Modular structural system

• US 7,677,010 B2
• Filed: 07/03/2007
• Issued: 03/16/2010
• Est. Priority Date: 07/03/2007
• Status: Expired due to Fees

• Current Assignee: Alfred H. Boots
• Original Assignee: Alfred H. Boots
• Inventors: Boots, Alfred H.
• Primary Examiner(s): Glessner; Brian E
• Application Number:
  US11/773,064
• Publication Number:
  US 20090007500A1
• Time in Patent Office: 987 Days
• Field of Search: 526/481, 526/531, 526/532, 526/541, 526/551, 526/552, 526/569, 52/813, 403/169, 403/170, 403/717, 403/176, 403/217, 403/218, 403/219
• US Class Current: 52/655.1
• CPC Class Codes: A47B 47/021 Racks or shelf units A47B47/03 takes precedence
• CPC Class Codes: E04B 1/5806 with a cross-section having an open profile
• CPC Class Codes: E04B 1/585 with separate connection devices
• CPC Class Codes: Y10T 403/34 Branched
• CPC Class Codes: Y10T 403/341 Three or more radiating members
• CPC Class Codes: Y10T 403/342 Polyhedral
• CPC Class Codes: Y10T 403/347 Polyhedral
• CPC Class Codes: Y10T 403/44 Three or more members connected at single locus
• CPC Class Codes: Y10T 403/443 All encompassed
• CPC Class Codes: Y10T 403/447 Mutually contacting

Abstract

A modular structural system includes a hub in the general shape of a polygon, such as a hexagon or octagon, which may be somewhat rounded or may have a regular shape. The system includes a plurality of other structural members, such as hub spokes, for interfacing adjacent the hub, and leg spokes, for interfacing with the hub or with the hub spokes. The system also includes cross braces for providing additional support between the hub spokes and leg spokes. The hub, the hub spokes, leg spokes, and cross braces are joined by bores in the individual pieces and a plurality of dowels or rods placed into the bores. From these modular pieces, and currently available structural members, many useful and recreational structures may be assembled and then disassembled, such as frames, garden structures, furniture, shelving, and the like.

Claims

1. A modular structural system, comprising:

an elongated hub having a generally elongated polygonal shape, and further comprising a longitudinal axis and a plurality of faces on a perimeter of the hub, the faces oriented along the axis, the hub also comprising two ends, and wherein each face and at least one end further comprises a bore;

at least one hub spoke, the hub spoke having a longitudinal axis and comprising a general shape of an elongated cylinder, an elongated cube or an elongated rectangle, with a first notch on a first end and a bore in the first notch substantially at right angles to the longitudinal axis, the bore proceeding from the notch to an outer surface of the first end, and a second end comprising second and third notches taken in a direction perpendicular to the first notch, such that the second end has a general shape of a rounded rectangle or square, and further comprising a bore substantially in the center of the second end;

at least one leg spoke, the leg spoke having a longitudinal axis and comprising a general shape of an elongated cylinder, an elongated cube, or an elongated rectangle, with a first notch on a first end and a bore in the notch substantially at right angles to the longitudinal axis, the bore proceeding from the notch to an outer surface of the first end, and a second end further comprising a bore in the longitudinal direction and substantially in the center of the second end; and

a cross brace having a longitudinal axis, the cross brace in a general shape of a flat rectangle having a first flat end with a longitudinal bore substantially in the center of the first flat end, and a second rounded end, and further comprising a bore through the cross brace at about a right angle to the longitudinal axis.

2. The system of claim 1, wherein the hub comprises six or eight faces and the ends are substantially in the shape of a hexagon or octagon.

3. The system of claim 1, wherein the second and third notches in the hub spoke are taken at an angle dependent on the plurality of faces of the elongated hub.

4. The system of claim 1, wherein the first notch in the hub spoke is taken at about a right angle to the longitudinal axis of the hub spoke.

5. The system of claim 1, wherein the second and third notches in the hub spoke are taken at an angle to allow positioning of six or eight hub spokes around a perimeter of the hub.

6. The system of claim 1, wherein the notch of the leg spoke is taken at about a right angle to the longitudinal axis of the leg spoke.

7. The system of claim 1, wherein the first end of the leg spoke has a shape of a half-cylinder and the second end has a shape of a circular cross-section with a bore.

8. The system of claim 1, wherein the cross brace has the shape of a tombstone.

9. The system of claim 1, wherein the second rounded end of the cross brace is in the form of a half circle with the bore through the cross brace located at about a center of the circle.

10. The system of claim 1, wherein at least two elements of the modular structural system are configured for assembly to each other:

i. with a plurality of dowels, and further comprising a plurality of dowels;

or ii. with a plurality of threaded fasteners, and further comprising a plurality of threaded fasteners.

11. The system of claim 1, wherein elements of the system are combined to form a structure.

18. A method of preparing the structural system of claim 1 to form a structure, the method comprising:

furnishing at least one hub; and

joining the at least one hub to a plurality of spokes selected from the group consisting of the leg spokes and the hub spokes with dowels to form a structure.

19. The method of claim 18, wherein the hub comprises an elongated generally hexagonal or octagonal shape.

20. The method of claim 18, wherein the structure is supported above ground by a plurality of rods or dowels.

21. The method of claim 18, further comprising either reinforcing joints between at least two elements of the structure, the elements selected from the group consisting of a plurality the hubs, the leg spokes, the hub spokes and the cross braces or bracing the structure with a plurality of the cross braces and dowels, wherein the dowels join the at least one hub, the spokes, and the braces by inserting the dowels in the bores or orifices in the hub, the spokes, and the braces.

22. The method of claim 18, further comprising reinforcing joints between elements of the structure with external tubing, shrink-wrap tape, or plastic bands.

23. The method of claim 18, further comprising joining elements of the structure to an available structural member.

24. The method of claim 18, further comprising joining elements of the structure permanently by a method selected from the group consisting of gluing, welding, brazing, and soldering.

12. A modular structural system, comprising:

a hub having a longitudinal axis and a plurality of faces on a perimeter of the hub, the faces oriented along the axis, the hub also comprising two ends, wherein a plurality of faces and each end further comprises a bore;

at least one hub spoke, the hub spoke having a longitudinal axis and comprising a general shape of an elongated cylinder with a first notch near a first end and a bore in the first notch substantially at right angles to the longitudinal axis, the bore proceeding from the notch to an outer surface of the elongated cylinder, and a second end comprising second and third notches taken in a direction perpendicular to the first notch, such that a shape of the second end is a rounded rectangle or square, and further comprising a bore substantially in the center of the second end;

at least one leg spoke, the leg spoke having a longitudinal axis with a first notch near a first end and a bore in the notch substantially at right angles to the longitudinal axis, the bore proceeding from the notch to an outer surface of the first end, and a second end further comprising a bore in the longitudinal direction and substantially in the center of the second end; and

a cross brace having a longitudinal axis, the cross brace in a shape of a flat rectangle having a first flat end with a longitudinal bore substantially in the center of the first flat end, and a second end, and further comprising a bore through the cross brace at about a right angle to the longitudinal axis.

13. The modular structural system of claim 12, wherein the second and third notches in the hub spoke are taken from an outer surface of the second end toward a center of the hub spoke, a depth of the notch decreasing as the second and third notches near the center of the hub spoke.

14. The modular structural system of claim 12, wherein the second and third notches in the hub spoke are taken at an angle dependent on the plurality of faces of the elongated hub.

15. The modular structural system of claim 12, wherein the hub spoke further comprises at least a fourth or a fifth notch, the fourth and fifth notches taken from an outer surface of the second end toward a center of the hub spoke and in a direction generally perpendicular to the first notch and also perpendicular to the second and third notches, and generally along a direction of the longitudinal axis.

16. The modular structural system of claim 12, further comprising a reinforcement for joints between elements of the modular structural system, the reinforcement selected from the group consisting of tubing, shrink-wrap tape, and plastic bands.

17. The modular structural system of claim 12, further comprising an available structural member, wherein the system is configured for joining to the available structural member.