Non-standard, reinforced load-bearing cell for a simplified, interconnecting cellular construction system

Abstract

The teachings are generally directed to a construction system that includes a three-dimensional, load-bearing cell that can be modular, releasably connectable with other construction components, reinforced with bracing for higher strength, and exceed industry size limits, for use in a building or non-building structure. The load-bearing cell can be constructed on-site and can have a dimension that exceeds size standards set for transporting construction materials to a construction site as compared to pre-fabricated cellular structures. These construction cells are a novel, technical contribution for at least the reason that they overcome the technical industry size limitations that add cost and complexity to construction. The teachings provide (i) an ability to save on the complexities and amounts of materials, equipment, and labor needed in a construction project, (ii) a reduction in costs, and (iii) a novel, simplified, and bid-winning approach to the art of construction.

1 . A three-dimensional, load-bearing cell for use in a cellular construction system for a building or non-building structure, the cell comprising:
 a vertical-load-bearing bar; and,   a horizontal-load-bearing bar attached to the vertical-load-bearing bar;   wherein,   the load-bearing cell is constructed on-site and has a dimension that exceeds size standards set for transporting construction materials to a construction site as compared to pre-fabricated cellular structures that are required to follow the size standards; and,   the load-bearing cell is configured to attach to a second cell using a cell-to-cell connector, the load-bearing cell and the second cell being connected through the cell-to-cell connector in a face-to-face, edge to edge, or vertex to vertex arrangement in the cellular construction of the building or non-building structure.   
     
     
         2 . The load-bearing cell of  claim 1 , wherein the load-bearing cell is used as a shell support structure or a core support structure, is composed of prefabricated assembly components that are readily transportable to the site, and is more readily assembled and interconnected within the building or non-building structure when compared to non-cellular load-bearing structures that are otherwise used for the shell support structure or the core support structure of the building or non-building structure. 
     
     
         3 . The load-bearing cell of  claim 1  further comprising an internal cross-bracing across the inner volume of the cell that functions to subdivide load-induced stresses into smaller distributed force components. 
     
     
         4 . The load-bearing cell of  claim 1 , wherein the vertical load-bearing bar has a fitting that is complementary to the cell-to-cell connector, and the cell-to-cell connector is a single-unit node having at least one pair of connectors for connecting the load-bearing cell to the second cell. 
     
     
         5 . The load-bearing cell of  claim 1 , wherein the cell-to-cell connector comprises a first plate having the at least one pair of bar connectors and a second plate forming a plane that intersects a plane formed by the first plate at an angle θ ranging from about 0 degrees to about 45 degrees, the second plate positioned between at least two pair of bar connectors on the first plate, each pair of bar connectors having a first connector on a first side of the first plate and a second connector on a second side of the first plate, the first side opposing the second side. 
     
     
         6 . The load-bearing cell of  claim 5 , wherein the angle θ comprises an angle of incline that ranges from greater than 0 degrees to about 45 degrees upon which the building or non-building structure is constructed on a support surface. 
     
     
         7 . The load-bearing cell of  claim 5 , wherein the angle θ comprises an angle of assembly formed by a stacking of load-bearing cells within the building or non-building structure. 
     
     
         8 . A frame structure system, comprising:
 a series of inter-connected, modular three dimensional geometrical frame structures connected in a face-to-face arrangement, each individual frame structure comprising a series of bars connected to define faces of a three dimensional geometrical frame structure that includes a base face; and,   at least one bar forming a bracing for a face of the geometrical frame structure;   wherein, the geometrical frame structure comprises a plurality of bars that form a cross-bracing for the base face.   
     
     
         9 . The system of  claim 8 , wherein the geometrical frame structure comprises bars forming a triangular frame structure within a vertical face of the geometrical frame structure, the triangular frame structure positioned within the upper part of the face. 
     
     
         10 . The system of  claim 8 , wherein the geometrical frame structures comprise one or more diagonal bars to cross-brace vertical faces of the frame. 
     
     
         11 . The system of  claim 8 , wherein the geometrical frame structures comprise one or more diagonal bars extending across the interior of the frame. 
     
     
         12 . The system of  claim 8 , wherein each geometrical frame structure comprises at least 6 bars. 
     
     
         13 . The system of  claim 8 , wherein the geometrical frame structures comprise cuboid frame structures formed from 14 bars, twelve bars forming the edges of the cuboid frame structure, and two bars forming a cross-bracing for a base face. 
     
     
         14 . The system of  claim 8 , further comprising a means for interconnecting the geometrical frame structures in a face-to-face, vertex-to-vertex, or edge-to-edge configuration. 
     
     
         15 . The system of  claim 8 , further comprising a means for connecting a structure to a base surface. 
     
     
         16 . The system of  claim 8 , wherein geometrical frame structures are connected side-by-side and/or on top of each other to form a core support structure or a shell support structure for a building or non-building structure. 
     
     
         17 . A method of constructing the system of  claim 8 , comprising:
 delivering a plurality of load-bearing bars to a construction site, each bar in the plurality of load-bearing bars having a dimension that was preselected for forming the geometrical frame structure without further resizing of the load-bearing bar; and,   forming the geometrical frame structures on-site.   
     
     
         18 . An apparatus for transporting and constructing the system of  claim 8 , comprising:
 a container for transporting pre-selected bars used in forming the geometrical frame;   a frame structure for constructing the system and configured for receiving the pre-selected bars from the containers and holding the pre-selected bars in a desired position to define the faces of the geometrical frame; and   a configuration for facilitating connecting the bars to form the geometrical frame structure.   
     
     
         19 . A cellular construction system, comprising:
 A single-unit, node module configured with a means for interconnecting a series of structural, three-dimensional load-bearing cells, the series including a first cell and a second cell;   the first cell comprising a first axial load bearing bar having a first respective complementary portion for mating with a first connector of the node module;   the second cell comprising a second axial load bearing bar having a second respective complementary portion for mating with a second connector of the node module;   wherein,   the node module connects the first cell to the second cell using a process that includes (i) mating the first connector of the node module to the first respective complementary portion and (ii) mating the second connector of the node module to the second respective complementary portion, such that the first cell and the second cell are connected in a face-to-face, edge to edge, or vertex to vertex arrangement in the creation of a cellular building or non-building structure; and   the first cell or the second cell is constructed on-site and has a dimension that exceeds size standards set for transporting construction materials to a construction site as compared to pre-fabricated cellular structures that are required to follow the size standards.   
     
     
         20 . The cellular construction system of  claim 19  further comprising an elastic coating on a surface of the single-unit node module where the node module connects the first cell to the second cell.