform for bolting the
wall to the floor and joining corners, as shown in FIG. 32,
including any adjustment for the height of the wall, window, or
door opening.
[0118] A hexagon frame building structure 70 is shown in FIGS. 33,
34, and 35. Hexagon frame building structure 70 can be constructed
from any of a wide variety of materials, depending upon the
particular application. A wide variety of fabrication methods can
also be utilized, including but not limited to extruding, molding,
casting, etc. In a preferred embodiment of the present invention,
the hexagon frame building structures 70 are extruded recycled
plastic composites (70 percent oak wood fiber and 30 percent
plastic in a more preferred embodiment). Preferably, channels and
stamped metal are applied during the fabrication process. Channels
are provided to slide and lock the edges of the hexagons together.
Further, adhering a solid board to each side of this frame can
provide full hollow panels.
[0119] The hexagon frame building structures 70 of the present
invention also allow reinforced materials and spacers to be
inserted between the hexagon frame building structures 70, due to
the open configuration of the structures 70. Further, concrete can
be poured between the hexagon frame building structure 70 system to
form a permanent structure like a wall, floor, road bed, bridge
(see FIGS. 60 and 61) and other possible structure.
[0120] In one embodiment of the present invention, the hexagon
frame building structures 70 contain six cavities. A vacuum is
pulled in these cavities to provide the capability for insulation
cavities. Insulation or other substances with a thermal storage and
release function can be added to this cavity. The preferred
insulative material to be inserted into the frame cavities is a
bladder full of phase change materials (PCM's) (which can be
obtained from Oak Ridge National Lab, Oak Ridge Tenn. U.S.A.).
Additionally attic insulation materials, called RCR, that absorbs
heat during the day and release heat at night, are a preferred
insulative material. This phase change material is insulation that
consists of perlite embedded with hydrogenated calcium chloride.
The phase change material changes from a solid to liquid at
82.degree. F., absorbing heat (from a hot attic for instance)
during the day, before the heat can penetrate a home. When attic
temperatures cool at night, the phase change material solidifies
and releases the heat back into the attic, moderating outdoor
temperatures.
[0121] A preferred board for use when applying phase change thermal
materials is Concrete Hardie Board. If a hexagon frame building
structures 70 is glued to a sheet of hexagon building structure
panels, half of a panel is produced. In one embodiment, these
panels are provided with gypsum board for the finished wall. Other
embodiments employ Concrete Hardie Board to finish the floor.
[0122] A hexagon frame building structure that is split along flats
71 is shown in FIGS. 36, 37, and 38. A hexagon frame building
structure that is split along points 72 is shown in FIGS. 39, 40,
and 41. A partial wall assembly of the hexagon frame building
structures 70 and the partial hexagon frame building structures 71
and 72, of FIGS. 33, 36, and 39, is shown in FIGS. 42 and 43. The
full and partial hexagon frame building structures 70, 71, and 72
are assembled into a wall (preferably 3.5 inches in thickness). The
six alignments fastening holes 4 of each hexagon frame building
structures 70 are equally spaced and are located as described in
detail above.
[0123] Referring again to hexagon building structures in FIGS. 44,
45, and 45A, the alignment of the fastening holes 4 of the hexagon
building structure 7 with the fastening holes 4 of the hexagon
building structures 8, 9, and 10, is clearly shown. The hexagon
building structures form a central structure 100 for increased load
bearing capability. These six alignments fastening holes 4 are
found by drawing lines between each corner-point and the two
closest non-adjacent, corner-points (forming two isosceles
triangles). The intersecting points of these lines define the
location of the alignments fastening holes 4, which are equally
spaced. The size of the alignments fastening holes 4 can be varied
in order to fit a particular fastening system (or in the case of
carbon foam heat exchangers, as described below in further detail,
the conduit location).
[0124] "A" frame building end walls 101 and 102, are shown in FIG.
46. When the walls are assembled with hexagon flat ends on the
floor, the roof 103 has a pitch of 60 degrees. Depending upon the
type of window and door configurations selected, new hexagon
derivative building structures 1 04 may be produced. Alternatively,
full hexagon building structures 7 are used, which results in the
window size being reduced. The hidden lines 105 produced by the
offset layering of the hexagon building structures 7 and hexagon
derivative building structures in the second layer, are shown in
FIG. 47.
[0125] Panel materials are selected based upon many different
criteria, including but not limited to, climate and bug resistance
requirements. In one preferred embodiment, the panels 1, and 2 are
manufactured from wood chipboard. Some other suitable materials
include foam, aluminum, steel, fiberglass, concrete, aluminum foam,
create, plastics, composites, and the natural fibers native to the
home can be selected as building material. The thickness of foam or
boards can also be changed to meet the specific builder
requirements. In a preferred embodiment, the present invention
primarily uses {fraction (7/16)}-inch Weyerhaeuser chipboard and
2-inch foam, however any metal wood, plastic, concrete fiber, or
other material can also be combined. Screws, bolts, and other
fasteners are selected by the builders to fit their existing tools
and engineering needs. Carpets, hardwood floors, tile, gypsum
board, finish wood paneling, and any other suitable finishing
materials can be pre-assembled on hexagons.
[0126] As previously mentioned, in another preferred embodiment of
the present invention the offset layered tessellations take the
shape of square building structures 106, as shown in FIG. 48. In
this embodiment, four alignment-fastening holes 107 are utilized to
produce the common point-to-center fastener locations. Additional
alignments fastening holes can be added for specific applications,
however, the holes 107 are the preferred number and are positioned
in the preferred locations.
[0127] Referring now to FIGS. 49 and 49A, the front 111 and back
112 of two layered offset square building walls are shown. The
square building walls have a 45 degree pitched roof 120. Further,
the construction of the square building walls preferably also
utilizes square derivative rectangle building structures 113 (shown
in FIG. 52), triangle building structures 114 (shown in FIG. 53),
trapezoid building structures 115 (shown in FIG. 54), and triangle
quarter-section building structures 116 (shown in FIG. 55), in
addition to the square building structures 106.
[0128] Referring now to FIGS. 50 and 50A, the front 121 and back
122 of another set of two offset layered square building walls are
shown. In this embodiment the square building walls also have a 45
degree pitched roof. Once again, the construction of the square
building walls preferably also utilizes square derivative rectangle
building structures 113, triangle building structures 114,
trapezoid building structures 115, and triangle quarter-section
building structures 116, in order to form doors openings. The
hidden lines 118 produced by the offset layering of the square
building structures 106 and square derivative building structures
(rectangle building structures 113, triangle building structures
114, trapezoid building structures 115, and triangle
quarter-section building structures 116) in the second layer, are
shown in FIG. 50B, as well as corresponding point-to-center
locations.
[0129] A square tessellation panel 106 is shown in FIG. 51. Common
fastening points 107 are located in the center of each of the
four-quarter sections. Preferably, the insulation foam core 108 has
oriented strand boards (OSB) 109 and 110 adhered to the core 108.
Due to the difficulty in cutting concrete, square tessellation
panel 106 are a preferred configuration when James Hardie concrete
fiberboard is utilized as a building material. Further, square
tessellation panels 106 make effective floors and roofs, because
concrete can easily be cut and applied to a square shape, and floor
covering (i.e. tongue and groove flooring) can come adhered to the
concrete fiberboard. Marble, granite, glass, and other difficult to
cut materials are better in square form.
[0130] Referring now lo FIGS. 56-58, in one embodiment of the
present invention, the hexagon building structures are fabricated
from a glowing layered plastic developed by Cambridge Display
Technology (CDT) of Cambridge, England. In accordance with the
present invention, computer and television displays are made from
these light-emitting polymers (LEP's). Preferably, these computer
and television displays are only approximately 2-millimeters
thick.
[0131] Other miniature display technologies are field emission
devices, which essentially rely on miniaturized versions of
electron guns used in cathode ray tubes. These new emerging flat
technologies are also compatible with the offset layering hexagon
building structure technique of the present invention. To make
polymer light-emitting diodes (LED), very thin layers of
fluorescent polymer are sandwich between two electrodes. The
tooling of these displays to all the needed sizes of is very
expensive. Each application requires a new display size. The
tessellation offset layering of the present invention is well
suited for efficiently constructing flat display technology in
order to meet customer's requirements.
[0132] Display technologies constructed in accordance with present
invention integrate display electrical connections from one offset
tessellation layer to one or more other offset tessellation layers,
thus, producing a light enhancing screen that projects an even
display of light. In light-emitting polymers, this "macro" offset
layering can be the poly(p-phenylene vinylene), or PPV layer offset
from the CN-PPV layer, including the offset of the protective
transparent substrate. These joining lines can be angled to further
provide an even display of light where one circuit joins the other.
A dramatic advantage of utilizing the present invention for this
type of structure, is that to the customer the display appears
substantially as one large screen, while to the display
manufacturer the screen component sizes are common tessellations
and small enough to produce a wide range of sizes, thus reducing
costs.
[0133] In a preferred embodiment of the present invention that
incorporates the offset layering of light-emitting polymer
tessellations, hexagon tessellations are employed on one layer,
while another layer employs another shaped tessellation, such as
square tessellations. (This alternative technique can also be used
with the offset layering of hexagon or square building structures).
Due to factors such as crystal lattice structure, different
materials are prone to effectively produce different types of
tessellations. Thus, preferably a material and tessellation matched
for optimal configuration parameters.
[0134] The offset layering of hexagon building members in
accordance with the present invention, is particularly effective
when utilized in conjunction with display technologies, because the
human eye does not readily distinguish hexagon angles in a scan.
Further, the fabrication of display technologies with hexagon
building members is complete without the requirement of any hexagon
derivative shapes, because the display can be optically turned on
or off to make light emit from only half of the hexagon split at
the points or flats of the hexagon. Thus, a completely square
display can be produced from offset layered hexagon building
members. Additionally, uneven edges of the hexagon display assembly
can be covered with an opaque frame. In some embodiments of the
present invention, more than two layers of tessellations are
employed.
[0135] The screen technology of a cathode ray tube desktop monitor,
or CRT can be combined with a low-power cold cathode to produce a
display module less than eight millimeters thick. This technology
is known as ThinCRT.TM. (produced by Candescent Technologies.RTM.
Corporation, 6320 San Ignacio Ave. San Jose, Calif. 95119) and has
been developed with the demands of portable multimedia in mind--to
deliver bright true color fidelity, brighter video-rate images with
no motion smearing, wider viewing angles and lower power
consumption than prior art. The offset layering of hexagon building
members in accordance with the present invention is ideally
compatible with ThinCRT technology for flat panel displays.
[0136] Unlike semiconductor devices, where costs typically decline
over time as consumer demands push reducing the size of these
devices, the opposite effect is true for displays. Display screens
continue to grow larger, and thus, the need for these displays
screens to be manufactured with a scaleable technology, such as the
hexagon building member offset layering technology of the present
invention, continues to increase. By utilizing the present
invention, larger sizes of displays screens can be manufactured
with little increase of effort, due to an efficient offset layering
tessellation architecture of the present invention. Further, fewer
tools and processes are needed than that required by the prior
art.
[0137] Referring again to FIG. 56, a preferred embodiment of the
present invention incorporates a cathode/backplate 130 is a matrix
of row and column traces. Each crossover lays the foundation for an
addressable field of microscopic cathode emitters. Each crossover
has up to 5000 emitters, 150 billionths-of-a-meter in diameter.
This emitter density assures a high quality image through
manufacturing redundancy, and long-life through low operational
stress. Emitters generate electrons when a small voltage is applied
to both row (base layer) 131 and column (top layer) 132. This
method of emission is known as "cold cathode" and is very power
efficient because the devices do not have to be heated. Faceplate
picture elements (pixels) are formed by depositing and patterning a
black matrix, standard red, green, and blue TV phosphors 134 and a
thin aluminum layer 133 to reflect colored light forward to the
viewer. A focusing grid is layered on the cathode, collimating
electrons to strike the corresponding subpixel, ensuring color
purity and power efficiency.
[0138] FIGS. 57 and 58 illustrates ThinCRT display utilizing the
offset layering hexagonal building member architecture of the
present invention. The cathode/backplate circuits 130 and
faceplates 137 are aligned by point-to-center offset layering (as
described in detail above), and are sealed with the driver
electronics attached. Total display thickness is less than 8
millimeters. Each pixel is illuminated by thousands of tiny
electron emitters providing an even display of light through
seamless tileable tessellation patterns (preferably hexagons)
formed from pixel layers and cathode layers created from a basic
geometric hexagon grid. Emitters produced from carbon nano-tubes
need to be circuited and this tessellation offset layering provides
a uniform base. Alternatively, other tessellations can be applied
to form the seamless grid, like squares, triangles, or complex
shapes.
[0139] Beneficially, hexagon grid seams can be at right angles to
the surface plane or slightly angled in order to provide an
overlapping seam for phosphors application on that angle or a
stepped fit ledge. This phosphors placement eliminates the visible
seam, thus, further illustrating the ideal computability of the use
of the offset layering hexagonal building member architecture of
the present invention with CRT technologies. Additionally,
different CRT technologies can be layered in between different
functioning structures of the present invention.
[0140] Retroreflective sheeting is based on transparent microprism
films (manufactured by Reflexite Corporation 120 Darling Drive
Avon, Conn. 06001). Microprism retroreflective sheets are produced
in a variety of colors and reflect color back to the source of
light. These sheets can be cut or cast in hexagon tessellation
forms for offset layering in accordance with the present invention,
thereby producing images with multiple colors in the same plane.
Referring again to FIG. 8, in a CRT display of the present
invention, the red 140, blue 141, and green 142 colored hexagons
are selected and joined such that at least one of the six hexagon
points 143, 144, 145, 146, 147, and 148, is touching all three
different colors. This allows light projecting through the hexagon
from a back light source 149 to be angled such as to allow most
desired colors to be produced.
[0141] Multiple layers of colors can be applied to achieve the
color desired and the color film can be pure transparent colored
film or reflective opaque backed film. In one embodiment of the
present invention, this type of apparatus is manufactured on a
microscopic level. Top electrodes and transparent electrodes are
positioned in each of the six hexagon corner locations. Microscopic
hexagon sheeting can be manufactured by Frenel Optics 1300 Mount
Read Blvd, Rochester N.Y. 14606. Alternatively, grid patterns of
other tessellation are utilized in this offset layering
architecture of the present invention, since curved tessellations
can be easier to shape. However, hexagon is the preferred shape for
this optical color grid. In accordance with the present invention,
projected or reflective observable colors are also modified by
moving a light source large enough to cover several of the colors
around the intersecting points of the hexagon-building members. The
movement of the light relative to the intersecting points creates
the resultant color mix.
[0142] In yet another embodiment of the present invention, the
hexagon building structure is constructed from materials that
include carbon foam, reticulated aluminum foam, copper foam,
sintered metals, cast foams, and molded natural pumice, allowing
the hexagon members to act as heat exchangers (see FIGS. 59 and
60). Fluid heat exchanger tubes fabricated from materials such as
copper or graphite are inserted into the alignments fastening holes
4 (shown in FIG. 1) and stacked in the substantially round hexagon
assembly 34 in (shown FIGS. 22 and 23). In another preferred
embodiment, the heat exchanger tubes are inserted into the conduit
holes 12 located in the plane of the hexagon building structures 7.
Hexagon heat exchangers also have tubes positioned axially through
the plane. A heat exchanger constructed in accordance with the
present invention integrates directly into a building for passive
solar heating (or if on the ground, in the floor for ground based
cooling). The carbon foam integrates very effectively with a heat
exchanger of the present invention since carbon foam has
substantially more thermal capability than copper.
[0143] Referring again to FIG. 59, hexagon carbon foam members 200
are clearly shown. The hexagon carbon foam members 200 are the same
shape throughout the heat exchanger assembly 201. The heat
exchanger assembly 201 is formed from offsetting hexagon carbon
foam members 200 in alternating layers (in the same offset layering
manner as previously described above with respect to other aspects
of the present invention). Heat exchanger tubes 202 are inserted
through alignments fastening holes 4 in order to hold the hexagon
carbon foam members 200 together, as well as to integrate the
thermal conductivity of the carbon foam. Tubes 202 represent the
plumbing fluids that are passed during the functioning of a heat
exchanger.
[0144] Heat exchangers typically require fluid transfer. The
assembly of heat exchanger tubes 202 adapt to normal round tubes
inherent in heat exchanger design. Thermalgraph.RTM. foam
(manufactured by Amoco in Atlanta Ga., U.S.A.) is a sheet of carbon
that conducts in the direction of its plane. In one preferred heat
exchanger embodiment of the present invention, Thermalgraph.RTM.
foam is integrated as a layer within ORNL carbon foam (which
conducts in every direction). Alternatively, Thermalgraph.RTM. foam
is used as a complete replacement for ORNL carbon foam members 200.
Thermagraph.RTM. conducts in the hole where it is cut so it works
very well as hexagon 200. In other preferred embodiments of the
present invention solid carbon foam, solid metals, ceramics,
carbons, polymers, glasses, or other materials make up heat
exchanger materials. These tubes can be inserted along the plane as
shown in the above-mentioned hexagon assembly 201 of FIG. 59.
[0145] In another preferred embodiment of the present invention, a
hexagon carbon foam heat exchanger assembly 203 is formed from
closely tiled hexagons 200 and tubes 202, as shown in FIG. 60. The
assemblies 203 are close fitting tiled hexagons that are not offset
when layered. In this embodiment, the tubes do not hold the
hexagons together as in assembly 201. This is an advantageous
configuration in an embodiment where the tube bundles need to be
pulled apart or spaced for fluid flow. This configuration is also
beneficial in an embodiment where a slightly larger offset hexagon
assembly 201 is positioned to fix a non-offset hexagon assembly 203
in a controlled space. In some embodiments, spacers are placed on
the hexagons 200 in order to hold the hexagons 200 in a desired
space and provide a path for fluid flow between the hexagons 200.
(See new drawing with spacers).
[0146] FIGS. 63-66 illustrates the preferred hexagonal shaft joint
fastener 300 with a threaded ratchet head 302 mating to a hexagon
fastener ratchet seat 308 and 309. FIG. 64 illustrates a
perspective close exploded view of a hexagon 311 with the male
hexagonal shaft fastener 300 of FIG. 63 aligned with the hexagonal
molded hole 307 of FIG. 64. FIG. 66 illustrates a perspective view
of all six hexagonal ratchet fastener seats 308. Male hexagonal
shaft joint fasteners 303 are inserted through hexagonal molded
holes 307 until head 301 is seated on seat 308. Female threaded
head 302 is rotated freely on threads 304, until ratchet 305
contact mating ratchet 309. A spanner wrench is inserted into holes
306 to rotated the head down ratcheting 305 and 309 together, until
head 302 seats with 308 on hexagon 311, mechanically compressing
layers of two or more hexagons. Ratchet surfaces 305 and 309
prevent the fastener from rotating due to structural vibration,
securing the building for the live of building. Ratchet surfaces
compress and expand as they are being forced together or withdrawn
by force rotating the head 302. Male fasteners 303 are inserted
from the outside, which is the long shaft 303, and cannot rotate
out, because of the hexagonal shaft 303 and mating hexagonal hole
307 prevents rotation. Hexagonal shaft 303 has a raised bump 303a
to hold the fastener in the hexagon making assembly easier. These
raised bumps can be put in numerous locations to pressure hold the
hexagonal shaft in the hexagon during assembly. This is a tamper
proof fastener that cannot be rotated. People can feel secure
within the wall side facing head 302 fasteners.
[0147] FIG. 67 is an alternate tamper resistant fastener head 312.
The bouquet type fastener 3 13 flares out on bevel 314 preventing
rotation. This is less favorable, because the threads are much
smaller to provide the bevel 314. This fastener does not have a
need for ratchet 309 in the hexagon, because the bouquet 313
frictions against 314 resists reverse rotation.
[0148] FIGS. 68 and 69 is another alternative fastener that
provides a male press fit fastener 315 and 1/4-turn fastener 316
that insert into female dowel retainer 317. Dowel retainer 317 has
two female fastener fixtures 318 that are identical and yet provide
two separate means of fastener retention press fit flange 319 and
1/4-turn slot 320. Hexagon dowel plate 321 fits into six hexagon
holes 322. Hexagon holes 322 mates to the dowel retainer and
fasteners.
[0149] In FIGS. 63-69 this invention teaches how a shaped hole can
be applied to layer, offset, and layer tessellations like hexagon.
Square, triangle, rectangle, polygons, and other infinitely
variable curved tileable shapes also have an unmet need to apply a
shaped shaft to secure the fastener from one side and compress the
building together mechanically in a friction fitting or
mechanically locked fastener. These wholes can be slotted so the
hexagon pressure is on the side of the hexagons and not on the
fastener system. Fastener holes can be rotated as long as all the
"shaped fasteners are rotated at the same angle relative to a flat
corresponding flat edge. Three holes could be placed around the
single fastener to increase strength. Vibration will not rotate the
heads off and people outside can not dismantle the building. Shaped
fastener shafts will not rotate in a matting hole. The preferred
arrangement in this invention is a hexagonal shaft where each of
the small hexagon holes are oriented pointing one of the points to
each of the six flat sides of the hexagon. This hexagon shaped
orientation provides registered holes for offset layering of
hexagons. A shaped hexagonal hole is disclosed, but it is
understood that other shaft and hole shapes can be applied, if all
oriented the same way for symmetrical assembly.
[0150] FIG. 70 is a side view of a preferred fastening means when
walls are spaced and filled with straw bales or cast with
concrete.
[0151] FIG. 71 is a section view of a fastener head 333 with an
insert 334. These inserts can be cast in or pushed into a barbed
molded hole 335. These have mounting value when placing finish
sheathing like sheetrock "plasterboard, or decorative paneling.
Sheetrock insert 334 would be protruding out past the sheetrock
thickness or preferable just below the sheetrock thickness.
Sheetrock can be hung on these barbed insets 334 without breaking
through the surface of the sheetrock. This does not work on ceiling
hung sheetrock and so inset 334 has to penetrate through the
sheetrock to locate it and then a washer type fastener is pounded
on the barbed insert. Sheetrock is a building code firewall and
this building fastener provides the means of hanging sheetrock to
the plastic.
[0152] FIG. 72 illustrates a perspective view of a preferred
hexagon conduit pattern. A star 400 is formed where the points of
the star are located at the mid-point 401 of each flat edge of the
hexagon. A rhombus 402 forms at each point 403 of the hexagon. An
inner hexagon 404 forms in the center of the hexagon and is
oriented the same as the hexagon perimeter. An equilateral triangle
forms between the inner hexagon 404 and mid-point 401. Applying
this preferred pattern eliminates conduits that are not matched to
others in an assembly. All conduits mate up and form full conduit
throughout an assembly. Where hexagons are layers and offset in
this invention.
[0153] FIG. 73 illustrates a perspective view of a corner assembly
of preferred hexagon conduit pattern in FIG. 72 and fastener in
FIGS. 63, 64, 66, and 67. Applying this pattern is not limited to
the fasteners in this invention. FIG. 73 provides a conduit system
405 that mates and forms full conduit when hexagons 406 are layered
in a point to center arrangement with conduit facing the conduit of
opposing hexagons 407.
[0154] FIG. 74 illustrates a cross sectional side view of fasteners
configured for multiple layers. Fastener 408 can only mechanically
lock four other hexagons in this illustration. This invention
teaches how any number of layers of hexagons can be fastened
together by offsetting the fasteners perpendicular to the face of
the hexagons. Each fastener 408 is inserted in the same pair of
hexagons 409 and alternately inserted in two different pairs of
hexagons 410 and 411 locking six hexagon layers together. This
stepped pattern can continue any number of layers building a locked
together wall. Fastener 412 is for the outside or inside wall to
finish off the fastener system.
[0155] FIG. 75 illustrates how sheathing panels can be glued to
hexagon assemblies to make single structurally insulated panels.
Hexagons edges 413 protrude outside the sheathing edge and will
assemble into another panel by inserting and overlapping the
hexagons in the panel. Glue or fasteners can be inserted through
the overlapping hexagons from each full panel locking the panels
together.
[0156] Curved hexagons can be injected or molded. GE Plastics makes
a brand name Norolide and it is the preferred material where users
want to meet water fire sprinkler building codes. These GE polymers
are ideas to place fill materials in.
[0157] Bentonite is a natural mined mineral that has an adsorption
of water 100 layers thick on its surface. This mineral is used in
paper form and paint form to seal The present invention allows
common tessellations to be integrated with tube bundles in order to
make heat exchangers in a larger number of geometries, ranging from
flat radiator-like devices to flat plane-type heat exchangers. The
tubes can be extruded shapes like squares, triangles, hexagons,
polygons or other shapes, without departing from the scope of the
present invention. Tubes groves can be cut along the plane of these
hexagons to make flat plane oriented heat exchangers for floors,
walls, working surfaces, and other industrial cooling systems like
refrigeration beds. These tube groves in FIG. ? increases
structural stability by preventing hexagons from shifting in the
plane direction. Some beat exchanger materials like reticulated
aluminum foam can be compressed onto the surface of a tube
insertions, which may have corrugated surfaces holding the tube and
hexagon in rigid location. In another embodiment of the present
invention, FIGS. 59 and 60 also illustrate how helium hexagons are
assembled to make aircraft fuselages (as will be described in
further detail below).
[0158] A super critical fluid MuCell microcellular process is the
preferred foam for tessellation building material, because it can
be foamed out of virtually any polymer at any density, and filled
with a voluminous number of fillers like carbon fibers, glass
fibers, ground glass, wood fibers, and other minerals.
[0159] A microcellular thermoplastic foam technology was invented
at Massachusetts Institute of Technology is being commercialized by
Trexel of Wobern, Mass. The innovative new process uses high-cell
nucleation rates within the foaming material to create foams with
small, evenly distributed and uniformally sized cells (generally
5-50 micron in diameter). Trexel claims have been validated that
the foam materials produced by this process, called MuCell.RTM.,
have properties and uniformity superior to conventionally foamed
products. MuCell uses Super Critical Fluids (SFCS) of atmospheric
gases to create evenly distributed and uniformly sized microscopic
cells throughout the polymer. It's suitable for structural-foam
molding, as well as other injection-molding applications, blow
molding, and extrusion, and does not require chemical blowing
agents, hydrocarbon-based physical blowing agents, nucleating
agents, or reactive components.
[0160] MuCell process enables molders to foam materials that cannot
be foamed successfully with conventional technologies, such as
high-temperature sulftones, polyertherimides, liquid-crystal
polymers, and thermoplastic elastomers such as high-temperature
elastomers such as Kraton.RTM. and Santoprene.RTM., and realize a
20-50% weight reduction and a reduction in Shore A hardness.RTM..
Some polymers can reduced in weight by 93% and others 9%. There is
a wide range of materials that will seal in the small molecule of
helium into closed MuCell cells of a polymer.
[0161] MuCell microcellular foam process follows four basic
steps:
[0162] 1. GAS DISSOLUTION: A supercritical fluid (SCF) of an
atmospheric gas is injected into the polymer through the barrel to
form a single-phase solution. The super critical fluid delivery
system, screw, and injectors design for the MuCell process allow
for the rapid dissolution rate required. This invention teaches a
helium gas to produce a buoyant material. 2. NUCLEATION: A large
number of nucleation sites are formed (orders of magnitude more
than with conventional foaming processes) where controlled cell
growth occurs. A large and rapid pressure drop is necessary to
create the large number of uniform sites. 3. CELL GROWTH: Cells are
expanded by diffusion of gas into bubbles. This invention teaches
helium gas diffusion. Processing conditions provide the pressure
and temperature necessary to control cell growth 4. SHAPING: Any
shaped mold design controls part shape. This invention teaches
using polymers that will trap helium permanently. For example, a
choice is polycarbonate and combinations of the above-mentioned
polymers as well as others. Hydrogen gas can be injected into the
foam, but will ignite and this has function where it is desirable
to destroy high altitude weather balloons for example. Phosphors
can also be introduces into the cells in a controlled manor to
provide extruded flat panels TV's or monitors. Mineral fills can be
applied to this invention. Minerals like bentonite can be used as
fill in this material. This invention teaches a bentonite component
montmorillonite, where the mineral is modified to integrate to the
polymer and later adsorb moisture in some application as well as
just act as a very uniform filler. This invention teaches
montmorillinite is the preferred material because it naturally
forms a "T" bond from its high negative and positive charge, cat
ion sites. The very flat mineral is a best "modified" custom
mineral, because it has such a high exposed surface area to modify
to bond to the polymer in a very uniform or surface coating. This
invention teaches a modification of montmorillinite where the
montmorillinite forms on the wall of the mold in one case and
uniformly integrated within MuCell in the other case. Minerals and
other metals will combine with montmorillinite. Moisture is the
biggest layer on montmorillinite and when injecting polymers with
water-saturated montmorillinite (bentonite family of minerals)
under the MuCell process the water steams through the polymer
structurally reticulating the foam. This produces reticulated foam.
Montmorillinite can be viewed as the carrier mineral of a range of
other "agents" into the MuCell process. This invention teaches that
polymer binders of zeolite molecular sieves can be produced under
MuCell's process providing foamed zeolites with increased surface
area multiples more than current pellets provide much larger
monoliths can be "foamed" with the same effective surface area as
thousands of pellets. This type of foam can be cst into hexagons
and used for "transpiration" cooling of a building, where the
moisture draws the heated molecules out of the building keeping the
building cool or frozen, which is dependent on the rate. MuCell's
process is ideal for hexagons injected centrally, because a very
high energy release occurs during MuCell injection, which naturally
wants to form a circle. Hexagons only have six points to fill in
not far from the edges of the circular force being stopped by the
flat edges of the hexagon.
[0163] After hexagons are formed a coating of infrared paint is
applied to the hexagon surface reflecting heat away from the
hexagons and retaining heat within the hexagon. This paint is
similar to Army tank coating used to reduce infrared signature of
men within the tanks.
[0164] Referring again to FIG. 1, the foam 3 can be manufactured
from many different substances, including but not limited to
neoprene, hypalon, vinyl nitrile, nitrile, (NBR), epichlorohydrin,
or urethane foam. Closed cell foam is manufactured in several
densities. The more air or gas pressure applied during the foaming
process, the more or less dense the foam becomes as a final
product. Nitrogen gas is typically applied to the gas to make
closed cell foam, because trapping nitrogen in the closed cell foam
rather than air reduces oxidation. In a preferred embodiment of the
present invention, the nitrogen is replaced with helium, producing
a new neoprene closed cell helium material. In the present
invention helium gas (or another suitable lightweight gas or gas
mixture) is used to form closed cell foam, trapping the lightweight
gas in the closed cells.
[0165] The present invention advantageously traps helium in the
closed cells to produce foam that will float in the air. The foam
density is determined by the pressure of gas volume applied to the
foaming process and can be very dense or of very low density (to
the point of being extremely fragile). The mole weight of helium is
0.004. In one atmosphere, one-cubic foot of helium will lift
approximately 0.0646 pounds off the ground. Each engineering
project utilizing this invention will determine the requisite
helium foam density based on strength and lift requirements.
Applications designed to encounter only low levels of stress (such
as telecommunications or high atmospheric satellite broadcast and
transmission systems) use very low-density fragile foam, because
the equipment is installed only once, and with very minimal
handling or need of impact resistance. In contrast, a personal
airplane will be higher density foam for strength, because of
landing impact and frequent human handling.
[0166] Helium closed cell foam can be shaped into a hexagon
building structures 7, as shown in FIG. 1. The closed multi-cell
material can form many small shapes, including but not limited to
tubes, squares, triangle polygons, hexagons, honeycombs, and other
shapes, without departing from the scope of the present invention.
Further, in some embodiments of the present invention, loose beads
filled with helium are packed in the cavities (like existing
aircraft voids) or in hexagon building structures that are
specifically engineered to have cavities to hold these beads or
relatively small bladders. Multiple balloons are contemplated as
well.
[0167] Referring now to FIG. 9, in one embodiment of the present
invention, carbon fiber composite sheathings 7a and 7b are applied
to the hexagon building structures 7 making them substantial
structural panels by adding strength to the helium hexagon foam
panel. Long rods, preferable graphite carbon fiber rods (or tubes)
are inserted in the alignments fastening holes 4 (shown in FIG. 1)
or another desired location. In yet another embodiment,
substantially round hexagon assemblies 34 (shown in FIGS. 22 and
23) are stacked forming the fuselage of a plane or a boat haul. In
the embodiment of the present invention shown in FIG. 44,
alignments fastening holes 4 are sized and configured for rod
fastener insertion to connect hexagon building structure 7 to
hexagon building structures 8E 9, 10) as well as any number of
other layers and shapes.
[0168] In still other embodiments of the present invention, flat
wings and shaped wings are derived using the assembly methodology
of present invention. Graphite rods, cable, rope, plastic, carbon
fiber, tapes adhesives, or any other fastener can also be used to
build desired shapes. Once a shape is constructed, skin can be
wrapped around it. The skin is applied using a variety of methods,
including but not limited to fiber glassing, carbon fiber spinning,
painting, plastic vinyl wrapping, dipping, and shrink-wrapping. Any
cavities in the hexagons can be filled with a foaming agent or
other material. Hexagons can be built into personal aircraft or
industrial aircraft, toys or any other floating application where
floating is desired.
[0169] Any shape helium foam parts can be tooled by molding,
machining, extruding, hot knife, wire cutting, saw, and water jet
cutting techniques. Future shaping by extrusion, ultrasonic,
dielectric, microwave, and lithography, chemical or laser is also
possible. Some embodiments of the present invention utilize helium
closed cell foams for buoyant aircraft. Many base materials will
foam other than neoprene and are applied in alternate embodiments
of the present invention. Aluminum foam is a good candidate for
aircraft. Indeed, many metals can be foam manufactured in
accordance with the present invention, such as titanium. Flexible
foams are also available and are considered good species of foam
for helium.
[0170] Honeycomb cores are used in the fabrication of lightweight
structures typically used in the aerospace and commercial markets
and are employed as the material for hexagon building structure 7
in some embodiments of the present invention. The-core material is
typically "sandwiched" between skins of aluminum or other high
strength composite material. A bonding adhesive is used to attach
the "skin" material to the honeycomb core while the in the presents
of a helium gas trapping the helium in the honeycomb. The resultant
honeycomb panel offers one of the highest strength to weight
constructions available. Aircraft engine nacelles flaps, overhead
bins, floor panels, and galleys all are constructed from honeycomb
core. Honeycombs can be cut into hexagon shapes, or other
tessellations, with fasteners referenced for use in embodiments of
the present invention.
[0171] Helium gas can be used as the fill gas for the bubbles
packaging (such as SealedAir.RTM. Bubble packaging manufactured by
Sealed Air, Park 80 East, Saddle Brook, N.J. 07663) making the
packaging float in air. This bubble helium packaging can be
engineered geometrically to match and be sealed into the honeycomb
materials referenced above, by sealing the bubbles packaging in
additional skin for strength. The plastic can be selected for
adhesive bonding, dielectric, or ultrasonic sealing. This sealed
helium packaging is used as filler in many parts of aircraft or
other structures in accordance with the present invention.
[0172] Applications of this technology range from air floating to
water floating structures or devices. Space structures are also
possible and would aid earth-launching weight. Toys, signs, planes,
bridges, boats, trains, barges, cargo, underwater systems, air or
watercraft, manned or unmanned systems are possible. Homes and
furniture could be built to float in air. An untrained aviator
farmer could apply agriculture chemical or biological agents from
air. Any air, water, land, space transport, or fixed floating type
device could be assembled from this invention. Extremely
lightweight planes can be produced that have an actual weight
(without helium) that is substantially larger. Carbon foam and
other heat adsorbent material can be employed to heat the helium
obtaining extra lift. These materials are covered and uncovered to
control heat. Phase change heat storage systems are also applied to
the present invention to keep the system in high elevation at night
by heat recovery.
[0173] Prior art in helium systems consist of bladder or balloon
type containment. None of this prior art could be accelerated in
the air without distorting the shape or destruction. A hole in the
bladder type configuration generally loses all the gas in that
section. A hole of the same size in the present invention does not
significantly impact this helium foam because the present invention
teaches a closed cell helium foam that compartmentalizes the gas in
millions of individual chambers (in the case of large systems).
Thus, this structure can float in the air, be cut without
dramatically reducing buoyancy, and has structural strength so
building structures can be shaped, coated, and assembled into a
variety of configurations. Reticulated foams are open cell, and can
still be used as a helium vessel of the present invention, if a
coating is placed completely around the foam to seal the helium in
the foam.
[0174] In still another aspect of the present invention, aircraft
related systems are being directed through the air by thin layer
composite unimorph ferroelectric driver "wafer" (U.S. Pat. No.
5,632,841 Hellbaum et al.). Motion occurs when high frequency
voltage is applied to the wafer driver directing airflow to move
the whole aircraft related systems. Hexagon wafers can effectively
morph the whole surface of a craft. This technique can be applied
to water equipment as well.
[0175] Polyimide foam can be foamed in place for installation and
repair, resulting in dramatic labor and material cost savings. This
low-density foam can be processed into neat or syntactic foams,
foam-filled honeycomb or other shapes, and micro spheres. Small
glass micro sphere have iron tunnels that cause them to leak helium
gas. These same iron tunnels allow glass spheres to be filled with
helium, which can then be sealed shut by polyimide thin films or
metalizing the iron tunnels shut. These products offer excellent
thermal and acoustic insulation, and high-performance structural
support as well as other benefits. Polyimide foam meets aerospace
industry demands for high-performance structural foam with
increased stiffness but without large weight increases.
[0176] The process for this foam begins with a monomeric solution
with salt-like properties to yield a homogeneous polyimide
precursor solid residuum. The resulting precursor can be processed
into polyimide neat or syntactic foams, foam-filled honeycomb or
other shapes, and microspheres, all of which produce useful
articles through normal foaming techniques. These spheres can be
opened vacuumed clean of gas and moisture filled with helium and
reclosed. These helium filled foam spheres are ideal for containing
the helium, which is a very small molecule that escapes most
polymer or latex bladders. These polyimide foams can be coated
around other helium filled foam structures like urethane foam
structures or reticulated foam filled with helium to form gas tight
monolith helium filled foam. Any composite, such as carbon graphite
materials, carbon foams, metal aluminum foam, paper, paper fiber
products, cloth, and fiberglass can be coated with these foams to
seal in helium. Very low-density materials can also be coated with
polyimide foam to seal in helium.
[0177] This process can produce foam and microsphere materials by
reacting a derivative of a dianhydride (e.g., ODPA, BTDA, PMDA)
with a diamine (e.g., ODA, PDA, DDS). A mixture of two or more
polyimides can be combined or used separately to make a variety of
polyimide foams with varying properties. Foams and microspheres can
be fabricated to specific densities from approximately 0.5 to over
20 pounds per cubic foot.
[0178] A preferred method of the present invention converts the
above-mentioned low-density stable polyimide foam into a
low-density stable carbon foam or fiber composite by applying
microwave energy. In some methodologies of the present invention,
pressure is applied during heating the polyimide resin as an added
control of density. The resultant carbon foam is very thermally
conductive. Aluminum molds are preferred for this process because
they do not require a mold release agent. In some alternate
embodiments, other molds are selected because they will bond to the
carbon end product and become the final integrated net shape
products. Carbon foam, carbon fiber, and graphite composites, are
all products that can be produced by microwaving a cast or molded
shape of polyimide foam. The foam can be cast, molded, and formed
on a variety of materials. This foam is transparent and can be
backlit illuminating a building. This foam can me easily molded
into curved shapes and dome tessellation components.
[0179] The unique quality this stable foam has is its integration
to other materials and then conversion to carbon materials by
microwave or other heat energy. A preferred embodiment of the
present invention microwaves polyimide foams to achieve control of
polyimide density. This invention teaches converting carbon
materials and controlling density to produce reticulated carbon
foam having near original polyimide foam density. By controlling
the density and form of the foam prior to carbonizing the foam, new
levels of material density and material integration can occur.
[0180] Microwaving is a radiant energy source so when converting
polyimide foam to carbon materials only a portion of the foam needs
to be converted based on the power and direction the microwaves are
directed. Metals like magnetic materials can be added to the foam
prior to microwaving the materials into carbon materials. These
metals can be positioned to reflect the microwaves into a pattern
that localizes the carbon conversion of the polyimide. Insulators
and conductive carbons result from this process. These processes
can be stopped at any point during conversion to get carbon,
graphite, or other composites of the polyimide foam. No other
process provides the localization of producing insulation and
conductive materials as an integrated product. Carbon fibers
(chopped, or long fibers), fiberglass, metals, or other fibers can
me molded into this composite system. Paper molds can be cast onto
and then removed to form complex shapes.
[0181] In a preferred embodiment of the present invention, aluminum
foam material is utilized to construct foam panels, hexagon
building structures 7, and other tessellation shapes. Additionally,
aluminum foam can be applied to obtain a final net shape on the
outer structure of a hexagon assembly. Hard aluminum foam cores can
have complex exact shapes on the outside. The final outer skin
hexagonal composite can also be a unimorph ferroelectric driver
"wafer" that provides electronic control of the surface shape.
[0182] Silica carbonate aluminum foam exhibits a combination of
qualities not found in other low-density materials including
sufficient strength to serve as structural members, good thermal
qualities for insulation, resistance to fire and immunity to
electromagnetic fields. Aluminum foam is strong enough to build
panels without sheathing bonded to each side of the panel, just
aluminum foam is needed. Sheathing panels can be bonded into a
sandwich arrangement if extra strength is desired in application
where thickness and strength need to be at the highest density.
Aluminum foam can be heated in shaping the hexagon building
structures 7 into curved shapes in order to form a macro-sphere,
large tube, aerospace component, boat hull, auto body, or frame
components. Final net shape surfaces can be polyimide foams as
described above.
[0183] During the gas injection stage of aluminum foam production,
helium gas can be substituted for air. (Other gases and/or liquids
can also be substituted for air and combined with the aluminum
foam.) The combination of low aluminum alloy weight and helium gas
is ideal for making strong air-buoyant structures. Heat should be
applied along with any other coating to seal the helium into the
aluminum foam. Copolymides polyimides, or other suitable materials
can be added to the aluminum foam to form a gas tight seal for
helium gas. Carbon fiber, carbon foam, ceramic spheres, copper
foam, glass, and other structural material can be cast while the
foam is in the liquid state. Paper and burnable cores can also be
cast forming complex shapes.
[0184] Aluminum foam can be cast around a carbon foam or carbon
fiber monolith to produce gas tubes. In the case of the carbon
fiber, an insulated structural vessel will form around the carbon
fiber. A copolymide coating can be applied to the outside of the
carbon fiber to form a gas tight seal between the carbon fiber and
aluminum foam. The closed cell foam of the aluminum has small
fractures that require closure to produce a gas tight seal. This
aluminum foam can produce simple structural insulated foam around a
pressure vessel. Carbon fiber reduces gas pressure by adsorbing the
gas. Natural gas stores at 3000 pounds per square inch (psi) in a
typical pressure vessel, but when stored on carbon fiber gas
pressure is reduced to 500 psi. The aluminum foam as a structural
and insulating material further reduces the possible rupture of a
gas pressure or vacuum vessel. Thus, fuel vessels can be inserted
into hexagon building structures to store fuels. ORNL carbon foam
referred to above is porous foam and aluminum does not stick to it
when it is molded to its surface shape. The porous carbon foam can
have air passed through it to foam the silica carbonate aluminum
foam materials. The crucible containing the aluminum just prior to
foaming would be totally or partially made from carbon foam. This
carbon foam will not provide an opening for aluminum to flow
through, but does provide an air path for blowing air into the
aluminum foam replacing mechanical stirring and air insertion rods
that do not make uniform aluminum.
[0185] Reticulated aluminum foam can be manufactured by placing the
silica carbonate aluminum in a carbon foam closed tube. In one
embodiment the mold can be a hexagon mold with the walls of the
hexagon a graphite closed surface and two of the opposing flat ends
of the hexagon would be porous carbon foam, one to rest the molten
aluminum materials on and the other to pull a vacuum. When a vacuum
is pulled, the aluminum will foam into a reticulated porous
aluminum in the form of a hexagon. Hexagon molds are used in this
example, but any shape will work where there is a carbon foam
surface to rest the molten aluminum on and a vacuum surface to pull
gas through the aluminum reticulating it.
[0186] Hexagons can be applied as truck canopy, truck
transportation containers, homes, floors for computer wiring,
desks, furniture, and many other applications where sheathing of
other types is applied.
[0187] The present invention has been described in relation to a
preferred embodiment and several alternate preferred embodiments.
One of ordinary skill, after reading the foregoing specification,
may be able to affect various other changes, alterations, and
substitutions or equivalents thereof without departing from the
concepts disclosed. It is therefore intended that the scope of the
Letters Patent granted hereon be limited only by the definitions
contained in the appended claims and equivalents thereof.
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