Module construction system

Claim 2

A module construction system which can be used, and can be adapted to be used, to meet varying structural requirements for different construction applications, including use as aircraft runways, taxiways, and ramps, comprising: a. a plurality of identical load bearing structural modules, wherein each said identical structural module is substantially in the form of a rectangular solid having two side edges and two end edges, and wherein each said identical structural module comprises: 1. a flat upper skin, rectangular in form, of epoxy-fiberglass with an external coating of polyurethane, with said flat upper skin having two side edges and two end edges; 2. a flat lower skin, rectangular in form, of the same dimensions as, and in parallel spaced relationship to, said flat upper skin, with said flat lower skin made of epoxyfiberglass and with an external coating of polyurethane, and with said flat lower skin having two side edges and two end edges; 3. an aluminum honeycomb core, in the form of a rectangular solid and smaller in rectangular dimensions than said flat upper and lower skins, and centrally disposed between, abutting with, and bondeD to, said flat upper and lower skins, with said honeycomb core having a portion thereof oriented such that its strong dimension is positioned in the direction parallel to the side edges of said flat upper and lower skins, and with said oriented portion of said honeycomb core having a high density section of aluminum honeycomb core therein; 4. and, four edge members, two side edge members and two end edge members, of molded fiberglass reinforced plastic, with each said edge member disposed between said flat upper and lower skins, and abutting with and bonded to said flat upper and lower skins and said honeycomb core, and with each said edge member having a semi-cylindrical outwardly facing surface configuration of the same size; b. means for releasably connecting, in coplaner relationship, a plurality of said identical load bearing structural modules, side edge-to-side edge and end edge-to-end edge, wherein, said modules are adjacent; c. means for releasably connecting, in layered relationship, a plurality of said identical load bearing structural modules which are adjacent; whereby each load bearing structural module may be used, as needed, singly, and in an assembly of a plurality of releasably connected identical load bearing structural modules to form a larger and thicker structural unit which is of the desired size and shape, strength and stiffness.

Claim 3

a flat lower skin, rectangular in form, of the same dimensions as, and in parallel spaced relationship to, said flat upper skin, with said flat lower skin made of epoxy-fiberglass and with an external coating of polyurethane, and with said flat lower skin having two side edges and two end edges;

Claim 4

a flat lower skin, rectangular in form, of the same dimensions as, and in parallel spaced relationship to, said flat upper skin, with said flat lower skin made of epoxy-fiberglass and with an external coating of polyurethane, and with said flat lower skin having two side edges and two end edges;

Claim 5

A module construction system, as set forth in claim 1, wherein said means for releasably connecting, in coplaner relationship, a plurality of said identical load bearing structural modules side edge-to-side and end edge-to-end edge, is substantially a tongue and groove type arrangement, and wherein said means includes, as to each of said identical load bearing structural modules: a. a side edge tongue type portion which includes a first hollow aluminum right circular cylinder, having an outwardly facing surface, mating with, and removably attached to, one of said semi-cylindrical outwardly facing side edge members of said load bearing structural module, with said first hollow cylinder having therein at least two longitudinally aligned slots in the outwardly facing surface of said first hollow cylinder, and an engaging pin fixedly positioned in a vertical condition within said first hollow cylinder opposite to each slot, and a rubber gasket disposed between said first hollow cylinder and said side edge member; b. a side edge groove type portion which includes at least two longitudinally aligned latches, positioned in the other of said semi-cylindrical outwardly facing side edge members of said load bearing structural module, with each said latch being reversably movable outwardly, and a rubber gasket suitably slotted to permit the passage therethrough of said latches and affixed to the surface of said other semi-cylindrical outwardly facing side edge member; c. an end edge tongue type portion which includes a second hollow aluminum right circular cylinder, of the same outside diameter as said first hollow aluminum right circular cylinder and similarly having an outwardly facing surface, mating with, and removably attached to, one of said semi-cylindrical outwardly facing end edge members of said load bearing structural module, with said second hollow cylinder having therein at least two longitudinally aligned slots in the outwardly facing surface of said second hollow cylinder, and an engaging pin fixedly positioned in a vertical condition within said second hollow cylinder opposite to each slot, and a rubber gasket disposed between said second hollow cylinder and said end edge member; d. an end edge groove type portion which includes at least two longitudinally aligned latches, positioned in the other of said semi-cylindrical outwardly facing end edge members of said load bearing structural module, with each said latch being reversably movable outwardly, and a rubber gasket suitably slotted to permit the passage therethrough of said latches and affixed to the surface of saId other semi-cylindrical outwardly facing end edge member; thereby each said side edge tongue type portion of each of said identical load bearing structural modules is complementary with each said side edge groove type portion of each of said identical load bearing structural module; and thereby each said end edge tongue type portion of each of said identical load bearing structural modules is complementary with each said end edge groove type portion of each of said identical load bearing structural modules; whereby adjacent identical load bearing structural modules are releasably connectable, in coplaner relationship, side edge-to-side edge, by mating the side edge tongue type portion of one adjacent identical load bearing structural module to the complementary side edge groove type portion of another adjacent identical load bearing structural module, and by engaging each vertically positioned engaging pin of the side edge tongue type portion with a latch of the complementary side edge groove type portion; and, whereby adjacent identical load bearing structural modules are releasably connectable, in coplaner relationship, end edge-to-end edge, by mating the end edge tongue type portion of one adjacent identical load bearing structural module to the complementary end edge groove type portion of another adjacent identical load bearing structural module, and by engaging each vertically positioned engaging pin of the end edge tongue type portion with a latch of the complementary end edge groove type portion.

Claim 6

A module construction system, as set forth in claim 1, wherein said means for releasably connecting, in layered relationship a plurality of said adjacent identical load bearing structural modules, of which there is at least a first and a second of said identical load bearing structural modules, includes: a. a plurality of identical vertical hollow passages extending continuously through said flat upper skin, through said aluminum honeycomb core, and through said flat lower skin of each of said identical load bearing structural modules, with said plurality of identical vertical hollow passages have corresponding hollow passages similarly positioned in each of said identical load bearing structural modules, and with each of said plurality of identical vertical hollow passages having an end opening in said flat upper skin and an end opening in said flat lower skin, and with each of said plurality of identical vertical hollow passages being in the form of an inverted truncated cone having therein a captive nylon nut which is in the shape of an inverted cone with a center opening therethrough, a portion of which is threaded to accept an upset threaded bolt, and with said captive nylon nut surrounded and held by an inverted rubber cone within said respective hollow passage and with said rubber cone having a center opening therethrough; b. and, a plurality of identical upset threaded bolts, one said upset bolt for each of the said plurality of identical vertical passages to be used, with each said upset bolt removably inserted into its respective hollow passage in one, a first, of said plurality of identical load bearing structural modules, with each said upset bolt passing through said first load bearing structural module and fitting into a vertically aligned hollow passage of a second of said plurality of identical load bearing structural modules, with said second of said plurality of identical load bearing structural modules disposed in an inverted position and in layered relationship with the first said identical load bearing structural module, and with said upset bolt removably engaging the threaded portion of the captive nut within the vertically aligned hollow passage of said inverted second identical load bearing structural module; whereby said plurality of identical load bearing structural modules are releasably connected in layered relationship to form a thicker, stronger and stiffer structural unit.

Claim 7

an aluminum honeycomb core, in the form of a rectangular solid and smaller in rectangular dimensions than said flat upper and lower skins, and centrally disposed between, abutting with, and bondeD to, said flat upper and lower skins, with said honeycomb core having a portion thereof oriented such that its strong dimension is positioned in the direction parallel to the side edges of said flat upper and lower skins, and with said oriented portion of said honeycomb core having a high density section of aluminum honeycomb core therein;

Claim 8

an aluminum honeycomb core, in the form of a rectangular solid and smaller in rectangular dimensions than said flat upper and lower skins, and centrally disposed between, abutting with, and bondeD to, said flat upper and lower skins, with said honeycomb core having a portion thereof oriented such that its strong dimension is positioned in the direction parallel to the side edges of said flat upper and lower skins, and with said oriented portion of said honeycomb core having a high density section of aluminum honeycomb core therein;

Claim 9

and, four edge members, two side edge members and two end edge members, of molded fiberglass reinforced plastic, with each said edge member disposed between said flat upper and lower skins, and abutting with and bonded to said flat upper and lower skins and said honeycomb core, and with each said edge member having a semi-cylindrical outwardly facing surface configuration of the same size; b. means for releasably connecting, in coplaner relationship, a plurality of said identical load bearing structural modules, side edge-to-side edge and end edge-to-end edge, wherein, said modules are adjacent; c. means for releasably connecting, in layered relationship, a plurality of said identical load bearing structural modules which are adjacent; whereby each load bearing structural module may be used, as needed, singly, and in an assembly of a plurality of releasably connected identical load bearing structural modules to form a larger and thicker structural unit which is of the desired size and shape, strength and stiffness.

Claim 10

and, four edge members, two side edge members and two end edge members, of molded fiberglass reinforced plastic, with each said edge member disposed between said flat upper and lower skins, and abutting with and bonded to said flat upper and lower skins and said honeycomb core, and with each said edge member having a semi-cylindrical outwardly facing surface configuration of the same size; b. means for releasably connecting, in coplaner relationship, a plurality of said identical load bearing structural modules, side edge-to-side edge and end edge-to-end edge, wherein, said modules are adjacent; c. means for releasably connecting, in layered relationship, a plurality of said identical load bearing structural modules which are adjacent; whereby each load bearing structural module may be used, as needed, singly, and in an assembly of a plurality of releasably connected identical load bearing structural modules to form a larger and thicker structural unit which is of the desired size and shape, strength and stiffness.