GB2418437A

GB2418437A - Construction assembled from tubular composite rib-frame structure

Info

Publication number: GB2418437A
Application number: GB0513884A
Authority: GB
Inventors: John C A Barr; Kenichi Katagihara; Masami Kobayashi; Yoko Masuda
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-09-22
Filing date: 2005-07-06
Publication date: 2006-03-29
Anticipated expiration: 2025-07-06
Also published as: GB2418437B; GB2418437A8; GB0513884D0; JP2006118338A

Abstract

A rib-frame structure 1 comprises a plurality of rectangular rib-frames 2, the corners of which are connected together by corner members 4 so as to produce a tubular rib-frame structure. A plurality of rib-frame structures are joinable at opposed corner members to form a construction. The corner members may have a right-angled cross- section and cover corners of the rib-frames. The tubular rib-frame structures may be arranged in an end-to-end, side-by-side or an upper and lower relationship. Adjacent corner members are preferably fixed to each other by coupling means. They may project outwards from front and rear ends of the tubular structure. The rib-frames may be composed of a single plate of material or composed by integrally combining a plurality of plates.

Description

24 1 8437

A RIB-FRAME STRUCTURE AND METHOD OF MANUFACTURING IT

The present invention relates generally to rib-frame structures and their construction. Specifically, it relates to rib-frame structures used in the construction of quickly-constructed buildings, such as general residences, apartment houses, temporary housing, care homes, warehouses, dome structures, pillar or wall structures, and any other single-storey or multi-storey building.

A conventional structure used in the construction of such buildings is described in US-A-4,129,969. Here, the column portions are thicker than the beam portions of a coupling frame body enclosing a concrete tubular body.

One coupling structure is situated at an angle of 180 degrees in relation to another coupling frame body, and a pair of coupling frame bodies are mutually engaged and linked at the column portion side faces or beam portion upper ends, and are joined side-to-side or above and below, according to the required building spatial structure.

In this building structure, for example, adjacent structures are disposed at an angle of 180 degrees with respect to each other, and the mutual facing ends must be engaged and coupled. However, this takes much time and labour.

Furthermore, it takes many hours or days for the tubular concrete structure to cure, and a long installation period is needed for manufacturing such structures. Also, with concrete materials, the total weight of the entire structure is increased, thereby increasing the labour and energy required for rotating the structures by 180 degrees and for stacking the structures up. Consequently, it takes much time and effort to build a structure of a desired number of stories.

It is an object of the present invention to provide a method of construction using rib-frame structures and provide a rib-frame structure capable of being used easily in the field even by those not having professional knowledge, skill or experience about construction work.

It is a further object to shorten the construction period, reduce labour and energy expenditure and to provide an easily transportable rib-frame structure which saves on construction costs.

According to an aspect of the present invention there is provided a method of construction using rib- frame structures including: fabricating a rib-frame structure by sequentially arranging a plurality of substantially rectangular-shaped rib-frames along a specified longitudinal direction; and connecting corresponding corners of the rib-frames by fixing a corner member at each of the four corners of the rib frames so as to produced a tubular rib- frame structure; and forming a construction by placing a plurality of tubular rib-frame structures so formed in an adjacently proximate arrangement; and coupling adjacent tubular rib- frame structures by inter-connecting the opposing corner members of adjacent tubular rib-frame structures with coupling members to produce the construction.

According to another aspect of the present invention there is provided a rib-frame structure comprising: a sequential arrangement of a plurality of substantially rectangular-shaped rib-frames, the corners of which are fixed by corner members each spanning corners of each of the rib-frames so as to produce a tubular rib-frame.

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying schematic drawings, in which: Fig.1 is a perspective view of an assembled rib-frame structure; Fig.2 is a side view of the assembled rib-frame structure; Fig.3 is a front view of the assembled rib-frame structures Fig.4 is a side view of coupled rib-frame structures) Fig.5 is a plan view of coupled rib-frame structures; Fig.6 is a front view of coupled rib-frame structures; Fig.7 is a front view of rib-frame structures coupled in an alternative manner; Fig.8 is a front view of a plurality of coupled rib-frame structures) Fig. 9 is a side view of a rib-frame foundation structure; Fig.10 is a front view of adjacent rib-frame structures fixed to a foundation; Fig.ll is a perspective view of a pair of end-to-end coupled rib-frame structures; Flg.12 is a perspective view of a pair of rib-frame structures coupled in a side-by-side state; Fig.13 is a perspective view of rib-frame structures in a further coupled configuration; Fig.14 is a perspective view of coupled rib-frame structures in a stacked arrangement; Fig.15 is a perspective view of a pair of rib-frame structures coupled at corner members that do not project beyond the front or rear of the rib-frame structures; Fig.16 is a perspective view of a pair of coupled rib- frame structures coupled by means of flat corner members; Flg.17 is a perspective view of a rib-frame structure including side bracing) Fig.18 is a front elevation view of the bracing of Figure 17; Fig.19 is a front view of inner and outer mounted wall boards; Fig.20 is a perspective view of a rib-frame structure including upper and lower bracing; Fig.21 is an elevation view of an alternatively constructed rib-frame; Fig.22 is an elevation view of another alternatively constructed rib frame; Fig.23 is a plan view of an alternatively constructed rib-frame; Fig.24 is a perspective view of a pair of rib-frame structures coupled in an orthogonal arrangement; and Fig.25 is a perspective view of a pair of ribframe structures coupled in a stepped arrangement.

The Figures show rib-frame structures that are used for building a singlestorey or a multi-storey structure, in which a plurality of rib-frame structures 1 are assembled in a tubular form (as seen from the front), and are disposed adjacently in parallel, in end-to-end, side by-side, or top and bottom relation. A rib-frame structure comprises a series of ribframes 2 disposed in close proximity, or in contact, and corner angles 4, provided at each of the four corners of the structure.

Building structures are constructed from rib-frame structures 1 as shown in Figures 11 to 14.

Alternatively, and as shown in Figures 24 and 25 respectively, the ribframe structures 1 can be coupled in an orthogonal arrangement, where one end of one rib frame structure 1 is attached to the side of another rib frame structure 1, or in a stepped arrangement where rib frame structures 1 that are either or both laterally and vertically displaced with respect to one another, are coupled at overlapping sections.

The rib-frame structure 1 is formed as shown in Flq. 1, Fig. 2 or Fig. 3, in which rib-frames 2 are substantially rectangular-shaped (as seen from the front), or they may be square-shaped, and are formed having substantially the same size and shape, and are disposed at specified intervals in a longitudinal direction, and coupled and fixed in the longitudinal direction by coupling frames 3. Coupling frames 3 prevent buckling between front and rear facing sides of adjacent rib-frames 2, and are disposed between adjacent rib frames 2. Preferably, the rib- frames 2 are arranged so as to be parallel to one another.

Corner angles or corner members 4 are provided to cover corners of the rib-frames. The corners of the rib- frames 2 are therefore protected so as to avoid being broken or damaged.

Brackets 8 are fixed to the corners of the rib- frames 2 on the inside corners of the corner angles 4.

They are integrally coupled and fixed by means of bolts 13 and nuts 14 so as to form a tube.

The brackets 8 may also be inserted into gaps formed at corners of the rib-frames 2.

Inner wall boards 5, for covering the interior of the rib-frame structure 1, are fixed, for example, to the upper and lower inner sides, and right and left inner sides of the rib-frame structure 1 corresponding to a floor, wall or ceiling.

The outer wall board 6 for covering the outer side of the rib frame structure 1 is fixed to the upper and lower outsides, and/or to the right and left outsides of the rib frame structure 1.

The inner wall board 5 and outer wall board 6 are made of a fire-proof or a heat-insulating material.

The space between the inner and outer edges of the rib-frames 2 may be filled with a specified amount of filler (not shown) that has heat insulation or sound insulation properties, such as glass wool, natural wool, foamed plastics, waste paper, or the like.

The rib-frame 2 is composed of a single, such as wood for example, or a compounded plate material, such as an aggregate or composite material or reinforced laminated veneer lumber (LVL) plywood (single plate laminated material), for example. The term composite covers constructions fabricated from two or more materials, for example interconnected layers of different materials, or reinforcing fibres in a support matrix.

The material will have high structural strength, and preferably be fireproof, heat resistant, sound-proof, and moisture or humidity responsive, or the like. Also, it is preferably formed in a substantially square shape (as seen from the front).

The rib-frame may be also composed of a single thick plate of material (e. g. plywood) formed substantially in a square or rectangular shape (as seen from the front), or a plurality of coupled, thick plate members formed having a length that nearly corresponds to the length of the upper, lower, right or left side.

The rib-frame may be further composed of a plurality of thin plate members formed substantially in a square or rectangular shape, or a plurality of coupled thin plate members formed to have a length substantially corresponding to the length of the upper, lower, right or left side.

An intermediate plate may be placed between two plate members, or two plate members may be fixed across a specific interval, or the plate member may be formed as a hollow structure. The rib-frame 2 may be formed in a desired shape having corners, such as rectangular shape, pentagonal shape or a hexagonal shape.

A substantially L-shaped corner plate 9, composed of a single or compound material such as reinforced LVL plywood (single plate laminated plate), metal plate, or plastic plate is fixed to a fixing means (not shown) whilst also being fixed to front and rear sides of the corners of the ribframe 2.

The fixing means may be a single or plural nails, screws, bolts, pins, rivets, or adhesive, for example.

Alternatively, as shown in Figures 21 to 23, the rib frame 2 comprises corner plates 9 interconnected by bridging members 40, 41 and 42. The corner members are of a one-piece construction, and are connected to the bridging members via plate members 45 and fixing means (not shown). The fixing means can be nails, screws, bolts, pins, rivets, adhesive, or any other such suitable fixing means.

The plate members 45 span junctions between the corner plates 9 and the bridging members 40, 41 and 42, and can be positioned on either side of the rib frame 2.

Alternatively, the plate members are sandwiched between a pair of corner plates 9, and a pair of bridging members 40, 41, 42.

The corner plates 9 may be fabricated from a unitary, homogeneous or compound material, such as plywood, LVL, plastic, etc. The bridging members 40,41,42 can be made from a unitary' homogeneous or compound material, such as plywood or LVL, etc. Alternatively, the bridging members 40, 41, 42 are constructed from solid wood. The corner plates or bridging members do not have to be made of the same material. Also, they do not have to be the same size.

Figure 21 shows an elevation view of a rib-frame where the bridging members are of the same size as the corner plates, and Figure 22 shows an alternative arrangement where the bridging member 42 is oversized as compared to the corner plates 9.

Figure 23 shows a plan view of a rib frame where the plate members 45 are sandwiched between the corner plates and the bridging members.

Corner angles 4 are formed with a substantially L shaped section from steel, material processed by perlite (PL) rust preventive treatment or galvanizing, and formed so as to cover two orthogonal outer surfaces positioned at the four corners of the rib- frames 2, as seen from the front. The corner angles 4 are disposed in the longitudinally direction, and project by a specified length in a longitudinal direction from front and rear surfaces of the rib-frame structure 1.

Holes 4a for inserting bolts 15 are provided at both ends of the corner angles 4 in the portions projecting beyond the front and rear of the ribframe structure.

Also, L-shaped brackets 8 are fixed to the inside corners of the ribframe 2 at right angles to the corner angles 4, and are disposed in a plurality of specified locations at intervals along the length of the corner angles 4. Alternatively, the L-shaped brackets 8 may be replaced by simple rectangular plates that are welded to the corner angles 4.

Mutually orthogonal holes 8a for receiving bolts 13 are provided in brackets 8.

The illustrated embodiment has the configuration as described herein, and a method for building a construction using the rib-frame structures 1 is explained below.

As shown in Fig. 11, when serially coupling rib frame structures 1 together in a longitudinal direction, a rearmost rib-frame 2 of a leading rib-frame structure 1 and a foremost rib-frame 2 of a following rib-frame structure 1 are joined or bonded at specific intervals.

The corner angles 4 are provided with projecting ends at each of the four corners of the front and the rear of each rib-frame structure 1. The ribframe structures 1 are integrally coupled and fixed by means of bolts 17, nuts 18, and viscoelastic dampers 10 (described below).

The projecting ends of corner angles 4 and one coupling plate lea, comprising the viscoelastic damper 10, are integrally coupled and fixed by bolts 17 and nuts 18.

The viscoelastic damper 10 is composed of a vlscoelastic element lOc formed of a high molecular material such as an acrylic, a silicon-based material, a urethane, a rubber, a diene, or a styrene. The high molecular material is sandwiched between facing sides of a pair of coupling plates lea, lob, and is designed to absorb vibrations ranging from small deformations to large deformations.

Instead of the viscoelastic dampers 10 the rib- frame structures may, for example, be designed to be coupled and fixed by bolts and nuts, or other such coupling devices. They may be also designed to be coupled and fixed by coupling means composed of other materials such as metal, ceramics, plastics, etc. As shown in Fig. 12, when coupling rib-frame structures 1 side-by-side, a right side portion of a left side rib-frame structure 1 and a left side portion of a right side rib-frame structure 1 are mutually brought closer or bonded, and opposing corner angle projections are integrally coupled and fixed by bolts 17 and nuts 18 via viscoelastic dampers 10. The coupling plates lea, lOb, of the viscoelastic dampers 10 are fixed and coupled to the brackets led fixed to the corner angle projections.

Alternatively, as shown in Fig. 13, the rib-frame structure 1 may be coupled and fixed in parallel at the front or rear side, and/or at either side of the rib- frame structure 1 to form a wide rectangular shape.

As shown in Fig. 14, when coupling rib-frame structures 1 that are arranged vertically or stacked on top of each other, a lower side portion of an upper rib frame structure 1 and an upper side portion of a lower rib-frame structure 1 are mutually brought closer or bonded, and the opposite corner angles projections are integrally coupled and fixed, as shown in Fig. 6 and Fig. 7, by bolts 15 and nuts 16 through vibration absorbing rubber 20.

The vibration absorbing rubber 20 is disposed between upper and lower corner angles 4 of opposing rib- frame structures. However, they may also be disposed along the entire length of the corner angles 4, or the vibration absorbing rubber 20 may be interposed only at the four corners, and may not be interposed between corner angles 4.

As shown in Fig. 7, the separation of upper and lower rib-frame structures is less than the separation between right and left rib-frame structures. However, the reader should be aware that the separation between the front and rear, right and left, or upper and lower rib- frme structures 1 may be equal or different.

The right and left rib-frame structures disposed at either above or below may be coupled by means of viscoelastic damper 10. The bolts 15, 17, and nuts 16, 18 can be fitted by way of vibration absorbing rubber packing.

The front and rear, and right and left rib-frame structures may be integrally coupled and fixed by bolts and nuts 16 via vibration absorbing rubber 20 without resort to viscoelastic dampers 10.

Thus, by arranging a plurality of rib-frame structures 1 adjacent and parallel, in end-to-end, side by-side, or upper and lower relationship, any desired building of single-storey structure or multi-storey structure may be constructed as shown in Fig. 11 to Fig. 14.

Moreover, if the corner angles 4 are arranged in a mutually adjacent configuration, for example, front and rear, right and left, and upper and lower rib-frame structures 1 can be orthogonally crossed and coupled.

At a junction between rib-frame structures 1, a panel or board constituting a floor, wall, or ceiling for example, may be fixed, and an opening may be formed having a desired size, shape and position.

As shown in Fig. 9 and Fig. 10, when fixing the rib-frame structure 1 of the lowest floor to a foundation 21, the corner angles 4 are fixed on a wooden platform 22 by bolts 23 via vibration absorbing rubber 20, and this platform 22 is fixed by anchor bolts 24 buried in the concrete foundation 21.

Further, as shown in Fig. 14, when fixing a prefabricated roof structure 1A on a rib-frame structure 1 of the highest floor, it is fixed to the corner angles 4 provided at upper corners of the rib-frame structure 1 by bolts 1B.

As indicated by the broken lines in Fig. 2, when installing an opening frame 1C for a window, a door or a large entrance at a side wall of the rib-frame structure 1, the width of the opening 1C is substantially a multiple of the distance separating rib-frames, and the reinforcing material in the horizontal direction is same as the material of the rib-frame 2.

Thus, adjacently disposed rib-frame members 1 are brought closer to each other or bonded, and the corner angles 4 provided at the four corners of the rib-frame structures l are integrally coupled and fixed. Field modification or construction work can be easily undertaken by those not having professional knowledge, experience or skill in relation to construction work.

It is sufficient to install the pre-assembled rib frame structures 1, or stack up a plurality of rib-frame structures 1, and it is ideal for forming constructions within a limited area, or in a high-density residential or commercial district.

The construction period is shortened substantially, and the labour and energy required for construction can be reduced. Furthermore, a building of a desired single storey or multi-storey construction such as a dwelling house, an apartment, a temporary house, a care house or a warehouse can be constructed in a short period, and the construction cost can be reduced.

Since the rib-frame structure 1 is pre-fabricated in-a factory, and can be transported to the building site on a truck or other such vehicle, and since the rib frames 2 are composed of wood or an aggregate or composite material, and are therefore lighter than a metal or concrete structure, construction is possible by a smaller labour force.

The rib-frame structure 1 can be easily disassembled, and when the entire rib-frame structure 1 is made of a wood material, it can be recycled after disassembly.

The intervening spaces between front and rear, right and left, or upper and lower rib-frame structures 1, and the space between individual rib-frames 2, can be utilized as spaces for wires, cables, cords, pipes, ducts, etc. The coupling members of the invention correspond to viscoelastic dampers 10, bolts 15, nuts 16, and vibration absorbing rubber members 20 of the embodiment described, but the invention is not limited to the configuration of the embodiment described.

Fig. 15 shows an alternative embodiment in which the corner angles 4 formed with a length substantially the same as the length between the front and rear ends of the rib-frame structure 1 or the overall length of the rib-frame structure 1. In this embodiment, the corner angles 4 are mutually coupled and fixed, and the same effects and actions as for the above described embodiment are obtained.

Fig. 16 shows flat corner members 4, formed with a flat sectional shape and which are provided at right and left corners of the upper side of the rib-frame structures 1. Both ends of the corner members 4 project beyond the front and rear ends of the rib-frame structure 1, and are formed with an L-section, and hence are the same as in the previous embodiment. These corner members 4 can be utilized when coupling the rib-frame structures 1 ln an end-to-end, side-by-side, or upper and lower relationship.

The corner members 4 may alternatively be provided at the right and left corners of the lower sides of the rb-frame structures 1, or at the four corners of the rib-frame structures 1.

As shown in Fig. 17 and Fig. 18, two reinforcement braces 30, composed of iron, steel, or the like, are crossed between the corner angles 4. Upper ends of the braces 30 are linked to both ends of the corner angles 4 provided at the upper side corners, and the lower ends of the braces 30 are linked to ends of both corner angles 4 provided at the lower side corners of the rib-frame structure. The braces 30 are attached in a crossbraced arrangement.

The tension of each brace 30 can be adjusted by means of a turnbuckle 31 provided at its middle, and a vibration-proof structure is thus realized, and the necessary strength and rigidity can be obtained.

Alternatively, the braces 30 may be arranged in a V- formation (as seen from the side); the form is not limited to a cross. The braces 30 may be made of an aggregate or composite material, plywood, or other such wood or steel material.

As shown in Fig. 19, an inner wall board 5 for covering the interior of the rib-frame structure 1 is directly fixed to the right, left, upper and lower inner sides of the rib-frames 2 by means of fixing members. An outer wall board 6 for covering the right and left exterior surfaces of the rib-frame structure 1 may be fixed to support members 7 that are erected or positioned at specified intervals in the vertical direction along the right and left exterior sides of the rib-frames 2 by means of fixing members. This does not disturb the reinforcement provided by the braces 30.

In addition, the inner wall boards 5 may be fixed to the right and left inner sides of the rib-frames 2 by way of support members 7.

Alternatively, as shown in Fig. 20, two braces 30 may be crossed on the corner angles 4.

Alternatively, the inner wall board 5 may be fixed to the upper and lower inner sides of the rib-frame structure 1, or the outer wall board 6 may be fixed to the upper and lower outer sides of the rib-frame structure 1 and/or the left and right outer sides of the rib-frame, or any combination of sides may have wall boards affixed to them.

A strong, rigid and vibration-proof structure can be obtained, with one or a plurality of inner wall boards 5, outer wall boards 6 and braces 30 combined and provided on two, three or four sides of the upper, lower, right and left sides of the rib-frame structure 1.

If viscoelastic dampers 10 are not employed, the corner angles 4 may be directly coupled and fixed.

Claims

Claims 1. A method of construction using rib-frame structures including:

fabricating a rib-frame structure by sequentially arranging a plurality of substantially rectangular-shaped rb-frames along a specified longitudinal direction; and connecting corresponding corners of the rib- frames by fixing a corner member at each of the four corners of the rib- frames so as to produced a tubular rib-frame structure; and forming a construction by placing a plurality of tubular rib-frame structures so formed in an adjacently proximate arrangement; and coupling adjacent tubular rib-frame structures by inter-connecting the opposing corner members of adjacent tubular rib-frame structures with coupling members to produce the construction.
2. The method as claimed in claim 1 wherein each corner member has a right-angled cross-section.
3. The method as claimed in claim 1 or 2, wherein the tubular rib-frame structures are arranged in an end-to- end, a side-by-side, or an upper and lower relationship, the tubular rib- frame structures being proximate to each other, and opposite ends of the corner members that are provided at the four corners of the tubular rib- frame structures are integrally coupled and fixed to each other by means of coupling members.
4 The method as claimed in claim 1, 2 or 3, wherein the rib-frames are composed of a single plate of material or composed by integrally combining a plurality of plates.
5. The method as claimed in claim 1, wherein the rib- frames are of composite construction.
6. The method as claimed in any preceding claim, wherein the corner members project outwards from front and rear ends of the tubular ribframe structure.
7. A rib-frame structure comprising: a sequential arrangement of a plurality of substantially rectangular-shaped rib-frames, the corners of which are fixed by corner members each spanning corners of each of the rib-frames so as to produce a tubular rib-frame structure.
8. The rib-frame structure as claimed in claim 7, wherein each corner member has a substantially right- angled cross-section and covers corners of the rib- frames.
9. The rib-frame structure of claim 7 or 8, wherein the rib-frames are composed of a single plate of material or composed by integrally combining a plurality of plates.
10. The rib-frame structure of claim 7, 8 or 9, wherein 2S the rib-frames are of composite construction.
11. The rib-frame structure of claim 7, 8, 9 or 1O, wherein the corner members project outward from front and rear ends of the tubular rib-frame structure.
12. The method of constructing a rib-frame structure, substantially as hereinbefore described, and with reference to the accompanying drawings.
13 The method of forming a construction from rib-frame structures, substantially as hereinbefore described, and with reference to the accompanying drawings.
14 The rib-frame structure, substantially as hereinbefore described, and with reference to the accompanying drawings.
15. The construction made from rib-frame structures, substantially as hereinbefore described, and with reference to the accompanying drawings.