Patent Grant
11428005
This application is subject matter related to U.S. patent application Ser. No. 17/075,263, entitled “Internal Connector System for Structural Members,” invented by the inventor named in this application, and filed concurrently herewith, the disclosure of which is hereby incorporated by reference.
The present invention relates generally to the field of architectural construction, and more specifically to architectural construction of certain structures using alternative building materials, such as extruded structural members. Such building materials are particularly useful in construction of outdoor living structures, such as pergolas, gazebos, arbors, pavilions, and the like. Conventional fasteners were not designed to work with alternative building materials. A fastening system that takes advantage of features of extruded structural members would be useful.
One embodiment of the invention relates to a structural post that includes a base plate defining a plurality of through holes, and a post portion that includes at least a pair of internal walls and at least a pair of external walls. A connector block is configured to receive a locking screw and to engage with a bolt thread of a bolt. A lock plate has a plate thread that is configured to engage the screw thread of the locking screw, and the lock plate is configured to expand upon being drawn by the locking screw into tight engagement with the connector block. The expanded lock plate is configured to apply a force on one of the pair of internal walls and one of the pair of external walls.
A technical advantage of an embodiment of the present disclosure includes a structural post that is easily assembled with connectors that are internal to the post and hidden from view. The structural post and the connector systems may be manufactured with extruded metal parts, for example extruded aluminum parts. The post portions may be formed of alternative building materials that generally eliminate and/or significantly reduce the amount of natural wood used in certain construction projects. For example, the disclosed structural posts may be extruded metal parts that have an outer shell providing the appearance of natural timber. The extrusions provide channels to hold the internal connector system that would not be present in natural wood often used in the construction of outdoor living spaces. This summary is illustrative only and is not intended to be in any way limiting.
The disclosure will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements, in which:
Before turning to the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein is for the purpose of description only and should not be regarded as limiting.
The structural post 10 may be used to support an overhanging structure. Examples of an overhanging structures that may be supported by the structural post 10 include gazebos, arbors, pavilions, pergolas, and the like. According to one embodiment, a structural post 10 may be positioned at each of four corners of a pergola formed with alternative building materials such as aluminum extruded structural members.
A pergola constructed with four of the structural posts 10 may be sold as a kit to allow the purchaser to construct the pergola using the internal connector system disclosed. The pergola kit may include four disassembled structural posts 10 to be disposed at each corner of the pergola. Each structural post 10 may be connected to a pair of perimeter beams. Four perimeter beams form the perimeter of the pergola and are held up by the structural posts 10. The perimeter beams may be connected to the structural posts 10 using an internal connector system that hides all of the fasteners within the structural members (i.e. posts and beams). For example, the perimeter beams may be connected to the upper post portion 14 using the internal connector system shown and described in co-pending U.S. patent application Ser. No. 17/075,263, entitled “Internal Connector for Structural Members,” invented by Ian Hill, and filed concurrently herewith.
The structural post 10 may include one or more skirts, for example a base skirt 16 and an upper post skirt 18. The base skirt 16 and the upper post skirt 18 may be substantially identical with the exception that the base post skirt 16 is larger in size than the upper post skirt 18. An isometric view of a base skirt 16 (or an upper skirt 18) is shown in
Each of the lower post portion 12 and the upper post portion 14 of the structural post 10 is a hollow structure formed by external walls 22 and internal walls 24. Each of the lower post portion 12 and the upper post portion 14 may be identical with the exception of the size, (i.e. the length and the cross-sectional area), so the description of the lower post portion 12 applies to the upper post portion 14, unless otherwise indicated. According to certain embodiments, the lower post portion 12 of the structural post 10 may be formed of a composite material that includes an extruded metal core, for example an extruded aluminum core. The external walls 22 and the internal walls 24 may be formed by extruding a metallic material, such as aluminum. An extrusion die may be sized and shaped to simultaneously form the external walls 22 and the internal walls 24.
The external walls 22 may include a composite material that is co-extruded, glued, or otherwise applied to the external metal wall to give the structural post 10 an appearance of a wooden structure. The external walls 22 may be formed of a combination of the extruded aluminum and a cap of a wood-particle/polymer composite material that may be co-extruded with an engineered flexible adhesive to form the outer shell giving the appearance of natural timber. The internal walls 24 provide rigidity to the structural post 10. According to an embodiment, the internal walls 24 are spaced apart and parallel to the external walls 22 and run the length of the lower post portion 12 (or the upper post portion 14). A corner channel 26 is formed proximate each of the four corners of the lower post portion 12. The corner channel 26 is formed by two adjacent external walls 22 and two adjacent internal walls 24, and the corner channel 26 runs the length of the lower post portion 12.
The lower post portion 12 may be any suitable size in cross-section, for example the lower post portion 12 may be sized similarly to conventional wooden structural members. The lower post portion 12 may have a cross-sectional area common to lumber identified as 8″×8″ or 6″×6″ or 4″×4″. According to one embodiment, the lower post portion 12 may have a cross-sectional area that is sized to imitate cuts of lumber that are identified as 8″×8″ square post. The upper post portion 14 may have a cross-sectional area that is sized to imitate cuts of lumber that are identified as a 6″×6″ square post. According to an alternate embodiment, the lower post portion 12 may have a cross-sectional area that is sized to imitate cuts of lumber that are identified as 6″×6″ square post. The upper post portion 14 may have a cross-sectional area that is sized to imitate cuts of lumber that are identified as a 4″×4″ square post.
Although the upper post portion 14 and the lower post portion 12 are each shown with square cross-sections in the figures, this disclosure contemplates a variety of cross-sectional shapes for the structural members including circular. In an embodiment with post portions with a circular cross-section, the internal channels may have a square or rectangular cross-section to correspond with the locking features of the disclosed internal connector system. Also, according to an alternate embodiment, either one of or both the lower post portion 12 and the upper post portion 14 may be formed of a polymeric material that may be formed by extrusion or other polymeric forming process.
With reference to
The base plate 28 also includes a plurality of inner through holes 34. The inner through holes are positioned proximate each of the four corners of the base plate 28. The inner through holes 34 are positioned to align with the corner channels 26 when the lower post portion 12 is positioned on the base plate 28. The perimeter through holes 32 are positioned to be outside of the footprint of the lower post portion 12. The base plate 28 may be formed of any suitable sheet metal, for example steel. The inner through holes 34 may be countersunk on one side to receive a head of a bolt such that the bolt head is flush with the surface of the base plate 28.
The upper plate 30 may be sized smaller than the base plate 28. The upper plate 30 includes a plurality of perimeter through holes 32 that are disposed spaced apart around the perimeter of the upper plate 30, similar to that shown and described above with respect to the base plate 28. The perimeter through holes 32 are located to align with the corner channels of the lower post portion 12. The perimeter through holes 32 may be countersunk on one side to receive a bolt head and position the bolt head to be flush with the upper plate 30.
The upper plate 30 also includes a plurality of inner through holes 34 located to be aligned with the corner channels 26 of the upper post portion 14. The perimeter through holes 32 are disposed to be outside the footprint of the upper post portion 14. The fasteners and the perimeter through holes 32 are covered by the upper skirt 18, as shown in
The structural post 10 may be assembled by attaching the base plate 28 to the lower post portion 12 using the using an internal connector system 50 that is received in a corner channel 26 of the lower post portion 12. As described in further detail below, the internal connector system 50 is secured in the corner channel 26 and provides a threaded bore to receive a fastener. In this manner, the base plate 28 is connected to the lower post portion 12. A plurality of the perimeter through holes 32 each receives a suitable fastener to anchor the base plate 28 and the lower post portion 12 to a foundation to secure the structural post 10 upright. The structural post 10 may include the lower post portion 12 and the base plate 28, with the upper post portion 14 being omitted.
For example, a connector block 52 may be received in a corner channel 26 of the lower post portion 12, and the locking screw 56 may be tightened such that the lock plate 54 impinges on an internal wall 24 and an external wall 22 and thereby secures the lock plate 54 and connector block 52 assembly within the channel 26. A bolt 58 is received through an inner through hole 34 in the base plate 28 and threaded into the connector block 52. In this manner, the internal connector system 50 including the bolt 58 is disposed underneath the base plate 28 or within the lower post portion 12 (or the upper post portion 14) and hidden from view.
With continuing reference to
The connector block 52 includes a center through hole 70. The center through hole 70 functions as a blank through bore to allow the locking screw 56 to be received through the center through hole 70 and be threaded to a corresponding threaded through hole 92 in the lock plate 54. A semi-blind bore 72 is formed in a subsequent operation to the initial extrusion. The semi-blind bore 72 has a diameter that is larger than a through portion 74 of the center through hole 70. As such, an internal shoulder 76 is formed internal to the connector block 52. An internal thread 78 is formed in the wall of the semi-blind bore 72. The internal thread 78 is configured to engage the thread 60 of the bolt 58.
The thickness of the connector block 52 and the length of the locking screw 56 is such that the head 62 of the locking screw 56 seats on the internal shoulder 76. Turning the seated locking screw 56 draws in the lock plate 54 and increases tight engagement between the lock plate 54 and the connector block 52. This engagement expands the lock plate 54 and causes the wings 88, 90 to impinge on the walls of the corner channel 26 of the lower post portion 12 (or the upper post portion 14) and thereby secures the connector block 52 and lock plate 54 assembly within the corner channel 26.
The lower post portion 12 and the upper post portion 14 are connected by eight internal connector systems 50 and the upper plate 30. More specifically, the thread 60 of the bolt 58 is received in threaded engagement with the internal thread 78 of the semi-blind bore 72 of the connector block 52. The length of the connector block 52 allows sufficient material for the head 62 of the locking screw 56 and the shaft of the bolt 58 to be disposed in the same semi-blind bore 72.
With continuing reference to
The connector block 52 may include one or more perimeter voids 64, as shown in
According to certain embodiments, the center through hole 70 may not have material completely surrounding it, as shown in
Reference is made to
The body 86 of the lock plate 54 is a generally flat and straight wall that defines a center through hole 92. The center through hole is disposed to align with the center through hole 70 of the connector block 52. The center through hole 92 includes a thread 94 that is configured to engage with the thread of the locking screw 56. According to an embodiment, an annular boss 96 extends from the body 86 and provides additional material to allow for secure engagement of the locking screw 56 and the threaded center hole 92 of the lock plate 54.
An upper bend 98 is disposed at the junction of the body 86 and the first wing 88. A lower bend 100 is disposed at the junction of the body 86 and the second wing 90. The bends 98 and 100 allow the wings 88, 90 to extend from the body 86 at a non-perpendicular angle. According to one embodiment, the first wing 88 is formed by bending a flat plate to form the shape shown in
In operation, the locking screw 56 is turned to draw the lock plate 54 toward the connector block 52. The wings 88, 90 are forced by the chamfers 80, 82 of the connector block 52 to bend toward the annular boss 96, and thereby increase the height 107 of the lock plate 54 and the wing angle 105. The expansion of the height of the lock plate 54 causes the lock plate 54 to impinge and be secured to an external wall 22 and an internal wall 24 forming the corner channel 26.
According to an embodiment, an upper void 102 is formed on each side proximate the upper bend 98, and a lower void 104 is formed on each side proximate the lower bend 100. The upper void 102 and the lower void 104 facilitate expansion of the lock plate 54 by the connector block 52, and an increase in the wing angle 105 and the height 107. The upper void 102 facilitates elastic bending of the first wing 88 to open the wing angle 105 between the body 86 and the first wing 88. The lower void facilitates elastic bending of the second wing 90 to open the wing angle 105 between the body 86 and the second wing 90. The upper voids 102 and the lower voids 104 permit the expanding function of the lock plate 54 when the lock plate 54 is formed of a material having a thickness that would otherwise not expand or would not expand sufficiently to impinge on the walls of the corner channel 26.
In the relaxed state, the locking screw 56 may be in threaded engagement with the threaded center through hole 92 of the lock plate 54, but the locking screw 56 is not tightened to elastically bend and expand the wings 88, 90 of the lock plate 54. Tightening the locking screw 56 draws the lock plate 54 in tight engagement with the connector block 52, and the connector block 52, more specifically the chamfers 80, 82 of the connector block 52, apply a force to each of the wings 88, 90 of the lock plate 54 and cause elastic deformation of the lock plate 54 in a manner that the wing angle 105 between the body 86 and the wings 88, 90 increases, which causes the overall height 107 of the lock plate to increase. According to one embodiment, the height of the lock plate increases by approximately 7%, but increases in a range of 5% to 15% are contemplated by this disclosure. This increase in height 107 applies a frictional force to the walls forming the corner channel 26 of the lower post portion 12 or the upper post portion 14 and holds the connector block 52 and lock plate 54 assembly securely within the corner channel 26.
With reference to
The base plate 28 is secured to the lower post portion 12 by threading the bolt through the inner through holes 34 in the base plate 28 into each of the connector blocks 52 disposed in the corner channels 26. The locking screw 56 is already positioned in the center through hole 70 and seated on the internal shoulder 76. The head of the bolt 58 may be received in a countersunk hole on the underside of the base plate 28.
The upper plate 30 is secured to the upper post portion 14 using the internal connector system 50. Each of four internal connector systems are secured into a respective corner channel 26 of the upper post portion 14. More specifically, an internal connector system 50 is secured in the lower corner channels 26 of the upper post portion 14. Similarly to the lower post portion 12, the internal connector systems 50 may be secured within the corner channels 26 of the upper post portion 14 while the upper post portion 14 is in a horizontal orientation. In this manner, the internal connector system 50 can be positioned at an appropriate depth within the corner channels 26 without the internal connector system 50 falling through the corner channels 26. When the internal connector system 50 is positioned at the proper depth within the corner channels 26 of the upper post portion 14, the locking screw 56 is tightened to draw the lock plate 54 into tight engagement with the connector block 52 and expand the lock plate 54. The first wing 88 and the second wing 90 of the expanded lock plate 54 impinge on the internal wall 24 and the external wall 22 of the corner channel 26. The frictional forces between the first wing 88 and the internal wall 24 or external wall 22 and the frictional forces between the expanded second wing 90 and the internal wall 24 or the external wall 22 hold the connector block 52 in position within the corner channel 26 to allow it to receive the bolt 58.
The upper plate 30 is positioned such that the inner through holes 34 align with the center through holes 70 of the connector blocks 52. The bolt 58 is received through the inner through holes 34 and in threaded engagement with the internal thread 78 of the connector block 52, and thereby the upper plate 30 is secured to the upper post portion 14.
The assembly of the upper post portion 14 and the upper plate 30 is then positioned on the upper end of the lower post portion 12, such that the perimeter through holes 32 align with the center through hole 70 of the connector blocks 52 that were previously positioned in the corner channels 26 of the lower post portion 12. The bolt 58 is received through the perimeter through holes 32 and secured in threaded engagement with the internal thread 78 of the connector block 52. The head of the bolt 58 may be received in a countersunk perimeter through hole 32, such that the head of the bolt 58 is flush with the surface of the upper plate 30.
As shown in
With reference to
As utilized herein with respect to numerical ranges, the terms “approximately,” “about,” “substantially,” and similar terms generally mean+/−10% of the disclosed values. When the terms “approximately,” “about,” “substantially,” and similar terms are applied to a structural feature (e.g., to describe its shape, size, orientation, direction, etc.), these terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.
The term “coupled” and variations thereof, as used herein, means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above.
References herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below”) are merely used to describe the orientation of various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
It is important to note that the construction and arrangement of the structural post with internal connector system as shown in the various exemplary embodiments is illustrative only. Additionally, any element disclosed in one embodiment may be incorporated or utilized with any other embodiment disclosed herein. Although only one example of an element from one embodiment that can be incorporated or utilized in another embodiment has been described above, it should be appreciated that other elements of the various embodiments may be incorporated or utilized with any of the other embodiments disclosed herein.
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