U.S. patent application number 11/685279 was filed with the patent office on 2007-10-11 for integral connectors in tubular beams for building structures.
Invention is credited to William H. Porter.
Application Number | 20070234666 11/685279 |
Document ID | / |
Family ID | 38573621 |
Filed Date | 2007-10-11 |
United States Patent
Application |
20070234666 |
Kind Code |
A1 |
Porter; William H. |
October 11, 2007 |
INTEGRAL CONNECTORS IN TUBULAR BEAMS FOR BUILDING STRUCTURES
Abstract
Tubular beams for building frames include laser-cut ends to form
highly-accurate integrally-formed tab connectors for connecting the
beams together and to other building beams. The tab connectors are
integrally formed of continuous and contiguous material of the
metal beam and are spaced apart to closely engage a second beam for
secure and reliable and stress-distributed connection. The tab
connectors can be formed and/or bent to define a pocket oriented at
a desired angle for receiving a mating beam, such as for supporting
a roof truss at a desired pitch. Fasteners extend through holes in
the tabs and into or through the second beam for securing the beams
together. The tab connectors can be cut to many different shapes,
formed to any orientation, and made to accurately mate with
corresponding structure of the mating second beam, regardless of
the angle and size of the two beams.
Inventors: |
Porter; William H.;
(Saugatuck, MI) |
Correspondence
Address: |
PRICE HENEVELD COOPER DEWITT & LITTON, LLP
695 KENMOOR, S.E., P O BOX 2567
GRAND RAPIDS
MI
49501
US
|
Family ID: |
38573621 |
Appl. No.: |
11/685279 |
Filed: |
March 13, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60785705 |
Mar 24, 2006 |
|
|
|
Current U.S.
Class: |
52/334 |
Current CPC
Class: |
E04B 2001/2463 20130101;
E04B 2001/249 20130101; E04B 2001/2451 20130101; E04B 2001/2466
20130101; E04B 1/24 20130101; E04B 2001/2481 20130101; E04B 7/045
20130101; E04B 2001/2418 20130101; E04B 2001/2415 20130101 |
Class at
Publication: |
52/334 |
International
Class: |
E04B 1/16 20060101
E04B001/16 |
Claims
1. A building frame suitable to meet building code requirements for
human occupancy, comprising: a structural tubular metal beam
including a plurality of walls, with two or more of the walls
opposing each other and each including a tab connector extending
therefrom, each tab connector being formed from continuous and
contiguous material of the respective wall from which the tab
connector extends and each tab connector being bent to extend
parallel a common direction and to define a pocket therebetween
that extends at an acute angle to a longitudinal axis of the
tubular metal beam; a mating beam having opposing side surfaces,
the tab connectors being configured to closely engage the opposing
side surfaces of the mating beam, each tab connector including a
pattern of holes for fasteners, and the material of the structural
beam and the tab connectors being sufficiently thick and strong to
form a structural joint as part of the building frame meeting
building code requirements for human occupancy.
2. The building frame defined in claim 1, including at least one
second tab connector extending from a remaining one of the walls,
the second tab connector including a pattern of holes for
fasteners.
3. The building frame defined in claim 1, wherein the tab
connectors each comprise a flange with parallel linear edges.
4. The building frame defined in claim 1, wherein the tab
connectors each include a plurality of flanges having a first width
and supported by a necked area of reduced width.
5. The building frame defined in claim 1, wherein the remaining
walls include support flanges extending therefrom and being
configured to engage and support the mating beam in the pocket.
6. A structural juncture for use in a constructed building frame,
comprising: a first tubular metal beam defining a first
longitudinal direction and having an end, opposing first and second
walls, and opposing third and fourth walls forming a tube with the
first and second walls; a second beam defining a second
longitudinal direction having opposing first and second surfaces
forming a first dimension and having opposing third and fourth
surfaces forming a second dimension; a pair of tab connectors
formed inboard of the end of at least one of the first and second
walls and being integrally formed of continuous and contiguous
material of the metal beam; the pair of tab connectors being bent
outward from the associated one wall and being spaced apart the
first dimension, the second beam being positioned between the pair
of tab connectors; and a plurality of fasteners extending through
holes in the pair of tab connectors and into the second beam for
securing the second beam to the first beam.
7. The structural juncture defined in claim 6, including a second
pair of tab connectors formed in a second of the first and second
walls and being integrally formed of continuous and contiguous
material of the metal beam; the second pair of tab connectors being
bent outward from the associated second wall and being spaced apart
the first dimension, the second beam being positioned between the
second pair of tab connectors and secured thereto by the
fasteners.
8. The structural juncture defined in claim 7, wherein the
first-mentioned pair of tab connectors and the second pair of tab
connectors align to hold the second beam so that the second
longitudinal direction extends perpendicular to the first
longitudinal direction.
9. The structural juncture defined in claim 7, wherein the
first-mentioned pair of tab connectors and the second pair of tab
connectors align to hold the second beam so that the second
longitudinal direction extends at an acute angle to the first
longitudinal direction.
10. The structural juncture defined in claim 7, including a third
pair of tab connectors formed in at least one of the third and
fourth walls for holding an end of a third beam abuttingly against
sides of the first beam.
11. The structural juncture defined in claim 6, wherein the third
and fourth walls each include an integral plate-attachment flange
formed by a C-shaped cut made into the third and fourth walls, the
flange including holes for receiving fasteners that extend through
the flange into the second beam.
12. A structural juncture for use in a constructed building frame,
comprising: a first tubular metal beam defining a first
longitudinal direction and having an end, opposing first and second
walls, and opposing third and fourth walls forming a tube with the
first and second walls; a second beam defining a second
longitudinal direction having opposing first and second surfaces
forming a first dimension and having opposing third and fourth
surfaces forming a second dimension; a tab connector extending from
the first wall and formed integrally of continuous and contiguous
material of the first wall by first and second oppositely-facing
non-linear cuts made into an end of the first wall but without
similar cuts made into the second wall opposing the first wall, the
tab connector including holes suitable for securing the second beam
to the first beam to form the junction suitable for use in
constructing a building frame.
Description
[0001] This application claims benefit under 35 U.S.C. .sctn.119(e)
of provisional application Ser. No. 60/785,705, filed on Mar. 24,
2006, entitled LASER-CUT CONNECTORS IN TUBULAR BEAMS FOR BUILDING
STRUCTURES, the entire contents of which are incorporated herein by
reference.
BACKGROUND
[0002] The present invention relates to tubular beams suitable for
use in constructing building frames, and more particularly relates
to tubular steel beams having integrally-formed laser-cut
connectors accurately cut for connecting the beams together and for
connecting to other building structural members to form a building
frame. However, the present invention is not believed to be limited
to only laser cutting nor to only building structural members.
[0003] Constructing building frames of tubes, beams, and angle iron
has been around for some time. Most all junctures for building
beams require a welded piece or pieces to make the juncture. The
traditional way of cutting steel has been with a saw that cuts in
one plane, and that starts cutting from a side or end location on
the beam. After cutting, a plate with holes is welded to the end of
the cut tube for attachment to another beam, such as with threaded
fasteners. Notably the plate with holes must be accurately located
on the associated beam, and also the welding must be high quality,
since it is important that the assembled/connected beam arrangement
not over-stress the welds or over-stress the junctions. This is
necessary to avoid stress fractures around the welds and junction
failures over time, given normal cyclical loading and environmental
stress (i.e., wind, etc.) on building structures. Also, it is noted
that welding is a secondary operation that is expensive,
time-consuming, manually-intensive, and that requires significant
quality assurance to insure that quality long-lasting welds are
made.
[0004] It is essential in construction of frames for building that
the junctures be drawn together and not just slip fit. Thus, as
noted above, it is important that the assembled/connected beam
arrangement not stress the juncture unacceptably . . . since welds
and weld-adjacent beam walls can develop stress cracks and fail
over time. It is difficult to form highly accurate joints using
traditional saw cutting operations, since saw blades tend to wander
and wear, making them difficult to control with high accuracy.
Other factors also affect inconsistent cutting, such as the need to
repeatedly loosen and re-fixture a tubular beam for successive
cuts. All of this leads to inconsistent cut locations and
higher-than-desired tolerances, which in turn leads to additional
concerns about juncture stresses and integrity of junctures in an
assembled/connected beam arrangement of building structures.
[0005] Recently, cutting systems such as lasers, plasma arcs, water
jets, and other cutting systems have been developed. However,
corresponding connector designs for tubular beams have not yet been
proposed that are useful for building structures and building
frames.
[0006] Thus, a method having the aforementioned advantages and
solving the aforementioned problems is desired.
SUMMARY OF THE PRESENT INVENTION
[0007] The present invention focuses on different junctures for use
in a building frame constructed by bolting beams together, where
the junctures comprise tabs integrally formed from the material of
a structural tubular metal beam and extending from an end of the
tubular metal beam. By the present invention, separate brackets do
not need to be welded to the beam ends. Thus, the present invention
saves considerable cost by reducing separate components, by
reducing manpower, by reducing secondary operations, and by making
for a more efficient and repeatable assembly. The tabs are
structural and can be made suitable for use in connecting the metal
beam to building frame members in various arrangements and at
various angles to construct different building frames, even where
beams extend at acute angles to each other. The tabs are formed
from the continuous and contiguous material of the tubular metal
beam, such that separate welding and separate brackets are not
required. Yet the tabs are arranged and configured to withstand the
structural and functional requirements of beam junctures of
building frames.
[0008] In order to manufacture the beam ends, the tabs must be
accurately and precisely cut. Further, the cuts must be made by
cutting through a first wall of the tubular metal beam without
cutting into a second wall spaced behind the first wall. Thus,
traditional cutting by saws will not work. It is contemplated that
computer controlled laser cutting equipment will work best for the
present invention, though other means of cutting a single wall
thickness (without cutting a second wall spaced behind the first)
will work. It is noted that the present beams are structural
tubular steel beams suitable for constructing buildings of
substantial size and capacity, including permanent buildings
suitable for residential living.
[0009] In one aspect of the present invention, a building frame is
provided suitable to meet building code requirements for human
occupancy. The building frame includes a structural tubular metal
beam including a plurality of walls, with two or more of the walls
opposing each other and each including a tab connector extending
therefrom. Each tab connector is formed from continuous and
contiguous material of the respective wall from which the tab
connector extends and each tab connector being bent to extend
parallel a common direction and to define a pocket therebetween
that extends at an acute angle to a longitudinal axis of the
tubular metal beam. A mating beam is provided having opposing side
surfaces. The tab connectors are configured to closely engage the
opposing side surfaces of the mating beam, each tab connector
including a pattern of holes for fasteners, and the material of the
structural beam and the tab connectors being sufficiently thick and
strong to form a structural joint as part of the building frame
meeting building code requirements for human occupancy.
[0010] In another aspect of the present invention, a structural
juncture for use in a constructed building frame is provided
including a first tubular metal beam defining a first longitudinal
direction and having an end, opposing first and second walls, and
opposing third and fourth walls forming a tube with the first and
second walls. A second beam defines a second longitudinal direction
having opposing first and second surfaces forming a first dimension
and having opposing third and fourth surfaces forming a second
dimension. A pair of tab connectors are formed inboard of the end
of at least one of the first and second walls. The tab connectors
are integrally formed of continuous and contiguous material of the
metal beam. The pair of tab connectors are bent outward from the
associated one wall and are spaced apart the first dimension, with
the second beam being positioned between the pair of tab
connectors. A plurality of fasteners extend through holes in the
pair of tab connectors and into the second beam for securing the
second beam to the first beam.
[0011] In yet another aspect of the present invention, a structural
juncture for use in a constructed building frame includes a first
tubular metal beam defining a first longitudinal direction and
having an end, opposing first and second walls, and opposing third
and fourth walls forming a tube with the first and second walls,
and further includes a second beam defining a second longitudinal
direction having opposing first and second surfaces forming a first
dimension and having opposing third and fourth surfaces forming a
second dimension. A tab connector extends from the first wall and
is formed integrally of continuous and contiguous material of the
first wall by first and second oppositely-facing non-linear cuts
made into an end of the first wall but without similar cuts made
into the second wall opposing the first wall. The tab connector
includes holes suitable for securing the second beam to the first
beam to form the junction suitable for use in constructing a
building frame.
[0012] In another aspect of the present invention, methods of
computer-assisted cutting structural tubular steel beams suitable
for buildings are provided related to all of the above, where a
cutter makes a non-linear cut along a single first thickness of
metal and does not cut through a second thickness of metal spaced
behind the first thickness of metal . . . such as laser cutting.
The concave cuts form tabs from the integral material of the
tubular metal beam, which tabs are deformed and bent to a desired
orientation and position for engaging and attachment to a second
beam.
[0013] An object of the present invention is to use modern cutting
systems, such as lasers, plasma arcs, water jets and other cutting
systems, to cut tubular beams quickly and accurately in a wide
variety of designs suitable for building frames constructed for
human occupancy. When computers are coupled to these cutting
machines and systems, much less costly systems can be made by
cutting tabs with holes and bending the tabs in positions to align
with a matching part . . . such that very-accurately-made matching
parts can constructed for bolting and mechanically fastening
together without the need for welding.
[0014] These and other aspects, objects, and features of the
present invention will be understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0015] FIGS. 1-3 are related perspective views, FIG. 1 showing a
first laser cut metal tube with integral tabs, FIG. 2 showing the
integral tabs bent to form a first-type connection, and FIG. 3
showing the integral tabs connected to a wood beam or truss
member.
[0016] FIGS. 4-6 are related perspective views, FIG. 4 showing a
second laser cut metal tube with integral tabs, FIG. 5 showing the
integral tabs bent to form a second-type connection, and FIG. 6
showing the integral tabs connected to a wood beam or truss
member.
[0017] FIGS. 7-9 are related perspective views, FIG. 7 showing a
third laser cut metal tube with integral tabs, FIG. 8 showing the
integral tabs bent to form a third-type connection, and FIG. 9
showing the integral tabs connected to a second metal beam.
[0018] FIGS. 10-11 are front and side views of a fourth laser cut
metal tube with integral tabs, FIG. 10 showing a cut on the front
wall (and to avoid confusion does not show a similar cut on the
rear wall) and FIG. 11 showing a side wall.
[0019] FIG. 12 is a view similar to FIG. 10 but with the tabs bent
outward to a perpendicular position.
[0020] FIG. 13 is a view similar to FIG. 12, but with a wood truss
beam extending at an angle between the bent tabs and a horizontal
connector beam perpendicularly connected between the columns of
adjacent trusses.
[0021] FIG. 14 is a fragmentary side view, partially in cross
section, of a roof-to-side-wall assembled connection in a building
construction
[0022] FIG. 15 is a face view of a bent of an exemplary building
constructed using the present structural beams and joints.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0023] Tubular metal beams (typically steel beams) for building
frames, building structures, and outdoor shelter constructions of
the present disclosure include highly-accurate integrally-formed
laser-cut connectors (also called "tabs" herein) for connecting the
beams together. The tubular metal beams have tab connectors
extending from the end of opposing walls, or formed integrally near
ends of the walls. The tab connectors are integrally formed of
continuous and contiguous material of the metal beam itself, thus
saving considerable cost and secondary processing. The tab
connectors are spaced apart and oriented to closely engage a second
beam for secure, reliable and stress-distributed connection, which
is important in building structures. Fasteners extend through holes
in the tabs and into and/or through the second beam for securing
the second beam to the first beam. Where the beam is a wood product
(such as glulam, timber, cut wood, or other wood product), lag
screws, through bolts, pins, and the like can be used. By using a
laser cutter (or similar highly accurate cutter that can cut a
single wall without cutting completely through a "back wall" behind
the wall being cut), the tab connectors can be cut to any shape,
formed to any orientation, and made to accurately mate with
corresponding structure of the mating second beam, regardless of
the angle and size of the two beams and without regard to the cut
that will (or may not) be made in the "back wall."
[0024] The present disclosure focuses on different junctures for
use in a building frame constructed by bolting or mechanically
fastening beams together, where the junctures comprise tab
connectors integrally formed from the material of a structural
tubular metal beam and extending from an end of the tubular metal
beam. By the present constructions, separate brackets do not need
to be welded to the beam ends. Thus, the present constructions save
considerable cost by reducing separate components, by reducing
manpower, by reducing secondary operations, and by making for a
more efficient and repeatable assembly. The tab connectors are
structural and can be made suitable for use in connecting the metal
beam to building frame members in various arrangements and at
various angles to construct different building frames, even where
beams extend at acute angles to each other. The tab connectors are
formed from the continuous and contiguous material of the tubular
metal beam, such that separate welding and separate brackets are
not required. Yet the tabs are arranged and configured to withstand
the structural and functional requirements of beam junctures in the
harsh outdoor environment of building frames. Further, the tab
connectors are very accurately formed, such that they closely
engage opposing sides of the mating beam . . . thus reducing
sloppiness and unacceptable looseness in the connection due to
tolerances and clearances normally found in such connections and
joints.
[0025] In order to manufacture the beam ends, the tab connectors
must be accurately and precisely cut. This is not an easy task,
given traditional cutting methods and equipment and ways of
handling the heavy structural beams for buildings. Further, the
cuts must be made by cutting through a first wall of the tubular
metal beam without cutting into a second wall spaced behind the
first wall. Thus, traditional cutting by saws will not work.
Advantageously, using modern cutting systems, such as lasers,
plasma arcs, water jets and other cutting systems, single walls of
tubes can be cut and pieced in a wide variety of designs as
required. When computers are coupled to these cutting machines and
systems, much less costly systems can be made by cutting tab
connectors with holes and bending the tabs in positions to align
with a matching part . . . such that very-accurately-made matching
parts can be constructed for bolting together without the need for
welding. It is contemplated that computer controlled laser cutting
equipment will work best for the present invention, though other
means of cutting a single wall thickness (without cutting a second
wall spaced behind the first) will work. It is noted that the
present beams are structural tubular steel beams suitable for
constructing buildings of substantial size and capacity, including
permanent buildings suitable for residential living.
[0026] FIGS. 1-3 are related perspective views of a first system.
FIG. 1 shows a second laser cut metal tubular beam 50 well suited
and adapted for use as a building column. The beam 50 includes
opposing integral tab connectors 51 and 52 (also called "tabs"
herein) useful for forming a junction of the metal tube to a wood
beam or truss member. FIG. 2 shows the integral tab connectors 51
and 52 bent to form top and bottom sides of a pocket 54' oriented
at an acute angle to a longitudinal direction of the tubular beam
50. For example, where the beam 50 is used as a building column,
the angle of pocket 54' can be at a desired pitch angle for a roof
beam (see roof truss member 55). Flange supports 53 and 54 define
sides of the pocket 54' and can assist in stabilizing the juncture.
The illustrated tab connectors 51 and 52 are rectangular-shaped
flanges with linear parallel side edges. However, the tab
connectors can be other shapes, such as the one described below.
FIG. 3 shows a beam truss member 55 (which can be a glulam beam,
cut lumbar, other wood product beam, or other beam material)
extended into the pocket 54' and connected by suitable fasteners
such as lag bolts 56 (or nails, pins, through bolts, or the like).
The fasteners are extended through holes in the tabs 51 and 52 into
the truss member 55. Notably, the illustrated truss member 55
extends at an acute angle to the longitudinal direction of the
tubular beam 50. In this arrangement, the tubular beam 50 forms a
structural column of the building structure, while the beam member
55 forms a roof-supporting truss structure.
[0027] FIGS. 4-6 are related perspective views of a second system.
FIG. 4 shows a second laser cut metal tubular beam 60 with four
integral tab connectors 61, two each being formed in opposing walls
62 and 63. FIG. 5 shows the integral tab connectors 61 bent to form
a second-type connection. Specifically, the laser cuts and bent
tabs 61 define a "through pocket" 64' through the opposing walls 62
and 63. FIG. 6 shows a wood beam or truss member 64 positioned in
the pocket of tube 60, and including threaded fasteners 66 extended
through holes in the tabs 61 for securement. Notably, the pocket
64' can be formed at any angle "A" to the longitudinal directions
of the two beams 60 and 64 to achieve a desired roof pitch, for
example.
[0028] FIGS. 7-9 are related perspective views of a third system.
FIG. 7 shows a third laser cut metal tubular beam 70 with integral
tab connectors 71 laser cut into opposing walls 72 and 73.
[0029] FIG. 8 shows the integral tab connectors 71 bent outwardly
to form a third-connection arrangement. FIG. 9 shows the tube 70
abutting a second metal beam 74, with the integral tab connectors
71 abuttingly connected to a side of the second metal beam 74.
Notably, the beams 70 and 74 can be oriented at any angle "B" to a
vertical plane and at any angle to a horizontal plane "C" and at
any rotational position relative to each other, based on a designed
shape and orientation of the cuts on the ends of the beams 70 and
74.
[0030] FIGS. 10-11 are orthogonal side views of a tubular beam 101
laser cut to form a fourth connection. The beam 101 includes
opposing walls 102 and 103, and additional opposing walls 104 and
105. Notably, FIG. 10 shows the nearest wall 102 laser cut to form
the tab connectors 106, but prior to bending the tab connectors 106
outwardly (as shown in FIGS. 12-13). In FIG. 10, the back wall 103
is not yet cut to include the tab connectors (107). This is done to
more clearly illustrate the shape of the tab connectors 106 prior
to bending. The tab connectors 106 (and 107) include a plurality of
spaced apart flanges, each having a fastener hole and each
including a width. The flanges are connected to their base wall by
a necked portion of reduced width. This helps distribute stress and
reduces unacceptable concentrations of stress on the flange,
allowing the flange to flex to closely engage the mating surface on
the mating beam, but without unacceptably weakening the tab
connector nor subjecting it to long term fatigue failure. FIG. 11
illustrates a shape of the tab connector 109 prior to outward
bending. The walls 102 and 103 are each laser cut to form a
plurality of tabs 106 and 107, respectively (see FIGS. 12 and 13).
Notably, the tabs 107 are shifted vertically from the position of
tabs 106 so that they correspond to a desired pitch of the truss
member 108 being supported. The rectangular shaped tab 109 is laser
cut into the side wall 104 and a second similar tab connector can
be cut into the opposing wall 105 if desired (see FIGS. 11-12). The
tab connector 109 is bent outwardly to support a top beam plate for
a building wall, where the beam plate 109' extends between adjacent
trusses or "bents" of the building as shown in FIG. 13 and 15.
Optionally, the tab connector 109 is not bent outward . . . such as
if it is used on a bent positioned at an end of the building frame
where a building side wall will be constructed tight against the
column 101. Further, the connector 109 can be used to connect to
the beam 108 if desired.
[0031] FIG. 15 is a cross-sectional view of a building structure
120, showing what is commonly referred to in the industry as a
"bent." The joint construction shown in FIG. 14 is generally
located at numbers 121. A cross beam 122 can be optionally attached
to a top of the columns 101 if desired and if structurally
necessary for a particular building construction. Floor beams 123
are also connected between columns 101, and the entire building
structure 120 is supported on a foundation 124 using known
principles of conventional foundations. The building structure 120
can be finished using traditional construction material, or more
preferably are finished using structural insulated panels (SIPs
panels, known in the prior art), including side panels 125, roof
panels 126, and floor forming panels 127.
[0032] It is to be understood that variations and modifications can
be made on the aforementioned structure without departing from the
concepts of the present invention, and further it is to be
understood that such concepts are intended to be covered by the
following claims unless these claims by their language expressly
state otherwise.
* * * * *