Abstract:
Multiple node junctions have at least two nodes sharing an axis. Each node includes a node adaptor-mounting-surface at an angle Θ relative to the axis. An adaptor mounted to each node at the angle Θ relative to the axis uses an adaptor node-mounting-surface and at least one adaptor beam-mounting-surface. A beam having one or more adaptor-mounting-surfaces is mounted to the adaptors using beam adaptor-mounting-surfaces so that the beam is mounted at the angle Θ relative to the axis. The length of each adaptor corresponds to the spacing between each adaptor node-mounting-surface and its matching adaptor beam-mounting-surface. The lengths of the first and second adaptors are selected to accommodate the angle Θ. A framework, for example a free form glass wall or the like, can be created using a plurality of multiple node junctions according to embodiments of the present invention.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of priority under 35 U.S.C. § 119(e) of the following:  
         [0002]     U.S. Provisional Ser. No. 60/742,469 (Attorney Docket No. 1302-p01p) filed on Dec. 05, 2005, entitled MULTIPLE NODE JUNCTION STRUCTURE, the entire disclosure of which is incorporated herein by reference in its entirety for all purposes.  
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0003]     Not applicable.  
       REFERENCE TO SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISK APPENDIX  
       [0004]     Not applicable.  
     
    
     BACKGROUND  
       [0005]     1. Technical Field  
         [0006]     This invention relates generally to methods, systems and apparatus for erecting and supporting structures of various types, especially structures using what is commonly referred to as “free form” structures.  
         [0007]     2. Description of Related Art  
         [0008]     Various techniques and apparatus have been developed for constructing two-dimensional and three-dimensional frameworks and structures that permit free form shapes and configurations. Frequently, wide spanning yet lightweight structures can be assembled for roofs, halls, atria, domes and the like.  
         [0009]     Earlier connection systems joined two or more structural members (trusses or beams). All of those connections were realized by means of two node elements. The first node element is connected to the “top” fiber of the member and the second node element is connected to the “bottom” fiber of the member. These arrangements ensured a rigid connection of all structural members connected to each other by means of a minimum of two node elements. Those connections between the structural members could transfer normal forces and shear forces, but also significant bending moments. However, those connection systems had a limited adaptability of the angle between the axis through the two nodes and the longitudinal axis of the structural member (described as angle Θ, below).  
         [0010]     Other connection systems are disclosed in U.S. Pat. No. 5,398,475, entitled JOINT-ADAPTER FOR DOUBLY CURVED LATTICE GIRDERS, IN PARTICULAR SINGLE-LAYER TYPES, issued Mar. 21, 1995. These connection systems use a single, hollow node element, typically of cylindrical form. The angle between the node axis and the longitudinal axis of the structural member (that is, angle Θ) can be adapted in a wider range than some earlier systems. However, the transferable bending moment is limited by the relatively small height of the structural member.  
         [0011]     Other design systems require special machining of the interconnecting beams (for example, creating stepped or multi-level beam-mounting-surfaces) and various other components. These node connection systems also use one or two node elements. As before, the angle between the node axis and the longitudinal axis of the structural member (angle Θ) can be adapted in a wider range than some earlier systems. However, this range (only 80° to 100°) is too limited for the requirements of modern free-form structures.  
         [0012]     Systems, methods and techniques that improve upon earlier design systems and allow more variation and greater angular displacement of support beams, while still maintaining a lightweight structure and overcoming the shortcomings of earlier systems would represent a significant advancement in the art.  
       BRIEF SUMMARY  
       [0013]     Embodiments of the present invention include multiple node junctions having first and second nodes sharing an axis. The first node includes a node adaptor-mounting-surface at an angle Θ relative to the axis. An adaptor mounted to the first node uses an adaptor node-mounting-surface and at least one adaptor beam-mounting-surface. The adaptor node-mounting-surface engages the node adaptor-mounting-surface to mount the adaptor (for example, using a bolt or other mounting means) at the angle Θ relative to the axis. The second node likewise has a node adaptor-mounting-surface at the angle Θ relative to the axis. Similarly, a second adaptor is mounted to the second node and uses an adaptor node-mounting-surface and at least one adaptor beam-mounting-surface. As with the first node&#39;s structure, the second adaptor&#39;s node-mounting-surface engages the second node&#39;s adaptor-mounting-surface to mount the second adaptor at the axis angle Θ.  
         [0014]     A beam having one or more generally planar adaptor-mounting-surfaces is mounted (for example, by welding) to the first and second adaptors using the beam adaptor-mounting-surface(s) so that the beam is mounted at the angle Θ relative to the axis. The length of each adaptor corresponds to the spacing between each adaptor node-mounting-surface and its matching adaptor beam-mounting-surface. The lengths of the first and second adaptors are selected to accommodate the angle Θ. A beam extension can be used to accommodate other/further mounting surfaces. A framework, for example a free form glass wall or the like, can be created using a plurality of multiple node junctions according to embodiments of the present invention.  
         [0015]     Further details and advantages of the invention are provided in the following Detailed Description and the associated Figures.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]     The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings, wherein like reference numerals designate like structural elements, and in which:  
         [0017]      FIG. 1  is an isometric top view of one embodiment of the present invention may be used.  
         [0018]      FIG. 2  is an isometric bottom view of one embodiment of the present invention may be used.  
         [0019]      FIG. 3  is a top view of one embodiment of the present invention may be used.  
         [0020]      FIG. 4A  is a cross-sectional view of the structure of  FIG. 3  along the line A-A of  FIG. 3 .  
         [0021]      FIG. 4B  is another cross-sectional view of one embodiment of the present invention.  
         [0022]      FIG. 5  is a top view of a node blank usable in connection with embodiments of the present invention.  
         [0023]      FIG. 6  is a cross-sectional view of the node blank of  FIG. 5  along the line A-A of  FIG. 5 .  
         [0024]      FIG. 7  is a top view of a node usable with embodiments of the present invention.  
         [0025]      FIG. 8  is a cross-sectional view of the node of  FIG. 7  along the line A-A of  FIG. 7 .  
         [0026]      FIG. 9  is an isometric view of the node of  FIG. 7  along the arrow A of  FIG. 8 .  
         [0027]      FIG. 10  is a perspective view of an adaptor usable with embodiments of the present invention.  
         [0028]      FIG. 11  is another perspective view of an adaptor usable with embodiments of the present invention.  
         [0029]      FIG. 12  is a top view of an adaptor usable with embodiments of the present invention.  
         [0030]      FIG. 13  is a side cross-sectional view of an adaptor usable with embodiments of the present invention.  
         [0031]      FIG. 14  is a perspective view of a beam usable with embodiments of the present invention.  
         [0032]      FIG. 15  is a side view of a beam usable with embodiments of the present invention.  
         [0033]      FIG. 16  is a detailed side view of a beam usable with embodiments of the present invention.  
         [0034]      FIG. 17  is a detailed top view of a beam usable with embodiments of the present invention.  
         [0035]      FIG. 18  is a perspective view of a frame constructed according to one or more embodiments of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0036]     The following detailed description of the invention will refer to one or more embodiments of the invention, but is not limited to such embodiments. Rather, the detailed description is intended only to be illustrative. Those skilled in the art will readily appreciate that the detailed description given herein with respect to the Figures is provided for explanatory purposes as the invention extends beyond these limited embodiments.  
         [0037]     As described in more detail below, a multiple node support structure uses two or more nodes at the junction of two or more beams mounted thereto for supporting various structures. The multiple node junction structure uses node-mounting-surfaces and adaptors to permit beams connected to a junction to be mounted at various angles relative to one another and/or the nodes. The result is a support structure that is relatively lightweight and flexible, yet extremely strong and durable. It is usable in a variety of settings, including free form structures that require dramatic changes in support structure orientation with minimal structural intrusion into the design.  
         [0038]     More specifically, a number of improvements can be realized using embodiments of the present invention. The angle between the node axis and the longitudinal axis of the structural member (that is, angle Θ) can be adapted to a much greater range. No machining of the node cavity is required. The stepped beam ends and corresponding differences in adaptor lengths require only minimal machining of connection faces at the nodes. However, no handling of the whole beam for machining operations is required because the adaptors can be produced very accurately and are then only welded to the beam ends.  
         [0039]     One embodiment of the multiple node junction structure  100  of the present invention is shown in  FIGS. 1-4B . A first node  110  and a second node  120 , typically (though not necessarily) oriented as an “upper” node and a “lower” node, respectively, are spaced apart to create a node set or junction  105 . Nodes  110 ,  120  share an axis  130 . In some embodiments, the nodes are generally circular, cylindrical and/or toroidal and axis  130  passes through the center of each node. As will be appreciated by those skilled in the art, each node can be generally hollow when toroidal in shape or can be more solid, depending on the needed strength for a given structure. Each node has one or more adaptor-mounting-surfaces  114  (also seen as surfaces  714  in  FIGS. 7-9 ) that is oriented at an angle Θ relative to axis  130 . Using embodiments of the present invention, the angle Θ can vary from about 60° to 120°, including 90°, where the adaptor-mounting-surface of a node is parallel to axis  130 . The nodes  110 ,  120  can be tapped with holes  112 , if appropriate, as seen in  FIG. 3  (also seen as holes  712  in  FIGS. 7-9 ).  
         [0040]     Nodes  110 ,  120  and the like can be created using a standard blank, as shown in  FIGS. 5 and 6 . A toroidal blank  510  has a primary center bore  512  and secondary upper and lower bores  514  that make fabrication relatively easy and inexpensive. The outer cylindrical face of blank  510  can be machined to create adaptor-mounting-surfaces at desired angles and positions for a given structure. Moreover, as noted above, blanks  510  can be tapped to provide threaded holes for bolts or other mounting means that allow nodes to be mounted to adaptors as desired, as will be appreciated by those skilled in the art. Again, the taps may be drilled and threaded at desired angles and positions to permit customization of each node for a given free form or other structure. Blanks are processed to generate nodes such as the node  710  shown in  FIGS. 7-9 . Node  710  has a plurality of tapped holes  712  penetrating adaptor-mounting-surfaces  714 . Holes  712  and mounting surfaces  714  can be uniformly distributed around the periphery of the node  710  or can be sited at irregular intervals, as needed. Moreover, the adaptor-mounting-surfaces  714  can be uniform in their angular displacement Θ from the axis  720  of the node  710  or can have different angular displacements, again as needed.  
         [0041]     As seen in  FIGS. 1-4B , beams  140  are mounted to nodes  110 ,  120  using adaptors  150 . The beams  140  can provide support structure for glass or other building materials, as appropriate. The adaptors  150  provide a simplified way of mounting the beams  140  to the nodes  110 ,  120 . In some embodiments of the present invention, the adaptors  150  are welded to the beams  140  and any beam extensions  144  used as well.  
         [0042]     As seen in more detail in  FIGS. 10-13 , each adaptor  850  has a node-mounting-surface  852  that engages an adaptor-mounting-surface on a node when the structure is assembled. This engagement between a node-mounting-surface and an adaptor-mounting-surface means that an adaptor&#39;s longitudinal axis (which is parallel to the longitudinal axis of a beam mounted to adaptor) will be oriented at the angle Θ relative to the axis  130  also. Each adaptor  850  also has at least one beam-mounting-surface  854  that permits the adaptor  850  to be mounted to a beam by any appropriate means, such as welding or the like. In some embodiments of the present invention, multiple beam-mounting-surfaces can be found on an adaptor. For example, in  FIGS. 1-4B , each adaptor  150  has two beam-mounting-surfaces. Shown in more detail in  FIGS. 10-13 , one beam-mounting-surface  854  is generally parallel to the node-mounting-surface  852  and the other beam-mounting-surface  856  is perpendicular to the node-mounting-surface  852 . Each adaptor  850  can include a cavity  858  that provides ready access to a mounting means for mounting the adaptor to a node. In some embodiments of the present invention, such as those shown in  FIGS. 1-4B  and  10 - 13 , the mounting means is a bolt  860  that can be threaded through an access hole  857  in the adaptor  850  to engage a tapped hole in a node. Other methods and configurations for mounting adaptors to beams and for mounting adaptors to nodes will be apparent to those skilled in the art.  
         [0043]     Specific mountings of adaptors to beams are shown in  FIGS. 14-17 . A beam  910  can have multiple adaptors  950  mounted to it, as seen in  FIG. 14 . The beams can be made of any suitable material, which may depend on the structure and its weight and load-bearing demands, as will be appreciated by those skilled in the art. Steel and other materials are commonly used and others are known to those skilled in the art. In  FIGS. 14 and 15 , each adaptor  950  has been welded to beam  910  using two attachment surfaces. One is an end surface such as surface  854  of  FIG. 10 . A “bottom” surface of an adaptor, such as surface  856  of  FIG. 13  also can be used. The adaptor&#39;s end surface can be welded to a planar end  912  of the beam  910  in  FIGS. 15 and 16 . As will be described in more detail below, these planar ends of the beam  910  do not require special multiple level machining to accommodate adaptor pairs, which provides significant advantages over earlier structures that utilized stepped or otherwise specialized beam end configurations. The adaptors&#39; bottom surfaces are welded to a beam extension  914  that is welded to the end  912  of beam  910 , as seen in more detail in  FIGS. 16 and 17 . Other mounting schemes for the adaptors and beams will be apparent to those skilled in the art. The adaptors typically are mounted with access cavities  958  facing “up” or “down” to facilitate access to bolts or other mounting means during assembly. Of course other mounting means access configurations are available (for example, “side” access cavities, rivets, etc.) and will not be described in detail herein.  
         [0044]     As seen in  FIGS. 14-16 , adaptors mounted to the same end of a beam  910  may be of different lengths. For example, in  FIGS. 15 and 16  adaptor  950   a  is longer than adaptor  950   b . Because adaptors  950  are standardized as to shape and function, they can be easily adjusted as to length by simply cutting some adaptors shorter than others, as needed. This simple length adjustment to an adaptor pair on one end of a beam (that is, differential between adaptors in a given adaptor pair) provides dramatic angular flexibility without special or complicated processing of the beam and/or nodes involved. As explained in more detail below, this easy variability in adaptor length provides excellent adaptability of embodiments of the present invention for use in various structural settings and uses.  
         [0045]     Mounting of beams to nodes is shown in detail in  FIGS. 1-4B . Specifically in  FIGS. 3, 4A  and  4 B, a plurality of beams  140  are mounted to nodes  110 ,  120 . As will be appreciated by those skilled in the art, more than 2 nodes could be used in each node set, wherein an adaptor  150  would be provided for each such node and a single beam would use as many adaptors  150  as necessary to effectuate proper mounting to a given node set. In  FIGS. 3 and 4 A, bolts  180  are used as mounting means to mount adaptors  150  to nodes  110 ,  120 . Each adaptor-mounting-surface  114  engages a node-mounting-surface  152  to mount a given adaptor  150  at an angle Θ relative to axis  130 , as noted above. Again, adaptors  150  can be mounted to beams  140  in any suitable manner, for example by welding.  
         [0046]     In  FIGS. 4A and 4B  adaptor  150   b  is longer than adaptor  150   a . Adaptor  150   b  is longer to accommodate the angle Θ at which beam  140  is being mounted relative to axis  130 . This configuration requires providing adaptors of different lengths, but allows uniform node structure relative to node  110  and node  120  and allows the adaptor-mounting-surface of beam  140  to be simply planar, thus reducing the machining needed for individual beams  140  in the structure. Instead, relatively minor adjustments can be made to the lengths of adaptors to accommodate the various values of Θ provided in a structure (sometimes multiple values of Θ in a single junction or node set).  
         [0047]     As shown in more detail in  FIG. 4B , the needed length difference for adaptors  150   a  and  150   b  can be calculated using simple trigonometric functions/equations, as will be appreciated by those skilled in the art. As shown in  FIG. 4B , the length difference Δ for the adaptors can be calculated as Δ=(H−h)*tan(Θ−90°). When Θ is less than 90°, then adaptor  150   a  will be shorter than adaptor  150   b . When Θ is greater 90°, then adaptor  150   a  will be longer than adaptor  150   b . Finally, when Θ is 90° exactly, adaptors  150   a ,  150   b  will be the same length. A frame or grid  1810  of multiple node structures is shown in  FIG. 18 . Each junction  1820  on the frame  1810  consists of two or more nodes  1830  in a node set mounted to two or more beams  1840 . This type of structure allows free form construction and mounting of glass and/or other materials with a minimum of intrusion by the support structure.  
         [0048]     The many features and advantages of the present invention are apparent from the written description, and thus, the appended claims are intended to cover all such features and advantages of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, the present invention is not limited to the exact construction and operation as illustrated and described. Therefore, the described embodiments should be taken as illustrative and not restrictive, and the invention should not be limited to the details given herein but should be defined by the following claims and their full scope of equivalents, whether foreseeable or unforeseeable now or in the future.