Modular Beam Hole Patterns for Flexible Structural Assembly
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Solution Overview
Problem
Existing beam assemblies lack flexibility and tolerance in configuration and assembly, limiting their ability to form diverse and complex structures, particularly when using wood or metal beams.
Innovation Solution
A beam with modular side plates and end plates featuring specific hole patterns (A, B, and C) that allow for increased angular, lateral, and longitudinal connectivity options, enabling the formation of various structures through perpendicular and rotational alignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional wood or metal beams are used for structure assembly, then structural strength is achieved, but assembly flexibility and configuration options are limited
Solution Approach 1:
The beam is divided into multiple modular sections with standardized hole patterns, allowing independent configuration of each segment. This segmentation enables flexible assembly while maintaining manufacturing simplicity through repetition of standard components.
Solution Approach 2:
The beam design incorporates universal hole patterns (Pattern A, B, and C) that can be used across different beam configurations and assembly scenarios. These standardized patterns enable the same beam component to serve multiple structural functions, increasing versatility without proportionally increasing complexity.
2Adaptability or versatility
If custom sized wood boards are used, then specific structural dimensions are achieved, but assembly tolerance and configuration variety are reduced
Solution Approach 1:
The invention changes the critical parameter from custom board dimensions to standardized hole pattern configurations. By maintaining consistent hole patterns across different beam lengths and configurations, the design achieves both assembly tolerance and configuration variety, allowing beams to be cut to various lengths while preserving precise alignment capabilities.
3Strength
If metal beams with connectors are used, then structural strength is improved, but assembly complexity and time increase
Solution Approach 1:
The invention merges the beam body and connection features into a single integrated component. The hole patterns are directly formed in the beam sections themselves, eliminating the need for separate connectors or brackets. This integration maintains strong connections while significantly reducing assembly steps and time.
4Adaptability or versatility
If beams are designed with fixed hole patterns, then manufacturing simplicity is maintained, but assembly adaptability and tolerance are limited
Solution Approach 1:
The invention applies different hole patterns (A, B, and C) to specific locations on the beam based on local assembly requirements. Each pattern is optimized for its specific position, with Pattern A and B on side plates for lateral connections and Pattern C on end plates for longitudinal connections. This localized differentiation provides assembly adaptability while keeping each individual pattern relatively simple to manufacture.
Data Source
AI summary
A beam is provided with hole patterns allowing for increased configurations and tolerances for assembly into a structure. The beam has four side plates and two end plates. The four side plates can have any modular length that is determined by a number of repeating sections. Oppositely oriented side plates have sections with the same hole pattern. In one embodiment, two side plates have hole pattern A and the two other side plates have hole pattern B. The end plates have hole pattern C. Hole pattern A has outer corner and side holes that are straight slots with a longitudinal axis oriented perpendicular to end plate planes. Hole pattern B has outer corner and side holes that are straight slots with a longitudinal axis that is oriented parallel to the end plate planes. Hole pattern C has curved slots that lie on a perimeter of one of two circles.