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.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   This patent is related to U.S. Pat. No. 6,722,086, titled “Modular Structure System,” and to U.S. Pat. No. 6,854,238, titled “Structural Connection System for Frameworks,” and to U.S. patent application Ser. No. 11/458,321, titled “Spherical Hub for Modular Structural System,” all invented by Alfred H. Boots, the inventor of the subject matter disclosed and claimed herein. The entire contents of these patent documents are incorporated herein by reference for all purposes. 
   BACKGROUND 
   This patent generally relates to modular structural systems, and more particularly to generally polygonal three-dimensional hubs or connectors used in conjunction with modular structural systems. 
   Known modular structures generally include frame components or members configured for rapid assembly and disassembly. The frame members are required to (a) provide a durable and stable structure, and (b) be easy to handle and be installable by limited number of persons. The frame members can form a wide variety of shelter frames such as outdoor tents, circus tents, playground equipment, geodesic domes, greenhouses, swimming pool structures, etc. The frame members can also form internal structures, such as furniture, stands, shelving, etc. 
   Many known modular structural systems utilize and require telescoping members to assemble and disassemble a structure. These telescoping members are costly, complicated manufacture and tend to make the structure less rigid or strong. Some of those systems require inner and outer spring loaded tubes and a bolt or clamp that tightens the members together to form a member having a desired length. Other systems require an internal threaded rod or ball screw that cooperates with an internally threaded member. In operation, when the threaded member is turned relative to the rod or ball screw, the overall length of the member shortens or lengthens. Still other systems require a plurality of internal rods having threaded ends connected by a right angle gear and a second mating gear that couples to a handle, which extends outside of the member to enable an operator to turn the handle and thereby turn the rods to lengthen or shorten the member. 
   One known structural system disclosed in the above-identified U.S. Pat. No. 6,722,086 provides a modular system for constructing a tubular structure. The disclosed modular system provides for tubular structures to be assembled and disassembled in a direction perpendicular to a centerline of the tubing without having to move the tubing along its centerline. The modular system further allows the tubing to be positioned at various angles and allows curved tubing to be used. In an embodiment, the modular system includes a cylindrical hub and a connector that removably couples to the cylindrical hub. The connector has a first end that couples to the hub and a second that defines a notch. One of the walls of the notch connects to a flange that may extend in one or two directions from the centerline of the connector. The connector and flange removably couple to one end of an adapter, which contains a mating notch, wherein the adapter receives a tube. 
   Another known structural system disclosed in the above-identified U.S. Pat. No. 6,854,238 provides a modular frameworking system having various apparatuses and methods of attaching same. The disclosed framework includes a plurality of hubs which each include a plurality of pairs of opposing flat faces. Each face connects, in turn, to at least one connector. The disclosed frameworking system includes primary “T” shaped connectors that attach directly to the hubs and secondary “L” shaped connectors that attach to the primary connectors and thus the hub. An adapter is provided and connects at one end to a leg of the connector and at the other end to a structural member, e.g., a straight or curved tube, angle or channel. The adapter and structural member are readily removable from the hub and the connector. The connector can be curved and alternatively includes a hinge so that the connector can rotate. The connectors can attach to each face of the hub and can be rotated in multiple directions on any given face of the hub. 
   U.S. patent application Ser. No. 11/458,321, discloses spherical hubs, which make possible a variety of enclosed, three-dimensional structure. These structures, however, are somewhat limited because of the fairly wide space required to accommodate each node, and thus do not allow for more than a few spokes for each node. While each of these structural systems provides apparatuses and methods for assembling and constructing modular frameworks and structures, it would be desirable to provide a hub or core design that can further increase the flexibility and utility of these systems. Further, it would be desirable for the flexible hub to be simple and inexpensive to manufacture, thereby reducing the overall cost of the structural system in which it is utilized. 
   SUMMARY 
   One embodiment is a modular structural system. The modular structural system includes an elongated hub having a generally elongated polygonal shape, and further includes a longitudinal axis and a plurality of faces on a perimeter of the hub, the faces oriented along the axis, the hub also including two ends, and wherein each face and at least one end further including a bore. The system also includes at least one hub spoke, the hub spoke having a longitudinal axis and including 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 including 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 including a bore substantially in the center of the second end. The system also includes at least one leg spoke, the leg spoke having a longitudinal axis and including 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 including 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 including a bore through the cross brace at about a right angle to the longitudinal axis. 
   Another embodiment is a modular structural system. The modular structural system includes 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 including two ends, wherein a plurality of faces and each end further includes a bore, and at least one hub spoke, the hub spoke having a longitudinal axis and including 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 including 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 including a bore substantially in the center of the second end. The system also includes 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 including 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 including a bore through the cross brace at about a right angle to the longitudinal axis. 
   Another embodiment is a method for preparing a structure. The method includes furnishing a hub in a generally polygonal shape and having a plurality of faces, each face further including a bore, the hub also including a top face and a bottom face, at least one of the top and bottom faces including a bore, joining the hub to a plurality of spokes selected from the group consisting of leg spokes and hub spokes with dowels to form a structure. The method also includes optionally bracing the structure with a plurality of cross braces and dowels, wherein the dowels join the hub, the spokes and the braces by inserting dowels in bores or orifices in the hub, the spokes, and the braces. 
   Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIGS. 1-2  are perspective view of hub embodiments; 
       FIG. 3  is a perspective front and back view of a hub spoke embodiment; 
       FIG. 4  depicts perspective views of a first leg spoke embodiment; 
       FIG. 5  is a perspective front and back view of a second leg spoke embodiment; 
       FIG. 6  is a perspective front and back view of a cross brace embodiment; 
       FIG. 7  is a perspective view of a particular application in a garden or greenhouse of a structure using the modular structural system; 
       FIG. 8  is a perspective view of a second particular application of a structure using the modular structural system; 
       FIG. 9  is a perspective view of another embodiment of a hub spoke; 
       FIGS. 10-11  disclose braces for reinforcing modular structures; 
       FIG. 12  discloses additional structural members; and 
       FIG. 13  is an embodiment of a structure made from the modular structural system. 
   

   DETAILED DESCRIPTION 
   There are many embodiments of the present invention, of which this application presents only a few. One embodiment includes an elongated hub for use in a modular structural system, as shown in  FIG. 1 . An elongated hub  10  along longitudinal axis A has a generally polygonal cross-section, in this instance of an octagon. Each hub  10  has two end faces  11 , of which only one is shown. End face  11  has a hole  13  or bore in about the center of the face. The bore may be of any dimension, but those in  FIG. 1  are preferably about ¼ inch in diameter. Other bore dimensions may be used. Each side face  12  of the eight side faces has a transverse bore  14 , and is also about ¼ inch in diameter. In the embodiment of  FIG. 1 , bores  12 ,  14  are each about ½ inch to about ⅝ inch deep and interconnect at the center of the hub. In other embodiments, the bores are blind, and are about ⅜ inch to ½ inch deep. 
   Embodiments of the central hub are not limited to those having a generally octagonal cross-section.  FIG. 2  depicts a second embodiment, central hub  20  having a cross-section in the general shape of a hexagon. Central hub  20  has two end faces  21 , each with a blind hole bore  23  about ½ inch deep. Central hub  20  has six side faces  22 , each with a blind hole bore  24  also about ½ inch deep. In this embodiment, each bore  23 ,  24  is about ¼ in diameter and does not intersect with other bores in the center of the central hub. Embodiments are not limited to generally polygonal structures with an even number of sides, and other embodiments may have an odd number of sides. Each side preferably has a tapped bore in order to accommodate a connection to another threaded piece of the present modular structural system. As will be seen below, pieces of the modular structural system are preferably joined with wooden dowels, steel or aluminum rods, or other connecting or linking pieces. In this embodiment, threaded steel or aluminum rods are preferably used to connect with hub  20 . For example, threaded rod  25 , with optional nut  26  may be used to join two pieces. A bolt or a screw, such as socket head cap screw  27 , may also be used to join pieces. The head, which will be external to the joint, may be used to help hold or maneuver the structure. 
   Another structural element or piece that forms a part of the present modular structural system is a hub spoke that joins with the central hub. Hub spokes will radiate from side faces of the central hub. An embodiment of a hub spoke is depicted in  FIG. 3 . Hub spoke  30  is in the general shape of a modified, elongated cylinder along longitudinal axis B. Hub spoke  30  has a hub-end or front portion  31  and a rear portion  34 . Rear portion  34  has a notch  35  in the general form of a half-cylinder, i.e., about half the material removed. Rear portion  34  also has an orifice  36 , preferably a through-hole, in about the center of the rear portion. 
   Front portion  31  has a front face  32  in the general form of a rounded rectangle or square, surrounded by four trimmed side faces  33   a ,  33   b  (only 2 shown) and with a blind hole or orifice  33 . In the present orientation, left and right side faces  33   a  are at an angle of about 45 degrees to a vertical plane passing through longitudinal axis B, depicted in  FIG. 3  as angle C in a horizontal plane passing through axis B. Trimming the faces in this way allows a plurality of hub spokes  30  to connect with central hub  10 . Top and bottom trimmed faces  33   b  are at a similar angle in a transverse plane. In other embodiments, angle B may be at about 60 degrees for a central hub having a cross section in the general shape of a hexagon, as for central hub  20 . Other hub spokes may be shaped at different angles for hubs having other shapes. With the extra room allowed by trimming facets on both sides, and on the top and bottom, hub spoke  30  allows great freedom of design with the modular structural system. 
   Persons having skill in the art will recognize that the hub spokes are trimmed at an angle to enable close placement of as many hub spokes as there are faces on the central hub. If a hub with a cross section in the general shape of a polygon of n sides is used, each face of the hub will portend an angle of 360°/n. Working through the geometry of a shape of a cross-section of a general polyhedron or trapezoid formed at the hub end of a hub spoke, angle required for close-fitting of the hub spokes will be equal to the angle subtended by each face of the central hub. Thus, for an octagonal shape, a trim angle of about 45° is used, while for a hexagonal shape, an angle of 60° will be used. It will be understood that each of these is a maximum angle, and that more trimming may be used, which will result in a smaller angle. Using a greater angle (less trimming) will result in an interference, in which case hub spokes will not be able to fit together. Using a lesser angle (more trimming) will result in voids between the left and right side faces  33   a  and the corresponding faces of adjacent hub spokes. Thus, in the present embodiment of an octagonal hub, the side faces of the hub spokes would be trimmed at a 45° angle which is taken in the horizontal plane to the longitudinal axis B. 
   Another element of the present modular structural system is a leg spoke, as depicted in  FIGS. 4-5 . A first embodiment, in  FIG. 4 , is a leg spoke  40  which is similar in structure to the hub spokes described above, but in which the front portion is not trimmed because the leg spoke is not intended for close fitting to a central hub. Leg spoke  40  is in the general shape of an elongated cylinder with a longitudinal axis D. Leg spoke  40  includes a front portion  41  with a blind hole or orifice  43 . Rear portion  42  has a notch  45 , with about half the material removed, and a through hole or orifice  44 . Removing half the material leaves rear portion  42  in the general shape of a half-cylinder, while front portion  41  has the general shape of a cylinder. 
   Another embodiment of a leg spoke is depicted in  FIG. 5  Leg spoke  50  includes a front portion  51  in the general shape of a cube with a blind orifice or hole  53  and a rear portion  52 . Rear portion  52  is in the general shape of a half-cylinder with a through-orifice  54  and a notch  55 . Leg spoke  50  has a longitudinal axis E running in the direction of the front and back portions  51 ,  52 . Rear portion  52  is centered on front portion  51 . Orifice  53  runs along longitudinal axis E and orifice  54  is transverse to longitudinal axis E. 
   Another element of the present modular structural system is a leg brace, depicted in  FIG. 6 . Leg brace  60  is flat and has the general shape of a slice of bread along longitudinal axis F. The front portion  61  has a generally boxy shape, while rear portion  63  is rounded, especially at the “corners”  65 . Front portion  61  has a blind hole or orifice  62  along the longitudinal axis F, while rear portion  63  has a through orifice  64  that is transverse to the longitudinal axis and is placed through the shorter through-dimension or thickness of the leg spoke. Other configurations of a cross-brace may be used. The above elements, members of the present modular structural system, may be used alone or in combination with available structural members, such as channels and angle pieces, to construct useful structures. 
   Two applications using embodiments of the modular structural system are presented in  FIGS. 7-8 .  FIG. 7  depicts a trellis  70  for supporting climbing vines or other decorative objects, such as flowers or art work, such as children&#39;s projects. Trellis  70  includes an eight-sided central hub  10  connected with short dowels  71 , the dowels in this case about 1-2 feet long. This particular central hub  10  is a little less high, but still has the requisite number of sides, each side with an orifice. This embodiment also has an orifice on the top and bottom faces. Each dowel  71  connects to a leg spoke  40 , the leg spoke having a side orifice for connecting with dowels  71 . The leg spoke, in this orientation, also has a down-ward facing orifice for connecting with dowel  72 . Central hub  10  also has a down-ward facing orifice, as described previously, for interfacing with supporting dowel  73 . Dowels  72  and  73  are preferably sufficiently long that they can be pushed into the earth a reasonable distance, such as at least 8-12 inches. This distance will provide support for the leg spokes and hub, and will allow the structure good support in a breeze or other mild weather events. 
     FIG. 8  depicts a sturdier structure  80  for supporting a tomato plant in a garden. Support structure  80  includes a central hub  20  in a generally hexagonal shape with a central support dowel  81  for placement in the orifice (not shown) in the bottom face of central hub  20  and also in the ground. Six hub spokes  30 , one for each face of hub  20  with bore  24 , interface with central hub  20  via dowels  82 , each dowel about 6-8 inches long. Each hub spoke  30  interfaces with a short dowel  83 , about 2 inches long, and joining the hub spoke to a leg spoke  50  via bore  54  and to a cross brace  60  via bore  64 . The leg spokes are supported above the ground by bent or angled rods  84  joined to leg spokes  50  through orifice  53 . The cross braces  60  and the structure are reinforced by joining dowels  85 , each dowel  85  joining two adjacent cross braces through bore  64 . In one embodiment, one structure  80  is used to support a single tomato plant. 
   Other features may also be used with the structure as shown. For example, an additional leg spoke  40  may be joined horizontally to cross brace  60 . Note that the “top” portion of the cross brace, when joined to leg spoke  40  through their respective bores, allows rotation or pivoting of the cross brace within the notch of the leg spoke. Note that if aluminum or steel modular pieces are used to construct the tomato plant holder  80 , the joinder may be made permanent by simply spot-welding, brazing, or soldering the joints of the individual pieces. If wooden pieces are used, the structure may be made permanent by using any suitable adhesive or wood glue to join the pieces. 
   There are many embodiments of the present modular structural system. Another embodiment is depicted in  FIG. 9 , which discloses an additional hub spoke  90 . Hub spoke  90  has a forward portion with only two trimmed opposite faces  91 ,  92 , and orifice  93 , so that the forward portion faces may fit around a generally polygonal central hub, as described above. The hub spoke also has a rearward notch  95 , a transverse orifice  96 , and an axial orifice  97 . Trimming only two faces allows fewer hub spokes to be clustered about the central hub, while still allowing orientation of the spoke and the hub in a different direction. 
   There are also other ways to stiffen or reinforce structures made from the modular structural system. For example, thin steel or aluminum tubing may be used, as shown in  FIG. 10 , in which tube  100  is crimped around two leg spokes  40 . This will stiffen the joint between the individual spokes and make the assembly stiffer and stronger. Instead of metal tubing, plastic bands, similar to wide wire-ties, or shrink-wrap tubing, may be used, preferably with wooden pieces as shown in  FIG. 11 , although shrink-wrap tubing may also be used with metal embodiments. The bands may extend merely to one joint, or may encompass more than one joint. 
   Finally, there are many structures which may be made from the modular structural system. As noted above, the elements of the present modular structure system may be used with available structural members to construct or build useful structures. Examples of steel and aluminum, disclosed in  FIGS. 12A-12C , include angle-pieces  120  and channels  122 . Examples of available wooden structural members include board  124 . Inside-plant holder  130 , depicted in  FIG. 13 , is one example of these structures, using octagonal hubs  10  and dowels  131  with other structural members, including angle-pieces  120 , channels  122 , and boards  124 . The bottom board  124  in  FIG. 13  could be placed atop the bottom set of hubs  10 , rather than underneath. The board is shown underneath for clarity in the figure. Other embodiments include stairway guard rails, awning holders, structures for holding shelving, outdoor greenhouse structures, lean-tos, space-holders, and so forth. 
   It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. For instance, the hub pieces are generally in the shape of a polygon, such as a triangle square, pentagon, hexagon, or octagon. It is often more convenient, and safer for users, to manufacture such pieces with rounded corners, such that there is no longer a truly polygonal cross-section or shape. These rounded shapes are included in the meaning of the term “polygonal,” or specific embodiments, such as “hexagonal” or “octagonal.” The same rounding may apply to other pieces of this modular system. Such changes and modifications can be made without departing from the spirit and scope of the present subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.