U.S. patent application number 10/911129 was filed with the patent office on 2005-03-10 for connector for mounting structural components.
Invention is credited to Holmes, Eric, Howe, Ian.
Application Number | 20050050835 10/911129 |
Document ID | / |
Family ID | 34085129 |
Filed Date | 2005-03-10 |
United States Patent
Application |
20050050835 |
Kind Code |
A1 |
Howe, Ian ; et al. |
March 10, 2005 |
Connector for mounting structural components
Abstract
A structural mounting connector or spigot for mounting a glazing
frame section to a structure. The connector has a mounting section
receivable within a void or hollow end of a glazing frame section,
which mounting section has an upper flange or surface and a lower
flange or surface for accepting vertical fasteners such as screws
or pins which attach the connector to the glazing frame section.
The connector also has a connecting web between the top and bottom
flanges which contain elongated cavities or passageways for
receiving other fasteners, such as screws or bolts, by which the
mounting spigot section is affixed to a structure. The connecting
web has projections which have guide means to guide the vertical
screws or pins between the top and bottom flanges portions such
that the mounting spigot section is connectable to the glazing
frame section and the glazing frame section to the structure, with
the mounting spigot section and fasteners being concealed in the
glazing frame section. The mounting spigot section is able to be
cut to length and shape by a single cut taken in the same plane as
the cut in the glazing frame section to produce an angled join of
the glazing frame section to and flush with the structure.
Inventors: |
Howe, Ian; (Pakenham,
AU) ; Holmes, Eric; (Baxter, AU) |
Correspondence
Address: |
Milton S. Gerstein
6629 N. Francisco Avenue
Chicago
IL
60645
US
|
Family ID: |
34085129 |
Appl. No.: |
10/911129 |
Filed: |
August 4, 2004 |
Current U.S.
Class: |
52/780 |
Current CPC
Class: |
E04B 7/063 20130101;
E04D 2003/0806 20130101; E04D 2003/0868 20130101; E04B 2001/2656
20130101; E04B 2007/066 20130101; E04C 3/40 20130101; E04D 3/08
20130101 |
Class at
Publication: |
052/720.1 |
International
Class: |
E04C 003/30; E04B
001/32 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 4, 2003 |
AU |
2003100740 |
Claims
What is claimed is:
1. A connector for connecting a structural element to a structure,
comprising: A main body portion extending in a first, longitudinal
direction; said main body portion comprising a first end, a second
end, an upper surface section, a lower surface section, and
elongated transverse connecting means for connecting together said
upper and lower surface sections, said transverse connecting means
extending at least substantially along the length of said main body
portion and connecting said upper and lower surfaces sections in a
second direction that is perpendicular to said first longitudinal
direction; said elongated transverse connecting means having at
least one passageway means extending in said first longitudinal
direction for passing therethrough from said first end to said
second end at least one fastener element for securing said main
body portion to a structural element; said elongated transverse
connecting means comprises at least one transverse web section, and
a plurality of passageways formed in said at least one transverse
web section and extending in said first longitudinal direction for
passing therethrough from said first end to said second end a
plurality of fastener elements for securing said main body portion
to a structural element, one said passageway being located in
closer proximity to said upper surface section, and another said
passageway being located in closer proximity to said lower surface
section; each of said upper and lower surface sections comprising a
first side edge-surface and a second side edge-surface spaced from
said first side edge-surface in a third lateral direction
perpendicular to said first and second directions, and a central
mid-section extending in said first longitudinal direction; said at
least one transverse web section being located between said first
and second side edge-surfaces of said upper surface section and
said lower surface section.
2. The connector for connecting a structural element to a
structure, according to claim 1, wherein each said passageway
comprises a partially open, arcuate cavity defining an open
gap.
3. The connector for connecting a structural element to a
structure, according to claim 2, wherein each said open gap of a
said arcuate cavity faces in said third, lateral direction
perpendicular; said open gap of one said arcuate cavity facing
oppositely to a said open gap of an immediate adjacent said arcuate
cavity.
4. The connector for connecting a structural element to a
structure, according to claim 1, wherein said elongated connecting
means one said transverse web section connecting said upper surface
section and said lower surface section at said central mid-sections
thereof.
5. The connector for connecting a structural element to a
structure, according to claim 1, wherein said elongated connecting
means comprises a plurality of laterally spaced-apart transverse
web sections, said plurality of transverse web sections being
laterally and centrally offset between said upper surface section
and said lower surface section in said third direction; at least
one said transverse web section lying on one lateral side of said
central mid-sections taken in said third direction and at least
another said transverse web section lying on the other side of said
mid-sections taken in said third direction.
6. The connector for connecting a structural element to a
structure, according to claim 1, wherein said at least one
transverse web section comprises a plurality of
laterally-projecting guide means extending in said third, lateral
direction for guiding fasteners through said main body portion; at
least one of said plurality of laterally-projecting guide means
protruding from one lateral side of said at least one transverse
web section, and at least one other of said plurality of
laterally-projecting guide means protruding from the other lateral
side of said transverse web section.
7. The connector for connecting a structural element to a
structure, according to claim 6, wherein said ones of said
plurality of laterally-projecting guide means protruding from one
lateral side of said at least one transverse web section being in
alignment in said second direction, and said other ones of said
plurality of laterally-projecting guide means protruding from the
other lateral side of said at least one transverse web section
being in alignment in said second direction; said main body portion
further comprising laterally-opposite fastener-passing means
projecting from respective said first and second side edge-surfaces
of said upper surface section and said lower surface section, ones
of said laterally-opposite fastener-passing means projecting from
the first lateral side being in alignment with said ones of said
plurality of laterally-projecting guide means protruding from one
lateral side of said at least one transverse web section, and
others of said projecting fastener-passing means projecting from
the second lateral side being in alignment with said other ones of
said plurality of laterally-projecting guide means protruding from
the other lateral side of said at least one transverse web
section.
8. The connector for connecting a structural element to a
structure, according to claim 7, wherein each of said plurality of
guide means comprises a thin-wall section by which a fastener
passing through said upper surface section passes readily through,
and is guided to, said lower surface section.
9. The connector for connecting a structural element to a
structure, according to claim 1, in combination with a structural
component comprising a main housing having a first hollow-interior
end section and a second hollow-interior end section; said
connector being received entirely within one of said first and
second hollow end sections, whereby said one hollow end section may
be mounted to another structural component by said connector; said
structural component comprising connector-receiver means for use in
slidingly orienting said main body portion of said connector in
said one hollow end section; said connector-receiver means
comprising at least one of an interiorly-extending top and bottom
portion extending inwardly from side walls of said structural
component; said at least one of an interiorly-extending top and
bottom portion receiving at least one fastener element therein by
which said main body portion of said connector may be affixed to
said structural component; said structural component being one from
the group consisting of a: rafter, mullion, and transom.
10. The connector for connecting a structural element to a
structure, according to claim 1, wherein at least one of said first
and second ends of said main body portion is mitered to an angle
for flush connection to a structural component at said one end.
11. The connector for connecting a structural element to a
structure, according to claim 10, in combination with another said
connector; said another connector also having at least one of said
first and second ends of said main body portion mitered to the same
angle as said one end of said connector; said one mitered ends of
said connector and said another connector being in flush engagement
with each other and secured together via fastener elements passing
through aligned said passageways of said connector and said another
connector, whereby, after said component and said another component
are mounted in adjacent ends of two different structural
components, the two different structural components may be secured
together at adjacent ends via said connector and said another
connector to form a segmented frame section of a structural
frame.
12. A connector for connecting a structural element to a structure,
comprising: A main body portion extending in a first, longitudinal
direction; said main body portion comprising a first end, a second
end, an upper surface section, a lower surface section, and
elongated transverse connecting means for connecting together said
upper and lower surface sections, said transverse connecting means
extending at least substantially along the length of said main body
portion and connecting said upper and lower surfaces sections in a
second direction that is perpendicular to said first longitudinal
direction; said elongated transverse connecting means having
passageway means extending in said first longitudinal direction for
passing therethrough from said first end to said second end at
least one fastener element for securing said main body portion to a
structural element; at least one of said first and second ends of
said main body portion being mitered to an angle for flush
connection to a structural component at said one end; and further
in combination with another said connector; said another connector
also having at least one of said first and second ends of said main
body portion thereof mitered to the same angle as said one end of
said connector; said one mitered ends of said connector and said
another connector being in flush engagement with each other and
secured together via at least one fastener element passing through
aligned said passageway means of said connector and said another
connector, whereby, after said component and said another component
have been affixed together by at least one fastener element, the
two different structural components may be secured together at
adjacent ends via said connector and said another connector to form
a segmented frame section of a structural frame extending at said
mitered angle.
13. The connector for connecting a structural element to a
structure, according to claim 12, further comprising a plurality of
fastener elements, each said fastener element being bent at said
mitered angle and comprising a first section passing through one
said passageway means of said one connector and a second section
passing through one said passageway means of said another connector
aligned with said one passageway means of said one connector.
14. A method of coupling one structural element to another
structural element, where the one structural element has at least
one open and hollow end, using an elongated coupler having a main
frame extending in a first longitudinal direction, the main frame
having a first end and a second end spaced from said first end in
the first longitudinal direction, an upper surface section, a lower
surface section, and a middle section joining in a second direction
perpendicular to the first direction the upper and lower surface
sections, said method comprising: (a) securing one of said first
and second ends of said main frame to another structural element;
(b) after said step (a), mounting one end section of the one
structural element over said main frame until said main frame is
contained within the hollow interior of one end section of the one
structural element; and (c) after said step (b), securing the main
frame in the hollow interior of the one end section of the one
structural element; said step (b) comprising first passing the one
end section of the one structural element over the other end of the
first and second ends of the main frame, and then sliding the one
end section of the one structural element along said main frame in
the first longitudinal direction, until the end-edge of the one
end-section of the one structural element is flush against the
another structural element to which said main frame has been
secured; said step (c) comprising passing fastening elements in
said second transverse direction through at least one portion of
the one end-section of the one structural element and through the
upper and lower surface sections juxtapositioned at the portion of
the one end-section of the one structural element.
15. The method of coupling one structural element to another
structural element, according to claim 14, wherein said step of
passing fastening elements of said step (c) comprises guiding the
fastener elements through aligned guides formed in said main frame
between said upper and lower surface sections of the main
frame.
16. The method of coupling one structural element to another
structural element, according to claim 14, wherein said step (a)
comprises: (d) securing said one end of said main frame to an end
of another main frame of another similar elongated coupler; (e)
said step (d) comprising passing at least one fastening element
through both said main frame and said another main frame; (f) said
step (e) comprising passing at least one fastening element through
said first and second ends of both said main frame and said another
frame in the first longitudinal direction of each said main frame
and said another main frame.
17. The method of coupling one structural element to another
structural element, according to claim 16, further comprising
before said step (d): (g) cutting said one end of said main frame
to a desired angle; (h) cutting said one end of said another main
frame to said desired angle; (i) abutting said one angle-cut ends
against each other; (j) before said step (d), bending at least one
fastening element to at least close approximation to said desired
angle to form first and second straight sections extending
approximately at said desired angle; said step (f) comprising
passing said first straight section through said one main frame in
the longitudinal direction of said first main frame, and then
passing said second straight section through said another main
frame in the longitudinal direction of said first main frame, where
the longitudinal directions of said main frames extend at an angle
equal to said desired angle.
18. The method of coupling one structural element to another
structural element, according to claim 17, wherein said step (f)
comprises: (k) passing the first straight section of the fastener
element through a first passageway of said one main frame; and (l)
passing the second straight section of the fastener element through
a second passageway of said another main frame; (m) said step (k)
comprising passing the first straight section of the fastener
element through a first passageway having an arcuate gap; (n) said
step (l) comprising passing the second straight section of the
fastener element through a second passageway having an arcuate gap
facing laterally opposite to that which said arcuate gap of said
step (m) faces; whereby said first and second straight sections are
partially circumferentially supported by said first and second
passageways on diametrically opposite arcuate surfaces thereof.
19. The method of coupling one structural element to another
structural element, according to claim 14, further comprising
before said step (a): (d) inserting said main frame into a hollow
end section of a structural element in which is to be mounted for
affixing the structural element to a structure; (e) after said step
(d), cutting said main frame and said hollow end section together
to a desired angle; (f) removing said main frame from said hollow
end section, and thereafter performing said step (a).
20. A connector for connecting a structural element to a structure,
comprising: A main body portion extending in a first, longitudinal
direction; said main body portion comprising a first end, a second
end, an upper surface section, a lower surface section, and
elongated transverse connecting means for connecting together said
upper and lower surface sections, said transverse connecting means
extending at least substantially along the length of said main body
portion and connecting said upper and lower surfaces sections in a
second direction that is perpendicular to said first longitudinal
direction; said elongated transverse connecting means having at
least one passageway means extending in said first longitudinal
direction for passing therethrough from said first end to said
second end at least one fastener element for securing said main
body portion to a structural element; said elongated transverse
connecting means comprises at least one transverse web section, and
a plurality of passageways formed in said at least one transverse
web section and extending in said first longitudinal direction for
passing therethrough from said first end to said second end at
least one fastener element for securing said main body portion to a
structural element, one said passageway being located in closer
proximity to said upper surface section, and another said
passageway being located in closer proximity to said lower surface
section; said at least one transverse web section comprising a
plurality of laterally-projecting fastener-guide means extending in
said third, lateral direction for guiding fasteners through said
main body portion; at least one of said plurality of
laterally-projecting fastener-guide means protruding from one
lateral side of said at least one transverse web section, and at
least one other of said plurality of laterally-projecting
fastener-guide means protruding from the other lateral side of said
transverse web section.
21. The connector for connecting a structural element to a
structure, according to claim 20, wherein said ones of said
plurality of laterally-projecting guide means protruding from one
lateral side of said at least one transverse web section being in
alignment with each other in said second direction, and said other
ones of said plurality of laterally-projecting guide means
protruding from the other lateral side of said at least one
transverse web section being in alignment with each other in said
second direction.
22. The connector for connecting a structural element to a
structure, according to claim 21, wherein each of said upper and
lower surface sections comprising a first side edge-surface and a
second side edge-surface spaced from said first side edge-surface
in a third lateral direction perpendicular to said first and second
directions; said main body portion further comprising
laterally-opposite fastener-passing means projecting from
respective said first and second side edge-surfaces of said upper
surface section and said lower surface section, ones of said
laterally-opposite fastener-passing means projecting from the first
lateral side being in alignment with said ones of said plurality of
laterally-projecting guide means protruding from one lateral side
of said at least one transverse web section, and others of said
projecting fastener-passing means projecting from the second
lateral side being in alignment with said other ones of said
plurality of laterally-projecting guide means protruding from the
other lateral side of said at least one transverse web section.
23. The connector for connecting a structural element to a
structure, according to claim 22, wherein each of said plurality of
guide means and said fastener-passing means comprises a relatively
thin-wall section by which a fastener passes therethrough.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention is directed to a connector for
mounting one structural member or component to another. The present
invention has special applicability to the connection or mounting
of structural members associated with extruded glazing framework or
frames for skylights, windows, and the like. In particular, the
present invention is intended for use with the "INTALOK" glazing
mounting system manufactured and sold by Sky Roof P/L of Victoria,
Australia, and disclosed in U.S. Pat. No. 5,655,346, which patent
is incorporated by reference herein.
[0002] Currently in the glazing industry, extruded glazing frames,
such as those having hip and rafter components of closed and hollow
cross-sections for use in skylight framework, and the like, are
commonly joined together at intersections by the use of welds or
brackets, or in the case of window frames, by shear blocks.
However, welds destroy the coated finish of the frame components in
the region of the weld, and presently-used bracketing methods
require visible and unsightly fasteners, such as screws. Welded or
screwed joins are, thus, visually unattractive. In addition, when a
join is not a right-angle one, such as a compound angle join, or
when a number of joins having different angles of intersection, the
design and manufacture of numerous individually angled brackets is
particularly complex and time-consuming. In the use of these shear
blocks, a connector is first affixed to a first component by first
screws, and then a second component that is to be connected to
first component is attached to the connector by other screws
transverse to the first screws.
[0003] In above-mentioned U.S. Pat. No. 5,655,346, there is
disclosed a glazing framework having a base section or bar for
mounting the glazing, such as glass or plastic, of a skylight,
window and the like, by means of a T-shaped, glazing mounting cap,
with the glazing being sandwiched and held between the upper
surface of the base section or bar, and the glazing mounting cap.
Each base section or bar is of hollow-interior construction, and
has an upper, cooperating recess for receiving the locking portion
of the T-shaped glazing mounting cap. Each base section or bar may
act as a rafter base, hip, mullion or similar structural component,
when the skylight, window or the like, is constructed, by which the
glazing framework is structurally formed and mounted to building
components
[0004] The connector of the present invention is intended for use
in mounting a glazing-frame component, such as the rafter base or
bar, to a structural component, such as the hip rafter, or mullion,
or the like, in a way such that it readily and facilely allows
joinder of components without any exposed hardware, while providing
improved structural connection. In addition, the very same
connector may be used to connect right-angle joints, single-angle
joints, and double-miter joints, unlike the above-discussed
prior-art methods, which, therefore, reduces overall cost, obviates
the need for custom connection-hardware, and, therefore, reduces
overall installation time. Thus, the connector of the present
invention is a universal connector that is used at
component-interconnections regardless of the angle of such
intersection.
SUMMARY OF THE INVENTION
[0005] It is, therefore, the primary objective of the present
invention to provide a connector for connecting a structural
component to another structural component, which connector is
mounted entirely within the hollow interior of a structural
component, whereby the connector is hidden from view for aesthetic
reasons while also providing improved and enhanced structural
support to the connection between structural components.
[0006] It is, also, the primary objective of the present invention
to provide such a connector for connecting a structural component
to another structural component, which connector is mounted
entirely within the hollow interior of a structural component,
which structural components are part of a glazing framework for
forming a skylight, window, and the like.
[0007] It is, also, the primary objective of the present invention
to provide such a connector for connecting structural components
forming part of a glazing framework for forming a skylight, window,
and the like, which connector may be used for all types of
intersections between structural components, whether right angle,
acute angle, double mitered, and the like, while allowing fast and
easy securement between components.
[0008] Toward these and other ends, the connector for structural
components, such as those forming a glazing framework for skylights
and windows, is made of extruded aluminum, for example, and
comprises an elongated main body portion which is slidably
receivable in one end of the hollow interior of a structural
component to be attached to another structural component, such as a
rafter or common rafter component forming part of a glazing frame
to a hip rafter or hip of the building structure, or for connecting
similar structural components together that may form the transoms
and mullions of a glazing framework. The main body portion is
elongated in a first, longitudinal direction, and defines an upper
surface and a lower surface. Provided between the upper and lower
surfaces, there is at least one transverse web that is connected to
the upper and lower surfaces in a second, transverse
depth-direction as compared to the first, longitudinal direction,
which web preferably extends the entire length of the main body
portion in the first, longitudinal direction. In the case of one
such transverse web, the web is located centrally between the upper
and lower surfaces. The transverse web is provided with a plurality
of through-passageways or through-openings which receive
therethrough first fastening elements, such as fastening screws,
which fastening elements mount the connector to a structural
component, such as the hip, or hip rafter, of a structure. The main
body portion is also comprised of a plurality of transversely
spaced-apart, longitudinally-extending mounting ears or flanges
projecting in a third width-direction perpendicular to the first
and second directions, which mounting ears or flanges project
outwardly from either edge of the upper and lower surfaces, and
from opposite sides of the transverse web. Each mounting ear or
flange extends substantially along the length of main body portion
in the first longitudinal direction, and defines a central or
middle section of minimal thickness, which middle sections on the
same side of the transverse web are aligned in the second
transverse direction in order to allow second fastening elements,
such as a screws, to be operatively passed therethrough. The second
fastening elements passing through the mounting ears extend
perpendicularly with respect to the first fastening elements
passing through the transverse web, and are used for fastening the
coupler or connector to a structural component in which the
connector is to be a part. The connector is initially fastened to
the structural component, such as a hip, or other similar
component, to which another structural component of a glazing frame
is to be mounted. This initial mounting is achieved via the first
fastening elements passing through the transverse web. After
mounting of the connector of the invention to the hip, for example,
the structural component, such as the rafter, that is to be mounted
to the hip, is slid over the connector, whereby the connector
enters into, and is completely contained within, one end of the
hollow interior of the rafter, for example. Thereafter, the
connector is fastened to the rafter by means of the second
fastening elements by passing them through the aligned middle
sections of the plurality of ears or flanges on either side of the
transverse web. The connector may be cut to the desired angle at
its end to be mounted to the hip, which angle will be same as that
of the end of the rafter it is coupling to the hip. A similar
procedure applies when connecting two similar components, such as
transoms or mullions, in the hollow ends of which are mounted
connectors of the invention.
[0009] The connector of the present invention in combination with
the base disclosed in above-mentioned U.S. Pat. No. 5,655,346 serve
as a universal-type of glazing base, whereby this base may serve in
different capacities in a glazing framework. Thus, the base when
provided with the connector of the invention serves as a mullion or
post when used vertically in the glazing framework, as a transom
when used horizontally or purlin, or as a rafter when used at an
angle in the glazing framework. This very same base with the
connector of the invention is also used as a hip when placed at the
corner of a structure of which the glazing framework is to be part.
Two or more identical base sections may be connected together via
the connector of the invention at each end of each base section.
The length and overall girth of a base section will change
depending upon the type of structural member it is to serve as,
with the connector of the invention being correspondingly
dimensioned for fitting inside a hollow end of the base section.
However, regardless of the type of structural component that the
base is to be used as, the connector of the invention is used
identically in all, thereby serving as an universal connector for
all types of structural components associated with glazing
frameworks, whether rafter, hip, mullion, post, transom, purlin,
and the like.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The invention will be more readily understood with reference
to the accompanying drawings, wherein:
[0011] FIG. 1 is an isometric view showing the universal connector
for connecting structural components of a glazing framework;
[0012] FIG. 2 is an end view of either end of the connector of FIG.
1;
[0013] FIG. 3 is an end view of a prior-art base section in which
the connector of FIG. 1 is mounted in the hollow-interior end
thereof;
[0014] FIG. 4 is an end view of a prior-art base section of FIG. 3
showing the connector of FIG. 1 mounted in the hollow-interior end
thereof;
[0015] FIG. 5 is an end view similar to FIG. 2, but showing a
modification of the connector of FIG. 1;
[0016] FIG. 6 is an end view of a second type of prior-art base
section in which the connector of FIG. 5 is mounted in the
hollow-interior end thereof;
[0017] FIG. 7 is an end view similar to FIG. 4 and showing the
connector of FIG. 5 mounted in the hollow-interior end of the base
section of FIG. 6;
[0018] FIG. 8A is an elevation view of an angled join connector
formed by the interconnection of two connectors of FIG. 1, where
each connector has been angle-cut at one end and joined together
thereat for forming an angle-section for mounting two base sections
forming an angle-section of a segmented glazing framework;
[0019] FIG. 8B is a first end view of the angled join connector of
FIG. 8A;
[0020] FIG. 8C is a second end view of the angled join connector of
Fig, 8A;
[0021] FIG. 8D is a cross-sectional view taken along line 8D-8D of
FIG. 8C;
[0022] FIG. 9 is an elevation view showing the initial bending of a
fastening element for joining two separate mitered connectors in
order to form the angled join connector of FIG. 8A;
[0023] FIG. 10 is an enlarged view of the flush engagement between
the mitered ends of the two connectors forming the angled join
connector of FIG. 8A, showing the opposite sense of the opening of
the respective passageways passing the fastening element of FIG. 9;
and
[0024] FIGS. 11-18 are isometric assembly views showing the use of
the connector of the invention in mounting one end of a base
section to another structural component of a glazing framework.
DETAILED DESCRIPTION OF THE INVENTION
[0025] Referring now to the drawings in greater detail, and to
FIGS. 1-4 for now, the connector of the invention is indicated
generally by reference numeral 10. The connector 10 is preferably
made of structural-strength extruded aluminum, and has especial use
in the "INTALOK" glazing mounting system manufactured and sold by
Sky Roof Pty. Ltd. of Victoria, Australia, and disclosed in U.S.
Pat. No. 5,655,346. The connector 10 has an elongated main body
portion or frame 12 which consists of an upper flange or top
surface 14, and a lower flange or bottom surface 16. Connecting or
joining the upper and lower flanges 14, 16 is a transverse web 18,
which in the embodiment of FIGS. 1-4, is centrally located between
the upper and lower flanges 14, 16. The web 18 is provided with a
plurality of spaced-apart, elongated, arcuate passageways or
cavities, such as the three passageways 20, 22, 24, although more
or less may be provided. Each passageway 20, 22, 24 is preferably
not a perimetrically closed surface in order to leave a gap or
opening 20', 22', 24' in order to allow slight circumferential
expansion of the respective passageway, if necessary, when a
fastening element, such as a screw or bolt, is passed therethrough
for purposes of mounting the connector 10 to a structural
component, as described in detail hereinbelow. It is noted that the
lateral side to which each gap 20', 22', 24' preferably opens or
faces alternates among the passageways 20, 22, 24, as can be seen
in FIG. 2, so that, for example, when viewing FIG. 2, the gap 20'
faces the opposite side as that of gap 22' but to the same side as
gap 24'. It is, of course, within the purview of the invention to
allow for all gaps to face in the same direction, and to provide
completely enclosed passageways 20, 22, 24.
[0026] Extending from each side edge-surface of each of the upper
and lower flanges 14, 16 are channel sections 30, 32, and 34, 36,
respectively, preferably extending the full length of the main body
portion 12. Each channel section is formed with side walls in order
to form a channel 30', 32', 34', 36' therebetween. The respective
walls of each channel section are joined by a bottom wall section
30", 32", 34", 36", with each wall section having a middle or
central thin-walled portion, as best seen in FIGS. 1 and 2. These
thin-walled portions of the joining wall sections 30", 32", 34",
36" are thin enough so as to allow a drill or self-drilling
fastening element to pass readily therethrough, while still
providing structural integrity to the wall sections 30", 32", 34",
36". As explained hereinbelow in greater detail, fastening
elements, such as screws or bolts, pass through the wall sections
30", 32", 34", 36" for mounting the connector 10 in a hollow
interior end of a base section, which base section serves as a
structural component of a larger structure, such as a glazing
framework, where the base section may serve as a rafter, hip,
mullion, transom, purlin, and the like.
[0027] In linear alignment with the channel sections 30, 32, and
34, 36, respectively, are a plurality of laterally projecting, side
web sections or ears 40, 42, and 44, 46, respectively. Each web
section 40, 42, and 44, 46 is connected at one end to a respective
side surface portion of the central web 18 and between two
respective passageways 20,22,24, and defines a V-shaped, thin-wall
portion 40', 42'and 44', 46', respectively; each web section 40,42
and 44, 46, projects a distance away from a respective surface of
the web 18 such that each thin-wall portion 40', 42' and 44', 46'
is in alignment with a thin-wall portion of the wall sections 30",
32", 34", 36"; therefore, thin-wall portions 40', 44' are in
alignment with each other and with the thin-wall portions 30", 34",
while the thin-wall portions 42', 46' are in alignment with each
other and with the thin-wall portions 32", 36".
[0028] The combination of thin-walt portions 30", 40', 44', 34',
and the combination of thin-wall portions 32", 42', 46', 36',
define a pair of guides, one on either side of the connector 10, by
which fastening elements 50, such as screws or bolts, may pass and
be guided, which fastening elements are used for securing or
mounting the connector 10 to the interior hollow end of a
structural component of which it is to be part and used for
mounting the structural component 52 to another structural
component of a structure, as seen in FIG. 4. The interior of the
base section 52 is preferably provided with a pair of elongated,
upper, interior opposed tabs or ears 54, and a pair of elongated,
lower, interior tabs or ears 56, between which upper and lower
pairs of tabs the connector 10 is received. These upper and lower
tabs or ears 54, 56 also receive therein the fastening elements 50,
such as screws or pins, whereby the connector 10 is secured within
the hollow end of the base section 52. Additional fastening of the
connector in the hollow interior end of the base section 52 may be
achieved by passing screws or bolts through the side walls 56" of
the base section into adjacent portions of the connector 10, such
as the channel sections 30, 32, 34, 36, or even into the
conesponding portions of the transverse web 18, if needed.
[0029] The number of fastening elements 50 used may be varied
depending upon the length of the connector 10. Preferable, a series
of longitudinally spaced-apart fasteners 50 are used on each side,
which series of fasteners extend in the first direction
longitudinally along the length of the main body portion 12. The
structural component 52 is a base or base section, such as that
used in the "INTALOK" glazing mounting system manufactured and sold
by Sky Roof Pty. Ltd. of Victoria, Australia, and disclosed in U.S.
Pat. No. 5,655,346. The base section 52 may be a hip, rafter,
transom, mullion, purlin, or the like, with its length varying
depending on which structural member it is to serve as, and
according to the specific glazing framework of which it is part.
Accordingly, the length of the connector 10 may vary also depending
upon the type of structure with which it is to employed for
coupling base sections 52. The base section 52 has an
arcuate-shaped channel or groove 56' formed into its top surface in
which is received a cover or cap by which glazing is mounted to the
frame at the base section 52 thereof, which forms part of the
above-mentioned "INTALOK" glazing mounting system manufactured and
sold by Sky Roof Pty. Ltd. of Victoria, Australia, disclosed in
U.S. Pat. No. 5,655,346.
[0030] Referring now to FIGS. 5-7, there is shown a second
embodiment 60 of the connector of the invention. The connector 60
is similar to the connector 10, with the exception that instead of
the central web 18 of the connector 10, a pair of laterally
spaced-apart webs 64, 66 are used, which webs 64, 66 connect
between upper flange or top surface 70 and lower flange or bottom
surface 72 off-center from the center thereof. Each web 64, 66 is
provided with a plurality of passageways 74, 76, respectively,
identical to those of the web 18. Moreover, each of the upper and
lower flanges 70, 72 is provided with upper channel sections 78,
80, and lower channel sections 82, 84, respectively, like those of
the connector 10. In addition, each web 64, 66 is also provided
with laterally projecting web sections 86, 88, 90, and 92 like web
sections 40, 42, 44, 46, which are in alignment with respective
ones of the channel sections 78, 80, 82, 84, as may be seen in FIG.
5. Each laterally projecting web section 86, 88, 90, 92 protrudes
from, and is formed integrally with, one of the passageways 86, 88,
and faces the same way as the respective gap of its associated
passageway.
[0031] In the embodiment of FIGS. 5-7, the connector 60 is
generally of greater girth than the connector 10, and is used for
mounting a base section or component 52' of greater girth than the
base section 52 in which the connector 10 of the first embodiment
is mounted. Thus, the connector 60 is preferably provided with four
or more passageways 74, 76 for each web 64, 66, respectively,
whereby a total of eight are provided, allowing more fasteners to
be used and the concomitant greater structural integrity of the
mounting of the structural component 52' to which the connector 60
is secured via fasteners 50.
[0032] Referring now to FIGS. 8A, 8B, 8C, 8D, 9 and 10, there is
shown a pair of connectors 10 of the first embodiment fastened to
each other, where each connector 10 has been angle-cut, or mitered,
at an end 10'. The ends 10' of each connector 10 are placed in
flush engagement with other, as seen in FIGS. 8A and 8D, and
secured together by fasteners, such as by threaded rods or bolts 90
and nuts 92 which pass through aligned passageways or cavities 20,
22, 24 of the adjoined connectors 10 . In order to connect the two
angle-cut or mitered connectors 10, each threaded rod or bolt 90 is
of such length so as to pass through both two connectors 10 when
joined. To secure the mitered or angled connectors 10 together, one
first bends the threaded rod or bolt 90 to the desired angle, which
angle is that of the miter cut of the ends 10' of the connectors
10, as seen in FIG. 9, whereupon the first straight half or section
90' is passed through one of the passageways or cavities 20, 22, or
24 of one connector 10. Thereafter, the other straight half or
section 90" is then passed through the corresponding and aligned
passageway 20, 22, or 24 in the other of the two connectors 10
forming the angle-cut join connector. Nuts 92 are then tightened to
secure the threaded rod and to secure the two connectors. The same
procedure is done with one or more other threaded rods passing
through one or more other corresponding, aligned passageways or
cavities 20, 22 or 24 of the two connectors 10, such as passageways
24 as seen in FIGS. 8A-8D.
[0033] After the two angle-cut connectors 10 have been so secured,
then an end of each of a pair of base sections 52 is slid over a
respective one of connectors 10, which ends of the base sections
have been mitered to an angle similar to that of the ends 10',
after which, fasteners 50 secure the respective connector 10 in the
interior of the hollow end of the respective base section 52, in
the manner described hereinabove. This type of connection is used
especially for forming segments of an angled skylight, as well as
for other structures. The bent, threaded fastener 90 acts like a
post-tensioned, reinforced beam, where the threaded rod 90 is
placed mainly in tension when resisting a bending moment. The
connectors may, also, be joined at a double-miter.
[0034] Since the connector 10 is to be received within a hollow end
of a base section 52, the angle or miter of both the end 10' of the
connector 10 and the corresponding end of the base 52 in which the
connector 10 is to be received, may be cut together, as by a saw,
in just one operation by first placing the connector 10 within the
corresponding end of the base 52 in the manner that they will
assume when affixed to each other, and cutting both the end 10' of
the connector 10 and the correspond end of the base 52
together.
[0035] It is noted that when the two connectors 10 are coupled
together, each passageway 20, 22, or 24 of the first connector has
its gap or opening 20', 22', or 24' in the opposite sense as its
counterpart, aligned passageway 20, 22, or 24 of the other
connector, in order to counter-encase, or capture, the rod or bolt
90. This is seen in FIG. 10, where the arcuate wall of a respective
passageway 20, for example, in the first connector surrounds, the
shaft of the half-section 90" of the fastener 90 on one side
thereof, while the arcuate wall of the aligned passageway 20 in the
second, mating connector surrounds the shaft of the half-section
90' of the fastener 90 on the other side of the fastener, whereby
the passageways of the two connectors 10 have their arcuate walls
in the opposite sense. The same holds for the other aligned and
corresponding passageways or cavities 22 and 24 of the two
connectors 10.
[0036] Referring now to FIGS. 11-17, there is shown the manner by
which a connector 10 of the invention is used. The example of FIGS.
11-17 shows a coupler 10 that is to be mounted in the hollow
interior end of a base section 52, which base section, in the
example shown, is a rafter which is to be mounted to the side
surface 98' of another base section serving as a hip 98, for
example. In the example shown, the connection between the rafter
and the hip is at an angle, whereby both the connector 10 and its
receiving rafter 52 has been cut to the proper angle or miter in a
conventional manner. The end of the connector 10, and the
corresponding end of the base section 52, are cut to length and
shape by a single cut taken in the same plane as the cut required
in an end of the glazing frame section, to thereby produce an
angled join flush with the glazing frame section and the structure.
After miter-cutting the connector 10 to the proper angle, the
connector 10 is mounted to the appropriate section of the side
surface 98' of the hip 98 by means of the fastening elements, such
as bolts or screws (FIG. 12). Three such screws or bolts are
typically used and pass through the three passageways 20, 22, 24 of
the coupler 10, as described hereinabove (FIGS. 1-4).
Alternatively, the connector 60 of FIGS. 5-7, with six such
passageways, may be used depending upon the girth and use in which
the connector of the invention is used. After the connector 10 (or
connector 70) has been mounted to the hip 98, one hollow end 52" of
the receiving base section 52, that has been mitered to the same
angle as that of the connector 10, is slid longitudinally over the
attached connector 10 (FIG. 14), so that the connector 10 is
entirely received within the hollow interior end 52" of the base
section 52, such that the mounting connector and the fasteners are
fully concealed within the glazing frame section (FIG. 15).
Thereafter, fasteners, such as screws or pins 50 of FIG. 4, are
used to permanently secure the connector 10 and the end 52" of the
base section or rafter 52 together (FIG. 16), in the manner
discussed hereinabove with reference to FIGS. 2-4. The other end
52" of the base-section rafter 52 is similarly connected to another
base section serving as another structural component 102, such as a
mullion or another hip, for example, which other end 52" and
corresponding connector therefor may or may not be mitered, to form
a structurally integral unit, as seen in FIG. 17.
[0037] If a rafter, for example, is to be joined to a hip, for
example, and is to be connected at a simple right angle, then, of
course, the end of the connector 10 and the corresponding receiving
end of the rafter are not cut, in order to retain a right-angle
structural unit. The process of securement of a simple, right-angle
structural unit is the same as described above for the mitered
connector and base section, and is shown in FIGS. 18A-18C, where
the right-angle connector 10 of FIG. 18A is first attached to a
another base section serving as a purlin 108, for example, with a
surface face 108' (FIG. 18B). Thereafter, the base section 52
serving as a rafter, for example, is slid over the secured
connector 10 for receiving the connector 10 in the hollow interior
end thereof, whereupon the connector and the base section are
fastened together by pins or screws, as described above. The same
procedure is performed at the other end of the base section 52,
whereby a right-angle structural unit is formed (FIG. 18C).
[0038] It is noted that the relatively narrow, each elongated
connecting web section of the connectors 10 and 70 that connect the
upper and lower flanges together may be considerably wider, or
thicker, in the lateral direction as that shown in the drawings if
additional structural reinforcement and integrity is required, or
they may be spaced considerably much farther apart from each. In
addition, the channel sections 30, 32, 34, 36 may be eliminated,
and the fasteners may just be passed through extended portions of
the upper or lower surface section 14, 16.
[0039] While the connector 10 or 60 of the invention has been
described hereinabove with respect to use in a glazing frame or
framework, the connector of the invention may be used in other
structural environments where the coupling of similar structural
components into a frame, framework, or latticework, is to be
accomplished, where such components have hollow interiors or hollow
interior ends in which the connector of the invention may be
mounted.
[0040] While specific embodiments of the invention have been shown
and described, it is to be understood that numerous changes and
modifications may be made therein without departing from the scope
and spirit of the invention as set forth in the appended
claims.
* * * * *