Connector for mounting structural components

Description

BACKGROUND OF THE INVENTION

The present invention is directed to a connector for mounting one structural member or component to another. The present invention has special applicability to the connection or mounting of structural members associated with extruded glazing framework or frames for skylights, windows, and the like. In particular, the present invention is intended for use with the “INTALOK” glazing mounting system manufactured and sold by Sky Roof P/L of Victoria, Australia, and disclosed in U.S. Pat. No. 5,655,346, which patent is incorporated by reference herein.

Currently in the glazing industry, extruded glazing frames, such as those having hip and rafter components of closed and hollow cross-sections for use in skylight framework, and the like, are commonly joined together at intersections by the use of welds or brackets, or in the case of window frames, by shear blocks. However, welds destroy the coated finish of the frame components in the region of the weld, and presently-used bracketing methods require visible and unsightly fasteners, such as screws. Welded or screwed joins are, thus, visually unattractive. In addition, when a join is not a right-angle one, such as a compound angle join, or when a number of joins having different angles of intersection, the design and manufacture of numerous individually angled brackets is particularly complex and time-consuming. In the use of these shear blocks, a connector is first affixed to a first component by first screws, and then a second component that is to be connected to first component is attached to the connector by other screws transverse to the first screws.

In above-mentioned U.S. Pat. No. 5,655,346, there is disclosed a glazing framework having a base section or bar for mounting the glazing, such as glass or plastic, of a skylight, window and the like, by means of a T-shaped, glazing mounting cap, with the glazing being sandwiched and held between the upper surface of the base section or bar, and the glazing mounting cap. Each base section or bar is of hollow-interior construction, and has an upper, cooperating recess for receiving the locking portion of the T-shaped glazing mounting cap. Each base section or bar may act as a rafter base, hip, mullion or similar structural component, when the skylight, window or the like, is constructed, by which the glazing framework is structurally formed and mounted to building components

The connector of the present invention is intended for use in mounting a glazing-frame component, such as the rafter base or bar, to a structural component, such as the hip rafter, or mullion, or the like, in a way such that it readily and facilely allows joinder of components without any exposed hardware, while providing improved structural connection. In addition, the very same connector may be used to connect right-angle joints, single-angle joints, and double-miter joints, unlike the above-discussed prior-art methods, which, therefore, reduces overall cost, obviates the need for custom connection-hardware, and, therefore, reduces overall installation time. Thus, the connector of the present invention is a universal connector that is used at component-interconnections regardless of the angle of such intersection.

SUMMARY OF THE INVENTION

It is, therefore, the primary objective of the present invention to provide a connector for connecting a structural component to another structural component, which connector is mounted entirely within the hollow interior of a structural component, whereby the connector is hidden from view for aesthetic reasons while also providing improved and enhanced structural support to the connection between structural components.

It is, also, the primary objective of the present invention to provide such a connector for connecting a structural component to another structural component, which connector is mounted entirely within the hollow interior of a structural component, which structural components are part of a glazing framework for forming a skylight, window, and the like.

It is, also, the primary objective of the present invention to provide such a connector for connecting structural components forming part of a glazing framework for forming a skylight, window, and the like, which connector may be used for all types of intersections between structural components, whether right angle, acute angle, double mitered, and the like, while allowing fast and easy securement between components.

Toward these and other ends, the connector for structural components, such as those forming a glazing framework for skylights and windows, is made of extruded aluminum, for example, and comprises an elongated main body portion which is slidably receivable in one end of the hollow interior of a structural component to be attached to another structural component, such as a rafter or common rafter component forming part of a glazing frame to a hip rafter or hip of the building structure, or for connecting similar structural components together that may form the transoms and mullions of a glazing framework. The main body portion is elongated in a first, longitudinal direction, and defines an upper surface and a lower surface. Provided between the upper and lower surfaces, there is at least one transverse web that is connected to the upper and lower surfaces in a second, transverse depth-direction as compared to the first, longitudinal direction, which web preferably extends the entire length of the main body portion in the first, longitudinal direction. In the case of one such transverse web, the web is located centrally between the upper and lower surfaces. The transverse web is provided with a plurality of through-passageways or through-openings which receive therethrough first fastening elements, such as fastening screws, which fastening elements mount the connector to a structural component, such as the hip, or hip rafter, of a structure. The main body portion is also comprised of a plurality of transversely spaced-apart, longitudinally-extending mounting ears or flanges projecting in a third width-direction perpendicular to the first and second directions, which mounting ears or flanges project outwardly from either edge of the upper and lower surfaces, and from opposite sides of the transverse web. Each mounting ear or flange extends substantially along the length of main body portion in the first longitudinal direction, and defines a central or middle section of minimal thickness, which middle sections on the same side of the transverse web are aligned in the second transverse direction in order to allow second fastening elements, such as a screws, to be operatively passed therethrough. The second fastening elements passing through the mounting ears extend perpendicularly with respect to the first fastening elements passing through the transverse web, and are used for fastening the coupler or connector to a structural component in which the connector is to be a part. The connector is initially fastened to the structural component, such as a hip, or other similar component, to which another structural component of a glazing frame is to be mounted. This initial mounting is achieved via the first fastening elements passing through the transverse web. After mounting of the connector of the invention to the hip, for example, the structural component, such as the rafter, that is to be mounted to the hip, is slid over the connector, whereby the connector enters into, and is completely contained within, one end of the hollow interior of the rafter, for example. Thereafter, the connector is fastened to the rafter by means of the second fastening elements by passing them through the aligned middle sections of the plurality of ears or flanges on either side of the transverse web. The connector may be cut to the desired angle at its end to be mounted to the hip, which angle will be same as that of the end of the rafter it is coupling to the hip. A similar procedure applies when connecting two similar components, such as transoms or mullions, in the hollow ends of which are mounted connectors of the invention.

The connector of the present invention in combination with the base disclosed in above-mentioned U.S. Pat. No. 5,655,346 serve as a universal-type of glazing base, whereby this base may serve in different capacities in a glazing framework. Thus, the base when provided with the connector of the invention serves as a mullion or post when used vertically in the glazing framework, as a transom when used horizontally or purlin, or as a rafter when used at an angle in the glazing framework. This very same base with the connector of the invention is also used as a hip when placed at the corner of a structure of which the glazing framework is to be part. Two or more identical base sections may be connected together via the connector of the invention at each end of each base section. The length and overall girth of a base section will change depending upon the type of structural member it is to serve as, with the connector of the invention being correspondingly dimensioned for fitting inside a hollow end of the base section. However, regardless of the type of structural component that the base is to be used as, the connector of the invention is used identically in all, thereby serving as an universal connector for all types of structural components associated with glazing frameworks, whether rafter, hip, mullion, post, transom, purlin, and the like.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more readily understood with reference to the accompanying drawings, wherein:

FIG. 1 is an isometric view showing the universal connector for connecting structural components of a glazing framework;

FIG. 2 is an end view of either end of the connector of FIG. 1;

FIG. 3 is an end view of a prior-art base section in which the connector of FIG. 1 is mounted in the hollow-interior end thereof;

FIG. 4 is an end view of a prior-art base section of FIG. 3 showing the connector of FIG. 1 mounted in the hollow-interior end thereof;

FIG. 5 is an end view similar to FIG. 2, but showing a modification of the connector of FIG. 1;

FIG. 6 is an end view of a second type of prior-art base section in which the connector of FIG. 5 is mounted in the hollow-interior end thereof;

FIG. 7 is an end view similar to FIG. 4 and showing the connector of FIG. 5 mounted in the hollow-interior end of the base section of FIG. 6;

FIG. 8A is an elevation view of an angled join connector formed by the interconnection of two connectors of FIG. 1, where each connector has been angle-cut at one end and joined together thereat for forming an angle-section for mounting two base sections forming an angle-section of a segmented glazing framework;

FIG. 8B is a first end view of the angled join connector of FIG. 8A;

FIG. 8C is a second end view of the angled join connector of Fig, 8A;

FIG. 8D is a cross-sectional view taken along line 8D-8D of FIG. 8C;

FIG. 9 is an elevation view showing the initial bending of a fastening element for joining two separate mitered connectors in order to form the angled join connector of FIG. 8A;

FIG. 10 is an enlarged view of the flush engagement between the mitered ends of the two connectors forming the angled join connector of FIG. 8A, showing the opposite sense of the opening of the respective passageways passing the fastening element of FIG. 9; and

FIGS. 11-18 are isometric assembly views showing the use of the connector of the invention in mounting one end of a base section to another structural component of a glazing framework.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings in greater detail, and to FIGS. 1-4 for now, the connector of the invention is indicated generally by reference numeral 10. The connector 10 is preferably made of structural-strength extruded aluminum, and has especial use in the “INTALOK” glazing mounting system manufactured and sold by Sky Roof Pty. Ltd. of Victoria, Australia, and disclosed in U.S. Pat. No. 5,655,346. The connector 10 has an elongated main body portion or frame 12 which consists of an upper flange or top surface 14, and a lower flange or bottom surface 16. Connecting or joining the upper and lower flanges 14, 16 is a transverse web 18, which in the embodiment of FIGS. 1-4, is centrally located between the upper and lower flanges 14, 16. The web 18 is provided with a plurality of spaced-apart, elongated, arcuate passageways or cavities, such as the three passageways 20, 22, 24, although more or less may be provided. Each passageway 20, 22, 24 is preferably not a perimetrically closed surface in order to leave a gap or opening 20′, 22′, 24′ in order to allow slight circumferential expansion of the respective passageway, if necessary, when a fastening element, such as a screw or bolt, is passed therethrough for purposes of mounting the connector 10 to a structural component, as described in detail hereinbelow. It is noted that the lateral side to which each gap 20′, 22′, 24′ preferably opens or faces alternates among the passageways 20, 22, 24, as can be seen in FIG. 2, so that, for example, when viewing FIG. 2, the gap 20′ faces the opposite side as that of gap 22′ but to the same side as gap 24′. It is, of course, within the purview of the invention to allow for all gaps to face in the same direction, and to provide completely enclosed passageways 20, 22, 24.

Extending from each side edge-surface of each of the upper and lower flanges 14, 16 are channel sections 30, 32, and 34, 36, respectively, preferably extending the full length of the main body portion 12. Each channel section is formed with side walls in order to form a channel 30′, 32′, 34′, 36′ therebetween. The respective walls of each channel section are joined by a bottom wall section 30″, 32″, 34″, 36″, with each wall section having a middle or central thin-walled portion, as best seen in FIGS. 1 and 2. These thin-walled portions of the joining wall sections 30″, 32″, 34″, 36″ are thin enough so as to allow a drill or self-drilling fastening element to pass readily therethrough, while still providing structural integrity to the wall sections 30″, 32″, 34″, 36″. As explained hereinbelow in greater detail, fastening elements, such as screws or bolts, pass through the wall sections 30″, 32″, 34″, 36″ for mounting the connector 10 in a hollow interior end of a base section, which base section serves as a structural component of a larger structure, such as a glazing framework, where the base section may serve as a rafter, hip, mullion, transom, purlin, and the like.

In linear alignment with the channel sections 30, 32, and 34, 36, respectively, are a plurality of laterally projecting, side web sections or ears 40, 42, and 44, 46, respectively. Each web section 40, 42, and 44, 46 is connected at one end to a respective side surface portion of the central web 18 and between two respective passageways 20,22,24, and defines a V-shaped, thin-wall portion 40′, 42′and 44′, 46′, respectively; each web section 40,42 and 44, 46, projects a distance away from a respective surface of the web 18 such that each thin-wall portion 40′, 42′ and 44′, 46′ is in alignment with a thin-wall portion of the wall sections 30″, 32″, 34″, 36″; therefore, thin-wall portions 40′, 44′ are in alignment with each other and with the thin-wall portions 30″, 34″, while the thin-wall portions 42′, 46′ are in alignment with each other and with the thin-wall portions 32″, 36″.

The combination of thin-walt portions 30″, 40′, 44′, 34′, and the combination of thin-wall portions 32″, 42′, 46′, 36′, define a pair of guides, one on either side of the connector 10, by which fastening elements 50, such as screws or bolts, may pass and be guided, which fastening elements are used for securing or mounting the connector 10 to the interior hollow end of a structural component of which it is to be part and used for mounting the structural component 52 to another structural component of a structure, as seen in FIG. 4. The interior of the base section 52 is preferably provided with a pair of elongated, upper, interior opposed tabs or ears 54, and a pair of elongated, lower, interior tabs or ears 56, between which upper and lower pairs of tabs the connector 10 is received. These upper and lower tabs or ears 54, 56 also receive therein the fastening elements 50, such as screws or pins, whereby the connector 10 is secured within the hollow end of the base section 52. Additional fastening of the connector in the hollow interior end of the base section 52 may be achieved by passing screws or bolts through the side walls 56″ of the base section into adjacent portions of the connector 10, such as the channel sections 30, 32, 34, 36, or even into the conesponding portions of the transverse web 18, if needed.

The number of fastening elements 50 used may be varied depending upon the length of the connector 10. Preferable, a series of longitudinally spaced-apart fasteners 50 are used on each side, which series of fasteners extend in the first direction longitudinally along the length of the main body portion 12. The structural component 52 is a base or base section, such as that used in the “INTALOK” glazing mounting system manufactured and sold by Sky Roof Pty. Ltd. of Victoria, Australia, and disclosed in U.S. Pat. No. 5,655,346. The base section 52 may be a hip, rafter, transom, mullion, purlin, or the like, with its length varying depending on which structural member it is to serve as, and according to the specific glazing framework of which it is part. Accordingly, the length of the connector 10 may vary also depending upon the type of structure with which it is to employed for coupling base sections 52. The base section 52 has an arcuate-shaped channel or groove 56′ formed into its top surface in which is received a cover or cap by which glazing is mounted to the frame at the base section 52 thereof, which forms part of the above-mentioned “INTALOK” glazing mounting system manufactured and sold by Sky Roof Pty. Ltd. of Victoria, Australia, disclosed in U.S. Pat. No. 5,655,346.

Referring now to FIGS. 5-7, there is shown a second embodiment 60 of the connector of the invention. The connector 60 is similar to the connector 10, with the exception that instead of the central web 18 of the connector 10, a pair of laterally spaced-apart webs 64, 66 are used, which webs 64, 66 connect between upper flange or top surface 70 and lower flange or bottom surface 72 off-center from the center thereof. Each web 64, 66 is provided with a plurality of passageways 74, 76, respectively, identical to those of the web 18. Moreover, each of the upper and lower flanges 70, 72 is provided with upper channel sections 78, 80, and lower channel sections 82, 84, respectively, like those of the connector 10. In addition, each web 64, 66 is also provided with laterally projecting web sections 86, 88, 90, and 92 like web sections 40, 42, 44, 46, which are in alignment with respective ones of the channel sections 78, 80, 82, 84, as may be seen in FIG. 5. Each laterally projecting web section 86, 88, 90, 92 protrudes from, and is formed integrally with, one of the passageways 86, 88, and faces the same way as the respective gap of its associated passageway.

In the embodiment of FIGS. 5-7, the connector 60 is generally of greater girth than the connector 10, and is used for mounting a base section or component 52′ of greater girth than the base section 52 in which the connector 10 of the first embodiment is mounted. Thus, the connector 60 is preferably provided with four or more passageways 74, 76 for each web 64, 66, respectively, whereby a total of eight are provided, allowing more fasteners to be used and the concomitant greater structural integrity of the mounting of the structural component 52′ to which the connector 60 is secured via fasteners 50.

Referring now to FIGS. 8A, 8B, 8C, 8D, 9 and 10, there is shown a pair of connectors 10 of the first embodiment fastened to each other, where each connector 10 has been angle-cut, or mitered, at an end 10′. The ends 10′ of each connector 10 are placed in flush engagement with other, as seen in FIGS. 8A and 8D, and secured together by fasteners, such as by threaded rods or bolts 90 and nuts 92 which pass through aligned passageways or cavities 20, 22, 24 of the adjoined connectors 10 . In order to connect the two angle-cut or mitered connectors 10, each threaded rod or bolt 90 is of such length so as to pass through both two connectors 10 when joined. To secure the mitered or angled connectors 10 together, one first bends the threaded rod or bolt 90 to the desired angle, which angle is that of the miter cut of the ends 10′ of the connectors 10, as seen in FIG. 9, whereupon the first straight half or section 90′ is passed through one of the passageways or cavities 20, 22, or 24 of one connector 10. Thereafter, the other straight half or section 90″ is then passed through the corresponding and aligned passageway 20, 22, or 24 in the other of the two connectors 10 forming the angle-cut join connector. Nuts 92 are then tightened to secure the threaded rod and to secure the two connectors. The same procedure is done with one or more other threaded rods passing through one or more other corresponding, aligned passageways or cavities 20, 22 or 24 of the two connectors 10, such as passageways 24 as seen in FIGS. 8A-8D.

After the two angle-cut connectors 10 have been so secured, then an end of each of a pair of base sections 52 is slid over a respective one of connectors 10, which ends of the base sections have been mitered to an angle similar to that of the ends 10′, after which, fasteners 50 secure the respective connector 10 in the interior of the hollow end of the respective base section 52, in the manner described hereinabove. This type of connection is used especially for forming segments of an angled skylight, as well as for other structures. The bent, threaded fastener 90 acts like a post-tensioned, reinforced beam, where the threaded rod 90 is placed mainly in tension when resisting a bending moment. The connectors may, also, be joined at a double-miter.

Since the connector 10 is to be received within a hollow end of a base section 52, the angle or miter of both the end 10′ of the connector 10 and the corresponding end of the base 52 in which the connector 10 is to be received, may be cut together, as by a saw, in just one operation by first placing the connector 10 within the corresponding end of the base 52 in the manner that they will assume when affixed to each other, and cutting both the end 10′ of the connector 10 and the correspond end of the base 52 together.

It is noted that when the two connectors 10 are coupled together, each passageway 20, 22, or 24 of the first connector has its gap or opening 20′, 22′, or 24′ in the opposite sense as its counterpart, aligned passageway 20, 22, or 24 of the other connector, in order to counter-encase, or capture, the rod or bolt 90. This is seen in FIG. 10, where the arcuate wall of a respective passageway 20, for example, in the first connector surrounds, the shaft of the half-section 90″ of the fastener 90 on one side thereof, while the arcuate wall of the aligned passageway 20 in the second, mating connector surrounds the shaft of the half-section 90′ of the fastener 90 on the other side of the fastener, whereby the passageways of the two connectors 10 have their arcuate walls in the opposite sense. The same holds for the other aligned and corresponding passageways or cavities 22 and 24 of the two connectors 10.

Referring now to FIGS. 11-17, there is shown the manner by which a connector 10 of the invention is used. The example of FIGS. 11-17 shows a coupler 10 that is to be mounted in the hollow interior end of a base section 52, which base section, in the example shown, is a rafter which is to be mounted to the side surface 98′ of another base section serving as a hip 98, for example. In the example shown, the connection between the rafter and the hip is at an angle, whereby both the connector 10 and its receiving rafter 52 has been cut to the proper angle or miter in a conventional manner. The end of the connector 10, and the corresponding end of the base section 52, are cut to length and shape by a single cut taken in the same plane as the cut required in an end of the glazing frame section, to thereby produce an angled join flush with the glazing frame section and the structure. After miter-cutting the connector 10 to the proper angle, the connector 10 is mounted to the appropriate section of the side surface 98′ of the hip 98 by means of the fastening elements, such as bolts or screws (FIG. 12). Three such screws or bolts are typically used and pass through the three passageways 20, 22, 24 of the coupler 10, as described hereinabove (FIGS. 1-4). Alternatively, the connector 60 of FIGS. 5-7, with six such passageways, may be used depending upon the girth and use in which the connector of the invention is used. After the connector 10 (or connector 70) has been mounted to the hip 98, one hollow end 52″ of the receiving base section 52, that has been mitered to the same angle as that of the connector 10, is slid longitudinally over the attached connector 10 (FIG. 14), so that the connector 10 is entirely received within the hollow interior end 52″ of the base section 52, such that the mounting connector and the fasteners are fully concealed within the glazing frame section (FIG. 15). Thereafter, fasteners, such as screws or pins 50 of FIG. 4, are used to permanently secure the connector 10 and the end 52″ of the base section or rafter 52 together (FIG. 16), in the manner discussed hereinabove with reference to FIGS. 2-4. The other end 52″ of the base-section rafter 52 is similarly connected to another base section serving as another structural component 102, such as a mullion or another hip, for example, which other end 52″ and corresponding connector therefor may or may not be mitered, to form a structurally integral unit, as seen in FIG. 17.

If a rafter, for example, is to be joined to a hip, for example, and is to be connected at a simple right angle, then, of course, the end of the connector 10 and the corresponding receiving end of the rafter are not cut, in order to retain a right-angle structural unit. The process of securement of a simple, right-angle structural unit is the same as described above for the mitered connector and base section, and is shown in FIGS. 18A-18C, where the right-angle connector 10 of FIG. 18A is first attached to a another base section serving as a purlin 108, for example, with a surface face 108′ (FIG. 18B). Thereafter, the base section 52 serving as a rafter, for example, is slid over the secured connector 10 for receiving the connector 10 in the hollow interior end thereof, whereupon the connector and the base section are fastened together by pins or screws, as described above. The same procedure is performed at the other end of the base section 52, whereby a right-angle structural unit is formed (FIG. 18C).

It is noted that the relatively narrow, each elongated connecting web section of the connectors 10 and 70 that connect the upper and lower flanges together may be considerably wider, or thicker, in the lateral direction as that shown in the drawings if additional structural reinforcement and integrity is required, or they may be spaced considerably much farther apart from each. In addition, the channel sections 30, 32, 34, 36 may be eliminated, and the fasteners may just be passed through extended portions of the upper or lower surface section 14, 16.

While the connector 10 or 60 of the invention has been described hereinabove with respect to use in a glazing frame or framework, the connector of the invention may be used in other structural environments where the coupling of similar structural components into a frame, framework, or latticework, is to be accomplished, where such components have hollow interiors or hollow interior ends in which the connector of the invention may be mounted.

While specific embodiments of the invention have been shown and described, it is to be understood that numerous changes and modifications may be made therein without departing from the scope and spirit of the invention as set forth in the appended claims.

Claims

1. A connector for connecting a structural element to a structure, comprising: A main body portion extending in a first, longitudinal direction; said main body portion comprising a first end, a second end, an upper surface section, a lower surface section, and elongated transverse connecting means for connecting together said upper and lower surface sections, said transverse connecting means extending at least substantially along the length of said main body portion and connecting said upper and lower surfaces sections in a second direction that is perpendicular to said first longitudinal direction; said elongated transverse connecting means having at least one passageway means extending in said first longitudinal direction for passing therethrough from said first end to said second end at least one fastener element for securing said main body portion to a structural element; said elongated transverse connecting means comprises at least one transverse web section, and a plurality of passageways formed in said at least one transverse web section and extending in said first longitudinal direction for passing therethrough from said first end to said second end a plurality of fastener elements for securing said main body portion to a structural element, one said passageway being located in closer proximity to said upper surface section, and another said passageway being located in closer proximity to said lower surface section; each of said upper and lower surface sections comprising a first side edge-surface and a second side edge-surface spaced from said first side edge-surface in a third lateral direction perpendicular to said first and second directions, and a central mid-section extending in said first longitudinal direction; said at least one transverse web section being located between said first and second side edge-surfaces of said upper surface section and said lower surface section.
2. The connector for connecting a structural element to a structure, according to claim 1, wherein each said passageway comprises a partially open, arcuate cavity defining an open gap.
3. The connector for connecting a structural element to a structure, according to claim 2, wherein each said open gap of a said arcuate cavity faces in said third, lateral direction perpendicular; said open gap of one said arcuate cavity facing oppositely to a said open gap of an immediate adjacent said arcuate cavity.
4. The connector for connecting a structural element to a structure, according to claim 1, wherein said elongated connecting means one said transverse web section connecting said upper surface section and said lower surface section at said central mid-sections thereof.
5. The connector for connecting a structural element to a structure, according to claim 1, wherein said elongated connecting means comprises a plurality of laterally spaced-apart transverse web sections, said plurality of transverse web sections being laterally and centrally offset between said upper surface section and said lower surface section in said third direction; at least one said transverse web section lying on one lateral side of said central mid-sections taken in said third direction and at least another said transverse web section lying on the other side of said mid-sections taken in said third direction.
6. The connector for connecting a structural element to a structure, according to claim 1, wherein said at least one transverse web section comprises a plurality of laterally-projecting guide means extending in said third, lateral direction for guiding fasteners through said main body portion; at least one of said plurality of laterally-projecting guide means protruding from one lateral side of said at least one transverse web section, and at least one other of said plurality of laterally-projecting guide means protruding from the other lateral side of said transverse web section.
7. The connector for connecting a structural element to a structure, according to claim 6, wherein said ones of said plurality of laterally-projecting guide means protruding from one lateral side of said at least one transverse web section being in alignment in said second direction, and said other ones of said plurality of laterally-projecting guide means protruding from the other lateral side of said at least one transverse web section being in alignment in said second direction; said main body portion further comprising laterally-opposite fastener-passing means projecting from respective said first and second side edge-surfaces of said upper surface section and said lower surface section, ones of said laterally-opposite fastener-passing means projecting from the first lateral side being in alignment with said ones of said plurality of laterally-projecting guide means protruding from one lateral side of said at least one transverse web section, and others of said projecting fastener-passing means projecting from the second lateral side being in alignment with said other ones of said plurality of laterally-projecting guide means protruding from the other lateral side of said at least one transverse web section.
8. The connector for connecting a structural element to a structure, according to claim 7, wherein each of said plurality of guide means comprises a thin-wall section by which a fastener passing through said upper surface section passes readily through, and is guided to, said lower surface section.
9. The connector for connecting a structural element to a structure, according to claim 1, in combination with a structural component comprising a main housing having a first hollow-interior end section and a second hollow-interior end section; said connector being received entirely within one of said first and second hollow end sections, whereby said one hollow end section may be mounted to another structural component by said connector; said structural component comprising connector-receiver means for use in slidingly orienting said main body portion of said connector in said one hollow end section; said connector-receiver means comprising at least one of an interiorly-extending top and bottom portion extending inwardly from side walls of said structural component; said at least one of an interiorly-extending top and bottom portion receiving at least one fastener element therein by which said main body portion of said connector may be affixed to said structural component; said structural component being one from the group consisting of a: rafter, mullion, and transom.
10. The connector for connecting a structural element to a structure, according to claim 1, wherein at least one of said first and second ends of said main body portion is mitered to an angle for flush connection to a structural component at said one end.
11. The connector for connecting a structural element to a structure, according to claim 10, in combination with another said connector; said another connector also having at least one of said first and second ends of said main body portion mitered to the same angle as said one end of said connector; said one mitered ends of said connector and said another connector being in flush engagement with each other and secured together via fastener elements passing through aligned said passageways of said connector and said another connector, whereby, after said component and said another component are mounted in adjacent ends of two different structural components, the two different structural components may be secured together at adjacent ends via said connector and said another connector to form a segmented frame section of a structural frame.
12. A connector for connecting a structural element to a structure, comprising: A main body portion extending in a first, longitudinal direction; said main body portion comprising a first end, a second end, an upper surface section, a lower surface section, and elongated transverse connecting means for connecting together said upper and lower surface sections, said transverse connecting means extending at least substantially along the length of said main body portion and connecting said upper and lower surfaces sections in a second direction that is perpendicular to said first longitudinal direction; said elongated transverse connecting means having passageway means extending in said first longitudinal direction for passing therethrough from said first end to said second end at least one fastener element for securing said main body portion to a structural element; at least one of said first and second ends of said main body portion being mitered to an angle for flush connection to a structural component at said one end; and further in combination with another said connector; said another connector also having at least one of said first and second ends of said main body portion thereof mitered to the same angle as said one end of said connector; said one mitered ends of said connector and said another connector being in flush engagement with each other and secured together via at least one fastener element passing through aligned said passageway means of said connector and said another connector, whereby, after said component and said another component have been affixed together by at least one fastener element, the two different structural components may be secured together at adjacent ends via said connector and said another connector to form a segmented frame section of a structural frame extending at said mitered angle.
13. The connector for connecting a structural element to a structure, according to claim 12, further comprising a plurality of fastener elements, each said fastener element being bent at said mitered angle and comprising a first section passing through one said passageway means of said one connector and a second section passing through one said passageway means of said another connector aligned with said one passageway means of said one connector.
14. A method of coupling one structural element to another structural element, where the one structural element has at least one open and hollow end, using an elongated coupler having a main frame extending in a first longitudinal direction, the main frame having a first end and a second end spaced from said first end in the first longitudinal direction, an upper surface section, a lower surface section, and a middle section joining in a second direction perpendicular to the first direction the upper and lower surface sections, said method comprising: (a) securing one of said first and second ends of said main frame to another structural element; (b) after said step (a), mounting one end section of the one structural element over said main frame until said main frame is contained within the hollow interior of one end section of the one structural element; and (c) after said step (b), securing the main frame in the hollow interior of the one end section of the one structural element; said step (b) comprising first passing the one end section of the one structural element over the other end of the first and second ends of the main frame, and then sliding the one end section of the one structural element along said main frame in the first longitudinal direction, until the end-edge of the one end-section of the one structural element is flush against the another structural element to which said main frame has been secured; said step (c) comprising passing fastening elements in said second transverse direction through at least one portion of the one end-section of the one structural element and through the upper and lower surface sections juxtapositioned at the portion of the one end-section of the one structural element.
15. The method of coupling one structural element to another structural element, according to claim 14, wherein said step of passing fastening elements of said step (c) comprises guiding the fastener elements through aligned guides formed in said main frame between said upper and lower surface sections of the main frame.
16. The method of coupling one structural element to another structural element, according to claim 14, wherein said step (a) comprises: (d) securing said one end of said main frame to an end of another main frame of another similar elongated coupler; (e) said step (d) comprising passing at least one fastening element through both said main frame and said another main frame; (f) said step (e) comprising passing at least one fastening element through said first and second ends of both said main frame and said another frame in the first longitudinal direction of each said main frame and said another main frame.
17. The method of coupling one structural element to another structural element, according to claim 16, further comprising before said step (d): (g) cutting said one end of said main frame to a desired angle; (h) cutting said one end of said another main frame to said desired angle; (i) abutting said one angle-cut ends against each other; (j) before said step (d), bending at least one fastening element to at least close approximation to said desired angle to form first and second straight sections extending approximately at said desired angle; said step (f) comprising passing said first straight section through said one main frame in the longitudinal direction of said first main frame, and then passing said second straight section through said another main frame in the longitudinal direction of said first main frame, where the longitudinal directions of said main frames extend at an angle equal to said desired angle.
18. The method of coupling one structural element to another structural element, according to claim 17, wherein said step (f) comprises: (k) passing the first straight section of the fastener element through a first passageway of said one main frame; and (l) passing the second straight section of the fastener element through a second passageway of said another main frame; (m) said step (k) comprising passing the first straight section of the fastener element through a first passageway having an arcuate gap; (n) said step (l) comprising passing the second straight section of the fastener element through a second passageway having an arcuate gap facing laterally opposite to that which said arcuate gap of said step (m) faces; whereby said first and second straight sections are partially circumferentially supported by said first and second passageways on diametrically opposite arcuate surfaces thereof.
19. The method of coupling one structural element to another structural element, according to claim 14, further comprising before said step (a): (d) inserting said main frame into a hollow end section of a structural element in which is to be mounted for affixing the structural element to a structure; (e) after said step (d), cutting said main frame and said hollow end section together to a desired angle; (f) removing said main frame from said hollow end section, and thereafter performing said step (a).
20. A connector for connecting a structural element to a structure, comprising: A main body portion extending in a first, longitudinal direction; said main body portion comprising a first end, a second end, an upper surface section, a lower surface section, and elongated transverse connecting means for connecting together said upper and lower surface sections, said transverse connecting means extending at least substantially along the length of said main body portion and connecting said upper and lower surfaces sections in a second direction that is perpendicular to said first longitudinal direction; said elongated transverse connecting means having at least one passageway means extending in said first longitudinal direction for passing therethrough from said first end to said second end at least one fastener element for securing said main body portion to a structural element; said elongated transverse connecting means comprises at least one transverse web section, and a plurality of passageways formed in said at least one transverse web section and extending in said first longitudinal direction for passing therethrough from said first end to said second end at least one fastener element for securing said main body portion to a structural element, one said passageway being located in closer proximity to said upper surface section, and another said passageway being located in closer proximity to said lower surface section; said at least one transverse web section comprising a plurality of laterally-projecting fastener-guide means extending in said third, lateral direction for guiding fasteners through said main body portion; at least one of said plurality of laterally-projecting fastener-guide means protruding from one lateral side of said at least one transverse web section, and at least one other of said plurality of laterally-projecting fastener-guide means protruding from the other lateral side of said transverse web section.
21. The connector for connecting a structural element to a structure, according to claim 20, wherein said ones of said plurality of laterally-projecting guide means protruding from one lateral side of said at least one transverse web section being in alignment with each other in said second direction, and said other ones of said plurality of laterally-projecting guide means protruding from the other lateral side of said at least one transverse web section being in alignment with each other in said second direction.
22. The connector for connecting a structural element to a structure, according to claim 21, wherein each of said upper and lower surface sections comprising a first side edge-surface and a second side edge-surface spaced from said first side edge-surface in a third lateral direction perpendicular to said first and second directions; said main body portion further comprising laterally-opposite fastener-passing means projecting from respective said first and second side edge-surfaces of said upper surface section and said lower surface section, ones of said laterally-opposite fastener-passing means projecting from the first lateral side being in alignment with said ones of said plurality of laterally-projecting guide means protruding from one lateral side of said at least one transverse web section, and others of said projecting fastener-passing means projecting from the second lateral side being in alignment with said other ones of said plurality of laterally-projecting guide means protruding from the other lateral side of said at least one transverse web section.
23. The connector for connecting a structural element to a structure, according to claim 22, wherein each of said plurality of guide means and said fastener-passing means comprises a relatively thin-wall section by which a fastener passes therethrough.

Priority Claims (1)

Number	Date	Country	Kind
2003100740	Sep 2003	AU	national

Connector for mounting structural components

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Priority Claims (1)