Patent Publication Number: US-2019178276-A1

Title: Design and Methods for a Modular Construction Kit

Description:
REFERENCE TO RELATED APPLICATIONS 
     This application claims an invention which was disclosed in Provisional Application No. 62/597,369, filed 11 Dec. 2017, entitled “Design and Methods for a Modular Construction Kit”. The benefit under 35 USC § 119(e) of the United States provisional application is hereby claimed, and the aforementioned application is hereby incorporated herein by reference 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to Modular Construction Kits or Systems and specifically to specialty, lightweight, small parts that complement each other and enable construction using independently sourced bulk items. 
     BACKGROUND OF THE INVENTION 
     The current state of construction of self-designed or public domain designs often involves using parts that are expensive and difficult to integrate or have large transport costs for bulky items that might be required. 
     Some non-exclusionary examples are the design and construction of domes or frames for outside storage, tool hangers, garden trellises or lightweight supports for children&#39;s play structures, playhouses or clubhouses. The present disclosure seeks to incorporate a modular system of specialty parts designed to allow for both standardized and proprietary members that can work together with commonly available easily sourced materials like plastic tubing such as PVC, PEX and HDPE or metal such as aluminum or steel conduits, irrigation or sanitary pipes or plywood and plastic sheets which are available from many hardware stores or other outlets. Having small quantities of some of these bulky objects delivered or including them in a full construction kit however can raise the project cost above a desired budget. 
     This disclosure seeks to provide inexpensive modular systems that can help connect, support or assemble such designed items while leaving the large and bulky items that are nevertheless cheap to manufacture and readily available to be sourced at a local supplier. Many connectors and or supports for such materials are designed for a specific use so that connectors of pipes often must be hollow to allow fluid or wires to pass through and be of sanitary grade and a tight tolerance. However, in use for an alternate purpose, a specialty modular connecting system can incorporate plugs, caps, linkages, inserts or items that are not suitable for the materials original intended purpose but are therefore cheaper to manufacture and available for a wider range of functions. 
     BRIEF SUMMARY OF THE DISCLOSURE 
     The present invention comprises various items used as a modular system for connecting and securing construction items in place to build a physical item from a design. These include but are not limited to connectors and linkages that can be assembled with different configurations and properties for securing pipes, conduits, frames, sheets and panels of various materials together in a quick and secure fashion while allowing movement along specified degrees of freedom if required. 
     One embodiment of the disclosure is a connector section comprising a collar for various sized pipes, tubes and conduits that can be secured to an insert section acting as a connector for either the same or different sized pipe, tube or conduit using said pipes and conduits as structural members in a construction. Said collar-insert component then can attach one or more members at right angles, or with an adjustable pivot linkage, at various angles to the collared member. 
     Both the collar and the insert whether pivoted or not form a connector unit which is modular in its nature and function. The collar can be connected to other collars of similar or differing types and sizes. The inserts likewise can be connected to other inserts of similar or differing types and sizes. One embodiment is for the collar to be replaced with a hub from which structural members like pipes can be connected from the top and bottom as well as the sides again in various size combinations and angles. 
     The insert connectors attached to either collar or hub can be replaced with connectors that are external fittings rather than inserts and attach to the outer surface of the connecting structural member or pipe. The various connector types can join to the various collar or hub types with a variety of joiners some as lugs and complementary slots or cavities others as threaded connectors, clips or other linkage methods. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The inventive principals are illustrated in the figures of the accompanying drawings which are meant to be exemplary and not limiting, in which like references are intended to refer to like or corresponding parts and similar elements and in which: 
         FIG. 1  presents an example of a hub comprised of top and bottom sections and circumferential connectors joined via a separate bolt. 
         FIG. 2  shows an example of a pivot angle linkage. 
         FIG. 3  illustrates an example of a hub with spring clip fasteners that connect top and bottom sections and pivoting linkages for insert connectors that can be locked in at a set angle on the hub. 
         FIG. 4  presents Hubs with cavities that allow insert connectors to attach. 
         FIG. 5  illustrates a hub comprising top and bottom sections held in place with machine screws 
         FIG. 6  presents a hub with pivot insert connectors and various locking mechanisms. 
         FIG. 7  shows an example of a ratcheting pivot connector. 
         FIG. 8  illustrates a collar with an internal cavity for separate bolts or other fasteners that project out from the collar, the collar being held together via spring clips. 
         FIG. 9  presents a circumferential connector with a bolt and lock nut. 
         FIG. 10  shows a collar with an internal recessed groove and a bolt fastener. 
         FIG. 11  illustrates a Y profiled connector for differing internal diameter pipes. 
     
    
    
     DETAILED DESCRIPTION AND BEST MODE OF IMPLEMENTATION 
     While exemplary embodiment&#39;s are described below, it is not intended that these embodiment&#39;s describe all possible forms of the embodiment&#39;s of the disclosure. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. In addition, modifications may be made without departing from the essential teachings of the disclosure. Furthermore, the features of various implementing embodiment&#39;s may be combined to form further embodiment&#39;s of the disclosure. 
     Furthermore, to the extent that the term “includes” is used in either the detailed description or any claims, such term is intended to be inclusive in a manner similar to the term “comprising” as comprising is interpreted when employed as a transitional word in a claim. While the disclosure has been described with reference to specific embodiment&#39;s, those skilled in the art will understand that various changes may be made and equivalents may be substituted for elements thereof without departing from the true spirit and scope of the disclosure. 
     Referring to  FIG. 1  which shows an embodiment of a modular system which can be used for connecting pipes or tubes via their outside diameter by way of a circumferential connector  103   a  which has a bolt  103   b  and nut  103   c  inserted that can thread into a hub comprising of top  101   b  and bottom  101   a  sections. The hub is held together via machine screws  102  which secure the hub sections as one unit. An assembled connector with nuts  103  is shown both separated and in connected position with the hub. 
     Also referring to  FIG. 2  which illustrates a pivot linkage connector one component of which is threaded  201  and one which is a circumferential connector  202  connected by nut  204  and bolt  203  with a spring  205  arranged to allow separation for angle adjustment when the bolt and nut are loosened. The components can obviously be changed to two threaded components or two circumferential connector components or other type such as internal connectors or various components designed for particular members and retained at a set angle relative to each other. 
     Yet another embodiment is shown in  FIG. 3  where cubic hub sections  301   a  and  301   b  are connected together via integral spring clips. A pivot connector comprising a pivot base  302   a  is attached by integral threaded shafts and a nut  304  to the hub and an insert connector  302   b  is attached to the base pivot  302   a.  This allows for hinges and a wide range of movement for the connected members. Another insert connector  303  is shown as a fixed 90 degree connector. 
     Referring to  FIG. 4  the combination of inserts, hubs, collars and linkages  401  can include solid hubs  402  and  403  with cavities that match inserts or other connection components that are made for standardized off the shelf items like PVC conduit  404  or other common building or household supplies. 
     As shown in  FIG. 5  one embodiment is a hub arranged as a pair of complementary octagonal sections that allow a threaded insert. The hub sections  501   a  and  501   b  are assembled with machine screws  502  to form a working hub. The shape of the hub could be pentagonal, a decagon any polygonal shape or any regular or irregular polyhedra. The hubs can contain threads for screwing or clips or sockets like a bayonet socket depending on intended use, reuse and structural requirements. 
     Referring to  FIG. 6  several locking mechanisms can be used including but not limited to threaded sections and lock nuts, pins, cir-clips, bolts, screws or glue and items like Velcro or magnets. An angled pivot connector section  601   a  is mated with another angled connector which has a ribbed barrel  601   b  which fits a threaded female barrel connector  601   d  which uses a clip  601   c  to hold the two male and female sections in place both radially and longitudinally. This holds the connected structural member in place at a set angle with two degrees of freedom for its orientation. The assembled connector  601  can rigidly connect to a pipe  602  at a wide range of orientations. 
       FIG. 7  shows another embodiment of a pivoting connection with sections  701  and  702  where the joint can ratchet in one direction and not in the reverse as well as lock washers  703  and bolts  203  to hold them together. 
     A further embodiment is displayed in  FIG. 8  for a circular collar with a cavity for bolts, nuts, lugs or other fastener types, The sections  801  are integral spring clips and  802  is the cavity it slides into to lock the two sections in place. The two sections are the same but offset 90 degrees to allow the four integral spring clips to lock the sections in place rather than machine screws. Holes  803  are at positions around the perimeter and others can be drilled at any position to allow an infinite range of angles between connectors such as  803   b  and thus the structural members connecting to them. 
       FIG. 9  shows a circumferential connector with hole for various size bolts and a lock nut retaining it in place. Two holes on the barrel of the connector allow fixing the pipe or conduit to the barrel with screws through the pipe or button type spring clips. There is also an embodiment of an insert component  904   b  which has a sliding section  904   b  that can extend and hold the inner surface of a pipe via the action of a bolt  903   b  and nut  902   b    
       FIG. 10  shows an embodiment as a simple collar  1002   a  which fits a particular diameter structural section and has an inner recessed grove where a bolt or other fastener can be positioned. Again this embodiment allows any angle between attached structural members  404  and can be easily adapted with drilling for any angle between fasteners such as bolts  1002   b.    
     Referring to  FIG. 11  we illustrate a Y profile insert connector  1103  for a range of diameter tubes. The insert connector has a hole for a fastener shaft  1103   b  and a slot for a nut to suit  1103   a  the Y cross section allows three contact areas on the inner diameter of a tube while ridges on the blades allow contact points to have pressure applied on the inner faces of said tubes. Slots in two of the blades allow flexibility for the ridges to compress down on the blades which supplies a spring like force of the blades and ridges onto the tubes inner surface. 
     All connector types in the described embodiment&#39;s are designed for use on both ISO “International Organization for Standardization” and ANSI “American Standards Association” pipes and conduits as well as proprietary “structural grade” and specialized plastic and metal tubing and structural members. 
     One of our preferred embodiment&#39;s is for connectors that enable a selection of domes commonly referred to as Geodesic. These can comprise hubs that are of the correct angle and number of joins but allow the connection of plugs via inserts that then form the vertex connector set proper. Although the term Geodesic is used here generically many dome shapes are possible using a variety of connectors and one preferred embodiment is the series of geometric forms known as Platonic solids. 
     Some of these are the Dodecahedron and Icosahedron or geometric form comprising the Archimedean solids like the Truncated Icosahedron, Rhombicosidodecahedron or Truncated Icosidodecahedron. These can be used to provide dome shapes that have regular polygons making up their surface and importantly have edges that are all the same size. This allows users of the connectors to cut a set number of identical pipes or frame sections for use as the sides with no problems of distinguishing which members to use as they are all the same. Although the preferred embodiment uses geometric solids true Geodesic dome connectors made from modular sections can be included in many embodiment&#39;s. 
     One possible embodiment is the Truncated Icosahedron which is commonly identified as a shape used in soccer balls and made of regularly arranged pentagon and hexagon sections where only 3 edges ever meet at a vertex and the same hub can be used for the entire structure. The same is true for a truncated octahedron but it has less of a dome shape. We implement this embodiment by using an insert connector with the required angles and orientation for each of those geometric solids and connecting plugs to allow pipes to be used for the framework. 
     For sheets and non tubular items connectors with slots and adjustable faces such as used in vice or clamps as well as clips that hold onto the exterior of a pipe or tube and allow flexible attachment with items like cable ties and various bands or straps of metal or plastic.