Abstract:
A structural assembly has a first set of first elongate structural members alternately spaced apart from a second set of second elongate structural members by locking blocks, the first set defining a first plane and the second set defining a second plane forming an intersection at an angle with the first plane, the structural members and locking blocks defining an assembly of adjoined blocks and structural members at the intersection, and a compressive mechanism spanning the assembly of adjoined blocks and structural members at the intersection. Compressing the adjoined blocks and structural members by the spanning compression mechanism locks the blocks and structural members together in a manner to resist applied forces.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The present invention is in the field of construction, pertaining more specifically to the art of framing in construction and methods and apparatus for securing and locking structural members into position, applicable in many areas, such as construction for sub flooring, ceiling, roof, and other framings requiring structural members, and for structures in furniture, containers, models, and temporary shelters, among many other uses. 
         [0003]    2. Discussion of the State of the Art 
         [0004]    In the field of framing for construction joisting is regularly employed to form a load-bearing floor, roofing, or ceiling framework comprising of multiple structural members laid parallel to one another and fastened to common end plates or beams. A typical structural member defines the elongate member laid with other like members to form a sub-floor, roof, or a ceiling truss. In constructions of differing materials the structural members are laid somewhat uniformly in the arrangements or structures according to certain standards set for those types of constructions. A problem with standard joisting is that it is limited to simple or continuous spans with bearing-type connections and is particularly weak with respect to resisting force from certain directions variant from typical load-bearing (vertical) forces or dead weight. 
         [0005]    Depending on construction materials used in a particular project, there are various standard methods for securing structural members to each other and to end plates. Nails, screws, metal bracing, and other components may be used depending on specifications for the construction project. A problem with typical joisting and joisting with prefabricated truss works is that other than vertical load-bearing, there is no inherent structural integrity for resisting certain directional forces that can occur such as wind shear, earthquake, and other forces. 
         [0006]    Therefore, what is clearly needed is a structural member lock and positioning system that distributes load resistance to vertical members across the construction and adds structural strength to resist forces other than vertical load forces. 
       SUMMARY OF THE INVENTION 
       [0007]    In an embodiment of the present invention a structural assembly is provided comprising a first set of first elongate structural members alternately spaced apart from a second set of second elongate structural members by locking blocks, the first set defining a first plane and the second set defining a second plane forming an intersection at an angle with the first plane, the structural members and locking blocks defining an assembly of adjoined blocks and structural members at the intersection, and a compressive mechanism spanning the assembly of adjoined blocks and structural members at the intersection. Compressing the adjoined blocks and structural members by the spanning compression mechanism locks the blocks and structural members together in a manner to resist applied forces. 
         [0008]    In one embodiment the compressive mechanism comprises a rod, wire or cable passing through aligned openings in the adjoining blocks and structural members at the intersection, and one or more elements applying tension to the rod, wire or cable. Also in one embodiment the structural members and the blocks have complementary shape such that adjoining blocks and structural members engage at a specific angle defined by the engagement shapes of the blocks. 
         [0009]    In some embodiments the structural members have an I-beam shape with a central planar member and wider rails at each end, the locking blocks have channels to engage the wider rails, with sets of channels on opposite sides to engage adjacent structural members, with the sets of channels oriented at an angle to one another, defining the angle of the planes at the intersection. Also in some embodiments there may be a third set of structural members defining a third plane parallel to the first plane and a fourth set of structural members defining a fourth plane parallel to the second plane, the first and second planes intersecting at a first intersection at ninety degrees, the second and third planes intersecting at a second intersection at ninety degrees, the third plane and the fourth plane intersecting at a third intersection at ninety degrees, and the fourth plane and the first plane intersecting at a fourth intersection at ninety degrees, the four planes defining a rectangular box. 
         [0010]    In some embodiments there panels fastened to the separate sets of structural members, providing a top, a floor, and two sides to the structural assembly. 
         [0011]    In another aspect of the invention a method for making a rigid structural assembly is provided, comprising the steps of (a) spacing apart a first and a second set of elongate structural members alternately with locking blocks such that the first set defines a first plane and the second set defines a second plane in an intersection at an angle with the first plane, the structural members and locking blocks defining an assembly of adjoined blocks and structural members at the intersection; and (b) compressing the adjoined structural members and inter-spaced locking blocks at the intersection with a spanning compression mechanism. 
         [0012]    In one embodiment of the method the compressive mechanism comprises a rod, wire or cable passing through aligned openings in the adjoining blocks and structural members at the intersection, and one or more elements applying tension to the rod, wire or cable. In another embodiment the structural members and the blocks have complementary shape such that adjoining blocks and structural members engage at a specific angle defined by the engagement shapes of the blocks. 
         [0013]    Also in some embodiments of the method the structural members may have an I-beam shape with a central planar member and wider rails at each end, the locking blocks have channels to engage the wider rails, with sets of channels on opposite sides to engage adjacent structural members, with the sets of channels oriented at an angle to one another, defining the angle of the planes at the intersection. 
         [0014]    In some embodiments there may be a third set of structural members defining a third plane parallel to the first plane and a fourth set of structural members defining a fourth plane parallel to the second plane, the first and second planes intersecting at a first intersection at ninety degrees, the second and third planes intersecting at a second intersection at ninety degrees, the third plane and the fourth plane intersecting at a third intersection at ninety degrees, and the fourth plane and the first plane intersecting at a fourth intersection at ninety degrees, the four planes defining a rectangular box. Also in some cases there are panels fastened to the separate sets of structural members, providing a top, a floor, and two sides to the structural assembly. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWING FIGURES 
         [0015]      FIG. 1  is perspective view of a frame assembly according to an embodiment of the invention. 
           [0016]      FIG. 2  is a perspective view of the assembly of  FIG. 1  flipped around to illustrate the inside construction of the assembly. 
           [0017]      FIG. 3  is a perspective view of the structural members of  FIGS. 1 and 2 . 
           [0018]      FIG. 4  is a perspective view of the structural member lock of  FIG. 1  according to an embodiment of the invention. 
           [0019]      FIG. 5  is a plan view of a structural member assembly according to an embodiment of the invention. 
           [0020]      FIG. 6  is a perspective view of a structural member assembly locked at an angle other than 90 degrees. 
           [0021]      FIG. 7  is a plan view of an angled structural member assembly according to an embodiment of the invention. 
           [0022]      FIG. 8A  is a perspective view of a torsion locking block according to another embodiment of the present invention. 
           [0023]      FIG. 8B  is a perspective view of a torsion locking block according to another embodiment of the present invention. 
           [0024]      FIG. 9  is an illustration of a basic box structure according to an embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION  
       [0025]      FIG. 1  is perspective view of a frame assembly  100  according to an embodiment of the invention. Frame assembly  100  is a framing configuration in construction that provides a construction framing for floors, walls, and ceilings of a structure or building. Assembly  100  consists of multiple structural members  101  and  102  positioned and locked into place by multiple torsion locking blocks  103  placed between each of vertical structural members  101  and horizontal structural members  102 . In this example, structural members  101  and  102  are identical to one another in physical description and may be used as either vertical or horizontal members. 
         [0026]    Structural members  101  and  102  may be made of wood, steel, aluminum, or some other durable material suitable for building construction. Torsion locking blocks  103  may be made of wood, steel, aluminum, or some other durable material suitable for building construction. Structural members  101  and  102  have physical features that interface and engage with physical features on the joist-interfacing sides of torsion locking devices  103  in this configuration. 
         [0027]    In this example there are 4 vertical structural members  101  and 4 horizontal structural members  102  assembled with 7 torsion locking blocks  103 . This framing example may represent, for example, a junction of a sub floor and vertical wall framing of a building under construction. It will be appreciated by one with skill in the art of construction that the entire building frame is not represented in this example. In this case the structural members are secured at a right angle (90 degrees), common for floor-to-wall interfaces. The structural members are secured to the locking blocks at their ends in this example. In other construction configurations the angle may differ from 90 degrees and the structural members may intersect with torsion locking blocks at any intersection point placed along the length of those members. 
         [0028]    A compression system  105  is provided to compress the collective components of the assembly together in the geometric configuration shown. Compression system  105  comprises a solid and durable elongate bar or rod  107  that passes through openings located in structural members  101  and  102  and in torsion locking blocks  103 . System  105  may include compression washers and tensioning nuts applied to the ends of the assembly to secure and compress the assembly together. The elongate rod  107  used may be manufactured of steel or another solid and durable material capable of serving as a compression medium without failing under tensioning applied at the ends of the assembly. 
         [0029]    In alternative embodiments cable or wire may be used rather than a rod or bar, and various tensioning mechanisms may be used to compress the structural members and the locking blocks together. 
         [0030]    Assembly  100  is superior in strength to other construction geometries using structural members because the torsion locking blocks  103  together with the compression system  105  applied to secure the assembly provide transfer of shear, torsion, and moment forces laterally between adjacent structural members  101  and  102  in a direction substantially perpendicular to the direction of the structural members in the assembly. 
         [0031]    Assembly  100  includes multiple exterior and interior panels  104  that help to secure the structural members together with other structural members in the assembly. Panels  104  are attached in this example to the assembly at the outside and inside edges of the structural members. Panels  104  may be manufactured of plywood, metal sheeting, fiberglass sheeting, or other relatively stiff material. Panels  104  help to ensure transfer of shear and moment forces across the assembly, but are not essential in the broad aspects of this invention. Exterior panels  104  come together at the rear edge of the assembly and are fastened to the assembly with the aid of a blocking element  106  (interior blocking element visible). 
         [0032]    Blocking elements  106  are positioned both on the exterior and interior sides of the assembly and are connected between the structural members  101  and  102 , and torsion locking blocks  103 . Blocking elements  106  have fasteners that tie the components together when panels  104  are added to the assembly. Blocking elements  106  provide a continuous load path between the other elements of the assembly and further allow adjacent panels  104  to be connected or secured across their lateral intersection. Blocking elements  106  may be manufactured from wood, steel, aluminum, or some other solid and durable material capable of load transfer. 
         [0033]      FIG. 2  is a perspective view of the assembly of  FIG. 1  rotated to illustrate the inside construction of the assembly in this example. In this view blocking elements  106  are visible in position between horizontal structural members  102  and vertical structural members  101 . Fasteners holding blocking elements in position and to panels  104  are not visible in this example but are assumed present. The construction and type of fasteners used will depend on the material selection of the components in the assembly. The exact method of fastening is not relevant to the invention. 
         [0034]      FIG. 3  is a perspective view of one each of structural members  101  and  102  of  FIGS. 1 and 2 , shown isolated. Structural member  101  and structural member  102  are identical to each other in physical description in this embodiment, but may differ somewhat in other embodiments. In this example the shared physical features between structural members  101  and structural members  102  have the same element numbers and description. Each structural member  101  and  102  consists of substantially parallel rails  302  formed along longitudinal edges of the structural members. A thinner middle body  301  is disposed between rails  302  forming a complete structural member much in the manner of an I-beam. In a preferred embodiment, structural members  101  and  102  are contiguous parts formed of the same material. In some embodiments rails  302  may be separate components joined to middle body  301  to form a structural member that may function as a part formed of one material. 
         [0035]    In this example, rails  302  are rectangular in profile. The rectangular portion of each rail  302  on one side of body  301  is of a dimension that fits into channels provided on interfacing sides of the torsion locking blocks. The I-beam construction profile of structural members  101  and  102  provides sufficient transfer of load forces and is particularly suited for strength. Structural members  101  and  102  each have openings  303  in alignment with one another in appropriate configuration for assembly with the interspaced locking blocks. Openings  303  are sized to accept the tensioning bar or rod  107 . 
         [0036]    Structural members  101  and  102  have each have openings  303  at locations along each structural member where a torsion structural member lock may be placed, not necessarily just at the ends of the members. Further, structural members  101  and  102  may be of any required length for construction. The structural members may be assembled using a torsion structural locking block at any desired linear angle including 180 degrees. In one embodiment the angle of construction of the structural members is set by the construction of the torsion structural member locks. For example, a 90-degree angle would require a 90-degree torsion structural member lock. 
         [0037]      FIG. 4  is a perspective view of a torsion locking block  103  of  FIG. 1  according to an embodiment of the invention. Torsion locking block  103  may be manufactured of steel, wood, fiberglass, or other construction materials. Locking block  103  in this example is quadrilateral in shape having 4 sides, a top surface and a bottom surface. Sides  402  and  404  are the sides that interface with structural members. Sides  406  and  405  do not interface with structural members. Opposing sides of structural member block  103  are substantially parallel to each other as are the top and bottom surfaces. 
         [0038]    In one embodiment torsion locking block  103  is of a solid construction. In another embodiment, locking block  103  may be manufactured of separate components that fit together to function as one piece. One or more openings  407  are provided at or around the approximate center of locking block  103  extending from side  402  through side  404 . Opening  407  is a through-bore and has a diameter sufficiently large for accepting the tensioning rod  107 , or whatever tensioning element is to be used. 
         [0039]    Torsion locking block  103  has a pair of channels  401  along opposing edges of side  402 . Channels  401  are identical to one another in depth and function to accept the rails provided on the structural members  101  and  102 . Channels  401  are substantially symmetrical and extend the length of side  402  in a horizontal direction for supporting one of horizontal structural members  102  described further above. The spacing between the opposing shelf walls is just small enough to accept the spacing between the inner opposing walls of the rails of a structural member. Channels  401  have a depth measured from surface  402  that is just large enough to enable the structural member body in between the rails to interface flush against surface  402 . The fit is tight enough so that there is very little or no movement in the angle of the assembly. 
         [0040]    On surface  404  there is a like pair of channels  403  provided in orientation rotated approximately 90 degrees from channels  403  to accept vertical structural members  101  described earlier. In this embodiment, torsion locking block  103  is a 90-degree block, meaning that adjacent structural members abutting the locking block are disposed linearly at a 90-degree angle such as where a floor meets a vertical wall. However, other torsion locking blocks may be provided of varying angles between 0 and 180 degrees. 
         [0041]      FIG. 5  is a plan view of a structural member assembly  500  according to an embodiment of the invention. Structural member assembly  500  includes 2 horizontal structural members  102  spaced evenly apart in assembly from a vertical structural member  101  by 2 torsion locking blocks  103 . In this example, the assembly is secured and compressed by compression system  105 , which includes in this instance a rod  502  passing through the assembly and held in place by tensioning nuts  501  at either end of the assembly. Applying tension to the assembly provides the compression needed to ensure transfer of lateral shear and moment forces through the assembly, equally distributing the load. 
         [0042]      FIG. 6  is a perspective view of a structural assembly  600  locked at an angle other than 90 degrees. Assembly  600  is implemented at an angle other than 90 degrees by using a torsion locking block  603  having channels orientated at an angle other than 90 degrees. In this case, a horizontal structural member  602  has a locking interface located approximately at a center point of the length of the member, rather than at one end of the member. Vertical structural member  601  may be identical to structural member  101  described earlier. However, in this embodiment, the ends of structural member  601  are angled according to the angle of block  603 , instead of being cut off at a 90 degree angle. In this case, the angle of construction (linear angle formed by assembled structural members) will be the same angle set by the structural member locking blocks used in the assembly. 
         [0043]    In this example, the frame construction may be that of an interior wall intersecting with a floor that rises at the particular angle set by the torsion locking blocks. Blocking devices  106  are shown in place for fastening to panel coverings described earlier. 
         [0044]      FIG. 7  is a view of a structural member assembly  700  also according to an embodiment of the invention, comprising structural members  701  forming a wall structure, locked along interface  704  to members  702  forming a canted roof, with an optional eave extension as shown in the drawing. Interface  705  is a roof peak with one side of the roof locked to the other side using locking blocks (in this case diamond shaped to match the intersecting shapes of the members) and compression along the peak ridge. In this manner locking blocks may be provided having the appropriate engagement and locking angles for different roof angles, and structural members may be trimmed for length and end shapes to suit. 
         [0045]      FIG. 8A  is a perspective view of a torsion locking block  800  according to another embodiment of the present invention. Block  800  has a main body  801  and tongues  802  and  803  extending off of the main body of the block. Block  800  may be formed of a single piece of steel, wood, fiberglass, or some other durable construction material. In one embodiment, main body  801  and tongues  802  and  803  may be separate components joined together to function as one piece. In this embodiment block  800  is of a single contiguous construction. 
         [0046]    In this example, the sides of block  800  that interface with structural members are parallel to the end of each tongue  802  and  803 . That is to say the surfaces lie in the same plane. The back surfaces of tongues  802  and  803  are angled so that the tongues are thicker at the base of main body  801  and thinner at their open ends. Under compression in assembly, the framing may be further strengthened somewhat by the extra footprint provided by tongues  802  and  803 . The width dimension of tongues  802  and  803  is small enough to fit within the inside dimension between rails of the structural members so that the interfacing surface may be seated flush against the middle body of the structural members. A through opening  804  is provided in similar fashion as was described above for accepting a tensioning rod, cable or wire. 
         [0047]      FIG. 8B  is a perspective view of a torsion locking block  805  according to yet another embodiment of the present invention. Block  805  has a main body  806  and includes tongues  807  and  808  that interface with structural members in similar fashion as tongues  802  and  803 . Tongues  807  and  808  may be contiguously formed with main body  806  or they may be separate components joined to main body  806 . In this variation, tongues  807  and  808  are of a uniform thickness from the open ends to main body  806 . It is noted herein that block  800  and block  805  may be interchangeable in the same framing assembly without departing from the spirit and scope of the present invention. For example, block  800  may be placed in the portion of the assembly that bears more vertical load while block  805  may be suitable for portions of the assembly where there is less vertical load. 
         [0048]    It will be apparent to one with skill in the art that locking blocks  800  and  805  may both be provided as blocks that present a construction angle that departs from 90 degrees, as has already been discussed above for block  103 . Moreover, the overall thickness of block  103 , block  800  or block  805  may be changed considerably so that structural members may be secured in the assembly having more or less separation, including structural members immediately adjacent or quite widely separated. 
         [0049]      FIG. 9  illustrates a basic box structure  900  using the framing methods and elements of the invention, which may resist loads from any direction and simultaneous loads from multiple directions. Structure  900 , including all of the components described and properly assembled and tensioned may require as few as 4 vertical supports  905  (three are visible in the perspective view) to the ground or to a supporting structure below. In this example, a simple rectangular structure 20 feet wide, 20 feet tall, and 40 feet long uses wooden I-structural members and the framing components described above for floors and roof members spaced at 16 inches on center, with the wall structural members made of the same or similar elements, shapes and spacing but offset from the floor structural members by approximately 8 inches center-to-center. 
         [0050]    The top and floor are connected to the walls of the structure using torsion locking blocks according to an embodiment of this invention with a steel tension rod, wire or cable passing through the assembly at the intersections  901 ,  902 ,  903  and  904  of horizontal and vertical planes, from one end of the structure to the other end of the structure (40 foot length), and with appropriate tension applied. The top, floor, and walls of the structure are covered by plywood panels in this example, fastened using wood screws or nails, and the blocking components previously described along all of the panel edges completing the structural framing and form. The construction once formed according to the methods and apparatus of the invention is open on each end, although non-load bearing walls may be added including windows, doors, and other openings according to normal construction guidelines and rules. Doors, windows and the like may also be implemented in the long sides of the structure. 
         [0051]    Structure  900  is a basic structure that may pre-fabricated and shipped to a building site, and used there as the basic unit for a home. Structure  900  may be placed on and secured to a foundation, or other simple supports as shown, and a roof and missing walls added by conventional structural techniques, providing a house much more resistant to natural forces than in the current art. 
         [0052]    In one embodiment of the present invention, the components used for the framing may be pre-manufactured and then assembled forming the assemblies during the framing process at a building site. In another embodiment, entire flooring systems, roof systems, ceiling systems and walls may be assembled to specification and then the assemblies may be positioned and further assembled at the corners to secure the complete structure similar in some aspects to assembling a panelized construction. In alternative embodiments similar pre-loaded and pre-fabricated structures according to embodiment of this invention may be provided in a variety of sizes and shapes for a wide variety of purposes, such as storage structures, temporary housing units and the like, and for almost any construction purpose. 
         [0053]    The methods and apparatus of the invention apply to wood construction and steel construction both residential and commercial. Lighter structures may be envisioned that may be fabricated of polymers, fiberglass, aluminum, and other materials depending on load requirements. There are many possibilities. Further it will be apparent to the skilled artisan that there may be many alterations made to the embodiments described as examples in this specification without departing from the spirit and scope of the invention. For example, structural members are shown in examples as I-beam shapes, and engaging geometry of locking blocks comprise edge channels in the blocks to engage the rails of the I-beam shapes. There are, however, a very wide variety of complementary engaging shapes that may be used, all of which are within the spirit and scope of the invention. There are similarly a wide variety of shapes and geometric variations that may be used beyond the simple example described herein. The apparatus and methods of the invention are useful for many sorts of construction where different surfaces may intersect. The invention for these and other reasons is limited only by the breadth of the following claims.