U.S. patent application number 11/107216 was filed with the patent office on 2005-09-29 for fastening system for use with a structural member.
This patent application is currently assigned to Pop-In Pop-Out, Inc. Invention is credited to Kuenzel, Rainer.
Application Number | 20050210771 11/107216 |
Document ID | / |
Family ID | 33313104 |
Filed Date | 2005-09-29 |
United States Patent
Application |
20050210771 |
Kind Code |
A1 |
Kuenzel, Rainer |
September 29, 2005 |
Fastening system for use with a structural member
Abstract
A fastening system provides for connecting structural members
with blind fasteners. The fasteners are movably positionable along
an elongated opening of a chamber, such as a channel, anchored with
the structural members. A structural member may have multiple
chambers. The fasteners are constructed with a holding portion of
elongated members. The elongated members are movable for insertion
into the chamber and for engaging the opposed margins of the
channel.
Inventors: |
Kuenzel, Rainer; (Hunt,
TX) |
Correspondence
Address: |
AKIN, GUMP, STRAUSS, HAUER & FELD
1111 LOUISIANA STREET
44TH FLOOR
HOUSTON
TX
77002
US
|
Assignee: |
Pop-In Pop-Out, Inc
Kerrville
TX
|
Family ID: |
33313104 |
Appl. No.: |
11/107216 |
Filed: |
April 15, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11107216 |
Apr 15, 2005 |
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10696332 |
Oct 29, 2003 |
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10696332 |
Oct 29, 2003 |
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10418448 |
Apr 17, 2003 |
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Current U.S.
Class: |
52/155 |
Current CPC
Class: |
F16B 13/0858 20130101;
F16B 13/0833 20130101; F16B 35/045 20130101 |
Class at
Publication: |
052/155 |
International
Class: |
E02D 005/74 |
Claims
I claim:
1. A fastening system adapted for use with a structural member, the
fastening system comprising: a plurality of opposed margins
attached with the structural member forming an elongated opening of
a chamber; and a fastener comprising a holding portion, wherein the
holding portion comprises: a plurality of elongated members,
wherein the plurality of elongated members are moveable between an
insertion position for insertion through the elongated opening and
an extended position for positioning with the plurality of opposed
margins; wherein the holding portion is positionable in the
chamber, and wherein the fastener is movable along the elongated
opening to a plurality of locations relative to the structural
member.
2. The fastening system of claim 1, wherein the plurality of
opposed margins is anchored with the structural member.
3. The fastening system of claim 1, wherein the plurality of
opposed margins comprises parts of a channel fixed relative to the
structural member.
4. The fastening system of claim 3, wherein the channel defines the
chamber.
5. The fastening system of claim 1, wherein the plurality of
opposed margins and the structural member are fabricated from
different materials.
6. The fastening system of claim 1, wherein the plurality of
opposed margins is fabricated from metal.
7. The fastening system of claim 1, wherein the structural member
is fabricated from concrete.
8. The fastening system of claim 1, wherein the plurality of
opposed margins and the structural member are fabricated from the
same material.
9. The fastening system of claim 1, wherein the plurality of
opposed margins is formed with the structural member.
10. The fastening system of claim 1, wherein the fastener further
comprises a rod received with the holding portion, the rod
extending out of the elongated opening.
11. The fastening system of claim 10, wherein the rod is threadably
received within the holding portion.
12. The fastening system of claim 10, further comprising a
compression member on the fastener, wherein the compression member
moves the plurality of elongated members to the extended
position.
13. The fastening system of claim 10, wherein the holding portion
further comprises a lip on each of the elongated members.
14. The fastening system of claim 1, wherein each of the plurality
of elongated members comprises a lip; and wherein when the
plurality of elongated members are in the extended position, the
lips of at least two of the plurality of elongated members position
the fastener with the elongated opening.
15. The fastening system of claim 14, wherein each of the plurality
of elongated members further comprises a knob and a profile formed
in the elongated member.
16. The fastening system of claim 15, wherein the profile of a
first elongated member of the plurality of elongated members is
configured to receive the knob of a second elongated member of the
plurality of elongated members for alignment of the first elongated
member with the second elongated member.
17. A structural member, comprising: a structural mass; a chamber
positioned with the structural mass, the chamber comprising an
elongated opening; and a plurality of opposed margins defining the
elongated opening to the chamber; wherein the elongated opening is
sized to receive a fastener into the chamber, wherein the fastener
comprises a holding portion comprising a plurality of elongated
members, wherein the plurality of elongated members are moveable
between an insertion position for insertion through the elongated
opening and an extended position for positioning with the plurality
of opposed margins; and wherein the plurality of opposed margins is
configured to allow the fastener to slide along the elongated
opening to a plurality of locations relative to the structural
member.
18. The structural member of claim 17, wherein the plurality of
opposed margins is anchored with the structural mass.
19. The structural member of claim 17, wherein the plurality of
opposed margins is substantially flush with a surface of the
structural mass.
20. A holding portion of a fastener, the holding portion
comprising: a plurality of elongated members, each elongated member
comprising: a recess configured to receive a portion of a nut; a
knob and a profile formed on a surface; a bearing surface; and a
lip adjacent the bearing surface; wherein the plurality of
elongated members is moveable between an insertion position and an
extended position; and wherein the recess restricts a rotation of
the nut when the elongated members are in the extended position;
and wherein when the plurality of elongated members is in the
extended position, the lips of at least two of the plurality of
elongated members position the holding portion for engagement of
the rectangular bearing surfaces with a structural member.
21. The holding portion of claim 20, wherein the bearing surface
comprises a rectangular bearing surface.
22. The holding portion of claim 20, further comprising: a
compression member positioned with the plurality of elongated
members, wherein the compression member resists movement from the
extended position to the insertion position.
23. The holding portion of claim 22, wherein the knob of a first
elongated member of the plurality of elongated members engages the
profile of a second elongated member of the plurality of elongated
members to resist translational motion of the first elongated
member relative to the second elongated member.
24. A method for making a structural member, the method comprising:
providing a form for shaping a structural material; positioning a
plurality of opposed margins in the form to define an elongated
opening; blocking the elongated opening; and providing the
structural material into the form.
25. The method of claim 24, wherein the structural material is
concrete.
26. The method of claim 24, further comprising: positioning a
plurality of reinforcing members in the form; wherein the step of
positioning the plurality of opposed margins comprises anchoring
the plurality of opposed margins to the reinforcing members.
27. The method of claim 24, wherein the step of positioning the
plurality of opposed margins comprises providing a channel; and
wherein the step of blocking the elongated opening comprises
covering the elongated opening of the channel with a cover.
28. The method of claim 27, further comprising covering an end of
the channel with a cap.
29. The method of claim 24, wherein blocking the elongated opening
comprises positioning a spacer between the plurality of opposed
margins.
30. A method for fastening an element to a structural member, the
method comprising: positioning a plurality of opposed margins with
the structural member, defining an elongated opening; positioning a
holding portion of a fastener and a portion of a rod of the
fastener in a chamber of the structural member, wherein the holding
portion comprises a plurality of elongated members in an extended
position; engaging at least one of the plurality of elongated
members of the holding portion with each of the plurality of
opposed margins; and supporting the element with the rod.
31. The method of claim 30, further comprising: reducing an
engagement force of the plurality of elongated members of the
holding portion with the opposed margins; sliding the fastener
along the elongated opening; and increasing the engagement force of
the plurality of elongated members of the holding portion with the
opposed margin.
32. A structure, comprising: a first structural member, comprising:
a first chamber, comprising: a first pair of opposed margins,
forming a first elongated opening; a second structural member,
comprising: a second chamber, comprising: a second pair of opposed
margins, forming a second elongated opening; a second fastener, the
second elongated opening sized to receive the second fastener; and
an element fastened by the first fastener to the first structural
member and fastened by the second fastener to the second structural
member; wherein the first fastener is positionable to a plurality
of locations relative to the first elongated opening; and wherein
the second fastener is positionable to a plurality of locations
relative to the second elongated opening.
33. The structure of claim 32, wherein the first structural member
is a ceiling member and the second structural member is a wall
member.
34. The structure of claim 32, wherein the first structural member
is a first wall member and the second structural member is a second
wall member.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of co-pending
U.S. application Ser. No. 10/696,332, filed Oct. 29, 2003, which is
a continuation-in-part of co-pending U.S. application Ser. No.
10/418,448, filed Apr. 17, 2003, each of which is incorporated by
reference herein for all purposes.
STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] The present invention relates generally to fastening systems
and structural members and, in particular, to fastening systems
including a blind fastener.
[0006] 2. Description of the Related Art
[0007] The general concept of fastening is the fixing or bringing
together of two distinct items or devices with a fastener. In the
positioning of an element with a structural member, such as a wall,
ceiling, floor, substrate or other supporting structure, one
particular type of fastener, generally known as a blind fastener,
allows positioning of the element without access to one side of the
structural member. The blind fastener accomplishes this fastening
by allowing a holding portion and a rod (e.g., a stud, bolt, or the
like) to be inserted through an aperture in the structural member,
and then resists removal of the holding portion through the
aperture. There have been fasteners known in the past that are
moved through an aperture in a structural member during insertion
and, thereafter, resist removal of the fastener.
[0008] One type of blind fastener is what is known as a toggle
bolt. The general concept of a toggle bolt is a bolt with a nut
having pivotally attached elongated members or wings. The wings of
the toggle bolt retract during passage through the aperture and,
thereafter, spring open or expand to resist removal of the bolt
back through the aperture. Examples of toggle bolts include U.S.
Pat. Nos. 2,024,871; 4,793,755; 4,997,327; 5,209,621; 5,224, 807;
and 6,203,260. Three characteristics of the toggle bolt are (1)
each wing's bearing line area or contact with the blind side of the
structural member, (2) the plurality of components for "spring"
pivoting action of each wing, and (3) the sizing of the aperture,
having an area larger than the cross-sectional area of the bolt, to
allow insertion of the wings in their retracted position.
[0009] Another type of blind fastener is what is known as a "molly
bolt," also known as a "hollow wall anchor." The general concept of
a molly bolt is a bolt connected to a body having a pair of
elongated members or wings and two housings. The housings are
initially spaced apart from one another with the ends of each wing
being in contact with one of the housings. During insertion of the
molly bolt, the wings are retracted towards the bolt. Then, after
insertion, as the housings are moved closer to each other, the
wings extend outwardly. The general operation of the molly bolt is
discussed in U.S. Pat. Nos. 3,888,156; 4,152,968; 4,307,598; and
5,509,765. While molly bolts need not have a spring to extend the
wings outwardly, two characteristics of the molly bolt design are
(1) precision insertion of the body to ensure proper deformation of
the wings for the desired structural support, and (2) precision
threading and deforming of the wings to, once again, allow the
desired structural support.
[0010] Other types of blind fasteners include those proposed in
U.S. Pat. No. 4,086,840, issued to Kurlander, and U.S. Pat. No.
5,944,466, issued to Rudnicki, et al., along with rivets. The '840
Kurlander patent proposes a fastener having a nut integral with an
elastomeric conical member adapted to deform or collapse radially
and longitudinally when compressed. Upon insertion of the fastener
through an aperture in a structural member, the elastomeric conical
collapses radially inwardly. After insertion, the bolt is threaded
with the integral nut and the elastomeric conical member collapses
in a longitudinal direction against the structural member.
[0011] The '466 Rudnicki patent, concerned with loading by an
anchoring assembly or holding portion of fastener on the structural
member, proposes that the radial distance between the points of
support provided by an anchoring assembly and the bolt are too
short for large loads. (Col. 1, lns. 45-58). The '466 Rudnicki
patent proposes a fastener assembly to extend the radial distance
between the points of support provided by the anchoring assembly
and the bolt as a solution to this loading concern. (Col. 4, lns.
16-26). The proposed fastener assembly includes a face plate, an
anchoring assembly, and a positioner. The face plate is positioned
on a surface of the structural member. The anchoring assembly
includes a base portion and a support structure. Upon insertion of
the anchoring assembly through an aperture in the structural
member, the support structure extends outwardly from the base
portion to three or more radially equidistant regions isolated from
the peripheral edge of the aperture in the structural member.
[0012] It would be desirable to provide a simple, yet effective,
repositionable fastening system that provides desirable flexibility
and structural support to fasten an element to a structural member.
Additionally, it would be desirable to provide a fastener that
optimizes the bearing area to distribute the loading by the holding
portion on the fastening system.
[0013] It would also be desirable to provide a fastener that could
use an off-the-shelf nut in combination with any desired length,
style and/or size of threaded rod with a holding portion of limited
components to reduce manufacturing and inventory costs.
SUMMARY OF THE INVENTION
[0014] According to one embodiment of the invention, a fastening
system adapted for use with a structural member having a chamber
with an elongated opening is provided. The fastening system
includes opposed margins attached with a structural member and a
fastener configured to be restrained by the opposed margins. The
fastener can be positioned in a variety of locations within the
chamber. The fastener can also be selectively repositioned in
various positions along the opening.
[0015] According to another embodiment of the invention, a
structural member adapted for use with a fastener is provided. The
structural member includes a mass of material having one or more
chambers, each having opposed margins. Each chamber includes an
elongated opening on a first side defined by the opposed margins.
The elongated opening is sized to receive fasteners configured to
be restrained by the opposed margins. The elongated opening accepts
repositioning of fasteners at several locations within the
chamber.
[0016] According to still another embodiment of the invention, a
holding portion of a fastener for fastening an element to a
structural member in a chamber with an elongated opening is
provided. The holding portion includes a plurality of elongated
members and a compression member positioned with the elongated
members. The elongated members are moveable between an insertion
position and a predetermined extended position, and each includes a
lip. The compression member resists a movement from the
predetermined extended position to the insertion position. The
elongated members move to the predetermined extended position upon
positioning the compression member about the plurality of elongated
members. When the plurality of elongated members are assembled with
the compression member, the holding portion includes a restriction
recess, configured to receive the nut and to restrict a rotation of
the nut with a wall substantially parallel to a side of the nut
when the holding portion is in the predetermined extended position.
When the elongated members are assembled with the compression
member, the holding portion also includes a throughway sized to
receive a rod, which is configured to engage the nut. When the
elongated members are assembled with the compression member in the
predetermined extended position, the lips of at least two elongated
members are received in the elongated opening.
[0017] According to yet another embodiment of the invention, a
method for making a structural member is provided. The method
includes providing a form and positioning opposed margins within
the form so that the opposed margins define an elongated opening. A
non-solid version of a structural material is provided into the
form after blocking the elongated opening.
[0018] According to still yet another embodiment of the invention,
a method for fastening an element to a structural member is
provided. This method includes positioning opposed margins with the
structural member to provide an elongated opening and positioning a
holding portion of a fastener and a portion of a rod of a fastener
in a chamber of the structural member. The fastener includes a
plurality of elongated members. This method further includes
engaging at least one of the elongated members with each margin.
This method also includes supporting the element with the rod
extending from the structural member when the elongated members are
in the extended position.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] A better understanding of the present invention can be
obtained when the following detailed description of the disclosed
embodiments is considered in conjunction with the following
drawings, in which:
[0020] FIG. 1 is one embodiment of an internally threaded holding
portion of a fastener usable with various embodiments of the
present invention, shown in a perspective view;
[0021] FIG. 2 is a cross-sectional elevational view of the holding
portion of the fastener taken across line 2-2 of FIG. 1;
[0022] FIG. 3 is an end view of the embodiment of the holding
portion of the fastener shown in FIG. 1;
[0023] FIG. 4 is an illustration of the embodiment of the holding
portion of the fastener, shown in FIG. 1, in the insertion position
while being inserted through an aperture in a structural member
using a threaded rod;
[0024] FIG. 5 is an illustration of the embodiment of the holding
portion of the fastener, similar to FIG. 4, in the extended
position after insertion through the aperture;
[0025] FIG. 6 is an illustration of the embodiment of the extended
holding portion of the fastener, similar to FIG. 5, in the engaged
or bearing position to position the element, shown in the phantom
view, using a washer and nut threadably received on the threaded
rod;
[0026] FIG. 7 is another embodiment of an internally threaded
holding portion of a fastener, shown in a cross-sectional elevation
view;
[0027] FIG. 8 is an end view of the embodiment of the holding
portion of the fastener shown in FIG. 7;
[0028] FIG. 9 is an illustration of the embodiment of the holding
portion of the fastener of FIG. 7, after insertion through an
aperture in a structural member, using a threaded bolt along with a
tapered sleeve and a spacer of predetermined length to move the
holding portion to the extended position upon tightening the bolt
head of the bolt with the holding portion;
[0029] FIG. 10 is an illustration of the embodiment of the holding
portion of the fastener, similar to FIG. 9, in the extended
position and engaged or bearing position after the holding portion
is threaded upon the bolt;
[0030] FIG. 11 is yet another embodiment of the holding portion of
a fastener in a predetermined extended position, shown in a
cross-sectional view with a part of the holding portion shown in
phantom view, and the bolt shown in elevational view;
[0031] FIG. 12 is an illustration of the embodiment shown in FIG.
11, with the holding portion shown in the insertion position while
being inserted through an aperture in a structural member;
[0032] FIG. 13 is an illustration of the embodiment shown in FIG.
11, with the holding portion shown in the predetermined extended
and engaged or bearing position and element shown in phantom
view;
[0033] FIG. 14 is an end view of the embodiment of the fastener
taken along line 14-14 of FIG. 13 with the holding portion shown in
solid lines when in the predetermined extended position and shown
in phantom view when in the insertion position;
[0034] FIG. 15 is an embodiment of the holding portion of a
fastener usable with various embodiments of the invention, shown in
a cross-sectional view, having a recess to receive a nut and with
the holding portion shown in a predetermined extended position;
[0035] FIG. 16 is an embodiment of the fastener taken along line
16-16 of FIG. 15;
[0036] FIG. 17 is an embodiment of the fastener taken along line
17-17 of FIG. 15;
[0037] FIG. 18 is an embodiment of the holding portion of the
fastener, as shown in FIG. 15, in the insertion position while
being inserted through an aperture in a structural member using a
threaded bolt;
[0038] FIG. 19 is an embodiment of the holding portion of the
fastener, as shown in FIG. 15, in the predetermined extended
position and in the engaged or bearing position after the holding
portion is threaded with the bolt;
[0039] FIG. 20 shows some exemplary threaded rods for use with the
present invention;
[0040] FIG. 21 is an elevational view of the holding portion of the
fastener of FIG. 15 in the insertion position, similar to FIG. 18,
to better illustrate the compression member positioned with the
housing of the holding portion;
[0041] FIG. 22 is an elevational view of the holding portion of the
fastener of FIG. 15 with the holding portion in the predetermined
extended position;
[0042] FIG. 23 is a view of the holding portion taken along line
23-23 of FIG. 22;
[0043] FIG. 24A is a cross-sectional view of one embodiment of a
channel anchored in a mass of structural material to form a chamber
with a layer of material overlying the channel at the opening;
[0044] FIG. 24B is a cross-sectional view of another embodiment of
a channel in a mass of structural material;
[0045] FIG. 24C is a view of an embodiment of a fastener usable
with various embodiments of the invention, shown in a
cross-sectional view in the channel of FIG. 24A, with the holding
portion in a predetermined extended position inside the chamber and
an element shown in phantom view;
[0046] FIG. 25 is a view of the channel and the holding portion
taken along line 25-25 of FIG. 24C;
[0047] FIG. 26 is a cross-sectional view of the holding portion
taken along line 26-26 of FIG. 24C;
[0048] FIG. 27 is a cross-sectional view of the holding portion
taken along line 27-27 of FIG. 24C;
[0049] FIG. 28 is an elevational view of the fastener of FIG. 24C
in the extended position;
[0050] FIG. 29 is an elevational view of the fastener of FIG. 24C
in the insertion position entering the opposed margins, shown in
phantom view;
[0051] FIG. 30 is a cutaway view taken along line 30-30 of FIG.
29;
[0052] FIG. 31 is an elevational view of a wall and a door, with a
cutaway view of a stairwell showing various channels each with one
or more fasteners;
[0053] FIG. 32 is an elevational view of a wall, a floor, and an
upright support showing various channels, each with one or more
fasteners;
[0054] FIG. 33 is an elevational view of a ceiling with hanging
equipment or elements and a wall and a wall-to-wall connection
showing various channels and configurations, including a ceiling
channel connected to reinforcing elements, each channel having one
or more fasteners;
[0055] FIG. 34 is a cross-sectional view of the wall-to-wall
connection, taken along line 34-34 of FIG. 33; and
[0056] FIG. 35 is a top view of a form for making a structural
member according to embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0057] FIGS. 1 through 6, generally show a first embodiment of the
invention. In FIG. 1, a holding portion 20 includes a housing 30
and a plurality of elongated members or wings 40. In this
embodiment, each of the four equidistance elongated members 40 is
bent radially outwardly into an extended position. A resilience in
the material of the elongated members 40 tends to keep elongated
members 40 in this extended position--for example, resisting a
radial inwardly compression. Material for the elongated members 40
can include, but is not limited to, various forms of metal (e.g.,
aluminum), plastics, and the like. At the end of each plurality of
elongated members 40 are end areas 48, which together make up an
end surface area 44. The end surface area 44 is arranged and
configured to serve as a bearing surface, which will be described
in detail with reference to FIG. 6 below.
[0058] Turning now to FIG. 2, the housing 30 of the holding portion
20 includes an outside diameter 34, an inside diameter 36, and a
length of engagement 32. The length of engagement 32 in this
embodiment is the length of the housing 30 that is adapted for
engaging or coupling with a rod 50 (shown in FIG. 4). As can be
seen in FIG. 2, the housing 30 is internally threaded with
internally threaded roots 33 and internally threaded crests 35. As
such, the engagement with the rod 50 in this embodiment will be a
threaded coupling. While housing 30 is internally threaded in this
embodiment, it is contemplated that housing 30 in other embodiments
may be adapted to couple with the rod 50 in other manners, for
example, via fixed attachments, clamped attachment, rivets and the
like. As should become apparent to one of ordinary skill in the
art, the length of engagement 32 can be a variety of different
lengths depending on factors including, but not limited to, the
material used in the housing 30, the material used in the rod 50,
the coupling technique, and intended load to be supported by the
holding portion 20. The length of engagement 32 is preferably
greater than one-third of a length of a perimeter of the
cross-sectional area of the rod 50. In this embodiment, the
perimeter is the diameter of the rod 50 multiplied by the geometric
constant, pi (roughly 3.14). Therefore, the length of engagement 32
in this embodiment is preferably equal to or greater than the
diameter of the rod 50 (greater than one-third of a length of a
perimeter of the cross-sectional area of the rod 50). As will
become apparent to one of ordinary skill in the art, the length of
the perimeter of the cross-sectional area can change with different
shapes for the cross-sectional area of the rod 50--for example,
ovals, triangles, squares, rectangles, and the like. It is to be
expressly understood that the length of engagement 32 in other
embodiments can be less than one-third of a length of a perimeter
of the cross-sectional area of the rod 50. In such embodiments, the
coupling technique and material used in the holding portion 20
and/or rod 50 can define the length. Further discussion of the
length of engagement 32 follows below with reference to FIG. 6.
[0059] In the embodiment of FIGS. 1-6, the outside diameter 34
defines a cross-sectional area for housing 30, while the inside
diameter 36 defines a cross-sectional area corresponding to the rod
50. As both the rod 50 (shown in FIG. 4) and housing 30 are
threaded in this embodiment, the inside diameter 36 corresponds to
the "major diameter" of the internally threaded portion of the
housing 30 (e.g., root to root in the internally threaded housing
30 or crest to crest in the externally threaded rod 50).
[0060] Moving to FIG. 3, as referenced above, the inside diameter
36 of the holding portion 20 in this embodiment corresponds to the
internally threaded root to root of the internally threaded portion
of the housing 30. A minor diameter 38 is seen extending from crest
to crest of the internally threaded crest 35 of the housing 30.
[0061] With general reference to FIGS. 2 and 3, the circular area
defined by the outside diameter 34 in this embodiment is
substantially equivalent to the inside diameter 36 plus the end
areas 48 of the elongated members 40. In other words, as best shown
in FIG. 1, the end surface area 44 (total of end areas 48) in this
embodiment is substantially an annulus area between the circular
area defined by the outside diameter 34 and the inside diameter
36--each of the end areas 48 shaped as an annular arc. While the
annular arcs of the shaped end areas 48 in this embodiment are
shown with small gaps between them, it is contemplated that in
other embodiments even smaller gaps will exist.
[0062] With reference to FIGS. 2-4, an illustration of the
differences in cross-sectional areas is shown. When the aperture 65
in the structural member 60 is sized a cross-sectional area the
same size as the housing 30 (just allowing the housing 30 to pass
through the aperture 65), the end surface area 44 of the end areas
48 of the elongated members 40 will be substantially the same area
as the difference between the cross-sectional area of the aperture
65 and the cross-sectional area of the rod 50 (shown in FIG. 4).
With this configuration, a maximum end surface area 44 can be
extended through the aperture 65 (FIG. 4), allowing a reduced
bearing force per surface area--for example, a larger area to
distribute a load. Note that the aperture 65 can be a portion of a
larger opening, as discussed below with respect to FIGS. 24A-35, so
any reference to the aperture 65 also refers to the elongated
opening 401.
[0063] While the end surface area 44 described in the above
embodiment is the difference between the area defined by the
outside diameter 34 and the area defined by the inside diameter 36,
it is contemplated that in more complex embodiments the end surface
area 44 of end areas 48 of the plurality of elongated members 40
can exceed the area defined by the outside diameter 34 of the
housing 30. For example, the holding portion 20 could be a frustum
of a cone with a cylindrical bore extending the longitudinal
distance of the holding portion 20--for example, corresponding to
the diameter of the rod 50. In such an embodiment, the outside
diameter 34 could start at the apex of the frustum of the cone and
enlarge towards the base. The end surface area 44 of the end areas
48 of the elongated members 40 can be the difference between the
area defined by the diameter of the base of the frustum of the cone
and the internal diameter of the cylindrical bore extending to the
base. With this "frustum of a cone" embodiment, the end surface
area 44, similar to that described with reference to the above
embodiment, can be the difference between the cross-sectional area
of the aperture 65 and the cross-sectional area of the rod 50.
[0064] With reference to FIG. 4, the holding portion 20 is shown in
an insertion position, being pushed through the aperture 65 in the
structural member 60. The rod 50 is shown threaded to the housing
30 along a length of engagement 32 of the housing 30 of the holding
portion 20. The rod 50, while shown in this embodiment as a
threaded stud, in other embodiments can include a bolt, a smooth
stud, a rivet and the like. And, with each of the different types
of rods 50 used, the holding portion 20 can be adapted for an
appropriate coupling.
[0065] The insertion of the holding portion 20 through the aperture
65 of the structural member 60 will radially urge or compress the
plurality of elongated members 40 inwardly, against the
above-referenced resilience to stay in an outwardly extended
position-such that the elongated members 40 almost lay flush with
the rod 50. Once again, as discussed above, in this embodiment the
cross-sectional area of the inside diameter 36 of the housing 30
and the end surface area 44 of the plurality of elongated members
40 together are substantially the same as the cross-sectional area,
defined by the outside diameter 34 of the housing 30. With this
configuration, the bearing area of the end surface area 44 of the
end areas 48 of the plurality of elongated members 40 can be
substantially the difference between a cross-sectional area of the
aperture 65 and the rod 50, where the cross-sectional area defined
by the outside diameter 34 is the same as the cross-sectional area
of the aperture 65--just allowing the holding portion 20 to pass
therethrough.
[0066] It should be expressly understood that while the holding
portion 20 has been shown with a circular cross-sectional area in
this embodiment, in other embodiments the cross-sectional area can
take on different shapes e.g., squares, rectangles, triangles,
etc., which can ultimately depend on the rod 50 being used and the
aperture 65 through which the holding portion 20 will be
inserted.
[0067] FIG. 5 shows the holding portion 20 moving back to a memory
position after insertion through the aperture 65. The memory
position in this embodiment is the extended position caused by the
resilience in the material of the holding portion 20 tending to
urge the plurality of elongated members 40 into the extended
position.
[0068] FIG. 6 shows the holding portion 20 in a bearing position
with the surface area 62 of the structural member 60. In bringing
the holding portion 20 into contact with the blind surface area 62
from the position shown in FIG. 5, in this embodiment, the
elongated members 40 and housing 30 can maintain a positional
relationship with the rod 50--that is, the rod 50 need not be
further threaded through the housing 30 of the holding portion 20.
Rather, the holding portion 20 coupled to the rod 50 can be brought
into the bearing position by pulling the rod 50 until the end
surface area 44 of the end areas 48 of the elongated members 40
contacts the blind surface area 62 of the structural member 60. An
element 70 can be mounted to the rod 50; and, then by maintaining
tension of the rod 50, a washer 80 and nut 90 can be threaded on
the rod 50 to bring the element 70 into contact with an exposed
surface area 64 of the structural member 60. The friction force of
the end surface area 44 of the end areas 48 with the blind surface
area 62 prevents rotation of the holding portion 20. With this
maintenance of positional relationship, no further access is needed
on the blind side of the structural member 60. For example, the rod
50 in this embodiment need not be further threaded through the
housing 30 to bring the holding portion 20 into a bearing position
with the blind surface area 62. Additionally, the rod 50 in this
embodiment need not be further threaded through the housing 30 to
bring the element 70 into contact with the exposed surface area 64
of the structural member 60. As such, the holding portion 20 in
this embodiment is particularly helpful when limited access or
space is available on the blind side of the structural member 60.
While this positional relationship has been described with
reference to this embodiment, it is to be expressly understood that
further threading through the housing 30 of the holding portion 20
can occur, if desired, as will be described with reference to other
embodiments below.
[0069] The holding portion 20 through many of the features
described herein is configured to resist removal of the rod 50. In
this resistance of the removal of the rod 50, forces are
transmitted from the rod 50 through the length of engagement 32 to
the elongated members 40, forcing the elongated members 40 into a
bearing position with a blind surface area 62 of the structural
member 60. Thus, in the structural design of the holding portion
20, consideration is given to the following: (1) the length of
engagement 32 in coupling the rod 50 to the housing 30 to withstand
a loss of such coupling, (2) the elongated members 40 to withstand
buckling, and (3) the bearing surface area between the end surface
area 44 of the end areas 48 and the blind surface area 62 to
withstand crushing (e.g., a point load failure from too much force
per unit area) of the structural member 60. In the embodiment
described herein, the length of engagement 32 is threaded at a
length for a predetermined design load. As such, a specified number
of threads and/or specified length of engagement 32 should be used
to ensure that the housing 30 does not disengage with the rod 50
when a pull force is applied to the rod 50. For example, with
reference to the embodiment of FIGS. 1-6, stripping (a
disengagement) can occur either in the internal threads of the
housing 30 or in the external threads of the rod 50. As such, the
length of engagement 32 in this embodiment has a length large
enough to resist this stripping. Preferably, as referenced above,
the length of engagement 32 in the embodiment of FIGS. 1-6 is
greater than the diameter of the rod 50. As will become apparent to
one of ordinary skill in the art, the length of engagement 32 can
increase to account for a difference of materials between the
housing 30 and the rod 50. For example, one of the threaded
portions (either the housing 30 or the rod 50) could have a
material such as plastic while the other threaded portion (either
the housing 30 or the rod 50) could have a material such as steel,
the plastic generally deforming at a lower load than the steel. The
increase in the length of engagement 32 distributes a design load
along the length of engagement 32 resisting the stripping of either
the internal threads for the housing 30 or the external threads for
the rod 50--regardless of whether the weaker material (the one
which deforms first) is in the housing 30 or the rod 50.
[0070] To resist buckling in the elongated members 40, several
buckling factors should be considered, including the length of the
elongated members 40. Generally, for a given material, as the
length in the elongated members 40 increase, so should the
cross-sectional area of that elongated member 40 to adequately
prevent buckling. Additionally, in the embodiment of FIGS. 1-6, a
curvature in the elongated members 40 helps resist buckling. As can
be seen in the embodiment of FIGS. 1-6, each of the elongated
members 40 has a curvature that is arced. The structural benefits
of such an arced configuration in resistance to buckling should
become apparent to one of ordinary skill in the art. For example,
by illustration, a piece of paper on a desk sat on its end can
resist more compressive strength by being curved into an arc rather
than by simply being set planarly straight up. While an arced
curvature is shown in the embodiment of FIGS. 1-6 as a preferred
curvature, it is contemplated that other forms of curvature can be
used--for example, different angles of bending including bending at
right angles and corrugated designs.
[0071] To resist a crushing of the structural member 60, the end
surface area 44 of the end areas 48 of the elongated members 40 is
maximized (while not sacrificing simplicity of design) to
distribute the load over the blind surface area 62 of the
structural member 60. Preferably, this end surface area 44 will be
the difference between a cross-sectional area of the aperture 65
and the cross-area of the rod 50 to be inserted in the aperture 65.
In the bearing contact of the end surface area 44 of the end areas
48 of the elongated members 40, this embodiment will always have at
least three of the end areas 48 of the elongated members 40 in
contact with the blind surface area 62. Additionally, it is
contemplated that end areas 48 can be angled, similar to the end
areas 48B, described in detail below with reference to FIGS. 11-14
below.
[0072] As an illustrative use of the embodiment described with
reference to FIGS. 1-6, a rod 50 is inserted through an aperture 65
in a structural member 60 to fasten an element 70 to the structural
member 60. The rod 50 can be any of the commercially available rods
50 described, including, but not limited to, bolts, threaded studs,
smooth studs, rivets and the like. The structural member 60 can be
any number of structures--for example, a wall, a ceiling, a floor,
a door, a circuit board, plastic pieces, boards, substrates, etc.
Likewise, the element 70 can be any number of items, including
another structural member 60. Generally, the structural member 60
and element 70 are two distinct "things," which are desired to be
coupled to one another-preferably as shown in several embodiments
of the invention, the element 70 being coupled or fastened to the
structural member 60. The desired configuration and size of the rod
50 and holding portion 20 can be defined by the intended use. In
this embodiment, the rod 50 is initially coupled to the housing 30
(the coupling contact being at the length of engagement 32) of the
holding portion 20. The coupling of the rod 50 to the housing 30
can take on one of many coupling techniques, generally described
herein, which should be apparent to one of ordinary skill in the
art. The coupling technique in the embodiment of FIGS. 1-6 is a
threaded coupling. At rest, the elongated members 40 are urged
outwardly in an extended position by the resilience in the
material. After coupling the rod 50 to the holding portion 20, the
rod 50 and holding portion 20 are inserted into the aperture 65,
whereupon the aperture 65 radially compresses the outwardly urged
elongated members 40 inwardly into an insertion position. After
insertion through the aperture 65, the elongated members 40 return
to their memory position-their outwardly urged extended position.
An element 70 can then be received on the end of the rod 50
adjacent to an exposed surface area 64 of the structural member 60,
whereupon the rod 50 is pulled partially back through the aperture
65 allowing the end surface area 44 of the end areas 48 to come
into a bearing position with the blind surface area 62 of the
structural member 60. The friction force between the end surface
area 44 of the end areas 48 and the blind surface area 62 of the
structural member 60 resists rotation of the holding portion 20.
Therefore, the rod 50 maintains a positional relationship with the
holding portion 20. A washer 80 and nut 90 are then threaded on the
rod 50 engaging the element 70 with the exposed surface area 64 of
the structural member 60. The holding portion 20 resists removal of
the rod 50 through a length of engagement 32 in the housing 30 of
the holding portion to the elongated members 40, which distribute
their load over the end surface area 44 of the end areas 48 on the
blind surface area 62--reducing the bearing force per area on the
blind surface area 62 of the structural member 60.
[0073] In the embodiment of FIGS. 7-10, the holding portion 20A
includes an annular notch 100, which helps define movement of the
four equidistant elongated members 40A between an insertion
position and an extended position. As can be seen in FIG. 7, the at
rest position of the elongated members 40 is an insertion
position.
[0074] With reference to FIGS. 7 and 8, at the end of each of the
elongated members 40A is a tapered interior end 110 which, as will
be described below, facilitates the urging of the elongated members
40 to an extended position.
[0075] Turning now to FIG. 9, the holding portion 20A, coupled to a
rod 50A, is in an insertion position after being pushed through the
aperture 65 of the structural member 60. In this embodiment, the
rod 50A is shown as a bolt with a bolt head 52A. Thus, to urge the
elongated members 40A to an extended position (as seen in FIG. 10),
a tapered sleeve 120 and, if needed, a spacer 130 can be inserted
after the insertion of the holding portion 20A. The tapered sleeve
120 can take on a variety of shapes, depending on the configuration
and design of the elongated members 40A. For example, in the
illustrated embodiment, the tapered sleeve 120 has a circular
cross-sectional area. To facilitate the alignment of this tapered
sleeve 120, each of the elongated members 40A, as referenced above,
includes a tapered interior end 110, which is adapted to receive
the tapered sleeve 120. In addition to urging the elongated members
40A into an extended position, the tapered sleeve 120 centers the
rod 50A within the aperture 65. In some embodiments, the thickness
of the structural member 60 may not be known. As such, the spacer
130 can be inserted after the tapered sleeve 120, facilitating the
tapered sleeve 120 in urging the elongated members 40A to their
extended position and centering the rod 50A in the aperture 65. The
spacer, similar to the tapered sleeve 120, can take on a variety of
shapes. Preferably, the spacer 130 has a circular cross-sectional
area with at least one opening to allow the spacer 130 to be placed
over and around the rod 50A.
[0076] FIG. 10 shows the holding portion 20A in an extended
position and a bearing position with the blind surface area 62 of
the structural member 60. This bearing contact of the end surface
area 44A of the end areas 48A with a blind surface area 62 of the
structural member 60 is similar to that described with reference to
FIG. 6. It is contemplated that spacer(s) 130 of a plurality of
lengths would be provided for use with the holding portion 20A.
[0077] As an illustrative use of the embodiment described with
reference to FIGS. 7-10, a rod 50A is inserted through the aperture
65 in a structural member 60 to fasten an element 70 to the
structural member 60. Similar to the illustrative use, described
with reference to FIGS. 1-6 above, the element 70 and structural
member 60 can be any number of "things." In this embodiment, the
rod 50A (such as a bolt) can be inserted through the washer 80, the
element 70, the tapered sleeve 120, and, if needed, spacer(s) 130.
Then, the rod 50A can be threaded along the length of engagement
32A of the housing 30A of the holding portion 20A, whereupon the
holding portion 20A and a portion of the rod 50A are inserted
through the aperture 65 in the structural member 60. The tapered
sleeve 120, and, if needed, spacer(s) 130, can then be moved down
the rod 50A and further into the aperture 65, centering the rod 50A
and urging the elongated members 40A to an extended position. As
discussed, if needed, one or more spacers 130 can be inserted after
the tapered sleeve 120 by inserting the spacer 130 over and around
the rod 50A in contact with the tapered sleeve 120. The rod 50A can
then be partially be pulled back through the aperture 65 bringing
the end surface area 44A of the elongated members 40A into the
bearing position with the blind surface area 62 of the structural
member 60. Friction forces of the end surface area 44A of the end
areas 48A with the blind surface area 62 and friction forces with
the tapered sleeve 120 helps resist rotation of the holding portion
20A. To bring the element 70 into contact with an exposed surface
area 64 of the structural member 60, the rod 50A can be further
rotated through the housing 30A of the holding portion 20A. To
increase resistance between the holding portion 20A and the rod
50A, tension can be maintained on the rod 50A while threading to
increase the friction force between end surface area 44A of the end
areas 48A and the blind surface area 62 of the structural member
60. Additionally, the tapered sleeve 120 can be designed of a high
friction material, such that friction is created both between the
tapered sleeve 120 and the aperture 65 and the tapered sleeve 120
and the elongated members 40A. As will now be apparent to one of
ordinary skill in the art, the threaded rod 50 of FIGS. 1-6 can be
interchanged with the bolt described with reference to FIGS.
7-10.
[0078] With reference to FIGS. 11-14, another embodiment of the
invention is shown. In this embodiment, as generally shown in FIGS.
11 and 12, a rod 50B has a holding portion 20B slidingly coupled
thereto. The rod 50B in this embodiment has a shoulder 170, a
reduced diameter neck 150, and a head 140. The holding portion 20B
in this embodiment includes two elongated members 40B, a
compression member 200, and a housing 30B, which moves slidingly
with respect to the neck 150 of the rod 50B. The two elongated
members 40B are semicircular halves, which will be described in
more detail with reference to FIG. 14 below. The housing 30B
includes a first shoulder 160 and a second shoulder 180. The
compression member 200 is positioned and designed to create a
radially compressive force on an end of the holding portion 20B,
adjacent to the second shoulder 180. When the holding portion 20B
is in a predetermined extended position, as shown in FIG. 11, the
two elongated members 40 are moved outwardly to the predetermined
extended position until the housing surface or shoulders 41 engage
the neck 150 and the housing 30B slides towards the head 140 with
the second shoulder 180 preferably mating flush therewith. Upon
insertion of holding portion 20B and rod SOB into an aperture 65,
the two elongated members 40B are compressed radially inwardly into
an insertion position, expanding the compression member 200. The
housing 30B slides towards the shoulder 170 of the rod 50B, with
the first shoulder 160 preferably mating flush therewith.
[0079] With reference to FIGS. 11-14, the ends of each of the
elongated members 40B include lips 190, which have been configured
to center the holding portion 20B (and hence, the rod 50B) in a
central location within the aperture 65. The lips 190 in this
embodiment contact an annular surface area 67 (best seen in FIG.
13) of the aperture 65. In FIG. 14, the lips 190 are shown
contacting the annular surface area 67 (shown in phantom) at an
upper and lower part of the annular surface area 67. To help ensure
that the lips 190 comes in contact with the annular surface area
67, a tension wire 210 can be utilized. The tension wire 210 in
this embodiment is put through a loop (best seen in FIGS. 12 and
14) inside a wrench flat 220 at the end of the rod 50. The loop in
the wrench flat 220 is preferably smaller than the diameter of the
rod 50B; and, when the rod 50 is threaded as shown, preferably
smaller than a minor diameter 38 (for example, seen in FIG. 3). As
seen in FIG. 12, as the rod 50B and holding portion 20B are
inserted through the aperture 65 in the direction, indicated by
arrow 500, the tension wire 210 is pulled to ensure that the
elongated members 40B are not inadvertently pushed through the
aperture 65. As soon as tips 46B of the elongated members 40B clear
the annular surface area 67 of the aperture 65, the compression
member 200 automatically urges the lips 190 for contact with the
annular surface area 67 of the aperture 65.
[0080] With reference to FIGS. 12 and 14, the end areas 48B of the
two elongated members 40B can be seen. In FIG. 14, the end areas
48B extend just beyond the circumference 69 (shown in phantom) of
the cross-sectional area of the aperture 65. The end areas 48B in
this embodiment have an angled configuration which allows full
bearing contact with the blind surface area 62.
[0081] Turning once again to FIG. 13, the tension wire 210 can
provide the force necessary to establish friction force between the
end areas 48B and blind surface area 62 of the structural member
60--thus, allowing the nut 90 to be threaded on the rod 50B, while
the holding portion 20B maintains its positional relationship with
the bolt or rod 50B. As an additional aid, a wrench (not shown) can
be clamped on to the wrench flats 220 helping to maintain the
positional relationship of the holding portion 20B with the bolt or
rod 50B by preventing rotation of the rod 50B.
[0082] As an illustrative example of the use of the embodiment
described with reference to FIGS. 11-14, a rod 50B having a housing
30B, coupled thereto is inserted into the aperture 65, whereupon
the elongated members 40B are compressed radially inward into an
insertion position. Upon clearance of tips 46B of the elongated
members 40B of the annular surface area 67 of the aperture 65, the
compression member 200 urges the lips 190 into contact with the
annular surface area 67 of the aperture 65. Then, an element 70 can
be received on the rod 50B, whereupon a force is applied on the
tension wire 210 bringing the end areas 48B into a bearing position
for full bearing contact. While maintaining tension on the tension
wire 210 (to increase the friction force between the end areas 48B
and the blind surface area 62), a washer 80 and nut 90 are inserted
on the rod 50B to threadably mate the element 70 into contact with
an exposed surface area 64 of the structural member 60.
Additionally, a wrench (not shown) can be clamped on to the wrench
flats 220 helping to maintain the positional relationship of the
holding portion 20B with the bolt or rod 50B. The holding portion
20B resists removal of the rod 50B through the head 140, first
shoulder 180, and elongated members 40B, which have a full
distributed load over the end areas 48B on blind surface area
62--reducing the bearing force per area of the blind surface area
62 of the structural member 60.
[0083] With reference to FIGS. 15-23, another embodiment of the
invention is shown. In this embodiment, as generally shown in FIG.
15, a rod 50C has a nut 300 threadably coupled thereto within a
holding portion, generally indicated 20C. The holding portion 20C
in this embodiment includes elongated members 40C, a compression
member 200, and a housing 30C. The nut 300 is positioned within
interior formed recess 310 in the housing 30C. The two elongated
members 40C in this embodiment are each generally semicircular. The
housing 30C forms the exterior of the recess 310. The compression
member 200, positioned in an annular groove 316 (best seen in FIG.
21), is designed to create a radially compressive force on the end
of the holding portion 20C, adjacent to the housing 30C. The
housing 30C and elongated members 40C will preferably be integral
and made from zinc, aluminum, brass, steel, or stainless steel. The
compression member 200 will preferably be continuous and made from
neoprene, steel, or spring wire. As will be explained in detail
below, when the holding portion 20C is in the extended position, as
shown in FIG. 15, or in the insertion position, as shown in FIG.
18, the recess 310 resists rotation of the nut 300. The angle of
the extension of the elongated members 40C is preferably
predetermined. As way of an example, in FIG. 15, the predetermined
angle of the elongated members 40C in the extended position is
approximately 30.degree.. In FIG. 18, the predetermined angle of
the elongated members 40C in the insertion position is
approximately 4.degree. or less. Those skilled in the art will
appreciate that the actual angles of the predetermined extended
position and the insertion position of the elongated members may be
any desired angles where the predetermined angle in the insertion
position is less than the predetermined angle in the extended
position.
[0084] With reference to FIGS. 15-19, the end of each of the
elongated members 40C includes lips 190, which have been configured
to center the holding portion 20C with the aperture 65. One or more
of the lips 190 in this embodiment can come in contact with an
annular surface area 67 (best seen in FIG. 19) of the aperture 65.
In FIG. 19, while the lips 190 are shown contacting the annular
surface area 67 at an upper and lower part of the annular surface
area 67, it may be that only one lip is in contact with the surface
area 67. As shown in FIG. 18, the rod 50C and holding portion 20C
are inserted through the aperture 65 in the direction indicated by
arrow 600. As soon as tips 46C of the elongated members 40C clear
the annular surface area 67 of the aperture 65, the compression
member 200 urges the lips 190 to the predetermined extended
position. Those skilled in the art will appreciate that because of
housing shoulders 314, as best seen in FIGS. 15, 17, 18, 21, 22 and
23, the lips 190 can be opened to a predetermined extended position
where the lips 190 are less than the cross-sectional area of the
holding portion 20C in the insertion position. This approximate
cross sectional area of the holding portion 20C in the insertion
position is shown in FIG. 16. In other words, because the annular
surface area 67 of the aperture 65 will be greater than the
cross-sectional area of the elongated members 40C in the insertion
position, the holding portion 20C allows the lips 190 to be
received in the aperture 65 from either side of the structural
member 60.
[0085] Turning to FIGS. 15, 16, and 18, the holding portion 20C
includes interior recess 310 having a plurality of angles and sides
to correspond to the plurality of angles and sides of the nut 300.
As FIGS. 15, 16, and 18 indicate, the nut 300 is blocked from
rotation by the interior surface defining the recess 310 in the
housing 30C. As best shown in FIG. 15, the holding portion 20C
threadably engages with a rod 50C via the length of engagement 32
of the nut 300 within the recess 310. Those skilled in the art will
now appreciate that the housing 30C resists rotation of the nut 300
because of the blocking shoulders 312 in the recess 310 relative to
the nut 300.
[0086] Turning to FIG. 17, showing the cross-sectional view of the
holding portion 20C in the predetermined extended position, similar
to FIGS. 15, 19, 22 and 23, the end areas 48C of the elongated
members 40C can be seen. As discussed above, in the predetermined
extended position, the position of the lips 190 are less than the
cross-sectional area of the holding portion 20C in the insertion
position. As best shown in FIG. 19, the end areas 48C extend beyond
the circumference 69 of the cross-sectional area of the aperture
65. As also best seen in FIG. 19, the end areas 48C in this
embodiment have an angled configuration which allows alignment for
full bearing contact with the blind surface area 62 of the
structural member 60.
[0087] With reference to FIG. 18, an element 70 can be mounted to
the rod 50C. The rod 50C, having a nut 300 threadably coupled
thereto along the length of engagement 32 of the nut 300 within a
holding portion 20C, is inserted along direction of arrow 600 into
aperture 65, whereupon the elongated members 40C are compressed
radially inward into an insertion position. Upon clearance of tips
46C of the elongated members 40C of the annular surface area 67 of
the aperture 65, the compression member 200 urges the lips 190
outwardly to the predetermined extended position. The rod 50C is
further threaded to the nut 300, whereupon a tension force is
applied by the rod 50C, bringing the end areas 48C into a contact
and bearing position for bearing contact with surface area 62.
This, in turn, brings the element 70 into contact with exposed
surface area 64 of the structural member 60.
[0088] The holding portion 20C of this embodiment of the invention
(best seen in FIGS. 15-23) has many advantages. First of all, those
skilled in the art will appreciate that each of the plurality of
elongated members 40C could be identical. Thus, savings in
manufacturing and inventory costs can be anticipated as a result of
being able to use only one form (or mold), or other way of forming,
for the integral housing 30C and elongated members 40C for the
holding portion 20C. Additionally, because of the unique
configuration of the holding portion 20C of this embodiment, an
off-the-shelf nut 300 could be assembled with the properly sized
recess 310 of the holding portion 20C. This again results in
reduction of manufacturing and inventory costs as the nut 300 can
be purchased in quantities when needed for assembly with the
holding portion 20C.
[0089] FIG. 20 is an illustration of some exemplary threaded rods
for use with an embodiment of the invention. Those skilled in the
art will appreciate that, with this embodiment, any type of
threaded rod can be used. FIG. 20 indicates some typical threaded
rods that may be advantageously used with this embodiment,
including a flat head bolt 50D, an allen head bolt 50E, a half
round head bolt 50F, a counter sunk head bolt 50G, a phillips head
bolt 50H, a longer phillips head bolt 501, and a threaded stud 50J
with nut 400. Of course, the nut 400 could be identical to nut 300.
This again will result in savings in manufacturing and inventory
costs. Additionally, those skilled in the art will now appreciate
that the holding portion 20C allows the nut 400 to be threaded on
the stud 50J, while the holding portion 20C maintains its
positional relationship with the stud 50J and the structured member
60.
[0090] FIGS. 21-23 provide side and front views of housing
shoulders 314 used to limit the extension of the lips 190 to a
position less than the cross-sectional area of the holding portion
20C in the insertion position. Further, as best shown in FIGS. 21
and 22, because the aperture 65 will be greater than the
cross-sectional area of the elongated members 40C in the insertion
position, the holding portion 20C advantageously allows the lips
190 to be received from either side of the structural member 60.
That is, the lips 190 travel in the direction of arrow 600, as
shown in FIG. 21, and then when the lips 190 are in the extended
position, they travel in the opposite direction from the position
shown in FIG. 22 back into the aperture 65. Those skilled in the
art will now appreciate that the because the lips 190 may be
received from either side of the structural member 60, one or more
end areas 48C may always be brought into a continued and bearing
position with the blind surface area 62 of the structural member
60. In FIG. 21, the compression member 200 is positioned in the
annular groove 316. With reference to FIG. 22, those skilled in the
art will now appreciate that if the aperture 65 is oversized
relative to the holding portion 21C, only one or more of the lips
190 may be in contact with the surface 67 when the holding portion
20C is in the extended position.
[0091] As used herein, the term "anchored" is defined as being
securely positioned within, on, or being made from the underlying
material. The term "fastener" is defined as the combination of a
holding portion and a rod, equivalent to the holding portions and
rods discussed herein. The holding portion can include either an
integral length of engagement, such as a threaded portion, or may a
separate engaging component, such as a nut.
[0092] With reference to FIGS. 24A-30, various embodiments of the
invention are shown in whole or in part. In some embodiments, as
generally shown in FIGS. 24A-24C, a cross-section of a channel 410
is shown anchored in a mass or volume of structural material 610,
so as to form a chamber 408 in the structural material 610. The
channel 410 may be formed from the same material as the structural
material 610, or the channel 410 can be made of a different
material, as illustrated in FIGS. 24A-25. In the embodiments shown
in FIGS. 24A-34 the structural material 610 is concrete, although
other materials, including, but not limited to, foam or metal, are
contemplated. The channel 410 is preferably a metal, such as steel,
iron, or aluminum, plastic, or other resilient material.
[0093] In FIGS. 24A and 24C, one embodiment of a channel 410 is
shown. In this embodiment, rear corners 412 of the channel 410 are
shown extending outwardly from the sidewalls 411 of a rear wall 413
of the channel 410. In this embodiment, the sidewalls 411 tend
inwards as they extend rearward until an inflection from which they
extend outwardly to form the protrusion of the rear corners 412. In
FIG. 24B, another embodiment of a channel 410A is shown. As shown
in this embodiment, the rear corners 412A of the rear wall 413A
extend perpendicularly outwardly from the substantially straight
sidewalls 411A. In other embodiments, the rear corners 412A extend
at other angles with respect to the rear wall 413A.
[0094] With reference to FIGS. 24A and 24B, the channel 410 is
shown anchored in the structural material 610. Although FIGS.
24A-24C show channel 410 as being embedded within the structure
material, it is contemplated that a portion of the channel could
extend beyond the surface of the structural material 610. The
channel 410 may also be anchored to an exterior surface of the
structural material 610. Alternatively, the channel 410 can be
integral with the structural material 610, having been formed
therein. The channel 410 can be of any dimension, including length,
width, depth, or height. The chamber 408 can be formed in the
structural material 610 without the channel 410.
[0095] In the embodiment of FIG. 24A, a front surface 403 of the
structural material 610 is shown being separated from the front
side of the channel 410 by a depth 404 of the structural material
610. In the embodiment of FIG. 24B, the front surface 403 of the
structural material 610 is shown approximately flush with the front
side of the channel 410. An opening 401 is shown in the chamber
408, the channel 410, and the structural material 610. As the
chamber 408 is shown from the side, a length of the chamber 408 is
not visible, but may be any length. Channel 410 includes opposed
margins 414 that define the opening 401, so that a width 402 of the
opening 401 is narrower than a width 416 of the chamber 408 formed
by the channel 410. As shown, each margin 414 has a width 415. In
the embodiments of FIGS. 24A and 24B, the thickness 422 of the
channel 410, 410A is also shown. This channel thickness 422 can be
any thickness desired for various applications. Although the
channel as shown in FIGS. 24A, 24B, or 24C appears to have a
uniform thickness 422, it is contemplated that side walls 411,
margins 414 and the rear wall 413 can have non-uniform thicknesses
422. For example, margins 414 could have a thickness that is a
multiple of the thickness of the corresponding rear wall 413.
[0096] As shown in FIGS. 24A and 24B, inside bearing surfaces 418
of the margins 414 are constructed to bear weight when used to
secure elements (e.g., element 70 shown in FIG. 24C) using a
fastener with a holding portion, such as the holding portions 20,
20A, 20B, 20C, and 20D disclosed herein in FIGS. 1, 7, 11, 15, and
28, respectively. The bearing surface 418 meets the surfaces 67D of
the opening 401 at corners 420. In the embodiment of FIG. 24A, the
surface area 67D of the opening 401 is larger than shown in other
embodiments due to the depth 404 of the structural material 610
along the opening 401. The bearing surface 418 is an example of the
blind surface area 62, and any reference herein to the blind
surface area 62 also refers to the bearing surface 418.
[0097] Generally referring to FIGS. 24C-30, an embodiment of a
holding portion, generally designated 20D, is shown inserted into
the chamber 408 in the channel 410. As best shown in FIG. 24C, a
rod 50C (shown as a bolt) has a nut 300 threadably coupled thereto
within recess 310. The holding portion 20D includes two elongated
members 40D and a compression member 200D. Turning now to FIGS.
28-29, the elongated members 40D have rectangular bearing surfaces
48D and tips 46D that allow alignment for full bearing contact with
the inside bearing surfaces 418 of the opposed margins 414. As best
shown in FIG. 24C, the nut 300 is positioned between the elongated
members 40D within the interior formed recess 310. The compression
member 200D, positioned in a groove 316A, best seen in FIGS. 27-29,
is designed to create a compressive force on the end of the holding
portion 20D, adjacent to the recess 310.
[0098] Since holding portion 20D is similar to holding portion 20C,
either holding portion 20C or 20D can combine with the rod 50C to
make a fastener so that the end areas 48C or 48D are substantially
coplanar when the corresponding holding portion 20C or 20D is in
the extended position, as shown in FIGS. 15 and 24C, respectively.
The geometries of the end areas 48C, 48D differ based on intended
uses. The generally arcuate end areas 48C are intended to contact a
bearing surface 62 after being inserted in the generally rounded
aperture 65, while the generally rectangular end areas 48D are
intended to contact a bearing surface 418 above and below after
being inserted into the elongated opening 401. The holding portion
20D can also be used with the aperture 65. Note that compression
members 200C and 200D also have different geometries, generally
circular and generally rectangular with a loop and a missing side,
respectively. As best shown in FIG. 18, the shoulders 312 of the
recess 310 of the holding portion 20C are substantially parallel to
the sides of the nut 300 when the holding portion 20C is in the
insertion position. In contrast, as best shown in FIG. 24C, the
shoulders 312 of the recess 310 of the holding portion 20D are
substantially parallel to the sides of the nut 300 when the holding
portion 20C is in the extended position.
[0099] Referring again to FIGS. 24A-30, each elongated member 40D
is preferably identical and preferably made from a metal, such as
zinc, aluminum, brass, steel, or stainless steel, plastic, or the
like. The compression member 200D will preferably be unitary and
preferably be made from neoprene, steel, or spring wire. In other
embodiments, compression member 200D can have other geometries or
compositions. As explained in detail herein, when the holding
portion 20D is in the extended position, such as shown in FIG. 28,
or in the insertion position, such as shown in FIG. 29, the
blocking shoulders 312 of the recess 310, best seen in FIG. 30,
resist rotation of the nut 300. The angle of the elongated members
is preferably predetermined, similar to other holding portion 20
embodiments described herein. Those skilled in the art will
appreciate that the actual angles of the predetermined extended
position and the insertion position of the elongated members may be
any desired angles where the predetermined angle in the insertion
position is less than the predetermined angle in the extended
position.
[0100] With reference to FIGS. 24C, 25, 28, and 29, the end of each
elongated member 40D includes lips 190D configured to position the
holding portion 20D with the elongated opening 401 in the chamber
408. As best shown in FIG. 25, the rectangular bearing end areas
48D, shown in phantom view, contact the opposed margins 414. The
bearing end areas 48D sum to form the end surface area for this
embodiment. Referring to FIG. 24C, the chamber 408 is shown
substantially filled with the holding portion 20D. In other
embodiments, the chamber 408 may be larger.
[0101] As shown in FIGS. 28 and 29, the rod 50C and holding portion
20D are inserted through the elongated opening 401 between the
opposed margins 414. As soon as tips 46D of the elongated members
40D clear the plane of the opening 401 between the margins 414, the
compression member 200D urges the lips 190D to the predetermined
extended position. Those skilled in the art having benefit of this
disclosure will appreciate that because of the housing shoulders
314, as best seen in FIGS. 24C, 28, and 29, the lips 190D are
limited to a predetermined extended position where the lips 190D
are within the cross-sectional area of the holding portion 20D in
the insertion position. In other words, because the spread of the
elongated members 40D in the insertion position is less than the
width 402 of the opening 401, the holding portion 20D allows the
lips 190D to be received within the opening 401. Referring to FIGS.
24C and 25, in this extended position inside the chamber 408, the
end areas 48D contact the inside surface 418 of the opposed margins
414. The lips 190D at least partially fill the opening 401 between
the margin edges 420.
[0102] Turning now to FIG. 26, an elongated member's knob 450 and
corresponding profile 451 are shown. The wire clip compression
member 200D is also shown. Having each elongated member 40D
identical reduces cost in manufacturing and inventory. The cutaway
of the rod 50C is shown inside the throughway 452 created by the
combined elongated members 40D.
[0103] Turning now to FIG. 27, the groove 316A to position the
compression member 200D of the holding portion 20D is shown. The
incline from the tips 46D of the elongated members 40D from the
compression member 200D in the groove 316A is also shown.
[0104] Turning to FIGS. 28 and 29, the relative positions of the
knob 450 and corresponding profile 451 are shown in phantom view
along with the direction of insertion 600. It will be appreciated
by those of skill in the art having benefit of this disclosure that
the embodiments of the holding portion 20D having the knobs 450 and
the corresponding profiles 451 will resist relative lateral
movements between the elongated members 40D. As the holding portion
20D is moved to the insertion position, the compression member 200D
expands in the groove 316A, as shown in FIG. 29. When the holding
portion 20D is urged to the extended position, the compression
member 200D returns to the shape shown in FIG. 28.
[0105] Returning to FIG. 30, a plan view of elongated member 40D
shows the housing shoulders 314 on opposite sides of the throughway
452. While the knob 450 and the profile 451 may be reversed in
positions, the knob 450 and the profile 451 are configured to mate
with a corresponding profile 451 and knob 450 on another elongated
member 40D. A portion of the recess 310 formed by the blocking
shoulders 312 and the lip 190D are also shown. The shapes of the
knobs 450 and the profiles 451 are illustrative only, and the knobs
450 and the profiles 451 may have other geometries.
[0106] FIGS. 31-34 show various embodiments of structural members
and combinations thereof. The structural members include walls 620,
630, 640, 650 (also called sidewall 650), ceiling 644, and floors
622, 632, 642. Although the illustrated embodiments of the
structural members typically include flat surfaces, no such
limitation should be inferred. One advantage of the channels 410,
410A used in combination with fasteners with holding portions 20D
seen in FIGS. 24C-34 is that the channels 410, 410A provide for
location flexibility in the mounting of various elements. The
holding portions 20D can be slid along the elongated openings of
the channels 410, 410A, or removed and reinserted in the channels
410, 410A, to secure the elements in a myriad of positions along
the channels 410, 410A. Removal may include reducing an engagement
force of the elongated members 40D of the holding portion 20D with
the plurality of opposed margins 414. Reinsertion includes
increasing the engagement force of the elongated members 40D of the
holding portion 20D after sliding or removal.
[0107] Turning now to FIG. 31, a structural member, a wall 620,
composed of the structural material 610, includes a plurality of
channels 410 configured to receive holding portions 20D for
securing various elements to the wall 620. A portion of a stairway
512 with steps 512B is shown in cutaway view secured to the wall
620 using fasteners with holding portions 20D through a stairway
sidewall 512A. The channels 410 used to secure the stairway 512 are
substantially parallel and offset. Notches 512C in the stairway
sidewall 512A, for securing the stairway 512, may be used to adjust
the vertical positioning of the stairway 512 by a small amount,
typically less than one inch. Hinges 511 of a door 510 are secured
to the wall 620 using parallel, but not offset, channels 410 by
fasteners using holding portions 20D. The stairway 512 and the door
510 are secured above floor 622. In other embodiments, the channels
410 may be vertical or angled instead of horizontal in orientation.
With vertical channels 410 or channels 410 with other orientations,
the notches 512C may be omitted.
[0108] As seen in FIG. 32, a wall 630 composed of structural
material 610 includes a plurality of channels 410A configured to
receive fasteners with holding portions 20D for securing various
elements to the wall 630. Fasteners with long rods 50K and holding
portions 20D in vertical channel 410A secure a structural support
508A to the wall 630, while fasteners with rods 50C and holding
portions 20D in horizontal channel 410A secure a structural support
508B to a floor 632. The structural supports 508 each integrate a
channel 410A for receiving holding portions 20D using an
appropriately sized rod 50. A beam 514 (here a shelf) is secured to
the structural supports 508A and 508B using angle brackets 70. The
shelf 514 may be repositioned up or down using the
repositionability feature of the fasteners with holding portions
20D secured in the channel 410A.
[0109] Turning to FIG. 33, a ceiling 644, composed of structural
material 610, includes a channel 410A configured to receive
fasteners with holding portions 20D for securing one or more
elements 505 (here a light) to the ceiling 644. The channel 410A in
the ceiling 502 is secured by reinforcing elements 503 (here
rebar). It is contemplated that the channels 410A can be securely
anchored to the structural material 610 using anchors, nuts and
bolts, rivets, or other suitable mechanism (e.g. welding, when the
structural material 610 is metal or includes a form of metal, such
as the rebar). The reinforcing elements 503 further secure the
structural integrity of the channel 410 in the structural material
610 and may advantageously allow for a greater load bearing force
to be placed on the holding portion 20D in the channel 410A. It is
contemplated that weighty elements 505 (e.g., air conditioning
units) could be hung from the ceiling 502 using fasteners described
herein.
[0110] Also in FIG. 33, a wall 640 is secured to the ceiling 644
using fasteners with angle brackets 70 and holding portions 20D in
the channels 410A in the wall 640 and the ceiling 644. The channels
410A in the wall 640 are in recesses 520, allowing for cosmetic
finishing after installation, covering up the holding portions 20D
and the angle brackets 70. Through the use of a cutaway, the wall
640 is shown connected to a sidewall 650.
[0111] In FIG. 34, the wall 640 is secured to the sidewall 650
using angle brackets 70 and holding portions 20D in channels 410A.
Both the wall 640 and the sidewall 650 have recesses 520. The
sidewall recess 520 is an interior recess, while the wall recess
520 is an edge recess, similar to the recess shown in FIG. 33. The
recesses 520 are covered with a finishing layer 525, such as
finished plasterboard, to cover cosmetically the connection between
the wall 640 and the sidewall 650.
[0112] Turning to FIG. 35, an embodiment of a form 550 includes
form walls 551A, 551B, 551C, and 551D for holding a non-solid
structural material 610, such as wet concrete, until appropriately
solidified, dried or cured. The form walls 551 form a shell for the
structural member being produced. As illustrated, the form 550
outlines a generally rectangular solid, but other geometries are
contemplated. An optional structural support 552 provides a fixed
separation distance between form walls 551B and 551D. The upper
left channel 410A is positioned to be approximately flush with the
surface of the resulting structural member, so only a cover 561
(such as film, tape, etc.) is needed to cover the opening 401. A
cap 560 at the bottom end of the upper left channel 410A keeps
non-solid structural material 610 out of the channel 410A. The left
lower channel 410A is substantially perpendicular to the upper left
channel 410A, with the chamber 408 visible, similar to FIG.
24B.
[0113] The upper right channel 410A of FIG. 35 is positioned to be
anchored below the surface of the resultant structural member. A
spacer 565 maintains the opening 401 in the structural material 610
because the opening will not be flush with the form wall 551B. The
cover 561 may not be necessary when the spacer 565 is present. A
cap 560 covers the bottom end of the right upper channel 410A.
Similar to the left side, the lower right channel 410A is shown
substantially perpendicular to the upper right channel 410A, with
spacer 565 maintaining access to the chamber 408 therein when the
non-solid structural material 610 is added to the form 550. In some
embodiments, the channels 410A are spaced from the edge of the
structural member to create the recess 520 shown in FIGS. 33 and
34.
[0114] As shown in FIG. 35, the channels 410A are connected to
reinforcing elements 503 (here e.g., welded to rebar). The rebar is
shown either parallel or perpendicular to the channels 401A. The
orientation of the reinforcing elements 503 and the elongated
openings 501 of the channels 401A is a matter of design choice.
[0115] A method of making a structural member may include the
following steps. Having provided a form, such as the form 550,
opposed margins 414 are positioned in the form 550. The opposed
margins 414 may be positioned in the form 550 before providing
structural material 610 into the form 550. The opposed margins 414
define the elongated opening 401 by their placement. The elongated
opening 401 is blocked to prevent filling of the opening 401 by
structural material 610. Non-solid structural material 610 is then
provided into the form 550 and allowed to solidify, harden, cure,
etc. If desired, reinforcing elements 503 may be positioned in the
form 550. The opposed margins 414 may be anchored to the
reinforcing elements 503. The opposed margins 414 may be attached
to or a part of a channel 410. In other embodiments, the opposed
margins 414 may be a separate piece attached to another member that
forms the chamber 408 when the opposed margins 414 are added. A cap
560 can be used to block an end of the chamber 408. A cover 561
and/or a spacer 565 can be used to block the elongated opening 401
of the chamber 408.
[0116] The chamber 408 may also be created within the structural
material 610 after the structural member is formed. For example, if
the member is made of concrete, a portion of the concrete can be
removed to create the chamber 408 or to accommodate the channel
410. If securing the channel 410 more firmly within the structural
material 610 is desired, a filler material bondable with concrete
(e.g. an epoxy) can be added before the channel 410 is positioned
in the concrete. Once the channel 410 is placed within the
concrete, the filler material will fill any void space between the
channel 410 and the concrete. Other means for securing the channel
410 to the structure material 610 include anchors, nuts and bolts,
rivets, or securing mechanisms (e.g. welding, when the structural
material 610 is metal or includes metal, such as rebar) as
previously discussed.
[0117] Note that in various embodiments, the holding portions 20
may be freely substituted freely for each other along with other
appropriate components that work together. Also in various
embodiments, the elongated opening 401 is of differing sizes. For
example, on one embodiment, the elongated opening 401 has a length
less than two widths of the holding portion 20D. In another
embodiment, the elongated opening 401 is substantially the same
length as two holding portion 20D widths. In yet another
embodiment, the elongated opening 401 has a length greater than two
holding portion 20D widths. In still yet another embodiment, the
elongated opening 401 length is within a range of approximately six
to approximately twenty widths of the holding portion 20D. In other
embodiments, the elongated opening 401 length is a fraction of the
length of the structural member, or the entire length. Further, in
various embodiments, different structural members may be made from
different structural materials 610. A given structural member may
be of uniform or non-uniform construction, being made of one or
more structural materials 610.
[0118] It is contemplated that the maximum load that may be
suspended or held by one of the fasteners described herein may be
calculated in various embodiments from the tensile strength of the
bolt or rod 50 used therein. By way of example and not limitation,
common structural steel with a tensile strength of around 60,000 to
75,000 pounds-force per square inch (PSI) may be used. It is
further contemplated that for a rod 50 of given diameter, assuming
an applied tensile stress of 6,000 PSI, the following loads could
be held, including a five-to-one safety factor: 1/4 inch diameter
would hold up to 160 pounds; {fraction (1/2)} inch diameter would
hold up to 760 pounds; one inch diameter would hold up to 3,300
pounds; one and 12 inch diameter would hold up to 7,700 pounds, and
2 inch diameter would hold up to 13,800 pounds. Other steel alloys
may hold twice as much at the same size. Plastics, nylons, and
other non-ferrous materials may not hold as much. No experimental
tests have been made.
[0119] The foregoing disclosure and description is intended only to
be illustrative and explanatory thereof. To the extent foreseeable,
various changes in the size, shape, and materials, as well as in
the details of illustrative construction and assembly, may be made
without departing from the spirit of the invention.
* * * * *