STATEMENTS REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
Not applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to fastening systems and structural members and, in particular, to fastening systems including a blind fastener.
2. Description of the Related Art
The general concept of fastening is the fixing or bringing together of two distinct items or devices with a fastener. In the positioning of an element with a structural member, such as a wall, ceiling, floor, substrate or other supporting structure, one particular type of fastener, generally known as a blind fastener, allows positioning of the element without access to one side of the structural member. The blind fastener accomplishes this fastening by allowing a holding portion and a rod (e.g., a stud, bolt, or the like) to be inserted through an aperture in the structural member, and then resists removal of the holding portion through the aperture. There have been fasteners known in the past that are moved through an aperture in a structural member during insertion and, thereafter, resist removal of the fastener.
One type of blind fastener is what is known as a toggle bolt. The general concept of a toggle bolt is a bolt with a nut having pivotally attached elongated members or wings. The wings of the toggle bolt retract during passage through the aperture and, thereafter, spring open or expand to resist removal of the bolt back through the aperture. Examples of toggle bolts include U.S. Pat. Nos. 2,024,871; 4,793,755; 4,997,327; 5,209,621; 5,224, 807; and 6,203,260. Three characteristics of the toggle bolt are (1) each wing's bearing line area or contact with the blind side of the structural member, (2) the plurality of components for “spring” pivoting action of each wing, and (3) the sizing of the aperture, having an area larger than the cross-sectional area of the bolt, to allow insertion of the wings in their retracted position.
Another type of blind fastener is what is known as a “molly bolt,” also known as a “hollow wall anchor.” The general concept of a molly bolt is a bolt connected to a body having a pair of elongated members or wings and two housings. The housings are initially spaced apart from one another with the ends of each wing being in contact with one of the housings. During insertion of the molly bolt, the wings are retracted towards the bolt. Then, after insertion, as the housings are moved closer to each other, the wings extend outwardly. The general operation of the molly bolt is discussed in U.S. Pat. Nos. 3,888,156; 4,152,968; 4,307,598; and 5,509,765. While molly bolts need not have a spring to extend the wings outwardly, two characteristics of the molly bolt design are (1) precision insertion of the body to ensure proper deformation of the wings for the desired structural support, and (2) precision threading and deforming of the wings to, once again, allow the desired structural support.
Other types of blind fasteners include those proposed in U.S. Pat. No. 4,086,840, issued to Kurlander, and U.S. Pat. No. 5,944,466, issued to Rudnicki, et al., along with rivets. The '840 Kurlander patent proposes a fastener having a nut integral with an elastomeric conical member adapted to deform or collapse radially and longitudinally when compressed. Upon insertion of the fastener through an aperture in a structural member, the elastomeric conical collapses radially inwardly. After insertion, the bolt is threaded with the integral nut and the elastomeric conical member collapses in a longitudinal direction against the structural member.
The '466 Rudnicki patent, concerned with loading by an anchoring assembly or holding portion of fastener on the structural member, proposes that the radial distance between the points of support provided by an anchoring assembly and the bolt are too short for large loads. (Col. 1, lns. 45-58). The '466 Rudnicki patent proposes a fastener assembly to extend the radial distance between the points of support provided by the anchoring assembly and the bolt as a solution to this loading concern. (Col. 4, lns. 16-26). The proposed fastener assembly includes a face plate, an anchoring assembly, and a positioner. The face plate is positioned on a surface of the structural member. The anchoring assembly includes a base portion and a support structure. Upon insertion of the anchoring assembly through an aperture in the structural member, the support structure extends outwardly from the base portion to three or more radially equidistant regions isolated from the peripheral edge of the aperture in the structural member.
It would be desirable to provide a simple, yet effective, repositionable fastening system that provides desirable flexibility and structural support to fasten an element to a structural member. Additionally, it would be desirable to provide a fastener that optimizes the bearing area to distribute the loading by the holding portion on the fastening system.
It would also be desirable to provide a fastener that could use an off-the-shelf nut in combination with any desired length, style and/or size of threaded rod with a holding portion of limited components to reduce manufacturing and inventory costs.
SUMMARY OF THE INVENTION
According to one embodiment of the invention, a fastening system adapted for use with a structural member having a chamber with an elongated opening is provided. The fastening system includes opposed margins attached with a structural member and a fastener configured to be restrained by the opposed margins. The fastener can be positioned in a variety of locations within the chamber. The fastener can also be selectively repositioned in various positions along the opening.
According to another embodiment of the invention, a structural member adapted for use with a fastener is provided. The structural member includes a mass of material having one or more chambers, each having opposed margins. Each chamber includes an elongated opening on a first side defined by the opposed margins. The elongated opening is sized to receive fasteners configured to be restrained by the opposed margins. The elongated opening accepts repositioning of fasteners at several locations within the chamber.
According to still another embodiment of the invention, a holding portion of a fastener for fastening an element to a structural member in a chamber with an elongated opening is provided. The holding portion includes a plurality of elongated members and a compression member positioned with the elongated members. The elongated members are moveable between an insertion position and a predetermined extended position, and each includes a lip. The compression member resists a movement from the predetermined extended position to the insertion position. The elongated members move to the predetermined extended position upon positioning the compression member about the plurality of elongated members. When the plurality of elongated members are assembled with the compression member, the holding portion includes a restriction recess, configured to receive the nut and to restrict a rotation of the nut with a wall substantially parallel to a side of the nut when the holding portion is in the predetermined extended position. When the elongated members are assembled with the compression member, the holding portion also includes a throughway sized to receive a rod, which is configured to engage the nut. When the elongated members are assembled with the compression member in the predetermined extended position, the lips of at least two elongated members are received in the elongated opening.
According to yet another embodiment of the invention, a method for making a structural member is provided. The method includes providing a form and positioning opposed margins within the form so that the opposed margins define an elongated opening. A non-solid version of a structural material is provided into the form after blocking the elongated opening.
According to still yet another embodiment of the invention, a method for fastening an element to a structural member is provided. This method includes positioning opposed margins with the structural member to provide an elongated opening and positioning a holding portion of a fastener and a portion of a rod of a fastener in a chamber of the structural member. The fastener includes a plurality of elongated members. This method further includes engaging at least one of the elongated members with each margin. This method also includes supporting the element with the rod extending from the structural member when the elongated members are in the extended position.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
A better understanding of the present invention can be obtained when the following detailed description of the disclosed embodiments is considered in conjunction with the following drawings, in which:
FIG. 1 is one embodiment of an internally threaded holding portion of a fastener usable with various embodiments of the present invention, shown in a perspective view;
FIG. 2 is a cross-sectional elevational view of the holding portion of the fastener taken across line 2-2 of FIG. 1;
FIG. 3 is an end view of the embodiment of the holding portion of the fastener shown in FIG. 1;
FIG. 4 is an illustration of the embodiment of the holding portion of the fastener, shown in FIG. 1, in the insertion position while being inserted through an aperture in a structural member using a threaded rod;
FIG. 5 is an illustration of the embodiment of the holding portion of the fastener, similar to FIG. 4, in the extended position after insertion through the aperture;
FIG. 6 is an illustration of the embodiment of the extended holding portion of the fastener, similar to FIG. 5, in the engaged or bearing position to position the element, shown in the phantom view, using a washer and nut threadably received on the threaded rod;
FIG. 7 is another embodiment of an internally threaded holding portion of a fastener, shown in a cross-sectional elevation view;
FIG. 8 is an end view of the embodiment of the holding portion of the fastener shown in FIG. 7;
FIG. 9 is an illustration of the embodiment of the holding portion of the fastener of FIG. 7, after insertion through an aperture in a structural member, using a threaded bolt along with a tapered sleeve and a spacer of predetermined length to move the holding portion to the extended position upon tightening the bolt head of the bolt with the holding portion;
FIG. 10 is an illustration of the embodiment of the holding portion of the fastener, similar to FIG. 9, in the extended position and engaged or bearing position after the holding portion is threaded upon the bolt;
FIG. 11 is yet another embodiment of the holding portion of a fastener in a predetermined extended position, shown in a cross-sectional view with a part of the holding portion shown in phantom view, and the bolt shown in elevational view;
FIG. 12 is an illustration of the embodiment shown in FIG. 11, with the holding portion shown in the insertion position while being inserted through an aperture in a structural member;
FIG. 13 is an illustration of the embodiment shown in FIG. 11, with the holding portion shown in the predetermined extended and engaged or bearing position and element shown in phantom view;
FIG. 14 is an end view of the embodiment of the fastener taken along line 14-14 of FIG. 13 with the holding portion shown in solid lines when in the predetermined extended position and shown in phantom view when in the insertion position;
FIG. 15 is an embodiment of the holding portion of a fastener usable with various embodiments of the invention, shown in a cross-sectional view, having a recess to receive a nut and with the holding portion shown in a predetermined extended position;
FIG. 16 is an embodiment of the fastener taken along line 16-16 of FIG. 15;
FIG. 17 is an embodiment of the fastener taken along line 17-17 of FIG. 15;
FIG. 18 is an embodiment of the holding portion of the fastener, as shown in FIG. 15, in the insertion position while being inserted through an aperture in a structural member using a threaded bolt;
FIG. 19 is an embodiment of the holding portion of the fastener, as shown in FIG. 15, in the predetermined extended position and in the engaged or bearing position after the holding portion is threaded with the bolt;
FIG. 20 shows some exemplary threaded rods for use with the present invention;
FIG. 21 is an elevational view of the holding portion of the fastener of FIG. 15 in the insertion position, similar to FIG. 18, to better illustrate the compression member positioned with the housing of the holding portion;
FIG. 22 is an elevational view of the holding portion of the fastener of FIG. 15 with the holding portion in the predetermined extended position;
FIG. 23 is a view of the holding portion taken along line 23-23 of FIG. 22;
FIG. 24A is a cross-sectional view of one embodiment of a channel anchored in a mass of structural material to form a chamber with a layer of material overlying the channel at the opening;
FIG. 24B is a cross-sectional view of another embodiment of a channel in a mass of structural material;
FIG. 24C is a view of an embodiment of a fastener usable with various embodiments of the invention, shown in a cross-sectional view in the channel of FIG. 24A, with the holding portion in a predetermined extended position inside the chamber and an element shown in phantom view;
FIG. 25 is a view of the channel and the holding portion taken along line 25-25 of FIG. 24C;
FIG. 26 is a cross-sectional view of the holding portion taken along line 26-26 of FIG. 24C;
FIG. 27 is a cross-sectional view of the holding portion taken along line 27-27 of FIG. 24C;
FIG. 28 is an elevational view of the fastener of FIG. 24C in the extended position;
FIG. 29 is an elevational view of the fastener of FIG. 24C in the insertion position entering the opposed margins, shown in phantom view;
FIG. 30 is a cutaway view taken along line 30-30 of FIG. 29;
FIG. 31 is an elevational view of a wall and a door, with a cutaway view of a stairwell showing various channels each with one or more fasteners;
FIG. 32 is an elevational view of a wall, a floor, and an upright support showing various channels, each with one or more fasteners;
FIG. 33 is an elevational view of a ceiling with hanging equipment or elements and a wall and a wall-to-wall connection showing various channels and configurations, including a ceiling channel connected to reinforcing elements, each channel having one or more fasteners;
FIG. 34 is a cross-sectional view of the wall-to-wall connection, taken along line 34-34 of FIG. 33; and
FIG. 35 is a top view of a form for making a structural member according to embodiments of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIGS. 1 through 6, generally show a first embodiment of the invention. In FIG. 1, a holding portion 20 includes a housing 30 and a plurality of elongated members or wings 40. In this embodiment, each of the four equidistance elongated members 40 is bent radially outwardly into an extended position. A resilience in the material of the elongated members 40 tends to keep elongated members 40 in this extended position—for example, resisting a radial inwardly compression. Material for the elongated members 40 can include, but is not limited to, various forms of metal (e.g., aluminum), plastics, and the like. At the end of each plurality of elongated members 40 are end areas 48, which together make up an end surface area 44. The end surface area 44 is arranged and configured to serve as a bearing surface, which will be described in detail with reference to FIG. 6 below.
Turning now to FIG. 2, the housing 30 of the holding portion 20 includes an outside diameter 34, an inside diameter 36, and a length of engagement 32. The length of engagement 32 in this embodiment is the length of the housing 30 that is adapted for engaging or coupling with a rod 50 (shown in FIG. 4). As can be seen in FIG. 2, the housing 30 is internally threaded with internally threaded roots 33 and internally threaded crests 35. As such, the engagement with the rod 50 in this embodiment will be a threaded coupling. While housing 30 is internally threaded in this embodiment, it is contemplated that housing 30 in other embodiments may be adapted to couple with the rod 50 in other manners, for example, via fixed attachments, clamped attachment, rivets and the like. As should become apparent to one of ordinary skill in the art, the length of engagement 32 can be a variety of different lengths depending on factors including, but not limited to, the material used in the housing 30, the material used in the rod 50, the coupling technique, and intended load to be supported by the holding portion 20. The length of engagement 32 is preferably greater than one-third of a length of a perimeter of the cross-sectional area of the rod 50. In this embodiment, the perimeter is the diameter of the rod 50 multiplied by the geometric constant, pi (roughly 3.14). Therefore, the length of engagement 32 in this embodiment is preferably equal to or greater than the diameter of the rod 50 (greater than one-third of a length of a perimeter of the cross-sectional area of the rod 50). As will become apparent to one of ordinary skill in the art, the length of the perimeter of the cross-sectional area can change with different shapes for the cross-sectional area of the rod 50—for example, ovals, triangles, squares, rectangles, and the like. It is to be expressly understood that the length of engagement 32 in other embodiments can be less than one-third of a length of a perimeter of the cross-sectional area of the rod 50. In such embodiments, the coupling technique and material used in the holding portion 20 and/or rod 50 can define the length. Further discussion of the length of engagement 32 follows below with reference to FIG. 6.
In the embodiment of FIGS. 1-6, the outside diameter 34 defines a cross-sectional area for housing 30, while the inside diameter 36 defines a cross-sectional area corresponding to the rod 50. As both the rod 50 (shown in FIG. 4) and housing 30 are threaded in this embodiment, the inside diameter 36 corresponds to the “major diameter” of the internally threaded portion of the housing 30 (e.g., root to root in the internally threaded housing 30 or crest to crest in the externally threaded rod 50).
Moving to FIG. 3, as referenced above, the inside diameter 36 of the holding portion 20 in this embodiment corresponds to the internally threaded root to root of the internally threaded portion of the housing 30. A minor diameter 38 is seen extending from crest to crest of the internally threaded crest 35 of the housing 30.
With general reference to FIGS. 2 and 3, the circular area defined by the outside diameter 34 in this embodiment is substantially equivalent to the inside diameter 36 plus the end areas 48 of the elongated members 40. In other words, as best shown in FIG. 1, the end surface area 44 (total of end areas 48) in this embodiment is substantially an annulus area between the circular area defined by the outside diameter 34 and the inside diameter 36—each of the end areas 48 shaped as an annular arc. While the annular arcs of the shaped end areas 48 in this embodiment are shown with small gaps between them, it is contemplated that in other embodiments even smaller gaps will exist.
With reference to FIGS. 2-4, an illustration of the differences in cross-sectional areas is shown. When the aperture 65 in the structural member 60 is sized a cross-sectional area the same size as the housing 30 (just allowing the housing 30 to pass through the aperture 65), the end surface area 44 of the end areas 48 of the elongated members 40 will be substantially the same area as the difference between the cross-sectional area of the aperture 65 and the cross-sectional area of the rod 50 (shown in FIG. 4). With this configuration, a maximum end surface area 44 can be extended through the aperture 65 (FIG. 4), allowing a reduced bearing force per surface area—for example, a larger area to distribute a load. Note that the aperture 65 can be a portion of a larger opening, as discussed below with respect to FIGS. 24A-35, so any reference to the aperture 65 also refers to the elongated opening 401.
While the end surface area 44 described in the above embodiment is the difference between the area defined by the outside diameter 34 and the area defined by the inside diameter 36, it is contemplated that in more complex embodiments the end surface area 44 of end areas 48 of the plurality of elongated members 40 can exceed the area defined by the outside diameter 34 of the housing 30. For example, the holding portion 20 could be a frustum of a cone with a cylindrical bore extending the longitudinal distance of the holding portion 20—for example, corresponding to the diameter of the rod 50. In such an embodiment, the outside diameter 34 could start at the apex of the frustum of the cone and enlarge towards the base. The end surface area 44 of the end areas 48 of the elongated members 40 can be the difference between the area defined by the diameter of the base of the frustum of the cone and the internal diameter of the cylindrical bore extending to the base. With this “frustum of a cone” embodiment, the end surface area 44, similar to that described with reference to the above embodiment, can be the difference between the cross-sectional area of the aperture 65 and the cross-sectional area of the rod 50.
With reference to FIG. 4, the holding portion 20 is shown in an insertion position, being pushed through the aperture 65 in the structural member 60. The rod 50 is shown threaded to the housing 30 along a length of engagement 32 of the housing 30 of the holding portion 20. The rod 50, while shown in this embodiment as a threaded stud, in other embodiments can include a bolt, a smooth stud, a rivet and the like. And, with each of the different types of rods 50 used, the holding portion 20 can be adapted for an appropriate coupling.
The insertion of the holding portion 20 through the aperture 65 of the structural member 60 will radially urge or compress the plurality of elongated members 40 inwardly, against the above-referenced resilience to stay in an outwardly extended position-such that the elongated members 40 almost lay flush with the rod 50. Once again, as discussed above, in this embodiment the cross-sectional area of the inside diameter 36 of the housing 30 and the end surface area 44 of the plurality of elongated members 40 together are substantially the same as the cross-sectional area, defined by the outside diameter 34 of the housing 30. With this configuration, the bearing area of the end surface area 44 of the end areas 48 of the plurality of elongated members 40 can be substantially the difference between a cross-sectional area of the aperture 65 and the rod 50, where the cross-sectional area defined by the outside diameter 34 is the same as the cross-sectional area of the aperture 65—just allowing the holding portion 20 to pass therethrough.
It should be expressly understood that while the holding portion 20 has been shown with a circular cross-sectional area in this embodiment, in other embodiments the cross-sectional area can take on different shapes e.g., squares, rectangles, triangles, etc., which can ultimately depend on the rod 50 being used and the aperture 65 through which the holding portion 20 will be inserted.
FIG. 5 shows the holding portion 20 moving back to a memory position after insertion through the aperture 65. The memory position in this embodiment is the extended position caused by the resilience in the material of the holding portion 20 tending to urge the plurality of elongated members 40 into the extended position.
FIG. 6 shows the holding portion 20 in a bearing position with the surface area 62 of the structural member 60. In bringing the holding portion 20 into contact with the blind surface area 62 from the position shown in FIG. 5, in this embodiment, the elongated members 40 and housing 30 can maintain a positional relationship with the rod 50—that is, the rod 50 need not be further threaded through the housing 30 of the holding portion 20. Rather, the holding portion 20 coupled to the rod 50 can be brought into the bearing position by pulling the rod 50 until the end surface area 44 of the end areas 48 of the elongated members 40 contacts the blind surface area 62 of the structural member 60. An element 70 can be mounted to the rod 50; and, then by maintaining tension of the rod 50, a washer 80 and nut 90 can be threaded on the rod 50 to bring the element 70 into contact with an exposed surface area 64 of the structural member 60. The friction force of the end surface area 44 of the end areas 48 with the blind surface area 62 prevents rotation of the holding portion 20. With this maintenance of positional relationship, no further access is needed on the blind side of the structural member 60. For example, the rod 50 in this embodiment need not be further threaded through the housing 30 to bring the holding portion 20 into a bearing position with the blind surface area 62. Additionally, the rod 50 in this embodiment need not be further threaded through the housing 30 to bring the element 70 into contact with the exposed surface area 64 of the structural member 60. As such, the holding portion 20 in this embodiment is particularly helpful when limited access or space is available on the blind side of the structural member 60. While this positional relationship has been described with reference to this embodiment, it is to be expressly understood that further threading through the housing 30 of the holding portion 20 can occur, if desired, as will be described with reference to other embodiments below.
The holding portion 20 through many of the features described herein is configured to resist removal of the rod 50. In this resistance of the removal of the rod 50, forces are transmitted from the rod 50 through the length of engagement 32 to the elongated members 40, forcing the elongated members 40 into a bearing position with a blind surface area 62 of the structural member 60. Thus, in the structural design of the holding portion 20, consideration is given to the following: (1) the length of engagement 32 in coupling the rod 50 to the housing 30 to withstand a loss of such coupling, (2) the elongated members 40 to withstand buckling, and (3) the bearing surface area between the end surface area 44 of the end areas 48 and the blind surface area 62 to withstand crushing (e.g., a point load failure from too much force per unit area) of the structural member 60. In the embodiment described herein, the length of engagement 32 is threaded at a length for a predetermined design load. As such, a specified number of threads and/or specified length of engagement 32 should be used to ensure that the housing 30 does not disengage with the rod 50 when a pull force is applied to the rod 50. For example, with reference to the embodiment of FIGS. 1-6, stripping (a disengagement) can occur either in the internal threads of the housing 30 or in the external threads of the rod 50. As such, the length of engagement 32 in this embodiment has a length large enough to resist this stripping. Preferably, as referenced above, the length of engagement 32 in the embodiment of FIGS. 1-6 is greater than the diameter of the rod 50. As will become apparent to one of ordinary skill in the art, the length of engagement 32 can increase to account for a difference of materials between the housing 30 and the rod 50. For example, one of the threaded portions (either the housing 30 or the rod 50) could have a material such as plastic while the other threaded portion (either the housing 30 or the rod 50) could have a material such as steel, the plastic generally deforming at a lower load than the steel. The increase in the length of engagement 32 distributes a design load along the length of engagement 32 resisting the stripping of either the internal threads for the housing 30 or the external threads for the rod 50—regardless of whether the weaker material (the one which deforms first) is in the housing 30 or the rod 50.
To resist buckling in the elongated members 40, several buckling factors should be considered, including the length of the elongated members 40. Generally, for a given material, as the length in the elongated members 40 increase, so should the cross-sectional area of that elongated member 40 to adequately prevent buckling. Additionally, in the embodiment of FIGS. 1-6, a curvature in the elongated members 40 helps resist buckling. As can be seen in the embodiment of FIGS. 1-6, each of the elongated members 40 has a curvature that is arced. The structural benefits of such an arced configuration in resistance to buckling should become apparent to one of ordinary skill in the art. For example, by illustration, a piece of paper on a desk sat on its end can resist more compressive strength by being curved into an arc rather than by simply being set planarly straight up. While an arced curvature is shown in the embodiment of FIGS. 1-6 as a preferred curvature, it is contemplated that other forms of curvature can be used—for example, different angles of bending including bending at right angles and corrugated designs.
To resist a crushing of the structural member 60, the end surface area 44 of the end areas 48 of the elongated members 40 is maximized (while not sacrificing simplicity of design) to distribute the load over the blind surface area 62 of the structural member 60. Preferably, this end surface area 44 will be the difference between a cross-sectional area of the aperture 65 and the cross-area of the rod 50 to be inserted in the aperture 65. In the bearing contact of the end surface area 44 of the end areas 48 of the elongated members 40, this embodiment will always have at least three of the end areas 48 of the elongated members 40 in contact with the blind surface area 62. Additionally, it is contemplated that end areas 48 can be angled, similar to the end areas 48B, described in detail below with reference to FIGS. 11-14 below.
As an illustrative use of the embodiment described with reference to FIGS. 1-6, a rod 50 is inserted through an aperture 65 in a structural member 60 to fasten an element 70 to the structural member 60. The rod 50 can be any of the commercially available rods 50 described, including, but not limited to, bolts, threaded studs, smooth studs, rivets and the like. The structural member 60 can be any number of structures—for example, a wall, a ceiling, a floor, a door, a circuit board, plastic pieces, boards, substrates, etc. Likewise, the element 70 can be any number of items, including another structural member 60. Generally, the structural member 60 and element 70 are two distinct “things,” which are desired to be coupled to one another-preferably as shown in several embodiments of the invention, the element 70 being coupled or fastened to the structural member 60. The desired configuration and size of the rod 50 and holding portion 20 can be defined by the intended use. In this embodiment, the rod 50 is initially coupled to the housing 30 (the coupling contact being at the length of engagement 32) of the holding portion 20. The coupling of the rod 50 to the housing 30 can take on one of many coupling techniques, generally described herein, which should be apparent to one of ordinary skill in the art. The coupling technique in the embodiment of FIGS. 1-6 is a threaded coupling. At rest, the elongated members 40 are urged outwardly in an extended position by the resilience in the material. After coupling the rod 50 to the holding portion 20, the rod 50 and holding portion 20 are inserted into the aperture 65, whereupon the aperture 65 radially compresses the outwardly urged elongated members 40 inwardly into an insertion position. After insertion through the aperture 65, the elongated members 40 return to their memory position-their outwardly urged extended position. An element 70 can then be received on the end of the rod 50 adjacent to an exposed surface area 64 of the structural member 60, whereupon the rod 50 is pulled partially back through the aperture 65 allowing the end surface area 44 of the end areas 48 to come into a bearing position with the blind surface area 62 of the structural member 60. The friction force between the end surface area 44 of the end areas 48 and the blind surface area 62 of the structural member 60 resists rotation of the holding portion 20. Therefore, the rod 50 maintains a positional relationship with the holding portion 20. A washer 80 and nut 90 are then threaded on the rod 50 engaging the element 70 with the exposed surface area 64 of the structural member 60. The holding portion 20 resists removal of the rod 50 through a length of engagement 32 in the housing 30 of the holding portion to the elongated members 40, which distribute their load over the end surface area 44 of the end areas 48 on the blind surface area 62—reducing the bearing force per area on the blind surface area 62 of the structural member 60.
In the embodiment of FIGS. 7-10, the holding portion 20A includes an annular notch 100, which helps define movement of the four equidistant elongated members 40A between an insertion position and an extended position. As can be seen in FIG. 7, the at rest position of the elongated members 40 is an insertion position.
With reference to FIGS. 7 and 8, at the end of each of the elongated members 40A is a tapered interior end 110 which, as will be described below, facilitates the urging of the elongated members 40 to an extended position.
Turning now to FIG. 9, the holding portion 20A, coupled to a rod 50A, is in an insertion position after being pushed through the aperture 65 of the structural member 60. In this embodiment, the rod 50A is shown as a bolt with a bolt head 52A. Thus, to urge the elongated members 40A to an extended position (as seen in FIG. 10), a tapered sleeve 120 and, if needed, a spacer 130 can be inserted after the insertion of the holding portion 20A. The tapered sleeve 120 can take on a variety of shapes, depending on the configuration and design of the elongated members 40A. For example, in the illustrated embodiment, the tapered sleeve 120 has a circular cross-sectional area. To facilitate the alignment of this tapered sleeve 120, each of the elongated members 40A, as referenced above, includes a tapered interior end 110, which is adapted to receive the tapered sleeve 120. In addition to urging the elongated members 40A into an extended position, the tapered sleeve 120 centers the rod 50A within the aperture 65. In some embodiments, the thickness of the structural member 60 may not be known. As such, the spacer 130 can be inserted after the tapered sleeve 120, facilitating the tapered sleeve 120 in urging the elongated members 40A to their extended position and centering the rod 50A in the aperture 65. The spacer, similar to the tapered sleeve 120, can take on a variety of shapes. Preferably, the spacer 130 has a circular cross-sectional area with at least one opening to allow the spacer 130 to be placed over and around the rod 50A.
FIG. 10 shows the holding portion 20A in an extended position and a bearing position with the blind surface area 62 of the structural member 60. This bearing contact of the end surface area 44A of the end areas 48A with a blind surface area 62 of the structural member 60 is similar to that described with reference to FIG. 6. It is contemplated that spacer(s) 130 of a plurality of lengths would be provided for use with the holding portion 20A.
As an illustrative use of the embodiment described with reference to FIGS. 7-10, a rod 50A is inserted through the aperture 65 in a structural member 60 to fasten an element 70 to the structural member 60. Similar to the illustrative use, described with reference to FIGS. 1-6 above, the element 70 and structural member 60 can be any number of “things.” In this embodiment, the rod 50A (such as a bolt) can be inserted through the washer 80, the element 70, the tapered sleeve 120, and, if needed, spacer(s) 130. Then, the rod 50A can be threaded along the length of engagement 32A of the housing 30A of the holding portion 20A, whereupon the holding portion 20A and a portion of the rod 50A are inserted through the aperture 65 in the structural member 60. The tapered sleeve 120, and, if needed, spacer(s) 130, can then be moved down the rod 50A and further into the aperture 65, centering the rod 50A and urging the elongated members 40A to an extended position. As discussed, if needed, one or more spacers 130 can be inserted after the tapered sleeve 120 by inserting the spacer 130 over and around the rod 50A in contact with the tapered sleeve 120. The rod 50A can then be partially be pulled back through the aperture 65 bringing the end surface area 44A of the elongated members 40A into the bearing position with the blind surface area 62 of the structural member 60. Friction forces of the end surface area 44A of the end areas 48A with the blind surface area 62 and friction forces with the tapered sleeve 120 helps resist rotation of the holding portion 20A. To bring the element 70 into contact with an exposed surface area 64 of the structural member 60, the rod 50A can be further rotated through the housing 30A of the holding portion 20A. To increase resistance between the holding portion 20A and the rod 50A, tension can be maintained on the rod 50A while threading to increase the friction force between end surface area 44A of the end areas 48A and the blind surface area 62 of the structural member 60. Additionally, the tapered sleeve 120 can be designed of a high friction material, such that friction is created both between the tapered sleeve 120 and the aperture 65 and the tapered sleeve 120 and the elongated members 40A. As will now be apparent to one of ordinary skill in the art, the threaded rod 50 of FIGS. 1-6 can be interchanged with the bolt described with reference to FIGS. 7-10.
With reference to FIGS. 11-14, another embodiment of the invention is shown. In this embodiment, as generally shown in FIGS. 11 and 12, a rod 50B has a holding portion 20B slidingly coupled thereto. The rod 50B in this embodiment has a shoulder 170, a reduced diameter neck 150, and a head 140. The holding portion 20B in this embodiment includes two elongated members 40B, a compression member 200, and a housing 30B, which moves slidingly with respect to the neck 150 of the rod 50B. The two elongated members 40B are semicircular halves, which will be described in more detail with reference to FIG. 14 below. The housing 30B includes a first shoulder 160 and a second shoulder 180. The compression member 200 is positioned and designed to create a radially compressive force on an end of the holding portion 20B, adjacent to the second shoulder 180. When the holding portion 20B is in a predetermined extended position, as shown in FIG. 11, the two elongated members 40 are moved outwardly to the predetermined extended position until the housing surface or shoulders 41 engage the neck 150 and the housing 30B slides towards the head 140 with the second shoulder 180 preferably mating flush therewith. Upon insertion of holding portion 20B and rod SOB into an aperture 65, the two elongated members 40B are compressed radially inwardly into an insertion position, expanding the compression member 200. The housing 30B slides towards the shoulder 170 of the rod 50B, with the first shoulder 160 preferably mating flush therewith.
With reference to FIGS. 11-14, the ends of each of the elongated members 40B include lips 190, which have been configured to center the holding portion 20B (and hence, the rod 50B) in a central location within the aperture 65. The lips 190 in this embodiment contact an annular surface area 67 (best seen in FIG. 13) of the aperture 65. In FIG. 14, the lips 190 are shown contacting the annular surface area 67 (shown in phantom) at an upper and lower part of the annular surface area 67. To help ensure that the lips 190 comes in contact with the annular surface area 67, a tension wire 210 can be utilized. The tension wire 210 in this embodiment is put through a loop (best seen in FIGS. 12 and 14) inside a wrench flat 220 at the end of the rod 50. The loop in the wrench flat 220 is preferably smaller than the diameter of the rod 50B; and, when the rod 50 is threaded as shown, preferably smaller than a minor diameter 38 (for example, seen in FIG. 3). As seen in FIG. 12, as the rod 50B and holding portion 20B are inserted through the aperture 65 in the direction, indicated by arrow 500, the tension wire 210 is pulled to ensure that the elongated members 40B are not inadvertently pushed through the aperture 65. As soon as tips 46B of the elongated members 40B clear the annular surface area 67 of the aperture 65, the compression member 200 automatically urges the lips 190 for contact with the annular surface area 67 of the aperture 65.
With reference to FIGS. 12 and 14, the end areas 48B of the two elongated members 40B can be seen. In FIG. 14, the end areas 48B extend just beyond the circumference 69 (shown in phantom) of the cross-sectional area of the aperture 65. The end areas 48B in this embodiment have an angled configuration which allows full bearing contact with the blind surface area 62.
Turning once again to FIG. 13, the tension wire 210 can provide the force necessary to establish friction force between the end areas 48B and blind surface area 62 of the structural member 60—thus, allowing the nut 90 to be threaded on the rod 50B, while the holding portion 20B maintains its positional relationship with the bolt or rod 50B. As an additional aid, a wrench (not shown) can be clamped on to the wrench flats 220 helping to maintain the positional relationship of the holding portion 20B with the bolt or rod 50B by preventing rotation of the rod 50B.
As an illustrative example of the use of the embodiment described with reference to FIGS. 11-14, a rod 50B having a housing 30B, coupled thereto is inserted into the aperture 65, whereupon the elongated members 40B are compressed radially inward into an insertion position. Upon clearance of tips 46B of the elongated members 40B of the annular surface area 67 of the aperture 65, the compression member 200 urges the lips 190 into contact with the annular surface area 67 of the aperture 65. Then, an element 70 can be received on the rod 50B, whereupon a force is applied on the tension wire 210 bringing the end areas 48B into a bearing position for full bearing contact. While maintaining tension on the tension wire 210 (to increase the friction force between the end areas 48B and the blind surface area 62), a washer 80 and nut 90 are inserted on the rod 50B to threadably mate the element 70 into contact with an exposed surface area 64 of the structural member 60. Additionally, a wrench (not shown) can be clamped on to the wrench flats 220 helping to maintain the positional relationship of the holding portion 20B with the bolt or rod 50B. The holding portion 20B resists removal of the rod 50B through the head 140, first shoulder 180, and elongated members 40B, which have a full distributed load over the end areas 48B on blind surface area 62—reducing the bearing force per area of the blind surface area 62 of the structural member 60.
With reference to FIGS. 15-23, another embodiment of the invention is shown. In this embodiment, as generally shown in FIG. 15, a rod 50C has a nut 300 threadably coupled thereto within a holding portion, generally indicated 20C. The holding portion 20C in this embodiment includes elongated members 40C, a compression member 200, and a housing 30C. The nut 300 is positioned within interior formed recess 310 in the housing 30C. The two elongated members 40C in this embodiment are each generally semicircular. The housing 30C forms the exterior of the recess 310. The compression member 200, positioned in an annular groove 316 (best seen in FIG. 21), is designed to create a radially compressive force on the end of the holding portion 20C, adjacent to the housing 30C. The housing 30C and elongated members 40C will preferably be integral and made from zinc, aluminum, brass, steel, or stainless steel. The compression member 200 will preferably be continuous and made from neoprene, steel, or spring wire. As will be explained in detail below, when the holding portion 20C is in the extended position, as shown in FIG. 15, or in the insertion position, as shown in FIG. 18, the recess 310 resists rotation of the nut 300. The angle of the extension of the elongated members 40C is preferably predetermined. As way of an example, in FIG. 15, the predetermined angle of the elongated members 40C in the extended position is approximately 30°. In FIG. 18, the predetermined angle of the elongated members 40C in the insertion position is approximately 4° or less. Those skilled in the art will appreciate that the actual angles of the predetermined extended position and the insertion position of the elongated members may be any desired angles where the predetermined angle in the insertion position is less than the predetermined angle in the extended position.
With reference to FIGS. 15-19, the end of each of the elongated members 40C includes lips 190, which have been configured to center the holding portion 20C with the aperture 65. One or more of the lips 190 in this embodiment can come in contact with an annular surface area 67 (best seen in FIG. 19) of the aperture 65. In FIG. 19, while the lips 190 are shown contacting the annular surface area 67 at an upper and lower part of the annular surface area 67, it may be that only one lip is in contact with the surface area 67. As shown in FIG. 18, the rod 50C and holding portion 20C are inserted through the aperture 65 in the direction indicated by arrow 600. As soon as tips 46C of the elongated members 40C clear the annular surface area 67 of the aperture 65, the compression member 200 urges the lips 190 to the predetermined extended position. Those skilled in the art will appreciate that because of housing shoulders 314, as best seen in FIGS. 15, 17, 18, 21, 22 and 23, the lips 190 can be opened to a predetermined extended position where the lips 190 are less than the cross-sectional area of the holding portion 20C in the insertion position. This approximate cross sectional area of the holding portion 20C in the insertion position is shown in FIG. 16. In other words, because the annular surface area 67 of the aperture 65 will be greater than the cross-sectional area of the elongated members 40C in the insertion position, the holding portion 20C allows the lips 190 to be received in the aperture 65 from either side of the structural member 60.
Turning to FIGS. 15, 16, and 18, the holding portion 20C includes interior recess 310 having a plurality of angles and sides to correspond to the plurality of angles and sides of the nut 300. As FIGS. 15, 16, and 18 indicate, the nut 300 is blocked from rotation by the interior surface defining the recess 310 in the housing 30C. As best shown in FIG. 15, the holding portion 20C threadably engages with a rod 50C via the length of engagement 32 of the nut 300 within the recess 310. Those skilled in the art will now appreciate that the housing 30C resists rotation of the nut 300 because of the blocking shoulders 312 in the recess 310 relative to the nut 300.
Turning to FIG. 17, showing the cross-sectional view of the holding portion 20C in the predetermined extended position, similar to FIGS. 15, 19, 22 and 23, the end areas 48C of the elongated members 40C can be seen. As discussed above, in the predetermined extended position, the position of the lips 190 are less than the cross-sectional area of the holding portion 20C in the insertion position. As best shown in FIG. 19, the end areas 48C extend beyond the circumference 69 of the cross-sectional area of the aperture 65. As also best seen in FIG. 19, the end areas 48C in this embodiment have an angled configuration which allows alignment for full bearing contact with the blind surface area 62 of the structural member 60.
With reference to FIG. 18, an element 70 can be mounted to the rod 50C. The rod 50C, having a nut 300 threadably coupled thereto along the length of engagement 32 of the nut 300 within a holding portion 20C, is inserted along direction of arrow 600 into aperture 65, whereupon the elongated members 40C are compressed radially inward into an insertion position. Upon clearance of tips 46C of the elongated members 40C of the annular surface area 67 of the aperture 65, the compression member 200 urges the lips 190 outwardly to the predetermined extended position. The rod 50C is further threaded to the nut 300, whereupon a tension force is applied by the rod 50C, bringing the end areas 48C into a contact and bearing position for bearing contact with surface area 62. This, in turn, brings the element 70 into contact with exposed surface area 64 of the structural member 60.
The holding portion 20C of this embodiment of the invention (best seen in FIGS. 15-23) has many advantages. First of all, those skilled in the art will appreciate that each of the plurality of elongated members 40C could be identical. Thus, savings in manufacturing and inventory costs can be anticipated as a result of being able to use only one form (or mold), or other way of forming, for the integral housing 30C and elongated members 40C for the holding portion 20C. Additionally, because of the unique configuration of the holding portion 20C of this embodiment, an off-the-shelf nut 300 could be assembled with the properly sized recess 310 of the holding portion 20C. This again results in reduction of manufacturing and inventory costs as the nut 300 can be purchased in quantities when needed for assembly with the holding portion 20C.
FIG. 20 is an illustration of some exemplary threaded rods for use with an embodiment of the invention. Those skilled in the art will appreciate that, with this embodiment, any type of threaded rod can be used. FIG. 20 indicates some typical threaded rods that may be advantageously used with this embodiment, including a flat head bolt 50D, an allen head bolt 50E, a half round head bolt 50F, a counter sunk head bolt 50G, a phillips head bolt 50H, a longer phillips head bolt 501, and a threaded stud 50J with nut 400. Of course, the nut 400 could be identical to nut 300. This again will result in savings in manufacturing and inventory costs. Additionally, those skilled in the art will now appreciate that the holding portion 20C allows the nut 400 to be threaded on the stud 50J, while the holding portion 20C maintains its positional relationship with the stud 50J and the structured member 60.
FIGS. 21-23 provide side and front views of housing shoulders 314 used to limit the extension of the lips 190 to a position less than the cross-sectional area of the holding portion 20C in the insertion position. Further, as best shown in FIGS. 21 and 22, because the aperture 65 will be greater than the cross-sectional area of the elongated members 40C in the insertion position, the holding portion 20C advantageously allows the lips 190 to be received from either side of the structural member 60. That is, the lips 190 travel in the direction of arrow 600, as shown in FIG. 21, and then when the lips 190 are in the extended position, they travel in the opposite direction from the position shown in FIG. 22 back into the aperture 65. Those skilled in the art will now appreciate that the because the lips 190 may be received from either side of the structural member 60, one or more end areas 48C may always be brought into a continued and bearing position with the blind surface area 62 of the structural member 60. In FIG. 21, the compression member 200 is positioned in the annular groove 316. With reference to FIG. 22, those skilled in the art will now appreciate that if the aperture 65 is oversized relative to the holding portion 21C, only one or more of the lips 190 may be in contact with the surface 67 when the holding portion 20C is in the extended position.
As used herein, the term “anchored” is defined as being securely positioned within, on, or being made from the underlying material. The term “fastener” is defined as the combination of a holding portion and a rod, equivalent to the holding portions and rods discussed herein. The holding portion can include either an integral length of engagement, such as a threaded portion, or may a separate engaging component, such as a nut.
With reference to FIGS. 24A-30, various embodiments of the invention are shown in whole or in part. In some embodiments, as generally shown in FIGS. 24A-24C, a cross-section of a channel 410 is shown anchored in a mass or volume of structural material 610, so as to form a chamber 408 in the structural material 610. The channel 410 may be formed from the same material as the structural material 610, or the channel 410 can be made of a different material, as illustrated in FIGS. 24A-25. In the embodiments shown in FIGS. 24A-34 the structural material 610 is concrete, although other materials, including, but not limited to, foam or metal, are contemplated. The channel 410 is preferably a metal, such as steel, iron, or aluminum, plastic, or other resilient material.
In FIGS. 24A and 24C, one embodiment of a channel 410 is shown. In this embodiment, rear corners 412 of the channel 410 are shown extending outwardly from the sidewalls 411 of a rear wall 413 of the channel 410. In this embodiment, the sidewalls 411 tend inwards as they extend rearward until an inflection from which they extend outwardly to form the protrusion of the rear corners 412. In FIG. 24B, another embodiment of a channel 410A is shown. As shown in this embodiment, the rear corners 412A of the rear wall 413A extend perpendicularly outwardly from the substantially straight sidewalls 411A. In other embodiments, the rear corners 412A extend at other angles with respect to the rear wall 413A.
With reference to FIGS. 24A and 24B, the channel 410 is shown anchored in the structural material 610. Although FIGS. 24A-24C show channel 410 as being embedded within the structure material, it is contemplated that a portion of the channel could extend beyond the surface of the structural material 610. The channel 410 may also be anchored to an exterior surface of the structural material 610. Alternatively, the channel 410 can be integral with the structural material 610, having been formed therein. The channel 410 can be of any dimension, including length, width, depth, or height. The chamber 408 can be formed in the structural material 610 without the channel 410.
In the embodiment of FIG. 24A, a front surface 403 of the structural material 610 is shown being separated from the front side of the channel 410 by a depth 404 of the structural material 610. In the embodiment of FIG. 24B, the front surface 403 of the structural material 610 is shown approximately flush with the front side of the channel 410. An opening 401 is shown in the chamber 408, the channel 410, and the structural material 610. As the chamber 408 is shown from the side, a length of the chamber 408 is not visible, but may be any length. Channel 410 includes opposed margins 414 that define the opening 401, so that a width 402 of the opening 401 is narrower than a width 416 of the chamber 408 formed by the channel 410. As shown, each margin 414 has a width 415. In the embodiments of FIGS. 24A and 24B, the thickness 422 of the channel 410, 410A is also shown. This channel thickness 422 can be any thickness desired for various applications. Although the channel as shown in FIGS. 24A, 24B, or 24C appears to have a uniform thickness 422, it is contemplated that side walls 411, margins 414 and the rear wall 413 can have non-uniform thicknesses 422. For example, margins 414 could have a thickness that is a multiple of the thickness of the corresponding rear wall 413.
As shown in FIGS. 24A and 24B, inside bearing surfaces 418 of the margins 414 are constructed to bear weight when used to secure elements (e.g., element 70 shown in FIG. 24C) using a fastener with a holding portion, such as the holding portions 20, 20A, 20B, 20C, and 20D disclosed herein in FIGS. 1, 7, 11, 15, and 28, respectively. The bearing surface 418 meets the surfaces 67D of the opening 401 at corners 420. In the embodiment of FIG. 24A, the surface area 67D of the opening 401 is larger than shown in other embodiments due to the depth 404 of the structural material 610 along the opening 401. The bearing surface 418 is an example of the blind surface area 62, and any reference herein to the blind surface area 62 also refers to the bearing surface 418.
Generally referring to FIGS. 24C-30, an embodiment of a holding portion, generally designated 20D, is shown inserted into the chamber 408 in the channel 410. As best shown in FIG. 24C, a rod 50C (shown as a bolt) has a nut 300 threadably coupled thereto within recess 310. The holding portion 20D includes two elongated members 40D and a compression member 200D. Turning now to FIGS. 28-29, the elongated members 40D have rectangular bearing surfaces 48D and tips 46D that allow alignment for full bearing contact with the inside bearing surfaces 418 of the opposed margins 414. As best shown in FIG. 24C, the nut 300 is positioned between the elongated members 40D within the interior formed recess 310. The compression member 200D, positioned in a groove 316A, best seen in FIGS. 27-29, is designed to create a compressive force on the end of the holding portion 20D, adjacent to the recess 310.
Since holding portion 20D is similar to holding portion 20C, either holding portion 20C or 20D can combine with the rod 50C to make a fastener so that the end areas 48C or 48D are substantially coplanar when the corresponding holding portion 20C or 20D is in the extended position, as shown in FIGS. 15 and 24C, respectively. The geometries of the end areas 48C, 48D differ based on intended uses. The generally arcuate end areas 48C are intended to contact a bearing surface 62 after being inserted in the generally rounded aperture 65, while the generally rectangular end areas 48D are intended to contact a bearing surface 418 above and below after being inserted into the elongated opening 401. The holding portion 20D can also be used with the aperture 65. Note that compression members 200C and 200D also have different geometries, generally circular and generally rectangular with a loop and a missing side, respectively. As best shown in FIG. 18, the shoulders 312 of the recess 310 of the holding portion 20C are substantially parallel to the sides of the nut 300 when the holding portion 20C is in the insertion position. In contrast, as best shown in FIG. 24C, the shoulders 312 of the recess 310 of the holding portion 20D are substantially parallel to the sides of the nut 300 when the holding portion 20C is in the extended position.
Referring again to FIGS. 24A-30, each elongated member 40D is preferably identical and preferably made from a metal, such as zinc, aluminum, brass, steel, or stainless steel, plastic, or the like. The compression member 200D will preferably be unitary and preferably be made from neoprene, steel, or spring wire. In other embodiments, compression member 200D can have other geometries or compositions. As explained in detail herein, when the holding portion 20D is in the extended position, such as shown in FIG. 28, or in the insertion position, such as shown in FIG. 29, the blocking shoulders 312 of the recess 310, best seen in FIG. 30, resist rotation of the nut 300. The angle of the elongated members is preferably predetermined, similar to other holding portion 20 embodiments described herein. Those skilled in the art will appreciate that the actual angles of the predetermined extended position and the insertion position of the elongated members may be any desired angles where the predetermined angle in the insertion position is less than the predetermined angle in the extended position.
With reference to FIGS. 24C, 25, 28, and 29, the end of each elongated member 40D includes lips 190D configured to position the holding portion 20D with the elongated opening 401 in the chamber 408. As best shown in FIG. 25, the rectangular bearing end areas 48D, shown in phantom view, contact the opposed margins 414. The bearing end areas 48D sum to form the end surface area for this embodiment. Referring to FIG. 24C, the chamber 408 is shown substantially filled with the holding portion 20D. In other embodiments, the chamber 408 may be larger.
As shown in FIGS. 28 and 29, the rod 50C and holding portion 20D are inserted through the elongated opening 401 between the opposed margins 414. As soon as tips 46D of the elongated members 40D clear the plane of the opening 401 between the margins 414, the compression member 200D urges the lips 190D to the predetermined extended position. Those skilled in the art having benefit of this disclosure will appreciate that because of the housing shoulders 314, as best seen in FIGS. 24C, 28, and 29, the lips 190D are limited to a predetermined extended position where the lips 190D are within the cross-sectional area of the holding portion 20D in the insertion position. In other words, because the spread of the elongated members 40D in the insertion position is less than the width 402 of the opening 401, the holding portion 20D allows the lips 190D to be received within the opening 401. Referring to FIGS. 24C and 25, in this extended position inside the chamber 408, the end areas 48D contact the inside surface 418 of the opposed margins 414. The lips 190D at least partially fill the opening 401 between the margin edges 420.
Turning now to FIG. 26, an elongated member's knob 450 and corresponding profile 451 are shown. The wire clip compression member 200D is also shown. Having each elongated member 40D identical reduces cost in manufacturing and inventory. The cutaway of the rod 50C is shown inside the throughway 452 created by the combined elongated members 40D.
Turning now to FIG. 27, the groove 316A to position the compression member 200D of the holding portion 20D is shown. The incline from the tips 46D of the elongated members 40D from the compression member 200D in the groove 316A is also shown.
Turning to FIGS. 28 and 29, the relative positions of the knob 450 and corresponding profile 451 are shown in phantom view along with the direction of insertion 600. It will be appreciated by those of skill in the art having benefit of this disclosure that the embodiments of the holding portion 20D having the knobs 450 and the corresponding profiles 451 will resist relative lateral movements between the elongated members 40D. As the holding portion 20D is moved to the insertion position, the compression member 200D expands in the groove 316A, as shown in FIG. 29. When the holding portion 20D is urged to the extended position, the compression member 200D returns to the shape shown in FIG. 28.
Returning to FIG. 30, a plan view of elongated member 40D shows the housing shoulders 314 on opposite sides of the throughway 452. While the knob 450 and the profile 451 may be reversed in positions, the knob 450 and the profile 451 are configured to mate with a corresponding profile 451 and knob 450 on another elongated member 40D. A portion of the recess 310 formed by the blocking shoulders 312 and the lip 190D are also shown. The shapes of the knobs 450 and the profiles 451 are illustrative only, and the knobs 450 and the profiles 451 may have other geometries.
FIGS. 31-34 show various embodiments of structural members and combinations thereof. The structural members include walls 620, 630, 640, 650 (also called sidewall 650), ceiling 644, and floors 622, 632, 642. Although the illustrated embodiments of the structural members typically include flat surfaces, no such limitation should be inferred. One advantage of the channels 410, 410A used in combination with fasteners with holding portions 20D seen in FIGS. 24C-34 is that the channels 410, 410A provide for location flexibility in the mounting of various elements. The holding portions 20D can be slid along the elongated openings of the channels 410, 410A, or removed and reinserted in the channels 410, 410A, to secure the elements in a myriad of positions along the channels 410, 410A. Removal may include reducing an engagement force of the elongated members 40D of the holding portion 20D with the plurality of opposed margins 414. Reinsertion includes increasing the engagement force of the elongated members 40D of the holding portion 20D after sliding or removal.
Turning now to FIG. 31, a structural member, a wall 620, composed of the structural material 610, includes a plurality of channels 410 configured to receive holding portions 20D for securing various elements to the wall 620. A portion of a stairway 512 with steps 512B is shown in cutaway view secured to the wall 620 using fasteners with holding portions 20D through a stairway sidewall 512A. The channels 410 used to secure the stairway 512 are substantially parallel and offset. Notches 512C in the stairway sidewall 512A, for securing the stairway 512, may be used to adjust the vertical positioning of the stairway 512 by a small amount, typically less than one inch. Hinges 511 of a door 510 are secured to the wall 620 using parallel, but not offset, channels 410 by fasteners using holding portions 20D. The stairway 512 and the door 510 are secured above floor 622. In other embodiments, the channels 410 may be vertical or angled instead of horizontal in orientation. With vertical channels 410 or channels 410 with other orientations, the notches 512C may be omitted.
As seen in FIG. 32, a wall 630 composed of structural material 610 includes a plurality of channels 410A configured to receive fasteners with holding portions 20D for securing various elements to the wall 630. Fasteners with long rods 50K and holding portions 20D in vertical channel 410A secure a structural support 508A to the wall 630, while fasteners with rods 50C and holding portions 20D in horizontal channel 410A secure a structural support 508B to a floor 632. The structural supports 508 each integrate a channel 410A for receiving holding portions 20D using an appropriately sized rod 50. A beam 514 (here a shelf) is secured to the structural supports 508A and 508B using angle brackets 70. The shelf 514 may be repositioned up or down using the repositionability feature of the fasteners with holding portions 20D secured in the channel 410A.
Turning to FIG. 33, a ceiling 644, composed of structural material 610, includes a channel 410A configured to receive fasteners with holding portions 20D for securing one or more elements 505 (here a light) to the ceiling 644. The channel 410A in the ceiling 502 is secured by reinforcing elements 503 (here rebar). It is contemplated that the channels 410A can be securely anchored to the structural material 610 using anchors, nuts and bolts, rivets, or other suitable mechanism (e.g. welding, when the structural material 610 is metal or includes a form of metal, such as the rebar). The reinforcing elements 503 further secure the structural integrity of the channel 410 in the structural material 610 and may advantageously allow for a greater load bearing force to be placed on the holding portion 20D in the channel 410A. It is contemplated that weighty elements 505 (e.g., air conditioning units) could be hung from the ceiling 502 using fasteners described herein.
Also in FIG. 33, a wall 640 is secured to the ceiling 644 using fasteners with angle brackets 70 and holding portions 20D in the channels 410A in the wall 640 and the ceiling 644. The channels 410A in the wall 640 are in recesses 520, allowing for cosmetic finishing after installation, covering up the holding portions 20D and the angle brackets 70. Through the use of a cutaway, the wall 640 is shown connected to a sidewall 650.
In FIG. 34, the wall 640 is secured to the sidewall 650 using angle brackets 70 and holding portions 20D in channels 410A. Both the wall 640 and the sidewall 650 have recesses 520. The sidewall recess 520 is an interior recess, while the wall recess 520 is an edge recess, similar to the recess shown in FIG. 33. The recesses 520 are covered with a finishing layer 525, such as finished plasterboard, to cover cosmetically the connection between the wall 640 and the sidewall 650.
Turning to FIG. 35, an embodiment of a form 550 includes form walls 551A, 551B, 551C, and 551D for holding a non-solid structural material 610, such as wet concrete, until appropriately solidified, dried or cured. The form walls 551 form a shell for the structural member being produced. As illustrated, the form 550 outlines a generally rectangular solid, but other geometries are contemplated. An optional structural support 552 provides a fixed separation distance between form walls 551B and 551D. The upper left channel 410A is positioned to be approximately flush with the surface of the resulting structural member, so only a cover 561 (such as film, tape, etc.) is needed to cover the opening 401. A cap 560 at the bottom end of the upper left channel 410A keeps non-solid structural material 610 out of the channel 410A. The left lower channel 410A is substantially perpendicular to the upper left channel 410A, with the chamber 408 visible, similar to FIG. 24B.
The upper right channel 410A of FIG. 35 is positioned to be anchored below the surface of the resultant structural member. A spacer 565 maintains the opening 401 in the structural material 610 because the opening will not be flush with the form wall 551B. The cover 561 may not be necessary when the spacer 565 is present. A cap 560 covers the bottom end of the right upper channel 410A. Similar to the left side, the lower right channel 410A is shown substantially perpendicular to the upper right channel 410A, with spacer 565 maintaining access to the chamber 408 therein when the non-solid structural material 610 is added to the form 550. In some embodiments, the channels 410A are spaced from the edge of the structural member to create the recess 520 shown in FIGS. 33 and 34.
As shown in FIG. 35, the channels 410A are connected to reinforcing elements 503 (here e.g., welded to rebar). The rebar is shown either parallel or perpendicular to the channels 401A. The orientation of the reinforcing elements 503 and the elongated openings 501 of the channels 401A is a matter of design choice.
A method of making a structural member may include the following steps. Having provided a form, such as the form 550, opposed margins 414 are positioned in the form 550. The opposed margins 414 may be positioned in the form 550 before providing structural material 610 into the form 550. The opposed margins 414 define the elongated opening 401 by their placement. The elongated opening 401 is blocked to prevent filling of the opening 401 by structural material 610. Non-solid structural material 610 is then provided into the form 550 and allowed to solidify, harden, cure, etc. If desired, reinforcing elements 503 may be positioned in the form 550. The opposed margins 414 may be anchored to the reinforcing elements 503. The opposed margins 414 may be attached to or a part of a channel 410. In other embodiments, the opposed margins 414 may be a separate piece attached to another member that forms the chamber 408 when the opposed margins 414 are added. A cap 560 can be used to block an end of the chamber 408. A cover 561 and/or a spacer 565 can be used to block the elongated opening 401 of the chamber 408.
The chamber 408 may also be created within the structural material 610 after the structural member is formed. For example, if the member is made of concrete, a portion of the concrete can be removed to create the chamber 408 or to accommodate the channel 410. If securing the channel 410 more firmly within the structural material 610 is desired, a filler material bondable with concrete (e.g. an epoxy) can be added before the channel 410 is positioned in the concrete. Once the channel 410 is placed within the concrete, the filler material will fill any void space between the channel 410 and the concrete. Other means for securing the channel 410 to the structure material 610 include anchors, nuts and bolts, rivets, or securing mechanisms (e.g. welding, when the structural material 610 is metal or includes metal, such as rebar) as previously discussed.
Note that in various embodiments, the holding portions 20 may be freely substituted freely for each other along with other appropriate components that work together. Also in various embodiments, the elongated opening 401 is of differing sizes. For example, on one embodiment, the elongated opening 401 has a length less than two widths of the holding portion 20D. In another embodiment, the elongated opening 401 is substantially the same length as two holding portion 20D widths. In yet another embodiment, the elongated opening 401 has a length greater than two holding portion 20D widths. In still yet another embodiment, the elongated opening 401 length is within a range of approximately six to approximately twenty widths of the holding portion 20D. In other embodiments, the elongated opening 401 length is a fraction of the length of the structural member, or the entire length. Further, in various embodiments, different structural members may be made from different structural materials 610. A given structural member may be of uniform or non-uniform construction, being made of one or more structural materials 610.
It is contemplated that the maximum load that may be suspended or held by one of the fasteners described herein may be calculated in various embodiments from the tensile strength of the bolt or rod 50 used therein. By way of example and not limitation, common structural steel with a tensile strength of around 60,000 to 75,000 pounds-force per square inch (PSI) may be used. It is further contemplated that for a rod 50 of given diameter, assuming an applied tensile stress of 6,000 PSI, the following loads could be held, including a five-to-one safety factor: ¼ inch diameter would hold up to 160 pounds; 1/2 inch diameter would hold up to 760 pounds; one inch diameter would hold up to 3,300 pounds; one and 12 inch diameter would hold up to 7,700 pounds, and 2 inch diameter would hold up to 13,800 pounds. Other steel alloys may hold twice as much at the same size. Plastics, nylons, and other non-ferrous materials may not hold as much. No experimental tests have been made.
The foregoing disclosure and description is intended only to be illustrative and explanatory thereof. To the extent foreseeable, various changes in the size, shape, and materials, as well as in the details of illustrative construction and assembly, may be made without departing from the spirit of the invention.
Patent Application
20050210771
