This invention relates to end caps for use with channeled members such as hollow channeled construction members.
Construction members used in construction, both residential and commercial, are made from a wide variety of materials such as lumber, steel, aluminum as well as plastics and composite materials including but not limited to composite materials that combine one or more resins/plastics with one or more fibers, including man-made and natural fibers.
As is well known, with the advent of newer materials such as composites including composite woods and composite fiber products, and plastics, it is possible to make structurally efficient members that often have hollow channel profiles. Some examples of hollow profiles are illustrated in U.S. Pat. Nos. 6,826,884; 6,844,040; and 6,651,398, the contents of which are in their entirety hereby incorporated herein by reference.
However there are disadvantages of using such hollow channel profile members including the fact that if not plugged or drained, the hollow channels can become a place where significant amounts of moisture can collect and/or travel down. The result can be that moisture may be directed into undesirable locations in a building. Also moisture that is retained in the hollow channels, may not easily evaporate away and this can result in bacteria, mildew etc forming in the channels. Additionally, some of the new materials while resistant to absorbing moisture, may, if exposed to moisture for a significant period of time, begin to absorb moisture, possibly with deleterious effects.
Other problems are associated with the channels are that they can accumulate debris and dirt, as well as attracting insects to the hollow channels.
Another drawback of using hollow channel profile members is that the end profiles are generally not considered to be aesthetically pleasing to the eye.
Accordingly, the need has been recognized to provide end plugs or end caps to attempt to seal and/or cover up the end channels of the construction members. However, known end caps have drawbacks including but not limited to their ability to be received into the channels but also be maintained in position during the lifetime of use of the member. This is particularly the case when the construction members are subjected to significant changes in temperatures. For example, when heated, such as by the environment, the end plugs may not expand to the same degree as the construction member, tending to allow the end cap to become dislodged.
Additional difficulties in providing a suitable end cap arise due to difficulties in maintaining precise dimensional tolerances in the manufacturing processes of the construction members. There may be some variations in size dimensions as between the same type of construction members as a whole (i.e. one board varies in at least some dimensions from another board. There may also or alternatively be variations in sizes of parts that are intended to be the same size (e.g. different channels in the same construction member might have variations on the dimensions of the channels.
Accordingly, an improved end cap is desired.
In accordance with an aspect of the present invention there is provided an end cap comprising a) a base having at least one surface; b) at least one finger extending outwards in a first direction from the at least one surface of the base; and c) at least one set of fins comprising first and second flexible fins extending outwardly generally from the at least one finger in an orientation that is generally orthogonal to the first direction, the fins being generally positioned on opposite sides of the finger; with at least a portion of the finger, the first and second fins being insertable into channel of a construction member such that each of the first and second fins is displaced and engages and exerts a force against an inner wall surface of the channel, whereby the end cap can be held in a fixed position relative to the construction member.
According to another aspect of the invention there is provided an end cap comprising: a base; a) at least one finger extending in a first direction from the base; b) a plurality of sets of fins each set of fins comprising a plurality of fins extending generally from the finger in an orientation that is generally orthogonal to the first direction, with at least a portion of the finger, and the plurality of sets of fins being insertable into a channel of a construction member such that each of the fins of the plurality of fins engages and provides a frictional engagement with an inner wall surface of the channel, whereby the end cap can be held in a fixed position relative to the construction member.
According to another aspect of the invention there is provided an end cap comprising: a base; at least one finger extending in a first direction from said base; and a plurality of sets of flexible fins each set of fins comprising first and second fins extending generally from said finger in an orientation that is generally orthogonal to said first direction, each set of fins being positioned longitudinally along an axis oriented generally in said first direction wherein said first and second fins are movable independently of each other.
Other aspects and features of the present invention will become apparent to those of ordinary skill in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
In figures which illustrate by way of example only, embodiments of this invention:
With reference to
In typical example embodiments the end cap can be cost effectively made from a suitable plastic material by known injection molding techniques, although other materials and manufacturing processes could be employed.
The material can be selected such that it has a co-efficient of thermal expansion, which is similar or substantially identical to the material from which the construction member is made. This will assist in ensuring that during heating or cooling of the construction member and end cap, such as due to external environmental conditions, there will be similar degrees of contraction/expansion of the end cap 10 and the construction member with which is will be used. However, similar coefficients of thermal contraction and expansion are not necessary as end cap 10 can accommodate different levels of expansion and contraction of the end cap and the construction member.
End cap 10 may, as illustrated, be formed generally as a generally flat plate. However, depending upon the particular application, other configurations are possible. As illustrated end cap 10 has a base 12, which is shown in
Extending generally orthogonal to, and outward from, rear surface 16, are a plurality of finger members 18. Finger members are generally rigid or semi-rigid in most embodiments. However is some example embodiments they may be able to deform (preferably resiliently) in the upward and downward direction. In the illustrated example embodiment, each finger 18 is formed from a generally H-shaped (i.e. a rotated I-beam) member having vertically and longitudinally extending flange members 20a, 20b, interconnected at a medial portion along their length by a horizontal and longitudinally extending web member 22. A plurality of spaced, opposed pairs of wall members 24a and 24b extend vertically up and down from opposite horizontally disposed inner surfaces of web 22 and the inward facing surfaces of flanges 20a, 20b. Wall members 24a and 24b act as reinforced diaphragm members.
Extending outward from the fingers 18 and which may, as in this embodiment, be integrally formed as part of the finger 18, are spaced sets of flexible and resilient fins generally designated 30. Each set of fins 30 may include a first set of opposed fins 26a, 26b, which are oriented vertically and extend outwardly from diaphragm members 24a and 24b respectively. Each set of fins 30 also includes a second set of opposed fins 28a, 28b, which are oriented horizontally. Opposed fins 28a, 28b extend horizontally outwards from outward facing surfaces of opposed flanges 20a, 20b. Opposed fins 26a, 26b may, as illustrated, be formed as extensions of upward and downwardly depending wall members 24a, 24b.
Each of the individual fins may in some example embodiments be uniform in side view and in other example embodiments, be generally configured as being generally narrowing (e.g. tapering uniformly or non-uniformly) in side view, or side section, particularly as shown in
It will also be noted that in the embodiment of
In other embodiments, there may not be complete disconnection between adjacent fins, but there is sufficient disconnection between adjacent fins to enable each fin to have at least some amount of movement that is independent of the adjacent fins.
With reference now to
As shown in
It will be appreciated that the cumulative effect of each of the fins creating frictional forces on the inner walls in each of the plurality of channels 42, creates a significant overall frictional force to resist axial forces that would tend to disengage the end cap 10 from deck board 42.
Additionally, as shown in
While in
Apart from merely engaging the inner walls of the channels 42 to provide an outward force creating a frictional resistance, in other example embodiments the fins might additionally or alternatively be employed to engage and be received in slots formed in the inner walls of the channels 42. In such embodiments, there are the same or similar benefits of having independent movement of each of the fins.
It will be appreciated that the footprint of the fins 26, 28 does not necessarily have to match in shape to the shape of the inner wall of the channels. For example a plurality of fins which can move independently of each other and arranged with a footprint having a generally circular configuration, can be utilized in a generally square or triangular shaped channel wall. Likewise a generally elliptical fin footprint, can be used in a generally rectangular channel. Various other suitable configurations can be provided, so long as a suitable connection force is established to hold the fingers in the channels.
The end cap 10 may be configured such that when the fingers 18 are fully received into the channels 42, the inner surface 16 will abut the faces of plates 44a, 44b and webs 46 to provide a seal, thus inhibiting moisture, insects and debris from entering the hollow channels. The configuration may also be such that side end portions of plate 12 extend outwardly a sufficient amount so that the end channels 50 are covered over with aesthetic appeal benefits.
In some applications, such as in use with a deck board, the end cap 10 inserted into one deck board, may be adjacent to and may be in close proximity with the end cap used in an adjoining deck board (i.e. the ends of the bases may be positioned closely adjacent to each other).
With reference now to
The foregoing relates to only exemplary embodiments of the invention, it being understood that numerous other modifications, variants, embodiments and changes are possible within the scope and spirit of the invention.