U.S. patent application number 12/045773 was filed with the patent office on 2008-07-03 for space truss structure surface slab assembly.
Invention is credited to Bunichi Shoji.
Application Number | 20080155931 12/045773 |
Document ID | / |
Family ID | 34410834 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080155931 |
Kind Code |
A1 |
Shoji; Bunichi |
July 3, 2008 |
SPACE TRUSS STRUCTURE SURFACE SLAB ASSEMBLY
Abstract
An apex rhombus is delimited over the center point of a square,
which is delimited by plotting four nadir rhombuses on the same
plane, and each of the nadir rhombuses and the apex rhombus are
jointed to form a group of pyramidal surfaces equipped with four
planar slopes having substantially the same height in a pyramidal
form. Two pyramidal surface slabs are assembled, each composed of
pyramidal surfaces around one pyramidal surface, each sharing one
nadir rhombus, adjacent each other, and arranged in a grid pattern
at an equal pitch in plural directions. The pyramidal surfaces
arranged in a grid pattern are each displaced by one-half pitch in
a specific direction, such that the apex rhombus of one of the
pyramidal surface comes in contact with the nadir rhombus of the
other pyramidal surface, whereby the two pyramidal surfaces are
placed one on the other.
Inventors: |
Shoji; Bunichi; (Mito,
JP) |
Correspondence
Address: |
ANTONELLI, TERRY, STOUT & KRAUS, LLP
1300 NORTH SEVENTEENTH STREET, SUITE 1800
ARLINGTON
VA
22209-3873
US
|
Family ID: |
34410834 |
Appl. No.: |
12/045773 |
Filed: |
March 11, 2008 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
11066301 |
Feb 28, 2005 |
|
|
|
12045773 |
|
|
|
|
Current U.S.
Class: |
52/633 |
Current CPC
Class: |
E04B 2001/1984 20130101;
E04B 2001/1987 20130101; E04B 2001/1981 20130101; B62D 33/046
20130101; E04B 5/04 20130101; E04B 2001/199 20130101; E04B 1/19
20130101 |
Class at
Publication: |
52/633 |
International
Class: |
E04C 3/02 20060101
E04C003/02; E04B 1/18 20060101 E04B001/18; E04B 5/18 20060101
E04B005/18 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 1, 2003 |
JP |
2003-308336 |
Claims
1. A space truss structure surface slab assembly comprising two
opposing pyramidal surface slabs joined together, wherein each of
said two pyramidal surface slabs comprises: an apex rhombus
delimited over the center point of a polygon delimited by plotting
a plurality of nadir rhombuses on one and the same plane, each of
said nadir rhombuses and the apex rhombus being jointed to form a
group of pyramidal surfaces equipped with a plurality of planar
slopes and having substantially the same height in a triangular
pyramid, said pyramidal surfaces being arranged in a grid pattern
at an equal pitch in two or three directions, wherein the apex
rhombus of one pyramidal surface slab and the apex rhombus of the
other pyramidal surface slab opposed thereto are integrally jointed
by bonding or welding whereby a space truss structure assembly is
formed.
2. The space truss structure surface slab assembly according to
claim 1, wherein at least one pyramidal surface slab is made of
sheet metal.
3. The space truss structure surface slab assembly according to
claim 2, wherein the at least one pyramidal surface slab is
produced by pressing a steel slab.
4. The space truss structure surface slab assembly according to
claim 1, wherein at least one pyramidal surface slab is made of a
thin wooden plate or plywood.
5. The space truss structure surface slab assembly according to
claim 1, wherein each of said nadir rhombuses and said apex
rhombuses is formed like a spearhead providing a sharp-edged
angle.
6. The space truss structure surface slab assembly according to
claim 1, wherein a planar surface plate is laminated outside each
of the two pyramidal surface slabs so that the space truss
structure assembly is sandwiched between them.
7. The space truss structure surface slab assembly according to
claim 6, wherein a thin building material including calcium
silicate board is used as the planar surface plate.
8. A space truss structure surface slab assembly comprising two
opposing pyramidal surface slabs joined together, wherein each of
said two pyramidal surface slabs comprises: an apex rhombus
delimited over the center point of a triangle or a square which is
delimited by plotting three, four or six nadir rhombuses on one and
the same plane, each of said nadir rhombuses and said apex rhombus
being jointed to form a group of pyramidal surfaces equipped with
three, four or six planar slopes and having substantially the same
height in a pyramidal form, said pyramidal surfaces being arranged
in a grid pattern at an equal pitch in two or three directions,
wherein the apex rhombus of one pyramidal surface slab and the apex
rhombus of the other pyramidal surface slab opposed thereto are
integrally jointed by bonding or welding whereby a space truss
structure assembly is formed.
9. The space truss structure surface slab assembly according to
claim 8, wherein at least one pyramidal surface slab is made of
sheet metal.
10. The space truss structure surface slab assembly according to
claim 9, wherein the at least one pyramidal surface slab is
produced by pressing a steel slab.
11. The space truss structure surface slab assembly according to
claim 8, wherein at least one pyramidal surface slab is made of a
thin wooden plate or plywood.
12. The space truss structure surface slab assembly according to
claim 8, wherein each of said nadir rhombuses and said apex
rhombuses is formed like a spearhead providing a sharp-edged
angle.
13. The space truss structure surface slab assembly according to
claim 8, wherein a planar surface plate is laminated outside each
of the two pyramidal surface slabs so that the space truss
structure assembly is sandwiched between them.
14. The space truss structure surface slab assembly according to
claim 13, wherein a thin building material including calcium
silicate board is used as the planar surface plate.
15. A space truss structure surface slab assembly comprising two
opposing pyramidal surface slabs joined together, wherein each of
said two pyramidal surface slabs comprises: an apex rhombus
delimited over the center point of a polygon delimited by plotting
a plurality of nadir rhombuses on one and the same plane, each of
said nadir rhombuses and the apex rhombus being jointed to form a
group of pyramidal surfaces equipped with a plurality of planar
slopes and having substantially the same height in a triangular
pyramid, said pyramidal surfaces being arranged in a grid pattern
at an equal pitch in two or three directions, wherein the apex
rhombus of one pyramidal surface slab and the apex rhombus of the
other pyramidal surface slab opposed thereto are integrally jointed
by bonding or welding whereby a space truss structure assembly is
formed.
16. The space truss structure surface slab assembly according to
claim 15, wherein at least one pyramidal surface slab is made of
sheet metal.
17. The space truss structure surface slab assembly according to
claim 16, wherein the at least one pyramidal surface slab is
produced by pressing a steel slab.
18. The space truss structure surface slab assembly according to
claim 17, wherein at least one pyramidal surface slab is made of a
thin wooden plate or plywood.
19. The space truss structure surface slab assembly according to
claim 17, wherein each of said nadir rhombuses and said apex
rhombuses is formed like a spearhead providing a sharp-edged
angle.
20. The space truss structure surface slab assembly according to
claim 17, wherein a planar surface plate is laminated outside each
of the two pyramidal surface slabs so that the space truss
structure assembly is sandwiched between them.
21. The space truss structure surface slab assembly according to
claim 20, wherein a thin building material including calcium
silicate board is used as the planar surface plate.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of U.S.
application Ser. No. 11/066,301, filed Feb. 28, 2005, the contents
of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a space truss structure
surface slab assembly.
BACKGROUND OF THE INVENTION
[0003] The Japanese Application Patent Laid-open Publication No.
10-181593 discloses the structure of a rolling stock car body. This
structure is made of a plurality of aluminum alloy hollow extruded
members having a closed cross section, and it comprises an outer
plate, an inner plate, and a partition for holding these plates at
a predetermined spaced interval and jointing them to form a
triangle.
[0004] The Japanese Application Patent Laid-open Publications No.
3340533 describes a truss panel type core material, wherein sheet
materials consisting of a wooden single plate or plywood sheet are
combined to form a truss, as seen when its cross section is viewed
from one side. This truss panel type core material is composed of a
top layer panel made of a sheet material, a bottom layer panel made
of a sheet material, and a saw blade-like intermediate web bonded
by an adhesive to each of the aforementioned top and bottom layer
panels. The aforementioned intermediate web is composed of a
plurality of strip-shaped sheet materials and bonding tapes, and
the front and back of the edge of the sheet material are cut off in
an oblique form relative to each other, wherein the tip ends of the
obliquely cut-off tapered portions are butted with each other, and
a bonding tape is attached on the back of each tapered portion.
[0005] The Japanese Application Patent Laid-open Publications No.
10-166481 discloses a panel core material provided between two
spaced panels arranged in parallel, wherein the aforementioned core
material is made of paper having a predetermined thickness, and a
cone-shaped portion of a plurality of approximately quadrangular
pyramidal members, each projecting in opposite directions, is
formed by a plurality of hexagonal inclined surfaces, with two
inclined surfaces on both sides having a rectangular edge jointed
with each other, and a head crest is jointed to the sides of both
ends of this inclined surface.
SUMMARY OF THE INVENTION
[0006] To make it possible to obtain getting a large-area plate or
assembly through use of hollow core materials according to prior
techniques, a hollow core material has been fabricated using
grid-like ribs or honeycomb boards, and this member is covered with
a surface slab, whereby a finished product is obtained. These prior
techniques, however, have the following inherent problems:
[0007] 1) A processed plate in any type of material has a low
dynamic efficiency for strength, and is characterized by a low
productivity.
[0008] 2) The surface slab thickness is increased if the hollow
core material has a coarse grid pitch, and the thickness of the
hollow grid member is decreased if the hollow core material has a
fine grid pitch. Thus, the economic efficiency is very low for the
required strength.
[0009] 3) A urethane resin or honeycomb paper is used as the hollow
material, but the scope of application is limited due to poor
strength, and inflammability is a problem in the case of
urethane.
[0010] 4) At present, there is no processed plate based on the use
of hollow core material, fabricated by prior known techniques,
which alone is applicable as the structure of a vehicle, ship,
aircraft or building.
[0011] To solve these problems, the object of the present invention
is to provide space truss structure surface slab assemblies having
different high strengths.
[0012] The configuration of the space truss structure surface slab
assembly in accordance with the present invention is as
follows:
[0013] An apex rhombus is delimited over the center point of a
polygon delimited by plotting a plurality of nadir rhombuses on one
and the same plane. Each of the aforementioned nadir rhombuses and
the apex rhombus are jointed to form a group of pyramidal surfaces
equipped with a plurality of planar slopes and having substantially
the same height in a triangular pyramid. Two pyramidal surface
slabs are assembled, each of which is composed of pyramidal
surfaces around one pyramidal surface, each sharing one of said
nadir rhombuses, adjacent to each other, and arranged in a grid
pattern at an equal pitch in two or three directions. The pyramidal
surfaces arranged in a grid pattern are each displaced by one-half
the pitch in a specific direction, in such a way that the apex
rhombus of one of the pyramidal surfaces is opposed to the nadir
rhombus of the other pyramidal surface, and the apex rhombus of the
other pyramidal surface is opposed to the nadir rhombus of the
counterpart, whereby said two pyramidal surfaces are assembled.
Furthermore, the apex rhombus of one pyramidal surface slab and the
nadir rhombus of the other pyramidal surface slab opposed thereto
are integrally jointed by bonding or welding, whereby a space truss
structure surface slab assembly is formed.
[0014] An apex rhombus is delimited over the center point of a
polygon--for example, triangle or square--, which is delimited by
plotting a plurality of--for example, three or four--nadir
rhombuses on one and the same plane. Each of the aforementioned
nadir rhombuses and the aforementioned apex rhombus are jointed to
form a group of pyramidal surfaces equipped with a plurality
of--for example, three or four--planar slopes and having
substantially the same height in a pyramidal form. Two pyramidal
surface slabs are assembled, each of which is composed of the
pyramidal surfaces around one pyramidal surface each sharing one of
said nadir rhombuses, adjacent to each other, and they are arranged
in a grid pattern at an equal pitch in two or three directions. The
pyramidal surfaces arranged in a grid pattern are each displaced by
half the pitch in the aforementioned specific direction, in such a
way that the apex rhombus of one of the pyramidal surfaces is
opposed to the nadir rhombus of the other pyramidal surface in
contact therewith, and the apex rhombus of the other pyramidal
surface is opposed to the nadir rhombus of the counterpart, whereby
said two pyramidal surfaces are placed one on top of the other and
are assembled. The apex rhombus of one pyramidal surface slab and
the nadir rhombus of the other pyramidal surface slab opposed
thereto in contact are integrally jointed by bonding or welding,
whereby a space truss structure assembly is formed.
[0015] A planar surface plate is laminated outside each of the two
pyramidal surface slabs so that the space truss structure assembly
is sandwiched between them.
[0016] An apex rhombus is delimited over the center point of a
polygon delimited by plotting four nadir rhombuses on one and the
same plane. Each of the aforementioned nadir rhombuses and the apex
rhombus are jointed to form a group of pyramidal surfaces equipped
with four planar slopes and having substantially the same height in
a triangular pyramid. Two pyramidal surface slabs are assembled,
each of which is composed of the pyramidal surfaces around one
pyramidal surface, each sharing one of said nadir rhombuses,
adjacent to each other, and arranged in a grid pattern at an equal
pitch in two or three directions. The pyramidal surfaces arranged
in a grid pattern are each displaced by one-half pitch in a
specific direction, in such a way that the apex rhombus of one of
the pyramidal surfaces is opposed to the nadir rhombus of the other
pyramidal surface, and the apex rhombus of the other pyramidal
surface is opposed to the nadir rhombus of the counterpart, whereby
said two pyramidal surfaces are assembled. Furthermore, the apex
rhombus of one pyramidal surface slab and the nadir rhombus of the
other pyramidal surface slab opposed thereto are integrally jointed
by bonding or welding, whereby a space truss structure surface slab
assembly is formed.
[0017] Thus, the present invention ensures economical production of
a panel core material applicable to a large or massive structure
obtained by volume production, and provides a truss structure
surface slab assembly of high strength by reducing the pyramidal
surface pitch. For example, it can be used to construct the hull
partition and bulkhead of a ship, a floor, wall and roof body of a
vehicle, and the floor, wall and roof of a building, without using
a column or beam. It allows construction of a massive glass surface
slab assembly, without using a metallic frame. The present
invention provides these structures at extremely low costs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a diagram representing how to configure a space
truss structure surface slab assembly;
[0019] FIG. 2 is a diagram representing details of the partial view
of FIG. 1;
[0020] FIG. 3 is a diagram showing a two-piece set of pyramidal
surface slabs prior to assembly;
[0021] FIG. 4 is a diagram showing the assembly as a first
embodiment;
[0022] FIG. 5 is a diagram representing an alternative to the
arrangement of FIG. 3;
[0023] FIG. 6 is a diagram representing an alternative to the
structure of FIG. 4;
[0024] FIG. 7 is a diagram representing details of another
pyramidal surface;
[0025] FIG. 8 is a diagram showing a two-piece set of pyramidal
surface slabs prior to assembly;
[0026] FIG. 9 is a diagram showing a pyramidal surface slab
representing a second embodiment;
[0027] FIG. 10 is a diagram representing how to configure a space
truss structure surface slab assembly according to a third
embodiment;
[0028] FIG. 11 is a diagram representing details of the partial
view of FIG. 8;
[0029] FIG. 12 is a diagram showing a two-piece set of pyramidal
surface slabs prior to assembly;
[0030] FIG. 13 is a diagram showing the assembly according to the
third embodiment;
[0031] FIG. 14 is a diagrammatic cross sectional view of a
pyramidal surface slab already formed;
[0032] FIG. 15 is a diagrammatic cross sectional view of a space
truss structure surface slab assembly;
[0033] FIG. 16 is a diagram showing an alternative arrangement to
that of FIG. 12;
[0034] FIG. 17 is a diagram showing an alternative arrangement to
that of FIG. 13;
[0035] FIG. 18 is a diagram showing an alternative arrangement to
that of FIG. 14;
[0036] FIG. 19 is a diagram showing an alternative arrangement to
that of FIG. 15;
[0037] FIG. 20 is a diagram representing the dynamic properties of
a space truss structure surface slab assembly;
[0038] FIG. 21 is a stress mechanism diagram;
[0039] FIG. 22(a) is a diagram showing a prior example, and FIG.
22(b) is a diagram which shows an example of the use of corrugated
cardboard;
[0040] FIG. 23 is a diagram showing an example of using the present
invention as the truck deck plate of a truck, and the roof and wall
body of a container car;
[0041] FIG. 24(a) is a diagram showing an example of application of
the present invention to an aircraft body and floor, and FIG. 24(b)
is a diagram which shows an example of application of the present
invention to a propeller;
[0042] FIG. 25(a) is a diagrammatic side view representing an prior
example, FIG. 25(b) a diagrammatic cross sectional view showing the
prior art example, and FIG. 25(c) is a diagram showing a deck and
bulkhead of a ship such as a tanker;
[0043] FIG. 26 is a diagram showing a floor slab and wall slab of a
building, such as a house;
[0044] FIG. 27 is a diagram showing an example of application of
the present invention to a glass wall slab and roof slab having a
great height;
[0045] FIGS. 28(a) and 28(b) are diagrams showing an example of
application of the present invention to a large-sized circular tank
of a pressure vessel, wherein FIG. 28(a) is a plane view, and FIG.
28(b) is a cross sectional view; and
[0046] FIG. 29(a) is a diagram showing a prior example of a ship
structure, and FIG. 29(b) is a diagram which shows a space truss
structure surface slab hull structure in accordance with the
present invention.
EMBODIMENTS OF THE PRESENT INVENTION
Embodiment 1
[0047] A description of preferred embodiments will be provided with
reference to the drawings:
[0048] FIGS. 1 through 4 show a first embodiment of the present
invention.
[0049] FIG. 1 shows how to configure a space truss structure
surface slab assembly. FIG. 2 provides details of a partial view in
FIG. 1. FIG. 3 shows a two-piece set of pyramidal surface slabs
prior to assembling. FIG. 4 shows the assembly thereof as a first
embodiment.
[0050] In FIG. 1, two pyramidal surfaces 1 and 2 are used to
configure the space truss structure surface slab assembly.
[0051] Referring first to FIG. 2, the configuration of the
pyramidal surface slabs 1 and 2 will be described. Pyramidal
surface slabs 1 and 2 are fabricated from one of sheet material,
for example, a metal sheet formed through injection processing by a
stamping die. As will be described later, except for the metal
sheet, a non-metallic material such as corrugated cardboard,
lumber, plywood, plastics and glass can be used as a sheet
material.
[0052] As shown in FIG. 2, in the pyramidal surface slabs 1 and 2,
an apex rhombus 15 is delimited over the center point of a square
10 by plotting four nadir rhombuses 11, 12, 13 and 14. Accordingly,
the apex rhombus 15 is formed on a half pitch line. Each of the
nadir rhombuses 11, 12, 13 and 14 and apex rhombus 15 are jointed
to form a group of pyramidal surfaces represented as an assembly of
the pyramidal surface 20 having substantially the same height as
four planar quadrangular pyramids. Here the term "nadir rhombus" is
defined to include the edge line of the nadir and its surrounding,
and the term "apex rhombus" is defined to include the edge line of
the apex and its surrounding. The term "rhombic portion" refers to
the entire edge line. Using the pyramidal surface group as this
pyramid, the pyramidal surfaces 20a, 20b and 20c around one
pyramidal surface 20 share one of the nadir rhombuses, for example,
the nadir rhombus 11 as a common nadir rhombus, together with the
pyramidal surface 20c. To put it another way, the common point is a
point that is used in common. A set of pyramidal surface slabs 1
and 2 are shaped in a form arranged in a grid pattern adjacent to
each other. Further, pyramidal surfaces are arranged regularly in
the longitudinal and lateral directions at the same pitches P.sub.1
and P.sub.2. One pyramidal surface is surrounded by eight adjacent
pyramidal surfaces (four are in line contact, while the other four
are in point contact). In this case, it is surrounded by one in the
lateral direction on the paper surface, one in the vertical
direction and one each in the oblique diagonal line direction. One
pyramidal surface 20 has a square nadir and is surrounded as
described above. A nadir rhombus is formed in each square portion
at a position as a neighboring point of the four adjacent pyramidal
surfaces. This nadir rhombus is also a final point reached by the
external lines of the slopes 16, 17, 18 and 19 extending toward the
aforementioned square from the apex rhombus. Here the term
"rhombus" is used because four edge lines extend in four directions
from one point as the nadir, as shown in the drawing, and a rhombic
form is visually perceived.
[0053] The apex rhombus is formed like a spearhead providing a
sharp-edged angle. If this portion is made flat, the space truss to
be described later cannot be formed. As will be described later,
this sharp-edged portion is used for welding or bonding. The height
of the pyramidal surface can be set in accordance with the purpose
of use.
[0054] A row of pyramidal surfaces formed on a set of pyramidal
surface slabs 1 and 2 by processing and molding are arranged at an
equal pitch in a grid pattern in a specific direction--in this
case, two directions, namely, lateral and vertical directions (or
two directions of oblique line)--in the present embodiment. Thus,
the rows of the apex rhombuses and nadir rhombuses are also
arranged at an equal pitch in a grid pattern in the lateral
direction and vertical direction.
[0055] Two sets of pyramidal surface slabs 1 and 2 formed in this
manner are arranged opposite to each other, as shown in FIG. 1, and
the rows of pyramidal surfaces are displaced a half pitch and they
are jointed. Thus, the apex rhombus of each pyramidal surface comes
in contact with the nadir rhombus of the other pyramidal surface,
and the apex rhombus of the other pyramidal surface is brought into
contact with the nadir rhombus of the counterpart so as to be
overlapped one on top of the other.
[0056] In the manner described above, they are arranged in an
opposed form and are moved in the arrow marked direction so that
they are placed one on top of the other. Referring to FIG. 1, the
aforementioned procedure of overlapping will be described.
[0057] In FIG. 1, two sets of pyramidal surface slabs 1 and 2 are
used to configure an assembly. The lower pyramidal surface slab 1
faces upward and the pyramidal surface 20 is protruded upwardly
(convex). The upper pyramidal surface slab 2 faces downward and the
pyramidal surface 20A (having the same configuration as the
pyramidal surface 20, represented with "A" suffixed thereto) is
protruded downwardly (concave). In this arrangement, the apex
rhombus of one of the pyramidal surfaces comes in contact with the
nadir rhombus of the other pyramidal surface in the form opposite
thereto, and the nadir rhombus comes in contact with the apex
rhombus in the form opposite thereto. Viewed from the other
pyramidal surface, the apex of the other pyramidal surface comes in
contact with the nadir rhombus of the counterpart pyramidal
surface, and the nadir rhombus comes in contact with the apex
rhombus opposite thereto. Overlapping is effected in the
aforementioned manner.
[0058] In the case of overlapping them, two sets of pyramidal
surface slabs 1 and 2, each equipped with pyramidal surfaces 20 and
20A, appear to be engaged with each other. In this way, two sets of
pyramidal surface slabs 1 and 2 are overlapped. The apex rhombus
and nadir rhombus as engaged concave and convex points are assumed
as forming a one-point contact point, and all overlapped apex
rhombuses and nadir rhombuses are used as intersections, whereby
jointing is carried out by bonding or welding.
[0059] Whether bonding or welding is used can be determined in
conformity with the material of the pyramidal surface slabs 1 and
2. The edge line of two overlapped rhombuses is jointed by
intermittent bonding or continuous welding, as required.
[0060] FIG. 3 shows that the pyramidal surface slabs as
continuously molded plates of planar quadrangular pyramids having
the same shape are overlapped and jointed, with two rhombic
portions placed opposite to each other, so that a space truss
structure surface slab assembly will be formed. The two sets of
pyramidal surface slabs 1 and 2 serve as panel core materials. As
described above, the pyramidal surface slabs 1 and 2 are each
displaced by a half pitch (P.sub.1 and P.sub.2) and are placed
opposite to each other. This arrangement allows the apex rhombus 15
of the pyramidal surface slab 1 to be placed opposite to the nadir
rhombus 12' of the other pyramidal surface slab 2. The apex rhombus
15' of the other pyramidal surface slab 2 is placed opposite to the
nadir rhombus 13 of the counterpart pyramidal surface slab 1. The
slope 18 is placed opposite to the space formed between the
counterpart pyramidal surfaces. This is applicable as well to the
case of the slope 18'. The slopes 18 and 18' are formed by a sheet.
Thus, their back is formed as a grooved space. In the present
embodiment, P.sub.1.dbd.P.sub.2.
[0061] In FIG. 3, one set consists of two pyramidal surface slabs,
which are overlapped in mutually opposite positions. Each apex and
the nadir overlapped relative thereto are jointed by bonding or
welding. The rhombic portions as edge lines of the overlapped seam
are jointed continuously or intermittently by bonding or welding,
as required. However, jointing of the rhombus is not mandatory.
[0062] When a set of two pyramidal surface slabs are used for
jointing, a grid pattern jointed to the pyramidal surface slabs of
the upper and lower chords can be obtained. This linear grid plays
an important role for the space truss structure surface slab
assembly.
[0063] As shown in FIG. 4, finish layers 31 and 32 (surface slab or
reinforcing flat plate) can each be laminated on the pyramidal
surface slabs 1 and 2 of the upper and lower chords. To put it
another way, the space truss structure surface slab assembly 100
formed as a core member is sandwiched between the finish layers 31
and 32.
[0064] FIGS. 5 and 6 illustrate an alternative to the examples
shown in FIGS. 3 and 4. In the examples shown in FIGS. 3 and 4, the
apex rhombus of one pyramidal surface and the nadir rhombus of the
other pyramidal surface disposed opposite thereto are integrally
jointed by bonding or welding, whereby a space truss structure
surface slab assembly is formed. In the example of the variation
shown in FIG. 5, the apex rhombus of one pyramidal surface slab and
the apex rhombus of the other pyramidal surface slab located
opposite thereto are integrally jointed by welding, whereby a space
truss structure surface slab assembly is formed, as seen in FIG.
6.
Embodiment 2
[0065] FIGS. 7 through 9 show a second embodiment of the present
invention. FIG. 7 shows the details of the pyramidal surface;
while, FIGS. 8 and 9 show how to assemble a two-piece set of the
pyramidal surface slabs used in the present embodiment.
[0066] To configure a space truss structure surface slab assembly,
two pyramidal surface slabs 101 and 102 are used in a manner
similar to that shown in FIG. 1. Referring to FIG. 7, the
configuration of the pyramidal surface slabs 101 and 102 will be
described. The pyramidal surface slabs 101 and 102 are produced
from one plate-like material, for example, a metallic plate, by a
molding operation using a stamping die.
[0067] As shown in FIG. 7, the pyramidal surface slabs 101 and 102
are delimited by plotting three nadir rhombuses 111, 112 and 113.
An apex rhombus 115 is delimited above the center point of a
triangle 110, and each of the nadir rhombuses 111, 112 and 113 and
the apex rhombus 115 are plotted to form a group of pyramidal
surfaces provided as an assembly of the pyramidal surface 120
equipped with three planar slopes 116, 117 and 118 and having
substantially the same height in a triangular pyramid. Using this
pyramidal surface group, the pyramidal surfaces 120a and 120b
around one pyramidal surface 120 share one of the nadir
rhombuses--for example, the nadir rhombus 111--as a common nadir
rhombus, with the pyramidal surface 120.
[0068] In the manner as stated above, one set of pyramidal surface
slabs 101 and 102 is arranged at an equal pitch in a grid pattern.
Further, the pyramidal surfaces are regularly arranged in two
oblique directions and a lateral direction (direction can be
changed by turning the paper surface) at the same pitch widths
P.sub.3 and P.sub.4. One pyramidal surface is surrounded by six
adjacent pyramidal surfaces in a manner somewhat different from
that in the first embodiment. One pyramidal surface is surrounded
by two adjacent pyramidal surfaces upwardly, two adjacent pyramidal
surfaces laterally, and two adjacent pyramidal surfaces downwardly
through the planar triangles 141, 142 and 143 formed around it. One
pyramidal surface has a triangular bottom and is surrounded in the
above-stated manner. The nadir rhombus is formed at a triangular
corner as an adjacent point of the three adjacent pyramidal
surfaces. This nadir rhombus is also a final point reached by the
external lines of the planar slopes 116, 117 and 118 extending from
the apex rhombus toward the aforementioned triangle.
[0069] The apex rhombus is formed in a spearhead shape providing a
sharp corner. The rows of the pyramidal surfaces, which are formed
on the pyramidal surface slabs 101 and 102 by molding, are arranged
at an equal pitch in a grid pattern in a specific direction--in
this case, three directions, namely, two oblique directions and one
lateral direction--in the present embodiment. Thus, the rows of the
apex rhombuses and nadir rhombuses are also arranged at an equal
pitch in a grid pattern in two oblique directions and one lateral
direction. The pyramidal surface slabs 101 and 102 formed in this
manner are arranged opposite to each other, and the rows of the
pyramidal surfaces are displaced by a half pitch and they are
jointed. Thus, the apex rhombus of each pyramidal surface comes in
contact with a nadir rhombus of the other pyramidal surface, and
the apex rhombus of the other pyramidal surface is brought into
contact with a nadir rhombus of the counterpart, so that they are
overlapped one on top of the other.
[0070] FIG. 7 shows that the pyramidal surface slabs, provided as
continuously molded plates of thin-sheet planar triangular pyramids
having the same shape, are overlapped and jointed, with two rhombic
portions placed opposite to each other, so that a space truss
structure surface slab assembly will be formed. The two sets of
pyramidal surface slabs 101 and 102 serve as panel core
materials.
[0071] As described above, the pyramidal surface slabs 101 and 102
are each displaced by a half pitch (P.sub.3 and P.sub.4) and are
placed opposite to each other. This arrangement allows the apex
rhombus 115 of the pyramidal surface slab 101 to be placed opposite
to the nadir rhombus 112' of the other pyramidal surface slab 112.
The apex rhombus 115' of the other pyramidal surface slab 102 is
placed opposite to the nadir rhombus 113' of the counterpart
pyramidal surface slab 100. In this manner, they are arranged in
mutually opposite sides and are placed one on top of the other, in
the same manner as demonstrated in FIG. 1.
[0072] In FIG. 8, one set consists of two pyramidal surface slabs,
which are overlapped in mutually opposite positions. Each apex and
the nadir overlapped thereto are jointed by bonding or welding. The
rhombic portions as edge lines of the overlapped seam are jointed
either continuously or intermittently by either bonding or welding,
as required. However, jointing of the rhombus is not mandatory.
[0073] When a set of two pyramidal surface slabs are used for
jointing, a grid pattern jointed to the pyramidal surface slabs of
the upper and lower chords can be obtained. This linear grid plays
an important role for the space truss structure surface slab
assembly.
[0074] As shown in FIG. 9, the finish layers 131 and 132 can each
be disposed so as to sandwich the pyramidal surface slabs 101 and
102 of the upper and lower chords therebetween.
[0075] In the two preceding embodiments, a pyramidal surface slab
provided as a square or triangular pyramidal surface has been
described. It is also possible to use a polygonal form, such as a
pentagonal or other form.
[0076] The illustrated examples also may be formed to include the
variation shown in FIG. 6.
Embodiment 3
[0077] FIG. 10 shows an example of a third embodiment in which a
pyramidal surface slab containing a hexagonal pyramidal surface is
employed. FIGS. 10 through 13 show the details of the third
embodiment. FIG. 10 shows how to configure a space truss structure
surface slab assembly, and FIG. 11 shows details thereof in a
partial view of FIG. 10. FIG. 12 and FIG. 13 show how to assemble a
two-piece set of pyramidal surface slabs used in the present
embodiment.
[0078] In FIG. 10, two sets of pyramidal surface slabs 1 and 2 are
used to configure a space truss structure surface slab
assembly.
[0079] Referring to FIG. 11, the configuration of the pyramidal
surface slabs 1 and 2 will be described. The pyramidal surface
slabs 1 and 2 are produced from one plate-formed material--for
example, sheet metal--by a molding operation using a stamping die.
As shown in FIG. 11, an apex rhombus 47 is delimited over the
center point of a hexagon 40 that is delimited by plotting six
nadir rhombuses 41, 42, 43, 44, 45 and 46. Accordingly, the apex
rhombus 47 is formed on a half pitch line.
[0080] Each of the nadir rhombuses 41, 42, 43, 44, 45 and 46 and
the apex rhombus 47 are jointed to form a group of pyramidal
surfaces as an assembly of the pyramidal surface 50 having
substantially the same height as four planar hexagonal pyramids.
Using this pyramidal surface group, the pyramidal surfaces 50a, 50b
and 50c around one pyramidal surface 50 share one of the nadir
rhombuses--for example, the nadir rhombus 41--as a common nadir
rhombus, with the pyramidal surface 50. The common point is a point
used in common.
[0081] In the manner as stated above, one set of pyramidal surface
slabs 1 and 2 is formed so as to be arranged at an equal pitch in a
grid pattern. Further, the pyramidal surfaces are regularly
arranged in the longitudinal and lateral directions at the same
pitch width P.sub.6 in parallel. One pyramidal surface is
surrounded by six adjacent pyramidal surfaces. One pyramidal
surface 50 has a hexagonal bottom and is surrounded in the
above-stated manner. The nadir rhombus is formed at the hexagonal
corner as the adjacent point of six adjacent pyramidal surfaces.
This nadir rhombus is also a final point reached by the external
lines of the slopes 61, 62, 63, 64, 65 and 66 extending from the
apex rhombus toward the aforementioned hexagon.
[0082] The apex rhombus is formed in a spearhead shape providing a
sharp corner. If this portion is made flat, the space truss to be
described later cannot be formed. As will be described later, this
sharp-edged portion is used for welding or bonding. The height of
the pyramidal surface can be set in accordance with the purpose of
use.
[0083] A row of the pyramidal surfaces formed on the pyramidal
surface slabs 1 and 2 by molding are arranged at an equal pitch in
a grid pattern in a specific direction--in this case, two
directions, namely, lateral and vertical (or two directions of
oblique lines) directions--in the present embodiment. Thus, the
rows of the apex rhombuses and nadir rhombuses are also arranged at
an equal pitch in a grid pattern in the lateral direction and
vertical direction.
[0084] Two sets of pyramidal surface slabs 1 and 2 formed in this
manner are arranged opposite to each other, as shown in FIG. 10,
and the rows of the pyramidal surfaces are displaced by a half
pitch and they are jointed. Thus, the apex rhombus of each
pyramidal surface comes in contact with a nadir rhombus of the
other pyramidal surface, and the apex rhombus of the other
pyramidal surface is brought into contact with a nadir rhombus of
the counterpart so that they are overlapped one on top of the
other.
[0085] In the manner described above, they are arranged in an
opposed form and are moved in the arrow marked direction so that
they are placed one on top of the other. Referring to FIG. 10, the
aforementioned procedure of overlapping will be described.
[0086] In FIG. 10, two sets of pyramidal surface slabs 1 and 2 are
used to configure an assembly. The lower pyramidal surface slab 1
faces upward and the pyramidal surface 50 is protruded upwardly
(convex). The upper pyramidal surface slab 2 faces downward and the
pyramidal surface 50A (having the same configuration as the
pyramidal surface 50, represented with "A" suffixed thereto) is
protruded downwardly (concave). In this arrangement, the apex
rhombus of one of the pyramidal surfaces comes in contact with the
nadir rhombus of another pyramidal surface in the form opposite
thereto, and the nadir rhombus comes in contact with an apex
rhombus in the form opposite thereto. Viewed from the other
pyramidal surface, the apex of the other pyramidal surface comes in
contact with the nadir rhombus of the counterpart pyramidal
surface, and the nadir rhombus comes in contact with the apex
rhombus opposite thereto. Overlapping is effected in this
manner.
[0087] In the case of overlapping between them, two sets of
pyramidal surface slabs 1 and 2, each equipped with pyramidal
surfaces 50 and 50A, appear to be engaged with each other. In this
way, two sets of pyramidal surface slabs 1 and 2 are overlapped.
The apex rhombus and nadir rhombus provided as engaged concave and
convex points, are assumed to form a one-point contact point, and
all overlapped apex rhombuses and nadir rhombuses are used as
intersections, whereby jointing is effected by bonding or
welding.
[0088] Whether bonding or welding is used can be determined in
conformity to the material of the pyramidal surface slabs 1 and 2.
The edge line of two overlapped rhombuses is jointed by
intermittent bonding or continuous welding, as required.
[0089] FIG. 12 shows that the thin-sheet pyramidal surface slabs
provided as continuously molded slabs of planar hexagonal pyramids
having the same shape are overlapped and jointed, with two rhombic
portions placed opposite to each other, so that the space truss
structure surface slab assembly will be formed. Two sets of
pyramidal surface slabs 1 and 2 serve as panel core materials. As
described above, the pyramidal surface slabs 1 and 2 are each
displaced by a half pitch P.sub.6 and are disposed opposite to each
other. This arrangement allows the apex rhombus 47 of the pyramidal
surface slab 1 to be located opposite to the nadir rhombus 47' of
the other pyramidal surface slab 2. The apex rhombus 47 of the
other pyramidal surface slab 2 is disposed opposite to the nadir
rhombus 41 of the counterpart pyramidal surface slab 1. This is
applicable to the case of the slope 61. The slopes 61 and 61' are
formed by a sheet. Thus, their back is formed as a grooved
space.
[0090] In FIG. 12, one set consists of two pyramidal surface slabs,
which are overlapped in mutually opposite positions. Each apex and
the nadir overlapped thereto are jointed by bonding or welding. The
rhombic portions provided as edge lines of the overlapped seam are
jointed continuously or intermittently by bonding or welding, as
required. However, jointing of the rhombus is not mandatory.
[0091] When a set of two pyramidal surface slabs are used for
jointing, a grid pattern jointed to the pyramidal surface slabs of
the upper and lower chords can be obtained. This linear grid plays
an important role for the space truss structure surface slab
assembly.
[0092] As shown in FIG. 13, the finish layers 131 and 132 (surface
slab or reinforcing flat plate) can each be laminated on the
pyramidal surface slabs 1 and 2 of the upper and lower chords. To
put it another way, the space truss structure surface slab assembly
100 formed as a core member is sandwiched between the finish layers
131 and 132.
[0093] Referring to FIGS. 14 and 15, the dynamic properties and
features of the space truss structure surface slab assembly
represented by the aforementioned embodiments will be
described.
[0094] FIG. 14 is a cross sectional view of pyramidal surface slabs
already formed, and FIG. 15 is a cross sectional view of a space
truss structure surface slab assembly 100 formed by jointing the
pyramidal surface slab of the upper plate with the pyramidal
surface slab of the lower plate.
[0095] The pyramidal surface slabs 1 and 2 provided as single units
already formed in FIG. 14 constitute the pyramidal surface slabs
used for assembling the space truss structure surface slab assembly
100. The pyramidal surface slabs are always used as a space truss
structure surface slab assembly by integrally jointing the
pyramidal surface slab 2 of the upper plate with the pyramidal
surface slab 1 of the lower plate.
[0096] As shown in FIG. 15, the contact points a.sub.3 and b.sub.3
that occur at the point b.sub.3 on the line of the chord member
b.sub.1 of the pyramidal surface slab 2 of the upper plate, and the
point a.sub.3 on the line of the chord member a.sub.1 of the
pyramidal surface slab 1 of the lower plate are bonded or welded to
form one integral body.
[0097] The surface b.sub.1 of the pyramidal surface slab of the
upper plate of the space truss structure surface slab assembly 100
in FIG. 15, constructed in the aforementioned manner, and the
surfaces a.sub.1 of the lower plate are made hollow in a concave
pyramidal form. The space truss structure surface slab assembly 100
constructed by jointing provides a structural slab characterized by
extremely high strength, and it can be used, without another
reinforcing flat plate being provided particularly on the outer
surfaces of the pyramidal surface slab of the upper plate and the
pyramidal surface slab of the lower plate.
[0098] A structural slab of still higher strength can be obtained
by providing another flat plate for reinforcement on the outer
surfaces of the pyramidal surface slab 2 of the upper plate and the
pyramidal surface slab 1 of the lower plate (FIGS. 4 and 9). These
structural slabs formed in multiple layers will provide a
multi-layered space truss structure surface slab assembly of still
higher strength as a panel core material.
[0099] FIGS. 16 through 19 provide alternatives to the arrangements
shown in FIGS. 12 through 15, respectively. In the example shown in
FIGS. 12 through 15, the apex rhombus of one pyramidal surface slab
is jointed with the nadir rhombus of the other pyramidal surface
slab placed opposite thereto, by bonding or welding, whereby a
space truss structure surface slab assembly in the form of an
integral body is constructed. In the variations shown in FIGS. 16
through 19, the apex rhombus of one pyramidal surface slab is
jointed with an apex rhombus of the other pyramidal surface slab
placed opposite thereto, by bonding or welding, whereby a space
truss structure surface slab assembly in the form of an integral
body is constructed.
[0100] The dynamic properties of the space truss structure surface
slab assembly will be described with reference to FIG. 20. The
points V.sub.1 and V.sub.2 shown in FIG. 20 represent support
points of the space truss structure surface slab (hereinafter
referred to as "structure surface slab"). The structure surface
slab is a uniform slab devoid of direction in strength as a
slab.
[0101] As shown in FIG. 20, when a load is applied on the upper
surface of the structure surface slab, the bending moment on the
point 0 at the center of the slab section is maximized. This
bending moment works as a compression on the upper surface side of
the structure surface slab, and as a tension on the lower surface
side, and both bending moments of the slab section are converted to
an axial force by the top chord b.sub.1 and lower chord
a.sub.1.
[0102] For the axial stress of each, compressive stress is reduced
from U.sub.1 to U.sub.2 on the upper surface side in the direction
of the support points V.sub.1 and V.sub.2. Likewise, on the lower
surface side, tension is reduced in the direction of support points
V.sub.1 and V.sub.2 from D.sub.1 to D.sub.2.
[0103] The stress of the diagonal member of the rhombus ab line in
FIG. 15 becomes a stress formed as a pair of compression and
tension stresses. Since it transmits the stress of the applied slab
load to the support points V.sub.1 and V.sub.2, the stress of the
diagonal member conversely is increased in the direction of the
support points V.sub.1 and V.sub.2 from C.sub.1 to C.sub.2. The
stress mechanism described so far is also applicable to the case of
a general space truss slab, such as a steel pipe. One of the big
differences from this structure surface slab can be described as
follows: In the case of a space truss slab in the form of a steel
pipe, the pipe is subjected to compressive buckling, with the
result that the strength is affected by the compressive buckling
and the dynamic efficiency is reduced. By contrast, in the case of
the structure surface slab, all members are formed as truss surface
members having a two-dimensional expansion, without the truss
member being made of wire. As this structure surface slab is shown
in FIG. 15, both the chord members a.sub.1 and b.sub.1 and the
diagonal member ab work as a V-shaped planar member, as shown in
FIG. 21; therefore, there is very little reduction in the strength
due to buckling as in the case of a pipe member, with the result
that this arrangement ensures a substantial improvement in the
strength and rigidity of the slab.
[0104] Thus, a saving of material resources and a significant cost
reduction will be achieved by the substantial improvement in
dynamic efficiency.
[0105] FIG. 21 shows the stress mechanism wherein both the chord
members a.sub.1 and b.sub.1 and the diagonal member ab are planar
and work as a member having dynamically equivalent effective widths
B.sub.1 and B.sub.2.
[0106] If both members work as V-shaped or inverted V-shaped
members having effective widths, the barycentric portion "0" of
each triangular surface in the figure is continuous to the V-shaped
and inverted V-shaped portions of these members in planar terms.
This arrangement provides a stress mechanism that is very effective
in protecting each member against buckling.
[0107] The following Tables 1-8 indicate the specifications for
producing the aforementioned pyramidal surface slab, using the
materials of <1> galvanized plate, <2> copper plate,
<3> calcium silicate board, <4> Gypsum board, <5>
synthetic resin, <6> plywood, <7> paper and pulp and
<8> glass. The specification items in these Tables are
described below. The Tables are followed by descriptions of
specific applications.
[0108] Galvanized sheet: Galvanized plate formed by zinc
plating
[0109] Galvanized steel plate: Galvanized plate of galvalium
[0110] Plate thickness: Plate thickness of material in use (mm)
[0111] Slab thickness: Space truss structure surface slab
production (mm)
[0112] Molding method: Truss surface slab molding method
[0113] Specific weight: Ratio of the total dead weight of finished
truss surface slab relative to slab thickness
[0114] Formwork: Formwork material for concrete
[0115] Scaffolding board: Temporary work sheet materials for the
construction site
[0116] Roof slab: Slab material to be installed between roof
beams
[0117] Floor slab: Floor slab material installed between building
floor beams
[0118] Pixel pitch: Size of the molded truss structure surface slab
elements (mm)
[0119] SS400 steel plate: Name of Japanese standards authorized for
the building structure
[0120] Single extrusion: Press molding method
[0121] Floor and wall slab: Slab material for building floor and
wall
[0122] Slab size: Size of the space truss structure surface slab
assembly product
[0123] Calcium silicate board: Building board materials by use of
calcium silicate
[0124] ALC plate: Building slab materials of aerated concrete
[0125] Gypsum board: Building board material wherein both surfaces
of the gypsum is wrapped in paper as a core material
[0126] Furnace molding: Sheet glass
[0127] The cement/pulp recycled paper refers to the semi-liquid raw
material obtained by a process wherein the main material made of
mere final recycled paper is subjected to pulp liquefaction and is
stirred after being mixed with cement and reinforcing fiber. This
is molded in the form of a plate to obtain a core plate for a Rnan
truss surface slab by use of completely pollution-free reinforced
non-combustible paper of excellent properties.
[0128] The resin/pulp/recycled paper refers to the war material
mixed with resin instead of cement.
TABLE-US-00001 TABLE 1 (1) Galvanized plate Core thickness
t/{square root over ( )}3 Filled Truss surface slab core Surface
plate By laser spot welding Dead Pixel with Specific Plate Molding
Plate Slab Slab size weight pitch rock gravity Slab type thickness
method Slab type thickness thickness Application m kg/m.sup.3 mm
wool .gamma. Galvanized 0.4 Continuous Galvanized 0.3 15 Formwork 1
.times. 1, 1 .times. 2, 11.0 19.1 x 0.73 sheet steel plate 20 1
.times. 3, 1 .times. 4 26.1 0.55 30 40.3 0.37 Galvanized 0.5
Continuous Galvanized 0.35 20 Scaffolding 0.4 .times. 2, 13.4 25.7
x 0.67 sheet steel plate 30 board 0.4 .times. 3, 39.8 0.45 0.4
.times. 4 Galvanized 0.6 Continuous Galvanized 0.5 30 Roof slab 1
.times. 3, 1 .times. 4, 17.3 39.1 .smallcircle. 0.58 sheet steel
plate 50 1 .times. 6, 1 .times. 8 67.3 0.35 Galvanized 0.8 Single
Galvanized 0.6 80 Floor slab 1 .times. 4, 1 .times. 6, 22.0 108.8
.smallcircle. 0.28 sheet 1.2 extrusion steel plate 0.8 100 1
.times. 8, 1 .times. 10 31.4 135.2 0.31 1.2 0.8 120 31.4 163.5 0.26
Application: Best suited for the substrate body slab of a solar
battery. Aluminum, titanium and stainless steel can also be used as
the surface plate. Usable as roof and body slabs for a container
car and rolling stock. Provides the roof and floor slabs of
extra-light weight and long size comparable to the ALC slab. Best
suited for condominium handrail wall. All slabs required to provide
incombustibility can be used for this product.
TABLE-US-00002 TABLE 2 (2) Copper plate Core thickness t/{square
root over ( )}3 Filled Truss surface slab core Surface plate By
laser welding Dead Pixel with Specific Plate Molding Plate Slab
Slab size weight pitch rock gravity Slab type thickness method Slab
type thickness thickness Application m kg/m.sup.3 mm wool .gamma.
SS400 1.6 Single SS400 steel 1.2 100 Floor and 1 .times. 3, 1
.times. 4, 44.0 132.8 .smallcircle. 0.44 steel extrusion plate wall
slabs 1 .times. 6, 1 .times. 8 plate SS400 2.3 Single SS400 steel
1.6 150 Floor and 1 .times. 4, 1 .times. 6, 61.7 200.1
.smallcircle. 0.41 steel extrusion plate wall slabs 1 .times. 8, 1
.times. 10 plate GSS400 3.2 Single GSS400 2.3 200 Floor and 1
.times. 4, 1 .times. 6, 86.4 265.9 .smallcircle. 0.43 steel
extrusions steel plate wall slabs 1 .times. 8, 1 .times. 10 plate
SS400 5.0 Single SS400 steel 3.2 250 Floor and 1 .times. 4, 1
.times. 6, 128.8 326.2 .smallcircle. 0.52 steel extrusion plate
wall 1 .times. 8, 1 .times. 10 plate slabsb GSS400 8.0 Single
GSS400 4.5 300 Floor and 1 .times. 6, 1 .times. 8, 196.4 385.4
.smallcircle. 0.65 steel extrusion steel plate wall slabs 1 .times.
10, 1 .times. 12 plate SS400 9.0 Single SS400 steel 6.0 500 Floor
and 1 .times. 6, 1 .times. 8, 235.6 660.7 .smallcircle. 0.47 steel
extrusion plate wall slabs 1 .times. 10, 1 .times. 12 plate
Application: Used in car body slab, bridge floor slab, slabs of
ship side wall, desk and bulkhead, massive oil tanker wall slab,
etc. Provides building materials as structures of new type floor
and wall slabs characterized by extra-light weight, high strength
and long size
TABLE-US-00003 TABLE 3 (3) Calcium silicate board Core thickness
t/{square root over ( )}3 Bonded by cement or its Filled Truss
surface slab core Surface plate related material Dead Pixel with
Specific Plate Molding Plate Slab Slab size weight pitch rock
gravity Slab type thickness method Slab type thickness thickness
Application m kg/m.sup.3 mm wool .gamma. Cement/ 6 Continuous
Calcium 6 50 Wall slab 1 .times. 3, 1 .times. 4, 20.3 19.8
.smallcircle. 0.41 pulp silicate 60 1 .times. 6, 1 .times. 8 33.9
0.34 recycled board paper Cement/ 10 Continuous Calcium 10 80 Floor
and 1 .times. 4, 1 .times. 6, 33.8 28.3 .smallcircle. 0.42 pulp
silicate 100 wall slabs 1 .times. 8, 1 .times. 10 56.6 0.34
recycled board 120 84.9 0.28 paper Cement/ 12 Continuous Calcium 12
150 Floor and 1 .times. 4, 1 .times. 6, 40.5 110.3 .smallcircle.
0.27 pulp silicate 200 wall slabs 1 .times. 8, 1 .times. 10 181.0
0.20 recycled board paper Application: Various new types of
building materials characterized by extra-light weight and long
size comparable to the ALC slab.
TABLE-US-00004 TABLE 4 (4) Gypsum board Core thickness 100% Bonded
by cement or its Filled Truss surface slab core Surface plate
related material Dead Pixel with Specific Plate Molding Plate Slab
Slab size weight pitch rock gravity Slab type thickness method Slab
type thickness thickness Application m kg/m.sup.3 mm wool .gamma.
Cement/ 10 Continuous Fiber- 15 100 Floor and 1 .times. 4, 1
.times. 6, 43.3 42.4 .smallcircle. 0.43 pulp filled 120 wall slabs
1 .times. 8, 1 .times. 10 70.7 0.36 recycled gypsum paper board
Cement/ 15 Continuous Fiber- 21 150 Floor and 1 .times. 4, 1
.times. 6, 62.7 67.9 .smallcircle. 0.42 pulp filled 200 wall slabs
1 .times. 8, 1 .times. 10 138.6 0.31 recycled gypsum paper board
Application: Various new types of building materials characterized
by extra-light weight and long size comparable to the ALC slab.
TABLE-US-00005 TABLE 5 (5) Polyester based plate Core thickness
Bonded by resin or its t/{square root over ( )}3 Truss surface slab
core Surface plate related material Dead Pixel Specific Plate
Molding Plate Slab Slab size weight pitch Color gravity Slab type
thickness method Slab type thickness thickness Application m
kg/m.sup.3 mm type .gamma. Polyester 3 Continuous Polyester 3 30
Roof and 1 .times. 3, 1 .times. 4, 8.4 17.0 Clear 0.28 based based
50 wall slabs 1 .times. 6, 1 .times. 8 45.3 0.17 plate plate 60
59.4 0.14 Polyester 9 Single Polyester 6 80 Roof and 1 .times. 4, 1
.times. 6, 21.0 45.3 Clear 0.26 based extrusion based 100 wall
slabs 1 .times. 8, 1 .times. 10 73.5 0.21 plate plate 120 101.8
0.18 Application: Provides a synthetic resin board as a full-scale
building material characterized by extra-light weight and long
size. Also provides roof and wall slabs without metallic frame.
Also provides roof and wall slabs with curved corner by integral
molding. Also provides a full-scale skylight when used with Wired
sheet glass.
TABLE-US-00006 TABLE 6 (6) Plywood Core thickness t/{square root
over ( )}3 Truss surface slab core Surface plate Bonded by woody
material Dead Pixel Specific Plate Molding Slab Plate Slab Slab
size weight pitch Color gravity Slab type thickness method type
thickness thickness Application m kg/m.sup.3 mm type .gamma.
Cement/pulp 3 Continuous Plywood 3 30 Furniture 1 .times. 2, 1
.times. 3, 9.5 17.0 x 0.32 recycled 40 deck and 1 .times. 4, 1
.times. 6 31.1 0.24 paper frame plate Cement/pulp 4 Continuous
Plywood 3 30 Formwork and 1 .times. 2, 1 .times. 3, 11.6 11.3 x
0.39 recycled 40 scaffolding 1 .times. 4, 1 .times. 6 25.5 0.29
paper 50 board 39.6 0.23 Cement/pulp 10 Single Plywood 6 80 Roof,
floor 1 .times. 3, 1 .times. 4, 27.4 39.6 .smallcircle. 0.34
recycled extrusion 100 and wall 1 .times. 6, 1 .times. 8 67.9 0.27
paper 120 slabs 96.2 0.23 Cement/pulp 18 Single Plywood 9 150 Floor
and 1 .times. 4, 1 .times. 6, 47.3 84.9 .smallcircle. 0.32 recycled
extrusion 12 200 wall slabs 1 .times. 8, 1 .times. 10 50.6 147.1
0.25 paper 12 250 50.6 217.8 0.20 Cement/pulp 30 Single Plywood 15
300 Floor slab 1 .times. 4, 1 .times. 6, 78.9 212.1 .smallcircle.
0.26 recycled extrusion 18 400 eliminating 1 .times. 8, 1 .times.
10 82.2 345.1 0.21 paper 21 500 the need of 85.5 478.0 0.17 using a
beam Application: Provides plywood building materials of extra low
weight, furniture board and formwork, and the floor and wall slabs
of long size at a reduced price.
TABLE-US-00007 TABLE 7 (7) Paper/pulp Truss surface slab core
Surface plate Bonded for paper ware Dead Pixel Core thickness Plate
Molding Plate Slab Slab size weight pitch t/{square root over ( )}3
Slab type thickness method Slab type thickness thickness
Application m kg/m.sup.3 mm Remarks Corrugated 0.3 Continuous
Corrugated 0.3 5 Reinforced 1 .times. 1, 1 .times. 2, 0.6 1.70
High-strength cardboard cardboard 6 corrugated 1 .times. 3, 1
.times. 4 4.53 corrugated (original) (original) cardboard 5.94
cardboard Resin- 0.5 Continuous Resin- 0.5 10 Paper ware 1 .times.
1, 1 .times. 2, 1.4 9.9 High-strength impregnated impregnat- 15
board and 1 .times. 3, 1 .times. 4 17.0 paper board paper ed paper
20 formwork 24.0 Resin- 1.5 Continuous Resin- 1.0 50 Building 1
.times. 2, 1 .times. 3, 3.5 59.4 High-strength impregnated
impregnat- 60 material of 1 .times. 4, 1 .times. 6, 73.5 paper
board paper ed paper 100 slab product 1 .times. 8 130.1
Application: Provides a corrugated cardboard characterized by a
stunning strength comparable to the plywood. Provides full-scale
paper products as various types of building material slabs.
TABLE-US-00008 TABLE 8 (8) Glass Core thickness t/{square root over
( )}3 Truss surface slab core Surface plate Bonded by sealant Dead
Pixel Specific Plate Molding Plate Slab Slab size weight pitch
Color gravity Slab type thickness method Slab type thickness
thickness Application m kg/m.sup.3 mm type .gamma. Sheet 10 Furnace
Wired 6.8 100 Wall and 1 .times. 6, 1 .times. 8, 85.4 65.6
Transparent 0.85 glass molding sheet roof slabs 1 .times. 10 glass
Sheet 15 Furnace Wired 9 150 Wall and 1 .times. 8, 1 .times. 10,
121.8 101.8 Transparent 0.81 glass molding sheet roof slabs 1
.times. 12 glass Sheet 20 Furnace Wired 12 200 Wall and 1 .times.
10, 1 .times. 12, 162.4 135.8 Transparent 0.81 glass molding sheet
roof slabs 1 .times. 15 glass Sheet 25 Furnace Wired 15 250 Wall
and 1 .times. 12, 1 .times. 15, 203.0 169.7 Transparent 0.81 glass
molding sheet roof slabs 1 .times. 20 glass Application: Provides
wall and roof slabs of massive size from a sheet glass, without
using a metallic frame material. Also provides a floor slab for
pedestrians.
[0129] To improve efficiency in the industry, a great variety of
hollow structure slabs have been put into commercial use. To
produce a plate-formed hollow structure slab, the aforementioned
space truss structure surface slab assembly using a pyramidal
surface slab can be said to provide a structural mechanism that
ensures the maximum dynamic high efficiency at an unprecedented
level. This technique provides all sorts of industries with hollow
structure slabs, independently of the type--from small plates to
large plates. Since dynamic high efficiency directly leads to
economical advantages, all sorts of structure slabs are ensured by
unprecedented massive cost cutting and resource saving. Thus, the
progress and contribution of the space truss structure surface slab
according to the present invention can be said to be stunning
beyond comparison.
[0130] Referring to FIGS. 22(a) to 29(b), examples of the method of
use and characteristics for each application of the present
invention will be described.
[0131] The aforementioned space truss structure surface slabs can
be used in a great variety of hollow structure slabs in the
industry, independently of their type.
[0132] The structure surface slab can be used over a wide range
from small to large slabs for the pitch size in the truss pyramid
formation.
[0133] The specific method of use and characteristics of the
structure surface slab of the present invention will be described
in the ascending order of pitch size--from small to large pitches
of the pyramid surface slab.
[0134] Example of Use in Corrugated Cardboard
[0135] Corrugated cardboard is made of a paper roll bonded on both
sides of corrugated paper so that it is sandwiched between them, as
shown in FIG. 22 (a). Strength has directionality, and there is a
limit to the size of paper ware. When used in a massive box and
other large items, it is formed as a multi-layered structure in
some cases. It is not very strong--it is not suited to packing
heavy equipment in excess of 100 kg. When corrugated cardboard is
formed using the aforementioned space truss structure surface slab
construction, the pyramidal surface slab of the paper can be
continuously molded by a rotary type die. Accordingly, this is
processed as a two-piece set in a structure surface slab, and two
paper rolls are pressure-bonded to this from both sides. This can
be easily molded into a multi-layered form.
[0136] As shown in FIG. 22 (b), when the corrugated cardboard is
formed by a space truss structure surface slab construction, a
board without directionality in strength can be easily obtained. It
has a stunning strength. A desired massive package unachievable
with prior known technique can now be obtained by changing the
board thickness variously. The slab has strength comparable to
solid concrete panel plywood, and provides a package box capable of
packing hundreds of kilograms of heavy equipment.
[0137] The aforementioned pyramidal surface slab is formed as a
corrugated cardboard, and the aforementioned space truss structure
surface slab assembly is constructed wherein the aforementioned
apex rhombuses and nadir rhombuses are bonded.
[0138] Example of Use in Furniture Body Board and Step
[0139] When a furniture body board and step are fabricated with a
hollow slab, a wooden grid and honeycomb paper are used as core
material on a substrate, and finishing plywood and other materials
are bonded thereto from both surfaces, according to prior known
techniques. If this is fabricated using the space truss structure
surface slab as the core material, an unprecedented high-strength
board can be easily obtained. Thus, board of a desired thickness
can be produced at a very low cost. For the board for furniture,
the core material formed of a small-pitch pyramidal surface slab
using paper impregnated with resin is sufficient. Thus, this is
used as a core material and both surfaces are finished with plywood
and other materials.
[0140] Due to a very light weight and tremendous strength, a board
having a massive size that has not been achieved so far can be
obtained at a low price. Further, the pyramid pitch of the
structure surface slab is much smaller than the previously used
wooden grid pitch, and the thickness of the finishing panel used on
both surfaces can be very small.
[0141] The aforementioned pyramidal surface slab provides a space
truss structure surface slab assembly constructed by a thin wooden
board or plywood.
[0142] An Example of Use in a Truck Deck Plate and a Container Car
Roof and a Wall Body
[0143] The truck deck plate and container car roof and wall body
used heretofore have been made of light metal plate that is molded
and other materials, with rib material inserted therein. As shown
in FIG. 23, on the other hand, a space truss structure surface slab
can be used in such a deck board, and to can be used to improve the
rigidity of a container car roof and wall by use of an integral
molding procedure. Especially, the roof and wall of the container
car is formed by changing the pitches of both the inner and outer
plates of the pyramidal surface slab, whereby the corners can be
molded into an integral unit, without using a rib. This provides a
roof and wall and body of extremely high rigidity. If a light metal
plate is used for finishing both the inside and outside, a smart
body free from any protrusions can be ensured. FIG. 23 is a cross
sectional view of the structure surface slab used in the roof, wall
and floor.
[0144] A space truss structure surface slab assembly is
constructed, wherein two types of space truss structure surface
slab assemblies, where the pitch of a pyramidal surface arranged in
a grid pattern is changed, are used in one structure.
[0145] An Example of an Aircraft Body and Floor
[0146] Heretofore, an aircraft body and floor have been finished by
assembling the hollow slabs where the rid material and honeycomb
paper of the grid are used as core materials, and by laminating a
light metal plate thereto both inside and outside. As shown in FIG.
24(a), on the other hand, a space truss structure surface slab can
be molded and processed in such a curved form, and this allows such
a body to be made into a highly rigid structure by integral molding
with the floor slab. FIG. 24(a) is a cross sectional view of the
space truss structure surface slab when used in the body and floor,
and FIG. 24 (b) is a cross sectional view of the space truss
structure surface slab when used in a propeller.
[0147] A space truss structure surface slab assembly is molded and
processed on a curved surface, using the aforementioned two
pyramidal surfaces.
[0148] Example of Use in the Deck and Bulkhead of a Tanker and
Other Type of Ship
[0149] Heretofore, to fabricate the deck and bulkhead of a tanker
and other ships, the rib materials have been arranged in a grid
pattern using section steel, and the steel plate is welded on both
surfaces, as shown in FIGS. 25(a) and 25(b). In this case, if the
grid pattern of the rib material has a coarse pitch, the area of
the steel plate of one block is increased, thereby increasing the
thickness of the steel plate laminated on both surfaces.
Conversely, if the grid pattern has a fine pitch, the area of the
steel plate of one block is decreased. However, this leads to an
increase in the number of rib members to be used and in the amount
of the steel material to be used. In designing a structure
according to this method, both the grid material and steel plate
are determined by the strength to bending stress. This method is
characterized by very low dynamic efficiency and poor
profitability. The construction work is basically labor-intensive
work and provides almost no advantages of volume production.
[0150] If the aforementioned space truss structure surface slab
assembly is used in a ship's deck and bulkhead, as shown in FIG.
25(c), the advantages of volume production are introduced into the
process from steel plate to pyramidal surface using a large-sized
press. Since the space truss structure surface slab using steel
plate provides for a highly efficient production of slabs of very
high strength, excellent effects can be obtained. The pitch of the
pyramidal surface slab is much smaller than that of the rib
material of a grid pattern, so that the thickness of the plates to
be attached to both surfaces can be very small, with the result
that a substantial cost cutdown and a saving of resources, as well
as a dynamic characteristic of high efficiency, can be
achieved.
[0151] As the aforementioned pyramidal surface slab, a space truss
structure surface slab assembly is produced by pressing the steel
plate.
[0152] Example of Use in Floor and Wall Slabs of a Building
[0153] Except for a reinforced concrete structure, all the floors
and walls of buildings, such as apartment houses, for example, have
use of a pillar and beam. The floors and walls are handled as
finishing materials and do not constitute a structure in such
buildings. The space truss structure surface slab assembly shown in
FIG. 26 can be completely used, without a pillar or beam, as the
main structure of the wooden and steel frame structures of a
building, other than a reinforced concrete structure. FIG. 26 is a
cross sectional view representing the space truss structure surface
slab used as a structure. The desired thickness and size of the
structure surface slab can be obtained by changing the pitch of the
pyramid mold. Further, a slab having a very high degree of strength
and resistance can be easily produced. This has the advantage of
providing a structure consisting of a structure surface slab alone
without the previously required pillar and beam. Another advantage
gained therefrom is that the member of the pyramidal surface slab
used as the building material for such a slab can be molded at a
very low cost.
[0154] If waste paper currently assumed as waste that cannot be
recycled, it can be recycled can be used to form the pyramidal
surface slab of the core material. The final waste paper is
re-decomposed and is covered with cement. This is subjected to
continuous molding, such as rotary type molding. This arrangement
permits easy fabrication of the member of the pyramidal surface
slab of the space truss structure surface slab. This is combined,
and a sheet building material, such as calcium silicate, is
laminated on both surfaces. Then, a structure surface slab serving
as a slab building material can be created. The recycled paper
covered with cement is non-flammable, and the structure surface
slab made thereof represents the introduction of a very economical,
highly value-added building material that has never appeared so
far. It is anticipated that its use will cause the concept of a
building to undergo a radical change.
[0155] A sheet building material, such as a calcium silicate board,
is used as a flat plate, and a space truss structure surface slab
assembly to be laminated on both surfaces is produced.
[0156] An Example of Use in a Glass Wall and Roof Slabs of Massive
Height
[0157] A glass-walled building of endlessly increased size has come
to be designed in recent years. However, there is no way of
designing a 30-meter high glass walled building, without using any
metallic frame members. However, this object can be achieved if the
aforementioned space truss structure surface slab assembly is made
of glass. FIG. 21 is a cross sectional view of a structure surface
slab made of glass.
[0158] The structure surface slab made of glass is manufactured as
follows: A mold for the pyramidal surface slab having the pitch and
height required for molding is placed in a horizontal position and
a glass plate is placed thereon. When it has been heated to a
required temperature in a high-temperature furnace, the glass plate
is turned into a half-molten state (like starch syrup), and comes
into close contact with the surface of the mold, whereby the
aforementioned pyramidal surface slab is formed. This plate is
taken out of the furnace, and a hardened pyramidal surface slab is
obtained. Two pyramidal surface slabs are assumed to form one set,
and the substrate for the space truss structure surface slab is
processed. The glass plate is laminated on both surfaces in a
staggered arrangement, thereby obtaining a space truss structure
surface slab made of glass.
[0159] For a structure surface slab made of glass plate, the roof
corner can theoretically be molded at the same time, as shown in
FIG. 27, and molding of the corner on a curved surface is also
possible. This arrangement is anticipated to provide a heretofore
unimaginable massive glass wall having a high degree of
strength.
[0160] The aforementioned procedure provides a space truss
structure surface slab assembly wherein the pyramidal surface slab
is fabricated as a glass-made slab.
[0161] Example of Use in a Large Circular Tank of a Pressure
Vessel
[0162] A huge circular tank is typically used to store petroleum.
The circular tank is normally made of a steel plate laminated on
the top surface of a reinforced concrete floor slab. Most of the
walls are constructed similar to cover-less pails formed by welding
solid steel plate. Since the design is mostly determined by the
bending stress, the economic efficiency is very low.
[0163] A massive tank of this type is characterized by a huge
bending stress. To withstand this stress, the maximum thickness of
the plate to be used ranges from 20 through 50 mm, and its dead
weight is very large.
[0164] FIGS. 28(a) and 28(b) are plan views of a circular tank
using a space truss structure surface slab characterized by high
efficiency, extra-light weight and high strength.
[0165] Features of a Large-Sized Tank Using a Structure Surface
Slab
[0166] 1) The thickness of the steel plate used is very small due
to dynamically high efficiency, with the result that an extra-light
weight tank can be obtained.
[0167] 2) As a result, the amount of the steel used is reduced to
less than a half.
[0168] 3) This arrangement easily provides an extra-large tank that
cannot possibly be manufactured using previously known methods.
[0169] 4) A tank characterized by greater rigidity and holding
strength than those provided heretofore can be produced.
[0170] 5) A substantial cost cutdown is achieved as compared with
prior constructions.
[0171] 6) If the pyramidal surface slab has a greater thickness,
the pyramidal surface slabs separately pressed and molded are
assembled and can be fabricated by field welding, together with the
steel plates laminated on both surfaces.
[0172] 7) A wall slab of variable cross section can be easily
obtained wherein the upper slab of the tank wall is thinner, and
the lower slab exposed to a very great stress is thicker, as
required.
[0173] Example of Use as a Ship Hull Structure
[0174] The conventional ship hull structure is basically as shown
in FIG. 29(a). That is, the frame material is raised from the ship
bottom in a curved shape, and a deck beam is jointed thereto to
ensure a rigid hull structure. The direction of the deck beam
orthogonal to the frame material is determined in such a way that
an orthogonal beam for lateral stiffening is provided, and it is
jointed integrally with the frame material to withstand the
expected water pressure, if there is a floor beam at the
intermediate position, similarly to the case of the deck beam. For
the lengthwise direction of the ship, the orthogonal beams arranged
on the deck and ship bottom play an important role to withstand the
wave pressure applied from the longitudinal direction.
[0175] The space truss structure surface slab shown in FIG. 29(b)
can be used entirely if the hull can be welded as an integral
structure. An FRP material, iron material, aluminum material, etc.
are ideal materials for the hull structure.
[0176] Features when the hull structure is designed using a
structure surface slab
[0177] 1) The thickness of the plate of the material used is very
small due to a dynamically high efficiency, with the result that an
extra-light weight hull can be obtained.
[0178] 2) As a result, the amount of the FRP material and steel
used is substantially reduced.
[0179] 3) The structure surface slab is hollow without exception.
Thus, if the slab thickness is correctly determined in the design,
the specific weight of the slab is reduced, with the result that
the ship does not sink even if the interior of the ship is
submerged.
[0180] 4) A steel-made ship does not sink even if submerged.
[0181] 5) The hull slab, side plate slab, floor beam slab and deck
slab can be formed into integral structures characterized by
extra-light weight and high strength, without requiring use of a
frame material or rib material, such as an orthogonal beam.
[0182] 6) Whereas almost all of the previously used shipbuilding
work is labor-intensive work, the major slabs in the structure
surface slab production process are based on a volume production
method of press molding, with the result that the productivity is
much improved.
[0183] 7) If the pyramidal surface slab has a greater thickness,
the pyramidal surface slabs separately pressed and molded are
assembled and can be fabricated by field welding, together with the
steel plates laminated on both surfaces.
[0184] 8) The slab thickness for various sections of the hull can
be changed as required, so that the slab thickness of the variable
cross section can be designed as desired.
[0185] Further, if required, two or three space truss structure
surface slabs can be designed. The space truss structure surface
slab assembly of the present invention is applicable to all of the
following cases:
[0186] 1) A corrugated cardboard box having a massive strength for
packing heavy equipment in excess of 100 kg.
[0187] A 2-meter-by-4-meter large-sized plywood sheet characterized
by massive holding capacity, extra-light weight and low cost.
[0188] A 2-meter-by-5-meter large-sized table characterized by two
legs on both ends, extra-light weight and low cost.
[0189] A non-concrete floor building material of extra-light weight
that can be supported at intervals of 3 through 5 meters.
[0190] A 2-meter-by-4-meter large-sized plywood mold and steel
plate formwork characterized by extra-light weight and low
cost.
[0191] 2) A 30-meter high large-sized glass wall without metallic
reinforcement.
[0192] A 2-meter-by-6-meter roof slab and wall slabs formed by an
acryl resin slab
[0193] 3) A truck and rolling stock having an integrated floor,
wall and roof structure characterized by extra-light weight and
high rigidity
[0194] 4) A steel ship and FRP ship structure, without a frame,
that do not sink even when submerged
[0195] A structural building, such as an apartment house having an
integrated floor, wall and roof structure characterized by
extra-light weight and seismic resistance
[0196] 5) Very economical construction of a gigantic tank having a
diameter of 100 meters or more and a height of 50 meters or
more.
* * * * *