Box Beam Structures And Connections For Beam-supported Structures

Abstract

Box beams are provided having flanged lug sections on one side thereof adapting them for attachment to other structural components such as cross supports and beam-supported structures. Connections are provided for attaching structural components such as purlins to such beams, for instance, to form a cross-supported beam structure, in a manner that facilitates assembly and disassembly, and is adapted for mass fabrication of both components as modular units.

Description

Efforts to cut cost and facilitate construction in the building industry have led to the development of a large variety of modular types of beams, supports, panels and other types of structures that can be manufactured at a factory and assembled on the site to build any kind of structure. In most instances, the modular units require drilling, tapping and other operations in the course of assembly, which is of such a nature that it is not easy to disassemble the structure, either in whole or in part, for repair or for removal of the structure to another building site. It is, of course, important that the structure be assembled in a manner to minimize the number of through ports from outside to inside of the structure, so as to keep leakage entrances to a minimum. It is also important that the structure have a sufficient rigidity to withstand any of the types of weather conditions that are likely to be encountered, as well as provide adequate interior loading capabilities.

In accordance with the invention, box beams are provided that have flanged lug sections on at least one side thereof, adapting them for attachment to other structural components. Preferably, the lug sections are arranged in parallel rows, two rows on each beam, and the flanges extend on each side of each lug, in a T-configuration. Such beams are readily prepared as modular units by extrusion, lowering costs and ensuring availability in standard sizes.

Connections also are provided for attachmnt of any type of structural component to such beams via the flanged lugs. Such connections are arranged so as to engage the lug flanges, attaching thereto from below, and optionally, also at the sides thereof. Snap clips can embrace the flanged lugs; pins can engage them from below; these are merely exemplary.

A preferred embodiment of the invention features means for attachment of cross supports to beams which permit ready assembly or disassembly of the structures, without the necessity for any mechanical shaping, drilling or other fitting operations. Simple insertion of a removable pin is sufficient to provide a secure, rigid structure.

Such cross-supported beam structure according to the invention comprises, in combination, a plurality of beam supports, and a plurality of cross supports at an angle of from about 45.degree. to about 135.degree. to the longitudinal axis of the beams; a plurality of lug sections on one side of a plurality of the beam supports, with gaps between adjacent lug sections, arranged so that gaps on beams attached to cross supports are in alignment, the cross supports extending between and across the beam supports through the gaps of beam supports to which they are attached; apertures through the cross supports beneath the lug sections at such gaps; and means extending through the apertures for attaching the cross supports to the beams via the lugs, comprising pins extending through the aperture, and optionally but preferably having one turned end extending from beneath the lugs for grasping the pins to insert them through and remove them from the apertures.

The box beams of the invention are provided with at least one and preferably two rows of shaped lug sections along at least one exterior wall or side, to which structural members, cross supports or other modular unit structures are to be attached. The rows of flanged lug sections are parallel to each other, and relatively closely spaced, and extend as far along the beam as is necessary for the rigidity of attachment desired.

The flanged lugs can have any flanged cross-sectional configuration, provided the flange can retain a connector of the invention to the beam. The flange consequently extends outwardly from the lug. The lug can carry one flange, i.e. a right or left right-angled-configuration, or two flanges, i.e. a T-configuration, of which the two flanges can have the same or different widths and lengths. The lugs can themselves be I- or T- or right-angled.-beams, attached to or formed in the surface of the box beams.

Modular box beams can, for example, be extruded of aluminum, with continuous flanged lugs extending longitudinally therealong, in a T- or right-angled.-configuration. If intended for use in a large structure, such as a roof or floor-supporting structure, gaps can be cut through the rows of lugs at selected intervals, as slots wide enough to receive cross supports. A press fit between a cross support or the purlin and beam in the slot is especially advantageous, for a rigid structure.

The lug sections composing each row of flanged lugs are disposed at spaced intervals along the beam, with gaps therebetween that are shaped to receive the cross support members or a portion thereof. The gaps between lug sections of adjacent or distant beams to be attached to the supports are preferably in alignment, so that the cross supports extend end to end between and across the beams via the gaps. However, the gaps can also be offset, in any arrangement, in any desired pattern.

The gaps can be aligned at an angle to the beams that is appropriate for the cross support structure desired. Usually, the gaps are set at right angles to the longitudinal axis of the beams, but any angular position can, of course, be selected. Usually, the angle will be within the range from about 45.degree. to about 135.degree., with respect to the beam's longitudinal axis.

These flanged lug or box beams can receive any of a variety of types of connectors, and the structure of the connector is selected according to the structural component to be attached to the box beam.

In the case of cross supports, a convenient type of connector is a pin, passing through an aperture in the cross support beneath the flanged lug. The cross supports, which can, for example, be purlins, having a flat, I- or T-beam configuration, are provided with apertures at spaced intervals, corresponding to the spacing of the beam supports, at a location such that when the cross supports are in position in the gaps across the box beams, there is an aperture beneath at least one longitudinally-extending flange of at least one lug section of each beam to which it is to be attached. Two apertures can be provided, one on each side of each lug, and parallel rows of lugs also can be provided, in which case the cross supports can have apertures on either or both sides of each lug, between or outside each row of lug sections.

The apertures in the cross supports can be arrange for attachment of the cross supports to the beams at any position along the cross supports. End attachment of each cross support is usually required in any structure. In a beam structure extending over a large area, a number of connections to intermediate beams may be useful, in which case intermediate apertures are also provided.

Pin connectors of the invention are especially useful in attaching cross supports end-to-end to box beam supports, to form a long roof, wall, or floor structure. In this case, the box beams should be provided with two parallel rows of lugs, and the cross supports are then placed end-to-end, with the end of one through a gap in one row of lugs, and the abutting end of the next cross support through the gap in the parallel row of lugs on the same box beam. The pins lock the ends of the supports in place, and because at opposite ends of the cross support the pins are on opposite sides of the lugs, sliding of the cross supports in the slots is inhibited by the pin connectors.

The pin connectors in accordance with the invention can be round, triangular, square, or polygonal in cross-section, sized to fit snugly in the apertures of the cross supports in a press fit, and when in position therethrough to lodge securely against the lug flange and body, preferably one on opposite sides of each lug or pair of lugs, to prevent sliding movement of the cross supports with respect to the beams, as well as to prevent removal of the cross supports from the gaps in the beams, by lodging beneath the flanges as well as against the bodies of the lugs.

Each connector pin has a straight shaft portion, for insertion in the aperture and lodging against the body and flange of the lug. The pins can be entirely straight, from end to end. Usually, however, it is more convenient to provide a turned end of sufficient length to project out from beneath the flange, for access thereto beyond the lug flange. The turned end (or the straight end, if there is no turned end) provides a base against which force can be applied, such as by a hammer or pliers, in inserting the pin into and through and removing the pin from the apertures. After the pin has been inserted, if the pin and aperture are round, a turned end can be turned downwardly against the lug body, so that it is out of the way, concealed beneath the lug.

To disassemble the structure, one merely pushes the pin out of the aperture, releasing the cross support from the beam, which can then be removed.

A turned end also provides a convenient means for disassembly of the structure. All that is ncessary to take the structure down is to turn the pin so that the turned pin end can be grasped, and then withdraw it from its aperture.

It will be apparent that any cross-sectional configuration of cross support can be used, and that the gaps across the lugs can be shaped accordingly. Thus, I-beams, T-beams, box beams and other types of cross support configurations can be used.

The flanged lug box beams of the invention, with or without cross supports, can also be used to support a number of types of structural components, which can be attached to the flanged lugs by clips. The clips are provided with gripping ends that attach to the flanged lugs, at the outside edge, the inside edge, or both. Such clips can be resilient, i.e., snap clips, and therefore removable. They can also effect a permanent connection.

The clips are useful to attach roofing, wall panels, movable roof tracks, insulation sheets, acoustic panels, lighting shields, and other structures to the beams. The clips can grip the lugs between other structural components, such as cross supports.

The box beams and connectors of the invention as well as the cross supports used therewith can be made of metal or of plastic. Since the invention is especially intended for use as and with modular units, extrudable metals are particularly useful, such as, for example, aluminum, aluminum alloys, and titanium alloys, as well as structural steel. Plastics are also well suited for manufacture in extruded or molded shapes, and where they have sufficient strength they can also be employed. Typical useful plastics include polyamides, such as nylon, polycarbonates, polystyrene, phenol-formaldehyde, urea-formaldehyde, melamine-formaldehyde, polyester, polytetrafluoroethylene, and polytrifluorochloroethylene polymers. Plastic-coated metal structures are also useful, particularly where corrosion and weathering are to be inhibited.

Preferred embodiments of the invention are shown in the drawings, in which:

FIG. 1 represents an isometric view of one end of a box beam of the invention with two parallel rows of flanged lug sections, and showing a purlin in place between two lug sections;

FIG. 2 represents an isometric view showing the end of the purlin in FIG. 1, before attachment to the box beam of FIG. 1;

FIG. 3 is a cross-section of another portion of the box beam shown in FIG. 1, showing two abutting purlins connected at their ends to the lugs thereof;

FIG. 4 shows in cross-section another embodiment of box beam, with another type of lug flange configuration;

FIG. 5 shows a clip connector for attaching a structural component such as a track support for a movable roof structure;

FIG. 6 shows in cross-section a movable roof structure supported on a cross-supported-box beam structure of the invention; and

FIG. 7 is a view from the bottom of the cross-supported-box beam structure of FIG. 6.

The beam structure 1 shown in FIGS. 1 to 3 of the box type, made of extruded aluminum, with the exposed top exterior surface 2 provided with three channels 3, 4, 5 and two raised portions 6, 7 between the channels. The channels serve as gutters. Each raised portion 6, 7 extends longitudinally along the longitudinal axis of the box beam, from end to end, and integral therewith are two lugs 8, 9, which are parallel and which have a T-configuration, with a supporting body or base 10, 11 and flat T-tops 12, 13 integral therewith, defining flanges 14, 15, 16, 17 extending on each side of the supporting base 10, 11, with the two facing flanges 15, 16 being slightly narrower than the outside flanges 14, 17.

A plurality of slots 20, 21 are cut across each of the lugs at spaced intervals, for reception of cross supports, such as the purlins 25. The cross support or purlin 25 is also an extruded piece. The purlins can have any desired cross-sectional configuration, but the I-configuration shown is especially useful in a horizontal purlin for a roof, with a groove or slot 26 extending longitudinally of the flanged top 27 thereof. The top 27 and supporting body 28 project beyond the base 30 on each end thereof, and the body 28 is shaped with a longitudinal groove 29, circular in cross-section, extending from end to end, to facilitate attachment to other building components. The base 30 of the purline 25 has flanged sides 31, 32. The top 27 and end of body 28 extend sufficiently beyond the end of base 30 to project into the slot 20 of lug 8 of the beam, but not to the lug 9, due to the end of the base 30 abutting the base 10 of the lug 8, and at the same time the base 30 rests squarely on the surface 2 and raised portion 6 of the box beam.

The purlin is locked in this position by the round pin 50, which extends through the aperture 51 at the end of the purlin. The pin 50 fits snugly against the lower face of the flange 15, and also against the base 10 of the lug, and in this position locks the end of the purlin firmly in place in slot 20 on the beam, in which it fits snugly in a press fit.

In installation, the purlin end is readily inserted in the slot 20 in the beam, and locked in the position shown in FIG. 1. All that is necessary is that the end of the purlin be pushed through the slot 20 until the base 30 abuts base 10. The pin is then inserted in the aperture 51, with the turned end 50 facing out and up, and the pin is then driven home by striking the end 52 with a hammer. The hammer is then used to rotate the lug downwardly, as shown in FIG. 1, so the turned end faces in and is concealed between the two lugs 8, 9.

FIG. 3 shows completion of the next step, after insertion of a second purlin 25' in the slot 21 of the beam, and fastening this purlin in place by inserting pin 50' through aperture 51' of purlin 25' beneath flange 16 of lug 9. The abutting purlin ends are spaced slightly apart, to allow for dimensional changes of the purlins with temperature.

In a similar manner, the other ends of the purlins 25, 25' (not shown) are attached to beams at another portion of the structure. They may also be attached to beams at intermediate portions along their length. As shown in FIGS. 1 and 3, only one pin is needed at each end to lock the purlins in place, because the pins at each end are on opposite sides of the lugs beneath which they are attached, and thus prevent sliding of the purlin.

The lugs in FIGS. 1 to 3 have straight flanges. To obtain a more secure locking of the pins in position, and help to prevent any sidewise movement of the cross supports in the slots, it is also possible to form the lug flanges with a downturned portion, as shown in FIG. 4. In this case, the pins 50 are arranged to engage the body of the lug 40, the bottom of flange 42, and the downturned portion 44 of the flange. In this case, to facilitate insertion of the pins in the apertures, the ends 45 of the pins can be provided with an S-curve, to fit beneath the downturned flange of the lug.

FIGS. 5 and 6 show how the box beams of the invention (for illustration, cross-supported as in FIGS. 1 to 3, but this is not essential) can support a movable roof structure. The box beams 1 in between the purlins 25 carry aluminum box clips 18, whose twin gripping ends 19 terminate in flanged tips 22 whose bases bear on the tops of the lugs 8, 9, and which embrace the exterior flanges 14, 17 of lugs 8, 9 of the beam 1. The clips, which are in the form of channels that are extruded in this configuration, are attached at spaced intervals, to allow the purlins to cross between the lug sections to the movable roof track structure 23. The track structure includes track portion 24, exterior guides 33, and interior guides 34, arranged to accommodate the wheel-supporting frame 35 and retain it on the track. It will be apparent that the structure is easy both to assemble and to disassemble, with the clips being slid over or snapped onto the flanged lugs 8, 9, on installation, and removed in a similar manner. In this same way, clips can be used to attach wall, roof, and floor paneling to the box beams.

The clips 18 can be modified so that their gripping ends grasp the interior flanges 15, 16 of the flanged lugs 8, 9, with equivalent results. The structure of the clip is of course chosen with regard to the component to be attached. The box clip 18 is stronger than a clip with a single base, but a single base clip may be preferable for a wall panel, since the clip in that case need not carry a load.

Claims

Having regard to the foregoing disclosure, the following are claimed as the inventive and patentable embodiments thereof:

1. A box beam adapted for fabrication in modular units for attachment to structural components comprising a box beam body having four sides in a box configuration and integral therewith, a flanged lug extending outwardly from the surface of at least one side and longitudinally of the box beam, the flanged lug being arranged in spaced sections, a connector engaging the flanged lug, and a structural component extending between spaced sections of the lug from one side to the other of the lug and held therein via the connector, the connector being a pin extending through an aperture in the body of the structural component and engaging one side of the flanged lug, and preventing withdrawal of the component from such engagement.

2. A box beam according to claim 1, having at least two parallel rows of flanged lugs.

3. A box beam structure according to claim 1, in which the structural component is a cross support.

4. A box beam structure according to claim 1, in which the structural component is a track for a movable roof wheel assembly.

5. A box beam according to claim 1, in which the lug is right-angled.

6. A box beam according to claim 1, in which the lug is T-shaped.

7. A cross-supported box beam structure comprising, in combination, a plurality of box beam supports and a plurality of cross-supports at an angle of from qbout 45.degree. to about 135.degree. to the longitudinal axis of the beams; a plurality of lug sections on one side of a plurality of the box beam supports with gaps between adjacent lug sections, arranged so that gaps on box beams attached to cross-supports are in alignment; the cross-supports extending between and across the box beam supports through the gaps of box beam support lug sections to which they are attached; apertures through the body of the cross-supports beneath the lug sections at such gaps; and pins extending through the apertures for attaching the cross-supports to the box beams via the lugs, the pins having one straight end extending through the aper ture and one turned end extending from beneath the lugs for grapsing the pins to insert them through and remove them from the apertures.

8. A cross-supported beam structure in accordance with claim 7, in which the lugs are arranged as parallel rows of longitudinally-extending beam sections, with the lugs in the form of right-angled or T-beams, and pairs of pins fitted between rows of lugs hold the cross supports against movement in the gaps in either direction.

9. A cross-supported beam structure in accordance with claim 7, in which the beam supports are composed of modular box beam units.

10. A cross-supported beam structure in accordance with claim 7, in which the beam supports are made of aluminum.

11. A cross-supported beam structure in accordance with claim 7, in which the cross-supports are purlins which carry a track for a movable wall or roof structure.

12. A cross-supported beam structure in accordance with claim 7, in which the cross supports are purlins which are designed to carry a roofing structure.

13. A cross-supported beam structure in accordance with claim 7, in which the gaps are in the form of narrow slots engaging the sides of the cross supports in a press fit.

14. A cross-supported beam structure comprising, in combination, a plurality of box beam supports and a plurality of cross-supports at an angle of from about 45.degree. to about 135.degree. to the longitudinal axis of the beams; a plurality of lug sections on one side of a plurality of the box beam supports with gaps between adjacent lug sections, arranged so that gaps on box beams attached to cross-supports are in alignment; the cross-supports extending between and across the box beam supports through gaps of box beam support lug sections to which they are attached; apertures through the body of the cross-supports beneath the lug sections at such gaps; and pins extending through the apertures for attaching the cross-supports to the box beams via the lugs, the lugs being right-angled, and the pins fitting snugly in the corner of the right-angle.

15. A cross-supported beam structure comprising, in combination, a plurality of box beam supports and a plurality of cross-supports at an angle of from about 45.degree. to about 135.degree. to the longitudinal axis of the beams; a plurality of lug sections on one side of a plurality of the box beam supports with gaps between adjacent lug sections, arranged so that gaps on box beams attached to cross-supports are in alignment; the cross-supports extending between and across the box beam supports through the gaps of box beam support lug sections to which they are attached; apertures through the body of the cross-supports beneath the lug sections at such gaps; and pins extending through the apertures for attaching the cross-supports to the box beams via the lugs, the lugs being T-shaped, and the pins fitting snugly in one or both corners of the T.