ARCHITECTURAL CONNECTORS FOR MODULAR FRAMING SYSTEMS

Connectors for modular framing systems having T-shaped slots are disclosed. The connectors connect framing members to each other or connect floor panels to framing members. Architectural structures and modular framing systems containing the connectors are also disclosed.

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Description
BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to connectors for framing members of modular framing systems.

2. Description of Related Art

Modular framing systems are used to provide structures with metal frames without the need for welding. Such systems include framing members having T-shaped slots running lengthwise along their faces. The slots are adapted to receive connectors that can be oriented to cooperate with the interior surfaces of the slots for positioning and locking, often without mechanical modification of the framing member. Modular framing systems can be obtained from a variety of suppliers, including Bosch Rexroth Corp. of Buchanan, Mich. Bosch Rexroth's current line of products is described in a catalog entitled “Aluminum Structural Framing System,” Version 4.0 (2005), and summarized in the catalog's Introduction and Pictorial Table of Contents.

Framing members of a wide variety are available. Bosch Rexroth alone is a supplier of the following types of connectors: gussets, foundation brackets, inside-to-outside gussets, inside-to-inside gussets, corner connectors, connection screws, bolt connectors, end-to-end connectors, angle connectors, joining legs and more. In addition, many different connectors for modular framing systems are described in the patent literature.

For example, U.S. Pat. No. 3,901,612 to Canin discloses a connector having a flat leg mounted for sliding motion in the T-shaped slot of a first framing member, a screw mounted for rotation on the leg to project perpendicularly therefrom and a flat lug integral with the first leg as an extension thereof bent over the screw. The screw is threaded into a tapped bore opening into the flat end face of a second framing member while the flat lug is inserted into a correspondingly shaped groove of the second framing member to prevent relative rotation of the two framing members. This patent teaches the removal of material from one of the framing members at the joint to provide a trench for access to the connector, which weakens the framing member.

U.S. Pat. No. 4,073,113 to Oudot et al. discloses connectors having a body and a cap which has opposite end portions directed towards the body with respect to a central portion, the cap in a first position being insertable into a cavity of a framing member and being rotatable after insertion from said first position to a second position in which said end portions lie behind said flanges of the framing member. The connector further comprises means to urge together the body and the cap when the cap is in the second position so as to clamp said flanges, and the body and the cap being so shaped, as to deform at least one of said flanges during the clamping thereby securing the connector to the framing member in a manner inhibiting slippage.

U.S. Pat. No. 4,490,064 to Ducharme teaches a connector comprising a longitudinally serrated cylindrical portion, an enlarged head, and a groove circumferentially formed around the cylindrical portion intermediate the ends thereof. This connector suffers from the disadvantage that the head of the connector must be inserted into the slot at the end of a framing member and slid longitudinally to a desired position.

U.S. Pat. No. 6,481,177 to Wood discloses a connector for positioning a pair of structural framing members perpendicular to one another. The connector includes a pair of guides, each guide being shaped and sized to fit within a T-slot of one of the framing members for positioning. A strut diagonally connects the pair of guides, holding the guides in fixed positions relative to one another, usually mutually perpendicular.

U.S. Published Patent App. No. 2003/0152422 (Popovski) discloses a connector in which a T-headed bolt member is biased to assume a configuration in which it is ready for insertion into or removal from a T-shaped slot of a frame member and in which, by use of an activator in movement of the T-shaped bolt member to a locked position, the bolt member is automatically rotated to assume a position in which the head of T-shaped bolt engages shoulders of a T-shaped slot in the frame member.

U.S. Published Patent App. No. 2005/0076605 (Giaconi) discloses a method for making a self-supporting framework structure using a modular framing system including a quickly releasable connecting and locking device for joining the extruded sections of the structure and the supporting boards applied to them.

Despite the foregoing developments, there is still room for improvement of connectors for modular framing systems.

All references cited herein are incorporated herein by reference in their entireties.

BRIEF SUMMARY OF THE INVENTION

Accordingly, a first aspect of the invention comprises a connector for joining a framing member of a modular framing system to an architectural element, the framing member having at least one T-shaped slot extending lengthwise along at least one surface of the framing member, said connector comprising:

a first leg comprising: (a) a first proximal face adapted to contact a surface of the framing member and span across at least one T-shaped slot of the framing member, and (b) a first distal face opposite the first proximal face;

a plurality of first holes through the first leg, wherein the first holes are adapted to receive bolts also received by at least one T-shaped slot of the framing member;

at least one first projection on the first proximal face of the first leg, wherein the at least one first projection is adapted to be received by the framing member, provided that the first leg is adapted to be reversibly attached to the framing member by the bolts and the at least one first projection;

a second leg attached to the first leg at an angle from 1 to 179 degrees; and

second holes through the second leg and adapted to receive bolts for reversibly attaching the connector to the architectural element.

A second aspect of the invention comprises a connector for joining two framing members of a modular framing system, each framing member having at least one T-shaped slot extending lengthwise along at least one surface of each framing member, said connector comprising:

a first leg comprising: (a) a first proximal face adapted to contact a first surface of a first framing member and span across at least two parallel T-shaped slots of the first framing member, and (b) a first distal face opposite the first proximal face;

a plurality of first holes through the first leg, wherein the first holes are adapted to receive bolts also received by at least two T-shaped slots of the first framing member;

at least one first projection on the first proximal face of the first leg, wherein the at least one first projection is adapted to be received by at least one opening in the first framing member, provided that the first leg is adapted to be reversibly attached to the first framing member by the bolts and the at least one first projection;

a second leg joined to the first leg at an angle of 89-91 degrees, and comprising: (a) a second proximal face adapted to contact a second surface of a second framing member and span across at least two parallel T-shaped slots of the second framing member, and (b) a second distal face opposite the second proximal face;

a plurality of second holes through the second leg, wherein the second holes are adapted to receive bolts also received by at least two T-shaped slots of the second framing member; and

at least one second projection on the second proximal face of the second leg, wherein the at least one second projection is adapted to be received by at least one opening in the second framing member, provided that the second leg is adapted to be reversibly attached to the second framing member by the bolts and the at least one second projection.

A third aspect of the invention comprises a connector for joining a framing member of a modular framing system to a floor, the framing member having T-shaped slots extending lengthwise along at least one surface of the framing member, said connector comprising:

a first leg comprising: (a) a proximal face adapted to contact a surface of the framing member and span across at least two parallel T-shaped slots of the framing member, and (b) a distal face opposite the proximal face;

a plurality of first holes through the first leg and aligned with at least two T-shaped slots of the framing member, such that the first holes are adapted to receive bolts also received by at least two T-shaped slots of the framing member;

at least one first projection on the proximal face of the first leg, and adapted to be received within at least one T-shaped slot of the framing member;

a second leg joined to the first leg; and

second holes through the second leg and adapted to receive fasteners for reversibly fastening the second leg to the floor.

A fourth aspect of the invention comprises an architectural structure comprising:

a foundation at least partially embedded in soil;

a frame reversibly attached to the foundation and comprising framing members reversibly held together by first connectors;

floors reversibly attached to the frame by second connectors;

walls reversibly attached to at least one of the frame and the floors; and

a roof reversible attached to the frame,

wherein the architectural structure is adapted to withstand winds of up to 100 mph and the first and second connectors are connectors in accordance with the invention.

A fifth aspect of the invention comprises a modular framing system comprising connectors comprising:

a first leg comprising: (a) a first proximal face contacting a first surface of a first framing member and spanning across at least two parallel T-shaped slots of the first framing member, and (b) a first distal face opposite the first proximal face;

a plurality of first holes through the first leg, wherein the first holes receive bolts also received by at least two T-shaped slots of the first framing member;

at least one first projection on the first proximal face of the first leg, wherein the at least one first projection is received by at least one opening in the first framing member, provided that the first leg is reversibly attached to the first framing member by the bolts and the at least one first projection;

a second leg joined to the first leg at an angle of 89-91 degrees, and comprising: (a) a second proximal face contacting a second surface of a second framing member and spanning across at least two parallel T-shaped slots of the second framing member, and (b) a second distal face opposite the second proximal face;

a plurality of second holes through the second leg, wherein the second holes receive bolts also received by at least two T-shaped slots of the second framing member; and

at least one second projection on the second proximal face of the second leg, wherein the at least one second projection is received by at least one opening in the second framing member, provided that the second leg is reversibly attached to the second framing member by the bolts and the at least one second projection.

A sixth aspect of the invention comprises a connector for joining two framing members of a modular framing system, each framing member having at least one T-shaped slot extending lengthwise along at least one surface of each framing member, said connector comprising:

a proximal face adapted to contact a surface of a first framing member and span across at least one T-shaped slot of the first framing member;

a distal face opposite the proximal face;

a plurality of first holes through the connector, wherein the first holes are adapted to receive first bolts also received by at least one T-shaped slot of the first framing member;

at least one projection on the proximal face and adapted to be received by the first framing member; and

a plurality of second holes through the connector, wherein the second holes are adapted to receive second bolts also received by an end of a second framing member such that the first framing member is reversibly attached to the second framing member.

A seventh aspect of the invention comprises a connector for joining a diagonal compression brace to two framing members of a modular framing system, each framing member having at least one T-shaped slot extending lengthwise along at least one surface of each framing member, said connector comprising:

a first wing comprising: (a) a first proximal face adapted to contact a first surface of a first framing member and span across at least two parallel T-shaped slots of the first framing member, and (b) a first distal face opposite the first proximal face;

a plurality of first holes through the first wing, wherein the first holes are adapted to receive bolts also received by at least two T-shaped slots of the first framing member;

at least one first projection on the first proximal face of the first wing, wherein the at least one first projection is adapted to be received by at least one opening in the first framing member, provided that the first wing is adapted to be reversibly attached to the first framing member by the bolts and the at least one first projection;

a base joined to the first wing at a first angle;

a second wing joined to the base at a second angle, and comprising: (a) a second proximal face adapted to contact a second surface of a second framing member and span across at least two parallel T-shaped slots of the second framing member, and (b) a second distal face opposite the second proximal face;

a plurality of second holes through the second wing, wherein the second holes are adapted to receive bolts also received by at least two T-shaped slots of the second framing member;

at least one second projection on the second proximal face of the second wing, wherein the at least one second projection is adapted to be received by at least one opening in the second framing member, provided that the second wing is adapted to be reversibly attached to the second framing member by the bolts and the at least one second projection; and

a diagonal compression brace bolt adapted to pass through a hole in the base and reversibly attach a diagonal compression brace to the base.

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:

FIG. 1 is a perspective view of an embodiment of a moment connector of the invention joining a beam to a column;

FIG. 2 is rear perspective view of the embodiment of FIG. 1;

FIG. 3 is a perspective view of an embodiment of a corner connector of the invention joining a beam to a column;

FIG. 4 is rear perspective view of the embodiment of FIG. 3;

FIG. 5 is a perspective view of an embodiment of a floor hanger of the invention mounted on a framing member;

FIG. 6 is rear perspective view of the embodiment of FIG. 5;

FIG. 7 is a partial view of an embodiment of an architectural structure of the invention with a portion of the construction cut away to show embodiments of the inventive connectors and an embodiment of a modular framing system of the invention;

FIG. 8 is an exploded view of an embodiment of a column to beam connector of the invention;

FIG. 9 is a perspective view of the connector of FIG. 8 joining a column to a beam;

FIG. 10 is an exploded view of an embodiment of a diagonal compression brace connector of the invention; and

FIG. 11 is a perspective view of the connector of FIG. 10 joining a diagonal compression brace to a column-beam joint.

 DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

In general, prior art connectors for modular framing members were not designed for the type, magnitude or duration of loads required for use in buildings. The load carrying capacity of certain conventional connectors depends on friction, which depends on how tight the T-bolts are screwed into the framing members. Vibration or structural movement may diminish the friction bond of T-bolts over time. Therefore, there has been too much uncertainty in conventional modular framing systems for use as a building structure.

The connectors of the invention in conjunction with modular framing members provide frames capable of resisting building code defined loads (lateral: wind and seismic; and gravity: dead, live, snow) with safety factors, as required for construction of a multiple story (e.g., 2, 3, 4 or more story) residential structure. The load carrying capacity of the inventive connectors is based in part on shear transfer through projections (e.g., shear pins or shear blocks) inserted into the slots of the framing members and/or holes in the framing members, whereby the connectors provide calculable capacity, redundancy and duration for the joints that are consistent with use for a building structure.

Several different embodiments of the inventive connectors have been developed to connect modular framing members to each other, and/or to connect modular framing members to other architectural elements. These include the moment connector, the corner connector, the floor hanger, the column to beam connector and the diagonal compression brace connector.

Moment Connector

Moment connectors are designed to reversibly connect modular framing members to each other. Referring to FIG. 1, moment connector 10 connects beam 12 to column 14. Each of beam 12 and column 14 is a modular framing member having T-shaped slots 16 running longitudinally along surfaces thereof.

As shown in FIG. 2, moment connector 10 is preferably fabricated from a metal angle to which are attached shear pins 18 and through which are holes 20 for T-shaped fasteners 22 comprising bolts 24 and T-shaped nuts 26. A proximal face of first leg 11 contacts the surface of column 14 and spans across slots 16. A proximal face of second leg 13 contacts the surface of beam 12 and spans across slots 16. It is preferred that each leg of the connector spans across at least one or at least two of the parallel slots on the surface of an opposing structural member.

The width of moment connector 10 preferably matches the width of at least one of beam 12 and column 14, as shown in FIG. 1. Structural loads are transmitted through moment connector 10 from beam 12 to column 14 by T-shaped fasteners 22 and shear pins 18 which are preferably drilled and pressed into moment connector 10. T-shaped fasteners 22 engage T-shaped slots 16 in the modular framing members, using T-shaped nuts 26 to provide a distributed friction bond between moment connector 10 and the modular framing members. Pins 18 are inserted into pre-drilled holes (not shown) in beam 12 and column 14 to provide a shear attachment by which gravity and lateral loads are transferred from beam 12 to column 14.

Similar configurations with different numbers and sizes of shear pins 18 and T-shaped fasteners 22 may be designed for lesser or greater load conditions.

Moment connector 10 comprises at least one durable material. Suitable materials include but are not limited to metals and metal alloys, such as, e.g., stainless steel, iron, or the like. Moment connector 10 is an angle comprising two legs formed from a single mass of material (e.g., by folding a single plate of at least one metal to form two legs joined at an angle), or two legs formed from more than one mass of material (e.g., two legs bonded together to form an angle). Single mass embodiments can be formed by methods including but not limited to molding the metal connector in final form or molding a precursor of the metal connector, and modifying the precursor to provide the metal connector in final form. Multiple mass embodiments can be formed by methods including but not limited to welding or otherwise binding together two leg pieces to form an angle.

When moment connector 10 comprises metal, it is preferred to provide a metallic core coated with a non-metallic coating. Suitable non-metallic coatings include but are not limited to electrical insulating materials, thermal insulating materials, flame retardant materials, corrosion resistant materials and the like. The most preferred coatings are durable polymers such as an epoxy. Epoxy coatings prevent corrosion and prevent contact between dissimilar metals.

The thickness, length and angle of the legs of the steel angle may vary depending upon structural requirements for the joint. For example, in an embodiment of a two-story residential structure of the invention, each moment connector leg is 0.375″ thick, 5″ long and 3.25″ wide. In certain embodiments, moment connector legs have a thickness of 0.1-1″ or 0.25-0.75″ or 0.375-0.5″, a length of 1-10″ or 2.5-7.5″ or 4-6″, and a width of 1-8″ or 2-5″.

The angle of the legs relative to each other (i.e., between the distal faces of the legs) is from 1-179°, preferably about 90° (i.e., 89-91°), and more preferably 90°, as shown in FIGS. 1 and 2.

The size and shape of each of bolts 24, T-shaped nuts 26, and shear pins 18 may vary depending upon structural requirements for the joint comprising moment connector 10.

The term “bolt” as used herein refers to headed fasteners having external threads suitable for receiving a threaded nut, and is intended to encompass such fasteners regardless of whether they are identified as bolts or screws. Bolts in accordance with the invention can be tapered but are preferably untapered. Bolt size and composition are dictated by the structural requirements for the joint. Preferred bolts have a diameter of 5 to 15 mm or 8 mm or 10 mm, and a length of 10 to 50 mm or 20 mm or 30 mm. Bolts comprise at least one durable material, such as metals and metal alloys, with stainless steel being most preferred.

T-shaped nuts 26 are sized to fit within the T-shaped slots 16, and are preferably fabricated of the same materials as the bolts, with stainless steel being the most preferred material.

Shear pins 18 are preferably fabricated of the same material as bolts 24. In preferred embodiments, shear pins 18 have a diameter of ¾″ and a length of 1″, with stainless steel being the most preferred material.

Moment connectors are preferably used in conjunction with diagonally braced corner connectors at column to beam joints where diagonal bracing is not required. Moment connectors are preferably adapted to withstand a vertical force of at least 6 kips (kilopounds of force) and a horizontal force of at least 3 kips when installed.

Corner Connector

Corner connectors are designed to reversibly connect modular framing members to each other to form corners of the building frame. Referring to FIG. 3, corner connector 28 connects beam 12 to column 14. Each of beam 12 and column 14 is a modular framing member having T-shaped slots 16 running longitudinally along surfaces thereof.

Elements common to corner connector 28 and moment connector 10 include legs 11 and 13, shear pins 18, and holes 20 for T-shaped fasteners 22 comprising bolts 24 and T-shaped nuts 26. See FIGS. 3 and 4. In addition, corner connector 28 includes gusset 30 between the distal faces of the legs of the connector, turnbuckle 32 rotatably fixed to aperture 34 of gusset 30 by grooved pin 36 and clip 38 of clevis 40, and threaded rod 42 screwed into turnbuckle 32.

Corner connector 28 is preferably fabricated from a metal angle. The width of corner connector 28 preferably matches the width of at least one of beam 12 and column 14, as shown in FIG. 3. Structural loads are transmitted from corner connector 28 to beam 12 and column 14 by T-shaped fasteners 22 and shear pins 18 which are preferably drilled and pressed into corner connector 28. T-shaped fasteners 22 engage T-shaped slots 16 in the modular framing members, using T-shaped nuts 26 to provide a distributed friction bond between corner connector 28 and the modular framing members. Pins 18 are inserted into pre-drilled holes (not shown) in beam 12 and column 14 to provide a shear attachment by which gravity and lateral loads are transferred from beam 12 to column 14.

Similar configurations with different numbers and sizes of shear pins 18 and T-shaped fasteners 22 may be designed for lesser or greater load conditions. It is preferred that each leg of the connector spans across at least one or at least two of the parallel slots on the surface of an opposing structural member.

Corner connector 28 comprises at least one durable material. Suitable materials include but are not limited to metals and metal alloys, such as, e.g., stainless steel, iron, or the like. Corner connector 28 is an angle comprising two legs formed from a single mass of material (e.g., by folding a single plate of at least one metal to form two legs joined at an angle), or two legs formed from more than one mass of material (e.g., two legs bonded together to form an angle). Single mass embodiments can be formed by methods including but not limited to molding the metal connector in final form or molding a precursor of the metal connector, and modifying the precursor to provide the metal connector in final form. Multiple mass embodiments can be formed by methods including but not limited to welding or otherwise binding together two leg pieces to form an angle.

When corner connector 28 comprises metal, it is preferred to provide a metallic core coated with a non-metallic coating. Suitable non-metallic coatings include but are not limited to electrical insulating materials, thermal insulating materials, flame retardant materials, corrosion resistant materials and the like. The most preferred coatings are durable polymers such as an epoxy. Epoxy coatings prevent corrosion and prevent contact between dissimilar metals.

The thickness, length and angle of the legs of the steel angle may vary depending upon structural requirements for the joint. For example, in an embodiment of a two-story residential structure of the invention, each moment connector leg is 0.375″ thick, 8″ long and 3.25″ wide. In certain embodiments, corner connector legs have a thickness of 0.1-1″ or 0.25-0.75″ or 0.375-0.5″, a length of 1-15″ or 2-10″ or 7-9″, and a width of 1-8″ or 2-5″. The angle of the legs relative to each other (i.e., between the distal faces of the legs) is from 1-179°, preferably about 90° (i.e., 89-91°), and more preferably 90°, as shown in FIGS. 3 and 4.

The size and shape of each of bolts 24, T-shaped nuts 26, and shear pins 18 may vary depending upon structural requirements for the joint comprising corner connector 28.

Bolt size and composition are dictated by the structural requirements for the joint. Preferred bolts have a diameter of 5 to 15 mm or 8 mm or 10 mm, and a length of 10 to 50 mm or 20 mm or 30 mm. Bolts comprise at least one durable material, such as metals and metal alloys, with stainless steel being most preferred.

T-shaped nuts 26 are sized to fit within the T-shaped slots 16, and are preferably fabricated of the same materials as the bolts, with stainless steel being the most preferred material.

Shear pins 18 are preferably fabricated of the same material as bolts 24. In preferred embodiments, shear pins 18 have a diameter of ¾″ and a length of 1″, with stainless steel being the most preferred material.

The diagonal bracing of the corner connector comprises turnbuckle 32 rotatably fixed to aperture 34 of gusset 30 by grooved pin 36 and clip 38 of clevis 40, and threaded rod 42 screwed into turnbuckle 32. These components preferably comprise stainless steel, but can also comprise other durable materials such as metals and metal alloys.

When corner connector 28 comprises metal, it is preferred to provide a metallic core coated with a non-metallic coating. Suitable non-metallic coatings include but are not limited to electrical insulating materials, thermal insulating materials, flame retardant materials, corrosion resistant materials and the like. The most preferred coatings are durable polymers such as an epoxy. Epoxy coatings prevent corrosion and prevent contact between dissimilar metals.

Diagonally braced corner connectors increase the allowable vertical and lateral load capacity of the modular framing systems compared to previously available connectors.

The corner connectors shown in FIGS. 3 and 4 provide structural capacity adequate to meet the requirements of a three-story free-standing residential structure. Similar configurations with different numbers and sizes of shear pins and T-shaped fasteners may be designed for lesser or greater load conditions.

Corner connectors are preferably adapted to withstand a vertical force of at least 8.5 kips, a horizontal force of at least 8.5 kips and a diagonal force of at least 10 kips, when installed.

Floor Hangers

FIG. 5 shows a connector in accordance with a third aspect of the invention, wherein floor hanger 44 is adapted to connect framing member 46 to another object (not shown). Floor hanger 44 is particularly suitable for supporting and attaching prefabricated wood stress skin floor panels (see FIG. 7) to framing member 46.

Floor hanger 44 is an angle comprising first leg 48 joined to second leg 50, countersunk bolts 52, T-shaped nuts 54, holes 56 through first leg 48 for receiving bolts 52, holes 58 through second leg 50 for receiving additional fasteners (e.g., screw fasteners, not shown) and shear blocks 60. It is preferred that first leg 48 spans across at least one or at least two of the parallel slots on the surface of framing member 46.

Floor hanger 44 can be formed from a single mass of material (e.g., by folding a single plate of at least one metal to form two legs joined at an angle), or two legs formed from more than one mass of material (e.g., two legs bonded together to form an angle). Single mass embodiments can be formed by methods including but not limited to molding the metal connector in final form or molding a precursor of the metal connector, and modifying the precursor to provide the metal connector in final form. Multiple mass embodiments can be formed by methods including but not limited to welding or otherwise binding together two leg pieces to form an angle.

When floor hanger 44 comprises metal, it is preferred to provide a metallic core coated with a non-metallic coating. Suitable non-metallic coatings include but are not limited to electrical insulating materials, thermal insulating materials, flame retardant materials, corrosion resistant materials and the like. The most preferred coatings are durable polymers such as an epoxy. Epoxy coatings prevent corrosion and prevent contact between dissimilar metals.

The thickness, length and angle of legs 48 and 50 may vary depending upon structural requirements for the joint. For example, in an embodiment of a two-story residential structure of the invention, first leg 48 is 0.375″ thick, 9.625″ long and 6″ wide, and second leg 50 is 0.375″ thick, 2″ long and 6″ wide. In certain embodiments, first leg 48 has a thickness of 0.1-1″ or 0.25-0.75″ or 0.375-0.5″, a length of 1-12″ or 8-10″, and a width of 1-10″ or 4-8″, and second leg 50 has a thickness of 0.1-1″ or 0.25-0.75″ or 0.375-0.5″, a length of 0.5-5″ or 1-3″, and a width of 1-10″ or 4-8″.

In the embodiment depicted in FIGS. 5 and 6, first leg 48 is a long vertical leg attached to framing member 46, and second leg 50 is a short horizontal leg whose load-bearing face is adapted to be attached to a floor panel. The length of the vertical leg (first leg 48) is determined by the thickness of the floor panel. The short horizontal leg (second leg 50), which supports the floor panel, is deep enough to permit attachment to the bottom of the floor panel with threaded fasteners.

The angle of the legs relative to each other is from 1-179°, preferably about 90° (i.e., 89-91°), and more preferably 90°, as shown in FIGS. 5 and 6.

The size and shape of each of bolts 52, T-shaped nuts 54, and shear blocks 60 may vary depending upon structural requirements for the joint comprising floor hanger 44.

Bolt size and composition are dictated by the structural requirements for the joint. Preferred bolts have a diameter of 5 to 15 mm or 8 mm or 10 mm, and a length of 10 to 50 mm or 20 mm or 30 mm. Preferred bolts for hangers are countersunk, so that the bolt heads do not protrude beyond the face of the hangers. Bolts comprise at least one durable material, such as metals and metal alloys, with stainless steel being most preferred.

T-shaped nuts 26 are sized to fit within the T-shaped slots 16, and are preferably fabricated of the same materials as the bolts, with stainless steel being the most preferred material.

Shear blocks 60 are preferably fabricated of the same material as bolts 24. In a preferred embodiment, shear blocks 60 comprise rectangular stainless steel bars having a length of 0.375″, a width of 0.5″ and a thickness of 0.375″, and are welded into a 0.125″ groove in the proximal face of first leg 48.

Floor hanger is attached to the side of framing member 46 by countersunk bolts 52. For connection to a shallow beam, the countersunk fasteners attach to T-block nuts 54, which engage T-shaped slots 16 of framing member 46. For connection to deeper I-beams, the countersunk fasteners are through bolts inserted into pre-drilled holes in the web of the beam. Shear blocks 60 are inserted into slot 62 in framing member 46 to increase the shear load capacity of floor hanger 44. Prefabricated floor panels are preferably sized to fit snuggly within the building frame, supported by four floor hangers per panel.

The connector shown in FIGS. 5 and 6 is sized for a 10⅝″ deep×4′ wide floor panel spanning 16 feet. Similar configurations with different width and number countersunk connectors may be designed for other floor panel configurations.

Preferably, the floor hanger is adapted to withstand a vertical force of at least 4.5 kips and a horizontal force of at least 0.5 kips when installed.

Column to Beam Connector

Column to beam (CTB) connectors are designed to reversibly connect columns to beams. Referring to FIGS. 8 and 9, CTB connector 70 connects beam 12 to column 14. Each of beam 12 and column 14 is a modular framing member having T-shaped slots 16 running longitudinally along surfaces thereof.

CTB connector 70 is preferably fabricated from a metal plate to which are attached shear pins 18 and through which are holes 20 for T-shaped fasteners 22 comprising bolts 24 and T-shaped nuts 26. A proximal face of CTB connector 70 contacts the surface of column 14 and spans across slots 16. A distal face of CTB connector 70 contacts an end of beam 12.

CTB connector 70 preferably has a width matching a width of beam 12 and a height exceeding a height of beam 12, such that there is ready access to T-shaped fasteners 22 above and below beam 12. CTB connector 70 is reversibly fastened to beam 12 by countersunk bolts 72 passed through holes 74.

Structural loads are transmitted through CTB connector 70 from beam 12 to column 14 by T-shaped fasteners 22 and shear pins 18 which are preferably drilled and pressed into CTB connector 70. T-shaped fasteners 22 engage T-shaped slots 16 in the modular framing members, using T-shaped nuts 26 to provide a distributed friction bond between CTB connector 70 and the modular framing members. Pins 18 are inserted into pre-drilled holes 71 in column 14 to provide a shear attachment by which gravity and lateral loads are transferred from beam 12 to column 14.

Similar configurations with different numbers and sizes of shear pins 18 and T-shaped fasteners 22 may be designed for lesser or greater load conditions.

CTB connector 70 comprises at least one durable material. Suitable materials include but are not limited to metals and metal alloys, such as, e.g., stainless steel, iron, or the like.

When CTB connector 70 comprises metal, it is preferred to provide a metallic core coated with a non-metallic coating. Suitable non-metallic coatings include but are not limited to electrical insulating materials, thermal insulating materials, flame retardant materials, corrosion resistant materials and the like. The most preferred coatings are durable polymers such as an epoxy. Epoxy coatings prevent corrosion and prevent contact between dissimilar metals.

The dimensions of CTB connector 70 may vary depending upon structural requirements for the joint. For example, in an embodiment of a four-story residential structure of the invention, the CTB connector is 0.5″ thick, 10.625″ long and 3.5″ wide. In certain embodiments, the CTB connector has a thickness of 0.25-0.75″, a length of 6-16″, and a width of 2-6″.

The size and shape of each of bolts 24, T-shaped nuts 26, and shear pins 18 may vary depending upon structural requirements for the joint comprising CTB connector 70.

T-shaped nuts 26 are sized to fit within the T-shaped slots 16, and are preferably fabricated of the same materials as the bolts, with stainless steel being the most preferred material.

Shear pins 18 are preferably fabricated of the same material as bolts 24. In preferred embodiments, shear pins 18 have a diameter of ¾″ and a length of 1″, with stainless steel being the most preferred material.

CTB connectors are preferably used in conjunction with diagonal compression brace connectors at column to beam joints where diagonal bracing is required, such as in buildings having 2 or 3 or 4 or 5 floors.

Diagonal Compression Brace Connector

Diagonal compression brace (DCB) connectors are designed to reversibly connect diagonal compression braces to modular framing members of the building frame. DCB connector 80 comprises base 82 positioned between two wings 84, shear pins 18, and holes 20 for T-shaped fasteners 22 comprising bolts 24 and T-shaped nuts 26. See FIGS. 10 and 11. In addition, DCB connector 82 includes DCB bolt 86 and DCB bolt receiving hole 88 through base 82. DCB connector 80 connects diagonal compression brace 90 to beam 12 and column 14.

The width of DCB connector 80 preferably matches the width of beam 12, as shown in FIG. 11. Structural loads are transmitted from DCB connector 80 to other modular framing members by T-shaped fasteners 22 and shear pins 18 which are preferably drilled and pressed into DCB connector 80. T-shaped fasteners 22 engage T-shaped slots 16 in the modular framing members, using T-shaped nuts 26 to provide a distributed friction bond between DCB connector 80 and the modular framing members. Pins 18 are inserted into pre-drilled holes (not shown) in beam 12 and column 14 to provide a shear attachment by which gravity and lateral loads are transferred from beam 12 to column 14.

Similar configurations with different numbers and sizes of shear pins 18 and T-shaped fasteners 22 may be designed for lesser or greater load conditions. It is preferred that each wing 84 of DCB connector 80 spans across at least one or at least two of the parallel slots on the surface of an opposing structural member.

DCB connector 80 comprises at least one durable material. Suitable materials include but are not limited to metals and metal alloys, such as, e.g., stainless steel, iron, or the like. Base 82 and wings 84 of DCB connector 80 can be fabricated from a single mass of material, or from more than one mass of material. Single mass embodiments can be formed by methods including but not limited to folding a metal plate to provide the wings and base, molding the metal connector in final form or molding a precursor of the metal connector, and modifying the precursor to provide the metal connector in final form. Multiple mass embodiments can be formed by methods including but not limited to welding or otherwise binding together two wing pieces and a base.

When DCB connector 80 comprises metal, it is preferred to provide a metallic core coated with a non-metallic coating. Suitable non-metallic coatings include but are not limited to electrical insulating materials, thermal insulating materials, flame retardant materials, corrosion resistant materials and the like. The most preferred coatings are durable polymers such as an epoxy. Epoxy coatings prevent corrosion and prevent contact between dissimilar metals.

The thickness, length and angles of the DCB connector 80 may vary depending upon structural requirements for the joint. For example, in an embodiment of a four-story residential structure of the invention, the DCB connector is 0.5″ thick, 13.25″ long and 3.5″ wide. In certain embodiments, the DCB connector has a thickness of 0.25-1″, a length of 6-24″, and a width of 2-6″.

The angle of each wing 84 relative to base 82 is 1-179°, or 20-160°, or about 135° (i.e., 134-136°), as shown in FIGS. 10 and 11. The angle of one wing relative to the base can be the same as, or different from, the angle of the other wing to the base.

The size and shape of each of bolts 24, T-shaped nuts 26, and shear pins 18 may vary depending upon structural requirements for the joint comprising DCB connector 80.

Bolt size and composition are dictated by the structural requirements for the joint. Preferred bolts have a diameter of 5 to 15 mm or 8 mm or 10 mm, and a length of 10 to 50 mm or 20 mm or 30 mm. Bolts comprise at least one durable material, such as metals and metal alloys, with stainless steel being most preferred.

The size and composition of DCB bolt 86 is also dictated by the structural requirements for the joint. Preferred DCB bolts have a diameter of 8 to 18 mm, and a length of 75 mm or 200 mm. DCB bolts comprise at least one durable material, such as metals and metal alloys, with stainless steel being most preferred. DCB bolt 86 reversibly fastens DCB connector 80 to diagonal compression brace 90.

T-shaped nuts 26 are sized to fit within the T-shaped slots 16, and are preferably fabricated of the same materials as the bolts, with stainless steel being the most preferred material.

Shear pins 18 are preferably fabricated of the same material as bolts 24. In preferred embodiments, shear pins 18 have a diameter of ¾″ and a length of 1″, with stainless steel being the most preferred material.

Diagonal compression brace 90 is preferably a modular framing member having T-shaped slots 16 running longitudinally along surfaces thereof.

DCB connector 80 is preferably adapted to withstand a vertical force of at least 8.5 kips, a horizontal force of at least 8.5 kips and a diagonal force of at least 10 kips, when installed.

Modular Framing Systems and Architectural Structures

In addition to the connectors, the invention encompasses modular framing systems including the connectors and framing members having T-shaped slots, and architectural structures containing the modular framing systems.

Referring to FIG. 7, architectural structure 100 is a multiple story residential structure comprising frame 102 mounted on a foundation (i.e., wood piles 104 and wood beams 106) which is preferably at least partially embedded in soil. Frame 102 comprises framing members 108, moment connectors 10 and corner connectors 28. Floor panels 110 are fastened to frame 102 by floor hangers 44. A floor panel of the second floor is removed to show floor hangers 44. Roof panels 112 are fastened to frame 102 with standard angle brackets (not shown). Wall panels 114, incorporating operable windows 116, are fastened to the sides of floor panels 110 and roof panels 112. Bifold doors 118 and retractable sun shades 120 allow opening an entire wall of the structure to view and air if opaque wall construction is not desired.

Frames and architectural structures are not limited to the embodiments shown in FIG. 7. For example, while FIG. 7 shows a foundation system comprised of wood piles 104 and wood beams 106, the invention encompasses other types of foundations systems, such as but not limited to slab-on-grade foundations, spread footing foundations, etc. Roof panel 112 in FIG. 7 illustrates a flat roof condition, but the invention also encompasses pitched roofs of varying degrees. Wall panel 114 in FIG. 7 illustrates a parapet condition at the roof and vertically oriented panels, but the invention also encompasses roof overhangs and horizontally oriented wall panels. Bifold doors 118 in FIG. 7 illustrate a fully glazed wall which may be completely opened for ventilation, but other types of fixed or operable glazing may be substituted.

It is preferred that the framing system and more preferably the architectural structure including the framing system can be disassembled and reused. In such preferred embodiments of the invention: (a) frame 102 is reversibly attached to the foundation and comprises framing members 108 reversibly held together by moment connectors 10 and corner connectors 28; (b) floor hangers 44 are reversibly attached to the floor panels 110 and to framing members 108; (c) wall panels 114 reversibly attach to at least one of frame 102 and floor panels 110; and (d) roof panel 112 reversibly attaches to frame 102. Preferably, frame 102 is free of bracing and binding devices other than moment connectors 10, corner connectors 28 and floor hangers 44.

Even though the architectural structure is preferably adapted for relatively simple assembly and disassembly, it is still sufficiently durable to meet or exceed applicable building code standards of the International Building Code (IBC). For example, certain embodiments of the architectural structure of the invention are adapted to withstand winds of up to 75 mph, and preferably up to 100 mph (as measured in accordance with the IBC).

Although it is preferred that the modular framing system be used for architectural structures located outdoors, it is also within the scope of the invention to use the inventive framing system of the invention to build multileveled structures indoors. Such structures will typically subdivide space within a larger sheltering structure, such as a warehouse, a stadium, a convention center, or the like.

While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof.

Claims

1. A connector for joining a framing member of a modular framing system to an architectural element, the framing member having at least one T-shaped slot extending lengthwise along at least one surface of the framing member, said connector comprising:

a first leg comprising: (a) a first proximal face adapted to contact a surface of the framing member and span across at least one T-shaped slot of the framing member, and (b) a first distal face opposite the first proximal face;
a plurality of first holes through the first leg, wherein the first holes are adapted to receive bolts also received by at least one T-shaped slot of the framing member;
at least one first projection on the first proximal face of the first leg, wherein the at least one first projection is adapted to be received by the framing member, provided that the first leg is adapted to be reversibly attached to the framing member by the bolts and the at least one first projection;
a second leg attached to the first leg at an angle from 1 to 179 degrees; and
second holes through the second leg and adapted to receive bolts for reversibly attaching the connector to the architectural element.

2. The connector of claim 1, wherein the first leg is adapted to span across at least two parallel T-shaped slots of one surface the framing member.

3. The connector of claim 1, further comprising nuts and bolts adapted to reversibly join to form fasteners having a T-shaped terminus sized to fit within the at least one T-shaped slot.

4. The connector of claim 1, wherein the angle is 89-91 degrees.

5. The connector of claim 1, wherein the architectural element is an additional framing member.

6. The connector of claim 5, wherein the second leg comprises:

a second proximal face adapted to contact a surface of the additional framing member and span across at least one T-shaped slot of the additional framing member;
at least one second projection on the second proximal face of the second leg, wherein the at least one second projection is adapted to be received by the additional framing member; and
a second distal face opposite the second proximal face,
wherein: (a) the second holes are adapted to receive bolts also received by at least one T-shaped slot of the additional framing member, and (b) the second leg is adapted to be reversibly attached to the additional framing member by the bolts and the at least one second projection retained by the additional framing member.

7. The connector of claim 6, wherein the first leg is adapted to span across at least two parallel T-shaped slots of one surface of the framing member and the second leg is adapted to span across at least two parallel T-shaped slots of one surface of the additional framing member.

8. The connector of claim 6, wherein a first width of the first proximal face is equivalent to a width of the surface of the framing member, and a second width of the second proximal face is equivalent to a width of the surface of the additional framing member.

9. The connector of claim 6, further comprising a gusset joined between the distal faces of the first and second legs.

10. The connector of claim 9, further comprising a clevis attached to the gusset, a turnbuckle attached to the clevis and a threaded rod attached to the turnbuckle.

11. The connector of claim 1, wherein the architectural element is flooring.

12. The connector of claim 11, wherein the second leg comprises a load bearing face adapted to contact the flooring.

13. The connector of claim 11, wherein a first width of the first proximal face is equivalent to a width of the surface of the framing member.

14. The connector of claim 1, wherein the first leg and the second leg are formed from a single mass of at least one metal, or the first leg and the second leg are formed from more than one mass of at least one metal.

15. The connector of claim 1, comprising a metallic core coated with a non-metallic coating.

16. The connector of claim 15, wherein the metallic core comprises steel and the non-metallic coating comprises an epoxy.

17. The connector of claim 1, wherein the first holes are adapted to receive no bolts from T-shaped slots that receive at least one projection.

18. A connector for joining two framing members of a modular framing system, each framing member having at least one T-shaped slot extending lengthwise along at least one surface of each framing member, said connector comprising:

a first leg comprising: (a) a first proximal face adapted to contact a first surface of a first framing member and span across at least two parallel T-shaped slots of the first framing member, and (b) a first distal face opposite the first proximal face;
a plurality of first holes through the first leg, wherein the first holes are adapted to receive bolts also received by at least two T-shaped slots of the first framing member;
at least one first projection on the first proximal face of the first leg, wherein the at least one first projection is adapted to be received by at least one opening in the first framing member, provided that the first leg is adapted to be reversibly attached to the first framing member by the bolts and the at least one first projection;
a second leg joined to the first leg at an angle of 89-91 degrees, and comprising: (a) a second proximal face adapted to contact a second surface of a second framing member and span across at least two parallel T-shaped slots of the second framing member, and (b) a second distal face opposite the second proximal face;
a plurality of second holes through the second leg, wherein the second holes are adapted to receive bolts also received by at least two T-shaped slots of the second framing member; and
at least one second projection on the second proximal face of the second leg, wherein the at least one second projection is adapted to be received by at least one opening in the second framing member, provided that the second leg is adapted to be reversibly attached to the second framing member by the bolts and the at least one second projection.

19. The connector of claim 18, further comprising nuts and bolts adapted to reversibly join to form fasteners having a T-shaped terminus sized to fit within the T-shaped slots.

20. The connector of claim 18, adapted to withstand a vertical force of at least 6 kips and a horizontal force of at least 3 kips.

21. The connector of claim 18, further comprising a gusset joined between the first distal face of the first leg and the second distal face of the second leg.

22. The connector of claim 21, further comprising a clevis attached to the gusset, a turnbuckle attached to the clevis and a threaded rod attached to the turnbuckle.

23. The connector of claim 22, adapted to withstand a vertical force of at least 8.5 kips, a horizontal force of at least 8.5 kips and a diagonal force of at least 10 kips.

24. A connector for joining a framing member of a modular framing system to a floor, the framing member having T-shaped slots extending lengthwise along at least one surface of the framing member, said connector comprising:

a first leg comprising: (a) a proximal face adapted to contact a surface of the framing member and span across at least two parallel T-shaped slots of the framing member, and (b) a distal face opposite the proximal face;
a plurality of first holes through the first leg and aligned with at least two T-shaped slots of the framing member, such that the first holes are adapted to receive bolts also received by at least two T-shaped slots of the framing member;
at least one first projection on the proximal face of the first leg, and adapted to be received within at least one T-shaped slot of the framing member;
a second leg joined to the first leg; and
second holes through the second leg and adapted to receive fasteners for reversibly fastening the second leg to the floor.

25. The connector of claim 24, adapted to withstand a vertical force of at least 4.5 kips and a horizontal force of at least 0.5 kips.

26. A connector for joining two framing members of a modular framing system, each framing member having at least one T-shaped slot extending lengthwise along at least one surface of each framing member, said connector comprising:

a proximal face adapted to contact a surface of a first framing member and span across at least one T-shaped slot of the first framing member;
a distal face opposite the proximal face;
a plurality of first holes through the connector, wherein the first holes are adapted to receive first bolts also received by at least one T-shaped slot of the first framing member;
at least one projection on the proximal face and adapted to be received by the first framing member; and
a plurality of second holes through the connector, wherein the second holes are adapted to receive second bolts also received by an end of a second framing member such that the first framing member is reversibly attached to the second framing member.

27. A connector for joining a diagonal compression brace to two framing members of a modular framing system, each framing member having at least one T-shaped slot extending lengthwise along at least one surface of each framing member, said connector comprising:

a first wing comprising: (a) a first proximal face adapted to contact a first surface of a first framing member and span across at least two parallel T-shaped slots of the first framing member, and (b) a first distal face opposite the first proximal face;
a plurality of first holes through the first wing, wherein the first holes are adapted to receive bolts also received by at least two T-shaped slots of the first framing member;
at least one first projection on the first proximal face of the first wing, wherein the at least one first projection is adapted to be received by at least one opening in the first framing member, provided that the first wing is adapted to be reversibly attached to the first framing member by the bolts and the at least one first projection;
a base joined to the first wing at a first angle;
a second wing joined to the base at a second angle, and comprising: (a) a second proximal face adapted to contact a second surface of a second framing member and span across at least two parallel T-shaped slots of the second framing member, and (b) a second distal face opposite the second proximal face;
a plurality of second holes through the second wing, wherein the second holes are adapted to receive bolts also received by at least two T-shaped slots of the second framing member;
at least one second projection on the second proximal face of the second wing, wherein the at least one second projection is adapted to be received by at least one opening in the second framing member, provided that the second wing is adapted to be reversibly attached to the second framing member by the bolts and the at least one second projection; and
a diagonal compression brace bolt adapted to pass through a hole in the base and reversibly attach a diagonal compression brace to the base.

28. An architectural structure comprising:

a foundation at least partially embedded in soil;
a frame reversibly attached to the foundation and comprising framing members reversibly held together by first connectors;
floors reversibly attached to the frame by second connectors;
walls reversibly attached to at least one of the frame and the floors; and
a roof reversible attached to the frame,
wherein the architectural structure is adapted to withstand winds of up to 100 mph and the first and second connectors are connectors in accordance with claim 1.

29. The architectural structure of claim 28, wherein the architectural structure is located outdoors.

30. The architectural structure of claim 28, wherein the frame is free of bracing and binding devices other than the framing members and the first and second connectors.

31. The architectural structure of claim 28, wherein the architectural structure is a multiple story residence.

32. The architectural structure of claim 28, further comprising a column to beam connector and a diagonal compression brace connector.

33. In a modular framing system comprising framing members having at least one T-shaped slot extending lengthwise along at least one surface thereof and connectors joining the framing members to each other, the improvement wherein the connectors comprise at least one connector according to claim 1.

34. The modular framing system of claim 33, further comprising a column to beam connector and a diagonal compression brace connector.

35. In a modular framing system comprising framing members having at least one T-shaped slot extending lengthwise along at least one surface thereof and connectors joining the framing members to each other, the improvement wherein the connectors comprise:

a first leg comprising: (a) a first proximal face contacting a first surface of a first framing member and spanning across at least two parallel T-shaped slots of the first framing member, and (b) a first distal face opposite the first proximal face;
a plurality of first holes through the first leg, wherein the first holes receive bolts also received by at least two T-shaped slots of the first framing member;
at least one first projection on the first proximal face of the first leg, wherein the at least one first projection is received by at least one opening in the first framing member, provided that the first leg is reversibly attached to the first framing member by the bolts and the at least one first projection;
a second leg joined to the first leg at an angle of 89-91 degrees, and comprising: (a) a second proximal face contacting a second surface of a second framing member and spanning across at least two parallel T-shaped slots of the second framing member, and (b) a second distal face opposite the second proximal face;
a plurality of second holes through the second leg, wherein the second holes receive bolts also received by at least two T-shaped slots of the second framing member; and
at least one second projection on the second proximal face of the second leg, wherein the at least one second projection is received by at least one opening in the second framing member, provided that the second leg is reversibly attached to the second framing member by the bolts and the at least one second projection.

36. The modular framing system of claim 35, wherein a first width of the first proximal face is equivalent to a first width of the first surface of the first framing member, and a second width of the second proximal face is equivalent to a second width of the second surface of the second framing member.

37. The modular framing system of claim 35, further comprising a gusset joined between the distal faces of the first and second legs.

38. The modular framing system of claim 37, further comprising a clevis attached to the gusset, a turnbuckle attached to the clevis and a threaded rod attached to the turnbuckle.

39. The modular framing system of claim 35, wherein the connectors comprise a metallic core coated with a non-metallic coating.

40. The modular framing system of claim 39, wherein the metallic core comprises steel and the non-metallic coating comprises an epoxy.

41. The modular framing system of claim 35, further comprising a column to beam connector and a diagonal compression brace connector.

Patent History
Publication number: 20090000235
Type: Application
Filed: Jun 17, 2008
Publication Date: Jan 1, 2009
Applicant: KieranTimberlake Associates, LLP (Philadelphia, PA)
Inventors: Stephen James Kieran (Moylan, PA), Marilia Beatriz Martelli Rodrigues (Philadelphia, PA), Jon Eric Morrison (Downingtown, PA), Vassil Alexandrov Draganov (Chevy Chase, MD), Edward Paul Boa (Alstead, NH), Hans Rainer Porschitz (Alstead, NH), James Timberlake (Philadelphia, PA)
Application Number: 12/140,365
Classifications
Current U.S. Class: Joint, Connector (52/656.9); Elongated Supported Track Type (52/710); Connecting Feature For Modular-type Panels Having Article (e.g., Cabinet, Shelf Bracket) Attachment (52/36.5)
International Classification: E04C 2/38 (20060101); E04B 1/38 (20060101); E04B 2/58 (20060101);