FR2676241A1 - Self-supporting and stackable component for removable shelters and lightweight modular buildings - Google Patents

Abstract

The STRUCTAL method is an adaptable construction system with which it is possible to construct, manually, dismantleable modular galleries, by combination of the five basic devices which form the subject-matter of the present patent application, as does their method of combination: - standardised ribbed and stackable blocks which are called Arch stones and which, when assembled, form arches without any intermediate supports or scaffolding; - orifices for the removal of the rainwater, called Outflows, formed in the lateral walls of the Arch stones; - adjusted and boltable boxes, called Tenons, making it possible, on the one hand, to assemble or disassemble the Arch stones manually, and, on the other hand, to complete at the same time the sealing of the arches thus constructed; - external post-tensioning cables, called Stiffeners, which can pass through the Outflows and which ensure, with the aid of tensioning hooks, the securing of the arches to the ground and their mutual fixing; - a computerised calculation method permitting the digital three-dimensional design of the Arch stones, as a function of variable standards of capacity, strength and materials.

Description

Chapter 1: DESCRIPTION 1.1 TECHNICAL AREA
The STRUCTAL project is a constructive system for modular galleries by self-supporting and stackable elements in polymers.

It responds to widespread solvent needs which are poorly met by the current building and civil engineering industries.

At the crossroads of four classic markets: that of heavy constructions fixed to the ground and resistant to external aggressions by the weight and thickness of their materials; that of rigid mobile shelters such as caravans or motorhomes; that of flexible mobile shelters such as tents or inflatable structures; and finally that of glass-plate greenhouses and verandas, there is a large underserved area of needs.

This untapped market is that of light and resistant constructions, self-supporting, assembled and dismountable by hand, transportable, as desired, in small volumes (by van or car) or in large quantities (by trucks, trains, planes, boats), and extendable, modular or modular at will.

This is the area of the STRUCTAL project.

1.2 STATE OF THE PRIOR ART.

This field is not exploited at present because its exploitation should satisfy multiple requirements, which are only partially and separately taken into account by four branches largely disjunct from economics and technology: building, metal engineering, the plastic furniture industry, and IT.

1.2.1. Conflicting requirements for techniques in tack.

Constructions are needed that are: - capable of covering large areas - free of any intermediate support (no posts or
load-bearing partitions) - very light and easy to assemble or disassemble, possibly
by a single person, without any tools other than a screw wrench
and a stepladder - resistant and invariant to weather and storms - perfectly waterproof by themselves, without plaster or
covering - ventilated by vents, windows or various conduits - transportable in small packages - opaque, colored or transparent, in whole or in part, at
customer choice - fire resistant at least as much as more or less products
competitors - not requiring maintenance or upkeep - at least 30% cheaper than more or less solutions
competitors.

No current technique meets more than 5 of these 11 criteria.

1.2.2. The answers to these various requirements have never before been integrated into an overall technique.

These answers exist, but dispersed in five different trades: - stone architecture provides the technique of the vault, which responds to the need to cover large areas without intermediate support by the assembly of standard elements (segments or keystones ), whose weight alone, at the limit, is sufficient to ensure the cohesion of the whole; it thus integrates the functions of roof and walls in a single continuous surface.

It is the circular or elliptical profile vault which in itself offers the most lift for the minimum of material.

- the engineering of metal constructions (bridges, hangars, towers, pylons) provides the technique of stiffeners (triangular ribs, bolt beams, external tie rods). This type of element responds to the need to oppose a high resistance, despite a thickness and a weight as low as possible, to significant external constraints (wind, snow, aggressions, etc.) or interior (weight of partitions or pipes suspended).

- the furniture or plastic tool industry practices the technique of stackable objects (chairs, buckets, bins, cups ...). It thus responds to our desire to have products that can be stored or transported in small volumes by stacking standard hollow or molded elements.

- the chemical industry provides in the form of various polymers the resistant, transparent or colored materials, inexpensive, easy to machine and diversified which we need to produce large quantities of stable, light, solid, homogeneous and multifaceted objects.

- Finally, IT provides the means of calculation and drawing to automate and make the design and manufacturing of the physical elements of our construction system as flexible as possible.

According to very variable specifications, it determines in each case their exact shapes and dimensions, so as to maximize the performance of these elements for a given weight of materials, while allowing their manufacture in large quantities as well as the continuous adjustment of production to variations in demand.

1.3 STATEMENT OF THE INVENTION
The synthesis of these five techniques (see ≈1.2.2. Above) is a self-supporting system of you ribbed and stackable evenings made by computerized machining of synthetic polymers, and provided with assembly and reinforcement elements as well as comfort equipment.

The assembly of these segments and these elements form more or less long galleries, self-supporting by vault effect (see Figure 1/8), whose assembly and disassembly are done by hand, and which, once disassembled, can be stored by stacking.

1.3.1. Stackable segments.

The basic element (below called "Voussoir") is a rigid monobloc tray and flares (see figures (2/8) and (3/8)). It includes, around an axis of longitudinal symmetry Ox, a fixed number (in the same version of the system) of flat parts, dihedrons and orifices, namely (in the version presented here): - three flat parts: the base plane of the back wall, rectangular, ABCD the two side walls ABEF and CDHG, symmetrical with respect to Ox and inclined towards the outside - six dihedrons with an isosceles trapezoid profile, forming six ribs (N) in the bottom wall, which they cross transversely from one side wall to the other in three separate groups: a central group of two juxtaposed ribs two extreme groups of two juxtaposed ribs, neighboring respectively on the two short sides BC and DA of the bottom wall. The external slope of the rib immediately adjacent to the DA side is extended below the bottom plane by a baRM drip line.

- various rectangular or circular holes: two rectangular notches IJ and KL cut in the two side walls, at mid-distance, and perpendicular to their outer sides eight circular holes (t) in each side wall, four near the outside edge, four near from the bottom wall three larger circular holes (T), the
Spacers, in each side wall, one above the junction of the two central ribs of the bottom wall, the other two above the middle of the flat parts which separate these central ribs from the two groups of extreme ribs three circular orifices, one in the center, the other two at the ends of the baRM drip pan.

1.3.2. Assembly and equipment elements
A wide variety of detachable parts can be attached to the
Segments to assemble them or to equip them.

1.3.2.1. Assembly elements (they fall within the scope of
this patent application). There are three kinds: - longitudinal buttresses, called Tenons below (see
figure (5/8)). These are boxes of length close to
that of the voussoirs, pierced transversely with eight orifices
circulars corresponding to the holes (t) in the side walls
voussoirs.

- bolts (b), provided with nuts, of diameter equal to that of
orifices (t), and slightly longer than the width of the
Let's stick (see figure (4/8)).

- post-stress cables, called below the
Stiffeners, with a diameter smaller than that of the orifices (T),
and fitted with fixing hooks (see figures (5/8) and
(6/8))).

1.3.2.2. Elements of equipment (they do not fall within the scope of this patent application): they are intended to improve the comfort of users of buildings made in
Structural, and may include in particular: - rigid or flexible, opaque or transparent transverse sails, intended to form external or / and internal partitions of rooms, galleries or greenhouses made - dormers, windows, snuff boxes, skylights, vents or various conduits incorporated during manufacture in
Special segments - bars, cables and piping intended to be inserted under the arches assembled in the holes of the drip holes to support various elements of storage, lighting, or distribution of electricity, gas or water.

1.4 PRESENTATION OF FIGURES AND TABLES
Plate (1/8): Perspective view of an assembled Structural VOUTE.

Plate (2/8): Perspective view of a Structural VOUSSOIR.

Plate (3/8): Half-shot of a VOUSSOIR seen from above.

Plate (4/8): Perspective view of a TENON Structal and its
bolting device.

Plate (5/8): Elevation view of the fixing system of a
STIFFENER (connection between cable, hook and floor).

Plate (6/8): Partial perspective view of a STIFFENER in place on a Structural arch
Plate (7/8): Table of PARAMETERS defining the geometry of a segment in the automatic calculation process.

Plate (8/8): Example of a QUANTIFICATION MATRIX by the process of calculating the main parameters of a voussoir, according to various specifications.

1.5. EMBODIMENT.

The principle of realization of STRUCTAL buildings is that of the stone vault transposed into a synthetic material after elimination of the filling material: this gives a "kit" of construction in hollow segments, which can be handled without a machine and stacked in a limited volume when the building is dismantled; the main elements of the system can be dimensioned at will in their different parameters according to an Automatic calculation process.

1.5.1. System structure
The geometric structure of the System is defined by that of
Voussoirs, which are its basic elements.

The structure of a voussoir is defined, in the version presented here of the system, by 16 parameters or groups of dimensional parameters: a) A parameter common to all its parts: the thickness S of its
walls.

b) Four parameters for the flat parts:
- length L of You evening (EF = GH
- width 1 of the bottom wall (BC = AD = M * R)
- height h of the side walls
- angle V of inclination of the side walls on the plane of the bottom wall.

c) Three parameters defining the ribbing dihedrons:
- angle at the top W formed by each of the six ribs
- width Ln of the six ribs, measured in the plane of
the back wall
- width Lla of the drip plate baRM d) 8 groups of parameters defining the orifices:
- diameter dt of the 8 orifices (t) of a side wall (and of a
Tenon)
- coordinates of these orifices (t) in the side wall
- diameter dT of the 3 orifices (T) of a side wall
- coordinates of these orifices (T) in the same plane
- diameter of the 3 holes (tla) of the drip
- coordinates of these 3 orifices (tla) in the drip plane
- width i of the two notches IJ and KL
- length j of these two notches.

1.5.2. Calculation of the dimensions of the basic elements of the system
A computerized process makes it possible to calculate the basic components of the system (voussoirs) according to capacity objectives and performance standards adaptable to specifications and customer needs.

This process consists of:
- 1 6 parameters or groups of digital parameters described in the preceding paragraph; they completely define a set of components in the three dimensions (see table 1, plate 7/8);
- a Multiplan type program allowing these parameters to be quantified as a function of the desired performance standards (resistance to weight and wind), the dimensions desired for the vaults to be produced, and the materials chosen (see table 2, plate (8 / 8): example of quantification of certain important parameters according to various specifications).

1.5.3. System operation
The erection of STRUCTAL buildings consists first of assembling the voussoirs into arches of two voussoirs wide, then joining these arches together, finally consolidating the vaults thus obtained if necessary.

a) formation of arches.

We juxtapose 2, 3, ... n segments, side wall against side wall, and we join them, transverse wall against transverse wall, to 2, 3, ... n other segments, using tenons.

The outer slope of the extreme rib (EG) of a Voussoir is embeded on the extreme rib (ab), contiguous to the drip line, of the Voussoir of the next span.

Each Tenon fits on the central ridge formed by the side walls joined and juxtaposed with each 2x2 vault
Voussoirs, by inserting by its ends in the two groups of two vertical notches (IJ) and (KL); we then insert the bolts (b) into the holes (t) of the Tenon and parts of this crest that it covers, and we screw the 8 corresponding nuts.

b) Formation of the vaults.

The arch or the arches of 2 spans thus obtained, for example by assembly on the ground, is (are) then straightened (s) vertically, then joined to each other by the same set of
Let's stick, bolts and nuts as above.

c) Consolidation of the vaults.

The stiffeners also make it possible, either as a supplement or as a replacement for the Tenons, to consolidate the arches and arches formed. Simply pass the Stiffener cable through one of the three holes (T) provided at the bottom of the side walls of each
Segment of the span to be consolidated (for example in the Evacuator located between the two central ribs), then fix this cable to the ground by its tensioning hooks (see Figure (5/8)).

The disassembly of the arches takes place behind the assembly, first by relaxing and removing the stiffeners (if they are in place), then by unbolting and removing the tenons bay by bay, and finally by separating the Segments that made up each span.

1.6. INDUSTRIAL APPLICATIONS.

1.6.1. Possible product categories
They are very numerous, in accordance with the various types of gallery constructions that can be carried out with the system
STRUCTAL and for which there is a solvent demand. We can distinguish two main types.

1.6.1.1. Opaque buildings:
- garages
- garden sheds, construction sites, depots ...

- temporary accommodation (camping, military, refugees ...)
- roofing of existing buildings.

N.B .: these "opaque" galleries can be fitted with windows, skylights or various conduits (see ≈1.3.2.2 on equipment items); or transparent segments can be combined, in the proportion and in the desired locations, with opaque segments.

1.6.1.2. Transparent or translucent buildings.

- greenhouses or frames either for private gardens or
for large-scale crops
- exhibition halls or galleries
- circulation galleries for pedestrians, animals or
vehicles that we want to protect or on the contrary isolate.

 - roofing of existing buildings.

1.6.2. Dimensional adaptation by configuration to customer needs.

Thanks to the automatic calculation process described in 1.5.2., The 16 parameters or groups of parameters defining geometrically, in the version which is the subject of this patent application, the segment of a Structal range and the corresponding elements ( Tenon, Stiffener), lend themselves to two types of dimensional changes, depending on customer requests and regulatory standards.

1.6.2.1. Changes in proportions.

By varying the fundamental parameters (notably S, L, 1, h, V) of the Voussoir in relation to each other, we can at the same time vary the solidity, the height and the length of the buildable arch segment with a number of You given evenings in a given material.

1.6.2.2. Scale changes.

The same automatic calculation program makes it possible, by retaining roughly the same proportions in the segments, but by varying the size of these, to calculate and then to fabricate you evenings into arches which are roughly homothetic to each other. , but of very different dimensions: the smallest will have a few tens of centimeters in diameter and height, the largest will have a few tens of meters.

Of course, these changes of scale cannot be perfectly homothetic for all the parameters, because they lead to non-linear variations in certain constraints or performances of the voussoirs (in particular with regard to the weight of the assembled vault and the compression effects that she exercises).

The same applies to assembly and equipment elements.

1.6.3. Manufacturing
According to the specifications which will be specified and calculated by the automatic calculation program, various conventional techniques of the plastics industry allow to manufacture the segments, the tenons and the cables of the
Stiffeners in very homogeneous qualities, and with great flexibility in dimensions and quantities, for example:
- thermoforming or injection for segments and tenons
- extrusion and braiding for cables.

- heat blowing or laminating for partitions
In addition, the ancillary metal elements (bolts, nuts, tensioning hooks, etc.) will be purchased from specialized suppliers.

Claims (6)

Chapter 2: CLAIMS 1 - Self-construction device for modular and configurable modular galleries (see figure (1/8)), characterized by the combination of four physical sub-devices and an IT device: - standardized self-supporting and stackable boxes, called "VOUSSOIRS ", which can form a vault without intermediate supports or scaffolding; - circular orifices, called Evacuateurs, drilled in the side walls of the voussoirs, intended both to evacuate rainwater and to pass the cables of Stiffeners; - adjusted bolt-on bolts, called "TENONS allowing on the one hand to manually assemble or disassemble these segments, on the other hand to perfect the tightness of the vaults thus constructed; - external post-stress cables, called" RAIDISSEURS ", ensuring a reinforced cohesion of these vaults as well as their fixing to the ground ;; - an automatic calculation process allowing the three-dimensional digital design of the main components of the system (the segments), in a very wide range of dimensions, depending on varying standards of capacity, strength, materials and weight.

2. Device according to claim 1, characterized by standardized boxes intended to form an arch (the segments in the form of flared tubs (see figures (2/8) and (3/8)), consisting of a ribbed bottom ABCD and of 2 opposite walls ABEF and CDHG, integral with this bottom, inclined towards the outside by an angle (V) ABCD juxtaposed with these segments. The weight of this arch and its possible loads is thus transferred step by step on the outer walls of the two extreme segments, and consolidates the entire arch by compression. By assembling 2, 3, 4 n of these voussoirs wall against wall, we obtain a prismatic arch whose lower surface is a polyhedral arc of 2, 3, 4, ... n facets constituted by the bottoms  The 6 ribs with an isosceles trapezoid profile (N) which modulate the bottom of the segments in the transverse direction (figure (3/8)) ensure the stability of the profile of the said segments with regard to these compressive forces. When they are not assembled in vault (s), the segments are stackable one on the other thanks to the widening of the ABEF and CDHG walls and the V-shaped profile cut from the ribs (N); they only occupy a very small volume compared to the space they can cover when they are assembled in a vault.  3. Device according to claim 1 or claim 2, characterized by circular orifices (T), the Evacuators, formed in the side walls of the You evenings (see figure (2/8) or (3/8)) under the notches medians (IJ) and (KL) on the one hand, and in the middle of the plane spaces separating the group of central ribs from the groups of extreme ribs on the other hand; 4. Device according to claim 1, characterized by longitudinal shoemakers (the Tenons) with U-shaped profile (see figure (4/8)), of length equal - to a thickness S close - to that of a Voussoir, which s 'float on the adjoining and juxtaposed walls of the voussoirs placed side by side. Segments, tightly assembled in its air gap, thanks to vertical notches (IJ) and (KL) provided in the middle of each wall (see figure (2/8) or (3/8)): the Tenon fits from notch to notch, from the middle of Voussoirs to the middle of Voussoirs. This same Tenon can be fixed to these walls by a set of bolts (b) and nuts (see figure (4/8)) thanks to orifices (t) provided for this purpose in the Tenon and, opposite, in the walls (see figure (3/8)). Each Tenon allows you to join the segments transversely and lengthwise four to four. Indeed, each of them maintains by itself four half-walls, belonging to four 5. Device according to claim 1, characterized by post-tensioning cables (the stiffeners) which, if necessary (regions with strong winds for example), encircle each arch of the vault by passing through the Evacuators (T). These stiffeners are fixed, on each side of the vault, to the base thereof by metal hooks (see figure (5/8)), which are screwed either directly into the ground, or into longitudinal anchoring beams laid or sunk into this soil. The STRUCTAL construction system optionally includes concrete or metal beam elements to facilitate this anchoring. 6. Device according to claim 1 or claim 2, characterized by a computerized method of calculating the basic components of the system (the voussoirs) according to geometric dimensions and performance standards adaptable to the specifications and the needs of the customers.  in particular the angle (V), according to various specifications).  quantification of certain important parameters, including  chosen materials (see plate (8/8), table 2: example  desired dimensions for the vaults to be produced, and  desired (resistance to weight and wind),  these parameters based on performance standards  - a Multiplan type program to quantify  table 1); none of these parameters is fixed in advance;  Segments in three dimensions (see plate (7/8),  numerical parameters completely defining a set of  - a fixed structure of 16 parameters or groups of This process consists of: