U.S. patent number 3,849,237 [Application Number 05/132,390] was granted by the patent office on 1974-11-19 for structural member of sheet material.
Invention is credited to Lev Zetlin.
United States Patent |
3,849,237 |
Zetlin |
November 19, 1974 |
STRUCTURAL MEMBER OF SHEET MATERIAL
Abstract
A structural member entirely formed of sheet material suitably
connected together along surface portions thereof. The sheet
material is folded or otherwise formed into individual geometric
shapes bonded to one another along overlying surfaces thereof.
Inventors: |
Zetlin; Lev (Roslyn, NY) |
Family
ID: |
22453815 |
Appl.
No.: |
05/132,390 |
Filed: |
April 8, 1971 |
Current U.S.
Class: |
428/116; D25/144;
52/87; 52/789.1; 14/73; 428/178 |
Current CPC
Class: |
E04C
2/34 (20130101); E01D 1/00 (20130101); E01D
2101/34 (20130101); Y10T 428/24149 (20150115); E01D
2101/26 (20130101); E01D 2101/40 (20130101); Y10T
428/24661 (20150115); E01D 2101/00 (20130101) |
Current International
Class: |
E01D
1/00 (20060101); E04C 2/34 (20060101); B32b
003/12 (); E01d 019/12 () |
Field of
Search: |
;52/615,618,648,650,87
;161/68,69,119,127,131,133,134,136,159 ;156/197 ;94/13 ;14/6,73
;404/34-43 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
|
|
|
|
|
|
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129,793 |
|
Nov 1948 |
|
AU |
|
794,217 |
|
Apr 1958 |
|
GB |
|
Primary Examiner: Lesmes; George F.
Assistant Examiner: Epstein; Henry F.
Attorney, Agent or Firm: Sternberg, Esq.; Henry
Claims
Having thus described my invention, what I claim and desire to
protect by Letters Patent is:
1. A structural member comprising:
longitudinal web means of sheet material including a pair of
integrally connected, elongated first sheet sections relatively
inclined to one another and defining between themselves an
elongated channel;
a plurality of hollow shell elements of sheet material arranged in
side-by-side adjacency in and longitudinally distributed along said
elongated channel, each of said hollow shell elements having a
first pair of opposite side walls each of which comprising a second
sheet section generally parallel to and in substantially full
face-to-face contact with the respective one of said first sheet
sections and each of said hollow shell elements having a second
pair of opposed side walls intermediate of and generally transverse
to said first pair of side walls; and
means integrally connecting said hollow shell elements with said
longitudinal web means at said respective first and second sheet
sections thereof substantially along the full face-to-face contact
region therebetween so as to form said shell elements and said web
means into a composite integral structure.
2. The structural member according to claim 1 wherein said sheet
material is paper and said connecting means comprises adhesive
means for adhering the respective superposed surface portions to
each other.
3. The structural member according to claim 1, wherein said hollow
shell elements each have a second means integrally connecting one
of said intermediate side walls of one of said shell elements with
the adjacent intermediate side walls of the next adjacent one of
said shell elements in said channel.
4. A structural member according to claim 1 wherein said
longitudinal web means comprises an elongated substantially
rectangular sheet material folded along a substantially central
longitudinal fold line forming said pair of first sheet sections,
mutually inclined with respect to each other.
5. A structural element comprising:
a pleated sheet means having oppositely facing longitudinally
extending channels formed between the longitudinal fold lines
thereof, alternate ones of said fold lines forming the ridges and
the remaining ones thereof forming the troughs of said pleated
sheet means, respectively;
a plurality of pyramid-shaped hollow elements of sheet material
longitudinally distributed along and located in at least one pair
of adjacent ones of said oppositely facing channels, said hollow
elements having opposed wall portions thereof in face-to-face
contact with adjacent channel forming walls of said pleated sheet
means and said hollow elements in one of said pair of channels
having their bases located substantially in the plane defined by
said alternate fold lines, said hollow elements in said opposed one
of said pair of channels having their bases located substantially
in the plane defined by said remaining fold lines;
a plurality of transverse web means each including a pair of
integrally connecting mutually inclined sheet sections for
connecting, in each of said channels, adjacent ones of said hollow
pyramid-shaped elements, said hollow shell elements having
intermediate walls intermediate said opposed wall portions thereof
and said inclined sheet sections overlying portions of adjacent
ones of said intermediate walls of adjacent ones of said
pyramid-shaped elements; and
connecting means for connecting said overlying surfaces of said
transverse web means and said pyramid-shaped elements together and
for connecting together said pleated sheet means with the
corresponding overlying ones of said wall portions of the hollow
pyramid-shaped elements.
6. A structural member comprising:
longitudinal web means of sheet material including a pair of
longitudinally oriented, elongated, integrally connected, first
sheet sections each of said sheet sections having a surface portion
and said pair of surface portions being relatively inclined to one
another and defining between themselves an elongated channel:
a pair of adjacent hollow shell elements of sheet material
longitudinally distributed along and substantially in said
elongated channel, each of said hollow shell elements having a
first pair of opposite side walls, each of said side walls having a
surface portion and said pair of surface portions of said side
walls being relatively inclined to one another at substantialy the
same relative inclination as and in superposed relation,
respectively, with said surface portions of said first sheet
sections, and an intermediate second pair of opposed surface
portions, each of said first mentioned pair of surface portions of
said hollow shell elements being in substantially full face-to-face
contact with the respective surface portion of the longitudinal web
means which it overlies:
transverse web means of sheet material including a pair of
integrally connected second sheet sections located in said channel
and defining between themselves a second channel extending
transversely with respect to said first mentioned channel, one of
said second sheet sections being in superposed relation with one of
said second surface portions of one of said shell elements and the
other of said second sheet sections being in superposed relation
with the next adjacent one of said second surface portions of the
other of said shell elements; and
means integrally connecting said hollow shell elements with said
transverse web means and said longitudinal web means at said
respective superposed surface portions thereof, substantially along
the entire face-to-face region of contact therebetween, for forming
a composite integral structure exhibiting high load carrying
characteristics.
7. A structural member comprising:
longitudinal web means of sheet material including a pair of
integrally connected, elongated first sheet sections relatively
inclined to one another and defining between themselves an
elongated channel;
a plurality of hollow shell elements of sheet material arranged in
side-by-side adjacency in and longitudinally distributed along said
elongated channel, each of said hollow shell elements having a
first pair of opposite side walls each of which comprises a second
sheet section in superposed relation with and in substantially full
face-to-face contact with the respective one of said first sheet
sections and each of said hollow shell elements having a second
pair of opposed side walls intermediate of and generally transverse
to said first pair of side walls;
means integrally connecting said hollow shell elements with said
longitudinal web means at said respective superposed first and
second sheet sections thereof substantially along the full
face-to-face contact region there-between so as to form said shell
elements and said web means into a composite integral
structure;
second means integrally connecting one of said intermediate side
walls of one of said shell elements with the adjacent one of said
shell elements in said channel, said second means comprising
transverse web means including a pair of integrally connected
additional sheet sections located substantially in said channel and
defining between themselves a second channel extending transversely
with respect to said first mentioned channel, one of said
additional sheet sections being in superposed relation with said
one of said intermediate side walls of said one shell element and
the other of said additional sheet sections being in superposed
relation with the adjacent one of said intermediate side walls of
said adjacent one of said shell elements.
8. The structural member according to claim 7 wherein said hollow
shell elements and said longitudinal and transverse web means each
consists of a plurality of laminated sheets of paper.
9. The structural member according to claim 7 wherein said first
and second channels each have a V-shaped cross-section and each of
said hollow elements of sheet material is pyramid-shaped.
10. The structural member according to claim 9 wherein the apex
angle of said first V-shaped channel is substantially identical to
the apex angle formed by said first mentioned pair of opposite side
walls of said pyramid-shaped hollow elements whereby the latter may
be snugly nested therein.
11. The structural member according to claim 7 wherein each of said
first and second sheet sections and said hollow-shell elements
consists of laminated sheet material.
12. A structural member according to claim 7 wherein said
transverse web means comprises a diamond-shaped sheet of material
folded along the shorter diagonal thereof for forming said pair of
second sheet sections each having a triangular shape and inclined
with respect to each other.
13. A structural member comprising:
longitudinal web means of sheet material including a pair of
integrally connected, elongated, generally planar first sheet
sections relatively inclined to one another and defining between
themselves an elongated channel, each of said first sheet sections
having a first and a second longitudinal edge portion and all of
said edge portions being substantially parallel to each other with
adjacent ones of said first sheet sections being connected to one
another along said second edge portions thereof and said first edge
portions of said first sheet sections together defining a given
plane;
a plurality of hollow shell elements of sheet material arranged in
side-by-side adjacency in and longitudinally distributed along said
elongated channel, each of said hollow shell elements having a pair
of opposite side walls each of which comprises a second sheet
section in superposed relation with and in substantially full
face-to-face contact with the respective one of said first sheet
sections;
means integrally connecting said hollow shell elements with said
longitudinal web means at said respective superposed first and
second sheet sections thereof substantially along the full
face-to-face contact region therebetween so as to form said shell
elements and said web means into a composite integral structure,
each of said hollow shell elements having a second pair of opposed
side walls intermediate said first mentioned pair thereof, and
means integrally connecting, along a fold line substantially
located in said given plane, one of said intermediate side walls of
one of said shell elements with the adjacent intermediate side wall
of the next adjacent one of said shell elements in said
channel.
14. The structural member according to claim 13 wherein said
connected second sheet sections are respectively located on
opposite sides of and inclined with respect to a plane which is
normal to each of said pair of first sheet sections and which
includes said fold line.
15. The structural member according to claim 13 wherein said hollow
shell elements are pyramid-shaped, said hollow pyramid-shaped
elements being open at the bases thereof and being formed of a
folded flat sheet material, said pyramid-shaped hollow elements
being positioned in said first mentioned elongated channel with
said base portions thereof located generally in said given
plane.
16. The structural member according to claim 15 wherein said
connecting means comprises adhesive means for joining together said
hollow elements, said longitudinal web means, and said transverse
web means, at the corresponding overlying surface portions
thereof.
17. A structural member comprising:
longitudinal web means of sheet material including a pair of
integrally connected elongated first sheet sections relatively
inclined to one another and defining between themselves an
elongated channel;
a plurality of hollow, pyramid shaped, four sided shell elements of
sheet material arranged in side-by-side adjacency in and
longitudinally distributed along said elongated channel, each of
said hollow sheet elements having a first pair of opposed side
walls and a second pair of opposed side walls intermediate said
first pair, each of said first pair of side walls comprising a
second sheet section in superposed relation with and in
substantially full face-to-face contact with the respective one of
said first sheet sections;
means integrally connecting said hollow shell elements with said
longitudinal web means at said respective superposed first and
second sheet sections thereof substantially along the full
face-to-face contact region therebetween so as to form said shell
elements and said web means into a composite integral
structure;
each of said pyramid shaped hollow shell elements having base edge
portions forming an open rectangular base and adjacent transverse
ones of said base edge portions of adjacent ones of said shell
elements being in close proximity with one another;
and means integrally connecting one of said intermediate side walls
of one of said shell elements with the adjacent intermediate side
wall of the next adjacent one of said shell elements in said
channel.
18. The structural member according to claim 17 wherein said second
means comprises transverse web means having surface portions
overlying adjacent surface portions, respectively, of said
intermediate side walls of a pair of adjacent pyramid-shaped
elements whose adjacent transverse base edges are in close
proximity with one another.
Description
The present invention relates to structural members, particularly a
structural member which may be fabricated almost entirely of sheet
material and which is capable of supporting loads and resisting
stresses.
One object of the present invention is to provide a structure
comprised of one or more interconnected structural members of the
above type which is able to support loads while spanning the
relatively large distances required to be spanned by a bridge.
A further object of the present invention is to provide a
structural member of the type described above which may be formed
almost entirely of paper or similar sheet material.
A still further object of the present invention is to provide a
structural member of the above type which has a geometric
configuration suitable for imparting rigidity and strength to the
structures in which it is used.
Another object of the present invention is to provide a structural
member having the above characteristics and which also displays a
high strength to weight ratio.
A still further object of the present invention is to provide a
structural member such as described above which displays the
combined structural characteristics of a skeleton frame system and
those of a stressed-skin system.
Another object of the present invention is to provide a structural
member which, while possessing the above characteristics, may be
fabricated out of materials such as sheet metal, sheet plastics,
fiberous sheet materials, as for example, paper, or even a sheet
material comprised of a thin layer of concrete sprayed or otherwise
suitably formed on steel reinforcing mesh.
Another object of the present invention is to provide a structural
member, having the above characteristics, which is of modular
construction and whose modular elements may be mass-produced,
easily transported to, and readily assembled at, the site.
Still another object of the present invention is to provide a
lightweight, easily transportable, relatively inexpensive
structural member of the above type which is comprised
substantially entirely of mass-produceable modular elements of
sheet material.
A concomitant object of the present invention is to provide a
structural member having the characteristics described above and
which may be readily assembled with similar members to form a load
carrying structure such as a bridge.
In accordance with the present invention, a system of longitudinal
webs of sheet material and hollow shell elements of sheet material
are interconnected along overlying surfaces thereof for forming a
composite integral structure which displays the combined
characteristics of a truss and a stressed skin system.
More specifically, according to the preferred embodiment of the
invention there is provided a longitudinal web of sheet material
folded, along a longitudinal center-line thereof, into a V-shape.
Modular shell elements, also of sheet material and having the shape
of hollow pyramids, are longitudinally distributed along and nested
in the longitudinal web and bonded thereto along corresponding
overlying surfaces of the web and the shell elements. There results
a composite structure displaying the characteristics of a series of
interconnected triangular truss units providing the rigidity and
stability incident to such structural triangulation.
The foregoing objects and advantages of the invention will become
apparent from the following description of a preferred form and
certain alternate forms thereof and from the following
illustrations of those forms, in which:
FIG. 1 is a perspective, partially cut-away, view of a bridge
constructed in accordance with the preferred form of the present
invention;
FIG. 2 is a perspective view of the bridge of FIG. 1, showing the
internal construction at the underside thereof;
FIG. 3 is a transverse sectional view of the bridge taken along the
line 3--3 of FIG. 1, in the direction of the arrows;
FIG. 4 is an enlarged fragmentary longitudinal sectional view taken
along line 4--4 of FIG. 3, in the direction of the arrows;
FIG. 5 is an enlarged fragmentary longitudinal sectional view of
the bridge taken along line 5--5 of FIG. 3, in the direction of the
arrows;
FIG. 6 is an enlarged, perspective, partly sectional, partly
schematic view of groups of pyramidal elements arranged, in
accordance with the preferred embodiment of the present invention,
in the oppositely directed channels formed by a plurality of
longitudinal webs;
FIG. 7 is a schematic representation of the interfitting layers of
sheet material for forming the longitudinal web according to the
preferred embodiment of the invention;
FIG. 8 is an enlarged perspective view of a single pyramidal unit
according to the present invention;
FIG. 9 is an enlarged perspective, exploded, view of a pair of
sheet sections each folded into half-pyramid shape and together
forming an end closure for the opposite longitudinal ends of each
upright pyramid series;
FIG. 10 is an enlarged perspective view of an end closure member
for the opposite longitudinal ends of each series of inverted
pyramids;
FIG. 11 is an enlarged perspective view of a transverse web element
in accordance with the preferred embodiment of the present
invention;
FIG. 12 is a perspective view of a pyramid-closure member for
closing the open ends of the pyramidal members, according to one
embodiment of the invention;
FIG. 13 is a perspective, exploded, view of a portion of the
structure of FIGS. 1 and 2, showing the relationship between the
longitudinal webs, the upright and inverted pyramids, and the
end-closure members according to one embodiment of the present
invention;
FIG. 14 is a perspective view of the structure shown in FIG. 13,
showing, in addition thereto, in exploded form, the upright and
inverted transverse webs, the pyramid-closure members, and the
decking, according to one embodiment of the present invention;
FIG. 15 is an enlarged, fragmentary, longitudinal sectional, view
of a bridge built in accordance with the present invention, showing
the internal construction of the preferred form thereof; and
FIG. 16 is an enlarged, fragmentary, transverse sectional view of
the structure illustrated in FIG. 15.
According to the preferred construction a plurality of V-shaped
members interconnected side-by-side, in rank formation, form a flat
structure for use as a flooring, bridge, platform, pontoon, or the
like. A flat decking covering the top of the array of the
structural members, and secured thereto, serves as means for making
the overall composite structure even more rigid and, in the case of
a bridge, serves as a flat road-bed.
In its basic form, the present invention includes a substantially
V-shaped elongated longitudinal web member having at the interior
thereof a core consisting of a chain of hollow, preferably
pyramidallyshaped, shell members. A plurality of such V-shaped
longitudinal web members may be arranged compactly side-by-side to
form a unitary structure such as a flooring, bridge, platform, roof
or pontoon.
The pyramidal elements may be nested in the V-shaped longitudinal
member with the relatively large surface areas of a pair of opposed
walls of each of the pyramidal elements in superposed relation with
corresponding surface areas of the V-shaped member and said
superposed surface portions bonded to one another substantially
over the entire region of contact thereof. It will be noted that
not only do pyramidal elements display relatively large surface
areas for their volume, but according to the preferred form of the
invention, the entire surface area of the four triangular faces of
each pyramidal element is in a superposed relation with and bonded
to, other elements of the structure. Thus, a first pair of opposite
ones of the triangular faces of each pyramidal element overlie and
are bonded over substantially the entire surface thereof to
corresponding surface portions of the longitudinal web means while
the other pair of opposed triangular faces of each pyramidal
element are in overlying relation to and bonded over substantially
the entire surface area thereof to one of a pair of plane
triangular faces of a pair of transverse web means respectively. As
will be seen, pyramidally shaped closure elements also have
substantially their entire surface area in superposed relation with
and bonded to corresponding portions of the pyramidal elements, on
the one hand, and a deck member, on the other hand.
Referring now to the drawings, and initially to FIG. 1, there is
shown a bridge B comprising a longitudinal web means 10, a
plurality of pyramidal elements 20 and a decking 70. It will be
seen that the bridge B extends between a suitable pair of spaced
supports S.sub.1 and S.sub.2.
According to the present invention the entire structural member,
for example the bridge B, is formed of sheet material folded in a
prescribed manner and glued, or otherwise suitably bonded together,
along relatively large overlying surface portions thereof.
Preferably, the sheet material of which the structural system is
formed is paper or cardboard. The connections between the elements
forming the structural system of the invention are accomplished by
bonding together superposed, i.e., overlying surface areas of the
sheet material elements. Thus, the structural system according to
the present invention is comprised of a system of geometric folded
modules which are, according to the preferred embodiment, bonded
together at overlying surfaces thereof.
The structural system according to the present invention consists
of two basic elements. Each of these basic elements is fabricated
of sheet material, preferably a laminate of paper or cardboard such
as is commonly used in heavy duty packaging but other material such
as sheet metal, aluminum, plastics, sprayed concrete or mortar over
steel mesh is also suitable. The first element is a web 10 (FIG.
13) formed of a system of folded plates 11 developed by laminating
several longitudinally creased layers 12a, 12b, 12c, etc. (FIG. 7),
of paper, to each other. The longitudinal web means 10, thus
formed, includes at least one pair of integrally connected,
elongated, folded plates 11 having spaced surface portions 11a and
11b defining between themselves an elongated channel 13. In a
structural system such as the bridge B, for example, a plurality of
these folded elements 12 are transversely interlocked, as
illustrated in FIG. 7, so as to present a saw-tooth profile in a
transverse plane. The interlocked elements form the longitudinal
web means which extends longitudinally the length of the
bridge.
The second basic element is a hollow shell member of sheet
material, preferably in the form of a pyramid 20 (FIG. 8). A
plurality of these pyramidal elements 20 (inverted) and 20'
(upright) are positioned between the folded plates 11 on the top
and bottom of the first element 10 and nested in the respective
channels 13 and 13' formed by the first element. The pyramids 20,
20' are longitudinally distributed along and located in the various
elongated channels 13, 13', with each of the pyramids having a
first pair of opposite surface portions 21a, 21b in superposed
relation with the spaced surface portions 11a, 11b, respectively
forming the corresponding channel 13, 13'. The fold lines of the
longitudinal web means alternately form crests 14 and troughs 14'
which respectively lie in a pair of spaced parallel planes defining
the bounds of the structural system. The hollow shell pyramids 20
and 20' are open at their bases and are positioned in side-by-side
relationship in the corresponding elongated channels 13, 13', in
such a manner that preferably the bases of the pyramids 20 lie in
one, and the bases of the pyramids 20', in the other, of said
parallel planes. Thus, the pyramids 20 are located in upwardly
opening channels 13, while the pyramids 20' are located in
downwardly opening channels 13 and are inverted with respect to the
pyramids 20. Furthermore, the pyramids 20, 20' in a pair of
adjoining upwardly and downwardly opening channels 13, 13' are
preferably staggered (FIG. 6) with respect to each other, in such a
manner that the apices of the pyramids 20 will lie substantially in
the region of the line of contact between adjacent base edges of
adjacent pyramidal elements 20' located on the opposite side of the
plate element 11 separating the channels 13 and 13'. Thus, the apex
22' of an upright pyramid 20', in one of the channels 13', will
preferably be located in the region of the base edge line 23a of
the inverted pyramid 20 located adjacent thereto, in the next
adjoining channel 13, and so on for the remaining pyramid elements,
with the result that the inclined edges of the staggered inverted
and upright pyramids 20 and 20', in adjacent channels, are very
nearly co-linear and coact to resemble the chords of a truss.
While not here illustrated, it will be understood that pyramids 20
and 20', in adjacent channels 13 and 13', respectively, need not be
staggered with respect to each other, but could be positioned such
that the apex of each pyramid 20 will lie in the region of the
mid-point of base line 23' of the next adjacent upright pyramid 20'
on the opposite side of a plate element 11 therefrom.
The hollow-shell pyramidal elements 20, 20' are developed by
cutting out a suitable flat geometric shape of sheet material and
subsequently folding the latter along suitable fold lines 24 into
desired pyramidal shape (FIG. 8).
After being nested in the web element 10 the pyramids 20 are
preferably tied together with a third element, namely transverse
web means 30, shown in FIG. 11.
The transverse webs 30 are preferably in the form of diamond-shaped
sheets 31 folded along the short axes 32 thereof. As a result, each
member 31 includes a pair of integrally connected sheet sections 33
and 34, suitable for connecting together adjacent ones of the
pyramids 20 or 20', in the respective channel 13 or 13'. When
folded, the portions 33, 34 of the transverse web members define
between themselves second channels 35 extending transversely with
respect to the channels 13, 13' of the longitudinal web means. One
of the triangular sheet sections, e.g., 33, of the transverse web
member 30, is positioned in superposed relation with a second
surface portion 25b (FIG. 14) of one of a pair of longitudinally
adjacent pyramids 20a and the triangular sheet section 34 of the
transverse member 30 is positioned in superposed relation with the
adjacent one of the second surface portions 25a of longitudinally
adjacent pyramid 20b. Preferably, the aforesaid triangular sheet
sections 33, 34 of the transverse web member 30, will correspond
substantially to the shape of the second surface portions 25a, 25b
of the pyramids and will overly and be bonded to the corresponding
triangular second surface portions of such pyramidal elements,
respectively, for connecting together pairs of such pyramidal
elements in side-by-side relation. The transverse web members 30
cooperate with the pyramidal elements to even further stiffen the
longitudinal web means 10 and thus provide the latter with even
greater resistance to buckling. Accordingly, there is developed a
very reliable, rigid, structural system capable of economically and
efficiently spanning relatively large distances.
As a result of the above described surface-to-surface
interconnection of all the elements of the system, external loads
applied to the system are distributed therein in all directions,
thus alleviating stress concentrations in the directly loaded
parts.
A connecting means 50 which may be in the form of household glue or
a similar bonding means suitable for the particular sheet material
used, is provided for use in erecting the individual hollow shell
elements, the transverse web means and the longitudinal web means
and for integrally connecting all these elements together at the
aforesaid superposed surface portions thereof, to form the
composite integral structure just described.
The preferred embodiment of the structure further includes a
plurality of closure elements of sheet material. A first group of
these closure elements are the elements 60 which are preferably of
truncated pyramidal form (FIG. 12), configurated so as to
correspond to and be received in the open bases of the inverted
pyramids 20. Elements 60 have side wall surfaces 60a, 60b, 60c and
60d adapted to overlie portions of respective walls 25a, 25b, 25c
and 25d of the respective pyramid 20 in which the closure element
is nested. The closure elements 60 further have a closed end wall
61 which forms a closure for the otherwise open bases of the
pyramids 20. The closure surfaces 61 of all of these closure
members 60 are located substantially in the plane x, i.e., the
upper one of the aforesaid pair of parallel planes x and y which
delimit the web means 10. Together the end walls 61 form a
substantially flat continuous surface in plane x. The truncated
pyramidal closure pieces 60, illustrated in FIG. 12, are preferably
prefolded and prestressed so as to be properly bondable to the
inner surfaces of the corresponding pyramidal elements 20 after
being nested therein. Alternatively, the pyramids 20 may initially
be formed as hollow, fully enclosed, elements.
For closing the ends of each of the channels 13' (in which the
pyramids 20' are preferably staggered with respect to the pyramids
20 in the adjacent channels 13, by a distance equal to one-half the
length of a pyramid 20') there are preferably provided hollow end
closure elements 64 (FIG. 9) each of which corresponds
substantially in size and shape to one-half of a pyramidal element
20'. According to the preferred embodiment, the pyramids 20 and 20'
are of equal size. Each element is preferably formed of a pair of
glued-together folded sections 64a and 64b.
At the opposite longitudinal ends of each series of inverted
pyramids 20 there may, according to the preferred embodiment, be
provided end closures 63, such as illustrated in FIG. 10. End
closures 63 are preferably also in the form of hollow shell
elements each of which has three triangular sides and a triangular
open face. The apex of the intermediate one, 63a, of the triangular
sides, is located in the colinear base line of the remaining
triangular sides 63b and 63c. The hollow elements 63 form a flat
end closure 63a at the end of each string of longitudinally
distributed pyramidal elements 20.
The bridge B, according to the preferred embodiment of the present
invention, further includes a decking 70 for transferring the loads
evenly to the remainder of the structure. This decking, while
preferably also formed of sheet material, is so constructed as to
be capable of withstanding the concentrated wheel loading of motor
vehicles, including heavy trucks. As previously noted, the end
walls 61 of the closure elements 60 provide a flat continuous
surface on the top of the structural system capable of having
bonded thereto, as at 51, in face-to-face relation, the underside
of the flat decking member 70.
In its preferred form, the decking member 70 is comprised of a pair
of laminated layers 71 and 72 of a sheet material and an
intermediate layer 73 comprised of a series of parallely arranged
cylindrical tubes 74, also of sheet material. These tubes are
preferably in side-by-side contact with one another and preferably
extend transversely with respect to the length of the decking so as
to reinforce the pair of spaced flat layers 71 and 72 of laminated
sheet material located on opposite sides of and bonded to the
intermediate tube layer.
As a result of its unique design, the above described components of
the structural system (FIG. 14) may be readily assembled together
at the construction site by bonding these together along the
aforementioned overlying surface areas thereof. The large surface
areas available for bonding result in exceptionally strong and
reliable connections. The specific glues and cements best suited
for such bonding will depend on the particular sheet materials
involved, and are well known to those skilled in the art. A
high-load-bearing structural system, such as a bridge, may thus be
fabricated solely out of sheet materials, such as paper.
Preferably, each of the component parts, for example the pyramids
20, 20', the longitudinal web means 10, the transverse web means 30
and the closure elements 60 and 63, is fabricated out of
individual, stock size, sheets of paper, by cutting the latter into
desired shape, scoring the paper along desired fold lines and then
laminating together individual sheets of such scored paper in such
a manner that (as illustrated with respect to web 10, in FIG. 7)
alternate sheets of the paper are positioned with their region of
discontinuity in nonoverlapping relation. In FIG. 13, it will be
see, that, for example, the lines of discontinuity 26a and 27a of
the adjacent layers 26, 27, respectively, of a pyramidal element
20, are located at opposite edges of the pyramid and are not
adjacent to one another. Thus, the region of discontinuity of any
individual sheet is reinforced by a non-discontinuous region of an
adjacent sheet, so as to minimize any effect of such discontinuity
on the structural strength of the element. After folding into
desired shape, the scored folds of the pyramid may be filled with
flue to provide an even stronger structural joint along such fold
lines.
The term "paper" as used herein is intended to include such sheet
materials as paper board, liner board, fiber board and
cardboard.
Not only do the strength and stiffness properties of paper differ
greatly in compression and in tension, but paper is also an
anisotropic material, i.e., it displays different structural
properties along different axes thereof. According to the preferred
embodiment of the present invention, particular advantages result
from the latter special structural properties inherent in paper.
For example, the tensile strength of the paper is nearly twice as
great in the direction of the grain of the paper as it is in the
cross direction. According to the preferred embodiment, all of the
elements of the structure are comprised of folded and glued flat
surfaces shaped to take full advantage of the special properties of
paper. Thus the webs 10 are constructed with the grain of the paper
thereof extending in longitudinal direction, and the pyramids 20,
20' are constructed with the grain of the paper thereof extending
peripherally, i.e., in a direction about the apex. The pyramid
closure elements 60 are cut and prefolded so as to form
prestressed, i.e., spring-like inserts for the tops of the inverted
pyramids 20. Coated with glue, the closure elements 60 are inserted
into the open faces of the pyramids and press outwardly against the
pyramid walls to provide proper bonding along all adjoining
surfaces.
Since the structural system according to the present invention is
composed of hollow elements and since the hollow pyramidal elements
20 are bonded to the interior surfaces of the longitudinal web
means 10, the pyramidal elements are also subjected to the stresses
borne by those portions of the longitudinal web means to which they
are attached. Furthermore, the inclined corner portions, i.e., edge
portions 24 of each of the pyramidal units 20, 20', from the apex
22 down to the base 23 thereof, act as truss members, thereby
forming, with the other inclined edges of the remaining pyramidal
units, an integrated truss system.
Each of the edges 24, of the pyramidal elements, thus forms a cord
of a truss so that the resulting structure is made up of a series
of interconnected triangular truss units having the rigidity and
stability incident to structural triangulation. As a result of the
surface-to-surface interconnection of all of the elements of the
structure, applied external loads are distributed in all
directions, thus acting to reduce the otherwise high stresses in
the directly loaded portion.
By way of example, a paper bridge, approximately ten feet wide and
four feet deep, was constructed in accordance with the present
invention. The bridge, having a length of 32 feet was able to
easily bear the weight of a 12,000 pound truck when the latter was
driven over its 30 foot span numerous times. During load testing,
for support of the 12,000 pound truck, the paper structure
deflected only 1/2 inch within its 30 foot span. The bridge weighed
approximately 9,000 pounds and consisted entirely of paper and
glue. The sheet material (1) used for constructing the elements of
the structure, for example, the pyramidal elements, the
longitudinal webs, the transverse webs and the decking, was 0.1
inch thick Solid Fibre which consisted of four plies of -90 Kraft
liner-board (heavy duty paper) laminated together. The various
component elements of the structure were bonded together along
overlying surfaces thereof, as described above, forming laminated
sections such as, for example, section E (FIG. 15) 0.4 inches
thick, and section F (FIG. 15) 0.6 inches thick. Joined together,
these elements form a stressed-skin structure that behaves like an
orthotropic bridge. The sheets 12a, 12b, 12c, etc., as well as
sheets 26a and 27a, etc., were each 0.1 inch thick as per
above.
The deck 70 (FIGS. 15 and 16) was fabricated of parallel,
side-by-side, cylindrical paper tubes 74 also comprised of
laminated sheets of paper. By way of example, the tubes 74 have a
wall thickness of approximately 1/2 inch and an inside diameter of
approximately 3 inches. The tubes are sandwiched between a pair of
spaced flat layers 71 of laminated sheets of paper 1.
While the deck 70 has been illustrated with a core of cylindrical
paper tubes 74 laminated between flat layers of sheet material 71,
it will be understood that other deck structures, for example, one
having a sawtooth-shaped laminated core (not shown), similar to the
longitudinal web structure of web 10 described above (FIG. 3), and
sandwiched between the pair of laminated sheet layers 71, would
also be satisfactory and is intended to be included within the
scope of this invention.
By way of example, the pyramidal units of the latter bridge are
each approximately 21/2 feet high and have a rectangular open base
approximately 48 inches in length (longitudinal direction of web
10) and approximately 24 inches in width (transverse
direction).
The pyramids 20, 21' are longitudinally distributed, with adjacent
base edges thereof in close proximity to one another, in the
corresponding elongated channels 13, 13'. The apex angles of a pair
of opposite sidewalls 21a and 21b of the pyramidal elements 20 are
preferably chosen to correspond to the apex angle formed between
plates 11a and 11b of the longitudinal web means 10. The sheet
material used in the structure according to the present invention,
while preferably paper, may be any suitable sheet material, such as
sheet steel, sheet aluminum, sheet fiberglass, as well as other
structural plastic sheet materials, or the like.
It will be seen that the structure of this invention is such that
the component parts thereof can be simply and inexpensively
manufactured, transported and assembled together.
It can be seen that the structure described herein can have many
applications in addition to use as a supporting beam or bridge. For
example, a structure according to the present invention would be
useful in cases where buoyancy is desired. Thus, by using water
resistant materials, or water resistant coatings over water
permeable materials, a structure according to the present invention
could, for example, be used as a "pontoon" bridge. By using
additional closure pieces, similar to elements 60, to close off the
open ends of the bottom pyramids 20', a fully enclosed cellular
structure is formed. The air-filled, fully-enclosed, pyramidal
units and the enclosed spaces therebetween, result in a buoyant
structure.
It will be understood that a composite structural unit according to
the present invention, i.e., longitudinal web means and pyramidal
elements distributed therealong and connected thereto, as
described, lends itself admirably to use as a structural element.
Such structural element may, for example, be comprised of a single
V-shaped web 11a, 11b and a plurality of longitudinally distributed
pyramids 20 nested in the channel 13 thereof and connected thereto,
as taught herein. Such composite structural member can span
relatively large distances without requiring intermediate columnar
supports. The structural system of the present invention combines
the structural characteristics of a skeleton frame system with
those of a stressed skin system. Thus, the system according to the
present invention has an unusually high strength to weight ratio
because of the internally continuous braced skin-structure and
because of the fact that pyramidal elements have a high ratio of
surface area per unit volume and consequently are among the most
stable of all polyhedrons.
It can be seen that this invention provides improved strength
members for a bridge, or a roof, or the like, comprising uniquely
formed sheet material elements uniquely combined to provide a
supporting structure which is relatively light in weight and yet
very strong.
It will be understood that where sheet material other than paper is
used, for example plastic or light-gauge steel or aluminum, the
means for integrally connecting the sheet members at overlying
surface portions thereof may include such connecting means as
spot-welds, solder, rivets, heat seals and any other fastener or
bond which permits surface-to-surface connection between the flat
surfaces of the geometric shapes formed by folded sheets of such
materials. In lieu of the pyramidal elements, of course, other
hollow solid-geometric shaped elements can be used provided they
have flat surfaces which permit a surface-to-surface connection in
substantially the manner herein described.
It will also be understood that by increasing the thickness of the
sheet material or the number of sheets of material in each layer
and/or by increasing the number of pyramidal elements in a given
channel, the strength of the composite structure may be even
further increased.
While particular embodiments of this invention have been shown and
described, it will be obvious to those skilled in the art that
there are changes and modifications which may be made without
departing from the scope of the invention in its broader aspects,
and it is, therefore, intended in the claims to cover also such
changes and modifications as fall within the true spirit and scope
of this invention.
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