U.S. patent application number 15/850613 was filed with the patent office on 2018-06-21 for structural connector.
The applicant listed for this patent is GLASS VICE HOLDINGS LIMITED. Invention is credited to Warwick James ALLEN.
Application Number | 20180171620 15/850613 |
Document ID | / |
Family ID | 62557319 |
Filed Date | 2018-06-21 |
United States Patent
Application |
20180171620 |
Kind Code |
A1 |
ALLEN; Warwick James |
June 21, 2018 |
STRUCTURAL CONNECTOR
Abstract
Disclosed is a connector for connecting first and second timber
structural members together. The connector mounts to a face of the
first structural member and receives at least a portion of the
second structural member. The connector includes a lip portion and
an at least one projection. The projection is forced into tacking
engagement with the first structural member, causing the connector
to be tacked in place. The tacking engagement is effected when the
lip is placed into an underlapping association with a bottom
surface of the first structural member the connector undergoes at
least one of a) a pivoting the connector about the lip at the
underlapping association of the lip with the bottom surface and b)
a movement of the connector towards the first structural member and
parallel with its bottom surface. The tacking engagement holds the
connector in its placed orientation relative to the first
structural member.
Inventors: |
ALLEN; Warwick James;
(Auckland, NZ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
GLASS VICE HOLDINGS LIMITED |
Auckland |
|
NZ |
|
|
Family ID: |
62557319 |
Appl. No.: |
15/850613 |
Filed: |
December 21, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04B 2001/2415 20130101;
E04B 1/215 20130101; E04B 1/2403 20130101; E04B 1/2612 20130101;
E04B 2001/2424 20130101; E04B 1/40 20130101; E04B 2001/2442
20130101 |
International
Class: |
E04B 1/24 20060101
E04B001/24; E04B 1/21 20060101 E04B001/21; E04B 1/41 20060101
E04B001/41 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 21, 2016 |
NZ |
727826 |
May 22, 2017 |
NZ |
732142 |
Claims
1. A method of using a connector for connecting a first structural
member and second structural member, the connector comprising a
mounting face for mounting to a mounting surface of the first
structural member, a receiving channel for receiving at least a
portion of the second structural member, a lip portion and, at
least one projection, wherein both the lip portion and at least one
projection extend past the mounting face of the connector, the
method comprising the steps of (a) aligning the connector at a
desired position along an elongate direction of the first
structural member, (b) moving the connector towards an alignment
surface of the first structural member so as to cause the lip
portion to be in an at least partially underlapping association
with the alignment surface, (c) moving the connector towards a
desired orientation relative to the first structural member by
either pivoting the connector about the lip at the underlapping
association of the lip with the alignment surface and/or moving the
connector towards the first structural member and parallel with its
alignment surface, the pivoting and/or movement acting to direct
the mounting face towards abutment with the mounting surface of the
first structural member and to tackingly engage the at least one
projection with the first structural member such that the connector
may be held in its desired orientation, (d) fastening the tackingly
engaged connector at the mounting face to the mounting surface of
the first structural member using one or more fasteners, (e)
locating a second structural member within the receiving channel of
the connector, and (f) fastening the second structural member to
either the connector or the first structural member using one or
more fasteners.
2. The method of claim 1 wherein the lip of the connector extends
past the mounting face further than the at least one projection
extends past the mounting face.
3. The method of claim 1 wherein the at least one projection of the
connector is spaced apart from the lip portion.
4. The method of claim 1 wherein the at least one projection of the
connector and lip are spaced apart so as to be substantially at
opposed ends of the connector, the spacing of the projections and
lip allowing for a levering of the projections into the first
structural member about the underlapping association of the lip and
the alignment surface of the first structural member.
5. The method of claim 1 wherein the first and second structural
members are substantially rectangular members, and the alignment
surface of the first structural member is adjacent to and
substantially perpendicular to the mounting surface of the first
structural member.
6. The method of claim 1 wherein at least the first structural
member comprises a crushable material such as to be penetrated by
the at least one projection of the connector under forcing by hand
or hammer.
7. The method of claim 1 wherein at least the first structural
member is a timber member.
8. The method of claim 1 wherein an end portion of the second
structural member is received within the receiving portion of the
connector.
9. The method of claim 1 wherein an offset is provided between a
base of the receiving channel and the lip, the offset being equal
to a desired offset between the alignment surface of the first
structural member and a corresponding surface of the second
structural member which, when placed in the receiving channel,
rests on the base of the receiving channel.
10. The method of claim 1 wherein an offset of zero is provided
between a base of the receiving channel and the lip, such that when
the first and second structural members are connected by the
connector the at least a directly adjacent portion of the alignment
surface of the first structural member and the corresponding
surface of the second structural member which rests on/is adjacent
to the base of the receiving channel are substantially aligned.
11. The method claim 1 wherein the pivoting and/or movement of the
connector in step (c) to tackingly engage the projections with the
first structural member further comprises the step of pressing or
hammering the projections into said tacking engagement with the
first structural member.
12. A connector for connecting a first and second timber structural
members together, the connector being for mounting to a mounting
face of the first structural member and for receiving at least a
portion of the second structural member, wherein the connector
comprises a lip portion and an at least one projection such that in
use when the lip is placed into an underlapping association with an
alignment surface of the first structural member at least one of a)
a pivoting of the connector about the lip at the underlapping
association of the lip with the alignment surface and b) a movement
of the connector towards the first structural member and parallel
with its alignment surface forces the at least one projection into
tacking engagement with the first structural member so as to cause
the connector to be tacked in place, holding the connector in its
placed orientation relative to the first structural member.
13. The connector of claim 12 wherein the connector comprises a
base plate and two side plates upwardly extending from the base
plate to define a receiving channel to receive an end portion of
the second structural member, and at least one mounting flange
extending from a respective one of said base plate and one of said
two side plates, said mounting flange to abut a surface of the
first structural member and be secured thereto by at least one
penetrative fastener, and wherein at least one mounting flange
presents the at least one projection projecting from the mounting
flange.
14. The connector of claim 12 wherein the tacking engagement is
associated with the penetration of the first structural member by
the at least one projection such that the mounting flange abuts a
surface of the first structural member.
15. The connector of claim 12 wherein the tacking engagement of the
connector with the first structural member is assisted by pressing
by hand or hammer.
16. The connector of claim 12 wherein the lip portion and at least
one projection are provided at or towards two respective ends of
the connector.
17. The connector of claim 12 wherein the connector is a joist
hangar, the first structural member is a beam and the second
structural member is a joist.
18. The connector of claim 12 wherein the receiving channel
comprises at least an alignment zone characterized by a zone of
increasing length from a mouth of the channel to a base of the
channel, wherein the length of the channel is perpendicular to the
direction between the mouth and base of the channel, and in use
during the receiving of a second structural member within the
alignment zone of the amount of the second structural member along
an elongate direction received by the channel progressively
increases.
19. The connector of claim 12 wherein, in use, the tacking
engagement of the connector to the first structural member is such
that the connector may support its own weight on the mounting face
of the first structural member.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a structural connector for
connecting a first structural member to a second structural
member.
BACKGROUND TO THE INVENTION
[0002] In the construction of structures such as buildings it is
necessary to connect various different structural members to each
other in order to provide the greater overall structure. In
applications such as floors and decking within a building there are
commonly a number of structural elements commonly referred to as
joists which run between other structural elements such as bearers
or beams. Once fastened together the joists and bearers form the
structure for the floor or deck.
[0003] The connections between the structural members will to some
extent determine the structural capacity of the overall structure
being constructed. Additionally, as there may commonly be a large
number of structural members needing to be connected to each other,
such work may be time and labour intensive.
[0004] One common manner of connecting structural members, such as
the joists and bearers in a floor or deck, is by directly fastening
each to the other using nails or other fasteners such as screws.
Passing a fastener through both structural members, which may
commonly be aligned at right-angles to each other, may result in
unsatisfactory penetration of either structural member.
Additionally, as the fasteners are commonly at angles to the
surfaces of each structural member, the action of fastening may be
awkward to perform and may cause splitting of either member where
wooden members are used.
[0005] Failures to sufficiently anchor fasteners in each structural
member, or any splitting of the member during fastening, may result
in an unsatisfactorily weak connection, and even compromise the
overall strength of the structure.
[0006] It is an object of the present invention to provide an
improved connector for connecting a structural members to each
other, or at least to provide the public with a useful choice.
[0007] In this specification where reference has been made to
patent specifications, other external documents, or other sources
of information, this is generally for the purpose of providing a
context for discussing the features of the invention. Unless
specifically stated otherwise, reference to such external documents
is not to be construed as an admission that such documents, or such
sources of information, in any jurisdiction, are prior art, or form
part of the common general knowledge in the art.
SUMMARY OF THE INVENTION
[0008] In one aspect, the present invention may broadly be said to
be a method of using a connector for connecting a first structural
member and second structural member, the connector comprising
[0009] a mounting face for mounting to a mounting surface of the
first structural member,
[0010] a receiving channel for receiving at least a portion of the
second structural member,
[0011] a lip portion and,
[0012] at least one projection,
[0013] wherein both the lip portion and at least one projection
extend past the mounting face of the connector,
[0014] the method comprising the steps of
[0015] (a) aligning the connector at a desired position along an
elongate direction of the first structural member,
[0016] (b) moving the connector towards an alignment surface of the
first structural member so as to cause the lip portion to be in an
at least partially underlapping association with the alignment
surface,
[0017] (c) moving the connector towards a desired orientation
relative to the first structural member by either pivoting the
connector about the lip at the underlapping association of the lip
with the alignment surface and/or moving the connector towards the
first structural member and parallel with its alignment surface,
the pivoting and/or movement acting to direct the mounting face
towards abutment with the mounting surface of the first structural
member and to tackingly engage the at least one projection with the
first structural member such that the connector may be held in its
desired orientation,
[0018] (d) fastening the tackingly engaged connector at the
mounting face to the mounting surface of the first structural
member using one or more fasteners,
[0019] (e) locating a second structural member within the receiving
channel of the connector, and
[0020] (f) fastening the second structural member to either the
connector or the first structural member using one or more
fasteners.
[0021] Preferably the steps (a) to (f) are performed sequentially
in the order of (a)-(f).
[0022] Preferably the lip of the connector extends past the
mounting face further than the at least one projection extends past
the mounting face.
[0023] Preferably the at least one projection of the connector is
spaced apart from the lip portion.
[0024] Preferably the at least one projection of the connector and
lip are spaced apart so as to be substantially at opposed ends of
the connector, the spacing of the projections and lip allowing for
a levering of the projections into the first structural member
about the underlapping association of the lip and the alignment
surface of the first structural member.
[0025] Preferably the first and second structural members are
substantially rectangular members, and the alignment surface of the
first structural member is adjacent to and substantially
perpendicular to the mounting surface of the first structural
member.
[0026] Preferably at least the first structural member comprises a
crushable material such as to be penetrated by the at least one
projection of the connector under forcing by hand or hammer.
[0027] Preferably at least the first structural member is a timber
member.
[0028] Preferably an end portion of the second structural member is
received within the receiving portion of the connector.
[0029] Preferably an offset is provided between a base of the
receiving channel and the lip, the offset being equal to a desired
offset between the alignment surface of the first structural member
and a corresponding surface of the second structural member which,
when placed in the receiving channel, rests on the base of the
receiving channel.
[0030] Preferably the offset is zero, such that when the first and
second structural members are connected by the connector the at
least a directly adjacent portion of the alignment surface of the
first structural member and the corresponding surface of the second
structural member which rests on/is adjacent to the base of the
receiving channel are substantially aligned.
[0031] Preferably the pivoting and/or movement of the connector in
step c) to tackingly engage the projections with the first
structural member further comprises the step of pressing or
hammering the projections into said tacking engagement with the
first structural member.
[0032] In another aspect, the present invention may broadly be said
to be a connector for connecting a first and second timber
structural members together, the connector being for mounting to a
mounting face of the first structural member and for receiving at
least a portion of the second structural member,
[0033] wherein the connector comprises a lip portion and an at
least one projection such that in use when the lip is placed into
an underlapping association with an alignment surface of the first
structural member at least one of
[0034] a) a pivoting of the connector about the lip at the
underlapping association of the lip with the alignment surface
and
[0035] b) a movement of the connector towards the first structural
member and parallel with its alignment surface
[0036] forces the at least one projection into tacking engagement
with the first structural member so as to cause the connector to be
tacked in place, holding the connector in its placed orientation
relative to the first structural member.
[0037] Preferably the connector comprises a base plate and two side
plates upwardly extending from the base plate to define a receiving
channel to receive an end portion of the second structural member,
and at least one mounting flange extending from a respective one of
said base plate and one of said two side plates, said mounting
flange to abut a surface of the first structural member and be
secured thereto by at least one penetrative fastener.
[0038] Preferably at least one mounting flange presents the at
least one projection projecting from the mounting flange.
[0039] Preferably the tacking engagement is associated with the
penetration of the first structural member by the at least one
projection such that the mounting flange abuts a surface of the
first structural member.
[0040] Preferably the tacking engagement of the connector with the
first structural member is assisted by pressing by hand or
hammer.
[0041] Preferably the lip portion and at least one projection are
provided at or towards two respective ends of the connector.
[0042] Preferably the connector is a joist hangar, the first
structural member is a beam and the second structural member is a
joist.
[0043] Preferably the receiving channel comprises at least an
alignment zone characterized by a zone of increasing length from a
mouth of the channel to a base of the channel, wherein the length
of the channel is perpendicular to the direction between the mouth
and base of the channel, and in use during the receiving of a
second structural member within the alignment zone of the amount of
the second structural member along an elongate direction received
by the channel progressively increases.
[0044] Preferably, in use, the tacking engagement of the connector
to the first structural member is such that the connector may
support its own weight on the mounting face of the first structural
member.
[0045] In another aspect, the present invention may broadly be said
to be a connector for connecting a first structural member to a
second structural member, the structural connector comprising:
[0046] a base plate and two side plates upwardly extending from the
base plate to define a receptacle to receive an end portion of the
second structural member, and
[0047] at least one mounting flange extending from a respective one
of said base plate and one of said two side plates, said mounting
flange to abut a surface of the first structural member and be
secured thereto by at least one penetrative fastener
[0048] wherein at least one mounting flange presents at least one
projection projecting from the mounting flange to contact the
surface of the first structural member and capable of penetrating
the first structural member by pressing by hand or hammer to tack
the connector to the first structural member, prior to said
connector being secured to said first structural member by said at
least one penetrative fastener.
[0049] Preferably the second structural member is a joist.
[0050] Preferably at least one of the side plates and the base
plate can be secured to said joist by penetrative fasteners.
[0051] Preferably the penetrative fasteners are nails or threaded
fasteners such as screws that can be received in holes of said at
least one of said side plates and base plate.
[0052] Preferably the base plate and side plates are integrally
formed.
[0053] Preferable the base plate, side plates and mounting
flange(s) are integrally formed.
[0054] Preferable the base plate, side plates and mounting
flange(s) are integrally formed from a sheet metal.
[0055] Preferable the base plate, side plates and mounting
flange(s) are integrally formed by bending of a single piece of
sheet metal.
[0056] Preferably the projection is integrally formed with said
base plate and side plates and mounting flange(s).
[0057] Preferable the base plate, side plates, mounting flange(s)
and the at least one projection are integrally formed by bending of
a single piece of sheet metal.
[0058] Preferably the projection is provided at at least one and
preferably both of said mounting flanges.
[0059] Preferably the projection is provided at a region of at
least one said mounting flange, distal most the base plate.
[0060] Preferably each said mounting flange provides a respective
said projection.
[0061] Preferably the projection has a sharpened tip that is
presented to make first contact with said first structural member,
whereafter upon pushing the projection into the first structural
member, the mounting flange at a region adjacent said projection
can come into contact with said first structural member.
[0062] Preferably the projection has a sharpened tip that is
presented to make first contact with said first structural member,
whereafter upon pushing the projection into the second structural
member, the mounting flange at a region adjacent said projection
can advance towards said first structural member.
[0063] Preferably the projection is presented to make first contact
with said first structural member without any modification by a
user.
[0064] Preferably the projection has a plurality of sharpened
tips.
[0065] Preferably the base comprises a lip portion able in use to
underlap a lower face of the first structural member, so as to
provide an alignment of the connector with the first structural
member.
[0066] Preferably the lip portion extends substantially co-planar
with the base of the connector, such that the lower surfaces of the
first and second structural members may be provided also
substantially co-planar when the lip is underlapped with the lower
face of the first structural member and the second structural
member is located in the receptacle and on the base of the
connector.
[0067] Preferably the mounting flanges each comprise a mounting
face for mounting to the first structural member, and the lip
portion of the base extends past the mounting faces of the mounting
flanges.
[0068] Preferably the lip portion is frangibly or removably
connected to the base of the connector.
[0069] Preferably the frangible or removable connection between the
lip and the base comprises one or more weakened or cut-out
regions.
[0070] Preferably the frangible or removable connection is such
that a user may remove the lip portion from the base.
[0071] Preferably when the lip portion is removed from the base,
the base does not extend past the mounting faces of the mounting
flanges.
[0072] In another aspect the present invention may broadly be said
to be a joist hanger for connecting a first structural member, with
which said joist hanger is to be secured by penetrative fasteners,
to a joist, wherein at least one mounting flange is provided that
presents at least one projection extending away from the mounting
flange in a direction that in use causes it to contact the first
structural member, the projection able to be driven into the first
member to tack the joist hanger in place.
[0073] Preferably the joist hanger comprises a base plate and two
side plates upwardly extending from said base plate defining a
receptacle for receiving the end of a joist, the base plate
providing upward support to a so received joist and the side plates
providing lateral support for a so received joist.
[0074] Preferably at least one of the side plates and the base
plate can be secured to said joist by penetrative fasteners.
[0075] Preferably the penetrative fasteners are nails or threaded
fasteners such as screws that can be received in holes of said at
least one of said side plates and base plate.
[0076] Preferably the base plate and side plates are integrally
formed.
[0077] Preferable the base plate, side plates and mounting
flange(s) are integrally formed.
[0078] Preferable the base plate, side plates and mounting
flange(s) are integrally formed from a sheet metal.
[0079] Preferable the base plate, side plates and mounting
flange(s) are integrally formed by bending of a single piece of
sheet metal.
[0080] Preferably the projection is integrally formed with said
base plate and side plates and mounting flange(s).
[0081] Preferable the base plate, side plates, mounting flange(s)
and the at least one projection are integrally formed by bending of
a single piece of sheet metal.
[0082] Preferably the projection is provided at at least one and
preferably both of said mounting flanges.
[0083] Preferably the projection is provided at a region of at
least one said mounting flange, distal most the base plate.
[0084] Preferably each said mounting flange provides a respective
said projection.
[0085] Preferably the projection has a sharpened tip that is
presented to make first contact with said first structural member,
whereafter upon pushing the projection into the first structural
member, the mounting flange at a region adjacent said projection
can come into contact with said first structural member.
[0086] Preferably the projection has a sharpened tip that is
presented to make first contact with said first structural member,
whereafter upon pushing the projection into the second structural
member, the mounting flange at a region adjacent said projection
can advance towards said first structural member.
[0087] Preferably the projection is presented to make first contact
with said first structural member without any modification by a
user.
[0088] Preferably the projection has a plurality of sharpened
tips.
[0089] Preferably the base comprises a lip portion able in use to
underlap a lower face of the first structural member, so as to
provide an alignment of the connector with the first structural
member.
[0090] Preferably the lip portion extends substantially co-planar
with the base of the connector, such that the lower surfaces of the
first and second structural members may be provided also
substantially co-planar when the lip is underlapped with the lower
face of the first structural member and the second structural
member is located in the receptacle and on the base of the
connector.
[0091] Preferably the mounting flanges each comprise a mounting
face for mounting to the first structural member, and the lip
portion of the base extends past the mounting faces of the mounting
flanges.
[0092] Preferably the lip portion is frangibly or removably
connected to the base of the connector.
[0093] Preferably the frangible or removable connection between the
lip and the base comprises one or more weakened or cut-out
regions.
[0094] Preferably the frangible or removable connection is such
that a user may remove the lip portion from the base.
[0095] Preferably when the lip portion is removed from the base,
the base does not extend past the mounting faces of the mounting
flanges.
[0096] In another aspect the present invention may broadly be said
to be a method of connecting a first and second structural members
(eg a joist), the method comprising the steps of
[0097] providing a structural connector or joist hanger as herein
before described
[0098] aligning the connector to a desired orientation in relation
to the first structural member,
[0099] pressing or hammering the at least one projection at least
partially into the first structural member to tack the connector in
place in its desired orientation,
[0100] securing the connector to the first structural member using
one or more fasteners, and
[0101] locating the second structural member within the receptacle
of the connector.
[0102] Preferably the structural connector comprises a lip portion,
and the step of aligning the connector to a desired orientation in
relation to the first structural member involves at least aligning
the lip portion so that it underlaps a lower face of the first
structural member.
[0103] Preferably the step of underlapping of the lip portion is
taken where the first and second structural members are to be
aligned so that a lower surface of each structural member lies
substantially co-planar.
[0104] Preferably where the first and second structural members are
to be aligned so that a lower surface of each is not to lie
substantially co-planar, the method further comprises the step of
first removing a frangible lip portion from the base of the
connector.
[0105] The term "axis" as used in this specification means the axis
of revolution about which a line or a plane may be revolved to form
a symmetrical shape. For example, a line revolved around and axis
of revolution will form a surface, while a plane revolved around
and axis of revolution will form a solid.
[0106] The term "comprising" as used in this specification and
claims means "consisting at least in part of". When interpreting
each statement in this specification and claims that includes the
term "comprising", features other than that or those prefaced by
the term may also be present. Related terms such as "comprise" and
"comprises" are to be interpreted in the same manner.
[0107] This invention may also be said broadly to consist in the
parts, elements and features referred to or indicated in the
specification of the application, individually or collectively, and
any or all combinations of any two or more said parts, elements or
features, and where specific integers are mentioned herein which
have known equivalents in the art to which this invention relates,
such known equivalents are deemed to be incorporated herein as if
individually set forth.
[0108] The invention consists in the foregoing and also envisages
constructions of which the following gives examples only.
[0109] To those skilled in the art to which the invention relates,
many changes in construction and widely differing embodiments and
applications of the invention will suggest themselves without
departing from the scope of the invention as defined in the
appended claims. The disclosures and the descriptions herein are
purely illustrative and are not intended to be in any sense
limiting.
[0110] For the purpose of this specification, where method steps
are described in sequence, the sequence does not necessarily mean
that the steps are to be chronologically ordered in that sequence,
unless there is no other logical manner of interpreting the
sequence.
BRIEF DESCRIPTION OF THE DRAWINGS
[0111] Preferred embodiments of the invention will be described by
way of example only and with reference to the drawings, in
which:
[0112] FIG. 1 shows a connector of one embodiment of the present
invention,
[0113] FIG. 2 shows the connector of FIG. 1 engaged with and
secured to a first structural member and ready to receive a second
structural member,
[0114] FIG. 3 shows the connector of FIG. 2 wherein the connector
has received and been secured to a second structural member,
[0115] FIG. 4a shoes a side view of one embodiment of the
connector,
[0116] FIG. 4b shows a front view of one embodiment of the
connector,
[0117] FIG. 5 shows a flat panel design of a sheet of material used
to manufacture the connector in one embodiment of the present
invention,
[0118] FIG. 6 shows an alternate embodiment of the connector,
[0119] FIGS. 7a-c show alternate embodiments of the projection of
the connector,
[0120] FIGS. 8a-c show alternate configurations of the projection
or projections on the connector,
[0121] FIGS. 9a-d show views of a connector according to the
present invention,
[0122] FIGS. 10a-c show three different configurations of the
connector of FIGS. 9a-d,
[0123] FIGS. 11a-c show different configurations of the lip portion
and at least one projection,
[0124] FIG. 12 shows a connector in an association with a
structural member,
[0125] FIGS. 13a-d show various steps in the use of a connector in
connecting two structural members together.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0126] With reference to FIG. 1 a connector 10 for connecting a
first structural member 1 to a second structural member 2 is
shown.
[0127] The connector comprises a base plate 11 and two side plates
12, each side plate upwardly extending from the base plate. The
base plate 11 and side plates 12 define a receptacle 15 to receive
an end portion of the second structural member.
[0128] The connector further comprises at least one mounting flange
13 extending from one of the base plate 11 or side plates 12. As
seen in FIG. 1, the side plates 13 extend from each respective side
plate 12. In alternative configurations, the or each mounting plate
13 may extend from the base plate 11, or from both of the base 11
and a respective side wall or both side walls 12.
[0129] As seen in FIG. 2, the mounting flange or at least a portion
of the mounting flange may in use abut a face of the first
structural member 1. The or each mounting flange 13 may then in use
abut a face of the first structural member and be secured to the
first structural member 1 by at least one penetrative fastener.
Such fasteners may include nails, screws, bolts, or other commonly
used penetrative fasteners.
[0130] In some embodiments there may be a single mounting flange 13
provided with a connector 10. In the preferred embodiment there are
preferably more than one, and specifically two mounting flanges
13.
[0131] The connector 10 further comprises at least one projection
14 presented to contact the surface of the first structural member
1. The projection 14 is associated with a respective mounting
flange 13 such that it may contact a surface of the first
structural member 1 when the respective mounting flange is moved
towards abutment with a surface of the first structural member
1.
[0132] The projection 14 is capable of penetrating the first
structural member 1. Such penetration may be such that it is able
to be provided by hand, by pressing, or by hammer or other forced
or sudden contact. The configuration of the projection 14 is
preferably such that when the projection has penetrated the first
structural member the engagement between the connector 10 and first
structural member 1 is such as to hold the connector substantially
in place prior to the connector being secured more permanently to
the first structural member 1 by at least one penetrative
fastener.
[0133] The configuration of the projection and manner of its
engagement with the first structural member 1 are preferably such
as to result in a tacked connection, whereby the connector 10 is
attached to the first structural member 1 so as to at least support
its own weight, yet not so attached as to provide structural
connections sufficient for retaining the connector 10 against the
first structural member 1 under the load of the second structural
member 2 when received within the receptacle 15. It is envisaged
that such a tacked connection may be provided by the configuration
of the projection 14 and material of the first structural member 1,
such that the projection 14 may at least partially penetrate the
first structural member 1 by hand, without the use of any
additional tool. Alternatively, the tacked connection of the
projections 14 and the first structural member 1 may require the
application of an external tool such as a hammer to provide an
additional contact force to urge the projection 14 into the first
structural member.
[0134] The base plate 11 and two side walls 12 define the
receptacle 15 to receive an end portion of the second structural
member 2. The dimensions of the receptacle 15 may be customised to
suit the size of the desired second structural member. Where the
second structural member is a joist, connectors 10 may be provided
having receptacles 15 of dimensions suitable for receiving joists
of an array of standardised sizes.
[0135] The base plate 11 of a receptacle 15 is preferably
configured to provide upward support for the received portion of a
second structural member. Each side plate 12 is to provide lateral
support to the sides of the received joist.
[0136] In order to secure the connector 10 to each of the first
structural member 1 and second structural member 2, one or more
penetrative fasteners may be driven through the connector and into
the respective structural member. For example, one or more
fasteners may be driven through a mounting flange 13 and into the
first structural member 1, and one or more fasteners may be driven
through either or both of the side walls 12 or base plate 11 of the
receptacle 15 and into the second structural member 2.
[0137] Though in some embodiments the one or more penetrative
fasteners for securing the connector to the structural members may
be driven through the respective portions of the connector, in a
preferred form one or more apertures or holes 16 are provided in
the respective portions of the connector to facilitate the securing
of it to each structural member. Such holes or apertures 16 may
preferably be sized so as to correspond to the penetrative portion
dimensions of the penetrative fastener, but be sufficiently small
so as to prevent a head portion of the penetrative fastener from
passing through the aperture or hole 16.
[0138] It is contemplated that a connector of the present invention
may be formed by the attachment of various sub-elements to provide
the overall form of the connector. However, in at least some
preferred embodiments at least some portions of the connector 10
are formed integrally. For example, the base plate 11 and side
plates 12 may be integrally formed. Alternatively, the base plate
11, side plates 12, and mounting flange or mounting flanges 13 are
all integrally formed with each other. Further alternatively, but
preferably, each of the base plate 11, side plate 12 and the at
least one mounting flange 13 and its associated projection are all
integrally formed.
[0139] Such integral formation may be provided by forming the
connector 10, or such various sub-component of the connector as
have previously been described as being integral, from a single
folded sheet of material. Metal, such as stainless steel or
galvanized steel, may be common suitable materials for forming from
a sheet. However, depending on the application and structural
requirements other materials such as but not limited to plastics or
other composite materials may be suitable.
[0140] A flat panel design for such a folded sheet integral formed
connector is shown in FIG. 5. As seen in FIG. 5, the first set of
folds may be made along the lines 21 to define the base plate 11
and upwardly projecting side plates 12. A further fold may be made
along the lines 22 to define each mounting flange 13 from their
respective side plate 12. A final fold may be made along the lines
23 to form the projections 14 from the mounting flanges 13.
[0141] In a preferred form the projections 14 are formed by a
bending of the sheet of material from which the connector 10 is
formed, thus being integrally formed with the other components of
the connector. In alternative forms it is also possible that the
projections 14 may be comprised by separate components which are
then engaged with the connector 10 so as to project past their
respective mounting flange and performing the function of
contacting the surface of the first structural member and
penetrating it under a contact force.
[0142] The embodiment of the connector shown in FIG. 1 is seen
secured to the first structural member 1 in FIG. 2. As seen in FIG.
2 the projections 14 of each mounting flange 13 have been engaged
with the material of the first structural member, then a plurality
of fasteners 18 have been engaged with the connector 10 and first
structural member 1 to secure these components together. As seen in
FIG. 2 the connector is ready to receive a portion of the second
structural member 2 within the receptacle 15 of the connector.
[0143] FIG. 3 shows the configuration of FIG. 2 wherein the second
structural member has been received within the receptacle 15 and
the connector secured to the second structural member.
[0144] FIGS. 4a and 4b show a side view and front view respectively
of the connector 10. In the side view of FIG. 4A a side wall 12 is
visible along with the side of the mounting flange 13 and
projection 14. As shown in FIG. 4A each side wall 12 have a slanted
free edge 24. Such a configuration of the shape of the side plates
12 may be desirable in order to provide a sufficiently wide
supporting base plate 11, yet reduce wasted material towards the
upper portion of wide walls. However, in alternate embodiments it
may be desirable to remove the slanted edge 24 of one or each side
plate 12 and have the side plate 12 be of a substantially
rectangular or other shape. Such a configuration may be desirable
in order to provide increased area of the side plate 12 for fixing
penetrative fasteners to the second structural member 2.
[0145] The front view of the connector shown in FIG. 4B shows the
front faces of the two mounting flanges 13, the base 11, the
leading edges of each projection 14, and the receptacle 15 for
receiving a portion of the second structural member 2.
[0146] In a preferred embodiment the connector 10 as previously
described is provided with two mounting flanges 13, one mounting
flange being associated with each respective side plate 12. In most
applications it is anticipated that these two mounting flanges 13
should present substantially co-planar faces, so as to facilitate
the mounting of the connector 10 to the substantially planar face
of a first structural member, such as the side face of a bearer or
beam. However, for certain applications it is anticipated that the
faces of each mounting flange 13 may be angled relative to each
other such that they are not co-planar; this may facilitate
attachment to various other desired forms of first structural
members.
[0147] As seen in FIGS. 2 and 3, in some embodiments the
configuration of the base plate 11 relative to the mounting flange
13 may be such as to provide a both laterally and vertically
perpendicular relationship between the first structural member and
second structural member when secured together by the connector 10.
However, as shown in FIG. 6, the configuration of the connector 10
may be such as to provide the first structural member and second
structural member at a non-perpendicular vertical angle relative to
each other. Furthermore, the configuration of the side walls 12 and
base plate 11 relative to the mounting flange 13 may be such as to
provide the first and second structural members at a laterally
non-perpendicular angle relative to each other. For particular
applications combinations of these configurations may be provided,
so as to provide the first and second structural members secured
together at any desired lateral and vertical angle relative to each
other.
[0148] FIG. 6 shows a connector 10 secured to the first structural
member 1 by a plurality of penetrative fasteners 18, after having
its projection 14 engaged with the first structural member. The
second structural member 2 has then been placed in the receptacle
15 and is supported by the base plate 11 and side walls 12 of the
connector. As seen in FIG. 6 penetrative fasteners have not yet
been engaged with the second structural member to secure the
connector to the second structural member.
[0149] The embodiment of the connector shown in FIG. 6 furthermore
illustrates an alternative configuration wherein the angle between
the base plate 11 and mounting flange 13 is non-perpendicular.
[0150] In the configuration of FIG. 6 the base plate is slanted
downwards away from the mounting flanges 13, allowing the connector
to accommodate and receive in its receptacle 15 a second structural
member 2 which is downwardly angled away from the first structural
member 1. Such a configuration of the connector 10 may be desirable
for example in a roof application, where the second structural
member is a roof joist which is angled downwards from a central
beam or bearer, being the first structural member 1.
[0151] As the projection 14 of the connector projects past its
associated mounting flange 13, an immediate engagement between the
projection 14 and first structural member 1 may be provided as the
connector 10 is aligned to its desired position on the first
structural connector. This engagement between the projection and
the first structural member does preferably not require any
external action to initiate other than a contact force on the body
of the connector 10, particularly on one or each mounting flange
13.
[0152] Such a contact force is preferably a force of a magnitude
capable of being applied by hand, such as by the pushing with
fingers or thumb, or by the application of force with a hammer or
like object. As the projection 14 projects past the face of the
mounting flange no modification to the structure of the connector
10, such as bending of a component, is required in order to
initiate the engagement of a projection 14 with the first
structural member 1.
[0153] FIG. 7A to 7C show top-down views of the connector 10,
showing detail of different embodiments of the projection 14.
[0154] In FIG. 7A a primary embodiment is shown wherein the
projection 14 comprises a substantially triangular projection from
its associated mounting flange 13, the base of the triangle being
located approximate to the mounting flange, and the point of the
triangle projecting away from the mounting face of the mounting
flange 13. Such a triangular projection may be of a shallow depth,
wherein the base of the triangle is substantially wider than the
height of the triangle. Alternatively, configurations may be
provided for whereby the height of the triangle is similar to the
width of its base, or even greater than the width of its base.
[0155] While shown in FIG. 7A as having a base substantially equal
to the width of the mounting flange, the projection 14 may have a
base that is narrower than the width of the mounting flange 13.
[0156] As a primary purpose of the projections 14 is to provide for
a tacking engagement of the connector 10 with the first structural
member 1 before penetrative fasteners are required to be engaged,
in most embodiments the depth of the projections 14, being a
distance which they project away from their associated mounting
flange 13, should be such as to at least support the weight of the
connector 10 and preferably also small external bumping forces when
engaged with the first structural member without the tacked
connection being dislodged.
[0157] While a projection 14 of any projection depth may be engaged
with the first structural member, provided there is sufficient
sharpness of the projection and force applied to the projection, it
is furthermore desirable to provide a projection which may be fully
or substantially fully engaged with the first structural member
either by hand or by the application of an external force such as
with a hammer.
[0158] Accordingly, the projection may have one or more pointed
regions, as shown in each of FIGS. 7A-7C. Furthermore, the
projection may have a thin profile, able to prevent against
buckling while being engaged with the first structural member, but
not so thick as to unnecessarily inhibit the engagement. The
projection may also have one or more sharpened edges, to enhance
the projection's ability to be engaged with the first structural
member.
[0159] Preferably the depth and other characteristics of the
projections are such that they may be fully engaged with the first
structural member either by hand or by the application of an
external force such as by hammer, thus allowing their respective
mounting flange 13 to lie substantially flush with at least a
portion of the first structural member 1.
[0160] An alternate embodiment of the projections 14 is shown in
FIG. 7B wherein the projections 14 comprise a plurality of smaller
teeth or projection 17. Such a serrated formation of multiple teeth
or projections 17 may provide an increased surface area of
engagement between the projections 14 and first structural member
1, resulting in a more secure tacked connection between the
respective components.
[0161] Further alternatively in FIG. 7C the projections 14 are
shown each comprising a set of triangular projections. This set of
triangular projections together comprise a base link equal to the
width of the projections respective mounting flange 13.
[0162] While in foregoing embodiments the connector 10 has been
shown to comprise a plurality of projections 14, one associated
with each respective mounting flange 13, alternative embodiments
are contemplated wherein a single projection is associated with a
single mounting flange, or multiple projections are associated with
one or each mounting flange 13.
[0163] Shown in FIG. 8a is an embodiment of the connector 10
wherein the projections 14 are associated with the lower end of
each mounting flange 13, being the end proximate to the base plate
11.
[0164] Another alternative form is shown in FIG. 8b wherein each
mounting flange 13 has two associated projections 14, each
projection 14 of each mounting flange being associated with either
end of the mounting flange.
[0165] A further alternate embodiment is shown in FIG. 8c, wherein
the projections 14 of each mounting flange 13 extend from a side
portion of the mounting flange, being a portion most distal from
the receptacle 15 of the connector.
[0166] Any number of such configurations or combinations of such
configurations may be provided for within the scope of the present
invention so long as the projections 14 project from an associated
mounting flange to contact the surface of the first structural
member, and are capable of penetrating the first structural
member.
[0167] Having mind to the foregoing description of the connector 10
of the present invention, and particularly of FIGS. 1-8c, a method
of using the connector will now be described.
[0168] In order to securely connect two structural members
together, such as bearer and a joist, a connector 10 may be aligned
with the bearer, while proximate yet not in contact with the
bearer. The desired orientation may at least be defined by the
position and rotation of the receptacle 15 relative to the bearer,
as the receptacle receives the joist end portion and is thus
largely analogous with the future position of the joist end
portion.
[0169] Once the connector has been placed in the desired
orientation, the mounting flange 13 of the connector may be
advanced towards a surface of the bearer, so as to abut it. Due to
the projecting nature of the projection 14 associated with the
mounting flange 13, as the mounting flange is advance to abut the
surface of the bearer, the projection will come in contact with the
bearer.
[0170] In order to tack the connector into the desired orientation,
pressure must then be applied to the projections to force them into
engagement, at least partially, with the first structural
member.
[0171] Dependent on the configuration of the projection of the
connector and the material of the bearer the projection may be
forced in by pressure applied by the user by hand. Alternatively,
the user may tap or knock the projections into place using a hammer
or like implement.
[0172] Once the connector is tacked to the bearer by the
projection, the user may release the connector and have the
connector be maintained in its desired and tacked orientation. The
user may then attach one or more penetrating fasteners, such as
screws or nails or the like to secure the connector in its position
against bearer.
[0173] The joist end portion may then be located within the
receptacle 15, and likely butted against the bearer. Once in the
desired position, one or more penetrative fasteners may be attached
through the side walls or base plate of the connector and into the
joist to secure the joist and connector together.
[0174] As a result of this securing using a connector of the
present invention a structural connection between two structural
members, such as a bearer and a joist, may be provided wherein the
orientation of the structural members relative to each other may be
fixed with a significant degree of accuracy and ease.
[0175] Three potential embodiments of the connector 10 are shown in
FIGS. 10A to 10C. The connectors of FIGS. 10A to 10C illustrate
various configurations such that differing sizes of second
structural members 2 may be accommodated.
[0176] Also shown in the embodiments of FIGS. 10A to 10C is a lip
portion 25 of the base 11 of the connector 10. The lip portion 25
preferably extends from an edge of the base 11, such that it
projects past the faces of the mounting flanges 13 which, in use,
contact the first structural member. Where two structural members,
a first structural member 1 and a second structural member 2, are
to be aligned so that their lower surfaces are substantially
co-planar, the embodiment of the connector 10 having the lip
portion 25 may enable this alignment.
[0177] Details of a connector 10, particularly as shown in FIGS. 9A
to 10C, will now be described. The connector is for connecting
first and second structural members together. Examples of such
first and second structural members in common applications may be
timber beams and joists respectively. The connector 10 is for
mounting to a surface 26 of the first structural connector or beam,
and for receiving at least a portion of second structural member or
joist. Such a configuration of a connector 10 mounting to a face of
the first structural member 1 and receiving a portion of the second
structural member 2 is seen for example in FIG. 3.
[0178] The connector 10 comprises a lip portion 25 and at least one
projection 14. The relationship between the lip portion and at
least one projection are such that in use when the lip is placed
into an underlapping association with a bottom surface of the first
structural member 1, the at least one projection 14 may be forced
into a tacking engagement with the first structural member. This
forcing of the at least one projection may occur due to a pivoting
of the connector 10 about the lip portion 25 at the underlapping
association of the lip with the bottom surface of the first
structural member. Alternatively or in addition, the forcing of the
at least one projection may occur due to a movement of the
connector 10 towards the first structural member 1 and parallel
with its bottom surface. The bottom surface of the first structural
member 1 is a surface both adjacent and in most applications
substantially perpendicular to the mounting surface 26 of the first
structural member 1.
[0179] The tacking engagement of the at least one projection 14 and
first structural member is such to cause the connector to be tacked
in the position where it was placed relative to the first
structural member. The tacking engagement is preferably such that
the connector may be held, at least temporarily, in the position in
which it was placed. A user's hands may then be free to fasten the
connector to the first structural member, such as by the use of a
hammer and nail or screws, or a user may perform other tasks, all
the while the tacking engagement serving to hold the connector on
the first structural member without actively being retained there
by the user. Such a tacking engagement may be advantageous as it
effects the temporary fixing of the connector to the first
structural member, but does not require any additional parts or
further actions to be performed by the user other than simply the
alignment of and placement onto the first structural member of the
connector 10.
[0180] Where the at least one projection 14 is to project from the
mounting flange or flanges 13, the at least one projection is
preferably configured so that when tackingly engaged with the first
structural member the mounting flange 13 abuts the mounting surface
26 of the first structural member 1. This may require the
adaptation of the depth, width, or thickness of the projection or
projections dependent on the material of the first structural
member which it is to penetrate. For example, for softer woods, a
larger projection may be pressed or hammered with ease into the
timber. Conversely, in a harder timber first structural member a
less deep projection or projections may provide sufficient
engagement so as to perform the desired function of holding the
connector in its placed orientation relative to the first
structural member.
[0181] The tacking engagement of the connector and the first
structural member may be such that the tacking engagement is able
to be effected simply by the pivoting or movement of the connector
relative to the first structural member as previously described. In
addition or alternatively, the tacking engagement of the connector
with the first structural member may be assisted by pressing by
hand or by a hammer. For example, a user may apply pressure on the
connector proximate to the at least one projection 14 in order to
penetrate the first structural member and provide the tacking
engagement or, having provided an initial engagement of the tip or
tips of the at least one projection 14 with the first structural
member, a user may apply force with a hammer to force the
penetration of the first structural member by the at least one
projection 14. Where applicable, following the application of a
sufficient force by hand or hammer, or other tool, the connector is
to be provided tackingly engaged with the first structural member,
as described above.
[0182] Where the connector is placed with its lip in an
underlapping association with the bottom surface of the first
structural member and then the at least one projection 14 is
pivoted into engagement with the first structural member, it may be
desirable to provide the at least one projection spaced apart from
the lip. For example, the lip portion 25 and at least one
projection 14 may be provided at or towards two respective ends of
the connector, as seen for example in FIG. 9C. By placing the lip
portion and projection or projections at opposing ends of the
connector it may be easier for a user to align the lip 25 in its
underlapping configuration with the bottom surface of the first
structural member. Additionally, providing the lip 25 and
projection or projections 14 spaced apart may enhance the ability
for a user to pivot the projections 14 into engagement with the
first structural member 1 about the underlapping configuration of
the lip 25 and first structural member 1.
[0183] As shown in various embodiments described herein, the
connector 10 comprises a receiving channel or receptacle 15 for
receiving a portion of the second structural member or joist. The
receiving channel or receptacle 15 may define at least in part an
alignment zone. The alignment zone is characterised by a zone of
increasing length from a mouth of the channel 15 towards the base
11 of the channel. As seen for example in FIG. 2, the length of the
side plates 12 increase from the mouth of the receiving channel or
receptacle 15 towards the base 11.
[0184] Where an end portion of the second structural member or
joist 2 is to be placed into the receptacle 15 once the connector
10 has been securely fixed to the first structural member or beam,
the alignment zone may provide for the receipt within the
receptacle 15 of an increasing portion of the second structural
member or joist. This configuration may therefore allow for the
insertion of the joist into the mouth of the receptacle with some
angular misalignment, but as the joist progresses further through
the alignment zone towards the base 11 of the receptacle 15, to
progressively align the joist towards its desired final alignment
at which it rests when fully received within the receiving channel
YY or receptacle 15. As seen in FIG. 3, such an alignment of the
joist 2 may be at 90 degrees to the mounting flanges 13 and beam 1,
or in other configurations a connector 10 may accommodate any other
desired angle, being the angle of the side plates 12 relative to
the mounting flange or flanges 13.
[0185] In some forms the tacking engagement of the projections 14
with first structural member may be such that the mounting face 33
is substantially flush with the mounting surface 26 of the first
structural member. However, it is appreciated that the flush
mounting of the mounting face 33 of the connector with the mounting
surface 26 of the first structural member may not be necessary.
[0186] Ultimately, the desired tacking engagement over the
connector with the first structural member is such that at a
minimum the connector may support its own weight on the mounting
surface 26 of the first structural member, such that it may hold
itself in its placed position on the first structural member. A
method of using a connector 10 as described herein for connecting a
first and second structural members will now be described. This
method is the preferred method of performing the invention.
[0187] Such a connector 10 comprises at least a mounting face 33
for mounting to a mounting surface 26 of the first structural
member. It also comprises a receiving channel or receptacle 15 for
receiving at least a portion of the second structural member. The
connector 10 comprises a lip portion 25 and at least one projection
14. In the preferred form both the lip portion 25 and the at least
one projection 14 extend past the mounting face 33 of the connector
10.
[0188] In the use of such a connector 10, the connector is first
aligned at a desired position along an elongate direction of the
first structural member. For example, where the first structural
member is a beam within a flooring system along which joists are to
be spaced, the connector 10 is first aligned along the length of
the beam so that it corresponds with the desired placement of the
next joist on the beam 1.
[0189] Preferably the step of aligning the connector is conducted
when the connector 10 is spaced away from the first structural
member or beam 1 such that the at least one projection 14 and
preferably also the lip 25 do not engage with any part of the first
structural member or beam 1.
[0190] Once aligned along the elongate direction of the first
structural member, the connector 10 and particularly its lip
portion 25 is to be moved towards an alignment surface 27 of the
first structural member. Such a movement is for example seen in
FIG. 13a, where the connector 10 is moved in the direction of the
arrow 28.
[0191] The alignment surface 27 is a surface which is both adjacent
to and in most applications substantially perpendicular to the
mounting surface 26 of the first structural member. For example, as
seen in FIG. 13a, the alignment surface 27 is the bottom surface of
the beam 1, which is adjacent and substantially perpendicular to
the mounting surface 26.
[0192] The moving of the connector 10 towards the alignment surface
27 of the first structural member is to be movement so as to cause
the lip portion 25 to be in an at least partially underlapping
association with the alignment surface 27 of the first structural
member. An example of a lip portion 25 in a partially underlapping
association with an alignment surface 27 are shown in FIG. 13b.
[0193] Preferably the moving of the connector so that the lip is at
least partially underlapping with the alignment surface 27
maintains an orientation of the connector 10 relative to the first
structural member 1 and its mounting surface 26 such that the lip
25 may be underlapping with the alignment surface 27, but the at
least one projection 14 does not engage with the mounting surface
26.
[0194] Once the lip portion 25 is in an at least partially
underlapping association with the alignment surface 27, the
connector 10 is moved towards the orientation in which it is to be
mounted to the first structural member 1. This desired mounting
orientation will be in most applications an orientation where the
mounting face 33 is substantially flush with the mounting surface
26 of the first structural member 1.
[0195] The movement of the connector 10 with its lip 25 at least
partially underlapping the alignment surface 27 towards its desired
placement orientation relative to the first structural member is
shown in FIG. 13b. In FIG. 13b, the connector 10 is to be rotated
in the direction of arrow 29 in order to engage the at least one
projection 14 with the first structural member 1.
[0196] The movement of the connector towards its desired
orientation preferably also substantially aligns the mounting face
33 of the connector with the mounting surface 26 of the first
structural member.
[0197] As shown in FIG. 13b, the movement of the connector towards
its desired orientation may comprise a pivoting of the connector
about the underlapping association of the lip 25 and alignment
surface 27, in the direction of arrow 29.
[0198] Alternatively, where the lip 25 projects further from the
mounting face 33 than the at least one projection 14, the connector
10 may be provided in its at least partially underlapping
configuration while the mounting face 33 is substantially parallel
with the mounting surface 26 of the first structural member. In
such a situation, the movement of the connector towards its desired
orientation may be provided simply by a translation of the
connector 10 along the at least partial underlapping association of
the lip 25 of the alignment surface 27. This translation moves
mounting face 33 of the connector towards abutment with the
mounting surface 26 of the first structural member 1 in order to
tackingly engage the at least one projection 14 with the first
structural member 1. The connector 10 tackingly engaged to the
first structural member is shown for example in FIG. 12, where the
lip portion 25 of the connector 10 is also underlapping the
alignment surface 27 of the first structural member 1.
[0199] The tacking engagement may be able to be effected by the
movement of the connector towards its desired orientation as has
been described. Or, it may require some further action by a user,
such as pressing by hand on the connector, or blows with hammer or
other tool, in order to provide the tacking engagement.
[0200] Following the tacking engagement of the connector 10 with
the first structural member 1 by its at least one projection 14 the
connector 10 may be fastened to at the mounting face 33 of the
connector to the mounting surface of the first structural member
using one or more fasteners 18. The connector 10 when fastened to
the first structural member with a plurality of fasteners 18 is
shown in FIG. 13d.
[0201] In the configuration shown in FIG. 13c, the at least one
projection 14 is also fully driven into the first structural
member, if it was not previously fully driven in order to effect
the tacking engagement.
[0202] Once the connector 10 is securely fastened to the first
structural member 1, the second structural member may be located
within the receiving channel or receptacle 15 of the connector. As
seen in FIG. 13d the second structural member 2 has been moved in
the direction of the arrow 30 such that it is fully received within
the receiving channel or receptacle 15.
[0203] Once the second structural member 2 has been received within
the receiving channel or receptacle 15 the connector 10 may also be
fastened to the second structural member 2 by way of one or more
fasteners 18. The fasteners may be inserted through one or more
holes or apertures 16 provided in the body of the connector, or
they may simply be driven through the body of the connector and
into the second structural member. Once fastened, the structural
connection between the first and second structural members using
the connector 10 is completed.
[0204] For added strength, further fastening of the first and
second structural members to each other may be conducted, such as
by nailing the two members together. However the connector 10 holds
the first and second structural members in their connected
alignment relative to each other, and such further fastening does
not require any other holding of the structural members in order to
maintain their desired alignment.
[0205] As seen in FIG. 13d, the alignment surface 27 of the first
structural member 1 is aligned with a corresponding surface 32 of
the second structural member, which rests on the base 11 of the
connector 10. Where the beam 1 and joist 2 are of the same height,
as is the case in the configuration of FIG. 13d, this alignment of
the alignment surface 27 of the beam 1 and corresponding surface 32
of the joist 2 will serve to provide the opposing top surfaces of
the beam and joist aligned with each other. This result is effected
by the provision of the lip portion 25 coplanar with the base 11 of
the connector.
[0206] Thus the configuration of the connector 10 and particularly
of its lip 25 in relation to the base 11, determines the alignment
between both the bottom and top surfaces of a first and second
structural member when connected using the connector 10. In other
words, by the use of the connector to mount to a mounting surface
27 of a first structural member, as has been previously described,
and the receiving of a second structural member 2 within the
receiving channel or receptacle 15 of the connector, a
predetermined relationship between the alignment surface 27 and
corresponding surface 32, and resultingly also between the
respective top surfaces of the first and second structural members,
may be provided.
[0207] Simply the use of the connector as previously described will
result in this predetermined relationship of the surfaces of the
first and second structural members and their respective surfaces
to each other, without requiring any further steps or manual
alignment of the first or second structural members relative to
each other.
[0208] The previously described configurations of the connector
provide the lip portion 25 in the same plane as the base 11, such
that the alignment surface 27 of a first structural member will be
aligned with a corresponding surface 32 of a connected second
structural member, at least at the interface between the two
surfaces.
[0209] It may however be desirable to provide a predetermined
offset between the level of the lip portion 25 and the base 11 of
the connector 10. For example, such a situation may include where a
joist of a particular vertical dimension is to be connected with a
beam of a greater vertical dimension. In such a configuration an
offset between the lip portion 25 and base 11 which is equal to the
difference in height between the joist and the beam will allow the
beam and joist to be connected using the connector as has been
previously described and result in the alignment of the top
surfaces of the beam and joist, being those surfaces opposite the
alignment surface 27 and corresponding surface 32.
[0210] Where a joist to be connected to a beam of a lesser height
than the joist, an offset in the opposite direction could be used
in order to affect the alignment of the top surfaces of the beam
and joist of such a beam and joist.
[0211] While in most applications it may be desirable to align two
surfaces of the beam and joist, or at least an edge of two surfaces
of a beam and joist, the connector 10 of the present invention is
able to be adapted by varying the offset between the lip portion 25
and base 11 as has been described in order to provide any desired
offset between any two corresponding surfaces of a beam and
joist.
[0212] For different applications the respective distance past the
mounting face 33 of the connector of the lip portion 25 and at
least one projection 14 may be varied. For example, as seen in FIG.
11a, the at least one projection 14 extends further away from the
mounting face 33 of the connector than does the lip portion 25. As
seen in FIG. 11b, the lip portion 25 and at least one projection 14
extend a substantially equal distance away from the mounting face
of the connector. Finally, in FIG. 11c the lip portion 25 extends
further away from the mounting face of the connector than does the
at least one projection 14.
[0213] These different configurations may each be desirable in
different applications, dependent on variables such as the type of
material of the first structural member into which the at least one
projection 14 is to penetrate for the degree of tacking engagement
required in that particular application. It is contemplated that a
relatively short lip portion 25, such as shown in FIG. 11a or 11b,
may facilitate the snug fitment of the corner of the first
structural member 1 against at least part of the lip portion 25 and
at least a part of the mounting face of the connector which is
adjacent to the lip portion 25. This snug fitment may prevent a gap
developing either between the lower part of the mounting face 33 of
the connector and the mounting surface 26 or between the alignment
surface 27 and lip portion 25 when the at least one projection 14
is tackingly engaged with the first structural member. Any such gap
could result in an unintended offset between the alignment surface
27 and corresponding surface 32 of the second structural
member.
[0214] In a preferred form, as seen in FIGS. 11a to 11c of the at
least one projection is spaced apart from the lip portion along the
mounting face 33 of the connector. While shown spaced at opposed
ends of the connector 10, other spacings, such as with the at least
one projection 14 exposed part way along the mounting face of the
connector, may be desirable.
[0215] In most applications the spacing between the lip portion 25
and at least one projection 14 along the mounting face of the
connector should be such that they enable the substantially
separate operations of moving the connector so that the lip portion
25 is at least partially underlapping with the alignment surface
27, and the step of forcing the at least one projection 14 into
tacking engagement with the first structural member 1.
[0216] By providing a maximum of spacing between the lip portion 25
and at least one projection 14 along the mounting face of the
connector, as is seen in FIGS. 11a to 11c, a user may more readily
provide the described underlapping relationship, and preferably
also more readily provide a more complete underlapping association
of the lip portion 25 with the alignment surface 27, without
causing unintended interactions of the at least one projection 14
with the first structural member 1. The spacing apart of the lip
portion 25 and at least one projection 14 may be desirable to
enable the separate operation of the steps of underlapping the lip
and levering the projections at the at least one projection into
tacking engagement with the first structural member.
[0217] The connector 10 of the present invention may also be
described as having a first and second connected states relative to
a first structural member 1. Both the first and second connected
states comprise a connection between the connector 10 and first
structural member 1 such that the weight of the connector 10 may be
supported.
[0218] The first connected state corresponds to the tackingly
engagement of the at least one projection 14 with the first
structural member as has been described, and is affected without
the use of any fasteners or other components external to the
connector. In other words, the first connected state is affected
only by the interaction of the at least one projection with the
first structural member. Thus the connector 10 may be provided in
its first connected state, able to support the weight of the
connector and retain the connector 10 at its placed position on the
first structural member, by involving only the interaction between
the connector and first structural member of parts integral with
the connector. In order to affect the first connected state no
external fasteners or additional components, such as screws or
nails, are required.
[0219] The second connected state relates to a condition where the
connection between the connector 10 and first structural member 1
is such that a second structural member 2 may be received within
and supported by the receiving channel or receptacle 15 of the
connector 10.
[0220] It is contemplated that the lip portion 25 may enable a user
to more accurately set the connector 10 at the desired height to
cause the connected first and second structural members lower
surfaces to be provided at the same height. For example, rather
than locating the connector 10 into the desired vertical position
relative to the first structural member, holding or otherwise
securing in place, then tacking the projections 14 into the first
structural member to provide a preliminary hold, a user may simply
slide the mounting flanges 13 of the connector upwards against the
first structural member until the lip portion 25 is engaged with
the lower surface of the first structural member. Then simply by
maintaining the force to hold the connector against the lower
surface, the connector 10 may be maintained at least in its
vertical position relative to the first structural member but
preferably in its rotational position on the mounting face of the
first structural member prior to and as the projections 14 are
tacked into the first structural member.
[0221] As such, it is contemplated that the provision of the lip
portion 25 which projects past the mounting flanges 13 may expedite
the process of connecting first and second structural members where
it is desired to align the lower surfaces of those structural
members. Furthermore, it is contemplated that the lip portion 25
may enable increased accuracy of the co-planar fixing of the lower
surfaces of the structural members relative to each other due to
the fact that a simple force of the connector upwards to retain the
lip portion 25 in contact with the lower face of the first
structural member is all that is required to retain the connector
in its desired vertical position prior to tacking of the
projections 14 or attachment of one or more fasteners.
[0222] While it may commonly be desirable to fix first and second
structural members so that their lower surfaces are co-planar, the
connector 10 may also be used in other configurations. For example,
the connector 10 of any one of FIGS. 1 to 8C for example may be
provided in any desired placement on the face of a first structural
member, not just so that the base 11 is at the level of the lower
face of the first structural member. This may for example be
desirable where a first structural member of a greater height is to
be connected with a second structural member of a lesser height,
and their top surfaces are to be aligned. The placement of the
connector 10 away from the lower surface of the first structural
member 1 may therefore be desirable in order to locate the upper
surfaces of the first and second structural members co-planar with
each other. While such an application is contemplated for the
connectors shown in FIGS. 1 to 8C, it is also contemplated for
connectors having a lip portion 25 as previously described.
[0223] Views of such a connector capable of both applications is
shown in FIGS. 10A to 10D. As shown most clearly in FIGS. 10A and
10D, the base portion 11 of the connector 10 comprises a lip
portion 25 projecting substantially co-planar with the base 11 and
past the assembled location of the mounting flanges 13. In addition
to the features and functionality of the lip portion 25 as
previously described, the lip portion 25 shown in the embodiment of
FIGS. 10A to 10D preferably additionally comprises one or more
perforations, weakenings, or cuts 26 at the connection between the
lip portion 25 and base 11, such that the lip portion 25 is
frangible from the base 11. Preferably the perforations, cuts or
weakenings are such as to allow a user to bend, tear or sever the
lip portion 25 from the base 11, yet to still allow sufficient
structural connection between the lip portion 25 and base 11 so as
to retain their co-planar relationship to each other even during
the pressing of the lip portion 25 into a lower face of the first
structural member.
[0224] In a preferred form the weakening of the connection of the
lip portion 25 and base 11 is provided by one or more cutouts, such
as stamped cutouts, in the material between the lip portion 25 and
base 11. The weakening is preferably such as to enable or make it
easier to separate the lip 25 from the base 11, so that neither the
lip portion 25 nor base 11 project past the mounting flanges 13 and
the connector 10 may be mounted to other portions of the face of
the first structural member, as previously described. Such a
suitable weakening may be one that allows the separation of a lip
from the base under a tearing of the portion relative to each
other, or preferably by a repeated bending of the lip relative to
the base, in order to weaken and cause the yielding of the
remaining material of the connection between the lip and base 11.
An example of such a weakening, where a plurality of cuts or
punctures have been made in the connection between the lip 25 and
base 11, leaving two thin portions of material remaining, is shown
most clearly in FIGS. 10A and 10D.
[0225] While a projecting lip 25 of any depth desired may be
provided within the scope of the invention, in the preferred forms
the lip 25 will project past the mounting flanges 13 only so far as
to enable its function of contacting the lower surface of the first
structural member and allowing the alignment of the connector 10
therewith.
[0226] The weakening of the connection between the lip portion 25
and base 11 is preferably such that a user may readily separate the
lip from the base either by hand or by the use of small hand tools,
such as a pair of pliers or a hammer. For example, it may be
preferable that the user can bend the lip portion 25 at its
connection to the base 11 by hand so as to cause the weakening and
yielding of the material at the connection. Alternatively, this
bending and weakening may be performed by grasping with a pair of
pliers, or the bending back and forth of the lip 25 by contact with
a hammer.
[0227] The connection between the lip portion 25 and base 11 is
preferably such that upon the removal of the lip portion, no part
of the base 11 projects past the mounting flanges 13. This allows
the placement of the connector in non-underlapping configurations
with the first structural member, without interference from the lip
portion 25 or base 11 at the mounting flanges 13.
[0228] While in the preferred form the lip portion 25 is frangibly
connected to the base 11 such that it may be removed by a user, in
other forms the lip portion 25 may simply be bent away from its
initial substantially co-planar association with the base 11. The
bending is preferably such that the lip portion no longer projects
past the mounting flanges 13 and the connector may be mounted in
non-underlapping configurations as has previously been
described.
[0229] Where the lip portion 25 is to be bent away from its initial
configuration to allow the non-underlapping use of the connector in
association with a first structural member, the connection between
the lip portion and base preferably comprises one or more weakened
portions, scribes or cut-outs to enable to bending of the lip
portion at the connection.
[0230] Additionally shown in FIGS. 9A to 9C and 10A to 10D are
further details of the configuration of the projections 14. As seen
in the top-down view of FIG. 10A, the projections of this
embodiment comprise a projection of lesser width than the width of
its associated mounting flange 13. By providing a relatively
narrower projection 14 the cross sectional area of the projection
which is to be driven into the material of the first structural
member may be reduced. This reduction in area may cause a decrease
in the force required to tack the projections 14 into the first
structural member 1.
[0231] Additionally seen in the configuration of FIGS. 9A to 9C and
10A to 10D are that the projections 14 are provided towards the
outsides of the mounting flanges 13, being at a position away from
the receptacle 15. It is contemplated that such a configuration,
wherein the spacing between the projections 14 is increased, may
provide increased torsional stability of the connector 10 once the
projections 14 have been tacked into the first structural member.
This may particularly be desirable prior to and during the fixing
of the fasteners 18 through the connector 10 to the first
structural member 1.
[0232] As previously described, the first and second structural
members may respectively comprise a beam and a joist. Such beams
and joists may be of any material such that the at least one
projection 14 is capable of penetrating their surface and lodging
within them so as to provide the tacking engagement. The most
commonly used material in such beams and joists will be a timber
material or some form of a timber or some form of timber
composite.
[0233] The dimensions of the connector 10 of the present invention,
and more particularly the receptacle 15 of the connector 10, may be
varied to suit the desired application. For example, the width of
the base 11 may be varied within the scope of the invention in
order to accommodate a second structural member 2 of a particular
width. Similarly, the height of the side plates 12 and mounting
flanges 13 may be varied to suit the height of the first and second
structural members to which the connector is to be attached. For
various different potential applications it may further be
desirable to have a greater or lesser number of holes 16 of the
connector 10 to receive corresponding fasteners 18. For example, a
particular structural application may require the connector 10 to
form a connection between the first and second structural members
to a particular load carrying capacity, requiring a corresponding
number of fasteners 18.
* * * * *