The present application claims priority to U.S. Design patent application Ser. No. 29/756,106, filed Oct. 26, 2020, which is incorporated herein in its entirety.
This invention relates generally to beams for screened enclosures and methods for forming screened enclosures using the same.
Screened enclosures are commonly built to enclose patios, lanais, porches, swimming pools, decks, and other similar spaces. Such enclosures are generally constructed by installing vertical posts with horizontal beams spanning therebetween. Screen material, often in square or rectangular panels, will then fill the open spaces between the vertical posts and horizontal beams. In most cases, the screen panels forming the sides of the enclosure are secured to both the vertical posts and the horizontal beams.
Prior art posts and beams typically include two components that fit together to form a square or rectangular beam, i.e., self-mating beams or SMB systems. SMB systems may be secured together with or without the need for additional hardware or connectors. However, in the absence of additional connectors, such systems may have weaker structural integrity compared to other methods of joining, such as bolted or welded connections. Over time, self-mating beams may be prone to sagging or shifting, especially in areas with high winds or heavy rain, which could compromise the stability and durability of the enclosure. Moreover, SMB systems including connectors may require precise alignment and installation, which can be challenging for homeowners or contractors who are not experienced with this type of connection. Improper installation can result in misaligned or uneven sections, leading to gaps, leaks, or compromised structural integrity.
In large, screened enclosures, such as those featured in multi-story homes, the spacing between posts and beams may be expanded to form what is known as “picture windows.” In such openings, the distances spanned by the posts and beams may be quite large and may extend beyond the range afforded by conventional posts and beams. Thus, even oversized beams, which may be 2″×6″ to 2″×10″ in size, may not be sufficient.
Accordingly, there is a need for systems that are easier to install, may have improved longevity and structural integrity, and may offer a greater range of design options.
The present disclosure provides solutions to the aforementioned issues by providing one-piece extruded beams for screened enclosures that are lighter weight, easier to install, and afford greater installed longevity than prior art beams. The present disclosure further provides internal supports that may afford additional design options, providing secure connection between adjacent beams installed across large openings.
Accordingly, the present disclosure relates to a beam system for a screened enclosure. The system includes an elongated rectangular beam, i.e., support beam, having flat exterior sides and an interior channel extending longitudinally therethrough, and at least three spline grooves each adjacent an edge of the elongated rectangular beam. The spline grooves generally include an outward facing opening and a recessed portion, wherein the opening is configured to receive an edge of a screen panel and an elastomeric spline component to secure the screen panel to the rectangular beam.
According to certain aspects, a first exterior side of the elongated rectangular beam comprises a first spline groove that extends longitudinally along a length thereof, and a second exterior side adjacent to the first exterior side comprises second and third spline grooves that extend longitudinally along a length thereof. The first exterior side and a third exterior side may be sidewalls of the elongated rectangular beam each having a length less than the second exterior side and a fourth exterior side, which may be top and bottom walls of the elongated rectangular beam. According to this aspect, each of the third and fourth sides of the elongated rectangular beam are absent spline grooves.
According to certain aspects, the elongated rectangular beam may include four spline grooves each adjacent an edge of the elongated rectangular beam. Each of a second and forth exterior side of the elongated rectangular beam, which may be congruent sides, may comprise a first and second spline groove that extends longitudinally along a length thereof, and a third exterior side of the elongated rectangular beam may comprise a third and fourth spline groove that extends longitudinally along a length thereof.
According to certain aspects, the beam system may further comprise an insert sized and configured to fit within the interior channel of the rectangular beam, the insert comprising a central pillar having angular caps attached to opposing lateral ends, wherein the insert is configured to provide connection between two adjacent beams.
According to certain aspects, the angular caps may each comprise a first flat portion attached to the central pillar perpendicular thereto, two angled portions each attached to an opposite end of the first flat portion and extending outward away from the central pillar but inward toward a middle of the central pillar, and two second flat portions each attached to an end of the second angled portions and extending parallel with and inward toward a middle of the central pillar. The first flat portion of each angular cap generally fits against an inner side wall of the elongated rectangular beam, and wherein the second flat portions of each angular cap fit against inner top and bottom walls of the elongated rectangular beam.
According to certain aspects, the angular caps may each comprise a closed structure shaped as a pentagon having two right angles, wherein a first side of the closed structure that meets second and third sides at internal right angles faces an inner side wall of the elongated rectangular beam, wherein the closed structure is connected to the central pillar via a vertex of a fourth and fifth side of closed structure.
The angular caps of the inserts may each include a plurality of apertures extending along a longitudinal length thereof that are configured to provide connection with apertures in the elongated rectangular beam, such as via fastening elements.
The present disclosure further relates to kits comprising the beam system for a screen enclosure, i.e., a plurality of the rectangular beams and optionally any combination of (i) any of the inserts described hereinabove, (ii) sufficient amounts of precut screen panels and/or rolls of screen material, and (iii) elastomeric spline component.
The present disclosure further relates to kits configured for construction of a specific screened enclosure design, wherein the kits may include materials sized and configured for construction of the specific screened enclosure design, along with instructions for assembly. The kit may further include sufficient amounts of precut screen panels or rolls of screen material, and elastomeric spline component.
Aspects, features, benefits, and advantages of the embodiments herein will be apparent with regard to the following description, appended claims, and accompanying drawings. In the following figures, like numerals represent like features in the various views. It is to be noted that features and components in these drawings, illustrating the views of embodiments of the present invention, unless stated to be otherwise, are not necessarily drawn to scale.
In the following description, the present invention is set forth in the context of various alternative embodiments and implementations involving elongated rectangular beams for a screened enclosure, such as an enclosure useful to surround and enclose patios, lanais, porches, swimming pools, decks, and other similar spaces. The present invention further sets forth methods of forming a screened enclosure using the elongated rectangular beams.
Various aspects of the elongated rectangular beam and methods for forming a screened enclosure using the beams may be illustrated with reference to one or more exemplary implementations or embodiments. As used herein, the term “exemplary” means “serving as an example, instance, or illustration,” and should not necessarily be construed as preferred or advantageous over other variations of the devices, systems, or methods disclosed herein. “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where the event occurs and instances where it does not. In addition, the word “comprising” as used herein means “including, but not limited to”.
Various aspects of the elongated rectangular beam and enclosures formed therefrom may be illustrated by describing components that are coupled, attached, and/or joined together. As used herein, the terms “coupled”, “attached”, and/or “joined” are interchangeably used to indicate either a direct connection between two components or, where appropriate, an indirect connection to one another through intervening or intermediate components. In contrast, when a component is referred to as being “directly coupled”, “directly attached”, and/or “directly joined” to another component, there are no intervening elements shown in said examples.
Relative terms such as “lower” or “bottom” and “upper” or “top” and “left” or “right” may be used herein to describe one element's relationship to another element illustrated in the drawings. It will be understood that relative terms are intended to encompass different orientations of aspects of the elongated rectangular beam and enclosures formed therefrom in addition to the orientation depicted in the drawings. By way of example, if aspects of the elongated rectangular beam shown in the drawings are turned over, elements described as being on the “bottom” side of the other elements would then be oriented on the “top” side of the other elements as shown in the relevant drawing. The term “bottom” can therefore encompass both an orientation of “bottom” and “top” depending on the particular orientation of the drawing.
As used herein, the term “substantially” may be taken to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. Thus, the term substantially may mean an amount of generally at least about 80%, about 90%, about 95%, about 98%, or even about 99%.
It must also be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include the plural reference unless the context clearly dictates otherwise. Thus, for example, reference to “a” fastening element is a reference to one or more fastening elements and equivalents thereof known to those skilled in the art, and so forth. Unless defined otherwise, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art.
Words such as “then,” “next,” etc. are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods.
Referring now to the drawings,
A screened enclosure 10 may be formed using the support beams in either the horizontal 20 or vertical 30 orientation, as shown in
With reference to
According to one embodiment, a first exterior side 44 (left or right) of the support beams (20, 30) include a spline groove that extends longitudinally along a length ‘a’ of the support beam. A second exterior side 42 (top or bottom) that is adjacent to the first exterior side 44 includes two spline grooves that extend longitudinally along a length ‘a’ of the support beam. The spline grooves are formed as recessed portions of each of the first and second exterior sides (44, 42, respectively).
More specifically, and with reference to
With reference to
With specific reference to
Shown in
The support beams disclosed herein may be used in either the vertical 20 or horizontal 30 orientation and may be positioned such that the spline grooves on respective sides provide attachment of screen panels on one face of an opening. The support beams shown in
The support beams (20, 30, 20′, 30′) may be used to provide vertical and horizontal beams for both the sides of an enclosure and a roof of the enclosure.
Extruded beams may lack the support needed to span large diameter openings, such as the opening 25 shown in
As shown in
With continued reference to
The angled extension 124 extends away from the central pillar 110 at an angle q. Exemplary angles include at least 20°, or at least 30°, at least 40°, at least 50°, or even at least 60°. According to certain preferred aspects, the angled extension 124 of the angular cap (120a, 120b) extends away from the central pillar at an angle of about 40°. Moreover, the second flat portion 126 is oriented parallel with the central pillar 110. Each of the angled extension and the second flat portion extend inward toward an opposing end of the central pillar 110.
The thickness ‘c’ of the central pillar 110 and a thickness ‘f’ of the angular caps (120a, 120b) may be the same or different, and are designed based on a material and size of the insert 100 and support beam (20/30) into which the insert may be positioned.
With reference to
The inserts may include a comparable number of apertures as the support beam, such as shown in
Shown in
A view of the connection between two support beams is shown in
As shown in
Another embodiment insert 100′ is shown in
As with the insert 100 shown in
With specific reference to
According to certain aspects, combinations of support beams (20, 30, 20′, 30′) and inserts (100, 100′) may be provided as a kit for a screened enclosure. The kit may include support beams in any combination of height ‘z’ and width ‘b’, and inserts configured to fit within the support beams (i.e., heights ‘e’ and widths ‘d’ that allow the inserts to be accommodated within the inner channels of the support beams in the kit). Moreover, the kit may include support beams and insert of standard lengths, wherein the beams and insert would be cut to size during installation of a screened enclosure. Alternatively, the support beams and inserts may be provided in specific lengths as defined by a specific design of a screen enclosure.
The kit may further include fastening elements that allow the inserts to be secured within the support beams.
The kit may include precut screen panels sized to fit within openings of the enclosure and/or rolls or specific lengths of the elastomeric spline component. Alternatively, the screen material may be provided as a roll of material that is cut on site to fit within specific opening sized and configurations.
While specific embodiments of the invention have been described in detail, it should be appreciated by those skilled in the art that various modifications and alternations and applications could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements, systems, apparatuses, and methods disclosed are meant to be illustrative only and not limiting as to the scope of the invention.
Number | Date | Country | |
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Parent | 29756106 | Oct 2020 | US |
Child | 18139114 | US |