Field of the Invention

The present invention relates, in general, to construction modules and structures formed using the same. Background of the Invention

Structural elements such as, for example, walls, flooring, ceilings and furniture, are more often than not permanently formed. When a change is desired, these structural elements are usually destroyed and thrown away before new structural elements may be built in place of the old. This generates a lot of waste. In view of this, it would be desirable to provide a reusable construction module and structures formed using the same.

Summary of the Invention

Accordingly, in a first aspect, the present invention provides a construction module. The construction module includes a plurality of struts, each of the struts being coupled at at least one end to at least one adjacent strut. One or more first openings are provided on a first surface of at least one of the struts and one or more second openings are provided on a second surface of the at least one of the struts, the first and second surfaces being adjacent to one another. One or more recessed portions are provided in the at least one of the struts. In second aspect, the present invention provides a structure including a plurality of construction modules in accordance with the first aspect. The construction modules are interconnected and adjacent ones of the construction modules are coupled together by one or more of a group including one or more spacers and one or more connectors. Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention.

Brief Description of the Drawings The following detailed description of preferred embodiments of the invention will be better understood when read in conjunction with the appended drawings. The present invention is illustrated by way of example and is not limited by the accompanying figures, in which like references indicate similar elements. It is to be understood that the drawings are not to scale and have been simplified for ease of understanding the invention.

FIG. 1 is a perspective view of a first construction module in accordance with an embodiment of the present invention;

FIG. 2 is a perspective view of a second construction module in accordance with another embodiment of the present invention; FIG. 3 is a perspective view of a third construction module in accordance with yet another embodiment of the present invention;

FIG. 4 is a perspective view of a first spacer in accordance with an embodiment of the present invention;

FIG. 5 is a perspective view of a second spacer in accordance with another embodiment of the present invention;

FIG. 6 is a perspective view of a connector in accordance with an embodiment of the present invention; FIG. 7 is a perspective view of a structure formed with a plurality of construction modules in accordance with an embodiment of the present invention;

FIG. 8 is a perspective view of a covering in accordance with an embodiment of the present invention;

FIG. 9 is a perspective view of a covering in accordance with another embodiment of the present invention;

FIG. 10 is a perspective view of a fastening element for use with the covering of FIG. 9; FIG. 11 is a perspective view of a first reinforcement element in accordance with an embodiment of the present invention;

FIG. 12 is a perspective view of the first reinforcement element of FIG. 1 1 when in use;

FIG. 13 is a perspective view of a second reinforcement element in accordance with another embodiment of the present invention;

FIG. 14 is a perspective view of the second reinforcement element of FIG. 13 when in use;

FIGS. 15A through 15D are schematic diagrams of a plurality of structures formed with the construction modules of FIGS. 1 through 3; FIG. 16 is a perspective view of a mounting plate for wall-mounting a structure formed with the construction modules of FIGS. 1 through 3;

FIG. 17 is a perspective view of the mounting plate of FIG. 16 when in use; FIG. 18 is a perspective view of a base element for a free-standing structure formed with the construction modules of FIGS. 1 through 3;

FIG. 19 is a perspective view of a plurality of construction modules in accordance with still another embodiment of the present invention; and FIG. 20 is a schematic diagram of a structure formed with the construction modules of FIG. 19.

Detailed Description of Exemplary Embodiments

The detailed description set forth below in connection with the appended drawings is intended as a description of presently preferred embodiments of the invention, and is not intended to represent the only forms in which the present invention may be practiced. It is to be understood that the same or equivalent functions may be accomplished by different embodiments that are intended to be encompassed within the scope of the invention. In the drawings, like numerals are used to indicate like elements throughout. Referring now to FIG. 1 , a first construction module 10 is shown. The first construction module 10 includes a plurality of struts 12, each of the struts 12 being coupled at at least one end to at least one adjacent strut 12. A first opening 14 is provided on a first surface 16 of at least one of the struts 12 and a second opening 18 is provided on a second surface 20 of the at least one of the struts 12, the first and second surfaces 16 and 20 being adjacent to one another. Additionally, a plurality of recessed portions 22 is provided in the at least one of the struts 12.

Advantageously, provision of the second opening 18 on an adjacent surface to the first opening 14 increases the degree of connectivity of the first construction module 10 as the second opening 18 makes possible connection to an additional side of the first construction module 10. In the embodiment shown, a protruding portion 24 extends from a central portion of the at least one of the struts 12 and the second opening 18 is provided in the protruding portion 24.

In the present embodiment, a plurality of grooves 26 is provided on a distal surface of the protruding portion 24. Although two (2) grooves 26 are provided on the distal surface of the protruding portion 24 in FIG. 1 , it should be appreciated by those of ordinary skill in the art that the present invention is not limited by the number of grooves 26 provided in the distal surface of the protruding portion 24. In alternative embodiments, one or more grooves 26 may be provided on the distal surface of the protruding portion 24.

In the embodiment shown, a plurality of corner portions 28 is defined where adjacent ones of the struts 12 are coupled and each of the recessed portions 22 is provided between the central portion and a respective one of the corner portions 28 of each of the struts 12. Advantageously, the recessed portions 22 provide additional coupling points for connecting and securing adjacent construction modules. In the present embodiment, each of the recessed portions 22 includes a slot extending across a width of the at least one of the struts 12.

Each of struts 12 is designed to resist compression. In the embodiment shown, the struts 12 are arranged to define a plate structure having a hollow centre. Advantageously, the hollow centre allows passage of, for example, wires (not shown) through the first construction module 10. The plate structure of the present embodiment is formed with four (4) struts 12 and has a square shape. Nevertheless, it should be understood by those of ordinary skill in the art that the construction module of the present invention is not limited by the number of struts forming the construction module, by the shape defined by the struts or to plate structures. Fewer or more struts may be employed and/or different shapes of plate structures (for example, a plate structure with a triangular shape, a hexagonal shape or a rectangular shape) may be formed in alternative embodiments.

Alternative embodiments of the construction module will now be described below with reference to FIGS. 2 and 3. Referring now FIG. 2, a second construction module 40 is shown. The second construction module 40 differs from the previous embodiment in that the struts 12 are arranged to define a triangular prism having a plurality of hollow faces and a hollow core. A covering 42 is attached to respective ones of the struts 12 at a lateral face of the triangular prism. In the present embodiment, one (1 ) recessed portion 22 is provided in each of the struts 12A at the bases of the triangular prism and two (2) recessed portions 22 are provided in the strut 12B at the lateral edge of the triangular prism.

Referring now to FIG. 3, a third construction module 60 is shown. The third construction module 60 differs from the previous embodiments in that the struts 12 are arranged to define a cube having a plurality of hollow faces and a hollow core.

Advantageously, the hollow faces and the hollow core of the second and third construction modules 40 and 60 shown in FIGS. 2 and 3, respectively, not only allow passage of, for example, wires (not shown) through the second and third construction modules 40 and 60, but also allow for provision of, for example, one or more lighting elements within the second and third construction modules 40 and 60. This provides additional functionality, for example, in the form of a lighting feature, to structures that are formed with the second and/or third construction modules 40 and 60. The first, second and third construction modules 10, 40 and 60 may be formed as a single unit (see, for example, the first construction module 10 shown in FIG. 1 ) or from a plurality of interlocking strut members (see, for example, the second and third construction modules 40 and 60 shown in FIGS. 2 and 3, respectively). The first, second and third construction modules 10, 40 and 60 may be made, for example, of a polymeric material, a metallic material or a wood-plastic composite using conventional manufacturing methods such as, for example, injection molding, additive manufacturing or subtractive manufacturing.

Referring now to FIG. 4, a first spacer 80 is shown. The first spacer 80 includes a separator 82, a first mating element 84 extending from a first side of the separator 82, and a second mating element 86 extending from a second side of the separator 82. The first spacer 80 may be employed, for example, to connect a first first construction module 10 with a second first construction module 10. In such an embodiment, the first mating element 84 of the first spacer 80 is received in the second opening 18 of the first first construction module 10 and the second mating element 86 of the first spacer 80 is received in the second opening 18 of the second first construction module 10. In alternative embodiments, the first spacer 80 may also be used to connect the first construction module 10 with one of the second and third construction modules 40 and 60 in a similar manner.

Referring now to FIG. 5, a second spacer 100 is shown. The second spacer 100 includes a separator 102, a plurality of first mating elements 104 extending from a first side of the separator 102, and a plurality of second mating elements 106 extending from a second side of the separator 102. In the embodiment shown, the separator 102 comprises a square-shaped frame with pairs of the first and second mating elements 104 and 106 provided on opposing sides of the frame. Nevertheless, it should be understood by persons of ordinary skill in the art that the present invention is not limited by the shape of the separator 102 or the number of the first and/or second mating elements 104 and 106 provided on either side of the frame. The separator 102 may be formed of a different shape with fewer or more first and/or second mating elements 104 and 106 in alternative embodiments depending on the design of the construction modules.

The second spacer 100 may be employed, for example, to connect a first one of a second or third construction module 40 or 60 with a second one of a second or third construction module 40 or 60. In such an embodiment, the first mating elements 104 of the second spacer 100 are received in respective first or second openings 14 or 18 on a face of the first one of the second or third construction module 40 or 60 and the second mating elements 106 of the second spacer 100 are received in respective first or second openings 14 or 18 on a face of the second one of the second or third construction module 40 or 60.

Referring now FIG. 6, a connector 120 is shown. The connector 120 includes a bar 122 and a clip 124 at each end of the bar 122.

The connector 120 may be employed, for example, to connect a first one of a first, second or third construction module 10, 40 or 60 with a second one of a first, second or third construction module 10, 40 or 60. In such an embodiment, the clip 124 at a first end of the bar 122 is received in a recessed portion 22 of the first one of the first, second or third construction module 10, 40 or 60 and the clip 124 at a second end of the bar 122 is received in a recessed portion 22 of the second one of the first, second or third construction module 10, 40 or 60. Referring now to FIG. 7, a structure 150 is shown. The structure 150 includes a plurality of construction modules 10, 40 and 60. The construction modules 10, 40 and 60 are interconnected and adjacent ones of the construction modules 10, 40 and 60 are coupled together by one or more of a group including one or more spacers 100 and one or more connectors 120. In the embodiment shown, a plurality of coverings 152 is attached to corresponding faces of the construction modules 60. The coverings 152 serve an aesthetic function by helping to conceal the faces of and connections between the construction modules 10, 40 and 60, presenting a neat and homogeneous facade to the structure 150. The coverings 152 may be fully or partially opaque, translucent or transparent and may be used to create design features for the structure 150. For example, when the coverings 152 are partially or fully translucent or transparent, the arrangement and specific placement of the coverings 152 or the translucent portions of the coverings 152 may be used to create lighting features for a feature wall structure. Similarly, by, for example, varying the colour scheme of the coverings 152 or parts of the coverings 152, different designs may be created. The opacity and/or translucency of the coverings 152 or portions of the coverings 152 may be varied through selective placement of printed or hot-stamped vinyl, polyethylene terephthalate (PET), polycarbonate (PC) or laminate stickers on one or more surfaces of the coverings 152.

Referring now to FIG. 8, the covering 152 in the embodiment shown is provided with a plurality of fastening elements 154. The fastening elements 154 are configured to fasten the coverings 152 to the corresponding faces of the construction modules 10, 40 and 60. A distal end of each of the fastening element 154 is compressible to facilitate insertion of the fastening elements 154 into corresponding openings 14 and 18 in the faces of the construction modules 10, 40 and 60. In the embodiment shown, compressibility of the fastening element 154 is achieved through the provision of one or more slots 156 along a length of each of the fastening elements 154. To improve attachment of the coverings 152 to the corresponding faces of the construction modules 10, 40 and 60, one or more ribs 158 may be provided on each of the fastening elements 154 to create a tighter fit between the fastening elements 154 and the corresponding openings 14 and 18 in the faces of the construction modules 10, 40 and 60. To achieve a clean fit, one or more edges of each of the coverings 152 may be chamfered as shown. Referring now to FIGS. 9 and 10, a covering 160 and a fastening element 162 in accordance with an alternative embodiment are shown. The present embodiment differs from the previous embodiment in that the fastening element 162 is separately provided from the covering 160. In the present embodiment, the covering 160 includes a plurality of through holes 164 at positions corresponding to a plurality of openings 14 and 18 in the corresponding faces of the construction modules 10, 40 and 60. .

The fastening element 162 of the present embodiment includes a head 66 and a body 168 extending from the head 166. A distal end of the body 168 of the fastening element 162 is compressible. In the embodiment shown, one or more slots 170 are provided along a length of the body 168 of the fastening element 162 and one or more ribs 172 are provided on the body 168 of the fastening element 162.

As can be seen from FIGS. 8 through 10, the coverings 152 and 160 are not limited by shape or the number of fastening elements 154 and 162. The coverings 152 and 160 may be shaped differently and/or may be secured with fewer or more fastening elements 154 and 162 depending on the design of the construction modules.

To increase the strength of structures formed with the construction modules 10, 40 and 60, one or more reinforcement elements may be provided in a hollow space defined within the interconnected construction modules 10, 40 and 60. The one or more reinforcement elements may be one or more of a group including one or more latching devices and one or more reinforcement bars.

Referring now to FIG. 1 1 , a first reinforcement element 180 is shown. In the embodiment shown, the first reinforcement element 180 is a latching device. The latching device 180 includes an elongate body 182 having a first opposing surface 184 at a first end and a second opposing surface 186 at a second end. The latching device 180 may include a guide member 188 provided on at least one of the first and second opposing surfaces 184 and 186 of the elongate body 182. In the present embodiment, the latching device 180 includes a plurality of first catches 190 at the first end of the elongate body 182 and a plurality of second catches 192 at the second end of the elongate body 182.

The latching device 180 may be used with a third spacer 130. The third spacer 130 includes a separator 132, a first mating element 134 extending from a first side of the separator 132, a second mating element 136 extending from a second side of the separator 132, a first protrusion 138 extending from the first mating element 134, and a second protrusion 140 extending from the second mating element 136.

Referring now to FIG. 12, the latching device 180 is shown in use with a pair of third spacers 130. In use, the first and second mating elements 134 and 136 of the third spacers 130 are received in respective second openings 18 of the first construction modules 10 and the first and second catches 190 and 192 of the latching device 180 latch onto the first and second protrusions 138 and 140 of the third spacers 130. In the embodiment shown, the guide members 188 of the latching device 180 are received in and abut the grooves 26 provided on the distal surface of the protruding portions 24 of the struts 12 of the first construction modules 10. Advantageously, the engagement of the guide members 188 of the latching device 180 to the grooves 26 of the first construction modules 10 helps secure the latching device 180 in place relative to the first construction modules 10 to create a stronger and more rigid structure.

Referring now to FIGS. 13 and 14, a second reinforcement element 200 is shown. In the embodiment shown, the second reinforcement element 200 is a reinforcement bar. The reinforcement bar 200 includes one or more hollow sections 202. Advantageously, the one or more hollow sections 202 allow passage of, for example, wires (not shown) through the reinforcement bar 200. In the present embodiment, the reinforcement bar 200 comprises a plurality of sections 204, each of the sections 204 having a male mating portion 206 at a first end and a female mating portion 208 at a second end. When assembled into the reinforcement bar 200, the male mating portion 206 of one of the sections 204 is received in and engages with the female mating portion 208 of an adjacent one of the sections 204.

As can be seen from FIGS. 12 and 14, the first and second reinforcement elements 180 and 200 provide internal support to structures formed with the construction modules 10, 40 and 60 and help such structures resist compressive forces. In this manner, the first and second reinforcement elements 180 and 200 help prevent the structures formed with the construction modules 10, 40 and 60 from collapsing and help enhance overall structural integrity.

Referring now to FIGS. 15A through 15D, a plurality of structures 220, 240, 260 and 280 that may be formed with the construction modules 10, 40 and 60 is shown. In particular, FIG. 15A illustrates a feature wall 220 to which a television 222 is mounted, FIG. 15B illustrates a table 240, FIG. 15C illustrates a picture frame 260, and FIG. 15D illustrates a structure 280 of a raised platform 282 with a plurality of steps 284. Advantageously, as can be seen from FIGS. 15A through 15D, the construction modules 10, 40 and 60 may be combined in different configurations to create various functional objects.

The structures formed with the construction modules 10, 40 and 60 may be wall-mounted or free-standing.

Referring now to FIGS. 16 and 17, a mounting plate 300 for wall-mounting a structure 302 formed with a plurality of construction modules 304 is shown. A first side 306 of the mounting plate 300 is shaped to correspond to a face of the construction module 304 with a protruding portion 308 of the first side 306 of the mounting plate 300 corresponding to a hollow portion of the face of the construction module 308 and a plurality of recessed portions 310 of the first side 306 of the mounting plate 300 corresponding to inner surfaces of a plurality of struts 312 defining the face of the construction module 304. In the present embodiment, a second, opposing side 314 of the mounting plate 300 is a flat surface. In the embodiment shown, the mounting plate 300 has a same thickness T as the struts 312 and thus the mounting plate 300 is flush with the struts 312 when mounted. Advantageously, this together with the flat surface presents a neat finishing when the structure 302 is mounted with the mounting plate 300. A through-hole 316 provided in the mounting plate 300 is arranged to receive a screw or other implement for securing the mounting plate 300 to a mounting surface. When mounted, portions of the struts 312 defining the face of the construction module 304 are sandwiched between the recessed portions 310 of the first side 306 of the mounting plate 300 and a surface to which the structure 302 is mounted. Referring now to FIG. 18, a base element 350 for a free-standing structure formed with a plurality of construction modules is shown. The base element 350 includes a separator 352 and a plurality of mating elements 354 extending from a side of the separator 352. The mating elements 354 are arranged to be received in respective first or second openings on a face of the construction modules forming the free-standing structure. The opposing side of the separator 352 is flat.

One or more of the base elements 350 may be used to raise the freestanding structure off the ground and/or to keep a base of the free-standing structure level with portions of coverings attached to sides of the free-standing structure.

In the embodiment shown, the separator 352 comprises a square-shaped frame and two (2) mating elements 354 provided on one (1 ) side of the frame. Nevertheless, it should be understood by persons of ordinary skill in the art that the present invention is not limited by the shape of the separator 352 or the number of mating elements 354 provided on the side of the frame. The separator 352 may be formed of a different shape with fewer or more mating elements 354 in alternative embodiments depending on the design of the construction modules. Referring now to FIG. 19, a plurality of construction modules 400 is shown.

Each of the construction modules 400 includes a plurality of struts 402, each of the struts 402 being coupled at at least one end to at least one adjacent strut 402. A plurality of first openings 404 is provided on a first surface 406 of at least one of the struts 402 and a second opening 408 is provided on a second surface 410 of the at least one of the struts 402, the first and second surfaces 406 and 410 being adjacent to one another. Additionally, a recessed portion 412 is provided in the at least one of the struts 402.

In the present embodiment, the recessed portion 412 includes a slot extending across a width of the at least one of the struts 402. In the embodiment shown, the struts 402 are arranged to define a plate structure having a hollow centre. The present embodiment differs from the earlier embodiments in the arrangement of the struts 402 and the number and positioning of the first and second openings 404 and 408 and the recessed portions 412. The construction modules 400 of the present embodiment are each formed with six (6) struts 402 and have a hexagonal shape.

Referring now to FIG. 20, a schematic of a structure 450 formed with the construction modules 400 of FIG. 19 is shown. The construction modules 400 are interconnected to form the structure 450. Although not shown, adjacent ones of the construction modules 400 may be coupled together by one or more of a group including one or more spacers and one or more connectors. In the present embodiment, the structure 450 formed with the construction modules 400 is a sphere. As is evident from the foregoing discussion, the present invention provides a construction module that can be easily connected with other construction modules in a variety of different configurations to form various stable structures that are capable of withstanding high tension, compression, shear and torsion forces. Due to the modular nature, structural stability, aesthetic options and ease of assembly afforded by the construction modules of the present invention, the construction modules of the present invention may be used to create a range of useful products such as, for example, feature walls, customised furniture, ceiling features, display lighting panels and platforms. Furthermore, provision of the hollow faces and hollow spaces in the construction modules of the present invention allows for concealment of unsightly electrical components such as, for example, wiring, lighting, power sockets and switches. Advantageously, this presents an aesthetically pleasing finished product and also helps save cost as the construction modules of the present invention may be used for retrofitting purposes without having to take down existing fixtures. Because structures formed with construction modules of the present invention may be easily dismantled and reassembled in a non-destructive manner, the construction modules of the present invention may be reused and this is beneficial to the environment. While preferred embodiments of the invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions and equivalents will be apparent to those skilled in the art without departing from the scope of the invention as described in the claims. Further, unless the context clearly requires otherwise, throughout the description and the claims, the words "comprise", "comprising" and the like are to be construed in an inclusive as opposed to an exclusive or exhaustive sense; that is to say, in the sense of "including, but not limited to".