Patent Publication Number: US-2019177975-A1

Title: Structural element

Description:
FIELD OF THE INVENTION 
     The present invention relates to the field of structural units, and more particularly to the field of fast erection light structural units. 
     BACKGROUND OF THE INVENTION 
     Structural units are known. They vary in the constructional materials they are made from, and, in the erection methods. The most common structures are made of concrete with reinforcing steel. These structures are very strong, however, they are very heavy, expensive, and require relatively long erection period; preparation of molds, long curing periods of the concrete, laboratory tests for verifying final strength, etc. 
     Other structural units are made of a massive steel frame that may be erected by welding or bolting. A light cover, made of a variety of materials is then assembled on the steel frame. The light cover may consist of an aluminum frame onto which are assembled glass plates, gypsum plates, and the like. 
     There are also known and common wooden structural units. These units are known for their fast erection time and ease of construction. However, these units require construction of a wooden “frame”, including large and massive wooden logs and wooden bars. Upon finishing the construction of the frame, a “cover” is put on the “frame”. 
     It is the purpose of the present invention to provide a structural element for building a structural unit that significantly reduces or overcomes the aforementioned disadvantages. 
     It is another purpose of the present invention to provide a structural element for building a structural unit that may be erected in a fast manner and is cheap and light. 
     It is also a purpose of the present invention to provide a structural element for building a light and fast erected structural unit that may be built to several stories high, typically, up to five stories high. 
     It is yet another purpose of the present invention to provide a structural element for building a structural unit wherein the structural element provides both the frame and the cover of the unit. 
     SUMMARY OF THE INVENTION 
     A structural unit is formed from structural elements that are connected to each other in a simple manner. When all the structural elements are attached to each other, the structural unit may form a strong and rigid structure up to five stories high. 
     The advantage of the structural element of the present invention is that construction of a structural unit with a separate frame onto which a cover is assembled is successfully prevented. Thus, the structural unit includes both a frame and a cover formed using the structural element of the present invention. 
     There is provided, in accordance with an embodiment of the present invention, a structural element including a substantially flat central portion, a first web portion perpendicularly extending from an edge of the central portion, and a second web portion perpendicularly extending from an opposing edge of the central portion. The central portion and the first and second web portions are formed from a unitary steel sheet. The structural element is suitable for forming load bearing floors and/or walls in a structure. 
     In some embodiments, the first and second web portions include a flat portion and at least one longitudinally extending ridge. 
     In some embodiments, the flat central portion includes one or more longitudinally extending ridges. 
     In some embodiments, the first and second web portions include an inwardly directed end bend directed in a direction towards the central portion. 
     In some embodiments, the first and second web portions include an outwardly directed end bend directed in a direction away from the central portion. 
     In some embodiments, the first web portion includes an inwardly directed end bend directed in a direction towards the central portion and the second web portion includes an outwardly directed end bend directed in a direction away from the central portion. 
     In some embodiments, the at least one longitudinally extending ridge is inwardly directed in a direction towards the central portion. 
     In some embodiments, the at least one longitudinally extending ridge is outwardly directed in a direction away from the central portion. 
     There is provided, in accordance with an embodiment of the present invention, a structural unit formed from a plurality of structural elements, each structural element having a substantially flat central portion, a first web portion perpendicularly extending from an edge of the central portion, and a second web portion perpendicularly extending from an opposing edge of the central portion. The central portion and the first and second web portions are formed from a unitary steel sheet. The structural element is suitable for forming load bearing floors and/or walls in a structure. Also included is a ground slab to support the structure. 
     In some embodiments, the first and second web portions in each of the structural elements include a flat portion and at least one longitudinally extending ridge. 
     In some embodiments, the structure includes a frame formed using the structural elements. 
     In some embodiments, the structure includes one or more floors formed using the structural elements. 
     In some embodiments, the structure includes one or more walls formed using the structural elements. 
     In some embodiments, the structure includes a maximum of five stories. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a better understanding of the present invention and to show how the same may be carried out in practice, reference will now be made to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a structural unit built using structural elements, according to an embodiment of the present invention; 
         FIG. 2  is a perspective view of a structural element, according to an embodiment of the present invention; 
         FIG. 3  is a cross-sectional view showing the connection between the web portions of two consecutive structural elements, according to a first embodiment of the present invention; 
         FIG. 4  is a cross-sectional view showing the connection between the web portions of two consecutive structural elements according to a second embodiment of the present invention; 
         FIG. 5  schematically illustrates the construction of the balcony in the structural unit, according to an embodiment of the present invention; 
         FIG. 6  schematically illustrates the construction of a wall in the structural unit, according to an embodiment of the present invention; 
         FIG. 7  schematically illustrates the construction of a façade and roof in the structural unit, according to an embodiment of the present invention; 
         FIG. 8  schematically illustrates the construction of an internal floor and walls in the structural unit, according to an embodiment of the present invention; 
         FIG. 9  schematically illustrates the construction of a floor and a wall (interior and/or exterior) in the structural unit, according to an embodiment of the present invention; and 
         FIG. 10  schematically illustrates the construction of a floor (ledge) and exterior wall in the structural unit, according to an embodiment of the present invention. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Attention is drawn to  FIGS. 1 to 4  that show a structural unit  10  according to the present invention. For a matter of simplicity, the structural unit  10  will hereinafter be called “unit”. 
     It should be noted that directional terms appearing throughout the specification and claims, e.g. “forward”, “rear”, “upper”, “lower” etc., are used as terms of convenience to distinguish the location of various surfaces relative to each other. These terms are defined with reference to the figures, however, they are used for illustrative purposes only, and are not intended to limit the scope of the invention. 
     The unit  10  is formed from a plurality of structural elements  12  that make up the major portion of the unit  10 . Each of the structural elements  12  is produced out of a steel roll, having a given width, which is rolled and cut to the desired shape and length. 
     Each of the structural elements  12  is formed from a unitary piece that comprises a central portion  14  and two web portions  16  extending perpendicularly therefrom. The structural element  12  has an element length L and an element width W. Typically, each of the web portions  16  comprises a flat web portion  18  and a longitudinally extending ridge  20  that increases the rigidity of the web portion  16  and hence of the entire structural element  12 . If desired, and depending on the use, also the central portion  14  may be provided with a ridge, or a plurality of ridges, for increasing the total rigidity and bending resistance of the structural element  12 . 
     If desired, and depending on the use, the free end of each of the web portions  16  is provided with an inwardly directed end bend  22 . The end bend  22  significantly increases the rigidity of the web portions  16  and hence of the entire structural element  12 . Furthermore, the end bend  22  adds additional convenience and safety when transporting, conveying and using the structural element  12 . 
     In some embodiments, as shown in  FIGS. 2 and 3 , the ridges  20  of the web portions  16  are inwardly directed, thus enabling easy abutment of the flat web portion  18  of a given structural element  12  against the flat web portion  18  of the consecutive structural element  12 . The web portions  16  are then attached to each other by a multitude of self-drilling screws  24 . After the first alignment of two consecutive structural elements  12 , the application of the self-drilling screws  24  is easy, fast, and does not require any specific accuracy. Thus, after the application of the multitude of self-drilling screws, the two structural elements  12  are rigidly attached to each other and form a single unit. 
     In other embodiments, as shown in  FIG. 4 , the web portions  16  are formed such that a first web portion of a given structural element is formed with the ridge directed inwardly, while a second web portion of the same structural element is formed with the ridge directed outwardly. Thus, as shown in  FIG. 4 , when a web portion of a structural element is put adjacent a web portion of a consecutive structural element, the two ridges fit into each other in a male-female manner, thus providing additional fit and sturdiness between the structural elements. It is clear in this case, that the male ridge should be slightly smaller than the female ridge in order to provide perfect fit therebetween. 
     In order to form the structural unit  10 , as seen in  FIG. 1 , a multitude of structural elements  12  are attached to each other as described above and placed vertically on a pre-prepared base foundation. The base foundation may be formed from gravel or concrete to suit the floor tiling that will be later applied thereon. 
     Upon finishing connecting the vertically standing structural elements  12 , an upper horizontal structural element  12  is placed thereon and connected therewith by means of corner L-beams that are attached by self-drilling screws. Other type of attachment means may be used to connect the vertical and horizontal structural elements  12  and may include structural components such as beams and profiles (U-shaped, T-shaped, I-shaped, T-shaped, etc.) known in the art.  FIGS. 5 to 9  schematically illustrate exemplary connections of the structural elements  12  used to build the structural unit  10 , according to some embodiments of the present invention. Appropriate structural attachment elements are used to connect the structural elements  12  with other structural components. 
       FIG. 5 , for example, illustrates the construction of the balcony in the structural unit  10  (detail B) and includes multiple structural elements  12  horizontally and vertically arranged. Horizontal structural elements  12  are laid over a horizontal beam  13  which is supported on one side by a column  17  and on the other side by a vertical structural element  12  which also forms the exterior wall of the unit  10 . The horizontal structural elements  12  support a balcony deck structure  15 . 
       FIG. 6 , for example, illustrates the construction of a wall in the structural unit  10  (detail A) and includes vertical structural elements  12  attached to a floor  19  in one of the stories. The vertical structural elements  12  may be covered by blocks or other type of coverings (e.g. gypsum boards, metal lathe and plaster, among other known covering). 
       FIG. 7 , for example, illustrates the construction of a façade and roof in the structural unit  10  (detail D) and includes multiple structural elements  12  vertically and horizontally arranged. As may be appreciated from the figure, the horizontal structural elements  12  are supported at the ends by vertical structural elements  12  which also form a section of the façade of the structure  10 . The horizontal elements  12  support the roof structure  23 . 
       FIG. 8 , for example, illustrates the construction of an internal floor and walls in the structural unit  10  (detail E) and includes multiple structural elements  12  vertically and horizontally arranged. As may be appreciated from the figure, the horizontal structural elements  12  form the floor and are supported by the vertical structural elements  12  which form the walls. 
       FIG. 9 , for example, illustrates the construction of a floor and a wall (interior and/or exterior) in the structural unit  10  (detail F) and includes multiple structural elements  12  vertically and horizontally arranged. As may be appreciated from the figure, the horizontal structural elements  12  form the floor and are supported by the vertical structural elements  12  which form the walls. The horizontal structural elements  12  on one side of the wall may be oriented perpendicularly to those on the other side of the wall. 
       FIG. 10 , for example, illustrates the construction of a floor (ledge) and exterior wall in the structural unit  10  (detail C) and includes multiple structural elements  12  vertically and horizontally arranged. 
     As can be appreciated from the figures, when all the structural elements  12  are connected to each other to form the structural unit  10 , the overall strength and rigidity of the structural unit  10  is much stronger than the strength and rigidity of the individual structural elements  12 . 
     This form of building the structural unit  10  has been found to be efficient at least up to five stories height. In that manner, a cheap and fast erecting structure can be built, without the need of concrete columns or steel beams. 
     The structural unit  10  built according to the present invention enables considerable savings and advantages during the construction process;
     1. The transportation of prepared structural elements  12  to the erection site may be prevented.   2. The structural elements  12  may be rolled and cut on site, thus saving the transportation of a considerable volume of elements.   3. The on-site production of the structural elements  12  eliminates any damages to the structural elements  12  that may otherwise occur during transportation thereof.   4. Greater versatility and ability to provide on-site required amendments of the structural elements  12 , e.g., amending their length, etc.   5. It is not necessary to prepare molds for concrete casting.   6. It is not necessary to wait for concrete curing, thus saving a lot of time and reducing the erection period.   7. The structural elements  12  provide both the frame and the cover of the structural unit  10 .   8. It is not necessary to provide large steel beams for supporting the structural unit  10 , thus saving money, time, transportation, and erection.   9. The structural unit  10  is erected in a fast and economical manner, and provides adequate and stable accommodation up to five stories in height.   

     Although the present invention has been described to a certain degree of particularity, it should be understood that various alterations and modifications could be made without departing from the spirit or scope of the invention as hereinafter described. 
     For example, this structural unit may be used for building one, two, or up to five stories high. 
     The upper cover of the structural unit may be formed from structural elements as described above or similar thereto. 
     The structural elements may be provided with thermal insulation, as glass wool or the like, and closed by another sheet of metal, to form unit that is covered from its four sides. 
     Openings in the structural elements, e.g., for doors and windows, may be opened according to design needs. 
     In some cases, and according to design needs, steel beams may be added to the structural unit. However, these beams are an addition only, and do not form an essential part of the invention.