The present invention relates generally to fasteners for joining the edges of two generally planar members that are angularly offset from each other, and more particularly, to a fastener forming a hinged coupling between such planar members.
Many products sold today make use of generally planar members that are joined together along their edges to form a three-dimensional structure. One example of such a three dimensional structure is the pet shelter shown in prior U.S. Pat. No. 9,326,483, issued to Hall on May 3, 2016. The pet shelter described in such patent includes a series of nestable modules, and each such module includes several generally vertical side walls joined at their adjacent side edges, along with an upper horizontal top wall. Various embodiments include modules that have four side walls which form a square or rectangular pattern, five side walls forming a pentagon, six side walls forming a hexagon, etc. In each case, adjacent edges of two side walls are joined to form a “corner” of the three-dimensional structure.
In order to minimize the space occupied by such products in shipment, it is desirable to package such products in a compact, disassembled form, with the flat panels lying parallel to each other within the package, until the product is assembled by the retailer and/or end user. However, this objective imposes several challenges, including a) minimizing difficulty of assembly of the packaged components, b) minimizing the cost of production, c) allowing for assembly of different numbers of flat panels to form different shapes; d) ensuring that the assembled three-dimensional product is relatively stable and will not easily fall apart; and e) providing for attachment of a top, horizontal wall that generally covers the space surrounded by the underlying flat panels. The pet shelter referenced above is but one example of a three-dimensional structure formed by attaching side edges of several planar members, and other applications will readily come to mind.
Accordingly, it is an object of the present invention to provide a corner bracket structure for joining adjacent side wall edges of generally planar members that are angularly offset from each other.
It is another object of the present invention to provide such a corner bracket structure which facilitates rapid and easy assembly of a three-dimensional product from generally planar members.
It is a further object of the present invention to provide such a corner bracket structure which is inexpensive to manufacture, lightweight, and easy to produce.
Still another object of the present invention is to provide such a corner bracket structure which is easily adjusted to vary the angle of offset between adjacent side wall panels.
A still further object of the present invention is to provide such a corner bracket structure which forms a stable and reliable attachment between two joined side wall panels following assembly.
Yet another object of the present invention is to provide such a corner bracket structure which facilitates attachment of an upper planar member that generally covers the joined side wall panels of the three-dimensional product.
These and other objects of the invention will become more apparent to those skilled in the art as the description of the present invention proceeds.
Briefly described, and in accordance with a first preferred embodiment thereof, the present invention relates to a corner bracket structure, or fastening assembly, for fastening together a plurality of members. The corner bracket structure includes a first elongated member, sometimes referred to herein as an internal, or male, member, having at least one side edge. The side edge of the first elongated member includes two or more projections, each having a generally convex cross-section; in a preferred embodiment of the invention, these projections resemble barrels. These projections are longitudinally aligned with each other and spaced apart from each other by a first distance.
The corner bracket structure also includes a second elongated member, sometimes referred to herein as an external, or female, member, and also having at least one side edge. The side edge of the second elongated member includes an elongated channel or cavity having a generally concave cross-section. The elongated channel includes two or more retaining regions longitudinally aligned with each other, including at least a first retaining region adapted to retain a first projection of the first elongated member, and a second retaining region adapted to retain a second projection of the first elongated member. These first and second retaining regions are spaced apart from each other by a first recessed region adapted to receive the first projection of the first elongated member. Additional recessed regions may be provided between successive retaining regions for receiving a corresponding projection extending from the first elongated member; each of the recessed regions is longitudinally aligned with the retaining regions formed in the elongated channel of the second elongated member.
Preferably, the projections which extend from the first elongated member, and the retaining regions formed in the second elongated member are all of substantially equal length as each other. The recessed regions formed in the elongated channel of the second elongated member have a length that is at least as long as the length of projections extending from the first elongated member.
During assembly, the first elongated member is assembled to the second elongated member by inserting the first projection into the first recessed region; sliding the first elongated member relative to the second elongated member for sliding the first projection into the first retaining region, while simultaneously sliding the second projection into the second retaining region.
In the preferred embodiment, the first elongated member includes a generally flat plate for being secured to a first panel. Also, in the preferred embodiment, the second elongated member includes a generally flat plate for being secured to a second panel. Preferably, these flat plates each have a plurality of holes formed therein for receiving a corresponding plurality of fasteners for securing the generally flat plates to the first and second panels.
The projections of the first elongated member are longitudinally aligned with each other about a common longitudinal axis. The projections of the first elongated member and retaining regions of the second elongated member are preferably dimensioned in a manner which permits the second elongated member to rotate, relative to the first elongated member, through an angle of at least 40 degrees about such longitudinal axis after such projections are slidingly inserted into their respective retaining regions.
As mentioned above, it may be desired to secure a cover panel above the side wall panels. In one preferred embodiment of the present invention, a screw is adapted to be screwed into an end of the elongated channel of the second elongated member; this screw may pass through a cover that extends generally perpendicular to the elongated channel of the second elongated member. Such screw may serve the additional function of precluding or resisting further sliding and/or rotational motion of the projections relative to the retaining regions to prevent unintended disassembly of the adjacent side wall panels from each other.
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Recessed regions 216-222 are longitudinally aligned with retaining regions 206-214 for allowing projections 106-112 to slide from recessed regions 216-222 into retaining regions 208-214. Preferably, each of retaining regions 206-214 are of equal length, and each of recessed regions 216-222 are of equal length. In the preferred embodiment, all of the retaining regions 206-214 and all of the recessed regions 216-222 all have a common length equal to the length of the projections 104-112 of the first elongated member 100. Second elongated member 200 also includes a generally flat plate 224 for being secured to a panel (not shown in
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Those skilled in the art will now appreciate that an advantageous corner bracket structure has been described for joining adjacent side wall edges of generally planar members that are angularly offset from each other. The disclosed corner bracket structure facilitates rapid and easy assembly of a three-dimensional product from generally planar members, and forms a stable and reliable attachment between two joined side wall panels following assembly. The first and second elongated members may be formed of a plastic material, e.g., nylon, and may be injection molded, or formed in another inexpensive manner. The disclosed corner bracket structure is inexpensive to manufacture, lightweight, and easy to produce, and facilitates packaging of three-dimensional products in a much more compact, unassembled form. Moreover, the corner bracket structure may be easily adjusted to vary the angle of offset between adjacent side wall panels to form structures of varying shapes; thus the same corner bracket structure may be used with products of differing shapes. In addition, a top cover panel can be easily attached to the underlying base formed the joined side wall panels.
While the present invention has been described with respect to preferred embodiments thereof, such description is for illustrative purposes only, and is not to be construed as limiting the scope of the invention. For example, while the preferred embodiment uses the novel corner bracket to join two side wall panels, those skilled in the art will appreciate that the disclosed corner bracket could also be used to join a side wall panel to a fixed wall, or some other fixed object. In addition, while the preferred embodiment describes the use of the novel corner bracket to join generally planar side wall panels, it will be appreciated that the disclosed hinged corner bracket could be used to join together two non-planar objects, if desired. Various modifications and changes may be made to the described embodiments by those skilled in the art without departing from the true spirit and scope of the invention as defined by the appended claims.