BACKGROUND OF THE INVENTION
This invention provides an improved steel connector for joining a post to a beam, typically known as a column cap or a post cap. Typically, the joist and beam lie in a common plane with the end of the post abutting the bottom face of the beam or being in close proximity thereto. The use of the connector helps the connection to resist gravity, lateral and uplift loads.
Column caps and post caps are well known in the art. U.S. Pat. No. 963,585, granted to J. A. Kimball in 1910 teaches a sheet-metal, channel-shaped connector where legs for connecting to the post are bent down from the seat and then bent back on themselves 180 degrees to reach up and grab the sides of the beam. U.S. Pat. No. 1,848,085, granted to L. A. Eisenschmidt in 1932, also teaches a channel-shaped connector made from sheet-metal. In this patent the legs that grab the post are bent from the seat at its sides and the walls of the channel are bent up from the front and back edges of the seat. U.S. Pat. No. 2,084,758, granted to A. R. Anderson in 1937, also teaches a channel-shaped connector. In this case the legs for attaching the connector to the post are formed from portions that would otherwise be the walls of the channel and are bent down from the seat of the channel to grasp the post. This patent also teaches an extension on one of the sides of the channel that further strengthens the connection between the post and the beam. U.S. Design Pat. D256,663, granted to Tyrell T. Gilb in 1980, also teaches a channel-shaped connector where legs for attaching to the post are formed from the walls of the channel and are bent down from the seat of the channel to grasp the post. U.S. Pat. No. 5,488,810, granted to Jim W. Horton in 1996, teaches a sheet-metal, channel-shaped connector where the legs for attaching the connector to the post are cut from the seat and extend downwardly from the walls of the channel.
The present invention improves upon the prior art devices by maximizing the material used to make the connection to the post through the legs while not comprising the integrity of the seat or web of the connector, and being easy to install.
SUMMARY OF THE INVENTION
The present invention provides a connection between angularly joined supported and supporting members by means of a connector. Selected embodiment of the present invention improve on the prior art column caps by providing one or more projecting tabs to hold the column cap connector on the top of the post or supporting member, at least during installation, while still creating sufficient material for the legs to attach the column cap to the post or supporting member.
The connector of the present invention has a channel length with a central web portion and upstanding spaced and substantially parallel side walls to cradle a supported member such as truss or beam and depending legs to attach the connector to the supporting member, such as a post. The attachment legs are formed from the material of the web. The projecting tabs that support the connector on the top of the post can be formed from the web or seat of the connector or they can project from the side walls of the connector. The projecting tabs can remain in place interfacing with both the end face of the supporting post and the bottom surface of the supported member, or they can be designed to bend, such that during installation, when the connector is placed on the post and before it is connected to the post with fasteners the projecting tabs interface with the end face of the supporting member and hold the connector at the proper level, but when the supported member is received by the connector, the projecting tabs are bent out of the way, such that the supported member sits directly on the supporting member.
In one preferred embodiment attachment legs are provided that are formed from both the seat or web of the channel and the opposed side wall thus increasing the attachment length of the lengths. The legs extend farther down from the top of the post, distributing the fasteners entering along the length of the post and away from the end of the post which helps to prevent splitting of the post.
In one preferred embodiment, the attachment legs are wider where they attach to the side walls of the connector so as to increase the strength of the connector at this junction. In another preferred embodiment, the attachment legs are twisted so that two distinct surfaces of each attachment leg interface with two surfaces of the post, and fasteners are driven in the sides of the post beneath the extending portions of the beam.
Preferably, the connector of the present invention is formed from a flat blank of sheet steel which is cut, punched, and folded to form the final shape of the connector without welding or connecting additional pieces to the connector. In one preferred embodiment, the attachment legs are formed with alternating widening and narrowing portions so as to provide for the spacing of the fasteners that connect the attachment legs to the supporting member.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of the connection of the present invention using one form of the connector.
FIG. 2 is an exploded perspective view of the connection of the present invention shown in FIG. 1.
FIG. 3 is a perspective view the connector shown in FIG. 1.
FIG. 4 is a front elevation view of the connector of FIG. 1.
FIG. 5 is a side elevation view of the connector of FIG. 1.
FIG. 6 is a top plan view of the connector of FIG. 1.
FIG. 7 is a plan view of the sheet metal blank of the connector of FIG. 1.
FIG. 8 is a top perspective view of the connector and post of FIG. 1.
FIG. 9 is a top plan view of the connector and post of FIG. 1.
FIG. 10 is a perspective view of an alternate connector of the present invention.
FIG. 11 is a front elevation view of the connector of FIG. 10.
FIG. 12 is a side elevation view of the connector of FIG. 10.
FIG. 13 is a top plan view of the connector of FIG. 10.
FIG. 14 is a plan view of the sheet metal blank of the connector of FIG. 10.
FIG. 15 is a top plan view of the connector and post of FIG. 10.
FIG. 16 is a perspective view of an alternate connector of the present invention.
FIG. 17 is an exploded perspective view of a connection made with the connector shown in FIG. 16.
FIG. 18 is a front elevation view of the connector of FIG. 16.
FIG. 19 is a side elevation view of the connector of FIG. 16.
FIG. 20 is a top plan view of the connector of FIG. 16.
FIG. 21 is a plan view of the sheet metal blank of the connector of FIG. 16.
FIG. 22 is a top plan view of the connector and post of FIG. 16.
FIG. 23 is a perspective view of an alternate connector of the present invention.
FIG. 24 is a front elevation view of the connector of FIG. 23.
FIG. 25 is a side elevation view of the connector of FIG. 23.
FIG. 26 is a top plan view of the connector of FIG. 23.
FIG. 27 is a plan view of the sheet metal blank of the connector of FIG. 23.
FIG. 28 is a top plan view of the connector and post of FIG. 23.
FIG. 29 is a perspective view of an alternate connector of the present invention.
FIG. 30 is a front elevation view of the connection of the present invention made with the connector of FIG. 29.
FIG. 31 is a front elevation view of the connector of FIG. 29.
FIG. 32 is a side elevation view of the connector of FIG. 29.
FIG. 33 is a top plan view of the connector of FIG. 29.
FIG. 34 is a plan view of the sheet metal blank of the connector of FIG. 29.
FIG. 35 is a top plan view of the connector and post of FIG. 29.
FIG. 36 is a perspective view of an alternate connector of the present invention.
FIG. 37 is a front elevation view of the connection of the present invention made with the connector of FIG. 36.
FIG. 38 is a front elevation view of the connector of FIG. 36.
FIG. 39 is a side elevation view of the connector of FIG. 36.
FIG. 40 is a top plan view of the connector of FIG. 36.
FIG. 41 is a plan view of the sheet metal blank of the connector of FIG. 36.
FIG. 42 is a top plan view of the connector and post of FIG. 36.
DETAILED DESCRIPTION OF THE INVENTION
As shown in FIGS. 1, 2, 17, 30 and 37, the present invention is an improved connection 1 between a supported member 100, preferably a beam, and a supporting member 200, preferably a post, made with a connector 2, with the supporting member 200 in abutting relation or near abutting relation to the supported member 100, and preferably, in some embodiments, with portions of the connector 2 disposed between the supported member 100 and the supporting member 200.
As shown in FIGS. 2, 4, 5 and 6, the connector 2 has a first end 3 and a second end 4, and a web or seat 5. In the preferred embodiments, the web 5 is interrupted. The web 5 has first and second longitudinally extending edges 6 and 56 with first and second walls 7 and 57 secured to the respective edges 6 and 56. The first and second walls 7 and 57 have outer surfaces 8 and 58 facing away from the web 5, and inner surfaces 9 and 59 facing toward each other and inwardly toward the web 5. The walls 7 and 57 extend longitudinally along the first and second edges 6 and 56 and extend upwardly from the web 5 to support and stabilize the beam 100. The first wall has a top edge 36, and the second wall has a top edge 86.
As shown in FIG. 1, the connector 2 is adapted to receive a beam 100 on or above the web 5 and between the walls 7 and 57. As shown in FIGS. 8, 9, 15, 28 and 28, in selected embodiments, preferably portions of the web or seat 5 are designed to rest on the substantially planar end face 251 of the post 200. End face 251 of post 200 is defined by edges 252. The central web 5 is preferably disposed beneath and in supporting relation to the beam 100.
As shown in FIG. 1, the beam 100 preferably has a substantially planar bottom surface 101 that interfaces with portions of the web 5 of the connector 2 and the beam has first and second side surfaces 107 and 157 that are substantially planar and preferably interface with the inner surfaces 9 and 59 of the walls 7 and 57.
In all of the embodiments of the invention, the connector 2 has one or more central apertures 18 in the web 5. As shown in FIGS. 6, 8, 15, 20, 22, 26, 28, 33, 35, 40 and 42, web 5 has a first central edge 23 that borders a central aperture 18 and lies nearer to the first end 3 of the connector 2 than the second end 4 of the connector 2. The web 5 also has a second central edge 24 that borders a central aperture 18 and lies nearer to the second end 4 of the connector 2 than the first end 3 of the connector 2.
As shown in FIGS. 3, 4, 5 and 6, in all of the embodiments, the connector 2 also has first and second attachment legs 21 and 71. The first and second attachment legs 21 and 71 are formed from material removed from the web 5 to create the one or more central apertures 18. The leg 21 has an outer face 38 that preferably extends from the outer surface 8 of the first wall 7. The leg 21 projects from, is integrally joined to, and is preferably at least partially co-planar with the first wall 7. The second attachment leg 71 is also formed from material removed from the web 5 to create the central aperture 18. The attachment leg 71 has an outer face 88 that preferably extends from the outer surface 58 of the second wall 57. The second leg 71 projects from, is integrally joined to, and is, preferably, at least partially co-planar with the second wall 57.
As shown in FIGS. 1, 5 and 9, the attachment leg 21 also has inner face 39 that preferably extends from the inner surface 9 of the first wall 7, and the attachment leg 71 also has an inner face 89 that preferably extends from the inner surface 59 of the second wall 57. The post 200 is preferably formed with opposed planar side surfaces 207 and 257, portions of which are in registration with the inner faces 39 and 89 of the legs 21 and 71 when the connection 1 is made.
As shown in FIGS. 6, 8, 9, 13, 15, 20, 22, 26 and 28, and in select embodiments of the invention, along the first edge 23 of the web 5 that borders central aperture 18 and between the longitudinally extending edges 6 and 56 of the web 5 the first central edge 23 is provided with one or more projecting tabs 31 that overlie the end 251 of the post 200 when the connector 2 is attached to the post 200. Projecting tabs 31 along first central edge 23 extend toward second end 4 of the connector 2. Similarly, along the second central edge 24 of the web 5 that borders the central aperture 18 and between the longitudinally extending edges 6 and 56 of the web 5 the second central edge 24 is provided with one or more projecting tabs 31 that overlie the end 251 of the post 200 when the connector 2 is attached to the post 200. Projecting tabs 31 along second central edge 24 extend toward first end 3 of the connector 2. Projecting tabs 31 prevent the connector 2 from slipping down the post 200 during installation. The use of projecting tabs 31 in the web 5 also allows more material to be used to make the connection between the attachment legs 21 and 71 and the first and second walls 7 and 57.
As shown in FIGS. 1-15 and 29-42, in select embodiments of the invention, the central aperture or apertures 18 traverse both the first and second longitudinally extending edges 6 and 56 of the web 5, or one of the first and second longitudinally extending edges 6 and 56, to enter the first and second walls 7 and 57, forming notches 67 and 97 in the respective walls. Notch 67 in first wall 7 creates a first end portion 65 and a second end portion 68 in first wall 7 with the notch 67 between them. The first and second end portions 65 and 68 are connected by a bridge portion 66 that lies above the notch 67. Bridge portion 66 is spaced substantially away from longitudinal edge 6. Notch 97 in second wall 57 creates a first wall portion 95 and a second wall portion 98 that are separated by the notch 97 and connected by a bridge portion 96 that lies above the notch 97. Bridge portion 96 is spaced substantially away from longitudinal edge 56. As shown in FIGS. 3, 10 and 29, the central edge 23 of the web 5 continues to an upper portion 20 in the first wall 7 or second wall 57, and the central edge 24 of the web 5 continues to an upper portion 70 in the second wall 57 or the first wall 7. In these embodiments, the first and second legs 21 and 71 have extended portions or leg extensions 22 and 72 respectively made from material from the first or second walls 7 and 57 which extends the central aperture or apertures 18.
As best shown in FIGS. 4, 6, 7 and 8, in certain embodiments of the invention, along the first central edge 23 that borders the web 5 and between the longitudinally extending edges 6 and 56 of the web 5 the first central edge 23 angles away from second end 4 and toward first end 3 of the connector 2 where attachment leg 21 connects to first end portion 65 of first wall 7. Similarly, along the second central edge 24 that borders the web 5 and between the longitudinally extending edges 6 and 56 of the web 5 the second central edge 24 angles away from first end 3 and toward second end 4 of the connector 2 where attachment leg 21 connects to first end portion 95 of second wall 57. This angling of first and second central edges 23 and 24 where the attachment legs 21 and 71 join to the first and second wall 7 and 57 allows the attachment legs 21 and 71 to be wider and thus stronger. Preferably, the angling of the first and second central edges 23 and 24 is only for a portion of the first and second central edges 23 and 24 between the longitudinally extending edges 6 and 56 so as to not remove too much material from the web 5. Angling of central edges 23 and 24 creates angled sides 33 and 34 of attachment legs 21 and 71.
As shown in FIGS. 7, 14, 21, 27, 34 and 41 the connector 2 is preferably cut from a flat sheet metal blank. Fastener openings 30 are drilled or punched through the first and second wall portions 7 and 57. When the first and second wall portions 7 and 57 are bent up along the first and longitudinally extending parallel edges 6 and 56 of the channel length 2, the first and second attachment legs 21 and 71 are simultaneously bent down, enlarging the one or more central apertures 18.
As shown in FIGS. 7 and 14, the blanks between legs 21 and 71 and between leg extensions 22 and 72 can be cut in a wavering patterns so at to make alternating and corresponding narrowing and widening portions in the attachment legs 21 and 71 and leg extension 22 and 72. This allows for the spacing of fasteners 37 so as to prevent splitting of post 200. The fasteners 37 used are preferably nails, as shown in FIG. 17, or self-drilling and self-cutting threaded fasteners 37 as shown in FIG. 2. The fasteners 37 are also driven through the side walls 7 and 57 of the connector 2 into the supported member 100.
As shown in FIG. 1, the purpose of the connector 2 is to adequately position and secure a beam 100 in an anchored relation to a post 200. The post 200 is preferably formed from wood, but another form of building material or, in fact, any other material which is strong enough and to which the legs can be connected, as by welding, fastening or adhesively bonding is possible. Preferably, the connector 2 is made from cold-formed sheet steel.
As shown in FIGS. 30, 35, 36 and 42, the projecting tabs 31 that are able to interface with the end face 351 of the supporting member 200 can be provided along the first longitudinally extending edge 6 of the connector 2 and along the second longitudinally extending edge 56 of the connector 2. As shown in FIG. 37, in the embodiment shown in FIGS. 36-42, the one or more projecting tabs 31 that are able to interface with the end face 251 of the supporting member 200 can be moved out of interfacing engagement with the end face 251 of the supporting member 200 when the supported member 100 is received by the connector 2, such that the bottom surface 101 of the supported member 100 rests directly on the end face 251 of the supporting member 200. Preferably the projecting tabs 31 are cut and bent from the first and second side walls 7 and 57, and the edges of the projecting tabs 31 interface with the end face 251 of the supporting member. When the supported member is inserted between first and second side walls 6 and 56, during the formation of the connection, and the supported member 100 is set on the web 5, the first and second side surfaces 107 and 157 of the supported member 100 push the projecting tabs 31 out of interfacing engagement with the end face 251 of the supported member 200.
As shown in FIGS. 29-33, the first and second attachment legs 21 and 71 can be formed with upper planar portions 27 and 77 and lower angled portions 28 and 78. The lower angled portions 77 and 78 preferably wrap around the supporting member 200, and are preferably set orthogonally to the upper planar portions 27 and 28. The upper planar portion 27 of the first attachment leg 21 projects from, is integrally joined to, and is preferably co-planar with the first wall 7. The upper planar portion 77 of the second attachment leg 71 projects from, is integrally joined to, and is, preferably, at least partially co-planar with the second wall 57. The post 200 is preferably formed with first and second opposed planar side surfaces 207 and 257, portions of which are in registration with the inner faces 39 and 89 of the upper planar portions 27 and 77 of the first and second attachment legs 21 and 71 when the connection 1 is made. First and second opposed planar side surfaces 207 and 257 of the supporting member 200 are preferably in parallel relation to the first and second side walls 7 and 57 of the connector 2 and the first and second side surfaces 107 and 157 of the supported member 100. The supporting member or post 200 is also preferably formed with third and fourth opposed planar side surfaces 277 and 287 which are orthogonally disposed with respect to the first and second opposed planar side surfaces 207 and 257. Portions of third and fourth opposed planar side surfaces 277 and 287 are in registration with the inner faces 39 and 89 of the lower angled portions 28 and 78 of the first and second attachment legs 21 and 71, respectively, when the connection is made. As shown in FIG. 30, preferably the lower angled portions 28 and 78 of the first and second attachment legs 21 and 71 are connected to the third and fourth opposed planar side surfaces 277 and 287 with fasteners 37.
As is also shown in FIGS. 33, 34 and 35, the projecting tabs 31 from the longitudinally extending edges 6 and 56 can extend towards and be integrally connected to each other.
Patent Application
20210388599
