INTERNAL POST AND BEAM CONNECTION ASSEMBLY

Abstract

The present invention relates to a concealed, centerline load-bearing and adjustable connector which binds a plurality of structural members together on one or more axes to create a joint which is sturdy for construction applications and the like. The present invention is configured to withstand the variables associated with timber materials, and other like structural members, such as shrinkage and timber twisting, which can occur after the joint is in place. In this way, the present invention provides a concealed, centerline load-bearing and adjustable connector that is easier to install, can be assembled on or offsite, provides a secure joint which is as good or better than the mortise-and-tenon joints of the past, and is adjustable once in place.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) and the benefit of U.S. Provisional Application No. 61/368,315 entitled INTERNAL POST AND BEAM CONNECTION ASSEMBLY, filed on Jul. 28, 2010, by James Karczewski, the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates to a concealed, centerline load-bearing and adjustable connector which connects a plurality of structural members together on the same or multiple varying axes in a joint configuration suitable for construction applications.

Mortise-and-tenon joints are known in the art to connect timbers to one another for various construction and framing applications. The mortise-and-tenon joints of the past are very time consuming and require a considerable amount of skill and industry knowledge to form a proper joint that can withstand such things as timber shrinkage and the twisting of the timbers once in place. Standard mortise-and-tenon system connectors are not adjustable and often required laborious modification or complete reconstruction of the joint if changes have to be made. Standard mortise-and-tenon systems are also not amenable to site installations and adjustment, such that these systems require that joints be formed and complete before installation.

SUMMARY OF THE INVENTION

The present invention relates to a concealed, centered and adjustable connector assembly which binds a plurality of structural members, such as timbers, together to create a joint which is sturdy for construction applications and the like, as well as configured to withstand the variables associated with timber materials, such as shrinkage and timber twisting, which can occur after the joint is in place. In this way, the present invention provides a concealed, centered and multi-axes connector assembly that is easier to install, can be assembled on or offsite, provides a secure joint which is as good or better than the mortise-and-tenon joints of the past, and is adjustable once in place.

One aspect of the present invention is a connector assembly for connecting two or more structural members at joining surfaces. Each structural member to be joined includes a first hole or bored out cavity extending into the structural member in a generally perpendicular manner relative to the joining surface of the structural member. The term joining surface is used to describe the surface of the structural member which will abut an adjacent structural member to be joined thereto. The structural members further include a second hole or bored out cavity which extends through the structural member which intersects the first hole in a generally perpendicular manner. The connector assembly includes a plurality of structural member engagement assemblies wherein each structural member engagement assembly is adapted to be received in the first hole of a structural member that is to be joined to another structural member. Each structural member engagement assembly includes wedged apertures that are disposed on a body portion of the structural member engagement assembly. The wedged apertures are designed to align with the second hole extending through the structural member for engagement of the structural member engagement assembly with a cinching assembly as described below. At least one adjustable coupling assembly is adapted to couple adjacent structural member engagement assemblies. In this way, adjacent structural members to be joined will have structural member engagement assemblies disposed in the respective first holes of the structural member and the coupling device will then connect those two structural member engagement assemblies together in an adjustable manner such that the structural member engagement assemblies can move laterally within the structural members to ensure that the wedged apertures of the structural member engagement assemblies are properly aligned with the second holes of the structural member. The connector assembly further includes a plurality of cinching assemblies wherein each cinching assembly is operably coupled to a structural member engagement assembly and further wherein each cinching assembly is adapted to be received in the second hole of a structural member. In this way, the cinching assembly is perpendicular to the structural member engagement assembly after coupling.

Another aspect of the present invention is a connector assembly for connecting two or more structural members at joining surfaces, wherein each structural member includes first and second holes as described above. The connector assembly includes a plurality of structural member engagement assemblies configured to be received in the first holes of the structural members to be joined. The structural member engagement assemblies have apertures disposed thereon for receiving cinching assemblies as noted below. The connector assembly further includes at least one adjustable coupling assembly adapted to couple adjacent structural member engagement assemblies. The connector assembly further includes at least one cinching assembly operably coupled to any one of the plurality of structural member engagement assemblies and adapted to be received in the second holes of the structural members. The cinching assemblies include a pair of wedge connectors adapted to engage the apertures of the structural member engagement assemblies. The cinching assemblies further include a drive mechanism operably coupled to the wedge connectors for driving the wedge connectors laterally along an associated cinching assembly.

Yet another aspect of the present invention includes a connector assembly for connecting two or more structural members together, the structural members having first holes extending into the structural member, second holes extending through the structural member intersecting the first holes in a generally perpendicular manner, and third holes extending through the structural member intersecting the first holes in a generally perpendicular manner. In this way, the second and third holes are perpendicular to the first hole of a structural member. It is contemplated that the second and third holes can extend through the structural member in different planes of the structural member to produce multiple bearing points. The connector assembly comprises a plurality of structural member engagement assemblies configured to be received in the first holes of the structural members. The structural member engagement assemblies have a plurality of apertures disposed thereon. At least one adjustable coupling assembly is adapted to couple adjacent structural member engagement assemblies dispose within structural members to be joined. A plurality of cinching assemblies are included wherein any one cinching assembly of the plurality of cinching assemblies is adapted to be operably coupled to any one of the plurality of structural member engagement assemblies. The cinching assemblies are further adapted to be received in the second holes or the third holes of the structural members at the same or different planes of the structural member. Each cinching assembly includes a pair of wedge connectors adapted to engage the apertures of the structural member engagement assemblies. The cinching assemblies further include a drive mechanism operably coupled to the wedge connectors for driving the wedge connectors laterally along a cinching assembly.

These and other features, objects and advantages of the present invention will be further understood and appreciated by those skilled in the art upon studying the following specification and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a timber connector embodying the present invention;

FIG. 2 is a perspective view of an assembled structural member connector assembly;

FIG. 3 is a perspective view of a wedge connector;

FIG. 3A is a perspective view of a wedge connector;

FIG. 4 is a cross-sectional side elevational view of a wedge connector;

FIG. 4A is a cross-sectional side elevational view of a wedge connector;

FIG. 5 is a perspective view of the present invention in assembly;

FIG. 5A is a perspective view of joined structural members;

FIG. 6 is a perspective view of another embodiment of the present invention in assembly;

FIG. 6A is a perspective view of joined structural members;

FIG. 7 is a perspective view of another embodiment of the present invention in assembly;

FIG. 8 is a perspective view of another embodiment of the present invention in assembly;

FIG. 9 is a perspective view of another embodiment of the present invention;

FIG. 10 is a perspective view of another embodiment of the present invention;

FIG. 10A is a perspective view of joined structural members;

FIG. 11 is an exploded perspective view of another embodiment of the present invention;

FIG. 11A is an exploded perspective view of the assembly shown in FIG. 11;

FIG. 11B is a perspective view of the assembly as shown in FIGS. 11 and 11A;

FIG. 11C is a perspective view of joined structural members;

FIG. 12A is a side elevational view of joined timbers as found in the prior art;

FIG. 12B is a side elevational view of joined structural members as joined by an embodiment of the present invention;

FIG. 13 is an exploded perspective view of another embodiment of the present invention joining structural members and structural insulated panels (SIP panels);

FIG. 13A is an exploded perspective view of joined structural members and SIP panels;

FIG. 13B is an exploded perspective view of joined structural members and SIP panels;

FIG. 13C is a perspective view of joined structural members and SIP panels;

FIG. 14 is a perspective view of another embodiment of the present invention in assembly;

FIG. 14A is a perspective view of joined structural members;

FIG. 15 is a perspective view of a wedge connector;

FIG. 15A is a perspective view of a wedge connector;

FIG. 16 is a cross-sectional, side elevational view of a wedge connector; and

FIG. 16A is a cross-sectional, side elevational view of a wedge connector.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

For the purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as oriented in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in following specification, are simply exemplary embodiments. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be construed as limiting, unless expressly stated otherwise. Further, the following disclosure discloses a structural member connector assembly wherein embodiments are exemplified using timber as the structural members to be connected. However, the following disclosure is in no way intended to limit the present invention to a device for connecting timber as the present assembly may also be used for metal structures, composite structures, polymeric structures, and the like.

The reference numeral 2 (FIG. 1) generally designates a timber connector assembly for use in connecting a plurality of structural members, such as timbers and the like, which includes first and second ends 4 and 6 which are respectively the ends of structural member engagement assemblies or, in this embodiment, tube-like structures 8 and 10. Tube-like structures 8 and 10 have hollow cavities 9 and 11 and tube-like structures 8 and 10 are interconnected using a connector or coupling 12. The connector 12, as shown in FIG. 1, is a threaded connector which connects tube-like structures 8 and 10 using the threaded ends of tube-like structures 8 and 10 (which can be seen in FIG. 11, where the tube-like structures 208 have threaded ends 208′ that thread into connectors 214 which are similar to connectors 12 in FIG. 1). The connection between tube-like structures 8 and 10 with connector 12 can either be a threaded connection or otherwise adjustable connection securing the tube-like structures 8 and 10 in a linear arrangement with one another. In the embodiment disclosed herein, the structural member engagement assemblies are cylindrical in configuration, however, other configurations known in the art will be appreciated by those skilled in the art. The connection of the tube-like structures 8 and 10 via the threaded connector 12 allows for tube-like structures 8 and 10 to be adjusted laterally relative to each other which can help accommodate for timber shrinkage and other such assembly variables once the connector assembly 2 is assembled. The tube-like structures 8 and 10 further comprise wedged apertures, such as 14 and 14′ (not shown) for tube-like structure 8 and wedged apertures 16 and 16′ (not shown) for tube-like structure 10. The wedged apertures 14, 14′ and 16, 16′ pass through the hollow cavities 9 and 11 of the tube-like structures 8 and 10 to allow for connector cinching assemblies 17 to pass through the hollow cavities 9 and 11 in assembly. The wedged apertures 14, 14′ and 16, 16′ comprise beveled edges 15, which cooperate with connector cinching assemblies 17 to pull timbers together as further described below.

Cinching assemblies 17 comprise wedge connectors 18 and 20, which have beveled domes 19 and 21 (shown in FIGS. 3 and 3A) that wedgingly mate with the beveled edges 15 of the wedged apertures 14, 14′ and 16, 16′, respectively. In this way the connector cinching assemblies 17 impart force on the timbers to be connected by drawing them toward one another. The beveled domes 19 and 21 are designed to maintain full contact with the wedged apertures 14, 14′ and 16, 16′, even if the timbers twist in settlement. The wedge connectors 18 and 20 thread into threaded wedge connector couplings 22, or the wedge connectors can be fashioned as a unitary structure. The wedge connector assemblies 17 further comprise fasteners or bolts 24 which are used to connect wedge connectors 18 and 20 through the hollow cavities 9 and 11 of the tube-like structures 8 and 10. The connector assembly 2 further comprises a structural member connector guide or split ring 26 which, in assembly, is circumscribed about the centerline of the timbers which are to, be connected via the timber connector assembly 2.

As shown in FIG. 2, the connector assembly 2 is fully assembled, such that the bolts 24 (not shown) of the connector cinching assemblies 17 are disposed within the connector cinching assemblies 17 and are accessible within the threaded wedge connector couplings 22. In this arrangement, the bolts 24 pass through the non-threaded wedge connector 20 to the threaded wedge connector 18 to hold the connector cinching assembly 17 in place. As the bolt 24 is tightened, the wedge connector couplings 22 internally act on timber pieces to draw the timber pieces toward one another as further described below.

Turning to FIG. 3, wedge connector 18 is shown having an externally threaded section 28 which is used to thread the wedge connector 18 into the threaded wedge connector coupling 22 (not shown). The wedge connector 18 can be threaded into the wedge connector coupling 22 to varying degrees depending on the size of the tube-like structures 8 or 10 (not shown) in order to obtain a snug fit of the connector cinching assembly 17 (not shown). The wedge connector 18 further comprises a top surface 29 which has a beveled dome 19 disposed thereon. The beveled dome 19 wedgingly mates with the beveled edges 15 of the wedged apertures 14, 14′ and 16, 16′ of the tube-like structures 8, 10 in assembly (FIG. 1). The beveled dome 19 of wedge connector 18 is truncated at an aperture 32 which leads to a threaded channel 34. The threaded channel 34 engages the bolt 24 in assembly which allows the connector cinching assemblies 17 to cinch timbers together by the interaction between the beveled dome 19 and the beveled edges 15 of the wedged apertures 14, 14′ and 16, 16′.

FIG. 3A depicts wedge connector 20 which has an external threaded section 36 for engaging a threaded wedge connector coupling 22 (FIG. 1) to varying degrees along the threaded wedge connector coupling 22. Wedge connector 20, as compared to wedge connector 18, similarly has a top surface 37 with a beveled dome 21 which is truncated at an aperture 14 leading to a channel 42. The channel 42 of wedge connector 20 is not a threaded channel, such that the bolt 24 can pass through the wedge connector 20 and then pass through the tube-like structures 8, 10 (FIG. 1) of the connector assembly 2 to then engage threaded channel 34 of wedge connector 18 in assembly. In this way, as shown in FIG. 2, the beveled domes 19 and 21 of the wedge connectors 18 and 20 act against the beveled edges 15 of the wedged apertures 14, 14′ and 16, 16′ to cinch the timbers together as explained in more detail below. It is also contemplated that wedge connector 20 can be slightly undersized as compared to wedge connector 18, thereby requiring a smaller wedge connector coupling 22 to facilitate ease of assembly of the connector cinching assemblies 17. In this way, the undersized wedge connector 20 can account for unforeseen variables in the assembly of the connector assembly 2 and in the structural members to be connected.

As shown in FIG. 4, the wedge connector 18 has a channel 34 which is at least partially threaded. FIG. 4A is a cross section of wedge connector 20 which shows channel 42, which is non-threaded. It is contemplated that the externally threaded sections 28 and 36 of wedge connectors 18 and 20 can be three-quarter inch pipe thread, however, varying sizes of the wedge connectors 18 and 20 and threaded wedge connector couplings 22 are contemplated to join structural members of varying sizes.

It is further contemplated that the wedge connectors 18 and 20 can be one-piece wedge connectors wherein the wedge connector coupling 22 and the wedge connectors 18 and 20 are unitary whole members which do not have a threaded connection with a wedge connector coupling.

As shown in FIGS. 15 and 15A, wedge connectors 18a and 20a are unitary wedge connectors having beveled domes 19 and 21, respectively, as well as coupling portions 22. Wedge connector 18a has a threaded hole 34 disposed at the top of beveled dome 19 and wedge connector 20a has a threadless hole 42 disposed on the top of beveled dome 21. In operation, wedge connectors 18a and 20a function similarly to the wedge connectors 18 and 20, as described above. In the embodiment shown in FIGS. 15 and 15A, the wedge connectors 18a and 20a are one-piece unitary units that have been machined to have a coupling area 22 and beveled domes 19 and 21, respectively.

FIGS. 16 and 16A show cross sectional views of the wedge connectors 18a and 20a, respectively. The wedge connectors 18a, 20a have threaded cavities 23 which are disposed within the coupling portion 22 of the wedge connectors 18a, 20a for connecting the wedge connectors to structural member engagement assemblies as described below. The wedge connectors 18a, 20a further comprise inset sections 25 for housing a bolt used to connect the wedge connectors as further described below.

As shown in FIG. 5, two pieces of timber 50 and 52 are connected using a timber connection assembly 2 similar to the connector assembly 2 shown in FIGS. 1 and 2. Timber 50 has upper and lower abutting end surfaces 54 and 56 and timber 52 has upper and lower abutting end surfaces 58 and 60. The two pieces of timber 50 and 52 are joined at abutting end surfaces 56 and 58. Timbers 50 and 52 have bored-out sections or cavities 62, 64, respectively, which create tube-like channels within the timbers 50 and 52 which are disposed on the centerlines of the abutting end surfaces 56 and 58 of the respective timbers. With the bored-out sections or cavities 62, 64 located on the centerlines of the timbers 50 and 52, the centerlines of the timbers 50 and 52 become the bearing locations for the connected timbers. With the centerlines as the bearing points for the timbers to be connected, the present invention allows for ease of fabrication as all timbers to be connected can have flat-faced cuts on which the centerline is determined for boring-out sections, such as bored-out sections 62 and 64. With the present invention, the timbers do not need to actually have sections of the timbers insert into an adjacent timber (as shown in FIG. 12A), where generally the bottom surface of a connecting timber would serve as the bearing location for the joined timbers. With the present invention, the bearing location is always on the centerline of a connected structural member, which is the most secure location for a bearing point. This is true even when multiple structural members are connected at different angles, as further described below.

Bored-out cross channels 66 and 68 are disposed in a perpendicular fashion to channels 62 and 64. Circular cutout sections 70 and 72 (best shown in FIG. 11B) are disposed on the abutting end surfaces 56 and 58 of the timbers 50 and 52 for inserting the split ring 26 into both timbers 50 and 52. The split rings 26 allow for a quick friction fit of timbers before they are cinched into place. Tube-like structures 8 and 10 are inserted into the bored-out cavities 62 and 64 and connector cinching assemblies 17 are installed in bored-out cross sections or cavities 66 and 68. It is contemplated that the threaded wedge connector couplings 22 of the connector cinching assemblies 17 have a diameter which matches the diameter of the bored-out cavities 66 and 68 thereby allowing for maximum contact between the threaded wedge connector couplings 22 and the bored-out cavities 66 and 68 for maximum bearing capacity. It is further contemplated that the wedge connectors 20 can be undersized wedge connectors that easily drop into place of the bored-out cavities 66 and 68, while the wedge connectors 18 are of a specific diameter which correlates with the bored-out cavities 66 and 68, such that wedge connectors 18 can be frictionally fit into the bored-out cavities 66 and 68 and thereby held in place on their own for ease of installation when the user of the connector assembly 2 is adjusting the connector cinching assemblies 17 from the side of the timber that allows access to the head of bolt 24.

The tube-like structures 8 and 10 are connected using threaded connector 12 allowing for lateral adjustment of the tube-like structures 8 and 10 in assembly. As the connector cinching assemblies 17 are tightened using bolts 24 (FIG. 1), the timbers 50 and 52 are cinched together by the interaction of the beveled domes 19 and 21 of the wedge connectors 18 and 20 acting on the beveled edges 15 of the wedged apertures 14, 14′ and 16, 16′ of the tube-like structures 8 and 10, as shown in FIG. 1. Specifically, the timbers 50 and 52 are drawn together by the wedge connectors 18 and 20 acting or prying against the beveled edges 15 of the wedged apertures in such a manner that the wedge connectors 18 and 20 pry against a distal edge of a wedged aperture relative to the abutting end surfaces 56 and 58 of the timbers 50 and 52. In this way, the connector cinching assemblies 17 bear down on the timbers 50 and 52 at bored-out cavities 66 and 68 and draw them together as the beveled domes 19 and 21 engage the distal edges of the wedged apertures 14, 14′ and 16, 16′. This action pulls the tube-like structures further into the timbers in which they reside, thereby drawing two timbers together to form a tight connection. When fully tightened, the connector cinching assemblies 17 tightly join the timbers 50 and 52 into place for use in a construction assembly.

As shown in FIG. 5A, the timbers 50 and 52 are connected by the internal timber connection assembly 2. Bored-out cavities 66 and 68 are capped with plugs 74 for an aesthetically pleasing finished appearance to the joined timbers 50 and 52, which resembles the desired mortise-and-tenon look. Plugs 74 can also be flush with the timber surfaces. In this way, the present invention marries the traditional look of mortise-and-tenon joining with adjustable engineered componentry.

In another embodiment of the present invention, a timber connecting assembly 80 (FIG. 6) is shown. The timber connecting assembly 80 has similar components to the connector assembly 2 shown in FIG. 1, but, in this embodiment, the timber connecting assembly 80 has the ability to join three pieces of timber in perpendicular orientations to one another. Specifically, timbers 82, 83, and 84 are connected via a timber connector assembly 80 which comprises tube-like structures 86, connector cinching assemblies 88, and split rings 90. The tube-like structures 86 are placed in bored-out cavities 92 and the connector cinching assemblies 88 are placed within bored-out cavities 94 within the timbers. For establishing a nonlinear connection between timbers, a coupling system is used to attach tube-like structures with adjacent cinching assemblies. For example, as shown in FIG. 6, timber 83 is connected to timber 82 at an approximate 90° angle, wherein a tube-like structure 86 is disposed within timber 83 and coupled to a connector cinching assembly 88 by way of adjustable coupling 96. Similarly, timber 84 is connected to timber 82 in a perpendicular fashion, whereby the tube-like structure 86 disposed within timber 84 is connected to a tube-like structure 86, which is disposed within timber 82. The tube-like structures 86 disposed in timber 84 and timber 82 are connected to one another by a threaded coupling 98, which is adjustable and acts in a similar fashion to coupling 12 as shown in FIG. 1. In this embodiment, as connector cinching assemblies 88 are tightened, timbers 84 and 83 are pulled toward timber 82 on the Y axis, the X axis, and the Z axis, as indicated in FIG. 6. As shown in FIG. 6A, the timbers 82, 83, and 84 are joined with a timber connector assembly 80 (not shown) which is an internal assembly to the timbers 82, 83, and 84. Plugs 100 are used to cap bored-out cavities 94 to provide a finished look.

As shown in FIG. 7, a timber connector assembly 102 is shown connecting timbers 104, 105, and 106. The timber connector assembly 102 has tube-like structures 108, connector cinching assemblies 110, split rings 112, and threaded tube couplings 118. Timbers 104, 105 and 106 have bored-out cavities 114, 116 for housing the components of the connector assembly 102. In this configuration, the timber connector assembly 102 is connecting timbers 105 and 106 along the Z axis with timber 104 disposed between timbers 105, 106 on the Y axis. As shown in FIGS. 8, 9, and 10, timber connector assemblies 120, 122, and 124 can have various configurations to connect a multitude of timbers on various axes. Specifically, as shown in FIG. 10, the timber connector assembly 124 can connect timbers that are pitched or inclined, such as timber 126, thereby making the timber connecting assembly 124 customizable for various applications, such as roof rafters or truss components for providing support for a roof of a building structure.

As shown in FIG. 11, an exploded view of a timber connector assembly 200 is shown, much like the timber connecting assembly 120 shown in FIG. 8. The timber connecting assembly has tube-like structures 208 and intermediate tube-like structure 210, which has threaded ends on either side of the structure. All the tube-like structures 208, 210 have wedged apertures 216 with beveled edges 217. The tube-like structures 208, 210 have threaded ends 208′ and 210′, respectively. The threaded ends 208′ and 210′ fit into threaded couplings 214 which connect the tube-like structures 208, 210 to other tube-like structures and/or to connector cinching assemblies 218. The connector cinching assemblies 218 comprise wedge connectors 220, which are internally threaded as well as externally threaded, and wedge connectors 222, which are externally threaded only. The wedge connectors 220 and 222 are threaded into threaded couplings 224 by the external threads on the wedge connectors 220 and 222 (not shown). The wedge connectors 220 and 222 have beveled domes 221 which cooperate with the wedged apertures 216 and beveled edges 217 of the wedged apertures 216 of the tube-like structures 208, 210. The connector cinching assemblies 218 further comprise bolts 226 which pass through wedge connectors 222 and thread into wedge connectors 220. As the bolts 226 tighten down the connector cinching assemblies 218, the beveled domes 221 of the wedge connectors 220 and 222 cooperate with the beveled edges 217 of the wedged apertures 216 of the tube-like structures 208, 210 to effectively pull a timber (not shown) into a secure engagement with another timber (not shown).

In the embodiment shown in FIG. 11, a threaded coupling 230 is shown which is used to attach the threaded coupling 224 of the middle connector cinching assembly 218 to the threaded coupling 214 which effectively connects tube-like structure 208 to the center connector cinching assembly 218 in a perpendicular relationship. The threaded coupling 230 is an externally threaded coupling which threads with the internal threads of threaded couplings 224 and 214 thereby allowing for lateral adjustment of tube-like structure 208 relative to the center connector cinching assembly 218 in assembly. In this way, the connector cinching assemblies 218 serve as a timber joining location for timbers to be joined in a perpendicular relationship to the tube-like structure 208 with which that particular connector cinching assembly is associated. As shown in FIG. 11, the timber connector assembly 200 further comprises split rings 228 which are disposed around threaded couplings 214 where two timbers will meet at abutting end surfaces in assembly. While the connections shown in FIG. 11 are mainly threaded connections, other adjustable connection systems known in the art are contemplated.

As shown in FIG. 11A, timbers 232, 233, 234, and 235 are to be joined using connector assembly 200 as described above. The timbers 233-235 have bored-out cavities 238 which extend inwardly into the timber along the centerline (CL) of the timber from the lateral face of the timber serving as the point at which the timber will be connected to another timber. Disposed around the bored-out cavities 238 and centered on the centerline of the timbers 233-235 are circular split ring insets 242. The split ring insets 242 house the split rings 228, such that approximately half of the split ring 228 is disposed within a first timber piece and the other half of the split ring 228 is disposed within a second timber piece to provide a quick friction fitting of timbers to be connected. Timber pieces 233-235 further comprise bored-out cavities 240, which run perpendicular to bored-out cavities 238 and are used to house the connector cinching assemblies 218. In this embodiment, timber 232 has two bored out cavity sections 240 which run directly through the timber 232. The bored-out cavities 240 are used to access and adjust the connector cinching assemblies 218 of the timber connector 200 to ensure secure engagement of the timbers 232-235 to one another.

FIG. 11B shows timber connector 200 as assembled within the timbers (FIG. 11C). FIG. 11C shows timbers 232-235 connected to one another using the timber connector assembly 200 (not shown) wherein bored-out cavities 240 have been plugged with plugs 244, giving the connected timbers a finished appearance.

The connector assemblies as described above provided fully hidden, yet adjustable mechanical connections. The connector assemblies can be used to connect not only timbers, but any plurality of structural members that are capable of having bored-out cavities or apertures that can engage the cinching assemblies of the connector assembly.

The present invention also allows for reduced fabrication time in preparing members to be connected. Simple “butt” connection at abutting end surfaces of structural members simplifies the fabrication of the individual timber components by employing only flush sawn cuts and simple drilling operations without the need for traditional mortising and tenoning. The use of centerline mounting for the joined members allows for quick and efficient “self-centering” boring fixtures and tools to be used in the fabrication of the members.

Having connections in multiple axes that all center on centerline or neutral axes of members is another advantage of the present invention. This centerline joining ensures that stress points are located at low stress zones of the members to be joined. When dealing with connections made between multiple members, axes all center on the centerline or neutral axes of the members. In this way, the present invention takes away from an undesired off-setting or stacking effect of other timber joining systems that require varied load-bearing points both on and off the centerline of the joined members. By creating consistent centerline locations of connectors, neutral axes of joined members intersect at a common point for effective load transfer thereby minimizing the inducement of moments on the connection that can occur as the timbers twist, shrink, and settle over time.

Further, the radial pattern of the connector assemblies and the split rings allow for natural beam twist, common to some softwoods, to occur at the centerline bearing locations and are readily adapted to minimize stress on the joint when this occurs.

Shrinkage is often a common occurrence in joined timbers. As timbers shrink, stress is transferred to the joints and joints often need to be adjusted. With the present connector assembly, 3 timbers joined in series (for example) are readily capable of handling any shrinkage that may occur as all timber to timber connections can be adjusted where the abutting end surfaces of the timbers are joined. The use of threaded components in the tube-like structures allows for lateral adjustability of the connector assembly during the assembly process. This adjustability is preserved and even made more variable as multiple wedge connector locations are introduced. As shrinkage occurs in the settlement of timbers, the shrinkage decreases the timber size toward the bearing point. For example, in a traditional mortise-and-tenon joint as shown in FIG. 12A, the bearing location is disposed on the bottom surface of timber A as it connects with timber B. Therefore, as timber A shrinks in settlement, 100% of that shrinking effect occurs on the top surface of timber A toward the bearing location, as indicated by arrow C. With the present invention, as seen in FIG. 12B, the shrinkage of timber A occurs from both the upper and lower surfaces of timber A toward the bearing location (the centerline of timber A), as indicated by arrows C and D. Therefore, the present invention can reduce the effect of structure settlement due to beam shrinkage by up to 50% by allowing shrinkage from multiple surfaces of the timber to move in concert toward the centerline of a bearing location as constructed in accordance with the present invention. The effect of shrinking timbers is compounded when multiple timbers are joined on multiple axes with other timber connecting systems which must be in a stacked relationship without a common centerline bearing locus.

As shown in FIG. 13, an exploded view of a connector assembly 300 is shown which is used to connect structural members 302 (vertical), 303 (horizontal), and 304 (lateral). The structural members 302, 303, and 304 can be plastic materials, timber materials, or other composite materials suitable for construction applications. In the embodiment shown in FIGS. 13-13C, the structural members 302, 303, and 304 will be described as timbers, however, this designation is not intended to limit the use of the connector assembly 300 to timber connections only. As shown in FIG. 13, structural insulated panels (commonly referred to as SIP panels) are shown. Reference numeral 306 indicates vertical SIP panels and reference numeral 308 indicates horizontal SIP panels. The SIP panels are comprised of skins 310 and insulative materials 312 to which the skins 310 are generally adhered using adhesive or other known connection means. The SIP panel skins 310 have overhang portions 310′ which allow a group of connected timbers, which have a thickness that correlates to the insulative material 312 of the SIP panels, to slide in between the skins 310 of the SIP panels, such that a group of connected timbers surrounding a SIP panel can be fully concealed by the SIP panel skins 310 using the overhang portions 310′.

In the embodiment shown in FIG. 13, the connector assembly 300 comprises tube-like structures 316 and intermediate or terminal tube-like structures 318 which are connected using connectors 320 which, in this embodiment, are internally threaded and can be threaded onto tube-like structure 316 or intermediate tube-like structure 318 at their threaded ends 316′ and 318′, respectively. The connectors 320 can also be threaded to an intermediate threaded connector 321 which will then connect to another connector 320. As shown in FIG. 13 on the vertical axis, the connector assembly 300 has a tube-like structure 316 with a threaded end 316′ which connects to a connector 320 which connects to a threaded connector 321 which connects to a connector 320 which connects with a terminal or intermediate tube-like structure 318 which further connects to another connector 320. Where the tube-like structures 316 and intermediate or terminal tube-like structure 318 connect with a connector 320, there is the ability of the user of the connector assembly 300 to adjust the connector assembly 300 at these locations. Further, the user of the connector assembly 300 can also adjust at the location of the threaded connector 321.

In this embodiment, the vertical section of the connector assembly 300 described above is used to connect timber 302 to timber 304. A horizontal section of the connector assembly 300 is used to connect timber 303 to timber 304 and the horizontal section of the connector assembly 300 comprises a tube-like structure 316 having a threaded end 316′ which connects to connector 320 which then connects to a threaded connector 321 which then connects to wedge connector 322. Adjustments for this section of the connector assembly 300 can be made at the connection between the wedge connector 322 and the threaded connector 321 as well as the connection between the threaded connector 321 and the connector 320 and further at the connection between the connector 320 and the tube-like structure 316.

Connector cinching assemblies 326 as found in this embodiment comprise wedge connectors 322 having beveled domes 322′ wherein the wedge connectors 322 are one-piece connectors which are internally threaded on its outer casing and are either threaded or non-threaded at the aperture disposed on the top of the beveled dome. The wedge connectors 322 have threaded apertures on the beveled domes 322′ if the wedge connector 322 is located on the opposite side of the timber where the pin or bolt is inserted. The wedge connectors 322 serve as connection points with threaded connectors 321 using the internal threads of the outer casing of the wedge connectors 322. The tube-like structures 316 and the intermediate or terminal tube 318 have wedged apertures 328 which correspond to the beveled domes 322′ of the wedge connectors 322 in a similar fashion as the embodiments described above. Similarly, the timbers 302, 303, and 304 have bored-out sections 330 for the insertion of the connector assembly 300 similar to the embodiments described above. Also, the timber pieces have circular cutouts or insets 332 for the insertion of split rings 324 which hold the timbers together in a friction fit configuration as the connector assembly 300 is assembled.

As shown in FIG. 13A, the timbers 302, 303, and 304 are connected by the connector assembly 300 which is fully assembled internally within the timbers 302, 303, and 304.

As shown in FIG. 13B, the timbers 302, 303, and 304 are connected using the connector assembly 300 which is concealed within the timbers 302, 303, and 304, which are connected in a manner such that the load-bearing location of the timbers is on the centerline as indicated by CL in FIG. 13B. Bored-out sections or cavities 330 are shown in timbers 302 and 303, which provide access to the timber cinching assemblies 326 so that the user of the connector assembly 300 can adjust the bolts 324 which are concealed within the timbers 302, 303, and 304 in FIG. 13B. The vertical and horizontal SIP panels 306 and 308 have cutout sections 314 on their skins 310 which allow for the user of the connector assembly 300 to access the cavities 330 as found on timbers 302 and 303, as well as timber 304 on the underside (not shown).

FIG. 13C shows the SIP panels 306 and 308 joined together on the connected timbers 302, 303, and 304 where the cutout sections 314 of the skins 310 of the SIP panels 306 and 308 are shown to provide access to bored-out cavities 330 of the timbers 302 and 303 for the adjustment of the connector cinching assemblies 326 of the connector assembly 300.

In another embodiment of the present invention, FIG. 14, five structural members are connected using a structural member connection assembly 400. In this embodiment, timbers V, W, X, Y, and Z are all connected using the structural connection assembly 400. Specifically, timbers V, X, and Z are connected in a T-shaped formation using similar components as found in the connector assemblies described above. In a bored-out section of timbers V and Z, structural member engagement assemblies 402 are disposed. The structural member engagement assemblies 402, as found in timbers V and Z, have two transverse holes which are used to house horizontal cinching assemblies 404 and vertical cinching assemblies 406. In this way, the structural members V and Z are anchored at two points in perpendicular directions off the structural member engagement assemblies 402 using horizontal and vertical cinching assemblies 404, 406. Structural member engagement assembly connectors 412 are disposed between the structural engagement assemblies 402 of timbers V and Z and further connect to a structural engagement assembly 410 as disposed in a bored-out cavity of timber X. The bored-out cavity of timber X also has a transverse hole housing a horizontal cinching assembly 404A. At the abutting faces of the structural members V, X, and Z, split rings 326 are inserted into circular insets in a similar fashion as the split rings 26 are so positioned as discussed above. In the embodiment shown in FIG. 14, structural members W and Y are connected to the T-shaped configuration of structural members V, X, and Z at varied angles using structural member engagement assemblies 408 disposed in bored-out cavities within the structural members W and Y. In assembly, the structural member engagement assemblies 408 connect to threaded ends of the vertical cinching assemblies 406, which are threaded cavities of the wedge connectors. The structural members W and Y further comprise transverse holes in which horizontal cinching assemblies 404B are disposed, which engage with structural member engagement assembly 408. Split rings 426 are also disposed between the abutting surfaces of structural members W and V, as well as structural members Y and Z. In this way, the structural member connector assembly 400 firmly connects the timbers V, W, X, Y, and Z at multiple angles for use, for example, in a tress assembly.

FIG. 14A shows the structural members V, W, X, Y, and Z connected using the concealed structural member connector assembly 400 wherein plugs 428 have been used to cover the transverse holes disposed on the structural members.

The above description is considered of preferred embodiments only. Modifications of the disclosed connector assembly will occur to those skilled in the art and to those who make or use the disclosed connector assembly. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the invention.

Claims

1. A connector assembly for connecting two or more structural members at joining surfaces, wherein each structural member includes a first hole extending into the structural member in a generally perpendicular manner relative to the joining surface of the structural member, and a second hole extending through the structural member which intersects the first hole in a generally perpendicular manner, the connector assembly comprising:

a plurality of structural member engagement assemblies wherein each structural member engagement assembly is adapted to be received in the first hole of a structural member, and further wherein each structural member engagement assembly includes wedged apertures adapted to align with the second hole extending through the structural member;

at least one adjustable coupling assembly adapted to couple adjacent structural member engagement assemblies; and

a plurality of cinching assemblies wherein each cinching assembly is operably coupled to a structural member engagement assembly and further wherein each cinching assembly is adapted to be received in the second hole of a structural member.

2. The connector assembly as set forth in claim 1, wherein:

the cinching assemblies comprise a set of wedge connectors adapted to engage the wedged apertures of the structural member engagement assemblies.

3. The connector assembly as set forth in claim 2, wherein:

the cinching assemblies further comprise a drive mechanism operably coupled to the wedge connectors.

4. The connector assembly as set forth in claim 3, wherein:

the set of wedge connectors comprises a first wedge connector and a second wedge connector, wherein the first and second wedge connectors have coupling portions and beveled domes with apertures disposed thereon.

5. The connector assembly as set forth in claim 4, wherein:

the aperture of the first wedge connector is a threaded aperture.

6. The connector assembly as set forth in claim 5, wherein:

the drive mechanism is a bolt that couples the second wedge connector, the wedged apertures of a structural member engagement assembly, and first wedge connector, wherein the bolt is adapted to threaded into the threaded aperture of the first wedge connector.

7. The connector assembly as set forth in claim 6, wherein:

the wedged apertures of the plurality of structural member engagement assemblies further comprise beveled edges having an inwardly extending angle, the beveled edges further including a distal beveled edge furthest from the joining surface of the structural member and a proximal beveled edge nearest the joining surface of the structural member.

8. The connector assembly as set forth in claim 7, wherein:

the drive mechanism is configured to thread to the bolt into the aperture of the first wedge connector such that the beveled domes of the first and second wedge connectors act against the distal beveled edges of the structural engagement assemblies thereby drawing the structural member towards an adjacent structural member.

9. The connector assembly as set forth in claim 1, wherein:

the plurality of structural member engagement assemblies are tube-like structures having hallow cavities.

10. The connector assembly as set forth in claim 1, wherein:

the structural members further comprise insets disposed around the first holes adapted to receive split rings.

11. The connector assembly as set forth in claim 1, wherein:

the connector assembly is adapted to connect structural members on centerlines of the structural members such that load bearing points are disposed on the centerlines of the structural members.

12. The connector assembly as set forth in claim 5, wherein:

the coupling portions of the first and second wedge connectors are internally threaded cylinders adapted to receive a structural member engagement assembly.

13. A connector assembly for connecting two or more structural members at joining surfaces, wherein each structural member includes a first hole extending into the structural member in a generally perpendicular manner relative to the joining surface of the structural member, and a second hole extending through the structural member which intersects the first hole in a generally perpendicular manner, the connector assembly comprising:

a plurality of structural member engagement assemblies configured to be received in the first holes of the structural members, the structural member engagement assemblies having apertures disposed thereon,

at least one adjustable coupling assembly adapted to couple adjacent structural member engagement assemblies; and

at least one cinching assembly operably coupled to any one of the plurality of structural member engagement assemblies and adapted to be received in the second holes of the structural members, wherein the at least one cinching assembly includes a pair of wedge connectors adapted to engage the apertures of the structural member engagement assemblies, wherein the at least one cinching assembly further includes a drive mechanism operably coupled to the wedge connectors for driving the wedge connectors laterally along the at least one cinching assembly.

14. The connector assembly as set forth in claim 13, wherein:

the set of wedge connectors comprises a first wedge connector and a second wedge connector, wherein the first and second wedge connectors have coupling portions and beveled domes with apertures disposed thereon.

15. The connector assembly as set forth in claim 14, wherein:

the aperture of the first wedge connector is a threaded aperture.

16. The connector assembly as set forth in claim 15, wherein:

the drive mechanism is a bolt that couples the second wedge connector, the wedged apertures of a structural member engagement assembly, and first wedge connector, wherein the bolt is adapted to threaded into the threaded aperture of the first wedge connector.

17. The connector assembly as set forth in claim 16, wherein:

the wedged apertures of the plurality of structural member engagement assemblies further comprise beveled edges having an inwardly extending angle, the beveled edges further including a distal beveled edge furthest from the joining surface of the structural member and a proximal beveled edge nearest the joining surface of the structural member.

18. The connector assembly as set forth in claim 17, wherein:

the drive mechanism is configured to thread to the bolt into the aperture of the first wedge connector such that the beveled domes of the first and second wedge connectors act against the distal beveled edges of the structural engagement assemblies thereby drawing the structural member towards an adjacent structural member.

19. A connector assembly for connecting two or more structural members together, the structural members having first holes extending into the structural member, second holes extending through the structural member intersecting the first holes in a generally perpendicular manner, and third holes extending through the structural member intersecting the first holes in a generally perpendicular manner, the connector assembly comprising:

a plurality of structural member engagement assemblies configured to be received in the first holes of the structural members, the structural member engagement assemblies having a plurality of apertures disposed thereon,

at least one adjustable coupling assembly adapted to couple adjacent structural member engagement assemblies; and

a plurality of cinching assemblies wherein any one cinching assembly of the plurality of cinching assemblies is adapted to be operably coupled to any one of the plurality of structural member engagement assemblies, the cinching assemblies adapted to be received in the second holes or the third holes of the structural members, wherein the at least one cinching assembly includes a pair of wedge connectors adapted to engage the plurality of apertures of the structural member engagement assemblies, wherein the plurality of cinching assemblies of the plurality of cinching assemblies further include a drive mechanism operably coupled to the wedge connectors for driving the wedge connectors laterally.

20. The connector assembly as set forth in claim 19, wherein:

the wedge connectors further comprise coupling portions adapted to receive a structural member engagement assembly.