Modular system of interlocking beams and joints for design and assembly of structures

Abstract

The present invention relates to a modular build system featuring interlocking beams and joints, thereby facilitating flexible design and assembly of various structures. The beam includes fastener tracks, pins and fastener cavities and utility channels on their longitudinal faces, allowing for a secure connection. The fastener rail can be a dovetail rail, a T-slot rail, a V-slot rail, or a miter rail channel. The beams can be made of materials such as aluminum, wood, stainless steel, and extruded polymers, and have dimensions such as 2 x 2 inches or 5 x 5 inches. The system supports secondary beams and accessories, thereby enhancing functionality and aesthetics. The joint allows dimensional transitions between the beams. The system is easy to assemble, disassemble and reconfigure, thereby supporting a variety of applications, including residential, retail and industrial uses. Auxiliary components such as drawers and electrical accessories can be integrated. Cables or hoses can be laid out through center holes in the beams. The system is compatible with cloud-based CAD software to implement virtual designs, allowing users to create, share, and modify designs under the support of AI optimization. The invention also supports 3D printed custom accessories and leveling supports for uneven surfaces.

Description

[0001] Related applications This application claims priority to U.S. Provisional Patent No. 63 / 472,811, filed June 13, 2023, entitled "Modular System of Interlocking Beams and Junctions for the Design and Assembly of Structures," which is incorporated herein by reference. Background Technology

[0002] Structural frames are used in many practical applications as an economical and physically robust means / device for constructing systems and components. They are primarily used to support other parts and often act as load-bearing subsystems for objects and buildings. Structural frames and systems typically transfer loads through interconnected rigid or hinged elements or components.

[0003] Some existing framework systems on the market are created as modular systems, meaning that the system or structure is subdivided into smaller parts / sections that can be independently replaced or exchanged. A wide variety of modules and / or components (with different shapes and sizes) provide the flexibility to adapt the structure to different shapes and needs to achieve the desired structural outcome.

[0004] The advantage of modular systems lies in the ability to create a virtually unlimited number of final structures in one (1), two (2), or three (3)-dimensional space using a limited number of modular designs. Modular systems are advantageous because they do not require the user to fabricate (shape / manufacture) the final structure from raw materials. Therefore, modular systems often rely on prefabricated modules that the user purchases from a manufacturer and can then assemble into any desired and unique structural shape. Additionally, this form of construction reduces the cost of the final structure due to the large-scale production (economies of scale) of each individual module in the system.

[0005] While modular systems for building frames and structures are not new, most of these systems have a limited market reach (niche market). For example, some systems are solely for creating furniture, others are ultimately designed for building and large structural frames (MERO structures), still others are used as toys (LEGO), and yet another is used to create industrial machines / workspaces (T-slot and V-slot aluminum extrusion kits). Creating a modular system that serves more than one niche market is valuable. This is a modular system that can be used in many applications—from residential use for individuals and families to industrial, retail, commercial, and real estate applications.

[0006] The modular building system described in this article can serve markets such as, but not limited to, residential (home), retail, conference, work and education structures, catering services, entertainment and living spaces. Summary of the Invention

[0007] This invention relates to a modular construction system designed to facilitate flexible design and assembly of various structures using interlocking beams and joints. The beams in this system are characterized by fastener tracks, pins, and fastener cavities, as well as functional channels on each longitudinal plane, thereby achieving versatility and robust connections.

[0008] The beam's fastener tracks can be selected from dovetail tracks, T-slot tracks, V-slot tracks, or miter rail channels, providing a wide range of attachment options. Practical channels are strategically positioned at the corners or sides of the beam, thereby enhancing the system's modularity by allowing the integration of secondary beams and various fittings.

[0009] The beam's pin and fastener cavities include threaded holes, increasing the system's versatility. The beams can be manufactured from a variety of materials, including aluminum, wood, stainless steel, and extruded polymers. They are capable of achieving different cross-sectional dimensions, such as 2-inch x 2-inch and 5-inch x 5-inch square profiles.

[0010] The system supports attaching secondary beams or fittings to utility channels. These secondary beams can be made of materials such as wood, aluminum, stainless steel, polymers, and paper, and can include fastening features such as threaded holes, dovetail tracks, and T-slot tracks.

[0011] The joints in the system are designed to transition from one scale of the beam to another, thereby enhancing the flexibility and scalability of the structure. This design allows for easy assembly and disassembly of beams and joints, and they can be removed from the structure independently, facilitating maintenance and reconfiguration.

[0012] The modular nature of the system allows for the creation of reconfigurable and reusable structures, which can also be independent. Auxiliary components, such as drawers, panels, coat rails, mirrors, table tops, sliding doors, desk-tops, shelving, and various electrical fittings, can be attached to beams and joints, enabling the system to be highly versatile for a wide range of applications.

[0013] The beam includes a central hole for laying cables, hydraulic and pneumatic hoses, or storing batteries, thereby increasing its practicality. It is also characterized by attachment points for leveling supports or other beam-to-beam connections.

[0014] This modular construction system is suitable for a wide range of facilities, including residential, retail, conference, work, educational, food service, and entertainment environments. Beams and joints are designed with aesthetics in mind, using materials such as wood and aluminum to ensure visual appeal. The system is also designed to minimize environmental impact through the use of materials such as wood and aluminum.

[0015] The beams and joints can be expanded to various sizes, making them suitable for a wide range of applications, including garden and patio structures, outdoor structures, and automotive parts. The system is compatible with computer-aided design (CAD) software applications, enabling virtual design of the structure. This cloud-based CAD software allows users to create, share, and modify designs, generate bills of materials and assembly instructions, and even use AI to optimize design iterations based on user parameters.

[0016] The present invention also supports the use of custom fittings created using 3D printing technology and includes features for attaching leveling supports to create structures on uneven surfaces.

[0017] Additionally, the method of constructing modular structures using this system involves selecting beams with fastener tracks, pins, and fastener cavities, as well as utility channels; selecting suitable joints; and assembling them by interconnecting the beams and joints via these features. This method includes selecting fastener tracks from dovetail tracks, T-slot tracks, V-slot tracks, and miter rail channels; attaching secondary beams or fittings to utility channels; and ensuring that beams and joints can be easily disassembled without removing the entire structure.

[0018] Furthermore, the method includes integrating auxiliary components such as drawers, panels, coat rails, mirrors, countertops, sliding doors, tabletops, shelves, and electrical fittings into the structure; running cables, hydraulic and pneumatic hoses, or storing batteries through central holes in the beams; attaching leveling supports to the beams; and using CAD software applications to design modular structures. This CAD software is cloud-based and allows users to create, share, and modify designs, thus providing comprehensive support for building modular structures using this innovative system. Attached Figure Description

[0019] Figure 1 It is the cross-section of the extruded beam.

[0020] Figure 2 This is another embodiment of an extruded beam employing a dovetail geometry.

[0021] Figure 3 This is another embodiment of an extruded beam with a dovetail geometry for the longitudinal fastener track.

[0022] Figure 4 Another embodiment of the extruded beam is shown.

[0023] Figure 5 An extruded beam with two fastener blocks that can be used for beam-to-beam connections is shown.

[0024] Figure 6 Displaying a combination of utility beams and utility fastener blocks. Figure 4 and Figure 5 The extruded beam.

[0025] Figure 7 The complete assembled beam is shown using extruded beams and timber utility beams in utility channels.

[0026] Figure 8 The longitudinal fastener track shows that the extruded beam can be attached to another extruded beam.

[0027] Figure 9 The leveling support is described.

[0028] Figure 10 The assembly configuration of a total of five extrusion beams is shown—two vertical extrusion beams, a leveling support, and three horizontal extrusion beams.

[0029] Figure 11 The illustration shows the removal of a utility fastener block to create space for a single-threaded nut inserted into a longitudinal fastener track.

[0030] Figure 12 Includes a horizontal beam assembly that is attached to a vertical beam assembly.

[0031] Figure 13 The cross-section of an extruded beam is shown, incorporating two locking ribs within the utility channel to act as a locking feature of the utility beam.

[0032] Figure 14 The image shows an extruded beam that uses press-fit ribs as a locking mechanism for a utility beam or other fitting within a utility channel.

[0033] Figure 15 and Figure 16 The practical beam is shown attached to the extruded beam via studs.

[0034] Figure 17 An extruded beam with a long locating pin cavity along its longitudinal fastener track is shown.

[0035] Figure 18 The cross-section of the extruded beam, as well as the location and depth of the long locating pin cavity, are shown.

[0036] Figure 19 The milled area with pins for inserting long locating pins is shown (see...). Figure 21 The cross-section of the extruded beam.

[0037] Figure 20The beam fastener nut is shown passing through the longitudinal fastener track of the extruded beam.

[0038] Figure 21 The image shows a slotted long locating pin that aligns the beam fastener nut with one of the fixed long locating pin cavities along the extruded beam.

[0039] Figure 22 The slide assembly of the horizontal extrusion beam on a fixed long locating pin positioned within the vertical extrusion beam is shown.

[0040] Figure 23 yes Figure 22 Partial cross-sectional view of the extruded beam.

[0041] Figure 24 It is a four-beam assembly.

[0042] Figure 25 The cross-section of the extruded beam with a pin-milled area that creates a cavity for the insertion of a long locating pin is shown. Figure 27 ).

[0043] Figure 26 Showing Figure 25 An isometric view.

[0044] Figure 27 The extruded beam is shown after the fastener cavity and pin milling area have been added.

[0045] Figure 28 It is a complete beam assembly.

[0046] Figure 29 This demonstrates how a single-threaded nut can be inserted into a longitudinal fastener track to achieve an additional attachment.

[0047] Figure 30 and Figure 31 A single-thread nut that can enter the longitudinal fastener track without the need for a nut cavity is described.

[0048] Figure 32 The assembled table structure, consisting of vertical beams, horizontal beams, and leveling supports, is shown.

[0049] Figure 33 Examples of practical channels used for platform or countertop accessories are shown.

[0050] Figure 34 This demonstrates a possible variant or alternative profile that can be created using the same principles explained up to this point.

[0051] Figure 35 Another variation of the beam is depicted.

[0052] Figure 36The image shows a beam with a cavity within a mitered guide rail.

[0053] Figure 37 A composite beam assembly made of extruded beams is depicted.

[0054] Figure 38 An example of a beam with male dovetail joints at both ends is shown.

[0055] Figure 39 This is an example of a joint component that facilitates the connection of beams on each of their vertical sides.

[0056] Figure 40 The diagram illustrates the fastening / connection of the beam and the joint assembly.

[0057] Figure 41 a and Figure 41 b shows a beam with male dovetail joints, longitudinal dovetail tracks, and locating pin holes.

[0058] Figure 42 The joint components are shown.

[0059] Figure 43 The fastening / connection of the beam and the joint assembly is shown.

[0060] Figure 44 The sub-double structure is shown.

[0061] Figure 45 The sub-single structure is shown; it is one of the sub-modules that make up the joint assembly.

[0062] Figure 46 The sub-bolted connection structure is shown; it is one of the sub-modules that make up the joint assembly.

[0063] Figure 47 This shows a sub-Bolted-Flush Long bolted connection, which is one of the sub-modules that make up the joint assembly.

[0064] Figure 48 The image shows a sub-Bolted-Flush-Short bolted connection, which is one of the sub-modules that make up the joint assembly.

[0065] Figure 49 The sub-middle is one of the sub-modules that make up the joint assembly.

[0066] Figure 50 and Figure 51It demonstrates how to assemble joint components using bolted substructures, double-joint substructures, bolts, plungers, and female threaded round standoffs.

[0067] Figure 52 The joint components are shown.

[0068] Figure 53 The assembly of the joint features a dovetail joinery on the sides and a leveling support.

[0069] Figure 54 and Figure 55 The beam is shown using a nut opening to insert a dovetail nut into one end of a longitudinal dovetail track.

[0070] Figure 56 It demonstrates how dovetail reinforcements can be assembled into the longitudinal dovetail tracks of a beam.

[0071] Figure 57 This demonstrates how dovetail reinforcements can be assembled into the longitudinal dovetail tracks of a beam.

[0072] Figure 58 The structure is shown, consisting of eight joint components, vertical beams, and horizontal beams.

[0073] Figures 59-61 It is a replaceable beam cross section.

[0074] Figures 62-63 This is an example of a structure constructed using embodiments of the present invention. Detailed Implementation

[0075] Overview of various aspects of the embodiments The described and illustrated design demonstrates the high level of customization, practicality, and functionality that this system will offer users. This level of value and versatility is achieved through modules designed to provide means of attaching other modules / components to all sides of its geometry (all six sides of the beam). The described beam features fastener tracks (dovetail, T-slot, or miter guide channels / tracks on all four longitudinal faces), pins and fastener cavities (threaded holes, fastener (pin) cavities), and / or dovetail joints on its end faces. The unique feature of the described beam is its practical channels: specially designed allocation spaces at the corners or sides of the square or rectangular cross-section beam, whose unique design allows for the connection of various secondary beams or fittings, thus greatly expanding the practicality, functionality, and aesthetics of the final structure.

[0076] Beams within each set can be prefabricated in variable discrete lengths, limiting the number of beams that need to be prefabricated, thus producing a system where each beam is well connected in the final structure. Systems with beams of variable continuous length are also possible, but the challenge of properly fitting the beams / modules into the structure falls on the designer / user.

[0077] The selected features (fastener rails, pins and fastener cavities, and utility channels) provide the means for assembling structures of various sizes, shapes, functions, and markets.

[0078] The modular system described in this paper offers a variety of unique and novel practical designs and functions, allowing users to freely design and manufacture structures with the following characteristics: • Size scalability The described system is scalable, making the assembly / construction principles equally applicable to small structures (i.e., toys), medium-sized structures (i.e., closets, storage cabinets, furniture), and large structures (i.e., conference stands, gazebos, small dwellings). For example, one kit can include beams with a 2-inch x 2-inch square cross-section, while another kit can include beams with a 5-inch x 5-inch cross-section. All modules / components (joints and accessories) will scale according to the dimensions of each kit. Joints can be used to transition from one scale set to another.

[0079] • Easy to assemble / disassemble A key aspect of this system is that individual structural components (beams, secondary beams, joints, and fittings) can be removed from the structure without dismantling the entire structure or large parts thereof. For example, in a Lego structure, to remove Lego bricks from inside a wall, one would have to remove all the bricks on top of them. In contrast, the beams, secondary beams, and joints described here are designed to be removable independently. This facilitates maintenance by the user (e.g., replacing a single aging beam) and also provides the possibility of editing the structure by adding or removing individual components, thereby altering the structure itself to meet the client's modification needs. This results in the following system characteristics: o Reusability A single module of this system can be removed from one structure and used in another.

[0080] o Editability The structure can be upgraded to include more modules / components or downgraded by removing parts of the structure. An important aspect of this feature is that it can be achieved without dismantling the entire structure (or a significant portion thereof).

[0081] o Easy to maintainBecause individual modules / components of the structure can be removed without dismantling large parts of the structure, maintenance of individual modules / components can be carried out without affecting large parts (or all) of the structure.

[0082] • Independent structure This modular system allows users to create structures that do not require or rely on fastening to other existing structures (such as home walls). Thus, the created structures (e.g., clothing drawers) can maintain their structural integrity without permanently altering their surrounding structure (using fasteners in drywall or 2x4 timber).

[0083] • Auxiliary component type scalability The modular system presented provides users with the means to easily design and assemble a virtually unlimited number of structures, which will become the framework (canvas) for users to purchase, create / design, and attach other types of auxiliary components to the structure.

[0084] • Aesthetics Many modular systems on the market primarily serve industrial applications, and therefore are largely unused in markets such as residential and retail. The modular system described here is designed with aesthetics in mind—primarily using wood and aluminum—so its primary market target is driven by aesthetic demands.

[0085] • Environmental The system described aims to maximize the use of two materials considered to have a smaller environmental impact: wood, as it is a biomaterial; and aluminum, one of the most abundant metals with virtually unlimited recycling potential.

[0086] This article provides ample information and illustration of the overall concept for creating a modular framework system using two main systems (each with multiple implementations): 1) Composite beam with fastening rails and practical passageway 2) Interlocking beams and joints Composite beam with fastening rails and practical access: The first type of embodiment / variation presented primarily consists of extruded beams (generally described as aluminum beam extrusions). Extruded beams can be made of aluminum and anodized in various colors, allowing for color customization and appeal. Not limited to aluminum, extruded beams can also be made from other materials—such as different types of wood, other metals (e.g., stainless steel), and extruded polymers.

[0087] Extruded beams are uniquely novel due to their inclusion of practical channels—specifically designed distribution spaces at the corners, sides, or quarters of square or rectangular cross-section beams (their unique design allowing for the assembly of a wide variety of secondary beams or fittings along the beam's length). These designs offer users a higher level of customization and versatility. Core extrusions also include fastening tracks (dovetail tracks, T-slot / V-slot tracks, miter rail channels, etc.) generally positioned along the side surface of the extrusion, practical beams generally positioned between the fastening tracks, a center hole at the center of the beam's cross-section, and a fastener cavity—capable of serving various purposes (cable routing, hydraulic and pneumatic hoses, battery storage, etc.). Additionally, the center hole and fastener cavity can be threaded for bolting multiple fittings. The fastener cavity also serves as support for locating pins of varying geometries to provide shear strength between beam-to-beam connections.

[0088] The described longitudinal utility channel also includes various methods for fastening secondary beams and fittings—via threaded holes along their longitudinal length, press-fit features, snap-fits, or locking ribs. In the absence of such fastening features, the secondary beams and fittings can also be integrated with the utility channel, which is another option.

[0089] Extruded beams with practical channels that allow for the assembly of secondary beams will retain their unique practicality and functionality, regardless of the beam's cross-sectional size and length, thus giving the invention broad market and application value.

[0090] The following is a description of the novel and potentially wide-ranging applications of incorporating practical channels into the beam geometry of modular structural frame beams.

[0091] Aesthetic enhancement: One use of secondary beams that can be attached to utility passageways is to enhance the aesthetics and feel of the structure. As mentioned in the introduction, there are many modular aluminum frame systems on the market, but their metallic appearance makes them unsuitable for use outside of major industrial facilities. By attaching secondary beams to utility passageways of various materials and shapes, the aesthetics and feel of the structure can be significantly enhanced, allowing for its use in emerging markets such as residential (domestic), retail, conference, work and education structures, catering services, entertainment and living spaces.

[0092] These secondary beams can be made from various types of wood, but also from metals (aluminum, stainless steel, etc.), polymers, or paper. These longitudinal secondary beams themselves can also include different features that allow for greater functionality in the modular system. The longitudinal secondary beams, primarily serving as aesthetic components, can also include features that allow for the attachment of multiple fittings to further enhance the functionality of the modular system, such as fastening features (e.g., threaded holes), other dovetail joints, T-slot / V-slot joints, etc.

[0093] Furniture and storage systems: Practical passageways can also be used to attach various components, such as drawers, panels, clothes rails (attached to fastener tracks), mirrors, countertops, sliding doors, tabletops, sidewalls, and shelves (panels). Together with the frame structure, these can form furniture systems, cabinets, wardrobes and closets, shoe racks, (book) desks, workstations, tabletops, kitchen islands and counters, garage storage systems, bicycle racks, ski racks, roof racks, pantries, bed frames, dressing tables, television and media furniture, bookshelves, etc.

[0094] Electrical accessories: The secondary beam can be integrated with lighting fixtures and sockets, as well as power connectors such as outlets and receptacles, surge protectors, switches, USB ports, Ethernet ports and other network ports, telephone jacks, audio connectors, speakers, monitor and TV connectors such as HDMI or coaxial cable jacks.

[0095] The secondary beams themselves can be prefabricated with linear lighting systems using incandescent bulbs, LEDs, fluorescent lamps, neon lights, and CFL lights, with or without multi-color lighting fixtures.

[0096] Garden and terrace structure: The practical channel can be used to attach a variety of accessories, such as hydraulic pipes for irrigation systems, outdoor showers, pneumatic pipes (for natural gas in heating and cooking systems, UV lighting for plants, privacy screens for HVAC systems, horticultural structure panels, greenhouses, vertical and horizontal horticultural structures, etc.). Accessories and sensors can also be used to monitor and manage plant irrigation systems, such as nutrient delivery, soil properties (such as pH measurements), growth rates, etc.

[0097] Outdoor structure: Practical access can be used to attach a variety of accessories, such as all panels, doors, sidewalls, roofs, windows, countertops, wooden decks, partition tiles, and awning covers. Together with the frame structure, these can form canopies, pergolas, gazebos, sheds, tool sheds, outdoor dining structures, covered outdoor seating, beach dining and bars, kiosks, outdoor fireplaces, cabins, small houses, backyard homes, studio sheds, outdoor guest rooms, tiny homes, huts, camping structures, beach huts, and more.

[0098] Automotive parts: Composite beams with fastening rails and practical passageways can also be used to create and assemble car roof racks, van interiors, truck bed covers, truck tall caps, side panels, roof covers, truck bed organizers, car hooks, bicycle racks, and ski racks.

[0099] Therefore, it should be clear that these beam variations (consisting of core extruders with spaces / cavities for secondary beam assembly) allow for far greater customization than described in the illustrations and diagrams herein. This practicality is therefore unique and novel, and is crucial to the disclosure of this non-provisional patent. It is also noteworthy that beams with cross-sections other than square—where the central extruder has a cross / plus (+) shape, and the secondary beams can be assembled into each of its four quadrants—can similarly achieve the principles of functionality and practicality. An example of a different cross-section is one that can be fabricated with the central extruder in a symmetrical “Y” shape, where the secondary beams can be assembled into each of its three sides (separated from each other by 120°), thus forming a triangular beam. Similarly, it is possible to produce beams with other cross-sections such as pentagons, hexagons, etc.

[0100] Interlocking beams and joints: The second system presented in this paper describes beams and joints with square cross-sections, featuring dovetail joints on all six geometrical sides, and is illustrated as being made of wood. These embodiments / variations clearly demonstrate how users can choose their design preferences and apply them using simple assembly techniques; users can design and manufacture structures that would otherwise require woodworking expertise. The presented modules (beams and joints) and their design features are not limited to wooden structures. These modular designs and features can be applied to other materials (such as polymers), allowing the same design freedom and ease of assembly principles to be used by children to create their own structures to form playrooms, room decorations, toys, toy building models, pet dwellings, etc. Thus, the described designs (and their features) can be applied to a wide range of sizes. For example, beams and joints used to design and manufacture pergolas would require larger cross-section modules, possibly larger than 4 inches x 4 inches, while children's toy kits (made of wood or plastic) are best suited in the range of 2 inches x 2 inches or smaller. Medium-sized beams are more typically used for structures such as closets, garage storage cabinets, and retail displays, with beam sizes ranging from 2 inches x 2 inches to 4 inches x 4 inches being most suitable. These embodiments are primarily presented as beams with square cross-sections. However, some illustrations depict practical features that are equally applicable to beams with rectangular or even circular cross-sections. As mentioned, the most common example material used in these embodiments / variations is wood, as wood is likely to be most appealing to users. Another example provided is polymers as a raw material for creating toys, pet enclosures, etc. It should be understood that these designs and features can be transferred to other materials that may be more suitable for different markets.

[0101] Due to the modular nature of the structures that can be created using the described framework approach, it is possible to create systems where users can use online, cloud-based (CAD) computer-aided design software applications to create desired structures. The potential to integrate the (CAD) system with the final design of the desired structure offers the advantage that users can evaluate the final configuration and appearance of the structure before purchasing any physical parts. For users less proficient in CAD, professionals can provide personalized services for custom structural design. The system architecture can leverage 3D scanning technology to create and import virtual 3D spaces, where the desired structure will be installed into the CAD software, thereby facilitating the design of the desired structure.

[0102] Integration with cloud-based CAD software also allows users to create their own accessories, fixtures, and jigs, which can be manufactured using modern 3D printing equipment or submitted to potential dealers, suppliers, machine shops, woodworking shops, etc. for inquiries.

[0103] The software can also generate bills of materials and assembly instructions for the designed structure. For custom structures, the software can assist designers by identifying, defining, and indicating / recommending the types of connectors and / or fittings.

[0104] With the emergence of artificial intelligence (AI), a system has been developed: users upload a 3D virtual space along with descriptions of the features and uses they wish to include as part of the structure to the software, and the AI ​​can generate numerous iterations for the user and modify them according to the user's requests. Users can provide parameters such as dimensions, features, load requirements, accessories, materials, colors, wood types, and cost requirements.

[0105] The system's integration with cloud-based CAD software allows the public and others in the community to share their structural creations.

[0106] Exemplary embodiments This section covers different embodiments of extruded beams with fastening rails, pins and fastener cavities, and practical channels. A typical material for extruded beams can be aluminum—due to its strength-to-weight ratio, appearance, the possibility of different colors through anodizing, and its wide range of extrusion cross-sections.

[0107] One advantage of these variations is the excellent strength and stiffness provided by the aluminum components, while also offering a means of assembling secondary beams or fittings to fastener tracks and pins to fastener cavities, as well as practical channels covering the length and end faces of the beams.

[0108] As will be described, the system is designed to offer the benefits of customizability, ease of assembly, replacement, and editing of each beam component. For example, aluminum extrusions can be available in different anodized colors, while secondary beams can be longitudinal timber blocks of different tree species. Fastener blocks for beam-to-beam attachments can also be supplied in different anodized colors.

[0109] The main component / module of the described invention is the extruded beam 100 (generally, but not limited to, extruded aluminum). This novel extruded beam 100 allows structures to be created in 1D, 2D, or 3D space via beam-beam connections. The extruded beam 100 consists of longitudinal fastener tracks 101, 102, 103, 104 (which are positioned along the length of the beam extrusion and along the side surfaces), a center hole 105, pins and fastening holes 106, 107, 108, 109, and utility channels 110, 111, 112, 113.

[0110] The novelty of this extrusion configuration lies in the inclusion of practical channels 110, 111, 112, and 113 along the length of the beam. These practical channels are specially designed distribution spaces at corners, sides, or quadrants, and are generally positioned between fastener tracks of square or rectangular cross-section beams. Their unique design allows for the assembly of a wide variety of secondary beams or fittings along the beam's length. These openings / channels in the extrusion can be used for a variety of applications, such as, but not limited to: • Attachment of decorative blocks. Materials used for decorative blocks can be made from various types of wood, paper, polymer extrusions, additional aluminum extrusions, ceramics, etc.

[0111] • Attachment and installation of cables, lighting (light bulbs), batteries and other electrical components.

[0112] • Attachment and installation of irrigation systems, pipes, pumps, distributors, fluids, pneumatic devices, pipeline connections, etc.

[0113] Figure 1 The cross-section of the extruded beam 100 has a generally “+” shape that allows connection on four sides. The cross-sectional shape is characterized by four (4) utility channels 110, 111, 112, 113, four (4) pin & fastener holes 106, 107, 108, 109, four (4) longitudinal fastener tracks 101, 102, 103, 104, and one (1) center hole 105.

[0114] The longitudinal fastener tracks 101, 102, 103, and 104 are channels spanning the length of the beam extrusion, and they take the form of dovetail joints (dovetail tracks) or known T-slots, V-slots, or miter rails. Any cross-sectional shape can be used to constrain the movement of nuts, fasteners, or auxiliary components to all degrees of freedom except for longitudinal sliding along the track. Figure 1 It includes four longitudinal fastener rails 101, 102, 103, and 104, which are positioned on each side of the beam and spaced 90 degrees apart from each other.

[0115] The center hole 105 can be used for tapping threads or other fastening methods, for purposes such as attaching auxiliary components to the system (e.g., leveling supports). This channel can also be used to place, lay out, and / or store other components, such as batteries, fluid / pneumatic piping, electrical wiring, etc. The center hole 105 is depicted as circular, but depending on the application, it can also be any other desired geometry, such as a square hole.

[0116] The pin and fastener holes 106, 107, 108, and 109 can be used as surface supports for locating pins used to attach the end of one beam to the longitudinal track of another beam. This contact surface between the beam and the locating pin will be the load contact point under gravity. The depicted holes have a rectangular shape, but can be made into various geometries (such as circular), and can be used as female fastener thread features by tapping their ends, thereby allowing the connection of auxiliary parts and / or custom parts (such as beam end caps, pivot joints, etc.). These holes 106, 107, 108, and 109 can be connected to the center hole 105, so the extruder will have only a single hollow profile opening at its core, thereby reducing the complexity of the extruder, die making, and cost. As a variation of the depicted image, these holes 106, 107, 108, and 109 can also be separated from the center hole 105.

[0117] The utility channels / openings 110, 111, 112, and 113 are partially or completely vacated spaces in the extrusion, which allow for the attachment of a large number of components. These utility channels 110, 111, 112, and 113 provide novel and innovative value that is lacking in modular systems used to create structures currently available on the market, such as T-slot aluminum extrusions.

[0118] Utility channels 110, 111, 112, and 113 can be used to attach utility beams across their length. These utility beams can be in the form of decorative wooden beams, or they can be other aluminum extrusions with their own unique features, practicality, and functionality. Longitudinal utility beams can be made from different types of wood, but can also be made from metals (aluminum, stainless steel, etc.) or from polymers or ceramics. These utility beams can also include their own different features, allowing for greater functionality in the modular system. Longitudinal utility beams can have features ranging from fastening features (threaded holes, other dovetail tracks, T-slot / V-slot tracks, etc.) to features for other applications (such as lighting fixtures and electrical connections or fluid / pneumatic piping / connections, etc.). Utility beams can be solid or hollow, and can also be created in different cross-sectional geometries, such as triangles, rectangles, or even custom-designed unique cross-sections (such as support channels). These utility beams can be made from different aluminum extrusions (an example could be extrusions used for manufacturing windows and insulating windows), each with its own unique features and practicality. Practical beams can be made of rubber or foam materials, which serves as a means of creating soft edges to prevent impact injuries (e.g., when used in playground structures).

[0119] Figure 2In another embodiment of the extruded beam 114, the longitudinal fastener tracks 115, 116, 117, and 118 of the extruded beam 114 utilize dovetail geometry. Pins and fastener holes 119, 120, 121, and 122 are connected to a central hole 123 to create a single hollow profile. The geometry of the pins and fastener holes 119, 120, 121, and 122 has circular features and is also optimized to reduce the material usage of the extruded beam 114. The utility channels 124, 125, 126, and 127 are simple, empty rectangular profiles.

[0120] Figure 3 In another embodiment of the extruded beam 128, the longitudinal fastener tracks 129, 130, 131, and 132 of the extruded beam 128 utilize dovetail geometry. The pins and fastener holes 133, 134, 135, and 136 are not connected to the center hole 137, thus creating five distinct hollow profiles. The geometry of the pins and fastener holes 133, 134, 135, and 136 has circular features and is also optimized to reduce the material usage of the extruded beam 128. The utility channels 138, 139, 140, and 141 are simple, empty rectangular profiles.

[0121] Figure 4 Another embodiment of the extruded beam 142 is shown. Features (manufactured by milling, drilling, and tapping) are present at the ends of the extruded beam 142 for beam-to-beam assembly and attachment of additional fittings, such as leveling supports or caps. In this embodiment, the beam includes four tapped pin and fastener holes 143, 144, 145, 146 and a threaded center hole 147 on the extruded surface—these features enable attachment of the beam to other components with various geometries and functions. The diameter of the center hole 147 and the pin and fastener holes 143, 144, 145, 146 is not limited to the size depicted in this embodiment. The extruded beam is not limited to four pins and fastener holes.

[0122] This embodiment also includes four fastener cavities, two of which are in Figure 4 The cavities marked 148 and 149 are for incorporating up to four fasteners, which can be used for additional beam-to-beam connections or connections to other adapters and fittings. Within these cavities, four additional utility beam fastener holes can be drilled, two of which are... Figure 4 The components are marked 150 and 151 and threaded to attach multiple parts. The outlines of utility channels 152, 153, 154, and 155 do not include locking interfaces for attaching the utility beam; therefore, the inclusion of utility beam fastener holes 153 and 154 enables the fastening of the utility beam or other utility beam fittings (i.e., lighting, irrigation systems, etc.) to the extruded beam 142. In this embodiment, longitudinal fastener tracks 156, 157, 158, and 159 have a trapezoidal / dovetail geometry.

[0123] Figure 5 An extruded beam 142 is shown, comprising two fastener blocks 160 and 161 with bolts 162 and 163, and a beam fastener nut 164 for beam-to-beam connections. In this embodiment, the beam fastener nut 164 has a trapezoidal / dovetail cross-sectional geometry for securing itself in longitudinal fastener tracks 156, 157, 158, and 159, which also have trapezoidal / dovetail tenons. The beam fastener nut 164 has two threaded holes 165 and 166 at each end, and a pin hole 167 in the middle.

[0124] Up to four fastener blocks can be used to facilitate beam-to-beam attachments, as well as attachments to a variety of components with diverse geometries and features. Figure 5 A variation is shown in which two fastener blocks 160, 161 are used to attach beam fastener nuts 164 that can be used to fasten the extrusion beam 142 to other extrusion beams.

[0125] In this embodiment, fastener blocks 160, 161 are T-shaped with a central through-hole that allows bolts 162, 163 to pass through. This embodiment of fastener blocks 160, 161 includes a cutout 168 so that the heads of bolts 162, 163 do not extend beyond the outline of fastener blocks 160, 161.

[0126] Figure 6 Showing Figure 4 and Figure 5 The extruded beam 142 comprises four (4) utility beams 169, 170, 171, 172 and four (4) utility fastener blocks 173, 174, 175, 176. In this example, utility beams 169, 170, 171, 172 are wooden decorative features. Utility fastener blocks 173, 174, 175, 176 can be made of aluminum or similar hard metals, polymers, wood, or ceramics. Utility fastener blocks 173, 174, 175, 176 can be fitted with fastening bolts 177, 178, 179, which are thread-fitted to the utility beam fastener holes 150, 151. Figure 4 The geometry of utility fastener blocks 173, 174, 175, and 176 is shaped to fill the remaining space of fastener cavities 148 and 149. Figure 4 ).

[0127] The utility fastener blocks 173, 174, 175, and 176 are T-shaped. The two arm segments 180 and 181 of the utility fastener blocks 173, 174, 175, and 176 apply pressure to the utility beams 169, 170, 171, and 172. These arm segments 180 and 181 are slightly curved and include a thinner segment 182 that bends during fastening, resulting in a final flat, horizontal shape. This provides compensation for spring forces or absorbs vibrations under load, while simultaneously applying a fixing force to the utility beams 169, 170, 171, and 172.

[0128] Figure 7 The complete assembled beam is shown, which uses extruded beams 142 and utility beams 169, 170, 171, and 172, which are wood decorative blocks in utility channels 155, 156, 157, and 158. Utility beams 169, 170, 171, and 172 are fastened to the end of each extruded beam 145 using utility fastener blocks 173, 174, 175, and 176 and bolts 178 and 179. Beam fastener nuts 164 are attached to fastener blocks 160 and 161 via two bolts 162 and 163. In this embodiment, optional track beams 183 and 184 are inserted into longitudinal fastener tracks 156, 157, and 158 for decorative purposes. The track beams can be made of wood, ceramic, metal, polymer, etc. A cylindrical locating pin 185 (stud) can be inserted through the extrusion beam 142 and the beam fastener nut 164 to be attached to other extrusion beams in a fixed position using a threaded locating pin hole. One end of the locating pin 185 can be threaded into the locating pin hole to fix the position of the beam fastener nut 164.

[0129] This assembly configuration is designed for beam-to-beam attachments.

[0130] Figure 8 The diagram shows that the extrusion beam 142 can be attached to a longitudinal fastener track of another extrusion beam 186—by engaging beam fastener nuts 164 along this track and bolting the extrusion beam 142 to the beam fastener nuts 164 via fastener blocks 160, 161. The longitudinal position of the beam fastener nuts is secured by locating pins 185 screwed into threaded holes in the longitudinal fastener track 186.

[0131] Note: The position of the secondary beam along the longitudinal fastener track can be adjusted by loosening the bolts, moving it to the desired position, and then tightening it to the dovetail nut via the fastener block. The locating pin inside the center hole of the fastener nut can also be used to adjust the position of the secondary beam in the separate pre-drilled holes. This facilitates the design and assembly of the structure, as the beams are attached to the structure according to a standard hole pattern. For example, the fastener track hole pattern can be holes spaced 5 cm apart. Repeating this pattern for all beams in the structure facilitates adjustments to the distance and position of beam attachments.

[0132] Figure 9 A leveling support 187 is depicted, which utilizes a threaded center hole 188 on one side of an extruded beam 189. In this embodiment, the number of features added to the beam 189 is limited to accommodate only the leveling support 187 and utility fastener blocks 173, 174, 175, and 176. Therefore, this side of the extruded beam 189 terminates at utility fastener blocks 173, 174, 175, and 176 (as shown) and does not include the fastener blocks.

[0133] Figure 10 The assembly configuration of a total of five extrusion beams is shown—two vertical extrusion beams 190a and 190b with leveling supports 191a and 191b, and three horizontal extrusion beams 192a, 192b and 192c, which are assembled using the aforementioned fastening methods and components.

[0134] Figure 11 The utility fastener block is shown being removed to create space for a small single-threaded nut 193 (in this case, with a trapezoidal / dovetail cross-section) to be inserted into the longitudinal fastener track 194. The single-threaded nut 193 can be used to attach to a variety of fittings. Because both the single-threaded nut 193 and the longitudinal fastener track 194 have trapezoidal / dovetail cross-sections, once the single-threaded nut 193 is inside the longitudinal fastener track 194, it is fixed in all degrees of freedom except the longitudinal direction. After inserting the single-threaded nut 193, the utility fastener block can be reattached.

[0135] Figure 12 Including the horizontally positioned and the vertically positioned other beam assembly 195 attached. Figure 7 The beam assembly 195 has fastener cavities at different locations along the extruded beam, thereby allowing flush corner connections as shown. The fastener cavities can be positioned at any location along the beam extruder based on the desired application and can be manufactured to have space for fastener blocks and fastener utility blocks, or, depending on requirements, to have only one cavity for one of the blocks, or to have no cavities at all.

[0136] Figure 13The cross-section of extruded beam 196 is shown, which incorporates two locking ribs 197a, 197b, 197c, 197d, 197e, 197f, 197g, and 197h within utility channels 198a, 198b, 198c, and 198d to act as locking features for utility beams 199a, 199b, 199c, and 199d or other fittings. The locking ribs 197a, 197b, 197c, 197d, 197e, 197f, 197g, and 197h are oriented at 90 degrees to each other within the utility channels to secure utility beams 199a, 199b, 199c, and 199d or fittings, while allowing utility beams 199a, 199b, 199c, and 199d to slide along utility channels 198a, 198b, 198c, and 198d. In this scenario, the practical beams 199a, 199b, 199c, and 199d (decorative timber, i.e., corner timber blocks) are prevented from moving in all degrees of freedom except the longitudinal direction of the beams.

[0137] Figure 13 Also shown are timber decorative track beams 200a, 200b, 200c, and 200d, whose cross-sections match the geometry and size of the fastener track. In this configuration, the dovetail timber blocks are prevented from moving in all degrees of freedom except the longitudinal direction.

[0138] Locking ribs 197a, 197b, 197c, 197d, 197e, 197f, 197g, and 197h can be positioned at any location within the utility channel, including its edges. Locking ribs 197a, 197b, 197c, 197d, 197e, 197f, 197g, and 197h are not limited to the geometry shown in the figures.

[0139] Figure 14 The extruded beam 201 uses press-fit ribs 202a, 202b, 202c, 202d (in this example, a Christmas tree design) within the utility channels as locking mechanisms for utility beams 203a, 203b, 203c, 203d, or similar fittings. The press-fit ribs 202a, 202b, 202c, 202d prevent movement of utility beams 203a, 203b, 203c, 203d in all directions. All utility beams 203a, 203b, 203c, 203d attached to each utility channel have corresponding slots along their length, the dimensions of which are adapted to create a press-fit attachment with the beam.

[0140] Figure 15 and Figure 16The illustration shows utility beams 204a, 204b, 204c, and 204d attached to extrusion beam 205 via studs 206a, 206b, 206c, 206d, 206e, 206f, 206g, and 206h. Through holes exist in utility beams 207a, 207b, 207c, 207d, 207e, 207f, 207g, and 207h to allow studs 206a, 206b, 206c, 206d, 206e, 206f, 206g, and 206h to pass through. Threaded holes in extrusion beam 205 allow threaded engagement of studs 206a, 206b, 206c, 206d, 206e, 206f, 206g, and 206h. This configuration constrains all degrees of freedom of the utility beams 204a, 204b, 204c, and 204d when they are attached to the utility channels. This stud arrangement allows for positioning along the extruded beams at multiple locations.

[0141] Figure 17 An extruded beam 208 with long locating pin cavities 209a, 209b along its longitudinal fastener track is shown. The extruded beam can be fastened at these fixing points via the long locating pins and fastening nuts. The long locating pin cavities can be positioned at any desired location along the longitudinal fastener track and / or can be evenly spaced across the length of all extruded beams used in the structure to facilitate design and assembly.

[0142] Figure 18 This refers to the cross-section of the extruded beam 208 and the location and representative depth of the long locating pin cavities 209a, 209b, 209c, and 209d. These cavities are not limited to the depths shown.

[0143] Figure 19 The cross-section of the extruded beam 208 is shown, with the red highlighted areas depicting the pin-milled regions 210a, 210b, 210c, 210d, and 211, which are milled to the desired depth to create a shape for inserting the long locating pin 214. Figure 21 (cavity)

[0144] Figure 20 A beam fastener nut 212 is shown traveling along a longitudinal fastener track on the extrusion beam 208. The beam fastener nut 212 includes a slotted opening 213 that mates with a long locating pin cavity on the extrusion beam 208. Once aligned, the long locating pin 214 ( Figure 21 This can be used to fix the position of the beam fastener nut 212 at the discrete position.

[0145] Figure 21 This shows a slotted elongated locating pin 214 aligned with one of the fixed elongated locating pin cavities along the extruded beam 208, aligning the beam fastener nut 212 with it. The elongated locating pin 214 passes through the slotted opening 213 of the beam fastener nut. Figure 20) and enter the long positioning pin cavity 209 ( Figure 18 The long locating pin 214 maintains the position of the beam fastener nut 212 to allow another extruded beam to be assembled onto the long locating pin 214.

[0146] Figure 22 The diagram shows the sliding assembly of a horizontal extrusion beam 215 on a fixed elongated locating pin 214 positioned within a vertical extrusion beam 208. As the horizontal extrusion beam 215 slides downwards and onto the elongated locating pin 214, the face of the horizontal extrusion beam 215 is flush with the vertical extrusion beam 208. The orientation of the horizontal extrusion beam 215 must such that the milled area 211 on the face of the extrusion beam 215 is oriented toward the elongated locating pin 214, thus allowing it to pass over.

[0147] Figure 23 yes Figure 22 A partial cross-sectional view of the extruded beam. After the horizontal extruded beam 215 is positioned on the long locating pin 214, the fastener blocks 216a, 216b can be attached to the beam fastener nut 212 to achieve final fixation.

[0148] Figure 24 This is a four-beam assembly. This configuration includes three horizontal beam sub-assemblies 217a, 217b, and 217c and one vertical beam assembly 217d. This figure illustrates the ability to create custom structures using beams of varying lengths fixed in variable positions. This structure includes a leveling support 218 attached to the bottom surface of the vertical beam assembly 217d.

[0149] Figure 25 The cross-section of the extruded beam 100 is shown, with highlighted areas depicting pin-milled regions 219a, 219b, 219c, and 219d, milled to the desired depth to create a shape for inserting a long locating pin 222. Figure 27 (cavity)

[0150] Figure 26 Showing Figure 25 An isometric view.

[0151] Figure 27 The extruded beam 100 is shown after the addition of fastener cavities 220a, 220b, 220c, 220d and pin milling areas 219a, 219b, 219c, 219d. The beam fastener nut 221 has the same function as the beam fastener nut 212; however, its geometry is modified to match the T-slot profiles of the longitudinal fastener tracks 101, 102, 103, 104 of the extruded beam 100. The elongated locating pin 222 can be the same as in the foregoing embodiments, but is not limited to these embodiments. Beam-to-beam attachment follows... Figures 20-23 The same assembly procedure described in [the document / document].

[0152] Figure 28 It is a complete beam assembly composed of the aforementioned components. As described in the previous embodiment, in order to attach this extruded beam 100 to another beam, the beam fastener nut 221 should be fastened within the longitudinal fastener track (not shown) of the other beam.

[0153] Figure 29 This demonstrates the ability to insert a single-threaded nut 223 into a longitudinal fastener track 101 for additional attachment. A nut cavity 224 creates an opening allowing the single-threaded nut 223 to be inserted into and then slide along the longitudinal fastener track 101 of the extrusion beam 100. The single-threaded nut 223 has a rectangular cross-section to match the rectangular cross-section of the fastener track 101.

[0154] The above two Figure 30 and Figure 31 A single-threaded nut 225 is depicted, which can be inserted into the longitudinal fastener track 101 without the use of the nut cavity 224. The geometry of the single-threaded nut allows the single-threaded nut 225 to be inserted into the longitudinal fastener track 101, and when the single-threaded nut 225 is rotated 90 degrees clockwise, the single-threaded nut 225 will be secured inside the longitudinal fastener track 101.

[0155] This single-threaded nut 225 has chamfers 226a and 226b at two of its corners, allowing rotation within the longitudinal fastener track 101. The remaining corners 227a and 227b (without chamfers) will contact the wall of the longitudinal fastener track 101, thus preventing further rotation. Since most bolts have right-hand threads, the single-threaded nut 225 requires... Figure 31 Insert the nuts in the indicated orientation to prevent them from rotating unintentionally.

[0156] If the thread of the single-thread nut 225 is left-handed, the required geometry of the single-thread nut is a mirror image of the geometry shown to prevent accidental rotation of the nut.

[0157] Long nuts vs. short nuts: Beam fastener nuts 212 ( Figure 21 , Figure 23 ) and beam fastener nut 221 ( Figure 27 , Figure 28 ) can be made of two (2) single-threaded nuts 223 ( Figure 29 ) or two (2) single-threaded nuts 225 ( Figure 30 , Figure 31 ) or two (2) threaded nuts 193 ( Figure 11 (replace)

[0158] Figure 32The assembled table structure is shown, consisting of four vertical beams 228a, 228b, 228c, and 228d, four horizontal beams 229a, 229b, 229c, and 229d, and four leveling supports 230a, 230b, 230c, and 230d. Three of the four usable passages of each horizontal beam are occupied by secondary timber beams, while the fourth usable passage is left empty to accommodate shared fittings.

[0159] Figure 33 This shows an example of a practical passageway used for a platform or countertop accessory. In this example, tabletop platform 231 occupies ( Figure 32 (As shown) Several adjacent horizontal beams form a practical passageway to create a table-like structure. Accessories (such as the tabletop shown) can be installed in both horizontal and vertical orientations as needed.

[0160] Figure 34 A possible variation or alternative profile that can also be created using the principles explained up to this point is demonstrated. The extruded beam 232 includes a total of six utility channels 233a, 233b, 233c, 233d, 233e, 233f and six longitudinal track beams 234a, 234b, 234c, 234d, 234e, 234f. Therefore, variations of the extruded beam can be created with eight utility channels and eight longitudinal tracks, and so on.

[0161] Figure 35 Another variation of the beam is depicted, in which beam 235 is composed of wood with rectangular longitudinal cuts, in which industry-standard T-slots / T-rails / mitered rails of various materials (aluminum, plastic, etc.) can be installed / joined / secured to beam 235. The current embodiment shows four mitered rails 236a, 236b, 236c, 236d, which can be bolted / joined to the milled channels of beam 235.

[0162] Figure 36 Beam 235 was shown. Figure 35 The milling operation creates cavities 237a and 237b within the slanted guide rails 236a, 236b, 236c, and 236d, and the machining / drilling / milling operation creates a center hole 238, with two small holes 239a and 239b at the top and bottom of the center hole 238.

[0163] The drawing also includes the versions of beam fastener nut 240, long locating pin 241, and fastener blocks 242a and 242b.

[0164] Figure 37A composite beam assembly is depicted, consisting of an extruded beam 243 made of aluminum or a polymer, and wood trim pieces 244a, 244b, 244c, and 244d, which are assembled into four functional channels of the extruded beam 243. The illustration depicts the extruded beam 243 with standard miter-joint guide channels / tracks common in the woodworking industry. Other fastening channels / tracks, such as T-slots, V-slots, or dovetail joints, are also possible. The wood trim pieces can be connected via... Figure 13 The connecting channels and ribs shown are assembled together, or they can be assembled by simply combining decorative blocks to the extrusion.

[0165] Interlocking beams and joints The main components / modules of the described invention are (1) interlocking beams and (2) interlocking joints, which together will form the main frame / skeleton of the desired final structure. The beams will have attachment / connection features along their length and at both ends, thereby allowing more beams to be interconnected in 1, 2, or 3 dimensions via different joint members or via beam-beam connections. The joints are individual components or sub-assemblies made of sub-components / sub-modules. Additionally, (3) auxiliary components (those that will serve different types of markets) can be designed to be compatible with the described system and can be attached to the structure via these beams, across their longitudinal attachment / connection features, attached to beam end connection features, or attached / connected to joint modules.

[0166] The system can use mortise and tenon features and techniques (such as, but not limited to, dovetail joints, T-slots, V-slots, dowel joints / pins, tongue-and-grove joints, etc.) and / or readily available fasteners (such as, but not limited to, nuts, bolts, screws, washers, etc.) as a means of interconnecting the various components and auxiliary components of the structure.

[0167] Raw Materials: Although this invention primarily describes wood as the primary raw material for system modules / components (beams, joints, and accessories), the raw materials are not limited to wood. For each application, any material with sufficient structural rigidity and consistency (hardness, tensile strength, shear strength, compressive strength, etc.) can be used as a raw material. Wood is primarily described in this application as a raw material for system components / modules due to its potentially low ecological impact, aesthetic appearance, and mechanical properties (low weight-to-strength ratio). Examples of materials suitable for modular systems include, but are not limited to: wood, crosslaminated timber, glued laminated timber, engineered wood, plywood, polymers, aluminum, metal alloys, composite materials, ceramics, etc.

[0168] The following is a description and illustration of a modular system for interlocking beams and joints. An example follows a modular system for a beam with a main cross-sectional dimension of 3 inches x 3 inches (described in detail below), wherein the beam has dovetail joints at both ends and dovetail "tracks" and locating pin holes on each of the four faces spanning the beam.

[0169] Figure 38 An example of a beam 500 is shown, comprising male dovetail joints 501a and 501b at both ends (a variation of the dovetail end can be a female dovetail end). Along the length of the beam 500, each of its four faces includes two dovetail longitudinal tracks 502a and 502b (a variation of this feature is the number of tracks per face, starting from non-zero, such as 1, 2, 3, etc.). The beam 500 also includes a locking feature 503 at each dovetail joint 501a and 501b. In this embodiment, half of the width of the locking feature 503 extends into the dovetail joint 501a, and the other half extends into the main beam 500 body.

[0170] The beam width dimension 504 determines the cross-sectional dimensions of the beam 500, which has a square cross-section.

[0171] Figure 39 This is an example of a joint assembly 505, which provides means of connecting a beam to each of its six vertical sides. The joint assembly 505 shows dovetail joints 506a, 506b, 506c and locking features 507a, 507b, 507c.

[0172] When the beam 500 end features a female dovetail joint, the joint component 505 sub-module can be made with a male dovetail joint to match this variation of the beam.

[0173] The joint assembly 505 is designed to work in conjunction with beam 500 or beam 510. Figure 40 Therefore, the joint width dimension 508 is equal to the beam width dimension 504. Figure 38 ).

[0174] Figure 40 This shows how the tenon 509 secures / connects beam 510 to the joint assembly 504. Except for its length, beam 510 has the same dimensions and features as beam 500.

[0175] The beam 510 is attached to the joint assembly 505 by fitting the male dovetail connector 501a of the beam 510 to the female dovetail connector 506a of the joint assembly 505.

[0176] After connection, a rectangular cavity 511 is left at the beam-joint interface. For further fixation and to prevent detachment, a tenon 509 can be inserted into the rectangular cavity 511. If necessary, the tenon 509 can be oversized relative to the rectangular cavity 511 in the longitudinal direction of the beam 510, thereby placing the beam-joint joint under tension.

[0177] The diagram shown here illustrates a tenon and locking feature with a rectangular cross-section. Variations can include oval, circular, bowtie / butterfly inlay, etc.

[0178] Figure 41 a and Figure 41 b shows beam 512 with male dovetail joints 513a, 513b, longitudinal dovetail tracks 514 on each of its four sides along the length of beam 512, and locating pin holes 515a, 515b, 515c (also present on each of the four sides of beam 512).

[0179] The beam width dimension 516 determines the cross-sectional dimensions of the beam 512, which has a square cross-section.

[0180] Figure 42 The joint assembly 517 is shown, which provides a means of connecting the beam 512 to each of its six vertical sides.

[0181] The joint assembly 517 shows dovetail joints 518a, 518b, 518c and locking features 519a, 519b, 519c.

[0182] When the end feature of beam 512 is a female dovetail, the joint assembly module 517 and sub-module can be made with a male dovetail to match this variation of the beam.

[0183] The joint assembly 517 is designed to work in conjunction with the beam 512. For this purpose, the joint width dimension 520 is equal to the beam width dimension 516. Figure 41 ).

[0184] Figure 43 This shows how tenon 521 completes the fastening / connection of beam 512 to joint assembly 517.

[0185] The beam 512 is attached to the joint assembly 517 by engaging the male dovetail joint 513a of the beam 512 with the female dovetail joint 518a of the joint assembly 517. The tenon 521 is inserted into a common locking feature to secure the beam-joint.

[0186] The diagram shown here illustrates a tenon and locking feature with a rectangular cross-section. Variations can include elliptical, circular, bowtie / butterfly inlay structures, etc.

[0187] Figure 44 The double-joint substructure 522 is shown, which is one of the sub-modules constituting the joint assembly 517. The double-joint substructure 522 is characterized by its two ends with dovetail tenons 523a, 523b, locking features 524a, 524b, a bridging portion 525 with a bridging portion height 526, bridging portion sizes 527a, 527b, a small groove 528, a large groove 529, a hole 530, and a joint height 531.

[0188] Bridging size 527a = Bridging size 527b.

[0189] Figure 45 A single-joint substructure 532 is shown, which is one of the sub-modules constituting the joint assembly 517. The single-joint substructure 532 is characterized by one end with a dovetail tenon 533 and a locking feature 534, a bridging portion 535 with a bridging portion height 536, bridging portion sizes 537a and 537b, a small groove 538, a large groove 539, a hole 540, and a joint height 541.

[0190] Bridging size 537a = Bridging size 537b.

[0191] Figure 46 The bolted connection substructure 542 is shown, which is one of the sub-modules constituting the joint assembly 517. The bolted connection substructure 542 is characterized by a dovetail tenon 543, a locking feature 544, a countersunk hole 545, and a bolted connection substructure height 546a, as well as sizes 546b and 546c.

[0192] Size 546b = 546c.

[0193] Figure 47 The bolted flat-head elongated substructure 547 is shown, which is one of the sub-modules constituting the joint assembly 517. The bolted flat-head elongated substructure 547 is characterized by a countersunk through hole 548, a height 549, and sizes 550a and 550b.

[0194] Size 550a = Size 550b.

[0195] Figure 48 The bolted flat-head short substructure 551 is shown, which is one of the sub-modules constituting the joint assembly 517. The bolted flat-head short substructure 551 is characterized by a countersunk through hole 552, a height 553, and sizes 554a and 554b.

[0196] Size 554a = Size 554b.

[0197] Figure 49 Intermediate substructure 555 is one of the sub-modules constituting the joint assembly 517. Intermediate substructure 555 is characterized by through hole 556, height 557, and sizes 558a and 558b.

[0198] Size 558a = Size 558b.

[0199] Feature size relationship: Figure 44 Joint height 531 = Figure 45 Joint height 541 Figure 44 Large groove 529 = Figure 47 Height 549 Figure 45 Large groove 539 = Figure 47 Height 549 Figure 44 Small groove 528 = Figure 48 Height 553 Figure 45 Small groove 538 = Figure 48 Height 553 Figure 46 Bolted connection substructure height 546 = ( Figure 48 (height 553) + ( Figure 44 (Joint height 531) Figure 44 Bridge size 527a = Figure 45 Bridge size 537a = Figure 46 Size 546b = Figure 47 Size 550a= Figure 48 Size 554a = Figure 49 Size 558a.

[0200] Figure 50 and Figure 51 It shows how the joint assembly 517 can be assembled using bolted substructures 542a, 542b, double-joint substructures 522a, 522b, bolts 559a, 559b, plungers 560a, 560b, and female threaded circular spacer.

[0201] Figure 52 The joint assembly 562 is shown, which can be assembled by using bolted connections of flat-head short substructures 551a, 551b, sub-single-connection structures 532a, 532b, bolted connection substructure 542a, bolts 559a, 559b, plunger 560a, and female threaded circular isolation post 561.

[0202] Figure 53The assembly 563 is shown, featuring four dovetail tenon-and-mortise structure sides and a leveling bracket 564. This configuration is suitable for use when creating structures on uneven or non-uniform floor surfaces. Dimension 565 represents the distance the studs can be adjusted. Continuous horizontal adjustment can be achieved through combinations of different stud lengths and adjustments to the height dimension 565. Note: The threaded engagement between the studs and the female threaded circular spacer (within dimension 565) requires a certain length—typically at least the stud diameter. As can be inferred, the assembly 563 can be assembled using appropriate combinations of the assembly sub-modules and the leveling bracket 564.

[0203] Figure 54 and Figure 55 One end of beam 512 is shown, with nut opening 566 for inserting dovetail nut 567 into longitudinal dovetail track 514. Nut opening 566 needs to have an opening that is longer and wider than the larger side 568 of the dovetail nut.

[0204] The trapezoidal dimensions of the longitudinal dovetail track 514 require dimensions that allow the trapezoidal side of the dovetail nut 567 to slide along the longitudinal dovetail track 514, but also to fix the dovetail nut in all degrees of freedom except the longitudinal direction of the beam.

[0205] Nut opening 566 is useful for adding or removing dovetail nuts 567 as needed by the user, without disassembling any beam of the structure.

[0206] Figure 56 This demonstrates how dovetail reinforcement 569 can be assembled into the longitudinal dovetail track 570 of beam 571. This reinforcement is useful because the wood is thinnest along its grain direction, which matches its longitudinal dimension. Therefore, the use of dovetail nuts may require reinforcement to withstand the nut force under load.

[0207] Figure 57 This demonstrates how dovetail reinforcements 572 and 573 can be assembled into the longitudinal dovetail track 570 of beam 571. This reinforcement is useful because the wood is thinnest along its grain direction, which matches its longitudinal dimension. Therefore, the use of dovetail nuts may require reinforcements to withstand the nut force under load. The difference between dovetail reinforcements 572 and 573 and dovetail reinforcement 569 is that, once assembled, both reinforcements cover all surfaces of the dovetail track 570.

[0208] Figure 58The structure shown is made of eight joint components 517a, 517b, 517c, 517d, 5174e, 517f, 517g, 517h, vertical beams 574a, 574b, 574c, 574d, and horizontal beams 575a, 575b, 575c, 575d.

[0209] in conclusion This invention relates to a modular construction system comprising interlocking beams and joints designed for flexible structural design and assembly. The system is characterized by beams including fastener tracks, pins, and fastener cavities, as well as utility channels on each of their longitudinal faces, enabling versatility and robust connections. These fastener tracks can be dovetail, T-slot, V-slot, or miter rail channels, providing a wide range of attachment options. The utility channels are strategically positioned at the corners or sides of the beams, enabling the integration of secondary beams and various fittings, further enhancing the system's modularity.

[0210] The beams can be manufactured from a variety of materials, including aluminum, wood, stainless steel, and extruded polymers, and they can be made in different cross-sectional sizes, such as 2-inch x 2-inch and 5-inch x 5-inch square profiles. This adaptability in materials and sizes makes the system suitable for a wide range of applications—from residential and retail to industrial and recreational facilities.

[0211] One of the key features of this system is its ease of assembly and disassembly. Beams and joints are designed for easy connection and separation without dismantling the entire structure, thus facilitating maintenance, reconfiguration, and reuse. The system's modular nature also supports scalability, enabling the creation of both small and large structures.

[0212] The beam is equipped with a variety of fastening and practical features, including a center hole for routing cables, hoses, or storing batteries, as well as the ability to attach leveling supports or other components. Auxiliary components such as drawers, panels, mirrors, and electrical fittings can be easily integrated into the structure, making the system highly adaptable to a wide range of applications.

[0213] This invention also includes the ability to perform virtual design using a cloud-based CAD software application. This software allows users to create, share, and modify designs, generate bills of materials and assembly instructions, and even use AI to optimize design iterations based on user parameters. Integration with 3D scanning technology further enhances the design process by creating a virtual 3D space for the intended structure.

[0214] In summary, the modular building system described in this invention provides a highly customizable, scalable, and versatile solution for easily and efficiently building a wide variety of structures.

Claims

1. An apparatus for a modular construction system, the apparatus comprising: Interlocking beams and joints, The beam includes fastener tracks, pins and fastener cavities, and utility channels on each of its longitudinal planes. The fastener track is selected from a combination of dovetail track, T-slot track, V-slot track, and oblique guide channel. The beams are made of a material selected from the group consisting of aluminum, wood, stainless steel and extruded polymers.

2. The device of claim 1, wherein the beam has a square cross-section with dimensions selected from the range of 2 inches x 2 inches to 5 inches x 5 inches.

3. The device according to claim 1 or 2, further comprising a secondary beam or fitting capable of being attached to the utility channel.

4. The apparatus of claim 3, wherein the secondary beam is made of a material selected from the group consisting of wood, aluminum, stainless steel, polymers and paper.

5. The device according to claim 3 or 4, wherein the secondary beam includes fastening features selected from a group consisting of a threaded hole, a dovetail track, and a T-slot track.

6. The device according to any one of the preceding claims, wherein the joint is designed to transition from one dimension of the beam to another.

7. The device according to any one of the preceding claims, wherein the beam and the joint are designed to be easy to assemble and disassemble.

8. The apparatus according to any one of the preceding claims, wherein the beam and the joint can be removed independently of the structure.

9. The apparatus according to any one of the preceding claims, wherein the beams and joints allow for the creation of reconfigurable and reusable structures.

10. The device according to any one of the preceding claims, wherein the beam and the joint are designed to create a freestanding structure.

11. The device according to any one of the preceding claims, further comprising an auxiliary component capable of being attached to the beam and the joint.

12. The apparatus of claim 11, wherein the auxiliary components comprise elements selected from the group consisting of drawers, panels, clothes rails, mirrors, countertops, sliding doors, tabletops, shelves, and electrical fittings.

13. The apparatus of claim 11 or 12, wherein the electrical accessory comprises elements selected from the group consisting of lighting fixtures, jacks, electrical sockets, surge protectors, switches, USB ports, Ethernet ports, telephone jacks, audio connectors, speakers, HDMI connectors, and coaxial cable jacks.

14. The device according to any one of the preceding claims, wherein the beam includes a central hole for laying cables, hydraulic and pneumatic hoses or storing batteries.

15. The apparatus according to any one of the preceding claims, wherein the beam includes features for attaching a leveling support or a beam-to-beam attachment.

16. The device according to any one of the preceding claims, wherein the beam and joint are designed for use in residential, retail, conference, work, educational, catering and entertainment facilities.

17. The device according to any one of the preceding claims, wherein the beams and joints are designed with aesthetic considerations in mind and use materials such as wood and aluminum.

18. The device according to any one of the preceding claims, wherein the beam and joint are designed to minimize environmental impact by using materials such as wood and aluminum.

19. The device according to any one of the preceding claims, wherein the beam and joint are designed to be expandable to different sizes for various applications.

20. The device according to any one of the preceding claims, wherein the beams and joints are designed for garden and terrace structures.

21. The device according to any one of the preceding claims, wherein the beam and joint are designed for use in an outdoor structure.

22. The device according to any one of the preceding claims, wherein the beam and the joint are designed for use in automotive parts.

23. The apparatus according to any one of the preceding claims, wherein the beam and joint are designed to be used with a computer-aided design software application, i.e., a CAD software application, for virtual design of the structure.

24. The apparatus of claim 23, wherein the CAD software application is cloud-based.

25. The apparatus of claim 23 or 24, wherein the CAD software application allows users to create, share, and modify designs.

26. The device according to any one of the preceding claims, wherein the beam includes a fastener track, a pin and a fastener cavity, and a utility channel.

27. The apparatus according to any one of the preceding claims, wherein the beam includes a fastener cavity and a pin milling area.

28. The device according to any one of the preceding claims, wherein the beam includes the depicted fastener nut and locating pin features.

29. The device according to any one of the preceding claims, wherein the beam includes a fastener nut.

30. The apparatus of claim 29, wherein the fastener nut has a rectangular cross-section to match the cross-section of the fastener track.

31. A method for constructing a modular structure using interlocking beams and joints, the method comprising the steps of: Select a beam with fastener rails, pins and fastener cavities, and utility channels on each of its longitudinal planes; The joints were designed to transition from one scale of the beam to another. The beam and joint are assembled by interconnecting the beam and joint via the fastener rails, pins and fastener cavities and utility channels.

32. The method of claim 31, further comprising the step of selecting a fastener track from the group consisting of a dovetail track, a T-slot track, a V-slot track, and a mitered guide channel.

33. The method of claim 31 or 32, further comprising the step of attaching a secondary beam or fitting to the utility channel.

34. The method of claim 33, wherein the secondary beam is made of a material selected from the group consisting of wood, aluminum, stainless steel, polymers and paper.

35. The method according to claim 31, 32, 33 or 34, further comprising the step of assembling the beams and joints such that they can be easily disassembled without removing the entire structure.

36. The method according to claim 31, 32, 33, 34 or 35, further comprising the step of integrating auxiliary components into the structure, wherein the auxiliary components include elements selected from the group consisting of drawers, panels, clothes rails, mirrors, countertops, sliding doors, tabletops, shelves and electrical fittings.

37. The method according to claim 31, 32, 33, 34, 35 or 36, further comprising the step of laying cables, hydraulic and pneumatic hoses or storing batteries through the central hole of the beam.

38. The method according to claim 31, 32, 33, 34, 35, 36 or 37, further comprising the step of attaching a leveling support to the beam to create a structure on an uneven surface.

39. The method according to claim 31, 32, 33, 34, 35, 36, 37 or 38, further comprising the step of designing the modular structure using a computer-aided design software application, i.e., a CAD software application.

40. The method of claim 39, wherein the CAD software application is cloud-based and allows users to create, share, and modify designs.

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