Traditional outdoor framing work, such as pergolas, can be complicated and may require professional building knowledge and technique. The works may also utilize many different types of hardware to fulfill different structure configurations. The multitude of hardware can lead to inventory difficulty, long built time, and high costs.
For example, traditional outdoor framing work can require various hardware fixtures to secure lumber in different configurations. The variety of hardware fixtures can increase the complexity of the work and can require material inventory management. In addition, traditional framing hardware can be aesthetically displeasing and may require additional work and hardware to cover and hide.
Features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention; and, wherein:
Reference will now be made to the exemplary embodiments illustrated, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended.
Before invention embodiments are disclosed and described, it is to be understood that no limitation to the particular structures, process steps, or materials disclosed herein is intended, but also includes equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular examples only and is not intended to be limiting. The same reference numerals in different drawings represent the same element. Numbers provided in flow charts and processes are provided for clarity in illustrating steps and operations and do not necessarily indicate a particular order or sequence. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.
An initial overview of the inventive concepts are provided below and then specific examples are described in further detail later. This initial summary is intended to aid readers in understanding the examples more quickly, but is not intended to identify key features or essential features of the examples, nor is it intended to limit the scope of the claimed subject matter.
The invention presents an outdoor framing module that can attach a horizontal beam to a vertical post to form a joint of an outdoor structure, such as a pergola, a pavilion, a panel, a fence, etc. The module can have a horizontal receiver with an opening to receive an end of the horizontal beam. The module can also have a vertical through receiver with opposite openings to receive the vertical post. The openings can have a geometry and size to fit common building lumber sizes, such as 6″×6″, 4″×4″, etc.
In one aspect, at least two modules can be combined to connect and fix multiple beams and posts in up to six directions. The modules can have a symmetric design that can be inverted with respect to one another and nested with one another. The through receivers of two modules can nest together to attach multiple beams to a common post.
The design of the module can reduce construction complexity, increase building accuracy and speed-up the building process. The modules can have pre-drill holes to receive standard fasteners, such as screws and bolts.
The design of the module can provide a system with a single design (for a given lumber size) so that multiple identical modules can be used to form all the joints of the outdoor structure to lower merchandise inventory quantities, and reduce design and order complexity. A single module design can accommodate multiple aspects of multiple outdoor structures. Thus, only a single module design may need to be stocked.
In addition, the modules can be designed for outdoor construction environments. The modules can be formed of coated galvanized steel to resist rust. In addition, the modules can be strong to hold the post and the beams and to provide structural rigidity. The modules can be formed of 11-gauge carbon steel sheet welded together.
In another aspect, the modules can be provided in at least two different sizes. One size can fit a cross-sectional width up to four inches, for example a 4×4 post and beam. Another size can fit a cross-sectional width up to 6 inches, such as 6×6 post and beam. Other sizes may be provided to accommodate different cross-sections, such as 6×4, 6×2, 4×2, etc.
The modules can make framing building structures simpler, even for non-professionals. The symmetric design of the module can accommodate different structural configurations. The modules can accommodate common post and beam materials, shapes and sizes. Thus, a builder does not need to determine multiple different kinds of hardware for the job or structure. The modules can make it easier to estimate the right amount of hardware for the building plan. The modules can also benefit merchandising by lowering the management complexity.
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The first blind receiver 124 can have a first opening 132 to receive the end of the beam 108. In one aspect, the first opening 132 can be planar and vertically oriented. In another aspect, the first opening 132 can have a square shape to match a square cross-sectional shape of the beam 108. The first blind receiver 124 can have a terminus 136 spaced-apart from and opposite the first opening 132 to abut to the end of the beam 108. The terminus 136 can resist the beam 108 from interfering with the second receiver 128. A first perimeter collar 140 can extend at least partially around the first opening 132, and can extend between the first opening 132 and the terminus 136. In one aspect, the first perimeter collar 140 can be continuous around a circumference of first opening 132, the terminus 136 and the blind receiver 124. The first blind receiver 124 can have a horizontal axis 144 extending through the first perimeter collar 140, and between the first opening 132 and the terminus 136. The first blind receiver 124 can also have a first dimension d1 (
The second through receiver 128 can be directly and rigidly affixed to the first blind receiver 124. The second through receiver 128 can have opposite second and third openings 148 and 152 aligned and spaced-apart from one another. In one aspect, the openings 148 and 152 of the second through receiver 128 can be planar and oriented horizontally. In another aspect, the openings 148 and 152 of the second through receiver 128 can be oriented parallel with respect to one another. A second perimeter collar 156 can extend between the second and third openings 148 and 152. In one aspect, the second perimeter collar 156 can be continuous around a circumference of the openings 148 and 152 and the second through receiver 128. The terminus 136 can form a portion of the second perimeter collar 156. The second through receiver 128 can have a vertical axis 160 through the opposite second and third openings 148 and 152. The vertical axis 160 can be perpendicular to the horizontal axis 144 of the first blind receiver 124. The second through receiver 128 can also have a second dimension d2 (
The second dimension d2 of the second through receiver 128 can be less than (d2<d1) the first dimension d1 of the first blind receiver 124. In one aspect, the second dimension d2 can be half of (d2=d½) the first dimension d1. The second through receiver 128 can be positioned to one side of the first blind receiver 124. The second opening 148 of the second through receiver 128 can be positioned flush, co-planer and on a same level with a top or bottom side 164 or 168 of the first perimeter collar 140 of the first blind receiver 124. The top and bottom sides 164 and 168 can be vertically positioned and horizontally oriented. The third opening 152 of the second through receiver 128 can be positioned intermediate opposite top and bottom sides 164 and 168 of the first perimeter collar 140 of the first blind receiver 124. A longitudinal thickness d2 of the through receiver 128 can be less than a vertical thickness d1 of the blind receiver 124. Thus, the second through receivers 128a and 128b of a pair of modules 120a and 120b can nest together when inverted with respect to one another and aligned with respect to one another, as shown in
In one aspect, the module 120 can have a pair of spaced-apart lateral plates 172 and 176. Each lateral plate 172 and 176 can have a larger rectangular panel 180 forming a lateral wall of the blind receiver 124 and the first perimeter collar 140, and a smaller rectangular panel 184, extending from and contiguous with the large panel 180, and forming a lateral wall of the through receiver 128 and the second perimeter collar 156. The larger and smaller rectangular panels 180 and 184 can be a single plate 172 and 176 cut or stamped from a single piece of material. A top or bottom side 188 of the smaller rectangular panel 184 can be flush with a top or bottom side 192 of the larger rectangular panel 180. In addition, the module 120 can also have a pair of spaced-apart, top and bottom, horizontal plates 196 and 200 that are vertically positioned and horizontally oriented. A top plate 196 can be coupled to a top vertical side 192 of the larger panels 180 and a bottom plate 200 can be coupled to a bottom 204 of the larger panels 180. Furthermore, the module 120 can have a pair of spaced-apart, longitudinal, vertical plates 208 and 212. A front plate 208 can be attached to a front of the smaller panels 184 and an intermediate plate 212 can be attached to the pair of lateral plates 172 and 176 between the larger and smaller panels 180 and 184. The front plate 208 can form part of the second perimeter collar 156. The intermediate plate 212 can form the abutment 136. The first perimeter collar 124 can be formed by the pair of lateral plates 172 and 176, the top plate 196 and the bottom plate 200. The second perimeter collar 128 can be formed by the pair of lateral plates 172 and 176, the front plate 208 and the intermediate plate 212.
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The pair of modules can be combined in at least two different orientations, including: 1) an aligned orientation, as shown in
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As used in this specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a layer” includes a plurality of such layers.
In this disclosure, “comprises,” “comprising,” “containing” and “having” and the like can have the meaning ascribed to them in U.S. Patent law and can mean “includes,” “including,” and the like, and are generally interpreted to be open ended terms. The terms “consisting of” or “consists of” are closed terms, and include only the components, structures, steps, or the like specifically listed in conjunction with such terms, as well as that which is in accordance with U.S. Patent law. “Consisting essentially of” or “consists essentially of” have the meaning generally ascribed to them by U.S. Patent law. In particular, such terms are generally closed terms, with the exception of allowing inclusion of additional items, materials, components, steps, or elements, that do not materially affect the basic and novel characteristics or function of the item(s) used in connection therewith. For example, trace elements present in a composition, but not affecting the composition's nature or characteristics would be permissible if present under the “consisting essentially of” language, even though not expressly recited in a list of items following such terminology. When using an open ended term in the specification, like “comprising” or “including,” it is understood that direct support should be afforded also to “consisting essentially of” language as well as “consisting of” language as if stated explicitly and vice versa.
The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein. Similarly, if a method is described herein as comprising a series of steps, the order of such steps as presented herein is not necessarily the only order in which such steps may be performed, and certain of the stated steps may possibly be omitted and/or certain other steps not described herein may possibly be added to the method.
The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.
The term “coupled,” as used herein, is defined as directly or indirectly connected in an electrical or nonelectrical manner. Objects described herein as being “adjacent to” each other may be in physical contact with each other, in close proximity to each other, or in the same general region or area as each other, as appropriate for the context in which the phrase is used. Occurrences of the phrase “in one embodiment,” or “in one aspect,” herein do not necessarily all refer to the same embodiment or aspect.
As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context. However, generally speaking the nearness of completion will be so as to have the same overall result as if absolute and total completion were obtained. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, a composition that is “substantially free of” particles would either completely lack particles, or so nearly completely lack particles that the effect would be the same as if it completely lacked particles. In other words, a composition that is “substantially free of” an ingredient or element may still actually contain such item as long as there is no measurable effect thereof.
As used herein, “adjacent” refers to the proximity of two structures or elements. Particularly, elements that are identified as being “adjacent” may be either abutting or connected. Such elements may also be near or close to each other without necessarily contacting each other. The exact degree of proximity may in some cases depend on the specific context.
As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint. It is understood that express support is intended for exact numerical values in this specification, even when the term “about” is used in connection therewith.
It is to be understood that the examples set forth herein are not limited to the particular structures, process steps, or materials disclosed, but are extended to equivalents thereof as would be recognized by those ordinarily skilled in the relevant arts. It should also be understood that terminology employed herein is used for the purpose of describing particular examples only and is not intended to be limiting.
Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in one or more examples. In the description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a thorough understanding of the technology being described. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
While the foregoing examples are illustrative of the principles of the invention in one or more particular applications, it will be apparent to those of ordinary skill in the art that numerous modifications in form, usage and details of implementation can be made without the exercise of inventive faculty, and without departing from the principles and concepts described herein. Accordingly, it is not intended that the invention be limited, except as by the claims set forth below.