Abstract:
A Tubular Framing System and Method. The system and method enables users to create structures from tube stock, such as carbon fiber or other composites without the need for a specialized workspace or customized tooling. The system allows the user to create joints, attachment points and mounting points for tubular and sheet composite material. When assembled, the joints between tubular segments and the attached termination fittings provide unparalleled tensile strength without the need for adhesives or special testing for verification. The system includes base assemblies, mid-span bracket and mounting assemblies and a wide range of versatile connectors that can provide the user with the flexibility to easily and rapidly create a wide variety of structures from strong and lightweight composite tube stock and aircraft-grade aluminum connectors.

Description:
[0001]    This application is filed within one year of, and claims priority to Provisional Application Ser. No. 62/173,306, filed Jun. 9, 2015. 
     
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
       [0002]    This invention relates generally to modular structural systems and, more specifically, to a Tubular Framing System and Method. 
       2. Description of Related Art 
       [0003]    As discussed herein, tubular framing systems are components that can be used to create structures by interconnecting tubular members. Steel and aluminum tubular framing systems are well-known, and have been practiced for decades. In recent years, the use of light-weight composite materials has become very popular. Carbon fiber has very desirable strength and weight characteristics that allow it to be substituted for metal components whenever feasibly possible. This has become particularly valuable in the aircraft industry because reducing aircraft weight allows the aircraft to carry more onboard fuel, while also reducing fuel consumption because there is less weight to keep aloft. 
         [0004]    Unlike the prior metal tubular structures, however, carbon fiber has serious restrictions. First, carbon fiber tubes cannot be welded to one another in order to create structures. Since the carbon fiber tubing is essentially a high-strength fiberglass, they can only be attached to one another by adhesive or by mechanical connection (or some combination of the two). One problem with adhesive bonded joints is that each glued joint will exhibit an unknown strength, since there are many variables involved in achieving a glued connection. The only way to be sure is to strength test each and every joint once they are glued. This quality assurance testing can only really be done in the facility in which the joint was glued, and not out in the field. 
         [0005]    Another problem with the adhesive approach is that the glue and the carbon fiber tubes will expand and contract at different rates in response to temperature fluctuations (which are common in the aviation environment). This difference in temperature sensitivity will ultimately result in a breakdown of the glued joints over time, thereby making these glued joints weak (and therefore unacceptable in many applications). 
         [0006]    A final problem with glued joints is that the glue joint is permanent. There is not opportunity to disassemble the glued joints once they are bonded. Any adjustment or modification to the tubular structure is therefore not possible. 
         [0007]    To date, a strictly mechanical system for interconnecting carbon fiber tubes (and panels) in order to form structures (e.g. shelf units, storage units, and many others) that exhibit the strength and weight-reducing benefits of the composite materials, while also providing the ability to create, assemble and disassemble the structures “in the field” has not been created. 
       SUMMARY OF THE INVENTION 
       [0008]    In light of the aforementioned problems associated with the prior systems and methods, it is an object of the present invention to provide a Tubular Framing System and Method. The system and method should enable users to create structures from tube stock, such as carbon fiber or other composites without the need for a specialized workspace or customized tooling. The system should allow the user to create joints, attachment points and mounting points for tubular and sheet composite material. When assembled, the joints between tubular segments and the attached termination fittings should provide unparalleled tensile strength without the need for adhesives or special testing for verification. The system should include base assemblies, mid-span bracket and mounting assemblies and a wide range of versatile connectors that can provide the user with the flexibility to easily and rapidly create a wide variety of structures from strong and lightweight composite tube stock and aircraft-grade aluminum connectors. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The objects and features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages, may best be understood by reference to the following description, taken in connection with the accompanying drawings, of which: 
           [0010]      FIG. 1  is an exploded perspective view of a preferred embodiment of an end assembly of the framing system of the present invention; 
           [0011]      FIG. 2  is a partially exploded perspective view of the end assembly of  FIG. 1 ; 
           [0012]      FIG. 3  is a perspective view of the end assembly of  FIG. 2 ; 
           [0013]      FIG. 4  is a side view of the main block of  FIGS. 1-3 ; 
           [0014]      FIG. 5  depicts the strength ratings of the corner assembly of  FIGS. 1-3 ; 
           [0015]      FIG. 6  is a perspective view of a preferred embodiment of a sidewall bracket assembly of the framing system of the present invention; 
           [0016]      FIG. 7  is a partial perspective view of the sidewall bracket assembly of  FIG. 6  employed in the assembly of the corner portion of the box structure; 
           [0017]      FIG. 8  is a partial perspective view from outside of the box structure of  FIG. 7 ; 
           [0018]      FIG. 9  is a perspective view of a preferred embodiment of a midspan bracket assembly of the framing system of the present invention; 
           [0019]      FIG. 10  is a perspective view of a preferred embodiment of an intermediate sleeve adapter of the framing system of the present invention; 
           [0020]      FIG. 11  is a preferred embodiment of a midspan base assembly of the framing system of the present invention; 
           [0021]      FIG. 12  is a perspective view of a preferred embodiment of an end bracket of the framing system of the present invention; 
           [0022]      FIG. 13  is a series of perspective views of the components comprising a preferred embodiment of a double midspan bracket assembly of the framing system of the present invention; 
           [0023]      FIG. 14  is a perspective view of a preferred embodiment of an adjustable joint assembly of the framing system of the present invention; 
           [0024]      FIG. 15  is a perspective view of the adjustable joint assembly of  FIG. 14  employed in the assembly of an adjustable joint of a pair of tube segments; 
           [0025]      FIG. 16  is a perspective view of a shelving assembly constructed using the framing system of the present invention; and 
           [0026]      FIGS. 17A and 17B  are side and perspective views of a preferred embodiment of a foot assembly of the framing system of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0027]    The following description is provided to enable any person skilled in the art to make and use the invention and sets forth the best modes contemplated by the inventor of carrying out his invention. Various modifications, however, will remain readily apparent to those skilled in the art, since the generic principles of the present invention have been defined herein specifically to provide a Tubular Framing System and Method. 
         [0028]    The system of the present invention is a collection of fittings, components and fasteners that are intended to be used to fasten segments of tubular material to one another in order to create a wide variety of structures. While the system will work with tubing material of virtually any type, it is intended to be used with composite (e.g. carbon fiber) material because of the substantial weight and strength benefits provided by that particular material. The user is able to fabricate these structures using the system of the present invention without the need for specialty tools or a specialized workspace. It is simply a matter of cutting the tubing into segments of the desired length, cutting a few holes in the walls of the tubing through which fasteners will attach the tubing to the fittings/components/assemblies of the instant system, and then assembling the joints between the tubing segments from a selection of the fittings, components and fasteners of the instant system. We will now proceed through a description of the most common components that make up the system of the present invention. 
         [0029]    The present invention can best be understood by initial consideration of  FIG. 1 . 1    FIG. 1  is an exploded perspective view of a preferred embodiment of an end assembly  10  of the framing system of the present invention. It should be understood that the term “end assembly” is not intended to limit the assembly  10  only for use at the end of a structure. In fact, as will be demonstrated herein below, the wide range of combinations of components of the present system will provide virtually limitless applications and positions for each component and/or assembly.  1  As used throughout this disclosure, element numbers enclosed in square brackets [ ] indicates that the referenced element is not shown in the instant drawing figure, but rather is displayed elsewhere in another drawing figure. 
         [0030]    The basic element of the end assembly  10  is the main block  12 . The main block  12 , and virtually all of the other components in the system, is made from aircraft grade aluminum (e.g. 6061-T6). The components are typically sized to interface with 1-inch, 1.5-inch or 2-inch (inner diameter) carbon fiber tubing, but other sizes would be available under this system, if desired. Two or more main sleeve adapters  14  are attached to the main block  12  by a plurality of adapter mounting bolts  22 . These bolts  22  and the others discussed herein below preferably are extremely strong—on the order of 170,000 pounds per square inch tensile strength. 
         [0031]    The main sleeve adapters  14  are selected by diameter so that they will fit snugly within the inner diameter of a segment of tubing. There is a central bore  13  through the adapters  14  along its longitudinal axis, as well as a plurality of tube mounting bores  16  (typically smooth-walled—without threads) running around the periphery of the central bore  13 . In this version, there are supplemental bores  18  in between each mounting bore  16 . The supplemental bores  18  simply reduce the weight of the sleeves  14  while still providing sufficient rigidity and strength to support the fabrication of structures. 
         [0032]    The peripheral face  15  of the sleeves  14  have two or more tube mounting bores  20  formed through them (actually there are typically a pair of bores  20  on opposing sides of the peripheral face  15 ). These bores  20  are threaded in order to engage tube mounting bolts [ 26 ] as depicted in  FIG. 2 . 
         [0033]      FIG. 2  is a partially exploded perspective view of the end assembly  10  of  FIG. 1 . In this view, the sleeves  14  have been secured to the main block  12  with the bolts [ 22 ]. Once they&#39;ve been attached, the user need simply slip tube segments  24  of the appropriate diameter and length over each sleeve  14 . As shown, tube mounting apertures  28  have been formed through each segment  24 . Once the segments  24  are in place, tube mounting bolts  26  are inserted through the apertures  28  so that they threadedly engage the tube mounting bores [ 20 ]. The final product is depicted in  FIG. 3 . 
         [0034]      FIG. 3  is a perspective view of the end assembly  10  of  FIG. 2 . As a completed junction of tube segments  24 , this assembly  10  forms a corner element  30  for a structure (e.g. such as a corner of a box). As shown in the side view of the main block  12  of  FIG. 4 , each face  32  of the block  12  is defined by a central bore  34  and a plurality of adapter mounting bores  36 . Each bore  36  is threaded in order to threadedly engage the adapter mounting bolts [ 22 ]. One further critical feature is depicted in  FIG. 4 , which is a side view of the corner element  30 . That feature is that the bores  36  are positioned at an angle (Θ) of 22.5 degrees from the reference axes A(r). The purpose of the rotated positioning is to provide room so that the bores  36  can penetrate as far as possible into the main block  12  without impinging on the bores  36  penetrating the other faces  32  of the main block  12 . 
         [0035]      FIG. 5  depicts the strength ratings of the end assembly  10  of  FIGS. 1-3 . Testing has revealed that a 1-inch tube attached to a 1-inch end assembly  10  can sustain at least 4,000 pounds per square inch of tensile force  38  applied to the tube segment  24 . A 1.5-inch configuration can sustain at least 6,000 psi, and a 2-inch configuration can sustain at least 8,000 psi. These strengths far exceed those provided by any prior composite tube structure without the need for adhesive or testing. Now turning to  FIG. 6 , we can commence a review of the other components of the system. 
         [0036]      FIG. 6  is a perspective view of a preferred embodiment of a sidewall bracket assembly  40  of the framing system of the present invention. The two main components of the assembly  40  are the inner base ring  42  and the corner bracket element  44 . The inner base ring  42  is selected to fit within the interior bore of a tubing segment [ 24 ], and has a plurality of bracket mounting bores  26  (there are 4 here) penetrating the outer face  48  of the ring in spaced relation. 
         [0037]    The corner bracket element  44  is named as such because it is not straight, but rather has a pair of “arms” that extend at 90 degrees from one another. The top face  50  of the element  44  has a pair of accessory mounting bores  52  formed through it and through the entire element  44 . These bores  52  are typically smooth-walled, and provide an attachment point for other elements in the system. There are panel mounting bores  60  formed through each end face  58  to provide an attachment point for panels (ideally made of carbon fiber). These are preferably threaded in order to accept mounting bolts very similar to the tube mounting points [ 26 ] discussed above. 
         [0038]    The bracket element  44  is attached to the outside of a tube segment by mounting bolts (not shown) passing through mounting bores  56  formed in the side faces  54  of the element  44 , then through apertures formed in the tubing segment, and threadedly engaging bracket mounting bores  46  formed in the inner base ring  42 .  FIGS. 7 and 8  show a box structure that can be created by utilizing the end assembly [ 10 ] and the sidewall bracket assemblies  40 . 
         [0039]    Three tube segments  24  have been interconnected to one another by end assembly  10 , so that the tube segments  24  extend at 90 degree angles from one another. Sidewall bracket assemblies  40  are attached to the segments  24  in appropriate locations along the length of the segments  24  such that the end faces [ 58 ] face outwardly. Panel members  62  are attached to the panel mounting bores [ 60 ] by mounting bolts that pass through apertures formed in the panels  62  for this purpose (presumably by the user/assembler). 
         [0040]      FIG. 9  is a perspective view of a preferred embodiment of a midspan bracket assembly  70  of the framing system of the present invention. As with the sidewall bracket assembly [ 40 ], this assembly  70  utilizes the inner base ring  42  that is inserted into the tube segment [ 24 ] when assembling the structure. 
         [0041]    A straight bracket element  66  bolts onto the outside of the tube segment [ 24 ] by mounting bolts [ 22 ] (typically shorter in length) that pass through the mounting bores  56  and apertures formed in the tube segment [ 24 ] and then threadedly engaging a bracket mounting bore [ 46 ]. 
         [0042]    The straight bracket assembly  66  has a pair of (typically smooth-walled, unthreaded) accessory mounting bores  52  formed through the top face  68  (through to the bottom face) of the element  66 .  FIG. 13  depicts one application for this straight bracket element  66 . 
         [0043]      FIG. 10  is a perspective view of a preferred embodiment of an intermediate sleeve adapter  74  of the framing system of the present invention. This adapter  74  has a wide variety of potential uses in the system of the present invention. It also inserts into a tube segment [ 24 ] in order to provide a base to which exterior elements can be bolted onto the outside of the tube segment [ 24 ]. 
         [0044]    The sleeve adapter  74  has a longitudinal bore  76  formed along its length (a through-hole). Bracket mounting bores  84  (threaded) are formed in the outer face  78  of the adapter  74 . Additionally, there are smooth-walled, somewhat larger transverse bores  82  that cross each other at the midpoint of the adapter  74 .  FIG. 11  depicts one use for the intermediate sleeve adapter  74 . 
         [0045]      FIG. 11  is a preferred embodiment of a midspan base assembly  80  of the framing system of the present invention. The intermediate sleeve adapter  74  is positioned within the interior of the tube segment [ 24 ]. A midspan base element  86  bolts to the bracket mounting bores [ 84 ] formed in the sleeve adapter  74  via base mounting bolts  92 . This assembly  80  can be positioned in the middle of a tube segment [ 24 ], rather than at its end. A main sleeve adapter  14  can then be attached to it by mounting bolts [ 22 ] to provide a midspan attachment point for a second tube segment [ 24 ]. 
         [0046]      FIG. 12  is a perspective view of a preferred embodiment of an end bracket  94  of the framing system of the present invention. End brackets  94  are utilized in a wide variety of arrangements with other components in the system. It is designed to provide an attachment point extending from the tip of a tube segment [ 24 ]. The inner portion  96  is designed to fit into the mouth at the end of a tube segment, and the tab portion  98  will extend from the end of the tube segment [ 24 ]. Tube mounting bores  20  (threaded) are located through the peripheral face  102 , in order to accept mounting bolts passing through apertures in the tube segment [ 24 ] and engaging the threads within the bores  20 . The tab portion  98  has a pair of smooth-walled attachment bores  106  extending between the side faces  104  of the tab portion  98 .  FIG. 13  depicts how some of these components can be combined to form useful structures. 
         [0047]      FIG. 13  is a series of perspective views of the components comprising a preferred embodiment of a double midspan bracket assembly  90  of the framing system of the present invention. As shown, an intermediate sleeve adapter  74  has been inserted into the end of a tube segment  24 . A pair of straight bracket elements  66  each attach to a pair of bracket mounting bores [ 84 ] provided by the sleeve adapter  74 . 
         [0048]    The second tube segment  24  has an end bracket  94  attached to it. In this particular arrangement, one of the straight bracket elements  66  (the one on the left) has threads on its accessory mounting bores [ 52 ] so that mounting bolts can threadedly attach to them. As should be apparent, the tab portion [ 98 ] can be placed between the two straight bracket elements, and then the mounting bolts  22  inserted and tightened down to the (left) straight bracket element  66 . This provides a secure attachment between the two tube segments [ 24 ], that is also easily disassembled when desired. 
         [0049]      FIG. 14  is a perspective view of a preferred embodiment of an adjustable joint assembly  100  of the framing system of the present invention. This mechanism provides an attachment between two tube segments [ 24 ] where the angle between the two tube segments [ 24 ] can be adjusted as desired by loosening and tightening the handle  114 . 
         [0050]    The assembly  100  comprises an assembly bolt  108  that holds the assembly together. The bolt  108  passes through a first axle element  110 A, a spacer element  112 , and then threadedly engages a second axle element  110 B. Turning the handle  114  will cause the assembly bolt  108  to turn, and thereby either tighten or loosen axle elements  110 A,  110 B (i.e. the squeezing force against the spacer element  112 ). When the bolt  108  is loosened, the axles  110 A,  110 B are free to rotate around the bolt  108  so that their relative angles can be changed (and then the bolt  108  can be re-tightened).  FIG. 15  depicts how an adjustable joint can be created utilizing this assembly  100 . 
         [0051]      FIG. 15  is a perspective view of the adjustable joint assembly  100  of  FIG. 14  employed in the assembly of an adjustable joint of a pair of tube segments  24 . Here, one axle element  110 A has been placed within the central bore [ 34 ] of the main block of a first corner element  30 A, and the threaded axle element  110 B has been placed within the central bore [ 34 ] of the main block of a second corner element  30 B. The spacer element [ 112 ] has been placed between the two corner elements  30 A,  30 B, and then the bolt [ 108 ] and handle [ 114 ] have been inserted through the first axle element [ 110 A], the spacer element [ 112 ], and then threads into the second axle element [ 110 B]. Once assembled, the user need simply place the tube segments  24 A,  24 B in the desired relative angles, and then turn the handle [ 114 ] to tighten the joint to hold the angular orientation of the tube segments  24 A,  24 B. 
         [0052]      FIG. 16  is a perspective view of a shelving assembly  116  constructed using the framing system of the present invention. A plurality of corner elements  30  and mid-span base assemblies  80  have been utilized to create a lightweight, strong storage unit. 
         [0053]      FIGS. 17A and 17B  are side and perspective views of a preferred embodiment of a foot assembly  120  of the framing system of the present invention. The assembly  120  is constructed by bolting a main sleeve adapter  14  to a foot element  122 . As should be apparent, this provides a stable base to form “feet” for structures created using the system of the present invention. 
         [0054]    Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiment can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.