CONNECTORS AND METHODS OF FABRICATING THE SAME

Abstract

A connector for coupling a first column segment having a first inner surface and a first end surface to a second column segment having a second inner surface and a second end surface such that the end surfaces are adjacent one another is provided. The connector includes a plurality of fasteners and a plurality of plates each having a front face, a rear face, and a plurality of fastener apertures extending from the front face toward the rear face. Each of the fastener apertures is sized to receive one of the fasteners when coupling the first column segment to the second column segment such that the plates are spaced apart from one another. Each of the front faces is contoured to seat flush against the first inner surface and the second inner surface when the plates span the adjacent end surfaces of the coupled-together column segments.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Non-Provisional application Ser. No. 15/044,910 filed on Feb. 16, 2016, which is incorporated by reference herein in its entirety.

BACKGROUND

The field of this disclosure relates generally to connectors and, more particularly, to a connector for use in coupling together tubular support members in a building frame.

Many known building structures have a frame that includes a plurality of beams and a plurality of columns. When erecting a taller (e.g., multistory) building, it is necessary to include columns that extend from the ground upwards for multiple stories. However, it can be difficult to transport full-length columns to the building site, and rather typically such columns are transported in segments that are ultimately welded together at the building site. However, depending on the completed height of the building structure, it may be difficult to assemble such columns at the building site. Moreover, assembling such columns at the building site by welding together the column segments can be time consuming and costly.

BRIEF DESCRIPTION

In one aspect, a connector for coupling a first column segment having a first inner surface and a first end surface to a second column segment having a second inner surface and a second end surface such that the end surfaces are adjacent one another is provided. The connector includes a plurality of fasteners and a plurality of plates each having a front face, a rear face, and a plurality of fastener apertures extending from the front face toward the rear face. Each of the fastener apertures is sized to receive one of the fasteners when coupling the first column segment to the second column segment such that the plates are spaced apart from one another. Each of the front faces is contoured to seat flush against the first inner surface and the second inner surface when the plates span the adjacent end surfaces of the coupled-together column segments.

In another aspect, a method of fabricating a connector for coupling a first column segment having a first inner surface and a first end surface to a second column segment having a second inner surface and a second end surface such that the end surfaces are adjacent one another is provided. The method includes forming a plurality of plates each with a front face, a rear face, and a plurality of fastener apertures extending from the front face toward the rear face. Each of the fastener apertures is sized to receive a fastener when coupling the first column segment to the second column segment such that the plates are spaced apart from one another. The method further includes forming each of the front faces with a contour that seats flush against the first inner surface and the second inner surface when the plates span the adjacent end surfaces of the coupled-together column segments.

In another aspect, a column for a moment-resisting frame is provided. The column includes a first hollow structural section (HSS) column segment having a first inner surface and a first end surface. The column also includes a second HSS column segment having a second inner surface and a second end surface. The column further includes a connector coupling the first HSS column segment to the second HSS column segment such that the end surfaces are adjacent one another. The connector includes a plurality of fasteners and a plurality of plates each having a front face, a rear face, and a plurality of fastener apertures extending from the front face toward the rear face. Each of the fastener apertures is sized to receive one of the fasteners when coupling the first HSS column segment to the second HSS column segment such that the plates are spaced apart from one another. Each of the front faces is contoured to seat flush against the first inner surface and the second inner surface when the plates span the adjacent end surfaces of the coupled-together HSS column segments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of a site at which an exemplary building frame is being erected;

FIG. 2 is an exploded view of an exemplary column that may be used in the frame shown in FIG. 1;

FIG. 3 is a perspective view of the column shown in FIG. 2 during a first stage of assembly;

FIG. 4 is a perspective view of the column shown in FIG. 2 during a second stage of assembly;

FIG. 5 is an exploded view of another exemplary column that may be used in the frame shown in FIG. 1;

FIG. 6 is a perspective view of the column shown in FIG. 5 after assembly; and

FIG. 7 is a schematic cross-sectional view of the assembled column shown in FIG. 6.

DETAILED DESCRIPTION

The following detailed description illustrates connectors and methods of fabricating the same by way of example and not by way of limitation. The description should enable one of ordinary skill in the art to make and use the connectors, and the description describes several embodiments of connectors, including what is presently believed to be the best modes of making and using the connectors. An exemplary connector is described herein as being used to couple together support members in a building frame. However, it is contemplated that the connector has general application to a broad range of systems in a variety of fields other than frames of buildings.

FIG. 1 is a schematic illustration of a site 100 at which an exemplary building frame 102 is being erected. In the exemplary embodiment, building frame 102 is a moment-resisting frame (e.g., a special moment frame or an intermediate moment frame) that includes a plurality of columns 104 and a plurality of beams 106. In some embodiments, columns 104 and beams 106 are fabricated from structural steel. In other embodiments, columns 104 and beams 106 may be fabricated from any other suitable material that facilitates enabling frame 102 to function as described herein.

In the exemplary embodiment, at least one column 104 of frame 102 includes a first column segment 108 and a second column segment 110 that are coupled together via a connector 112. More specifically, first column segment 108 has a first end 114 and a second end 116, and second column segment 110 similarly has a first end 118 and a second end 120. Column 104 is assembled onsite by coupling its associated first column segment 108 to its associated second column segment 110 at first end 114 and second end 120, respectively, using connector 112. Although first column segment 108 is illustrated as being coupled to a foundation 122 in the exemplary embodiment, first column segment 108 may not be coupled to foundation 122 in other embodiments (i.e., first column segment 108 may have any suitable position within frame 102, including a position that is elevated above foundation 122). Moreover, although second column segment 110 is illustrated as being lifted onto first column segment 108 using a crane 124 in the exemplary embodiment, second column segment 110 may be lifted onto first column segment 108 using any suitable method.

FIG. 2 is an exploded view of an exemplary column 200 that may be used in frame 102. Column 200 includes a first column segment 202, a second column segment 204, and a connector 206 for use in coupling first column segment 202 to second column segment 204. In the exemplary embodiment, each first column segment 202 and second column segment 204 is a hollow structural section (HSS). Alternatively, in some embodiments, first column segment 202 and/or second column segment 204 may be any suitable tubular column segment (e.g., at least one of first column segment 202 and second column segment 204 may not be a hollow structural section (HSS)). Moreover, in other embodiments, segments 202 and 204 may not be column segments, but may instead be another suitable type of tubular support member that is coupleable using connector 206, as described herein.

In the exemplary embodiment, first column segment 202 is defined by a pair of first side walls 208 and a pair of first end walls 210, each of which includes at least one first bolt hole 212 defined therein. First side walls 208 and first end walls 210 collectively define a first end surface 214 and a first inner surface 216 of first column segment 202. First inner surface 216 has a substantially rectangular cross-section at first end surface 214 (i.e., first inner surface 216 has four first inner corners 218 at first end surface 214, each first inner corner 218 being defined at the junction of a first side wall 208 and a first end wall 210). Likewise, in the exemplary embodiment, second column segment 204 has a pair of second side walls 220 and a pair of second end walls 222, each of which includes at least one second bolt hole 224 defined therein. Second side walls 220 and second end walls 222 collectively define a second end surface 226 and a second inner surface 228 of second column segment 204. Second inner surface 228 has a substantially rectangular cross-section at second end surface 226 (i.e., second inner surface 228 has four second inner corners 230 at second end surface 226, each second inner corner 230 being defined at the junction of a second side wall 220 and a second end wall 222). Notably, the substantially rectangular cross-section of first inner surface 216 at first end surface 214 is substantially the same size as the substantially rectangular cross-section of second inner surface 228 at second end surface 226. Although inner surfaces 216 and 228 of column segments 202 and 204, respectively, have cross-sections that are substantially rectangular and substantially the same size in the exemplary embodiment, inner surfaces 216 and 228 may have any suitable cross-sections in other embodiments. For example, at least one inner surface 216 and/or 228 may have a substantially square cross-section or a substantially circular cross-section, and/or inner surfaces 216 and 228 may not have cross-sections that are substantially the same size.

In the exemplary embodiment, connector 206 is a moment-resisting connector that includes a base (e.g., a flange 232), an insert 234, an actuator 236, and a housing 238 (shown in FIG. 4). Flange 232 has a pair of side segments 240 and a pair of end segments 242 that collectively define a top surface 243, a bottom surface 244, an inner surface 246, and an outer surface 248. Inner surface 246 forms a substantially rectangular central opening 250 (i.e., inner surface 246 has four inner corners 252, each inner corner 252 being defined at the junction of a side segment 240 and an end segment 242). Notably, opening 250 is substantially the same size as the substantially rectangular cross-section of first inner surface 216 of first column segment 202 and the substantially rectangular cross-section of second inner surface 228 of second column segment 204. Moreover, top surface 243 and bottom surface 244 extend outwardly from inner surface 246 to outer surface 248 such that outer surface 248 forms a substantially rectangular periphery of flange 232 (i.e., outer surface 248 has four outer corners 254, each outer corner 254 being defined at the junction of a side segment 240 and an end segment 242). In other embodiments, flange 232 and opening 250 may have any suitable shapes that facilitate enabling connector 206 to function as described herein (e.g., flange 232 and/or opening 250 may be substantially square or substantially circular in other embodiments). Alternatively, the base of connector 206 may not be in the form of flange 232, but may instead have any suitable shape that facilitates enabling connector 206 to function as described herein.

In the exemplary embodiment, insert 234 has a first plate 256 and a second plate 258 that, when positioned within opening 250 of flange 232, extend through opening 250 along a longitudinal axis 260 that is oriented substantially perpendicular to flange 232. As such, first plate 256 and second plate 258 define a pair of axial seams, namely a first seam 262 and a second seam 264. In other embodiments, insert 234 may have any suitable number of plates defining any suitable number of seams that facilitates enabling connector 206 to function as described herein (e.g., insert 234 may have four plates and four associated seams in other embodiments).

In the exemplary embodiment, first plate 256 includes a first side member 266 and a first end member 268 that are oriented substantially perpendicular to one another and adjoin one another at a first outer corner 270 such that first plate 256 has a substantially L-shaped cross-section. Notably, first side member 266 extends from first outer corner 270 to a first side edge 272, and first end member 268 extends from first outer corner 270 to a first end edge 274 such that first outer corner 270, first side edge 272, and first end edge 274 extend substantially parallel to axis 260. Moreover, first side member 266 has a plurality of first side bolt holes (e.g., an upper first side bolt hole 276 and a lower first side bolt hole 278), and first end member 268 has a plurality of first end bolt holes (e.g., an upper first end bolt hole 280 and a lower first end bolt hole 282). Likewise, second plate 258 includes a second side member 284 and a second end member 286 that are oriented substantially perpendicular to one another and adjoin one another at a second outer corner 288 such that second plate 258 has a substantially L-shaped cross-section. Notably, second side member 284 extends from second outer corner 288 to a second side edge 290, and second end member 286 extends from second outer corner 288 to a second end edge 292 such that second outer corner 288, second side edge 290, and second end edge 292 extend substantially parallel to axis 260. Moreover, second side member 284 has a plurality of second side bolt holes (e.g., an upper second side bolt hole 294 and a lower second side bolt hole 296), and second end member 286 has a plurality of second end bolt holes (e.g., an upper second end bolt hole 298 and a lower second end bolt hole 300). In other embodiments, first plate 256 and second plate 258 may have any suitable cross-sectional shapes that facilitate enabling connector 206 to function as described herein. For example, first plate 256 and second plate 258 may have an arcuate cross-section such that first plate 256 does not have first outer corner 270 and such that second plate 258 does not have second outer corner 288.

In the exemplary embodiment, first plate 256 and second plate 258 are substantially the same size and shape (e.g., first side member 266 is substantially the same size and shape as second side member 284, and first end member 268 is substantially the same size and shape as second end member 286). Moreover, first plate 256 and second plate 258 are oriented relative to one another such that first plate 256 and second plate 258 define a passage 302 along axis 260. More specifically, first plate 256 and second plate 258 are oriented such that first side member 266 opposes second side member 284, such that first end member 268 opposes second end member 286, and such that first outer corner 270 points away from second outer corner 288. Thus, first plate 256 and second plate 258 are spaced apart at seams 262 and 264 such that passage 302 has a substantially rectangular shape when viewed along axis 260. In other embodiments, plates 256 and 258 may have any suitable orientation relative to one another, and passage 302 may have any suitable shape that facilitates enabling connector 206 to function as described herein.

In the exemplary embodiment, plates 256 and 258 are positionable within opening 250 of flange 232 such that upper bolt holes 276, 280, 294, and 298 are above flange 232, and such that lower bolt holes 278, 282, 296, and 300 are below flange 232. Moreover, plates 256 and 258 are adjustably coupled to flange 232 by actuator 236 such that plates 256 and 258 are movable toward and away from axis 260 (and, therefore, one another) within opening 250 by operating actuator 236. Actuator 236 is a pin-type actuator (e.g., a threaded bolt or set screw) in the exemplary embodiment, and actuator 236 is extendable through an unthreaded bore 304 of flange 232, through a threaded bore 305 of first plate 256 at outer corner 270, across passage 302, through a threaded bore 307 of second plate 258 at outer corner 288, and into an unthreaded pivot slot 306 of flange 232 such that a grip 308 of actuator 236 (e.g., a bolt head) is accessible on the exterior of (or is external to) flange 232 at bore 304. Additionally, actuator 236 has a set of first threads 310 that engage first plate 256 at threaded bore 305 and are oriented in a first direction (i.e., right-handed threads), and actuator 236 also has a set of second threads 312 that engage second plate 258 at threaded bore 307 and are oriented in a second direction opposite the first direction (i.e., left-handed threads). Notably, actuator 236 is not threaded inside bore 304 or pivot slot 306, such that when grip 308 is turned clockwise, plates 256 and 258 move away from one another along actuator 236 such that seams 262 and 264 become wider and passage 302 becomes larger. Conversely, when grip 308 is turned counterclockwise, plates 256 and 258 move toward one another along actuator 236 such that seams 262 and 264 become narrower and passage 302 becomes smaller. In other embodiments, connector 206 may have any suitable type of actuator 236 that facilitates adjusting the position of plates 256 and 258 within opening 250 in the manner described herein.

In the exemplary embodiment, housing 238 (shown in FIG. 4) includes a first housing portion 314 and a second housing portion 316 that are sized to substantially enclose flange 232, actuator 236, and at least part of each plate 256 and 258 after plates 256 and 258 have been coupled to column segments 202 and 204, as set forth in more detail below. First housing portion 314 has a first tab 318 defining a plurality of first fastener apertures 320, and second housing portion 316 has a second tab 322 defining a plurality of second fastener apertures 324. First tab 318 and second tab 322 are oriented to seat against one another when first housing portion 314 is coupled to second housing portion 316. Moreover, first fastener apertures 320 are sized and spaced to align with second fastener apertures 324 when first tab 318 is seated against second tab 322, such that a plurality of fasteners 328 (e.g., bolts) can be inserted through aligned pairs of first and second fastener apertures 320 and 324 to fasten first housing portion 314 to second housing portion 316 via a plurality of associated nuts 329. In other embodiments, housing 238 may have any suitable number of portions that are coupled together in any suitable manner that facilitates enabling connector 206 to function as described herein.

FIG. 3 is a perspective view of column 200 during a first stage of assembly, and FIG. 4 is a perspective view of column 200 during a second stage of assembly. To assemble column 200 onsite when erecting frame 102, first column segment 202 is coupled to a suitable structure (e.g., foundation 122 or another support member of frame 102). Connector 206 is then seated on first column segment 202 by seating bottom surface 244 of flange 232 on first end surface 214 of first column segment 202, such that first plate 256 and second plate 258 of insert 234 are inserted into first column segment 202. More specifically, first plate 256 is inserted into first column segment 202 such that first side member 266 of first plate 256 is oriented substantially parallel with a first side wall 208 of first column segment 202 in spaced relation thereto, and such that first end member 268 of first plate 256 is oriented substantially parallel with a first end wall 210 of first column segment 202 in spaced relation thereto. Similarly, second plate 258 is inserted into first column segment 202 such that second side member 284 of second plate 258 is oriented substantially parallel with the other first side wall 208 of first column segment 202 in spaced relation thereto, and such that second end member 286 of second plate 258 is oriented substantially parallel with the other first end wall 210 of first column segment 202 in spaced relation thereto. Thus, lower first side bolt hole 278 and lower first end bolt hole 282 are each aligned with the first bolt hole 212 of its associated first side wall 208 and the first bolt hole 212 of its associated first end wall 210, respectively. Similarly, lower second side bolt hole 296 and lower second end bolt hole 300 are each aligned with the first bolt hole 212 of its associated first side wall 208 and the first bolt hole 212 of its associated first end wall 210, respectively.

After connector 206 is seated on first column segment 202, second column segment 204 is then lowered onto connector 206 using crane 124 such that first plate 256 and second plate 258 are inserted into second column segment 204 and such that second end surface 226 of second column segment 204 is seated on top surface 243 of flange 232. More specifically, first plate 256 is inserted into second column segment 204 such that first side member 266 of first plate 256 is oriented substantially parallel with a second side wall 220 of second column segment 204 in spaced relation thereto, and such that first end member 268 of first plate 256 is oriented substantially parallel with a second end wall 222 of second column segment 204 in spaced relation thereto. Similarly, second plate 258 is inserted into second column segment 204 such that second side member 284 of second plate 258 is oriented substantially parallel with the other second side wall 220 of second column segment 204 in spaced relation thereto, and such that second end member 286 of second plate 258 is oriented substantially parallel with the other second end wall 222 of second column segment 204 in spaced relation thereto. Thus, upper first side bolt hole 276 and upper first end bolt hole 280 are each aligned with the second bolt hole 224 of its associated second side wall 220 and the second bolt hole 224 of its associated second end wall 222, respectively. Similarly, upper second side bolt hole 294 and upper second end bolt hole 298 are each aligned with the second bolt hole 224 of its associated second side wall 220 and the second bolt hole 224 of its associated second end wall 222, respectively.

With second column segment 204 seated on connector 206, grip 308 of actuator 236 is then turned clockwise (e.g., via a wrench or suitable power tool) such that first threads 310 drive first plate 256 away from second plate 258 to seat first side member 266 and first end member 268 of first plate 256 against first column segment 202 and second column segment 204. Conversely, second threads 312 drive second plate 258 away from first plate 256 to seat second side member 284 and second end member 286 of second plate 258 against first column segment 202 and second column segment 204. A plurality of fasteners (e.g., bolts 330 such as, for example, blind bolts) are then inserted into first bolt holes 212 to engage first plate 256 via bolt holes 278 and 282, and to engage second plate 258 via bolt holes 296 and 300. A plurality of bolts 330 are then inserted into second bolt holes 224 to engage first plate 256 via bolt holes 276 and 280, and to engage second plate 258 via bolt holes 294 and 298. Upon tightening bolts 330, first plate 256 and second plate 258 are prevented from moving along actuator 236 (even though plates 256 and 258 are movably coupled to actuator 236), and axial movement of first column segment 202 relative to second column segment 204 is also prevented. After bolts 330 are tightened, first housing portion 314 and second housing portion 316 are then seated on flange 232 such that first tab 318 and second tab 322 are seated against one another. Fasteners 328 are then inserted into the aligned first fastener apertures 320 and second fastener apertures 324 to couple with nuts 329 and fasten first housing portion 314 to second housing portion 316 such that housing 238 completely encloses flange 232, actuator 236, and bolts 330.

FIG. 5 is an exploded view of another exemplary column 400 that may be used in frame 102. In the exemplary embodiment, column 400 includes a first column segment 402, a second column segment 404, and a connector 406 for coupling first column segment 402 to second column segment 404. Although each first column segment 402 and second column segment 404 is a hollow structural section (HSS) in the exemplary embodiment, column segments 402 and/or 404 may be any suitable tubular column segment (e.g., column segments 402 and/or 404 may not be a hollow structural sections (HSS)). Alternatively, segments 402 and 404 may be any suitable type of tubular support member between which connector 406 is useful.

In the exemplary embodiment, first column segment 402 has first side walls 408 and first end walls 410, and each wall 408 and 410 has at least one first bolt hole 412. Walls 408 and 410 collectively define a first end surface 414 and a first inner surface 416 of first column segment 402. In that regard, first inner surface 416 has a substantially rectangular cross-section at first end surface 414. More specifically, first inner surface 416 has four first inner corners 418 at first end surface 414, and each first inner corner 418 is defined at the junction of a first side wall 408 and a first end wall 410. In other embodiments, first column segment 402 may have any suitable number of walls oriented in any suitable manner such that first inner surface 416 has any suitable cross-sectional shape at first end surface 414. For example, first column segment 402 may be shaped such that first inner surface 416 has a substantially square or round (e.g., substantially circular) cross-sectional shape at first end surface 414.

In the exemplary embodiment, second column segment 404 has a pair of second side walls 420 and a pair of second end walls 422, and each wall 420 and 422 has at least one second bolt hole 424. Walls 420 and 422 collectively define a second end surface 426 and a second inner surface 428 (shown in FIG. 7) of second column segment 404. In that regard, second inner surface 428 has a substantially rectangular cross-section at second end surface 426. More specifically, second inner surface 428 has four second inner corners (not shown) at second end surface 426, and each second inner corner is defined at the junction of a second side wall 420 and a second end wall 422. The substantially rectangular cross-section of second inner surface 428 at second end surface 426 is substantially the same as the substantially rectangular cross-section of first inner surface 416 at first end surface 414. In other embodiments, second column segment 404 may have any suitable number of walls oriented in any suitable manner such that second inner surface 428 has any suitable cross-sectional shape at second end surface 426. For example, second column segment 404 may be shaped such that second inner surface 428 has a substantially square or round (e.g., substantially circular) cross-sectional shape at second end surface 426.

In the exemplary embodiment, connector 406 is a moment-resisting connector that includes an insert 434 having a plurality of plates, namely a first plate 456, a second plate 458, a third plate 460, and a fourth plate 462. In other embodiments, insert 434 may have any suitable number of plates that facilitates enabling connector 406 to function as described herein (e.g., insert 434 may have only two or three plates in some embodiments, or insert 434 may have five or six plates in other embodiments). In the exemplary embodiment, each plate 456, 458, 460, and 462 has a front face 461, a rear face 463, top edge 464, a bottom edge 466, and a pair of side edges 468 (i.e., a first side edge 469 and a second side edge 471) that are longer than edges 464 and 466, such that front face 461 and rear face 463 have a substantially rectangular planform shape. In other embodiments, each plate 456, 458, 460, and 462 may have any suitable shape (e.g., faces 461 and/or 463 may have a square shape, a triangular shape, an elliptical shape, or an amorphous planform shape). As such, each plate 456, 458, 460, and 462 may have any suitable number of edges arranged in any suitable manner in other embodiments.

In the exemplary embodiment, each respective plate 456, 458, 460, and 462 is a substantially flat body. More specifically, in the exemplary embodiment, each respective plate 456, 458, 460, and 462 has an end profile 465 and a side profile 467 that are substantially linear (i.e., profiles 465 and 467 are not bent or otherwise curved in the exemplary embodiment). In other embodiments, profiles 465 and/or 467 of plates 456, 458, 460, and 462 may have any suitable curvature that facilitates enabling plates 456, 458, 460, and 462 to function as described herein (e.g., end profile 465 of plates 456, 458, 460, and/or 462 may not be substantially linear but, rather, may be at least in part bent or otherwise curved). For example, if first column segment 402 and/or second column segment 404 has a round cross-section, then end profile 465 of at least one plate 456, 458, 460, and 462 may have a curvature that substantially mirrors the curvature of first column segment 402 and/or second column segment 404 to facilitate seating plate(s) 456, 458, 460, and/or 462 flush against inner surfaces 416 and/or 428 of first column segment 402 and/or second column segment 404, respectively, as set forth in more detail below.

Although plates 456, 458, 460, and 462 are substantially identical to one another (e.g., have substantially identical shapes) in the exemplary embodiment, at least two plates 456, 458, 460, and/or 462 may not be substantially identical in other embodiments (e.g., at least two plates 456, 458, 460 and/or 462 may have different side profiles 467 and/or end profiles 465 in some embodiments). For example, in one embodiment, at least one plate 456, 458, 460, and/or 462 may have a rectangular planform shape, while at least one other plate 456, 458, 460, and/or 462 may have an elliptical planform shape. Alternatively, in another embodiment, at least one plate 456, 458, 460, and/or 462 may have a profile 465 and/or 467 that is linear, while another plate 456, 458, 460, and/or 462 may have a profile 465 and/or 467 that is at least in part curved. Moreover, although plates 456, 458, 460, and 462 are separate from one another (i.e., are not integrally formed together or coupled together) in the exemplary embodiment, at least a pair of plates 456, 458, 460, and 462 may be integrally formed together in some embodiments, or may be formed separately from one another (and suitably coupled together) in other embodiments.

In the exemplary embodiment, each plate 456, 458, 460, and 462 has an upper region 470, a lower region 472, and an intermediate region 474 between upper region 470 and lower region 472. Intermediate region 474 extends from first side edge 469 to second side edge 471 between upper region 470 and lower region 472. Upper region 470 has at least one upper bolt hole 475, lower region 472 has at least one lower bolt hole 477, and intermediate region 474 does not have any bolt holes. Although upper region 470 and lower region 472 are illustrated as each having four bolt holes arranged in a square-shaped formation, upper region 470 and lower region 472 may have any suitable number of holes arranged in any suitable manner and sized to receive any suitable type of fastener. Although intermediate region 474 is illustrated as not having any bolt holes, intermediate region 474 may have at least one bolt hole (not shown) (or other suitable fastener aperture) in other embodiments. Moreover, although plates 456, 458, 460, and 462 are illustrated as all having the same number of bolt holes 475 and 477 arranged in the same square-shaped formation in the exemplary embodiment, at least two plates 456, 458, 460, and/or 462 may have a comparatively different number and/or arrangement of bolt holes 475 and/or 477 in other embodiments.

In the exemplary embodiment, column 400 is assembled by initially coupling plates 456, 458, 460, and/or 462 to first column segment 402. More specifically, first plate 456 is inserted into first column segment 402 adjacent one of the side walls 408 such that lower bolt holes 477 of first plate 456 are aligned with first bolt holes 412 of the first side wall 408. A bolt 478 is then inserted through each first bolt hole 412 and into the lower bolt hole 477 aligned therewith, such that the first plate 456 engages bolts 478 at lower bolt holes 477. When bolts 478 are rotated, first plate 456 functions as a nut for each bolt 478, such that bolts 478 pull first plate 456 toward the side wall 408 until first plate 456 is seated firmly and flush against first inner surface 416. Second, third, and fourth plates 458, 460, and 462 are coupled to the other first side wall 408 and the first end walls 410, respectively, in a similar manner (i.e., firmly and flush against first inner surface 416) using bolts 478. In some embodiments, plates 456, 458, 460, and/or 462 may not function as nuts that engage their respective bolts 478 but, rather, each such bolt 478 may be provided with its own separate nut (not shown), such that plates 456, 458, 460, and/or 462 do not engage their respective bolts 478. In other embodiments, bolts 478 may not need to be rotated to pull plates 456, 458, 460, and/or 462 into contact with walls 408 and 410 but, rather, plates 456, 458, 460, and 462 may instead be seated against their respective walls 408 and 410 with bolt holes 412 and 477 aligned, and a suitable fastener (e.g., a blind bolt) may then be inserted through each aligned pair of holes 412 and 477 to retain plates 456, 458, 460, and 462 in contact with walls 408 and 410.

With plates 456, 458, 460, and 462 coupled to first column segment 402 in the manner set forth above, intermediate regions 474 of plates are aligned with first end surface 414 of first column segment 402 along a longitudinal axis 401 (shown in FIG. 7) of first column segment 402, such that upper regions 470 of plates 456, 458, 460, and 462 project from first end surface 414 in spaced-apart relation. More specifically, second side edge 471 of first plate 456 projects from first end surface 414 and is spaced apart from, and oriented substantially parallel with, first side edge 469 of second plate 458. Second side edge 471 of second plate 458 projects from first end surface 414 and is spaced apart from, and oriented substantially parallel with, first side edge 469 of third plate 460. Second side edge 471 of third plate 460 projects from first end surface 414 and is spaced apart from, and oriented substantially parallel with, first side edge 469 of fourth plate 462. Second side edge 471 of fourth plate 462 projects from first end surface 414 and is spaced apart from, and oriented substantially parallel with, first side edge 469 of first plate 456. As such, top edges 464 of plates 456, 458, 460, and 462 are oriented along a substantially common plane (not shown) (i.e., are substantially coplanar) and are spaced apart from first end surface 414 along longitudinal axis 401 of first column segment 402.

In other embodiments, plates 456, 458, 460, and 462 may have any suitable orientation and spacing relative to one another that facilitates enabling connector 406 to function as described herein. For example, in one embodiment, second side edge 471 of first plate 456, and first side edge 469 of second plate 458, may be either integrally formed together, or suitably coupled together, such that first plate 456 and second plate 458 are oriented substantially perpendicular to one another to collectively define a first substantially L-shaped plate (not shown), much like plate 256 above, that seats against first inner surface 416. Likewise, in another embodiment, second side edge 471 of third plate 460 and first side edge 469 of fourth plate 462 may be either integrally formed together, or suitably coupled together, such that third plate 460 and fourth plate 462 are oriented substantially perpendicular to one another to collectively define a second substantially L-shaped plate (not shown), much like plate 258 above, that also seats against first inner surface 416. In such an embodiment, second side edge 471 of fourth plate 462 is spaced apart from, and oriented substantially parallel with, first side edge 469 of first plate 456, and second side edge 471 of second plate 458 is spaced apart from, and oriented substantially parallel with, first side edge 469 of third plate 460. Other arrangements and combinations of plates 456, 458, 460, and 462 are also contemplated without departing from the scope of this invention.

After plates 456, 458, 460, and 462 have been coupled to first column segment 402 in the manner set forth above, plates 456, 458, 460, and 462 are then inserted into second column segment 404 such that second end surface 426 is adjacent (e.g., abuts) first end surface 414. With upper bolt holes 475 aligned with the second bolt holes 424 of their respective walls 420 and 422, bolts 478 are then inserted into aligned pairs of holes 424 and 475 to couple plates 456, 458, 460, and 462 to second column segment 404 such that plates 456, 458, 460, and 462 are seated firmly and flush against second inner surface 428. In this manner, plates 456, 458, 460, and 462 are seated firmly and flush against first column segment 402 and second column segment 404 as they span first end surface 414 and second end surface 426. FIG. 6 is a perspective view of column 400 in its assembled configuration (with only first plate 456 and fourth plate 462 being visible in hidden lines), and FIG. 7 is a schematic cross-sectional view of column 400 in its assembled configuration (with only first plate 456 and third plate 460 visible). In other embodiments, connector 406 may have at least one plate (or other suitable housing structure) (not shown) that is coupled external to first column segment 402 and second column 404 firmly and flush across first end surface 414 and second end surface 426 in lieu of, or in addition to, plates 456, 458, 460, and 462 being coupled internal to first column segment 402 and second column segment 404 firmly and flush across first end surface 414 and second end surface 426.

Notably, in the exemplary embodiment, connector 406 provides a strictly mechanical connection of first column segment 402 to second column segment 404 (i.e., connector 406 does not have a welded joint, or otherwise does not require welding in the field in order to couple first column segment 402 to second column segment 404). Moreover, in the exemplary embodiment, no structure(s) other than plates 456, 458, 460, and 462 and bolts 478 are used to couple first column segment 402 to second column segment 404. In other embodiments, connector 406 may have a welded joint, and/or may require welding in the field in order to couple first column segment 402 to second column segment 404).

The methods and systems described herein facilitate erecting a moment-resisting frame at a building site. More specifically, the methods and systems facilitate coupling HSS column segments together onsite using a connector that is not welded to the HSS column segments. The methods and systems thereby facilitate eliminating the time that would otherwise be required to weld column segments to one another and/or to the connector. As such, the methods and systems facilitate transporting longer columns to a building site in segments and assembling the columns at the building site by coupling the associated column segments together using a moment-resisting connector that is strictly mechanical in nature. As such, the methods and systems facilitate reducing the time and cost associated with erecting a multistory, moment-resisting frame at a building site.

Exemplary embodiments of connectors and methods of fabricating the same are described above in detail. The methods and systems described herein are not limited to the specific embodiments described herein, but rather, components of the methods and systems may be utilized independently and separately from other components described herein. For example, the methods and systems described herein may have other applications not limited to practice with frames of buildings, as described herein. Rather, the methods and systems described herein can be implemented and utilized in connection with various other industries.

While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.

Claims

1. A connector for coupling a first column segment having a first inner surface and a first end surface to a second column segment having a second inner surface and a second end surface such that the end surfaces are adjacent one another, said connector comprising:

a plurality of fasteners; and

a plurality of plates each comprising a front face, a rear face, and a plurality of fastener apertures extending from said front face toward said rear face, wherein each of said fastener apertures is sized to receive one of said fasteners when coupling the first column segment to the second column segment such that said plates are spaced apart from one another, and wherein each of said front faces is contoured to seat flush against said first inner surface and said second inner surface when said plates span the adjacent end surfaces of the coupled-together column segments.

2. A connector in accordance with claim 1, wherein said connector is a moment-resisting connector.

3. A connector in accordance with claim 1, wherein said front face and said rear face of each plate has a substantially rectangular planform shape.

4. A connector in accordance with claim 3, wherein each of said plates is a substantially flat body.

5. A connector in accordance with claim 1, wherein said plates are substantially identical.

6. A connector in accordance with claim 1, wherein said plurality of plates comprises at least four plates.

7. A method of fabricating a connector for coupling a first column segment having a first inner surface and a first end surface to a second column segment having a second inner surface and a second end surface such that the end surfaces are adjacent one another, said method comprising:

forming a plurality of plates each with a front face, a rear face, and a plurality of fastener apertures extending from the front face toward the rear face, wherein each of the fastener apertures is sized to receive a fastener when coupling the first column segment to the second column segment such that the plates are spaced apart from one another; and

forming each of the front faces with a contour that seats flush against the first inner surface and the second inner surface when the plates span the adjacent end surfaces of the coupled-together column segments.

8. A method in accordance with claim 7, further comprising forming the connector as a moment-resisting connector.

9. A method in accordance with claim 7, further comprising forming the front face and the rear face of each plate to have a substantially rectangular planform shape.

10. A method in accordance with claim 9, further comprising forming each of the plates as a substantially flat body.

11. A method in accordance with claim 7, further comprising forming the plates to be substantially identical.

12. A method in accordance with claim 7, further comprising forming at least four plates.

13. A column for a moment-resisting frame, said column comprising:

a first hollow structural section (HSS) column segment comprising a first inner surface and a first end surface;

a second HSS column segment comprising a second inner surface and a second end surface; and

a connector coupling said first HSS column segment to said second HSS column segment such that said end surfaces are adjacent one another, wherein said connector comprises: a plurality of fasteners; and a plurality of plates each comprising a front face, a rear face, and a plurality of fastener apertures extending from said front face toward said rear face, wherein each of said fastener apertures is sized to receive one of said fasteners when coupling said first HSS column segment to said second HSS column segment such that said plates are spaced apart from one another, and wherein each of said front faces is contoured to seat flush against said first inner surface and said second inner surface when said plates span said adjacent end surfaces of said coupled-together HSS column segments.

14. A column in accordance with claim 13, wherein said connector is a moment-resisting connector.

15. A column in accordance with claim 13, wherein said front face and said rear face of each plate has a substantially rectangular planform shape.

16. A column in accordance with claim 15, wherein each of said plates is a substantially flat body.

17. A column in accordance with claim 13, wherein said plates are substantially identical.

18. A column in accordance with claim 13, wherein said plurality of plates comprises at least four plates.

19. A column in accordance with claim 13, wherein each of said first HSS column segment and said second HSS column segment is fabricated from structural steel.

20. A column in accordance with claim 19, wherein said connector is coupled to said first column segment and said second column segment without welding said connector to said first column segment or said second column segment.