WO1987005067A1

WO1987005067A1 - Coilable structural members

Info

Publication number: WO1987005067A1
Application number: PCT/AU1987/000039
Authority: WO
Inventors: James Haralampou
Original assignee: James Haralampou
Priority date: 1986-02-13
Filing date: 1987-02-13
Publication date: 1987-08-27

Abstract

A structural member (10) able to be coiled for storage which is rigid when bent the other way is comprised of block members (12) linked in a linear array by a flexible substrate (11) to form a unitary structure. The structural member might be brought to a rigid state in any of a straight line or complex curve by control of the properties of either or both of the block members and the substrate.

Description

Title: "COILABLE STRUCTURAL MEMBERS"

FIELD OF INVENTION This invention relates to a structural element, to various applications thereof, and particular structures that are enabled by the use of one or more of the structural elements.

BACKGROUND ART At various t'imes , a structural element has been utilised that is possessed of the property of being rigid in all but one plane and, within that one plane, being rigid to moments that would bend the element in one direction but being flexible in the opposite direct¬ ion so that the element may be that way coiled upon itself. To date, a structural element of the above type has been constructed by labour intensive techniques in which, typically, block members are laid up in a linear array and hingedly connected to their adjoining members of the array. Reference to the following specifications will show a range of prior types of structural member and the various applications to which the element has been applied.

U.S. Patent 436,104 (Hubartt) provides a ladder that may be coiled upon a drum for storage. The structural element comprises a linear array of elements of a basically block form, butted side to side and mechanically hinged on pivots transverse to the plane of one side of the array. Pivoting is allowed one way only to enable coiling. U.S. Patent 2651053 (Almoslino) provides a portable body support such as a chair that may be rolled one way into a small volume for storage and which, when pulled the other way, adopts preset geometric patterns depending on application. U.S. Patent 3199627 (Wagner et al) provides a ladder that may be rolled one way and is rigid to weight applied the other.

U.S. Patent 3103258 (Scruby) provides a further ladder of the above character. The last three of the references provide structural elements that are three dimensional in form, are laid up in a linear array in an abutting relation¬ ship with a filamentary or web material along one side of the array to establish a form of hinging between the blocks. Coiling one way is permitted as the block faces part around the pivot therebetween. Rigidity is achieved the other way because the block faces abut to prevent movement, either any movement so as to maintain the linear nature of the element, or a degree of move- ment before locking so that the element adopts some pre¬ determined shape before locking.

The references indicate that a variety of things may be achieved through use of the structural element, however,none of them describe an element that lends itself to ready mass production of a structural member that might be usefully applied in any number of different applications.

OUTLINE OF THE INVENTION It is an object of the present invention to provide a structural element of the above type which may be readily manufactured utilising presently available techniques so as to provide a structural element with useful properties at a minimum cost. Other objects, and various advantages, of the invention will herein- after become apparent..

The invention achieves its object by provision of an elongate structural member having a linear array of block members, the adjacent members of which are flexibly connected to one another along a line of fold- ing which is transverse the length of the array, each line of folding being adjacent a side of the block members and generally in the same plane, characterised in that the block members are incompressible or relatively incompressible and are secured to, or integrally formed with, a flexible substrate comprising a plurality of relatively inextensible filaments or woven web .

DESCRIPTION OF THE DRAWINGS The invention will now be described with reference to preferred embodiments shown in the accomp¬ anying drawings in which :-

FIG. 1 is a view of a portion of a structural membe ;

FIG. 2 is a view of the member of FIG. 1 showing how it may be bent into an arch;

FIG. 3 is a view of the member of FIG. 1 showing how it may be rolled up;

FIGS. 4 and 5 show an alternate form of structural membe ; FIG. 6 shows an arch which may be employed as the basic element of a number of structures;

FIGS. 7 and 8 show how the arch of FIG. 6 may be applied to two different structures which employ the structural member therein; FIG. 9 shows how the structural member may form a hoop which may be the basic element of a range of structures ;

FIG. 10 shows how the structural member may adopt a rigid elongate form; FIGS. 11 to 14 show how a plurality of arohes may be utilised in a shelter;

FIG. 15 shows a detailed view of how the arches of the shelter of FIGS. 11 to 14 may be hinged; FIG. 16 shows a means whereby the arches may be fixed in their fanned apart disposition; FIGS. 17 and 18 show an alternate means where¬ by the arches may be held in their fanned apart disposition;

FIG. 19 shows an erect fabric covered shelter; FIGS. 20 to 24 show various ways in which a canopy may be applied to a shelter of the type shown in FIG. 19;

FIGS. 25 to 30 show detailed sections through various forms that the structural members may adopt; FIGS. 31 and 32 show two structures developed using the hoop of FIG. 9;

FIGS. 33 and 3 show two additional structures which employ the arch of FIG. 6;

FIGS. 35 to 38 show how the structural member of FIG. 10 might be applied to a ladder;

FIG. 39 and 40 illustrate elaborations of the shelter structure of FIG. 19-

PREFERRED EMBODIMENTS As shown in FIG. 1, a structural member 10 may include a substrate 11 and a plurality of block members 12. The blocks 12 may have abutment faces 13 that are inclined with respect to an adjacent block such that when the structural member 10 is bent in one direction an arch (FIG. 2) may be formed and may be rolled up (FIG. 3) when bent or folded in other direction. It may be rolled up into a compact spiral. The degree of curvature of the structural member may be selected by the relative inclination of the adjacent block faces. It may be set by variation of the number of blocks which are provided per unit length. It might be varied by selection of different materials in the block so as to give a predetermined degree of compressibility. Where curvature is permitted by a degree of compress- ibility within the block, the inclination of the adjacent block faces may be omitted. In this latter situation, the structural member might be extruded (as is explained further below) and the block established by slitting or slotting. The degree of curvature may be varied by varying the number of slots per unit length (see FIGS. 4 and 5), the width of the slot, and compressibility of the block material, or by the degree of extension that exists in the substrate. A straight member might be provided where the block material is incompressible, the 10 substrate is non-extensible, and the blocks abut each other so as to resist any bending past the straight line configuration. Where arches are formed, the shape of the arch may be held by a tension member between the opposite ends of the structural member.

FIG. 6 shows the structural member 10 ζetain- in an arch form by a tensile member 16 stretched across the gap between opposite ends of the structural member 10. The means of attaching the tensile member 16 may vary but so that the arch may be rolled, if required, at least one end of the tensile member needs to be releas- able and various releasable locking members as are used in any system of belting or harness might be adapted to the purpose. The length of the tensile member might be adjustable so that the degree of tension in the arch might be varied. In permanent structures the tensile member might be fixed at both ends.

FIG. 7 shows a shelter 20 formed from four arches connected to common end plates 22 which are linked by tensile member 16 which serves to hold the member 10 in their arch form. The fanned apart arches are covered with a fabric 21. The arches are pivotally mounted so that they may be rotated to a closed side by side position and rolled together when the tensile member 16 is disconnected. FIG. 8 shows a structure employing spaced apart, parallel arches joined by rods such as 31 which span the gap between the arches and which are engaged in the blocks of the respective structural members. In FIG. 9, the length of the structural member, or its radius of curvature is such that the member 10 forms a complete ring when drawn back to its rigid form. The two ends may be releasably interconn¬ ected by any suitable means at 32. The hop thus formed becomes a basic element of a further range of structures.

In FIG. 10, a rigid beam is formed by a composite of two structural members 10 connected along one side along a hinge line 11 so that one member may overlay the other so that they act in combination to form a rigid beam ( this will be discussed in greater detail below). When folded apart to lie side by side, the pair may be coiled for storage. The beam of FIG. 10 might be used wherever a beam is required, such as in ladders (see below), as a tent pole, as a stowable boat mast, and in conjunction with the hoop or arch in com¬ posite structures.

FIGS. 11 to 19 show how the structural member might be used in the provision of a fabric covered shelter. The shelter or structure 20 has a plurality of members 10 secured to end blocks 22. From the rolled up configuration of FIG. 11, the configuration of FIG. 12 is achieved by unrolling. Fabric 21 is secured between adjacent members 10 as will become more clear- below. The tensioning web 16 is secured between the blocks 22 to arch the members 10 (in FIG.13). Once this configuration is achieved, the structure is erected by pivoting members 10 relative to blocks 22 so as to fan them apart (FIG.14). FIG. 15 shows how the plurality of members 10 might be mounted to the support blocks 22. The web 16 might be secured by the pin 33 at one end in an appropriate recess in a support block 22 and, by a suitable locking means 34, to the support block 22 at the other end. The manner of attaching, and the means for tensioning the web 16 will be varied according to application. Various forms of releasable catches might be adopted such as the webbing attached snap locks of seat belt and other harnesses. With larger structures, means might be provided for overcoming the forces required to tension the members adequately such as winches.

FIG. 16 shows the structure of FIG. 7 with the fabric removed. The structure has a plurality of members 10 pivotally secured to blocks 22. A further member 10 extends between these pivotally -secured structural members to ensure that the latter are maint¬ ained in the spaced apart configuration.

FIGS. 17 and 18 show an alternate means where¬ by the structural members 10 may be fanned apart and held in that position. Two arms 35 and 36 are pivotally mounted on brackets 37 and 38 on the outer of three members 10. Each arm 37 and 38 is pivotally connected at their other end to link 39 which is slidably engaged against the inner structural member. Any convenient means of selectively engaging the link 39 against the inner structural member might be employed. One means comprises utilising the gap between the blocks, k flange on link 39 might be slotted into a selected gap, or a purpose made groove across the block between the blocks so as to pin the link at- a selected location to hold the adjacent members at a set relative angle to the inner member. Arms 35 and 36 might be lengths of the structural member of the invention so as to allow coiling for storage. FIG. 20 shows how a pair of adjacent members 10 might be interconnected by a sheet of fabric. In FIG. 20, two layers 45 and 46 are shown. Layer 46 may be fashioned from fabric having the shape shown in FIG. 21 which assumes the shape shown in FIG. 23 when it is stretched between two adjacent members 10. Layer 46 is a single phylloid shape. Layer 45 can be a multi- phylloid shape as shown in FIG. 22. Portions 47 and 48 make up layer 45 after edges 49 and 50 are secured together to produce the profile shown in FIG. 24 when the layer 45 is tensioned between two adjacent members 10. Alternate forms are possible and shaping might be by other means such as by heat forming. Such a configuration of layers produce a void 51 for insulation purposes.. Detailed cross sections of various forms that the structural member might adopt are shown in FIGS. 25 to 30. These are formed with projecting edge flanges such as 52 in FIG. 25. In FIG. 25 the members have recesses 53 beneath flanges 52. Fabric 21 may have edge beads 21a which locate in recesses 53 to secure the fabric to the members 10. Substrate 11 comprises elongate filaments or webbing embedded therein ( shown by cross hatching) and is integrally formed with block 12. When the member of FIG. 25 is arched, the flanges assume the position of FIG. 26 to assist in holding the fabric bead within recess 53- A clip 54 giay also be secured to the member to enable items to be hung up within a .structure formed with the members 10.

As shown in FIG. 27 flanges 60 may be provided with end portions 61 which are shaped to receive a corresponding bead 21a of fabric 21„ Other cut outs, or recesses 62 may be provided so as to reduce weight and the quantity of material employed.

In FIG. 29, a high tensile cable 63 extends through a recess of each block 12 and is secured to mounting blocks at each end of member 10 to render the structure semipermanent.

FIG. 28 shows how block members 12 may have outwardly flaired flanges 65 and stacking recesses 66. Flanges 64 may have a fabric 21 secured thereto. These flanges may fold as illustrated when a plurality of like structural members are stacked.

The arrangement of FIG. 30 shows a block 12 having recess 67 to reduce weight, and recesses 53 for receiving fabric 21. The block has key hole shaped recesses 68 for receiving complementary projections 69 of a substrate 26.

FIG. 31 shows how the hoop might be used in the construction of a collapsible shower cubicle. Two hoops 90 are spaced apart by collapsible members 91 acting to develop tension in shower fabric or curtain 92 to bow the members 91 outwardly to their rigid position.

FIG. 32 shows how the hoop 90 might be used in a children's play pen with two hoops 90 spaced apart vertically by rods, bars, or tubes 93 from which may be hung a suspended floor 94 of fabric or other suitable material.

FIG. 33 shows how two arches 10 may form a chair when the arches are spaced apart by rigid members 100 from which a fabric or other style material may extend to form a seat 101, back 29, the two being tensioned from behind at 102 from the back bottoπ rig±ά connecting member 100. The arches are tensioned as before by tensile members 16.

E^IG. 34 shows a basic shelter formed from two arches with a fabric 161 or other sheet material hung thereon.

FIG. 35 shows a partial view of a structural member having two rows of block members 12 secured to a com on substrate 11. One row of blocks may be folded over onto the other row to form a substantially rigid pole or post like that shown in FIG. 36. With the rows arranged side by side as indicated by the broken outline, the arrangement may be rolled up. Thus, as shown in FIG. 3 a ladder 80 may be formed. This ladder may be rolled up when the rows of blocks are side by side and may provide a rigid ladder when the rows are arranged on top of one another. Thus, when the ladder is unrolled one row of blocks 12 may be moved as shown by the arrow in FIG. 35 to produce the ladder of FIG. 38. Rungs 71 may extend between the two adjacent rows of members at spaced intervals.

FIGS. 39 and 40 show how the shelter of FIG. 7 may be extended forwardly with an additional arch 10 forwardly spaced to support a shade cloth or suitable sheet material 85 (FIG. 39) or enclosure 86 with a flap 87 (FIG. 40).

The structural member may be utilised to form three basic elements, or rigid beam, an arch and a hoop. As seen above, these may be used in many different structures. They may substitute for the equivalent elements of many standard structures such as tents and shades where rods are used for poles and are bent to provide arches. The basic structural member may find use wherever a beam may be used within a structure where a degree of tension is applied along the length of the beam so as to curve the member to its rigid position. The size of the structure to which the member might be applied is not limited. The structural member may be effectively scaled up or down in size to suit chosen applications. The rigidity of an arch may be governed by the tension therein and the tensioning member may be provided with tension setting mechanisms, turnbuckles, winches etc., so as to enable large structures to be erected with a selected degree of rigidity.

The above described structural member may be a composite comprised of a strand of filaments or woven web embedded in or beneath one face of a substrate of resilient material which permits the coiling of the element and a block material which resists compression. The substrate and block material may be the same or different. The structural member might be formed by a continuous process such as extrusion with the extrudate being possessed of a desired profile and having the filament or woven web embedded therein within a homo¬ geneous or two component material ( resilient for the substrate, incompressible for the blocks). The extrud- ate may then be slit- or slotted down to the vicinity of the filaments or woven web to complete the structural member.

As an alternate process to the above, a substrate material may have the block material injection moulded onto it, or separately moulded blocks might be welded using a high frequency welding process, or otherwise bonded, such as by an ultrasonic or adhesive bonding technique, thereon.

A further means of providing the structural member comprises extruding a block material into or onto which a high tensile filamentary or belt material might be welded, adhered, or pressed with the application of heat- or solvents. Once formed, the composite might be slit or slotted as described above. ^* In the specification, both above and herein¬ after, filament or woven web includes monofilament warp; flat yarn, crimped yarn; ^*Harp oriented fabri or web; extruded strap; thermally bonded non-woven fabric; open weave unidirectional fabric; laminated polymer film belt; fibre reinforced polymer tape; metallic wires, straps and tapes; and including stretch modified monofilaments of polyamides, saturated polyester, high density polyethylene and polypropylene, aramid and graphite fibres in any of their forms as aforelisted. Selection of appropriate materials is largely governed by the following criteria. The laminating belt material ideally is possessed of a high tensile strength; high tensile modulus; high fatigue resistance; and flexibility. The block material ideally is possess- ed of a high compressive strength; high compressive modulus; high creep resistance; rigidity; processing ease; U.V. stability; light weight; good welding proper¬ ties; and low flammability. For a small shelter where less mechanically demanding conditions are to be met, materials such as polyester, polypropylene and nylon filament may be used in combination with mineral or fibre filled polypropylene or a polyethylene/ polypropylene copolymer or PVC extrudate.

Whilst the above has been described with reference to preferred embodiments, it will be clear that many modifications and variations might be made thereto by those that are skilled in the art which are within the scope and spirit of the invention as hereinbefore set forth.

Claims

CLAIMS:

1. An elongate structural member having a linear array of block members the adjacent members of which are flexibly connected to one another along a line of folding which is transversely the length of the array, each line of folding being adjacent a side of the block members and generally in the same plane characterised in that the block^* members are incompressible or relatively incompressible and are secured to, or integrally formed with, a flexible substrate comprising a plurality of relatively inextensible filaments or woven web.

2. An elongate structural member according to Claim 1 wherein the structural member is extruded in a continuous process with the filaments or woven web along one side edge and the block members are established by transverse slitting or slotting of the extrusion, the slits or slots being cut into its surface opposite the one side, the slits or slots extending therethrough to a point adjacent the filaments or woven web.

3. An elongate structural member according to claim 1 wherein the substrate is preformed and the block members are individually laid up thereon and are bonded thereto by a suitable bonding means.

4. An elongate structural member according to Claim 1 wherein the substrate comprises an elastomeric or resilient material with the filaments or web embedded therein and with locking flanges projecting therefrom and the block members are individually attached thereto by mating of the locking flanges within complementary locking grooves in the block members.^"

5. An elongate structural member as claimed in any one of the ^'preceding claims wherein the number of block members per unit length, the width of the gap between adjacent block members, and/or, the relative inclination of the adjoining faces of adjacent block members is either constant or varied along the length of the structural member so as to cause it to adopt a preselected shape when bent to its point of rigidity.

6. An elongate structural member as claimed in Claim 5 wherein an arch form is adopted when rigid and the member ends are drawn together by a tensile connecting means therebetween to hold the arch in its set position.

7. A structure comprising a plurality of elongate structural members as claimed in Claim 6 wherein the plurality are hingedly interlinked at their bases to provide a plurality of arches that may be fanned apart.

8. The structure of Claim 7 wherein adjoining structural members are provided with a fabric therebetween.

9- The structure of Claim 8 wherein the fabric is provided with an edge bead thereabout which is slotted within a complementary recess extending along the substrate edge.

10. An elongate structural member as claimed in any one of Claims 1 to 4 wherein two linear arrays are interconnected side by side at a lengthwise line of folding so that when laid side by side in a coplanar configuration, the member may be coiled, but when folded, one linear array over onto the other, the member is rigid in all directions,

11. A structure comprised of two spaced apart members as claimed in Claim 10 , the spaced apart members being interlinked by connecting members attached to block members at each end.

12. The structure of Claim 11 wherein the two elongate members form the side members of a ladder and the connecting members are its rungs, the connecting members being rigidly connected to their respective block members.

13- An elongate structural member as claimed in any one of Claims 1 to 4 wherein the substrate comprises edge flanges projected to each side thereof, the edge flanges providing means to interconnect the member with fabric.

14. An elongate structural member as claimed in Claim 13 wherein the flange is bonded face to face with the fabric edge.

15. An elongate structural member as claimed in Claim 13 wherein the flange comprises a locking recess in its outer edge into which a beading about a fabric edge may be slotted.

16. An elongate structural member as claimed in Claim 13 wherein the substrate comprises a locking recess beneath the flange to receive a fabric edge beading therein, the flange being folded downwardly thereover to lock the fabric edge therein when the structural member is arched.