Cellular structures

• US 10,094,085 B2
• Filed: 09/10/2010
• Issued: 10/09/2018
• Est. Priority Date: 03/11/2008
• Status: Active Grant

• Current Assignee: Terram Ltd. (Signature Aviation US Topco LLC)
• Original Assignee: Terram Ltd. (Signature Aviation US Topco LLC)
• Inventors: Walmsley, William W., Thomas, Basil John
• Primary Examiner(s): Jones, Robert S
• Application Number:
  US12/879,124
• Publication Number:
  US 20110033654A1
• Time in Patent Office: 2,951 Days
• Field of Search: 428116-118, 428356, 428465, 428376, 428190, 4283088, 42831111, 428 73, 428159, 428168, 4283126, 428 72, 405280, 4053024-3027, 40512945, 40512957, 40512955, 160 8405, 11247506
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 5/24 one layer being a fibrous or filamentary layer
• CPC Class Codes: B32B 7/12 using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: E02B 3/123 mainly consisting of stone, concrete or similar stony material
• CPC Class Codes: E02B 3/126 mainly consisting of bituminous material or synthetic resins
• CPC Class Codes: E02B 3/127 bags filled at the side
• CPC Class Codes: E02B 3/14 Preformed blocks or slabs for forming essentially continuous surfaces; Arrangements thereof preassembled to constitute flexible mats E02B3/122; pavements E01C5/00
• CPC Class Codes: E02D 17/20 Securing of slopes or inclines by soil E02D3/12; protection against snowslides or avalanches E01F7/04, E01F15/00; securing banks or like surfaces facing on bodies of water E02B3/12
• CPC Class Codes: E02D 17/202 with flexible securing means
• CPC Class Codes: Y10T 428/24157 Filled honeycomb cells [e.g., solid substance in cavities, etc.]

Abstract

A cellular structure includes a plurality of interconnected cells of fabric material. The cells are at least partially filled with a composite fill material that includes a particulate material and a bonding agent. A cellular unit made up of a plurality of the interconnected cells may have an associated load-bearing frame to enable lifting and/or transportation of the structure. The fill material is preferably resilient.

Claims

1. A structure, comprising:

a cellular unit embedded within a load-bearing frame;

the cellular unit having (i) an undulating outer surface defined by perimeter cells having outwardly facing walls;

(ii) a plurality of constrained interior cells surrounded by the perimeter cells, the constrained interior cells interconnected by intersecting internal walls comprising a fabric material; and

(iii) a composite fill material at least partially filling the perimeter cells and the plurality of interior cells, wherein the outwardly facing walls are not constrained and are free to bulge with the composite fill material and the composite fill material comprises a particulate material; and

the load-bearing frame configured to bear a load of the cellular unit and the composite fill material, the load-bearing frame comprising (i) an outer frame ring;

(ii) at least one cross-piece attached to the outer frame ring and configured to pass underneath the cellular unit; and

(iii) at least one upright member attached to the outer frame ring and extending in a vertical direction from the outer frame ring;

wherein the at least one upright member includes a first end proximate to the outer frame ring and a second end distal from the outer frame member, and wherein the first end includes a socket and the second end includes a hole aligned with the socket.

2. A structure as claimed in claim 1, wherein the bonding agent bonds together the particulate material, and the bonding agent bonds the composite fill material to the continuous fabric material.

3. A structure as claimed in claim 1, wherein the bonding agent comprises any one of more of an elastomeric material, a rubber-based adhesive, a resin comprising flexible particles, and a curable material.

4. A structure as claimed in claim 1, wherein the particulate material comprises sand, the bonding agent comprises adhesive, and the composite fill material comprises approximately 8% by weight of the adhesive.

5. A structure as claimed in claim 1, wherein:

the composite fill material comprises a material selected form the group consisting of a reinforcing material and a binding material;

or

the plurality of constrained interior cells is also at least partially filled with a second fill material, the second fill material comprising a material selected from the group consisting of a reinforcing material and a binding material.

6. A structure as claimed in claim 5, wherein the reinforcing material comprises fibres, and/or the binding material comprises fibres.

7. A structure as claimed in claim 6, wherein the fibres comprise synthetic fibres.

8. A structure as claimed in claim 1, wherein the load-bearing frame is flexible.

9. A structure as claimed in claim 1, wherein the load-bearing frame is resiliently coupled to the cellular unit.

10. A structure as claimed in claim 1, further comprising a second fill material disposed in at least some spaces between the cellular unit and the frame, wherein the second fill material is the same as or different from the first fill material.

11. A structure as claimed in claim 1, wherein the continuous fabric material is permeable.

12. A structure as claimed in claim 1, wherein the fill material is permeable.

13. A structure as claimed in claim 1, wherein the continuous fabric material comprises a nonwoven material or a geotextile material.

14. A structure as claimed in claim 1, wherein the perimeter cells comprise partly cylindrical cells.

15. A structure as claimed in claim 1, wherein at least one cross-piece comprises at least one diagonal cross-piece attached between a first corner and a second corner of the outer frame ring.

16. A structure as claimed in claim 1, wherein the at least one upright member extends past the cellular unit in the vertical direction.

17. A structure as claimed in claim 15, wherein the at least one diagonal cross-piece comprises two or more diagonal cross-pieces.

18. A structure as claimed in claim 1, wherein the fabric material comprises a continuous fabric material folded back and forth on itself and bonded to define the intersecting internal walls.

19. A structure as claimed in claim 1, wherein the composite fill material comprises a particulate material and a bonding agent.

20. A structure, comprising:

a cellular unit embedded within a load-bearing frame;

the cellular unit having (i) an undulating outer surface defined by perimeter cells having outwardly facing walls;

(ii) a plurality of constrained interior cells surrounded by the perimeter cells, the constrained interior cells interconnected by intersecting internal walls comprising a continuous fabric material folded back and forth on itself and bonded; and

(iii) a composite fill material at least partially filling the perimeter cells and the plurality of interior cells, wherein the outwardly facing walls are not constrained and are free to bulge with the composite fill material and the composite fill material comprises a particulate material and a bonding agent; and

the load-bearing frame configured to bear a load of the cellular unit and the composite fill material, the load-bearing frame comprising (i) an outer frame ring;

(ii) at least one diagonal cross-piece attached between a first corner and a second corner of the outer frame ring and configured to pass underneath the cellular unit; and

(iii) at least one upright member attached to the outer frame ring and extending in a vertical direction from the outer frame ring;

wherein the at least one upright member includes a first end proximate to the outer frame ring and a second end distal from the outer frame member, and wherein the first end includes a socket and the second end includes a hole aligned with the socket.