Structural connector and related assembly method using same
A structural connector for a manufacturing assembly includes a body portion sized to be substantially fitted into an open end of a first hollow structural component of a manufacturing assembly. The structural connector includes at least one flexible cantilevered ear portion which is sized to engage with a corresponding lateral opening provided in the first hollow structural component. Once seated, the connector accepts at least one fastener extending laterally through a second structural component which is fitted orthogonally, relative to the open end of the first structural component, permitting interconnection between the second structural component and the first structural component.
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This invention relates to the field of manufacturing assemblies and in particular to a structural connector used in manufacturing assemblies defined by at least two or more structural hollow structural members, such as box beams, and a preferred method of assembly using at least one said structural connector.
BACKGROUND OF THE INVENTIONThere are a variety of known manufacturing assemblies, such as those for free standing displays, scheduling boards, easels, and the like, that comprise a frame that requires the interconnection of at least two box beams in which some of the beams form joints with one another. Quite often, these beam members are made from an extruded aluminum or other lightweight material in order to provide sufficient strength and rigidity to the overall structure. The beams are essentially hollow and require the use of fasteners when mating the beams together, particularly those beams that interconnect with one another in the formation of orthogonal connections.
In a prior known assembly method design, depicted in
Therefore, there is a general need in the field of manufacturing assemblies to minimize the weight of assembled structures such as those described above which include the interconnection of at least one pair of box beams, but without sacrificing structural integrity.
There is another compelling need to improve or reduce costs in the manufacture of structures, such as those that are described above.
Therefore and according to a preferred aspect of the present invention, there is described a connector for mating at least two structural components, said connector being matingly fitted into a tubular end of a first structural component wherein said connector includes at least one flexible cantilevered ear portions, said at least one cantilevered ear portion having a protrusion for engaging a lateral opening of the tubular end of the first structural component when said connector is attached thereto, thereby securing said connector.
Once seated, the connector permits the engagement of at least one fastener, thereby permitting the attachment of a second structural component to the first structural component. The connector is seated within the open end of the tubular structural component wherein the second component can be assembled to the end containing the connector. Additionally, securing the at least one fastener to the connector also prevents the connector from being removed from the at least one structural component in that the fastener is mounted into the open region or gap that permits flexion of the cantilevered ear portions.
According to another preferred aspect of the present invention, there is disclosed an assembly method for interconnecting at least two structural components, said method comprising the steps of:
-
- inserting a structural connector into one open end of a first hollow structural member, said structural connector comprising a body portion which is sized to substantially engage the open end of said member end and including at least one flexible cantilevered ear portion;
- pushing said structural connector until protrusions of said at least one flexible cantilevered ear portion is caused to extend into a corresponding lateral opening provided in said structural member, thereby fixing said connector;
- aligning a second hollow structural member onto said tubular end of said first structural member such that fastener holes of said second structural member are axially aligned with corresponding fastener holes of said structural connector; and
- mounting said fasteners through the aligned fastener holes so as to fix said structural components together.
According to another preferred aspect of the present invention, there is disclosed an assembly comprising at least two hollow structural components, wherein a first of said structural components includes an open tubular end, said structure further including at least one structural connector for interconnecting said at least two hollow structural components, said at least one structural connector including a body portion sized to be substantially fitted into the open end of a structural component and having at least one flexible cantilevered ear portion, said at least one flexible cantilevered ear portion including a protrusion sized to engage a corresponding lateral opening in said structural component when seated therein.
Preferably, the structural connector includes a pair of flexible cantilevered ear portions on opposing lateral sides thereof wherein the structural connector and/or the at least one flexible cantilevered ear portion is made from a molded lightweight durable plastic, though it will be readily apparent that other suitable materials could be contemplated.
An advantage realigned by the present invention is that an effective manufacturing method is realized that does not impact the structural design of an assembly, but which can influence the overall weight and cost thereof.
These and other objects, features and advantages will become readily apparent from the following Detailed Description which should be read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The following description relates to a pair of embodiments of a structural connector as described for use with a specific manufacturing assembly. It will be readily apparent, however, from the discussion that follows that other suitable connector designs can be imagined using the inventive concepts described herein and that a number of suitable uses other than the specific manufacturing assembly depicted will be available by those of ordinary skill in the field. In addition, certain terms are used throughout the present discussion in order to provide a suitable frame of reference with regard to the accompanying drawings, such as “top”, “bottom”, “lateral”, “square”, “longitudinal”, “end” and the like. It is not intended, however, except where specifically indicated otherwise, that these terms are intended to be restrictive of the scope of the present invention.
Referring to
As shown in
Referring to
It should be further pointed out that varying configurations of the herein structural connector body design are possible, depending on the shape of the tubular structural component into which the structural connector 40 is fitted as well as other considerations, such as the type of assembly that the connector(s) is being used. In the embodiment described herein, a substantially rectangular cross section for a box beam is described, however, it will be readily apparent that similar connector configurations can be made to conform to other shapes, such as circles, ovals, triangles, and polyhedral configurations. In addition, and though only two flexible cantilevered ear portions 72 are detailed herein, it should also be readily apparent that any number of such features could be used to effect attachment, as described in greater detail below.
In terms of assembly and referring to
Still referring to
It should be readily apparent that the number of fasteners can be varied for use with the structural connector 56 and that the pair shown is intended to be merely exemplary.
Once the fasteners 90 are attached, the structural connector 56 cannot be removed from the first structural component 44 in that the shank of the fasteners now occupy the recesses 78 that permits flexion of each of the cantilevered ear portions 72. As a result, the presence of the fasteners 90 restricts the ability of the user to inwardly press the protrusions 76 in an effort to release the structural connector 56.
Variations to the design of the structural connector are possible. For example, a second version of a structural connector 110 is shown in
In terms of assembly, the structural connector 110 is seated with the tubular open end of a first structural component such as that previously described (not shown) with the end having the base portion 115 being inserted first. The connector is sized such that the ear portions 118 are caused to inwardly flex toward the lateral side walls 126 of the upper portion 117 due to the size mismatch between the protrusions 122 and the interior wall of the first structural component. Further insertion of the structural connector 110 causes the protrusions 122 to pass lateral openings in the component and cause the ear portions 118 to be restored to their original position due to the biasing spring force caused by their flexion, fixing the structural connector in place. A second structural component can then be attached by passing fasteners (not shown) through respective holes aligned with the fastener holes 130 provided in the base portion 115 of the connector 1 10 wherein the heads of the fasteners will engage the interior wall of the second structural component. Caps (not shown) can then be added to cover the exposed openings of the second structural component.
Parts List for
20 boxbeam
22 beam sections
24 bosses
26 fastener holes
40 manufacturing assembly
44 tubular (first) structural component
48 tubular (second) structural component
49 tubular structural component
50 open end
52 open end
56 structural connector
60 body portion
61 exterior walls
62 interior walls
67 facing surface
68 inner cavity
72 flexible cantilevered ear portions
76 protrusions
78 recesses
80 lateral openings
88 fastener holes
89 fastener holes
90 fasteners
91 opening
93 opening
98 caps
110 structural connector
114 body portion
115 lower base portion
117 upper portion
118 flexible cantilevered ear portions
122 protrusions
126 lateral side wall
130 fastener holes
134 gap
Though the present invention has been described in terms of certain preferred embodiments, it will be readily apparent that variations and modifications are possible to those of sufficient skill in the field in accordance with the claims as follows.
Claims
1. A structural connector for a manufacturing assembly involving at least two hollow components, said structural connector comprising:
- a body portion adapted to be fitted substantially within an open end of a hollow first component;
- at least one flexible cantilevered ear portion extending from said body portion, said at least one ear portion including a protrusion sized to extend into a lateral opening in said first component for fixing said connector therewith; and
- means for receiving at least one fastener for permitting interconnection between said first component and a second hollow component that is disposed orthogonally relative to said open end of said first component.
2. A structural connector as recited in claim 1, wherein said fastener receiving means includes at least one fastener hole disposed in a base portion of said connector.
3. A structural connector as recited in claim 1, wherein at least a portion of said structural connector is made from a highly flexible material.
4. A structural connector as recited in claim 1, wherein said connector is made from a molded plastic.
5. A structural connector as recited in claim 1, wherein said connector body portion is sized to seat substantially entirely within the open end of said first structural component.
6. A structural connector as recited in claim 1, including a pair of flexible cantilevered ear portions disposed on opposing lateral sides of said body portion.
7. A structural connector as recited in claim 6, including a pair of internal walls defining an inner cavity, said flexible cantilevered ear portions being disposed parallel to said internal walls and outboard therefrom.
8. A structural connector as recited in claim 7, including a recess between said internal walls and said ear portions into which said ear portions can inwardly flex.
9. A method for interconnecting at least two components of a manufacturing assembly, said method comprising the steps of:
- inserting a connector into one open end of a first hollow structural component, said connector comprising a body portion sized to substantially engage the open end of said first structural component and including at least one flexible cantilevered ear portions;
- inserting said connector into said open end until a protrusion formed at the end of said at least one flexible cantilevered ear portion is caused to extend into lateral openings formed in said first structural component, thereby fixing said connector;
- aligning a second hollow structural component relative to the open end of said first structural member such that fastener holes of said connector are axially aligned with corresponding fastener holes of said second structural component; and
- mounting fasteners through the aligned fastener holes to fix the first and second structural components together.
10. A method as recited in claim 9, wherein said second hollow structural component is disposed orthogonally relative to the open end of said first structural component.
11. A method as recited in claim 10, including the step of additional steps of mounting at least a third structural component to said assembly using a said connector.
12. A manufacturing assembly comprising:
- at least two structural components, each of said components being hollow and including at least one open end; and
- at least one connector for interconnecting at least two of said components, said connector including a body portion sized to be substantially fitted into the open end of a first structural component and further including at least one flexible cantilevered ear portion, said at least one ear portion including a protrusion sized for engaging a lateral opening formed in the open end of said first structural component when said connector is seated therein.
13. An assembly as recited in claim 12, wherein said at least one flexible cantilevered ear portion is made from a molded plastic material.
14. An assembly as recited in claim 12, wherein said connector is entirely made from a molded plastic.
15. An assembly as recited in claim 12, wherein each of said structural components are made of metal.
16. An assembly as recited in claim 12, wherein each of said structural components is made from extruded aluminum.
17. An assembly as recited in claim 12, wherein the body portion of said connector includes means for retaining at least one fastener, said second structural component being arranged orthogonally relative to the open end of said first structural component and having aligned openings permitting the passage of said at least one fastener through said openings of said second component, thereby permitting said first and second structural components to be attached to one another.
18. An assembly as recited in claim 17, wherein said connector includes a pair of interior walls defining an inner cavity and said ear portions are provided parallel to said interior walls and outboard relative thereto.
19. An assembly as recited in claim 18, including a gap between at least one interior wall and said at least one ear portion, providing spacing to permit said ear portion to be flexed inwardly when said connector is initially inserted into the open end of said first structural component.
20. An assembly as recited in claim 19, wherein said gap is sized to permit the passage of said at least one fastener when said second structural component is attached thereto.
21. An assembly as recited in claim 20, wherein the passage of a said fastener into said gap prevents flexion of said at least one cantilevered ear portion.
22. An assembly as recited in claim 12, wherein said connector includes at least one pair of flexible cantilevered ear portions, each of said pair of ear portions being disposed on opposing lateral sides of said body portion.
Type: Application
Filed: Sep 3, 2004
Publication Date: Mar 9, 2006
Applicant: W.A. Krapf, Inc. (Macedon, NY)
Inventors: Wallace Krapf (Macedon, NY), Daniel Rossborough (Victor, NY)
Application Number: 10/933,584
International Classification: E04C 2/38 (20060101);