BACKGROUND OF THE INVENTION
1. Field of the Invention
The subject invention relates to a frame assembly including a cornerlock.
2. Description of Related Art
Cornerlocks are used with frame assemblies to couple together frame members of the frame assemblies. The frame assembly includes frame members each having first and second ends, with each defining an interior and a screen mounted to the frame members. Certain cornerlocks include locking members coupled to one another. One of the locking members is inserted into the interior of one of the frame members. Another one of the locking members is inserted into the interior of another one of the frame members. The locking members frictionally engage the frame members. If the locking members are too large to be inserted into the frame members or if the locking members do not frictionally engage the frame members, the locking members must be manipulated, typically by force, to facilitate insertion and frictional engagement with the frame members. In particular, the frame members that have an arcuate configuration often have a cross-sectional profile which varies between the first and second ends. The variation in the cross-sectional profile causes the locking members to bind against the frame members while being inserted into the interiors, but prior to full insertion of the locking members within the interiors. The manipulation required to couple the locking members of the cornerlock with the frame members requires skill and labor which increases the time required to manufacture the frame assembly. As such, there remains a need to provide an improved frame assembly and cornerlock.
SUMMARY OF THE INVENTION AND ADVANTAGES
The subject invention provides a frame assembly for disposing within an opening of a structure. The frame assembly includes a first frame member and a second frame member each having a plurality of walls extending between a first end and a second end which is spaced from the first end. Each of the first and second frame members have a cross-section between the first end and the second end with each of the cross-sections defining an interior and being capable of varying between the first and second ends.
The frame assembly includes a cornerlock extending into each of the first and second frame members to couple together the first and second frame members. The cornerlock includes a first body member configured to mate with the interior of the first frame member and a second body member configured to mate with the interior of the second frame member. Each body member has a hinge end and a distal end spaced from the hinge end with the first and second body members rotatably coupled together at the hinge ends. The first body member has at least one arm extending from the hinge end to the distal end with the at least one arm deflectable about the hinge end to bias against and engage the first frame member within the interior of the first frame member and self-configure the first body member to the cross-section of the first frame member. Each of the first and second frame members have a mitered end with the cornerlock extending into the interiors of the first and second frame members at the mitered ends. The first and second frame members abut at the mitered ends in an angular configuration and with the cornerlock configured to rotate the first and second body members to correspond with the angular configuration of the first and second frame members such that the cornerlock is entirely disposed within a combination of the interiors of the first and second frame members at the mitered ends.
Accordingly, the deflection of the at least one arm caused by engagement with the first frame member facilitates the bias exerted by the at least one arm against the first frame member, which increases a frictional force between the first body member and the first frame member and retains the first body member in the interior of the first frame member. Furthermore, the deflection of the at least one arm allows the first body member to self-configure to the cross-section of the first frame member, which simplifies the skill and labor needed to assemble the frame assembly. In particular, the self-configuration of the first body member is desirable when the first frame member has an arcuate configuration because the cross-section of the first frame member typically varies between the first and second ends. Additionally, the self-configuration of the first body member facilitates retention of the first body member with frame assemblies of all different designs.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the subject invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings.
FIG. 1 is a perspective view of a frame assembly in an opening of a structure with the frame assembly showing frame members and an article.
FIG. 2 is an elevational view of the frame assembly showing the frame members and the article.
FIG. 3 is an elevational view of a cornerlock having first and second body members rotatably coupled together.
FIG. 4 is perspective view of the cornerlock having the first and second body members prior to coupling together.
FIG. 5 is a perspective view of the cornerlock having the first and second body members rotatably coupled together.
FIG. 6 is a perspective view of a first frame member and a second frame member each defining an interior with the cornerlock partially inserted into the interiors.
FIG. 7 is an elevational view of the first and second body members of the cornerlock partially inserted into the interiors of the first and second frame members.
FIG. 8 is an elevational view of the first and second body members of the cornerlock partially inserted into the interiors of the first and second frame members and the first body member having a pair of arms engaging walls of the first frame member and deflecting.
FIG. 9A is an elevational view of the first and second body members of the cornerlock fully inserted into the interiors of the first and second frame members and the first and second frame members having mitered ends abutting one another.
FIG. 9B is an elevational view of the first and second frame members abutting one another at the mitered ends.
FIG. 10 is a cross-sectional view of the first frame member taken along 10-10 in FIG. 8 showing a cross-section of the first frame member.
FIG. 11 is a cross-sectional view of the first frame member taken along 11-11 in FIG. 8 showing another cross-section of the first frame member.
FIG. 12 is perspective view of the cornerlock having the first body member defining a cavity and an opening and the second body members having a post with the first and second body members spaced from one another prior to coupling together.
FIG. 13 is a perspective view of the cornerlock having the first body member defining the cavity and the second body member having the post extending through the cavity to couple together the first and second body members.
FIG. 14 is an elevational view of the first and second body members of the cornerlock with the first and second body members each having a pair of arms.
FIG. 15 is an elevational view of a frame assembly having frame members with each having a substantially linear configuration.
FIG. 16 is a perspective view of the cornerlock having the first and second body members rotatably coupled together with the first body member having the at least one arm and a leg.
FIG. 17 is an elevational view of the cornerlock having the first and second body members rotatably coupled together with the first body member having the at least one arm and the leg.
FIG. 18 is a perspective view of the cornerlock having the first and second body members rotatably coupled together with the first body member having the at least one arm having a first section and a second section.
FIG. 19 is an elevational view of the cornerlock having the first and second body members rotatably coupled together with the first body member having the at least one arm having the first section and the second section.
DETAILED DESCRIPTION OF THE INVENTION
Referring to the Figures, wherein like numerals indicates like or corresponding parts throughout the several views, a frame assembly 20 for disposing within an opening 22 of a structure 24 is generally shown in FIG. 1. The structure 24 is typically a fireplace 26 as shown in FIG. 1 which includes a hearth 28 and a header 30 spaced from and substantially parallel to the hearth 28 with both the hearth 28 and the header 30 extending horizontally in planes transverse to one another. The fireplace 26 further includes a mantel 32 mounted to the header 30 and a pair of legs 34 spaced from and substantially parallel to each other and vertically oriented between the hearth 28 and the header 30. The hearth 28, the header 30, and the pair of legs 34 define the opening 22. The fireplace 26 further includes a firebox positioned between the hearth 28 and the header 30 and between the pair of legs 34. Although not required, the fireplace 26 typically includes a flammable fuel within the firebox such as a timber log, a hydrocarbon gas, or an electric heater each of which emits heat. The fireplace 26 may include a glass panel positioned adjacent to the firebox for inhibiting direct entry into the firebox.
The structure 24 may be a building, such as a commercial or residential building, with the opening 22 providing access into the structure 24, such as a fenestration. It is to be appreciated that the structure 24 does not have to be the fireplace 26 and may be any structure 24 having the opening 22.
The frame assembly 20 is typically a barrier positioned within the opening 22 for preventing movement of an object through the opening 22. It is to be appreciated that the object may be anything capable of moving through the opening such as an animate object, such as a person or an animal, or an inanimate object, such as a piece of furniture or a child's toy. When the structure 24 is the fireplace 26 as shown in FIG. 1, the frame assembly 20 is typically positioned within the opening 22 of the fireplace 26. If the fireplace 26 has the glass panel, the glass panel is positioned between the firebox and the frame assembly 20 with the frame assembly 20 spaced from the glass panel. The frame assembly 20 prevents the passage of the object through the opening 22 to contact the flammable fuel and/or the glass panel, which may have an elevated temperature due to the proximity of the glass panel to the flammable fuel.
When the structure 24 is the building, the frame assembly 20 prevents passage of the object through the opening 22 into and out of the building. Here, the object may include dirt, insects, animals, persons, etc. It is to be appreciated that the frame assembly 20 may have any configuration for preventing the passage of the object through the opening 22.
The frame assembly 20 comprises a first frame member 38a and a second frame member 38b, as shown in FIG. 2. More specifically, the frame assembly 20 has at least two frame members 38 which include the first and second frame members 38a, 38b. Typically, the frame assembly 20 comprises more than two frame members 38 as shown in FIGS. 2 and 15. The first and second frame members 38a, 38b refer to two of the frame members 38 which are adjacent to one another. Said differently, the first and second frame members 38a, 38b may be any two of the frame members 38 that are adjacent to one another. For illustrative purposes, two of the frame members 38 shown in the FIGS. 2 and 6-9B have been selected to illustrate the first and second frame members 38a, 38b. It is to be appreciated that any of the frame members 38 shown in the Figures may be referred to as the first and second frame members 38a, 38b.
As shown in FIG. 2, the first and second frame members 38a, 38b each have a plurality of walls 40 extending between a first end 42 and a second end 44 which is spaced from the first end 42. The first and second frame members 38a, 38b have a cross-section between the first end 42 and the second end 44 with each of the cross-sections defining an interior 48, as shown in FIGS. 7-9A, 10, and 11. Said differently, the plurality of walls 40 is configured to define the cross-section. As shown in FIGS. 10 and 11, the plurality of walls 40 is typically further defined as four walls 40 arranged to define a rectangular cross-section. It is to be appreciated that the plurality of walls 40 may be any number of walls 40 arranged to define any configuration of the cross-section, including but not limited to three walls 40 configured to define a triangular cross-section.
The cross-section refers to a profile of the frame members 38 as viewed along a longitudinal axis L of the frame members 38. Each cross-section is capable of varying between the first and second ends 42, 44. Variations in the cross-sections typically refers to variations of a length of at least one of the plurality of walls 40 and/or a variation in the shape of the plurality walls 40 as viewed along the longitudinal axis L. It is to be appreciated that the cross-section may vary in any particular way. As a non-limiting example of a variation in the cross-section, the first frame member 38a may have an arcuate configuration, as shown in FIGS. 7-9A. When the first frame member 38a is manufactured having the arcuate configuration, a plurality of folds 50 may form along one of the plurality of walls 40 which is closest to a center of curvature which defines the arcuate configuration. The formation of the plurality of folds 50 is a common result of the act of bending a metallic material. The plurality of folds 50 changes the cross-section of the first frame member 38a between the first and second ends 42, 44, as illustrated by comparison of FIGS. 10 and 11. Alternatively, the frame member 38 may have changes in the cross-section between the first and second ends 42, 44 for the purpose of production. It is to be appreciated that the cross-sections may vary for any design or aesthetic purpose.
As shown in FIGS. 2 and 15, each of the frame members 38 is positioned sequentially end to end. Furthermore, the first end 42 of the first frame member 38a abuts the second end 44 of the second frame member 38b. It is to be appreciated that the first end 42 of the first frame member 38a may abut the first end 42 of the second frame member 38b. Likewise, the second end 44 of the first frame member 38a may abut the second end 44 of the second frame member 38b. It is to be appreciated that the term “first end” and the term “second end” are interchangeable and may refer to either end of the frame members 38.
The frame assembly 20 further comprises an article 52 coupled to and supported by the first and second frame members 38a, 38b. As shown in FIG. 9B, the frame members 38 each may have a lip 54 to which the article 52 is coupled. Typically, when the structure 24 is the fireplace 26 as shown in FIG. 1, the article 52 is further defined as a screen 56, as shown in FIGS. 1, 2 and 15. The screen 56 allows passage of heat from the flammable fuel out of the firebox through the opening 22. Furthermore, air flows through the screen 56 allowing the screen 56 to dissipate heat better than, for example, the glass panel. As such, the screen 56 has a lower temperature than the flammable fuel and/or the glass panel. Therefore, if the screen 56 is contacted by the object, the object is less likely to incur heat-related damage than if the object contacted the flammable fuel or the glass panel. It is to be appreciated does not have to be the screen 56 and does not have to have heat dissipation properties as described above. Therefore, the article 52 may be any article for coupling to the frame members 38, including glass.
As shown in FIGS. 3-5 and 12-14, the frame assembly 20 further comprises a cornerlock 58 for use with the frame assembly 20 which supports the article 52. The cornerlock 58 extends into each of the first and second frame members 38a, 38b to couple together the first and second frame members 38a, 38b, as shown in FIGS. 6-9A. As described above, typically the first end 42 of the first frame member 38a abuts the second end 44 of the second frame member 38b. As such, the cornerlock 58 extends into the first end 42 of the first frame member 38a and into the second end 44 of the second frame member 38b. As described above, the terms “first end” and “second end” are interchangeable on the frame members 38. As also described above, the terms “first frame member” and “second frame member” may refer to any of the frame members 38. As such, the cornerlock 58 may couple any two adjacent frame members 38. Furthermore, the cornerlock 58 may be a plurality of cornerlocks 58 each coupling adjacent frame members 38. It is to be appreciated that the cornerlock 58 may be any number of cornerlocks 58 coupling any of the frame members 38. For the sake of simplicity, only one cornerlock 58 is referred to below coupling the first and second frame members 38a, 38b. It is to be appreciated that the description below may be applied to any cornerlock 58 and to any frame member 38.
The cornerlock 58 comprises a first body member 60 configured to mate with the interior 48 of the first frame member 38a, and a second body member 62 configured to mate with the interior 48 of the second frame member 38b. The first body member 60 may be cantilevered with the first frame member 38a and the second body member 62 may be cantilevered with the second frame member 38b. Said differently, the first body member 60 may extend into a portion of the interior 48 of the first frame member 38a and the second body member 62 may extend into a portion of the interior 48 of the second frame member 38b.
Each body member 60, 62 has a hinge end 64, 65 and a distal end 66, 67 spaced from the hinge end 64, 65. The first and second body members 60, 62 are rotatably coupled together at the hinge ends 64, 65.
The first body member 60 has at least one arm 68 extending from its respective hinge end 64 to the distal end 66. The at least one arm 68 is deflectable about the hinge end 64 to bias against and engage the first frame member 38a within the interior 48 of the first frame member 38a and self-configure the first body member 60 to the cross-section of the first frame member 38a. Said differently, the at least one arm 68 is configured to deflect and the hinge end 64 of the first body member 60 is rigid and configured to not deflect as the at least one arm 68 deflects.
To enable rotation between the first and second body members 60, 62, one of the first and second body members 60, 62 may have a post 70 at the hinge end 64, 65 and another one of the first and second body members 60, 62 may define a cavity 72 at the hinge end 64, 65 as shown in FIGS. 4, 5, 12, and 13. Typically, the second body member 62 has the post 70 and the first body member 60 defines the cavity 72. However, it is to be appreciated that the opposite may be true, i.e., the first body member 60 may have the post 70 and the second body member 62 may define the cavity 72.
Each of the first and second body members 60, 62 may have a primary portion 74, 75 extending along an axis A. The post 70 extends transverse to the axis A of the one of the first and second body members 60, 62. More specifically, as shown in the Figures, the post 70 extends perpendicular to the axis A. However, it is to be appreciated that the post 70 may extend at any angle transverse to the axis A.
The post 70 extends through the cavity 72 to rotatably couple together the first and second body members 60, 62. Said differently, the first and second body members 60, 62 rotate about their respective hinge ends 64, 65 which are coupled to one another.
As shown in FIGS. 4 and 5, the post 70 may have a shaft 76 and a shoulder 78 mounted to the shaft 76 and spaced from the primary portion 74, 75. The shaft 76 is disposed in the cavity 72 of the other one of the first and second body members 60, 62. The shoulder 78 and the primary portion 74, 75 of the one of the first and second body members 60, 62 abuts the primary portion 74, 75 of the other one of the first and second body members 60, 62 to rotatably couple together the first and second body members 60, 62. Specifically, as shown in the Figures, the second body member 62 has the shaft 76 and the shoulder 78 and the first body member 60 defines the cavity 72; however, it is to be appreciated that the opposite may be true, i.e., the first body member 60 may have the shaft 76 and the shoulder 78 and the second body member 62 may define the cavity 72. The shoulder 78 is typically formed by orbital riveting after the shaft 76 is disposed in the cavity 72, but may be formed by any suitable manufacturing method. The primary portion 74 of the first body member 60 is positioned between the shoulder 78 and the primary portion 75 of the second body member 62 such that the first body member 60 does not slide off of the shaft 76 of the second body member 62.
Alternatively, as shown in FIGS. 12 and 13, the other one of the first and second body members 60, 62 may define an opening 80 in communication with the cavity 72 to facilitate insertion of the post 70 into the cavity 72. Said differently, the opening 80 is transverse to the cavity 72 with the opening 80 providing entry into the cavity 72. As shown in the figures, the first body member 60 defines the opening 80. The opening 80 is transverse to a longitudinal axis of the cavity 72 through the first body member 60. Furthermore, the opening 80 is transverse to the axis A. The opening 80 may be anywhere along the first body member 60 for facilitating insertion of the post 70 into the cavity 72.
The one of the first and second body members 60, 62 which has the post 70 (typically, the second body member 62 as shown in the figures and described as such going forward) may have a pair of side members 82 extending from the primary portion 75 along the axis A spaced from and substantially parallel to each other at the hinge end 65, as shown in FIGS. 12 and 13. The side members 82 are positioned on opposing sides of the first body member 60 such that the hinge end 64 of the first body member 60 is between the side members 82. The post 70 extends between and is mounted to each of the pair of side members 82. The post 70 has a rectangular configuration. Said differently, the post 70 has a pair of long sides spaced from one another and a pair of short sides extending between the long sides. The rectangular configuration allows insertion of the post 70 through the opening 80 into the cavity 72 when one of the short sides faces the opening 80. When in the cavity 72 and rotated, the long sides are too large to exit the cavity 72, which retains the post 70 in the cavity 72. The primary portion 74 of the first body member 60 is positioned between the side members 82 of the second body member 62 such that the first body member 60 may not slide off of the post 70 of the second body member 62. It is to be appreciated that the first and second body members 60, 62 may be rotatably coupled to each other in any suitable way.
As shown in FIG. 3, the primary portion 74, 75 of the each of the first and second body members 60, 62 may have a pair of engagement surfaces 84 opposing one another for engaging the walls 40 within the interiors 48 of the respective first and second frame members 38a, 38b. As described above, the second body member 62 has the primary portion 75 extending along the axis A. At least one rib 86 extends from the primary portion 75 transverse to the axis A for engaging the second frame member 38b within the interior 48 of the second frame member 38b, as shown in FIGS. 7-9A. More specifically, one of the pair of engagement surfaces 84 defines the at least one rib 86. The at least one rib 86 may be further defined as a plurality of ribs 86 defined on each of the pair of engagement surfaces 84 of the primary portion 75 of the second body member 62. Although not shown in the Figures, it is to be appreciated that the at least one rib 86 may extend from the primary portion 75 of the second body member 62 and/or the primary portion 74 of the first body member 60.
As shown in FIGS. 2 and 7-9A, the second frame member 38b has a substantially linear configuration with the cross-section of the second frame member 38b generally consistent between the first and second ends 42, 44. The primary portion 75 has a width between the pair of engagement surfaces 84 that is substantially equal to the cross-section of the second frame member 38b for facilitating engagement of the primary portion 75 with the second frame member 38b and retention of the second body member 62 in the interior 48 of the second frame member 38b.
As described above, the cross-section of the frame members 38 may vary between the first and second ends 42, 44. As described above, the frame members 38 may have the arcuate configuration which may vary the cross-section between the first and second ends 42, 44. Such an arcuate configuration is shown with the first frame member 38a in FIGS. 7-9A. Although the first frame member 38a is shown with the arcuate configuration in the Figures, it is to be appreciated that the second frame member 38b may have the arcuate configuration. Said differently, any of the frame members 38 may have the arcuate configuration. Similarly, any of the frame members 38 may have the substantially linear configuration described above. Furthermore, the cross-section of any of the frame members 38 may vary for any reason, such as variations occurring through manufacturing and/or by specific design.
As described above, the at least one arm 68 is deflectable about the hinge end 64 to bias against and engage the first frame member 38a within the interior 48 of the first frame member 38a and to self-configure the first body member 60 to the cross-section of the first frame member 38a. Said differently, the at least one arm 68 engages at least one of the walls 40 of the first frame member 38a within the interior 48 and deflects about the hinge end 64 toward the axis A, as shown between FIGS. 7 and 8. The at least one arm 68 may deflect about the hinge end 64 toward and away from the axis A. The deflection of the at least one arm 68 corresponds with the engagement of the at least one arm 68 with the at least one of the walls 40, which facilitates the bias exerted by the at least one arm 68 against the first frame member 38a. The bias exerted by the at least one arm against the first frame member 38a increases a frictional force between the first body member 60 and the first frame member 38a that retains the first body member 60 in the interior 48 of the first frame member 38a. Furthermore, the deflection of the at least one arm 68 allows the first body member 60 to self-configure to the cross-section of the first frame member 38a. As described above, the cross-section may vary, for example, when the first frame member 38a has the arcuate configuration where the plurality of folds 50 extends into the interior 48. When the first frame member 38a has the arcuate configuration, the at least one arm 68 deflects to engage the first frame member 38a and self-configure the first body member 60 to the cross-section of the first frame member 38a along the arcuate configuration. To compensate for the extension of the plurality of folds 50 into the interior 48, the at least one arm 68 deflects toward the axis A with the at least one arm 68 engaging the plurality of folds 50 of the first frame member 38a.
The at least one arm 68 of the first body member 60 may be further defined as, and is typically, a pair of arms 68 extending from and independently deflectable about the hinge end 64. As shown between FIGS. 7 and 8, each of the pair of arms 68 biases against and engages the first frame member 38a within the interior 48 and self-configures the first body member 60 to the cross-section of the first frame member 38a. Said differently, the pair of arms 68 engages the walls 40 of the first frame member 38a within the interior 48. The pair of arms 68 engages the walls 40 at at least two points of contact. Typically, the pair of arms 68 each engage one of the walls 40 of the first frame member 38a such that the pair of arms 68 engage two of the walls 40; however, it is to be appreciated that the pair of arms 68 may engage any number of the walls 40. Each of the pair of arms 68 may independently deflect about the hinge end 64 toward and away from the axis A. Typically, the pair of arms 68 engages the first frame member 38a and deflects toward the axis A. The deflection of each of the pair of arms 68 corresponds with the engagement of each of the pair of arms 68 with the walls 40 of the first frame member 38a. The engagement of one of the pair of arms 68 with the first frame member 38a may be different than the engagement of another one of the pair of arms 68. As such, the pair of arms 68 may have different degrees of the deflection depending on the configuration of the walls 40 that the each of the pair of arms 68 engages. Each of the pair of arms 68 bias against the first frame member 38a which increases the frictional force between the first body member 60 and the first frame member 38a and retains the first body member 60 in the interior 48 of the first frame member 38a. Furthermore, the independent deflection of the pair of arms 68 allows the first body member 60 to self-configure to the cross-section of the first frame member 38a, as described in greater detail above.
Typically, the pair of arms 68 extends spaced from and substantially parallel to each other from the hinge end 64 to the distal end 66 with each of the pair of arms 68 independently deflectable toward and away from each other. The pair of arms 68 applies opposing bias to the first frame member 38a within the interior 48 and self-configures the first body member 60 to the cross-section of the first frame member 38a. Said differently, the pair of arms 68 engages the walls 40 at at least two points of contact opposing one another. Typically, the pair of arms 68 each engages opposing walls 40 of the first frame member 38a. As such, the deflection of the pair of arms 68 corresponds with the engagement of the at least one arm 68 with at least one of the walls 40, which facilitates the opposing bias exerted by the pair of arms 68 against the opposing walls 40 of the first frame member 38a further increasing the frictional force between the first body member 60 and the first frame member 38a that retains the first body member 60 in the interior 48 of the first frame member 38a. It is to be appreciated that the pair of arms 68 may engage any of the walls 40 while applying opposing bias to the first frame member 38a.
When the first frame member 38a has the arcuate configuration, the pair of arms 68 independently deflects to engage the first frame member 38a and self-configure the first body member 60 to the cross-section of the first frame member 38a along the arcuate configuration. To compensate for the extension of the plurality of folds 50 into the interior 48, at least one of the pair of arms 68 deflect toward the axis A with the at least one of the pair of arms 68 engaging the plurality of folds 50 of the first frame member 38a, as shown in FIG. 8.
Each of the pair of arms 68 are tapered toward each other at the distal end 66 for facilitating insertion of the first body member 60 into the interior 48 of the first frame member 38a. Said differently, the pair of arms 68 extend closer to each other and the axis A further toward the distal end 66. More specifically, each of the pair of arms 68 may have a first portion 87 adjacent the hinge end 64 and a second portion 89 adjacent the distal end 66 with the first portions 87 of the pair of arms 68 substantially parallel to one another for engaging the walls 40 of the first frame member 38a. The second portions 89 of the pair of arms 68 may angle toward each other at the distal end 66. Furthermore, each of the second portions 89 may be comprised of multiple sections such that second portions 89 progressively angle further toward each other toward the distal end 66. The tapering of the pair of arms 68 facilitates an increase in bias and deflection of the arms 68 as the first frame member 38a engages and moves along the arms 68. For example, as shown in FIG. 7, one of the plurality of folds 50 engages one of the pair of arms 68 along the engagement surface 84 toward the distal end 66 as the first body member 60 is inserted into the interior 48 of the first frame member 38a. As shown in FIG. 8, as the first body member 60 is inserted further into the interior 48 of the first frame member 38a, the one of the plurality of folds 50 moves along the taper and engages the engagement surface 84. The movement of the one of the plurality of folds 50 along the taper causes the one of the pair of arms 68 to deflect toward the axis A. As such, the taper of the pair of arms 68 toward each other eases the insertion of the first body member 60 into the interior 48 of the first frame member 38a by gradually increasing the engagement of the first frame member 38a with the arms 68 and the corresponding the deflection of and bias exerted by the arms 68.
The first body member 60 may have a brace 95 positioned between the hinge end 64 and the distal end 66 and extending between and coupled to each of the pair of arms 68. More specifically, the brace 95 extends between and is coupled to the first portion of each of the pair of arms 68, spaced from the second portion 89 of each of the pair of arms 68. The brace 95 further defines the deflection of each of the pair of arms 68 about said hinge end 64. More specifically, the brace 95 localizes the deflection of each of the pair of arms 68 about the hinge end 64 to substantially toward the distal end 66. In doing so, the amount of deflection of the arms 68 about the hinge end 64 may be designed according to the position of the brace 95 relative the hinge end 64. More specifically, the closer the brace 95 is to the hinge end 64, the greater the amount of deflection of each of the pair of arms 68.
It is to be appreciated that the at least one arm 68 of the first body member 60 may be a single arm. As one non-limiting example, the first body member 60 may further have a leg 92 extending from the hinge end 64 to the distal end 66, as shown in FIGS. 16 and 17. The leg 92 is typically resistant to deflection. The at least one arm 68 is further defined as a single arm 68 spaced from the leg 92 and deflectable about the hinge end 64. Typically, the leg 92 and the single arm 68 extend from the hinge end 64 to the distal end 66 in a substantially parallel configuration. It is to be appreciated that the leg 92 and the single arm 68 may extend from the hinge end 64 to the distal end 66 at any type of angle and in any configuration. The single arm 68 biases against and engages the first frame member 38a while simultaneously engaging the leg 92 with the first frame member 38a within the interior 48 of the first frame member 38a, self-configuring the first body member 60 to the cross-section of the first frame member 38a. Said differently, the bias of the single arm 68 against one of the walls 40 of the first frame member 38a moves the leg 92 (which is resistant to deflection) and the primary portion 74 away from the wall 40 and causes the leg 92 to engage another one of the walls 40. As such, the single arm 68 and the leg 92 engage the walls 40 of the first frame member 38a at at least two points of contact, further increasing the frictional force between the first body member 60 and the first frame member 38a which retains the first body member 60 in the interior 48 of the first frame member 38a.
As another non-limiting example, the at least one arm 68 may be further defined as a single arm 68 having a first section 94 and a second section 96 each extending between a first end 98, 102 and a second end 100, 104 as shown in FIGS. 18 and 19. The first section 94 extends in a first angular direction from the first end 98, adjacent the hinge end 64, to the second end 100. More specifically, the first end 98 of the first section 94 is typically coupled to the primary portion 74 of the first body member 60. The second section 96 extends in a second angular direction from the first end 102, adjacent the second end 100 of the first section 94, to the second end 104 of the second section 96 such that the first and second sections 94, 96 define an angle X1 and have a zig-zag configuration for engaging one of the plurality of walls 40 of the first frame member 38a at the second end 100 of the first section 94 and engaging another one of the plurality of walls 40 of the first frame member 38a at the second end 104 of the second section 96. As such, the second ends 100, 104 of the first and second sections 94, 96 of the single arm 68 engage the walls 40 of the first frame member 38a at at least two points of contact, further increasing the frictional force between the first body member 60 and the first frame member 38a which retains the first body member 60 in the interior 48 of the first frame member 38a while only requiring the single arm 68.
The angle X1 between the first and second sections 94, 96 is non-linear to facilitate the zig-zag configuration which causes the single arm 68 to engage at least two walls 40 of the first frame member 38a at at least two points of contact, further increasing the frictional force between the first body member 60 and the first frame member 38a which retains the first body member 60 in the interior 48 of the first frame member 38a while only requiring the single arm 68. Furthermore, the angle X1 between the first and second section 94, 96 is typically 90 degrees. It is to be appreciated that the angle X1 may be any suitable angle to engage at least two walls 40 of the first frame member 38a. The single arm 68 may have any number of sections. For example, as shown in FIGS. 18 and 19, the single arm 68 may have third, fourth, and fifth sections 106, 108, 110 each having a first end 112, 116, 120 and a second end 114, 118, 122. The third section 106 extends in a third angular direction from the first end 112, adjacent the second end 104 of the second section 96, to the second end 114. The fourth section 108 extends in a fourth angular direction from the first end 116, adjacent the second end 114 of the third section 106, to the second end 118. The fifth section 110 extends in a fifth angular direction from the first end 120, adjacent the second end 118 of the fourth section 108, to the second end 122. As such, the angle X1 between the first and second sections 94, 96 may be further defined as a first angle X1. Likewise, the second and third sections 96, 106 may define a second angle X2, the third and fourth sections 106, 108 may define a third angle X3, and the fourth and fifth sections 108, 110 may define a fourth angle X4.
The first, third, and fifth angular directions typically are substantially the same angular direction. Likewise, the second and fourth angular directions typically are substantially the same angular direction. As such, first angle X1 and the third angle X3 are equal and the second angle X2 and the fourth angle X4 are equal. As described above, typically the first angle X1 is 90 degrees. If the first angle X1 is 90 degrees, if the first, third, and fifth angular directions are substantially the same angular direction, and if the second and fourth angular directions are substantially the same angular direction; then each of the first, second, third, and fourth angles X1, X2, X3, X4 are 90 degrees.
Furthermore, all of the angular directions are typically positioned on the same plane. As such, the second ends 100, 114, 122 of the first, third and fifth sections 94, 106, 110 typically engage the same one of the plurality of walls 40 of the first frame member 38a while the second ends 104, 118 of the second and fourth sections 96, 108 typically engage the same one of the plurality of walls 40 other than the wall 40 engaged by the first, third, and fifth sections 94, 106, 110.
The zig-zag configuration promotes flexing of the single arm 68 into engagement with more than one of the walls 40 of the first frame member 38a. Specifically, the sections 94, 96, 106, 108, 110 flex relative to one another to self-configure the single arm 68 to the cross-section of the first frame member 38a having two points of contact with the first frame member 38a. In particular, the zig-zag configuration self-configures the single arm 68 to the varying cross-section of the first frame member 38a caused by the first frame member 38a having the arcuate configuration. It is to be appreciated that the cross-section of the first frame member 38a may vary for any reason.
It is to be appreciated that the at least one arm 68 may be any number of arms 68 deflectable about the hinge end 64 to bias against and engage the first frame member 38a within the interior 48 of the first frame member 38a and self-configure the first body member 60 to the cross-section of the first frame member 38a.
The first frame member 38a may have a substantially linear configuration as shown in FIG. 15. Furthermore, the cross-section of the first frame member 38a having the substantially linear configuration may vary between the first and second ends 42, 44. It is to be appreciated that the first frame member 38a may be shaped in any particular configuration and may have any particular cross-section, both constant and variable, between the first and second ends 42, 44. Furthermore, it is to be appreciated that the first body member 60 may be inserted into the interior 48 of the first frame member 38a at any one of the first and second ends 42, 44, the interior 48 of the second frame member 38b at any one of the first and second ends 42, 44, or the interior 48 of any of the frame members 38 at any one of the first and second ends 42, 44.
Furthermore, the second body member 62 may have at least one arm 88 extending from the hinge end 65 to the distal end 67, as shown in FIG. 14, with the at least one arm 88 deflectable about the hinge end 65 for biasing against and engaging the second frame member 38b within the interior 48 of the second frame member 38b and self-configuring the second body member 62 to the cross-section of the second frame member 38b. Said differently, the at least one arm 88 is configured to deflect and the hinge end 65 of the second body member 62 is rigid and configured to not deflect as the at least one arm 88 deflects. Although not illustrated, the at least one arm 88 engages at least one of the walls 40 of the second frame member 38b within the interior 48 and deflects about the hinge end 65 toward the axis A, similar to the deflection of the at least one arm 68 of the first body member 60 described above and illustrated between FIGS. 7 and 8. Hereinafter, descriptions of the engagement of the at least one arm 88 of the second body member 62 with the second frame member 38b shall refer to in-part or whole to FIGS. 7-9A with the intent that the engagement of the at least one arm 68 of the first body member 60 with the first frame member 38a shall teach and illustrate the engagement of the at least one arm 88 of the second body member 62 with the second frame member 38b.
The at least one arm 88 may deflect about the hinge end 65 toward and away from the axis A, as illustrated between FIGS. 7 and 8. The deflection of the at least one arm 88 corresponds with the engagement of the at least one arm 88 with the at least one of the walls 40, which facilitates the bias exerted by the at least one arm 88 against the second frame member 38b. The bias exerted by the at least one arm 88 against the second frame member 38b increases a frictional force between the second body member 62 and the second frame member 38b that retains the second body member 62 in the interior 48 of the second frame member 38b. Furthermore, the deflection of the at least one arm 88 allows the second body member 62 to self-configure to the cross-section of the second frame member 38b. As described above, the cross-section of the frame members 38 may vary. For example, the second frame member 38b may have an arcuate configuration, similar to the arcuate configuration described above for the first frame member 38a, with the second frame member 38b having the plurality of folds 50 extending into the interior 48. When the second frame member 38b has the arcuate configuration the at least one arm 88 deflects to engage the second frame member 38b and self-configure the second body member 62 to the cross-section of the second frame member 38b along the arcuate configuration. To compensate for the extension of the plurality of folds 50 into the interior 48, the at least one arm 88 deflects toward the axis A with the at least one arm 88 engaging the plurality of folds 50 of the second frame member 38b.
The at least one arm 88 of the second body member 62 may be further defined as, and is typically, a pair of arms 88 extending from and independently deflectable about the hinge end 65, as shown in FIG. 14. As illustrated between FIGS. 7 and 8, each of the pair of arms 88 biases against and engages the second frame member 38b within the interior 48 and self-configures the second body member 62 to the cross-section of the second frame member 38b. Said differently, the pair of arms 88 engages the walls 40 of the second frame member 38b within the interior 48. The pair of arms 88 engages the walls 40 at at least two points of contact. Typically, the pair of arms 88 each engage one of the walls 40 of the second frame member 38b such that the pair of arms 88 engage two of the walls 40; however, it is to be appreciated that the pair of arms 88 may engage any number of the walls 40. Each of the pair of arms 88 may independently deflect about the hinge end 65 toward and away from the axis A. Typically, the pair of arms 88 engages the second frame member 38b and deflects toward the axis A. The deflection of each of the pair of arms 88 corresponds with the engagement of each of the pair of arms 88 with the walls 40 of the second frame member 38b. The engagement of one of the pair of arms 88 with the second frame member 38b may be different than the engagement of another one of the pair of arms 88. As such, the pair of arms 88 may have different degrees of the deflection depending on the configuration of the walls 40 that the each of the pair of arms 88 engages. Each of the pair of arms 88 bias against the second frame member 38b which increases the frictional force between the second body member 62 and the second frame member 38b and retains the second body member 62 in the interior 48 of the second frame member 38b. Furthermore, the independent deflection of the pair of arms 88 allows the second body member 62 to self-configure to the cross-section of the second frame member 38b, as described in greater detail above.
Typically, as shown in FIG. 14, the pair of arms 88 extends spaced from and substantially parallel to each other from the hinge end 65 to the distal end 67 with each of the pair of arms 88 independently deflectable toward and away from each other. As illustrated between FIGS. 7 and 8, the pair of arms 88 applies opposing bias to the second frame member 38b within the interior 48 and self-configures the second body member 62 to the cross-section of the second frame member 38b. Said differently, the pair of arms 88 engages the walls 40 at at least two points of contact opposing one another. Typically, the pair of arms 88 each engages opposing walls 40 of the second frame member 38b. As such, the deflection of the pair of arms 88 corresponds with the engagement of the at least one arm 88 with the at least one of the walls 40 and facilitates the opposing bias exerted by the pair of arms 88 against the opposing walls 40 of the second frame member 38b which further increases the frictional force between the second body member 62 and the second frame member 38b and retains the second body member 62 in the interior 48 of the second frame member 38b. It is to be appreciated that the pair of arms 88 may engage any of the walls 40 while applying opposing bias to the second frame member 38b.
When the second frame member 38b has the arcuate configuration, the pair of arms 88 independently deflects to engage the second frame member 38b and self-configure the second body member 62 to the cross-section of the second frame member 38b along the arcuate configuration. To compensate for the extension of the plurality of folds 50 into the interior 48, at least one of the pair of arms 88 deflect toward the axis A with the at least one of the pair of arms 88 engaging the plurality of folds 50 of the second frame member 38b, as illustrated in FIG. 8.
As shown in FIG. 14, each of the pair of arms 88 may be tapered toward each other at the distal end 67 for facilitating insertion of the second body member 62 into the interior 48 of the second frame member 38b. Said differently, the pair of arms 88 extend closer to each other and the axis A the closer the arms 88 extend toward the distal end 67. More specifically, each of the pair of arms 88 may have a first portion 91 adjacent the hinge end 65 and a second portion 89 adjacent the distal end 67 with the first portions 91 of the pair of arms 88 substantially parallel to one another for engaging the walls 40 of the second frame member 38b. The second portions 93 of the pair of arms 88 may angle toward each other at the distal end 67. Furthermore, each of the second portions 93 may be comprised of multiple sections such that second portions 93 progressively angle further toward each other toward the distal end 67. The tapering of the pair of arms 88 facilitate an increase in bias and deflection of the arm(s) 88 as the second frame member 38b engages and moves along the arm(s) 88 as described above and shown in FIGS. 7-8 referring to the engagement of the first body member 60 and the first frame member 38a along the taper.
The second body member 62 may have a brace 97 positioned between the hinge end 65 and the distal end 67 and extending between and coupled to each of the pair of arms 88. More specifically, the brace 97 extends between and is coupled to the first portion 91 of each of the pair of arms 88, spaced from the second portion 93 of each of the pair of arms 88. The brace 97 further defines the deflection of each of the pair of arms 88 about said hinge end 65. More specifically, the brace 97 localizes the deflection of each of the pair of arms 88 about the hinge end 65 to substantially toward the distal end 67. In doing so, the amount of deflection of the arms 88 about the hinge end 65 may be designed according to the position brace 97 relative the hinge end 65. More specifically, the closer the brace 97 is to the hinge end 65, the greater the amount of deflection of each of the pair of arms 88.
As described above and shown in FIG. 14, the cornerlock 58 may have the first and second body members 60, 62 each with the at least one arm 68, 88. It is to be appreciated that the cornerlock 58 may be configured such that only the second body member 62 has the at least one arm 88.
It is to be appreciated that the at least one arm 88 of the second body member 62 may be a single arm. Although not explicitly shown in the Figures, it is to be appreciated that the second body member 62 may have a leg 124 extending from the hinge end 65 to the distal end 67 and the at least one arm 88 may be further defined as a single arm spaced from the leg and deflectable about the hinge end 65, similar to the leg 92 and the single arm 68 described above for the first body member 60 and shown in FIGS. 16 and 17.
Also, although not explicitly shown in the Figures, it is to be appreciated that the at least one arm 88 of the second body member may be further defined as a single arm having a first section and a second section (and typically further having third, fourth, and fifth sections) similar to the at least one arm 68 having the first and second sections 94, 96 in the zig-zag configuration described above for the first body member 60 and shown in FIGS. 18 and 19.
It is to be appreciated that the at least one arm 88 may be any number of arms 88 deflectable about the hinge end 65 to bias against and engage the second frame member 38b within the interior 48 of the second frame member 38b and self-configure the second body member 62 to the cross-section of the second frame member 38b.
It is to be appreciated that the second frame member 38b may shaped in any particular configuration and may have any particular cross-section, both constant and variable, between the first and second ends 42, 44. Additionally, it is to be appreciated that the second body member 62 may be inserted into the interior 48 of the second frame member 38b at any one of the first and second ends 42, 44, the interior 48 of the first frame member 38a at any one of the first and second ends 42, 44, or the interior 48 of any of the frame members 38 at any one of the first and second ends 42, 44.
Typically, the first and second body members 60, 62 are comprised of a metallic material. More typically, the first and second body members 60, 62 are comprised of a die-cast zinc alloy. It is to be appreciated that the first and second body members 60, 62 may be comprised of other metallic materials, such as aluminum and steel. Furthermore, the first and second body members 60, 62 may be comprised other materials such as a high-temperature plastic or a standard plastic. It is to be appreciated that varying the material of the first and second body members 60, 62 may alter the ability of the at least one arm 68 to deflect. As such, the composition of the first and second body members 60, 62 has a relationship with the bias exerted by the at least one arm 68.
Each of the first and second frame members 38a, 38b has a mitered end 90, as shown in FIGS. 9A and 9B. The cornerlock 58 extends into the interiors 48 of the first and second frame members 38a, 38b at the mitered ends 90. The first and second frame members 38a, 38b abut at the mitered ends 90 in an angular configuration. The cornerlock 58 is configured to rotate the first and second body members 60, 62 to correspond with the angular configuration of the first and second frame members 38a, 38b such that the cornerlock 58 is entirely disposed within a combination of the interiors 48 of the first and second frame members 38a, 38b at the mitered ends 90. More specifically, at least the first end 42 of the first frame member 38a and the second end 44 of the second frame member 38b are the mitered ends 90 with the first and second frame members 38a, 38b abutting at the mitered ends 90. It is to be appreciated that the second end 44 of the first frame member 38a, the first end 42 of the second frame member 38b, and the first and second ends 42, 44 of any other frame member 38 may be the mitered ends 90 with each of the mitered ends 90 configured to abut with the mitered end 90 of the adjacent frame member 38.
The cornerlock 58 is entirely disposed within a combination of the interiors 48 of the first and second frame members 38a, 38b. More specifically, the first body member 60 extends into the interior 48 of the first frame member 38a at the first end 42 up to the hinge end 64 and the second body member 62 extends into the interior 48 of the second frame member 38b at the second end 44 up to the hinge end 65. The abutment of the first end 42 of the first frame member 38a and the second end 44 of the second frame member 38b along the angular configuration fully encloses the cornerlock 58. As such, when fully assembled as shown in FIG. 9A, the cornerlock 58 is not visible from an exterior of the frame assembly 20. In doing so, the frame assembly 20 has a uniform, aesthetic transition between the first and second frame members 38a, 38b. It is to be appreciated that the cornerlock 58 may be partially disposed within the combination of the interiors 48 of the first and second frame members 38a, 38b.
The invention has been described in an illustrative manner, and it is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. As is now apparent to those skilled in the art, many modifications and variations of the subject invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, wherein reference numerals are merely for convenience and are not to be in any way limiting, the invention may be practiced otherwise than as specifically described.
Patent Grant
9879472
