This invention relates to a building system, and more particularly, to a system that utilizes an improved beam and coupling system for building a frame or structure.
The aluminum enclosure industry and patio screen enclosure roof systems typically utilized beams comprising two identical halves. The halves simply overlap and were stitched or screwed together with a plurality of screws to make one complete self-mating beam. In some applications, an entire extruded one-piece beam was used.
One problem with the prior art beam structures is a high failure rate during strong winds, especially hurricane-force winds. The box beam failed for many reasons including the fact that the beam web was simply overlapped and laid on top of each other. An improved beam system that overcame some problems of the prior art is shown in U.S. Pat. No. 7,877,962; U.S. Design Pat. Nos. D620,618; D620,619; D636,095; D666,743; D713,054 and D791,342, all of which are incorporated herein by reference and made a part hereof.
The beam structures of the prior art had to use a plurality of horizontal and vertical beams to create a frame onto which a mesh screen was mounted. Typically, a top spanning horizontal beam could only span approximately six to ten feet before a vertical column support or column beam had to be used to support the weight of the top beam. One problem with the designs and structures of the prior art is that the number of vertical and horizontal beams obstructed the view of persons inside the structure who were looking out. For example, if the structure was a lanai structure, it is not uncommon that people in the lanai like to view the scenery outside of the lanai, whether it be a scenic water view, a golf course view or a wooded area view, but the vertical and horizontal columns were aesthetically unpleasing and at least partially obstructed that view.
Another problem is that oftentimes main spanning beams typically did not have spline grooves and a separate beam having the spline grooves had to be secured thereto and used, adding parts and manufacturing costs to the structure. For example, it was not uncommon that a 1″×2″ beam having at least one or a plurality of spline grooves for receiving and securing the screen to the beams had to be mounted on top of a primary support beam that would be used for building the structure frame. The additional lanai screen beam was typically mounted onto the primary support beam and provided the spline groove or channel that was necessary to mount the mesh screen onto the frame. Of course, the additional 1″×2″ beam having the spline groove also added additional material and installation cost to the framing structure.
To overcome some of these problems, some attempts have been made to make the beams more robust by, for example, making the beam walls much thicker, so that they withstand longer span lengths. Several problems arise with increasing the size of the beams, including increased weight and cost to name a few. As the length of the beams increased along with the need to carry heavier loads, bigger and heavier beams had to be created. As enclosure sizes and span lengths increase, the box and hollow beams that were used to make the enclosures in the past had to be made with much thicker and heavier extrusions in order to achieve the span lengths desired. Unfortunately, these extrusions were typically more expensive and resulted in increased costs.
Some homeowners or builders are building larger and more dynamic structures, such as pool enclosures and lanais, with the same historical products, resulting in structures that have undesirable viewing obstructions, failure rates and/or costs.
Another problem with the typical beams of the past is that they had to utilize through-bolts and fascia fasteners to secure the beams together or to another structure. The through-bolts and fascia fasteners are aesthetically unpleasing.
Still another problem is that a typical building structure that was framed using a prior art beam system had to utilize steel cables or tie-downs for lateral structural support. The lateral tie-downs added material and installation costs to the overall structure.
Still another problem with the prior art framing structures is that the beams typically had to be mounted to other structures, such as a patio deck, floor or wall using a plurality of L-shaped brackets situated on opposite sides of the beam and fastened thereto and to the other structure. These brackets and fastenings all added additional installation time and cost. Some people found the mounting brackets to be aesthetically unpleasing as well.
There is, therefore, a need to provide an improved building structure having an improved beam and coupling system that overcomes one or more of the problems of the prior art.
One object of the invention is to provide an improved beam and coupling system for building a structure.
Another object of the invention is to provide a beam and coupling system that can span greater lengths.
Still another object of the invention is to provide a stronger beam and coupling system that has a large viewing area that is uninterrupted by horizontal or vertical support beams of the type used in the prior art.
Still another object of the invention is to provide a beam and coupling system that eliminates the need for fasteners on the fascia sides of the beam.
Still another object of the invention is to provide a beam and coupling system for making a frame that reduces or eliminates the need for through-fasteners or fasteners that are screwed into the fascia sides of the beam.
Still another object of the invention is to provide an improved beam and coupler system for creating a frame that reduces or eliminates the need for tie-down cables.
Another object of the invention is to provide a corner coupler for securing a plurality of beams together to form a corner of the framing structure.
Another object of the invention is to provide an elongated coupler for coupling or splicing two beams together.
Yet another object of the invention is to provide a coupler having at least a portion that can be mounted to a support structure, such as a patio deck, concrete slab, building wall, structure or the like.
Another object of the invention is to provide a system and method for coupling beams together to form a frame wherein a dimension of at least one coupler used with at least one beam and wherein a length of the coupler is directly proportional to a span length of the beam, such that a length of the coupler is directly proportional to a span length of the beam.
Another object of the invention is to provide improved couplers and a coupling system for coupling beams together or to a surface or structure.
Another object of the invention is to provide an improved beam that reduces or eliminates the need for additional screen support beams or systems.
In one aspect, one embodiment of the invention comprises a universal reinforcement coupling for use with at least one support beam used in building a structure, comprising a coupling for inserting into the at least one support beam, the coupling comprising a plurality of coupling surfaces that become positioned in operative relationship with a plurality of internal surfaces of the at least one support beam, and the at least one support beam being adapted and sized to receive the coupling.
In another aspect, another embodiment of the invention comprises a building system comprising at least one support beam having a plurality of beam walls defining a plurality of internal wall surfaces, respectively, that cooperate to define a beam aperture, and at least one coupling adapted and dimensioned to be received in the beam aperture, the at least one coupling comprising a plurality of coupling surfaces that become positioned in operative relationship with the plurality of internal wall surfaces, respectively, of the at least one support beam to facilitate enhancing a performance or characteristic of the at least one support beam.
In still another aspect, another embodiment of the invention comprises a building system for building a structure, the building system comprising at least one first support beam, at least one second support beam, and at least one coupler for coupling the first support beam to the second support beam together, the at least one coupler having at least a portion defining a predetermined configuration defining a first end adapted to be inserted into an end of the at least one first support beam and a second portion adapted to be inserted into an end of the second support beam, the at least one coupler facilitating improving at least one performance characteristic of the joined beams.
In yet another aspect, another embodiment of the invention comprises a coupler for use with at least one support beam of a building structure, the coupler comprising a body having at least a portion that is sized and adapted to fit into at least one end of the at least one support beam and to engage the internal walls thereof in order to buttress or support the at least one support beam, the body comprising a web having a first flange on a first end of the web and a second flange on a second end of the web, the first and second flanges each having a primary flange surface and at least one flange wall surface integrally or monolithically formed with the primary flange surface, and the at least one first flange wall surface being generally perpendicular to the primary flange surface.
In another aspect, another embodiment of the invention comprises a structure comprising a plurality of beams, and a plurality of internal couplers for coupling the plurality of beams together, the plurality of internal couplers each having a first end dimensioned and sized to be press fit or received in a first end of a first one of the plurality of beams and having a second end that is at least one of: adapted to be fixed to a support to mount the first end of the first one of the plurality of beams to a support surface or is sized to be press fit or received in a first end of a second one of the plurality of beams in order to secure the first one of the plurality of beams to a second one of the plurality of beams.
In another aspect, another embodiment of the invention comprises a beam comprising a body having a plurality of spline grooves, the plurality of spline grooves being oriented in order to support a roof screen and a wall screen.
In another aspect, another embodiment of the invention comprises a building system comprising at least one fastener for securing at least one support beam to at least one coupling, at least one fastener passing through only one of at least one plurality of beam walls before engaging the at least one coupling and does not pass through another of the at least one of the plurality of beam walls.
In another aspect, another embodiment of the invention comprises a building system comprising at least one support beam having a plurality of beam walls defining a plurality of internal wall surfaces, respectively, that cooperate to define a beam aperture, and at least one coupling adapted and dimensioned to be received in the beam aperture, the at least one coupling comprising a plurality of coupling surfaces that become positioned in operative relationship with the plurality of internal wall surfaces, respectively, of the at least one support beam to facilitate enhancing a performance or characteristic of the at least one support beam, the at least one coupling increasing an operation performance of the at least one support beam, thereby reducing or eliminating a need for cable tie-downs.
This invention, including all embodiments shown and described herein, could be used alone or together and/or in combination with one or more of the features covered by one or more of the following list of features:
The universal reinforcement coupling wherein the coupling is a corner coupler, a splicing coupler or a support coupler.
The universal reinforcement coupling wherein each of the support coupler, the splicing coupler and the corner coupler have at least a portion that is generally in the shape of an I in cross-section.
The universal reinforcement coupling wherein the coupling comprises at least a portion generally shaped as an I in cross-section and has a first flange, a generally opposing second flange and a web for joining the first and second flanges, the first and second flanges being generally U-shaped in cross section.
The universal reinforcement coupling wherein each of the generally U-shaped in cross-section first and second flanges comprise at least one beveled corner.
The universal reinforcement coupling wherein each of the generally U-shaped in cross-section flanges comprise a plurality of beveled corners.
The universal reinforcement coupling wherein the coupling comprises a web and a first flange located on a first end of the web and a second flange located on a second end of the web, each of the first and second flanges being generally perpendicular to the web and generally parallel to each other, at least one of the first flange or the second flange having a flange wall that extends generally parallel to the web.
The universal reinforcement coupling wherein at least one of the first flange or the second flange has at least one flange wall that extends generally parallel to the web.
The universal reinforcement coupling wherein at least one of the first flange or the second flange has a plurality of flange walls that extend generally parallel to the web and cooperate with a generally planar portion of the first flange or a generally planar portion of the second flange define a general U-shape in cross-section at each end of the web, the general U-shape of the first flange being generally opposed to the general U-shape of the second flange.
The universal reinforcement coupling wherein the coupling is sized and adapted to received inside an end of the at least one support beam.
The universal reinforcement coupling wherein the coupling comprises a beam generally shaped as an I-beam having a first flange and a generally opposing second flange, the first and second flanges each being generally U-shaped in cross section and each comprising a flange having a first flange wall, a second flange wall and a joining flange portion for joining the first and second flange walls, the first and second flange walls having at least one wall surface that becomes generally opposed and adjacent to a first internal beam wall surface and a second internal beam wall surface, respectively.
The universal reinforcement coupling wherein at least a portion of the coupling generally defines an I-beam in cross-section, the coupling being generally L-shaped and defines a corner coupling for coupling the at least one support beam to a second support beam such that their axes are not co-axial.
The universal reinforcement coupling wherein at least a portion of the coupling generally defines an I-beam shape in cross-section having a first end that is received in the I-beam and a second end that is fixed or mounted to a support surface, the first end being dimensioned and adapted for receipt in the at least one support beam.
The universal reinforcement coupling wherein the coupling is a splice coupling and at least a portion of the coupling comprises a first flange and a generally opposing second flange, the coupling being adapted to splice and support the at least one support beam to a second support beam such that their axes are coaxial and define an elongated beam.
The universal reinforcement coupling wherein the at least one support beam comprises an internal beam structure extending at least part of a length into the at least one support beam, at least a portion of the coupling having a predetermined shape to cooperate with at least one internal surface of the at least one support beam to define an aperture into which the internal beam structure may be received.
The universal reinforcement coupling wherein at least a portion of the coupling generally has a first flange and a generally opposing second flange, the first and second flanges having at least one recessed area, beveled corner or edge adapted to cooperate with at least one wall of the at least one support beam to define an internal channel.
The building system wherein the at least one coupling is a corner coupler, a splicing coupler or a support coupler.
The building system wherein each of the support coupler, the splicing coupler and the corner coupler have at least a portion that is generally in the shape of an I in cross-section.
The building system wherein at least a portion of the at least one coupling generally defines an I shape in cross-section adapted and dimensioned to be inserted in the at least one support beam.
The building system wherein at least a portion of the at least one coupling has at least a portion that is generally shaped like an I-beam having a first flange, a generally opposing second flange and a web coupling the first and second flanges, the first and second flanges being generally U-shaped in cross section and each comprising a first flange wall and a second flange wall and flange joining portion for joining the first and second flange walls, the plurality of internal wall surfaces comprising a first internal beam wall surface, a second internal beam wall surface and a third internal beam wall surface, and the first and second flange walls each having at least one surface that becomes generally opposed or adjacent to the first internal beam wall surface and the second internal beam wall surface, respectively, the flange joining portion becoming generally opposed or adjacent the third internal beam wall surface.
The building system wherein at least a portion of the at least one coupling defines an I-beam configuration in cross-section and the at least one coupling is generally L-shaped to define a corner coupling for coupling the at least one support beam to a second beam.
The building system wherein the at least one coupling comprises a first portion and a second portion that cooperate to define the L-shape, each of the first and second portions generally having at least a portion having an I-beam shape in cross-section.
The building system wherein the at least one coupling is a support coupling having a first end having at least a portion that defines a generally I-beam shape that is received in the at least one support beam and a second end that is fixed or mounted to a support surface.
The building system wherein the at least one coupling has a first flange and a generally opposing second flange, at least one of the first and second flanges being generally U-shaped in cross section, the at least one coupling being a splice coupling adapted to splice together the at least one support beam to a second support beam.
The building system wherein the at least one support beam comprises an internal beam structure extending at least part of a length of the at least one support beam, the at least one coupling having a predetermined shape to cooperate with at least one of the plurality of internal wall surfaces of the at least one support beam to define an aperture into which the internal beam structure may be received.
The building system wherein the internal beam structure is a retaining channel or spline groove.
The building system wherein the at least one coupling comprises at least a portion that defines a general I-beam shape having at least one flange having at least one beveled corner or edge that defines the predetermined shape.
The building system wherein the at least one coupling comprises at least a portion having a general shape of an I-beam with a first flange and a second flange, at least one of the first flange or second flange having at least one truncated or beveled corner adapted to accommodate an internal beam structure on at least one of the plurality of internal wall surfaces.
The building system wherein the at least one coupling comprises an I-beam and has a first portion and a second portion, a dimension or size of at least one of the first portion or the second portion being selected in response to a dimension or size of the at least one support beam.
The building system wherein the at least one coupling comprises a first portion having a first axis and a second portion having a second axis, the first and second axes being angled a predetermined angle with respect to each other.
The building system wherein the predetermined angle is about generally about 90 degrees so that the at least one coupling defines at least one corner coupling.
The building system wherein the first portion or the second portion generally defines an I-beam shape in cross-section having generally U-shaped flanges.
The building system wherein the at least one coupling has a second portion that also generally defines an I-beam shape in cross-section and has generally U-shaped flanges, the first and second portions being generally orthogonal with respect to each other.
The building system wherein the at least one coupling has a second portion that also generally defines an I-beam shape in cross-section and has generally U-shaped flanges, the first and second portions having axes that are generally coaxial.
The building system wherein the building system comprises at least one fastener for securing the at least one support beam to the at least one coupling, the at least one fastener passing through only one of the plurality of beam walls before engaging the at least one coupling and does not pass through another of the at least one of the plurality of beams walls.
The building system wherein the at least one fastener comprises a plurality of fasteners and the plurality of beam walls defines a plurality of fascia walls and a plurality of non-fascia or end walls, each of the plurality of fasteners comprising being mounted in one of the plurality of non-fascia or end walls and not any of the plurality of fascia walls.
The building system wherein a length of the at least one support beam is directly related to at least one dimension of at least a portion of the at least one coupling that is received in the at least one support beam.
The building system wherein the at least one dimension of the at least one coupling is a length of the portion of the at least one coupling that passes into the at least one support beam.
The building system wherein the at least one coupling is a corner coupler dimensioned and adapted to provide a corner coupling of the at least one support beam having a coupling strength that eliminates a need for any cable tie downs.
The building system wherein each of the at least one support beam has a plurality of spline grooves adapted to receive a spline for securing a screen onto the support beam.
The building system wherein the plurality of spline grooves comprise a first spline groove situated on a first end wall of each of the at least one support beam and a second spline groove situated on a side fascia wall of each of the at least one support beam.
The building system wherein the at least coupling comprises an insert end for inserting into at least one of the at least one support beam and a mounting end for mounting to a surface or substrate.
The building system wherein the surface or substrate is a deck or floor surface or building surface onto which the mounting end is mounted when the insert end is inserted into the at least one of the at least one support beam.
The building system wherein the at least one coupler is a corner coupler, a splicing coupler or a support coupler.
The building system wherein each of the support coupler, the splicing coupler and the corner coupler have at least a portion that is generally in the shape of an I in cross-section.
The building system wherein the predetermined configuration of the at least one coupler defines a general L-shape for coupling the first support beam to the second support beam to define a corner of the structure.
The building system wherein the predetermined configuration of the at least one coupler is generally straight or linear for splicing a first end of the first support beam to a first end of the second support beam such that axes of the first and second support beam are generally coaxial.
The building system wherein each of the first support beam and the second support beam comprise a plurality of beam walls having a plurality of internal wall surfaces that cooperate to define a beam aperture in each of the first support beam or the second support beam, and the at least one coupler being adapted and dimensioned to be received in each of the beam apertures, the at least one coupler comprising a plurality of coupling surfaces that become positioned in operative relationship with the plurality of internal wall surfaces, respectively, of the at least one support beam to facilitate enhancing a performance of the at least one support beam.
The building system wherein the at least one coupler defines a generally I-beam shape in cross-section that is adapted and dimensioned to be inserted into the first and second support beams.
The building system wherein the at least one coupler comprises at least a portion that defines a first flange, a generally opposing second flange, and a web coupling the first and second flanges, the first and second flanges being generally U-shaped in cross section and each comprising a first flange wall, a second flange wall and a flange joining portion for joining the first and second flange walls, each of the first flange walls becoming generally opposed or adjacent to a first internal beam wall surface of the at least one support beam, the second flange wall becoming generally opposed to a second internal beam wall surface of the at least one support beam, the flange joining portion becoming generally opposed or adjacent to a third internal beam wall surface adapted to receive at least one fastener for fastening the at least one support beam to the at least one coupler.
The building system wherein the at least one coupler is generally L-shaped and defines a corner coupling for coupling the at least one support beam to a second support beam.
The building system wherein the at least one coupler comprises a first flange and a generally opposing second flange, the first and second flanges being generally U-shaped in cross section, the at least one coupler being adapted to splice together and couple the first support beam to the second support beam.
The building system wherein at least one of the first support beam or the second support beam comprises an internal beam structure extending at least part of a length of the at least one support beam, the at least one coupler cooperating with at least one internal surface of the at least of the first support beam or the second support beam to define an aperture into which the internal beam structure may be received.
The building system wherein the at least one of the first flange or second flange comprises at least one beveled corner or edge that defines a predetermined shape.
The building system wherein the at least one coupler comprises a beam having at least a portion that defines a first flange and a second flange, at least one of the first flange or second flange having at least one truncated or beveled corner adapted to accommodate an internal beam structure of the at least one first support beam or the second support beam.
The building system wherein at least a portion of the at least one coupler generally comprises an I-beam shape having a first portion and a second portion, a dimension of at least one of the first portion or the second portion being directly proportional to a dimension of at least one of the first support beam or the second support beam.
The building system wherein the at least one first and the second support beams have generally the same cross-sectional dimension, regardless of length.
The building system wherein the first and second support beams have different cross-sectional dimensions, regardless of length.
The building system wherein the building system comprises a plurality of couplers each of which comprises a portion that generally comprises an I-beam shape, a first one of plurality of couplers being a support coupler for inserting into the first support beam and having a second end of the first support beam being fastened or secured to a support, a second one of the plurality of couplers being either a splice coupler or a corner coupler adapted and sized to be received into a second end of the first support beam and into a first end of the second support beam, thereby coupling the first and second support beams together to define either an elongated joined beam or a corner of the structure.
The building system wherein the structure defines at least one of a lanai, screen enclosure, car port, walkway cover or outdoor cover.
The coupler wherein the coupler is a corner coupler, a splicing coupler or a support coupler.
The coupler wherein each of the support coupler, the splicing coupler and the corner coupler have at least a portion that is generally in the shape of an I in cross-section.
The coupler wherein each of the at least one flange wall surface comprises a first flange wall and a second flange wall, both of which project from the primary flange surface, the primary flange surface and the at least one first and second flange wall surfaces cooperate to define a general U-shape.
The coupler wherein the coupler comprises a beveled, angled or curved wall surface that joins or couples the first and second flange wall surfaces and the primary flange surface.
The coupler wherein the beveled, angled or curved wall surface cooperates with at least one internal surface of the at least one support beam to define an elongated aperture for accommodating or receiving an internal beam structure of the at least one support beam.
The structure wherein at least one of plurality of internal couplers is a corner coupler, a splicing coupler or a support coupler.
The structure wherein each of the support coupler, the splicing coupler and the corner coupler have at least a portion that is generally in the shape of an I in cross-section.
The structure wherein at least one of the plurality of internal couplers is generally L-shaped corner coupler so that when it is received in the first ends of the first one of the plurality of beams and the second one of the plurality of beams, it causes the beams to define a corner or elbow of the structure.
The structure wherein at least one of the plurality of internal couplers is configured to engage a plurality of internal wall surfaces of any of the plurality of beams in which it is inserted.
The structure wherein each of the plurality of beams comprises at least a first portion that is generally in a shape of an I in cross-section and is sized and adapted to engage a plurality of internal surfaces of at least one of the plurality of beams when it is inserted therein.
The structure wherein each of the plurality of internal couplers comprises a first flange and a second flange integrally or monolithically formed in the web, at least one of the first flange or the second flange having at least one wall surface that is generally perpendicular to the first flange or the second flange, respectively, and generally parallel to the web.
The structure wherein each of the first and second flanges comprise a plurality of surfaces that are parallel to the web.
The structure wherein each of the first and second flanges have a plurality of flange walls generally opposing the web, each of the first flange, the second flange, and the plurality of flange walls engaging a first beam wall surface, a second beam wall surface and a third beam wall surface, respectively, of one of the plurality of beams into which the coupler has been inserted.
The structure wherein each of the first and second flanges have a plurality of generally orthogonal flange walls, each of the first flange, the second flange, and the plurality of flange walls engaging a plurality of internal beam wall surfaces, respectively, when each of the plurality of internal couplers are inserted therein.
The structure wherein each of the first and second flanges have a truncated or beveled edge portion that cooperates with at least one of the plurality of internal beam wall surfaces to define a channel or aperture adapted to receive a beam structure from at least one of the plurality of beams.
The structure wherein the structure defines at least one of a lanai, screen enclosure, car port, walkway cover or outdoor cover.
The structure wherein at least one of the plurality of internal couplers define an elbow or corner coupler for coupling at least two of the plurality of beams together at a predetermined angle.
The structure wherein at least one of the plurality of internal couplers define a generally straight coupler for coupling at least two of the plurality of beams such that their respective axes are generally coaxial.
The beam wherein the plurality of spline grooves comprising a first spline groove situated on a first end wall of at least one support beam and a second spline groove situated on a side fascia wall of the at least one support beam.
The beam wherein the plurality of spline grooves are oriented catty-corner or diagonally with respect to each other.
The beam wherein the beam is integrally or monolithically formed.
The beam wherein the beam is a self-mating beam having a first mating half and a second mating half that are mated together and cooperate to define the beam, the first mating half having a roof screen spline groove and the second mating half having a wall screen spline groove.
The building system wherein the at least one fastener comprises a plurality of fasteners and the plurality of beam walls defines a plurality of fascia walls and a plurality of non-fascia or end walls, each of the plurality of fasteners comprising being mounted in one of the plurality of non-fascia or end walls and not any of the plurality of fascia walls.
These and other objects and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
Referring now to
The embodiments illustrated in
The structure 10 is typically mounted to a support structure, such as a concrete or cement slab and/or the building 16 to which it is attached. Details of the structure 10 and its various components will now be described.
For ease of illustration,
The at least one splicing coupler 34 is generally elongated and linear and couples two beams, such as beams 28 and 30, together as illustrated in
Referring now to
For ease of description, the shape, configuration and operation of the first portion 32a and second portion 32b will be described, with it being understood that the couplers 34 and 36 of the other embodiments described herein have the same or generally similar cross-sectional shape and operate and function in the same or generally similar manner as that which is now being described in
For ease of illustration, the at least one coupler 32 is shown in
Referring back to
In the illustration being described, each of the beams 24 and 28 (
As best illustrated in
As previously mentioned, each of the at least one or plurality of couplers 32, 34 and 36 have a generally common cross-sectional configuration, although they could be slightly different in size, dimension or shape depending on the beam into which they are received. For ease of description, the configuration, mounting, shape and operation of the at least one coupler 32 and beam 28 will be described. The second portion 32b comprises a first flange 44, a second flange 46 and a rib or web 48 that is monolithically formed with the first and second flanges 44 and 46 as shown in
The flanges 44 and 46 have a first elongated portion 44a and 46a, respectively, which are generally parallel to each other and generally perpendicular to the rib 48. The flange 44 comprises a monolithic or integral first flange wall 44b and a second flange wall 44c, both of which are generally parallel to the rib 48 as shown. The flange walls 44b and 44c are integrally or monolithically formed and coupled to the flange elongated portion 44a by beveled or truncated wall portions 44d and 44e, respectively, as shown. The second flange 46 also comprises a third flange wall 46b and a fourth flange wall 46c, both of which are generally parallel to the rib 48. Note that the third and fourth flange walls 46b and 46c are also integrally or monolithically formed with the first elongated portion 46a by a truncated or beveled portion 46d and 46e as shown.
It is important to note that the beveled portion 44d comprises a surface 44d1 that cooperates with the interior surfaces 28d1 and 28a1 of the beam 28 to define an interior internal triangularly shaped aperture or channel 50. Likewise, the beveled portion 44e comprises a surface 44e1 that cooperates with the interior surfaces 28d1 and 28b1 to define an interior aperture or channel 52. The beveled portion 46d comprises a corner or surface 46d1 that cooperates with the interior surfaces 28c1 and 28a1 to define an interior aperture or channel 54. Finally, the beveled portion 46e comprises a surface 46e1 that cooperates with the interior surfaces 28c1 and 28b1 to define the interior generally rectangular shaped and elongated aperture or channel 56.
In the illustration being described, the channels 50-56 generally extend in the beam 28 the lengths L1 and L2 (
It is important to note that the truncated portions 44d, 44e, 46d and 46e all facilitate defining the interior channels 50-56, respectively, that have or define a predetermined shape. The channels 50-56 are adapted to accommodate an internal beam structure, such as an internal beam structure 60 (shown in the enlarged view in
Advantageously, the at least one corner coupler 32 is adapted, shaped and sized to accommodate the internal beam structure 60 and it has been found that the beveled corners facilitate inserting the at least one corner coupler 32 into the beams 24 and 28. It is significant to note that the spline groove or channel 66, for example, is located on the wall 28b and faces outward from the fascia wall surface 28b2 in the direction of arrow C as illustrated in
Advantageously, the at least one or a plurality of internal couplers 32, 34 and 36 are adapted, sized and shaped to accommodate the internal beam structure 60 of the beam being used. While the embodiment being shown shows that each of the flanges 44 and 46 have multiple truncated corners, it should be appreciated that each flange 44 and 46 may be provided with only one truncated corner, depending on the beam 28 being used. If the beam 28 has other internal beam structures that need to be accommodated, then the corners of the flanges 44 and 46 or other portions of the coupler 32 may be truncated, recessed or indented so that accommodating apertures or channels can be provided.
It is important to note the positioning of the screws or fasteners 80, which is a unique feature of the embodiments. In this regard, note that beam 28 has the generally opposing end walls 28c and 28d (
In contrast, it was not uncommon in the prior art that through-bolts were mounted completely through the fascia or side faces, such as ends or fascia walls 28a and 28b of beam 28, which is aesthetically unpleasing.
Advantageously, the embodiment being described eliminates or reduces the need for such through-bolts and fascia fasteners.
After the screws or fasteners 80 have secured the beams 24 and 28 to the corner key or corner coupler 32, as illustrated in
It is important to note that the couplers 32, 34 and 36 and, for example, the first and second portions 32a and 32b, are sized and adapted depending upon a plurality of factors, including the desired overall span length, such as an overall desired length of beams 28 and 30. In this regard, note that the first portion 32a and second portion 32b of the corner coupler 32 have the lengths L1 and L2, respectively, that are generally the same in the illustration being described. It should be understood, however, that these lengths L1 and L2 could be different. In general, the couplers 32, 34 and 36 are dimensioned and sized based upon engineering requirements for the building or structure 16. The coupler 34 has a length L5 (
After the beams 28 and 30 are coupled together, the coupler 32 is not visible to the naked eye as illustrated in
Referring now to
The coupler 34′ is adapted and sized to be received in the beams 28′ and 30′ and splice them as illustrated in
It should be understood that while the embodiment illustrated shows only one coupler 34′ coupling the beams 28′ and 30′, multiple couplers 34′ could be used in an overall span. Shorter couplers 34′ are required for shorter lengths, whereas longer couplers 34′ or multiple couplers 34′ may be required for longer lengths. Again, the overall length and size of the coupler 34′ is selected depending upon the size and dimensions of the beams 28′ and 30′ and overall span length desired and the size of the structure 10′ being built.
The coupler 34′ comprises the first portion 34a′ (
The intermediate or splicing coupler 34′ enables the coupling of beams 28′ and 30′ to provide an overall elongated beam which is beneficial for providing longer spans and increased large viewing aspect. In the illustration being described, the beams 28′ and 30′, once spliced together, can span a predetermined length selected by the user. In the illustration, the length is typically less than 50 feet. Note that in the prior art, beams of this length could only be achieved by increasing an overall size or dimension of the beam. For example, the wall thickness of the prior art beams was increased, which also typically increased the overall cost of the beam and structure.
Advantageously, the embodiments described herein can be used with beams, such as beams 28 and 30, that have reduced wall thicknesses compared to that of the prior art. It should be understood that the couplers 32, 34 and 36 could also be used with a split beam, such as the split beam shown or having the features of the beams shown in U.S. Pat. No. 7,877,962; U.S. Design Pat. Nos. D620,618; D620,619; D636,095; D666,743; D713,054 and D791,342, all of which are incorporated herein by reference and made a part hereof.
Another embodiment illustrates a support coupler 36” (
As with the prior embodiments, once the beam, such as beam 22″, is mounted to the surface or support structure 26″ with fasteners 82 (
As mentioned earlier, the coupler 36″ has a cross-sectional shape that is generally the same or similar to the cross-sectional shapes of the couplers 32 and 34 and functions and operates similarly as described earlier herein relative to
It should be understood that during construction of the structure 10 in one embodiment, the vertical beams 22 and 24 (
Some additional advantages and considerations of the embodiments are listed below:
Advantageously, the embodiments shown and described herein could be used alone or together and/or in combination with one or more of the features covered by one or more of the claims set forth herein, including but not limited to one or more of the features or steps mentioned in the Summary of the Invention and the claims.
While the system, apparatus and method herein described constitute preferred embodiments of this invention, it is to be understood that the invention is not limited to this precise system, apparatus and method, and that changes may be made therein without departing from the scope of the invention which is defined in the appended claims.
The present application is a continuation of U.S. application Ser. No. 16/014,384, filed Jun. 21, 2018, to which Applicant claims the benefit of the earlier filing date. This application is incorporated herein by reference and made a part hereof.
Number | Date | Country | |
---|---|---|---|
Parent | 16014384 | Jun 2018 | US |
Child | 16829560 | US |