FRAME SYSTEM WITH RELEASABLE COUPLERS

Abstract

Structure and method for assembling a structural frame for use in erecting temporary or permanent structures, which structural frame has a first component having at least one auxiliary elongated web section with an elongated entrance channel opening for allowing insertion into the hollow interior of a coupler component to which is attached a second component. The channel opening defines a wider gap portion through which a coupler component is inserted, and a narrower gap portion that secures the coupler therein attaching the coupler component to an end of the second component. The first and second components are firmly, yet removable, secured together by first inserting the first wider section of the coupler through the wider gap section of the entrance channel opening of the first component, and then sliding the coupler along the hollow interior of the first component until the wider section is located at and within the narrower gap section of the entrance channel opening of the first component.

Description

BACKGROUND OF THE INVENTION

The present invention relates to structural frame systems, especially those consisting of extruded-aluminum rails or rail-elements and post or post-elements connected together to form a structure, such as a booth, shelving, display, and the like.

Hitherto-known structural frame systems have consisted of particular types of frame members, such as posts and rails, which are joinable together by various means including clips, screws, or joiners to create frames for supporting other members, such as panels. A first such prior-art method has been used for supporting shelf panels, and comprises posts and rails where the posts may contain a series of relatively large holes or slots along their face by which rails containing protruding tabs at their ends are attached. In this method, a shelf-frame is constructed by joining the rails to the posts via the tabs being downwardly receivable within the holes or slots. This method is limited to the use of thin-wall materials, since the tabs, holes or slots are formed by processes such as stamping. Structural components compatible with these processes are typically thin-walled angle-sections, which are, structurally, less efficient than sections such as rectangular hollow sections. The assembled frame components are relatively limited in load-carrying capacity, and lack relative strength and stability. In addition, the completed frame is unsightly due to the exposed joining elements as well as vacant holes.

A second prior-art method employs posts and rails of hollow rectangular cross-section that are structurally stronger and more stable than the above-mentioned first prior-art method. This second prior-art method is limited in that the posts and rails may be joinable only by utilizing connectors which can be slid inside the ends of both sections. Consequently, a rail may not easily be joined into or removed from an already constructed frame. This method also lacks versatility and is cumbersome.

A third prior-art method employs rails and posts also of hollow rectangular cross-section and which have a continuous outside void or opening along the length of a side of the component. This void has a pair of continuous internal lips along the full length of the component. In this prior-art method, a multipart joiner is slid into the end of a rail, whereby a protruding part of the joiner or connector is slid into the void in the rail. This method relies upon the multipart joiner having shafts, housings, springs, screws and a single protruding bolt with a transversely-elongated head, with the rail and bolt assembly being rotated about the longitudinal axis of the rail after the bolt head has located in the void in the rail. A screw in the rail is hand tightened using a tool so that the shoulder of the bolt head can subsequently grip the lips of the void. This method is cumbersome and time-consuming to assemble, and the position of the rail along the post may need to be determined at each and every connection. This method also has unsightly exposed screws and requires special tools to assemble. In addition, owing to the use of a single bolt, the rail often lacks resistance to high torsion, and, since the end of the rail forcibly abuts against the face of the post surface to create a friction grip, marring may occur. Also, a rail may not be easily added or removed from a completed frame, since rails have depth in the longitudinal direction of posts.

A fourth prior-art method is similar to the above-mentioned third prior-art method, except that the joiner or connector has a reverse vise-arrangement at its exposed end within the rail, so that tightening of a grub-screw in the rail causes the reverse vise to open and thereby grip the lip inside the void in the post, so as to simultaneously grip the post and clamp the rail to the post via further tightening of the grub-screw with the tightening tool. This method may be equally cumbersome and time-consuming to assemble. In addition, the position of the rail along the post must be determined at each and every joinder. This method also employs exposed unsightly grub-screws, and requires tools to assemble. Also, since the end of the rail forcibly abuts against the face of the post to create a friction grip surface, marring of the post surface is possible, and, also, a rail is not easily added or removed from a completed frame since rails have depth in the longitudinal direction of posts.

SUMMARY OF THE INVENTION

It is the primary objective to provide a structural frame system that has frame members and joining couplers which are quickly and releasably joinable to each other.

It is another primary objective of the present invention to provide a structural frame system that includes posts or post-components, and rails or rail-components, and joining couplers whereby the rails are simply and rapidly slidably connectable to the posts, and whereby the couplers are concealed.

It is yet another primary objective of the present invention to provide a structural frame system that is capable of resisting large torques, and where rectangular hollow cross-sectional components are provided with the post components having pre-determined rail-mounting positions, whereby the coupling components of the system of the invention do not rely upon friction mounting of the components parts.

The structural frame system according to the present invention comprises first elongated, rectangular cross-sectioned components or post elements, and second elongated, rectangular cross-sectioned components or rail elements that are releasably joined or connected to the first components. The first and second elongated components are capable of supporting other members, such as panels, and the like. The first and second components are releasably connected together by means of separate joining means or couplers being capable of securely and releasably joining at least one first elongated component and at least one second elongated component.

The releasable coupling means or coupling element of the invention consists of a first connector element of a first elongated post component that slidably receives therein a second connector element mounted to an end of a second elongated rail component. Each first post component is provided with at least one elongated connector-receiving section that extends substantially along one surface face of the post component. This elongated connector-receiving section is provided with an exterior-facing groove or slot extending at least most of the length thereof. The elongated connector-receiving component has a plurality of spaced-apart teeth, projections or protuberances that periodically protrude into the gap formed by the groove or slot, whereby alternative narrower and wider entrance-openings or gaps are formed along the length of the groove or slot, whereby a connector mounted at an end of a second rail-component may enter into the elongated connector-receiving component of the post component via one of the wider entrance-openings or gaps and slid along the interior of the elongated connector-receiving component until located at one of the narrower entrance-openings or gaps, where it is retained in place. In a modification, instead of the spaced-apart teeth, projections or protuberances being formed in the elongated connector-receiving section, one or more separate mounting sleeve elements are fixedly mounted within the hollow interior of the elongated connector-receiving section, which sleeve element defines a gap having a width less than the width of the gap of the elongated connector-receiving section.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will better understood with reference to the accompanying drawings, wherein:

FIG. 1 is a front elevational view of a first elongated post-component of the invention;

FIG. 2 is a cross-sectional view of the embodiment of FIG. 1 at a position where the gap thereof is narrow;

FIG. 3 is an enlarged view of the cradle region of FIG. 2;

FIG. 4 is an end view of a second elongated rail component or element according to the present invention;

FIG. 5 is an end view of a modification of the second elongated rail component of FIG. 4 showing the end-surface thereof formed with ledges for mounting a panel, or the like;

FIG. 6 is an end view of the second elongated rail component on of FIG. 4 and shows a connector or coupler of FIG. 4 mounted to an end thereof,

FIG. 7 is a partially cut-away side elevational view of FIG. 6;

FIG. 8 is a bottom plan view of FIG. 7;

FIG. 9 is an isometric view of the coupler of the present invention;

FIG. 10 is an exploded view of the coupler FIG. 9;

FIG. 11 is an isometric view similar to FIG. 9 showing a modification thereof,

FIG. 12 is a side elevational view of the modification of FIG. 11;

FIG. 13 is a side elevational view similar to FIG. 12 but showing another modification of the coupler;

FIG. 14 is a side elevational view of the resilient retaining mounting member used in mounting the coupler of FIG. 3 attached to the end of a rail-component within a post component of FIG. 1;

FIG. 15 is a partially cut-away side elevational view similar to FIG. 7 and showing the resilient retaining mounting member of FIG. 14 in use;

FIG. 16 is a similar view to FIG. 3 and showing the resilient retaining mounting member of FIG. 14 seated in place passing the through and an end resting on a cradle thereat;

FIG. 17 is a view similar to FIGS. 1, 14 and 15 and shows the resilient retaining mounting member of FIG. 14 in place;

FIG. 18 is an isometric view of the release member of the present invention;

FIG. 19 is a front elevational view similar to FIGS. 1, 14 and 15 but showing a pair of second elongated rail components of FIG. 5 joined perpendicularly to a first elongated post component of FIG. 1, via couplers of FIG. 9, one rail component being joined at an angle to the first elongated post component;

FIG. 20 is a cross-sectional view of a modification of the first elongated post component and having an angled side with one elongated connector-receiving section therefor;

FIG. 21 is a cross-sectional view of another modification of the first elongated post component and having a convex-shape side with two elongated connector-receiving sections therefor;

FIG. 22 is cross-sectional view similar to FIG. 1 but showing two rail-components of FIG. 4 connected to the post component via couplers shown in FIG. 9, in the manner of FIG. 19, where each coupler is mounted between two differently radially-located projections or protuberances of a respective connector-elongated receiving section;

FIG. 23 is a view similar to FIG. 22 but showing a rail component having only one set of outer projections or protuberances for each elongated connector-receiving section with two rail-components mounted thereto;

FIGS. 24A and 24B are views similar to FIG. 1 but show a second embodiment of the post component whereby the protuberances or projections defining the gap of the elongated connector-receiving section of a post component are provided by separate slide members;

FIGS. 25A and 25B are views similar to FIG. 2 and show a separate slide member of the embodiment of FIG. 24, with the addition of screw-holes in the ends of the post component for receiving a coupler thereto so that the post component can be utilised as a rail component;

FIG. 26 is a view similar to FIG. 25 but with the absence of the separate slide member but with the addition of screw-holes in the ends of the post component for receiving a coupler thereto so that the post component can be utilised as a rail component;

FIG. 27 is a view similar to FIGS. 25 and 26 but showing the use of self-retaining flattenable bridge;

FIGS. 28 and 29 are views similar to FIG. 25 but where multiple radially spaced screw-holes are shown;

FIG. 30 is a side elevational view of a coupler similar to the coupler of FIG. 9 but showing the coupler having a spacing member;

FIG. 31A is a similar view to FIG. 30 except that double connection means is shown;

FIGS. 31B-31D are detailed views of the stages of entry of the lower guiding hook portion a coupler component into a mounting sleeve of FIG. 25A;

FIG. 32 is an enlarged isometric view of the separate slide member of FIG. 25A;

FIG. 33 is an end view of the separate slide member of FIG. 32 but with a flattenable bridge housed in the separate slide member being shown;

FIG. 34 is a front plan view of FIG. 33 and shows a hole in the flattenable bridge for removing the flattenable bridge;

FIG. 35 is an isometric view showing a modification of the resilient retaining mounting member represented by a flat spring for use with the separate slide member of FIG. 32;

FIG. 36 is a view showing an enlarged section through the separate member to define the location of the resilient retaining mounting member;

FIG. 37 is a view similar to FIG. 23 showing a rail component using separate slide members with one rail-component mounted thereto;

FIG. 38 is a view with a coupler component attached to the end of a first elongated post component rather than the end of a second elongated rail component;

FIG. 39 is a cross-sectional view showing two parallel elongated post components connected together by a double connector component of FIG. 31A which contains a thicker spacer member;

FIG. 40A is an exploded assembly view showing the mounting of couplers to the ends of a rail component along with a spacer member and anti-rotation protrusions extending from the face of the spacer member;

FIG. 40B is an exploded assembly view showing the attachment of a coupler component to an end of the rail component;

FIG. 40C is an exploded assembly view showing the mounting of a slide member via a U-shaped clip;

FIGS. 41A-41C are end views of a first elongated post component containing the separate slide member showing the stages of the insertion of a mounting sleeve within a hollow interior of a post component with camming members for causing the squeezing of the jaws of the mounting sleeve and the use of an actuating pin member for maintaining the jaw of the mounting sleeve squeezed;

FIGS. 42A and 42B are plan views of two versions of the actuating or locking pins used in FIG. 41C for maintaining the mounting sleeve in its locked, actuated position;

FIG. 42C is an end view showing the locking pins of FIGS. 42A and 42B mounted in place;

FIG. 43 is end view showing a modification of the shape of a rail component, which in this modification is circular in cross section;

FIG. 44 is a view similar to FIG. 37 showing the round rail component of FIG. 43 mounted to a post component and

FIG. 45 is a perspective view showing an example of a structure that ma be built using the component parts of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The structural frame system of the invention consists of elongated, hollow post components 10 as seen in FIGS. 1-3 and 19, elongated, hollow rail components 24 as seen in FIGS. 9-13 and 19, and coupler components 18 as seen in FIGS. 4-8 and 19. The elongated post and rail components may be made of any suitable material, such as extruded aluminum, while the coupler components may also be made of aluminum, or, suitable plastic or spring steel.

Referring now to FIGS. 1-3, each post component 10 is made of a hollow, elongated rectangular cross-sectioned main section 12 defining four surface-faces. In the preferred embodiment, extending from two perpendicularly adjoining walls 12′, 12″ are projecting or protruding hollow, elongated web sections 14, 16, each substantially having the same width and length as the main section 12. Each of the projecting or protruding hollow, elongated web sections 14, 16 defines an entrance opening or gap 14′, 16′, respectively, through which protrudes a coupler element 18, as described in detail hereinbelow. Each projecting or protruding hollow, elongated web sections 14, 16 also has one or more interiorly-projecting tabs or detents 18, 18′, and 20, 20′, respectively, with each set of tabs 18, 18′ or 20, 20′ lying in opposite juxtaposition to each other, and extending from opposite interior surfaces of the respective web section, as clearly shown in FIGS. 2. The degree to which each tab projects into the hollow interior of the respective web section may vary depending upon various factors. In the preferred embodiment, there are provided two pairs of longitudinally spaced-apart tabs 20, 20′, as seen in FIG. 1, and two pairs of longitudinally spaced-apart tabs 18, 18′, so as to define a narrow opening or gap section between opposing tabs 18, 18′ or opposing tabs 20, 20′, and a wider opening or gap section between the two pairs of longitudinally spaced-apart tabs 18, 18′, or 20, 20′. This wider opening or gap section 17 allows entry of a coupler component 18 into the hollow interior of the respective web section 14, 16 , upon which the coupler component is slid in one direction or the other in order to locate it at a narrower gap section 16″ between one of the pairs of opposing tabs or detents 20, 20″, or 18, 18′ of the respective web section, with the detents serving to help releasably mount and lock in place the respective coupler component thereat, as described in detail hereinbelow. Each post component 10 is also provided with a longitudinally-extending slot or guide-groove 22 extending substantially along the length of the exterior surface-face of each wall 12′, 12″, as best seen in FIGS. 1 and 2, as well as interiorly-projecting semicircular-shaped protuberances or ears 22′ through each of which is formed a through-hole 22″. As described in detail hereinbelow, each side surface or wall of the post component 10 has a guide-groove 22 used for guiding a coupler-retainer element 40 as discussed hereinbelow with reference to FIGS. 14-17.

Referring now FIGS. 4-8 and 19, there is shown a second component part used in the structural frame system of the invention, a rail component 24. Each rail component 24 consists of a main rectangularly cross-sectioned section 26 defining four walls. Interiorly of the rail component, there is provided a pair of longitudinally extending cross-webs 28′, 28″, spanning the interior width of the rail component. The upper cross-web 28′ defines a lower surface from which extends a downwardly-projecting receptacle or partial enclosure 30′, while the lower cross-web 28″ defines an upper surface from which extends an upwardly-projecting receptacle or partial enclosure 30″. Each receptacle is used for receiving and mounting a mounting screw associated with a coupler element 18, as described hereinbelow in detail. Each cross-web 28′, 28″ with associated receptacle 30′, 30″, respectively, may extend the entire length of the interior of the rail component, so that there are provided at each end of the rail component means for fastening mounting screws of a coupler component to an end or to both ends of the rail component. Alternatively, there may be provided single upper and lower cross-webs 28′, 28″ in the interior of the rail component at each end thereof. The upper and lower wall-surfaces of the rail component are preferably provided with an upper groove and a lower groove or cutout 34, 36, respectively, through which is mounted an edge-surface of a panel of a structure to be built, such as table, book case, booth, store house, and the like. In order to retain a panel in place, retaining tabs or detents 40, 40′, which tabs or detents may be similar to the upper interiorly-projecting tabs or detents 18, 18′ of the rail component of FIG. 1-3. In addition, exteriorly-extending detents 41, 41′ may also be provided on the upper portion of the rail component for use in spacing the component. A rail component may also be provided with two projecting or protruding hollow, elongated web sections similar to the two projecting or protruding hollow, elongated web sections 14, 16 of the post component in order to join rail components perpendicular to each other. Each rail component may also have a panel support ledge 29.

Referring now to FIGS. 9-13, there is shown the coupler component 19. The coupler 19 consists of two sections: A wider plate section 19′ and a narrower plate section 19″. Each section 19′, 19″ is provided with a pair of vertically spaced-apart holes that pass mounting screws for mounting the coupler to an end of a rail component, and also to a post component provided that has been fitted with cross-webs similar to the cross-webs 28′, 28″ of a rail component described hereinabove with reference to FIGS. 4-8, and as described hereinbelow with reference to FIGS. 27-31. The wider section 19′ has a width less than that of the wider gap section 17, whereby the coupler, after being first mounted to an end of a rail element, may then be inserted into the gap or slot 16′ of post component 10 via the wider gap section 17 thereof, and then slid in a first or second direction to bring the coupler 19 into the narrower gap section 16″ of the post component. The wider plate section 19′ of the coupler component 19 is provided with a perpendicular lip 21 that serves as a stop that limits or terminates longitudinal sliding entry of the coupler component within the narrower gap section 16″ of the post component, with the lip 21 limiting further insertion by its contact against the end-edge of a tab or detent 20, 20′, or 18, 18′, depending upon which longitudinal direction the coupler and attached rail element are slid during attachment for location at a chosen narrower gap section 16″. The wider section 19′ is wider than the gap-entrance of the narrower gap section 16″, but the narrower section 19″ is substantially equal to or less narrow than the gap-entrance of the narrower gap-section section 16″, thereby allowing the end of the rail section to project perpendicularly from face of the post element, or, in the case where a rail element has also been provided with one or more projecting or protruding hollow elongated web sections similar two projecting or protruding hollow, elongated web sections 14, 16 of a post component 10, allowing the end to project from a rail component. In the case where the narrower section 19″ of the coupler element is substantially equal to the gap-entrance, a force-fit connection is established between the coupler component 19 and the narrower-gap section 16″, whereby, for inserting a coupler component 19 which has been mounted to an end of rail component, one simply pounds or bangs it in using a rubber mallet, or the like. Similarly, when one wants to disassemble the joined parts, one simply pounds or bangs an end of the attached rail component to force the coupler component out of the narrower-gap section using a rubber mallet, or the like.

Referring also to FIGS. 14-17, in order to fixedly retain the coupler component 19 in place within the narrower-gap section 16″, there is provided a spring-steel retainer element 40 consisting of a main elongated portion 42, an upper bent portion 44, and a lower bent portion 46. The upper bent portion 44 is mounted in one of the through-holes 22″ of an elongated web sections 14 or 16, with each through-hole 22″ being located in closely juxtapositioned at an end of one of the narrower-gap sections 16″, which end is opposite to that against which the stop member or lip 21 of the wider coupler section 19′ abuts during assembly. Thus, sliding movement of the coupler within the narrower-gap section 16″ is prevented in one direction by contact between the lip 21 and the juxtapositioned end-edge of the respective detents 20, 20′ or 18′, 18′. As can be seen in FIG. 15, the bent end 46 is received in a groove 21′ extending along the width of the rear face of the wider section 19′ of the coupler 19 (FIG. 7). If it is desired to release the retainer element 40 in order to disconnect or disassemble the component parts, a release tool 50 (FIG. 18) is provided, which release tool is a right-angle member defining legs 52 and 54. By inserting the tool 50 first through a wider gap section 17, one then slides it toward the coupler to be released such that one of the legs 52, 54 strikes against the main section 42 of the retainer element, which forces the lower bent section 46 out of its retaining groove 21′ of the wider section 19′ of the coupler to thereby release the connection.

The post component may also be provided in different shapes to suit a particular structure desired to be built. For example, instead of having a rectangular cross-sectional shape, a post component 60 may be triangular in cross section, as shown in FIG. 20, or may be a post component 62 that has a cross section that is three-sided with one side having a convex shape, as shown in FIG. 21. In either modification, one or more protruding hollow, elongated web sections similar to the protruding hollow elongated web sections 14, 16 of the post component 10 of FIG. 1, are provided, which extend from the straight side walls. It is, also, noted that the cross-sectional shapes shown in FIGS. 20 and 21 may also be used for one or more rail components 24.

Referring to FIGS. 22-23, there are shown various ways of coupling two rail components to a post component, where the rail components are mounted perpendicular to each other and the post component. In FIG. 22, each rail component 24 is connected to one hollow elongated web sections 14, 16 by being located between the outer detents 18, 18′ and inner detents 19′, 19″, with the depth of the coupler component 19 being such as to allow a flush engagement of the end of the rail component against the wall-surface of the post component to which the rail component is attached. In FIG. 23, only detents 18, 18′ or 20, 20′ are provided, with the thickness of the wider plate section 21 of the coupler element substantially filling the void.

Referring now FIGS. 24A-39, there is shown the structural frame system of the present invention according to a second embodiment thereof. In this embodiment, the rail components are identical to the rail components 24 of the first embodiment. This second embodiment uses a post component 100 (FIGS. 24A-29) that is similar to the post component 10 of the first embodiment, and is made of a hollow elongated rectangular cross-sectioned main section 112 defining four surface-faces or walls. In the preferred embodiment, extending from two perpendicularly adjoining walls 112′, 112″ are protruding hollow elongated web sections 114, 116, each substantially having the same width and length as the main section 112. Each of the projecting or protruding hollow elongated web sections 114, 116 defines an entrance opening or gap 114′, 116′, respectively, through which protrudes a coupler element 118, as described in detail hereinbelow. In this embodiment, each projecting or protruding hollow elongated web sections 114, 116 is provided with a pair of interiorly-projecting entrances-lips or tabs 118, 118′, and 120, 120′, respectively, with each set of tabs 118, 118′ or 120, 120′ lying in opposite juxtaposition to each, and extending from opposite interior surfaces of the respective web section. The degree to which each lip or detent projects into the entrance of the respective web section may vary depending upon various factors. Slidably receivable in each elongated web sections 114, 116, is a coupler-receiving, flexible mounting sleeve 126 having a substantially elongated oval or rectilinear cross-sectional shape, which sleeve 126 defines an exit or mouth 126′ through which projects a portion of a coupler component attached to the end of rail component, as described in detail hereinbelow. This sleeve 126 is best seen in FIG. 32, and is preferably made of spring steel, and defines a slot or groove 130 for mounting a resilient spring member 136 (FIGS. 35, 36), used for securing a coupler element in the sleeve 126, which spring member 136 has an upper bent or hook portion 136′ that retains the spring member 136 to the sleeve 126. The sleeve 126 is mounted in place within the hollow interior of an auxiliary section by means of screws.

The sleeve 126 is loosely mounted within one of the elongated web sections 114, 116 by means of cams or wedge-elements 122 located in the interior portion of the web section in close juxtaposition to the associated surface-face or wall of the elongated main section 112 from which the respective web section 114 or 116 projects, as seen in FIGS. 25A-27. The lateral distance between the two cams 122 is such as to loosely retain the sleeve member 126 and cause compression of the sleeve member 126 as it is slid in the web section 114 or 116 and reaches the cam members 122. It is noted that sleeve member 126 is inserted into a web section 114 or 116 at one of the free ends of the web section, and then slid toward the pair of cam members. The free edge-surfaces 128 may be squeezed toward each other by the camming members 122. In any case, the free edge-surfaces 128 are to provide the equivalent of the narrower-gap section 16″ of the first embodiment of FIG. 1, whereby these free ends are clearly visible, as seen in FIG. 24A. If additional structural mounting of the sleeve member within a web section 114 or 116 is required or desirable, such may be attained by using a flexible and deformable bridge member 140 as seen in FIGS. 33 and 34. The bridge member 140 consists of two angle-members or legs 142, 144 that form a V-shape before insertion, and define serrated ends 142′, 144′. The bridge member 140 is first inserted into a sleeve member 126 such that the ends 142′, 144′ thereof protrude outwardly from the sleeve member via rear cutout 126′, as shown in FIG. 34. The width of the bridge member 140 is greater than the width, or height when viewing FIG. 32, of the cutout 126′ so as to be retained in place in the sleeve member, with the serrated ends 142′, 144′ projecting laterally outwardly through the cutout 126′. After the bridge member 140 has been inserted into the sleeve member, as shown in FIG. 33, it is then pressed to extend the legs 142, 144 thereof, until the serrated ends 142′, 144′ are forced under the camming members 122 and are wedged thereunder, as shown in FIG. 27. The bridge element 140 may also have a central hole 148 by which it may be fastened to the exterior surface-face or wall of the elongated main section 112 from which the respective web section 114 or 116 extends. When the bridge member is mounted, it is located between the surface-face or wall of the elongated main section 112 from which the respective web section 114 or 116 extends and the respective camming members 122, as clearly shown in FIG. 27.

The sleeve 126 may also be further constrained within the web section by means of a pair of projections 115 that are part of the entrances lips or tabs 118, 118′, and 120, 120′, and face interiorly inwardly, as shown in FIGS. 24B and 25B. These projections or tabs prevent longitudinal movement of the sleeve when mounted in place, when a rail component with attached coupler is attached. During connection of the rail component to the post component via the sleeve, the sleeve is pulled outwardly thereby, with these tabs or projections preventing removal of the sleeve. In this modification, a gap 117 is provided between the rear surface of the sleeve and the juxtapositioned wall or surface face of the elongated main section, which gap allows the sleeve to clear past the projections 115 in order to locate the sleeve at a different longitudinal location in the web section where a different pair of tabs 115′ identical to the tabs 115 are located. This gap 117 is of greater width than the width of the tabs 115 or 115′ in order to allow such clearance during installation of sleeves 126 in rail components before connection of the rail components to a post component.

The interior of each elongated main section 112 of each post component 100 is also provided with a plurality of interiorly-projecting screw-mounting receptacles 150 located at each end of the elongated main section 112 for fixedly receiving screws or fasteners for mounting a coupler component 118 thereto, whereby post components 100 may be mounted parallel to each other in the manner shown in FIG. 39. The number of screw-mounting receptacles 150 may vary, such as four as shown in FIG. 25, two as shown in FIG. 26, or a series of them arranged in a circle as shown in FIGS. 28 and 29.

Referring now to FIGS. 30, there is shown a coupler component 118 according to the second embodiment. The coupler component 118 is substantially the same as the coupler component 19 of FIG. 4 of the first embodiment, and includes a wider section 162, a narrower section 164, and screws 166; however, the coupler component 118 also includes a spacer element 168 which is used in order to space the end of a rail component from the surface of the mating post component, in a manner shown in FIG. 37, such that the end-surface of the rail component lies flush with the surface-face of the mating post component, or, in the case where rail components are connected together, lies flush with the surface-face of the other mating rail component. The spacer element 168 is necessary in this second embodiment owing to the fact that the separate slide member 126 is used. The wider section 162 is provided with a projecting guiding or camming bent end 168′ which first enters into the interior of sleeve member 126 as the coupled component that has been attached to an end of a rail component, or alternatively to a post component, is forcibly slid therein during coupling, to provide ease and facility of connection. This camming bent end 168′, or what might be called an automatic tensioning ramp, strikes the sleeve during assembly to thus automatically force the rail end inserted into the sleeve toward the side of the post element housing the sleeve., in the manner best seen in FIGS. 31B-31D.

In a modification the coupler component 118 of the second embodiment shown in FIG. 31A, a double connector 118′ is provided by which the ends of two rail components may be coupled together, in the manner shown in FIG. 39. The double connector 118′ consists of two regular coupler components 118 arranged back-to-back such that the narrower sections 164 face toward each other and are separated by a central spacer element 170, defining an upper and a lower cutout or recess 170′, 170″ in each of which is flush-mounted a bent end 172 of one of the wider sections 168. This double connector 118′ is used for connecting together two post components parallel to each other, as shown on FIG. 39, with the parallel-arranged, or back-to-back, post components being oriented 180m degrees opposite to each when mounted in such a back-to-back connection. For those rail components that are also provided with web-sections similar to web-sections 14 and 16 of the post component 10, the double connectors 118′ may also be used to connect together two rail components parallel to each other.

Referring now to FIGS. 40A-40C, there is shown a modification of the second embodiment. In this modification, a rail component 180, like the other embodiments, is provided with a main elongated portion 180′ and may also have its own elongated web section 180″ as described hereinabove. The ends thereof are also provided with receptacles 182 for receiving mounting screws 184 for mounting a coupler component 190 at each end. In this modification, each rail component 180 is also provided with an upper an lower dovetail groove 182′, 182″ for receiving mating projections of the coupler component 190, as described below. The coupler component 190 consists of a wide section plate 192 with holes for passing the screws 184, and a lower camming bent end portion 192′ like the camming bent end 168′ of the embodiment of FIG. 31A. In this modification, narrower section 194 is an approximate hour-glass shape defining camming surfaces 194′, 194″. The camming surface 194′ is used to force open the mounting sleeve 200 located in a web section of a post component to which the rail component is to be mounted, which sleeve 200 defines opposing camming surfaces opposing 202, 204 that cooperate with the camming surfaces 194′,194″ as described below. The coupler component also includes a spacer element 196 from which project rearwardly a pair of guide elements 196′, 196″ that are received in the grooves 182′, 182″, so as to counteract rotational or torsional forces during installation and eccentric loading of the rail component after assembly. Each of the narrow section 194 and spacer element 196 are provided with holes through which the mounting screws 184 pass, whereby the three elements of the coupler component are fixedly mounted to an end of the rail component. There may also be provided in this modification a self-lubricating plastic bearing plate 210 that fits in an end of a rail component, which bearing plate may be used in order to prevent the rough surfaces of the end of a rail component from scratching or damaging the surface of the soft component during sliding installation procedure. This plastic bearing plate 210 is provided with holes for passing the mounting screws 184, dove-tailed grooves 212, 214 similar to the grooves 182′, 182″, and coextensively aligned therewith after assembly, for passing the mating projections 196′, 196″ of the spacer element 196. The plastic bearing plate 210 is also provided with several interiorly-protruding, corner-alignment ears 214 for aligning the bearing in the end of the rail component, as well enlarged cutout portion 216 for clearance. Also, in this modification, the mounting sleeve 200 is fixedly mounted within a web section of a post component by means of rear mounting tabs 220, 222 defining through-holes through which passes U-shaped mounting clip 224 defining a pair of leg portions 224′, 224″ that pass through the holes in the mounting tabs 220, 222 of the sleeve. Each leg portion 224′, 224″ has a sharp, pointed tip whereby the clip 224 may be hammered, or otherwise, inserted to the surface face of the adjoining, juxtapositioned wall of the elongated main section of the post component from which extends the web section that mounts the sleeve 200, which adjoining, juxtapositioned wall is provided with holes for receiving the pointed tips 224′, 224″, such as holes 22″ of the interiorly-projecting semicircular-shaped protuberances or ears 22′ of the first embodiment shown in FIGS. 2 and 3.

As described above, the narrow section 194 defines camming surfaces. The camming surface or wedge surface 194′ is used initially during installation of the coupler component with attached rail-component end in a mounting sleeve 200 by contacting the cooperating opposing camming surfaces 202, to force apart the flexible mounting sleeve to allow entry of the coupler component, until the camming or wedge surface 194 has cleared the camming surfaces 204, whereupon the sleeve returns to its original position, thereby clamping the coupler component therein. In order to force the wedge surface 194 through, a rubber mallet, or the like, is used to bang or hammer it through. When it is desired to disassemble the rail component from the post component, one hammers the rail component in the opposite direction, whereby the camming surfaces 194″ of the narrow section 194 of the coupler component cooperate with the cooperating canted surfaces 204 of the mounting sleeve to thereby force open mounting sleeve to allow removal of the rail end from the post component. It is noted that the length of the indented portion 230 of the narrow section 194 of the coupler component is greater than the length of the combined canted surfaces 202, 204 so that, after assembly, the canted surfaces 202, 204 may return to their normal positions, with the width of this indented portion 230 being less than the space or gap between the opposing tips of the canted surfaces 202, and being less than the space or gap between the opposing tips of the canted surfaces 204. It is also noted that the combined thickness of the wider section 192 and narrow section 194 is such that, after the coupler component has been inserted into a mounting sleeve of a post component by means of the lower camming bent end portion 192′ of the wider plate section 192, the narrower section 194 is substantially located in the entrance of the mounting sleeve 200 defined between the free edge-surfaces thereof from which project the cooperating canted surfaces 202, 204, in the same manner as the embodiments shown in FIGS. 23 and 37, for example.

Referring now to FIGS. 41A-41C, there are shown the manner by which the free ends 128, or the jaw, of a mounting sleeve 126 may be closed or clamped to grip a male coupling component 19. FIGS. 41A and 41B show how the mounting sleeve 126, upon first insertion with the camming members 122, cause the jaw ends 128 closed to accomplish clamping. To maintain this clamping state, there are provided activating pins 300 that when inserted through holes formed in the lips 120, 120′, force inwardly the ends 128 of the mounting sleeve to thus clamp, or dead-lock, in place the mating male coupler component 19 or 190. The activating pins may be used instead of the camming surfaces 122 (FIG. 25A), or in addition thereto. Removal of the activating pins allow disassembly of the rail component from the post component.

FIGS. 42A shows a first modification of the activating pin. In FIG. 42A, an actuating pin 300′ is attached to a slide plate 302′ that slides in one of the dove-tail grooves 314 formed in the rail component The length of pin 300′ is such as to clamp the jaws of the mounting sleeve closed in a dead-lock state. In FIG. 42B, the length of the pin 300″ attached to a plate 302″ is shorter than the pin 300′ of FIG. 42A, and is used to just dead-lock the connection but not to activate jaws of the mounting sleeve. Each plate 302′, 302″ is provided with a hole 304′, 304″, respectively, for receiving a screw or rivet for locking the pin in place so it cannot slide back out.

It is, also, noted that there may be provided a rail component 24 or 180 that, rather than being rectilinear in cross section, is round, or even an oval shape may be used. FIG. 43 shows a circular cross-sectioned rail component 324, with FIG. 44 showing the rail component 324 attached to a post component 100.

Referring to FIG. 45, there is shown an example of a structure that may be built using the component parts of the present invention, which, in this example, is a table 400. Of course, numerous other structures may be constructed, whether permanent or temporary.

While specific embodiments of the invention have been shown and described, it is to be understood that numerous changes and modifications may be made therein without departing from the scope and spirit of the invention as set forth in the appended claims.

Claims

1. A structural frame system for use in erecting temporary or permanent structures comprising:

a first component comprising an elongated main section defining a longitudinal axis and having a cross section defining a plurality of walls, said elongated main section having at least one elongated web section connected to and projecting from at least one wall of said elongated main section and having a plurality of wall surfaces and a first end and a second end and a longitudinal axis substantially parallel to said longitudinal axis of said main section, said at least one elongated web section comprising an elongated entrance channel opening located opposite to the wall of said main elongated section to which said at least one elongated web section is connected for allowing insertion into the hollow interior of said at least one auxiliary elongated web section of a coupler component; the entrance channel opening defining a wider gap portion through which a coupler component is inserted into the hollow interior and a narrower gap portion that restrains a coupler component in the hollow interior; a second component having a first end and a second end, and at least one coupler-component mounting element mounted to at least one of said first and second ends of said second component; and at least one coupler component for connection to said at least one coupler-component mounting element and for reception in the entrance channel opening of said at least one auxiliary elongated web section of said at least one first component; said at least one coupler component comprising a first wider section and a second narrower section connected to said wider section, said wider section being inserted through said first wider gap portion and thereafter slid in the hollow interior of said auxiliary web section until being located at said narrower gap portion for retention therein, whereby said second narrower section may project at least partially outwardly from said narrower gap portion for mounting said at least one second component to said first component.

2. The structural frame system for use in erecting temporary or permanent structures according to claim 1, wherein said plurality of wall surfaces of said at least one auxiliary elongated web section comprises a first side wall extending from one end of said at least one of said plurality of walls from which said at least one auxiliary elongated web section projects, and a second side wall parallel to said first side wall and extending from the other end of said at least one of said plurality of walls from which said at least one auxiliary elongated web section projects, each of said first and second side walls comprising at least one elongated interiorly-projecting ear, said ears defining therebetween said narrower gap portion.

3. The structural frame system for use in erecting temporary or permanent structures according to claim 1, wherein said wider section of said at least one coupler component comprises a stop member for limiting the longitudinal passage of said coupler component past said narrow gap portion for assisting in retaining said coupler component therein.

4. The structural frame system for use in erecting temporary or permanent structures according to claim 3, further comprising at least one locking retaining element for locking said at least one coupler component in said hollow interior of said at least one auxiliary elongated web section at said narrower gap portion thereof, said at least one locking retaining element having a first portion capable of being mounted to said wall of said main elongated section to which said at least one auxiliary elongated web section is connected and a second portion operatively connectable to a portion of said coupler component for urging said coupler component toward against said narrower portion of said entrance channel opening.

5. The structural frame system for use in erecting temporary or permanent structures according to claim 1, comprising a plurality said first components, a plurality of second components, a plurality of coupler components, and a plurality of coupler components.

6. The structural frame system for use in erecting temporary or permanent structures according to claim 5, wherein each said first component consists of a main elongated section defining a longitudinal axis and having cross-sectional shape defining a plurality of walls and a first end and a second end; and a plurality of auxiliary elongated web sections connected to and projecting from corresponding respective said walls of said plurality of walls and each said web section defining a longitudinal axis and a having cross-sectional shape defining a plurality of wall surfaces and a first end and a second end, said longitudinal axes of each said main elongated section and said elongated web section being parallel to each other; each said auxiliary elongated web section comprising a said elongated entrance channel opening located opposite to said corresponding respective wall of said main elongated section to which it is connected for allowing insertion into the hollow interior thereof said of a coupler component.

7. The structural frame system for use in erecting temporary or permanent structures according to claim 5, wherein each of said plurality of wall surfaces of each of said plurality of auxiliary elongated web sections comprises a first side wall extending from one end of said corresponding respective wall from which said auxiliary elongated web section projects, and a second side wall parallel to said first side wall and extending from the other end of said corresponding respective wall from which said auxiliary elongated web section projects; each of said first and second side walls comprising at least one elongated interiorly-projecting ear, said ears defining therebetween said narrower gap portion.

8. The structural frame system for use in erecting temporary or permanent structures according to claim 1, wherein said coupler-component mounting element comprises receptacle-openings for receiving fasteners passing through said coupler component, the fasteners being received in said receptacle-openings for fixedly securing said coupler component to a said end of said second component.

9. The structural frame system for use in erecting temporary or permanent structures according to claim 1, further comprising at least one slidable mounting sleeve slidable in the hollow interior of said at least one auxiliary elongated web section, said slidable mounting sleeve defining entrance channel along one surface thereof such as to form a first leg portion and a second leg portion, said entrance channel being in alignment with said entrance channel opening of said auxiliary elongated web section; said entrance channel being narrower in width than said entrance channel opening of said auxiliary elongated web section so that said first and second leg portions close off part of said entrance channel opening of said auxiliary elongated web section to thus define said narrower gap section of said entrance channel opening of said auxiliary elongated web section; and at least one actuating and mounting element for actuating and retaining said at least one mounting sleeve in said hollow interior of said auxiliary elongated web section in an actuated state; said first and second leg portion being capable of being moved toward each other into a clamping state.

10. The structural frame system for use in erecting temporary or permanent structures according to claim 9, wherein said at least one actuating and mounting element consists of at least one chosen from the following group: an expandable bridge element having ends that grip the interior surface of said at least one auxiliary elongated web section; diametrically opposed camming elements projecting from opposite side surfaces of said at least one auxiliary elongated web section that actuate said mounting sleeve in said hollow interior by moving said first and second leg portions toward each other; and a pin element that extends through a portion of web section for maintaining said first and second leg portions in a clamping state.

11. The structural frame system for use in erecting temporary or permanent structures according to claim 9, further comprising at least one retaining element for retaining said coupler component in said mounting sleeve, said at least one retaining element having a first portion mountable to a rear portion of said mounting sleeve in close juxtaposition to said wall of said main elongated section to which said at least one auxiliary elongated web section is connected, and a second portion extending away from said first portion toward said entrance channel opening for biasing engagement with a portion of said coupler component positioned in said mounting sleeve for urging.

12. The structural frame system for use in erecting temporary or permanent structures according to claim 9, wherein said first wider section of said coupler component comprises a bent end portion facing away from second narrower section, said bent end portion contacting a forward portion of said mounting sleeve in a camming action and entering into the interior of said mounting sleeve for pulling an attached end of a second component against the juxtapositioned surface of said first component as said wider section of said coupling component is slid into said mounting sleeve.

13. The structural frame system for use in erecting temporary or permanent structures according to claim 12, comprising a plurality of first components, a plurality of second rail components, and a plurality of coupler components; and further comprising at least one double coupler consisting of a pair of coupler components mounted side by side such that said second narrower sections face each other; said double coupler further comprising a spacer mounted between said facing narrower sections, said double connector being used to mount two first components together parallel to each other, each of said two first components also comprising at least one said mounting element mounted to at least one of the ends thereof.

14. The structural frame system for use in erecting temporary or permanent structures according to claim 9, wherein said narrower section of said coupler component comprises first camming surfaces, and said first and second leg portions of said mounting sleeve having cooperating second camming surfaces for cooperating with said first camming surfaces during mounting of said coupler component in said mounting sleeve, said first and second camming surface forcing said first and second leg portions apart to widen said entrance channel to allow insertion of said coupler component therein and for retaining said coupler component therein after said first camming surfaces have cleared said second camming surfaces;

said narrower section of said coupler component further comprising third camming surfaces, and said first and second leg portions of said mounting sleeve further having cooperating fourth second camming surfaces for cooperating with said third camming surfaces during removal of said coupler component from said mounting sleeve, said third and fourth camming surface forcing apart said first and second leg portions to widen said entrance channel to allow removal of said coupler component therein and an attached second component from connection with a first component.

15. The structural frame system for use in erecting temporary or permanent structures according to claim 5, wherein each of said first components comprises an elongated post component, and each of said second components comprises an elongated rail component; each said post component comprising a main elongated section defining a longitudinal axis and a first end and a second end, at least one auxiliary elongated web section connected to and projecting from at least one of walls of each said first component and defining a longitudinal axis and a having cross-sectional shape defining a plurality of wall surfaces and a first end and a second end, said longitudinal axes of said main elongated section and said elongated web section being parallel top each other, said at least one auxiliary elongated web section comprising an elongated entrance channel opening located opposite to said wall of said main elongated section to which said at least one auxiliary elongated web section is connected for allowing insertion into the hollow interior of said at least one auxiliary elongated web section of a coupler component;

16. A coupler for use in a structural frame system used for erecting temporary or permanent structures, which coupler is attached to an end of a first component and received in a hollow interior of a second component, said coupler comprising:

a first wider plate section for entrance into an entrance channel opening of the second component and for subsequent sliding movement in the hollow interior of the second component, said first wider section having a width greater than the opening of a narrower gap portion of the entrance channel opening, whereby the coupler is restrained therein; said coupler component further comprising a second narrower plate section connected to said first wider plate section in face-to-face contact, said second narrower plate section being capable of projecting at least partially through the narrower gap portion of the entrance channel opening of the second component, whereby an end of a first second component affixed to said coupler projects outwardly from the entrance channel opening.

17. The coupler for use in a structural frame system used for erecting temporary or permanent structures according to claim 16, wherein said wider plate section comprises a stop member for limiting the longitudinal passage thereof past a narrower gap portion of an entrance channel opening; said first wider plate section comprising a bent end portion facing away from second narrower plate section for contacting a forward portion of a mounting sleeve in a camming action and entering into the interior of the mounting sleeve for pulling an attached end of a first component against the juxtapositioned surface of a second component as said wider plate section is slid into the mounting sleeve;

18. The coupler for use in a structural frame system used for erecting temporary or permanent structures according to claim 16, wherein said coupler is a double coupler consisting of a pair of couplers mounted side by side such that said second narrower sections face each other; said double coupler further comprising a spacer mounted between said facing narrower sections, said double connector being used to mount two first or second components together parallel to each other.

19. The coupler for use in a structural frame system used for erecting temporary or permanent structures according to claim 16, wherein said narrower plate section comprises first camming surfaces and second camming surfaces for cooperating with mating surfaces associated with a mounting sleeve, said first and second camming surface forcing the mounting sleeve open during assembly and disassembly of the coupler thereto for connecting and disconnecting one component from another.

20. A method of assembling a structural frame for use in erecting temporary or permanent structures, which structural frame comprises a first component having at least one elongated web section connected to and projecting from at least one wall thereof and having a plurality of wall surfaces and a first end and a second end, the at least one elongated web section comprising an elongated entrance channel opening located opposite to the wall of the main elongated section to which the at least one elongated web section is connected for allowing insertion into the hollow interior of the at least one auxiliary elongated web section of a coupler component; the entrance channel opening defining a wider gap portion through which a coupler component is inserted into the hollow interior and a narrower gap portion that restrains a coupler component in the hollow interior; a second component having a first end and a second end, and at least one coupler-component mounting element mounted to at least one of the first and second ends of the second component; and at least one coupler component for connection to the at least one coupler-component mounting element and for reception in the entrance channel opening of the at least one auxiliary elongated web section of the at least one first component; the at least one coupler component comprising a first wider section and a second narrower section connected to said wider section, said method comprising:

(a) attaching the coupler component to an end of the second component;

(b) inserting the first wider section of the coupler through the wider gap section of the entrance channel opening of the first component;

(c) sliding the coupler along the hollow interior of the first component until the wider section is located at and within the narrower gap section of the entrance channel opening of the first component;

(d) said step (c) comprising inserting the second narrower section of the coupler into and projecting out from the narrower gap section;

(e) securing the coupler within the hollow interior at the narrower gap section of the first component.