US20170159284A1

US20170159284A1 - Systems and methods for interlocking brackets

Info

Publication number: US20170159284A1
Application number: US15/372,335
Authority: US
Inventors: Jeffrey Getz
Original assignee: Farm Boy Builder LLC
Current assignee: Farm Boy Builder LLC
Priority date: 2015-12-07
Filing date: 2016-12-07
Publication date: 2017-06-08

Abstract

A framing assembly is disclosed comprising a bracket. The bracket comprises a first bracket section in communication with a second bracket section in orthogonal relation relative to the first bracket section. The first and second bracket sections comprise opposing flanges. The bracket further comprises first and second slots. The framing assembly further comprises a framing component. The framing component comprises a framing component middle portion, opposing framing component flanges defined along the framing component middle portion, and opposing framing component returns extending from the opposing framing component flanges, collectively defining a framing component interior portion. The first or second bracket section slidably engages within the framing component interior portion. The opposing framing component returns are received through the first and second slots of the bracket. The first or second bracket section may be slidably positioned at to predetermined location along the framing component within the framing component interior portion.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This is a non-provisional application that claims benefit to U.S. provisional application Ser. No. 62/264,142 filed on Dec. 7, 2015, U.S. provisional application Ser. No. 62/280,190 filed on Jan. 19, 2016, and U.S. provisional application Ser. No. 62/322,599 filed on Apr. 14, 2016, which are herein incorporated by reference in their entirety.

FIELD

The present disclosure generally relates to systems and methods for interlocking brackets; and in particular, to systems and methods of manufacturing and configuring specialized interlocking brackets for a framing assembly.

BACKGROUND

Conventional framing assemblies and systems are complicated, burdensome, and difficult to deploy on-site and have consequently failed to satisfy the needs of users in the construction and general framing industries. For example, conventional framing assemblies often require structural connections to be made to an open side, external side, or outside portion of a joist or stud which may require additional connecting components or sleeves and which can move the connecting point outside the edges of a connecting joist. One particular conventional framing assembly involves sleeves or tracks that attach to the outside of the joist and are implemented to connect adjacent joists. The attachment of tracks or sleeves on the outside of the joist creates an elevated component which can be detected and can lead to framing complications. Additional tedious manufacturing steps may need to be implemented when dealing with an elevated portion of a framing assembly which is time consuming and reduces the speed and efficiency of construction.
It is with these observations in mind, among others, that various aspects of the present disclosure were conceived and developed.

SUMMARY

A need exists for an improved framing assembly and methods of making the same. Accordingly, one embodiment of the present disclosure may take the form of a making of manufacturing a framing assembly comprising the steps of forming a framing component comprising: a framing component middle portion, a first framing component flange defined along a first side of the framing component middle portion, a first return defined along the first framing component flange, a second framing component flange defined along a second side of the framing component middle portion opposite the first framing component flange, and a second return defined along the second framing component flange with the second return in opposite orientation relative to the first return, wherein a framing component interior portion is defined collectively by the framing component middle portion, the first framing component flange, the second framing component flange, the first return, and the second return; and forming a bracket comprising: a first bracket section in communication with a second bracket section with a bracket bend defined between the first bracket section and the second bracket section, the first bracket section aligned in perpendicular relation relative to the second bracket section, wherein the first bracket section comprises a first bracket middle portion, a first bracket flange defined along a first side of the first bracket middle portion, and a second bracket flange defined along a second side of the first bracket middle portion opposite the first bracket flange, wherein the second bracket section comprises a second bracket middle portion, a third bracket flange defined along a first side of the second bracket middle portion, and a fourth bracket flange defined along a second side of the second bracket middle portion opposite the third bracket flange, a first slot defined along the first side of the first bracket middle portion, and a second slot defined along the second side of the first bracket middle portion opposite the first side, engaging the second bracket section within the framing component interior portion such that the first slot receives the first return and the second slot receives the second return.
Another implementation of the present disclosure may take the form of a method of making a framing assembly comprising forming a bracket defining a first bracket section and a second bracket section in perpendicular relation relative to the second bracket section; forming a first slot defined at a first side of the first bracket section; forming a second slot defined at a second side of the first bracket section opposite the first side; and providing a framing component, the framing component comprising a framing component middle portion, opposing framing component flanges defined along opposite sides of the framing component middle portion, and opposing framing component returns extending from the opposing framing component flanges collectively defining a framing component interior portion; and disposing the second bracket section within the framing component interior portion with the opposing framing component returns received within the first slot and second slot.
Yet another implementation of the present disclosure may take the form of a framing assembly comprising a bracket, comprising: a first bracket section and a second bracket section in communication with the first bracket section, the first bracket section aligned in perpendicular relation relative to the second bracket section; a first slot defined at a first side of the first bracket section; and a second slot defined at a second side of the first bracket section opposite the first side.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features, and advantages of the present disclosure set forth herein should be apparent from the following description of particular embodiments of those inventive concepts, as illustrated in the accompanying drawings. Also, in the drawings the like reference characters refer to the same parts throughout the different views. The drawings depict only typical embodiments of the present disclosure and, therefore, are not to be considered limiting in scope.

FIG. 1 is an exploded view of a framing assembly comprising a plurality of joists, brackets, and end rails, according to aspects of the present disclosure.

FIG. 2 is a perspective view of the framing assembly of FIG. 1 in an assembled state, according to aspects of the present disclosure.

FIG. 3A is a perspective view of a bracket for use with a framing assembly, according to aspects of the present disclosure.

FIG. 3B is a top plan view of the bracket of FIG. 3A in a preconfigured flattened state during an initial stage of manufacturing, according to aspects of the present disclosure.

FIGS. 4A-4B are perspective views of the bracket shown in FIG. 3A being engaged or coupled to an end rail as part of the framing assembly, according to aspects of the present disclosure.

FIG. 5A-5B are perspective views of the bracket shown in FIG. 3A being engaged or coupled to a joist as part of the framing assembly, according to aspects of the present disclosure.

FIGS. 6A-6C illustrate different configurations of mechanically coupling the bracket of FIG. 3A with the end rail of FIGS. 4A-4B and with the joist of FIGS. 5A-5B, according to aspects of the present disclosure.

FIG. 7 is a perspective view of another embodiment of the bracket with differently configured slots, according to aspects of the present disclosure.

FIG. 8 is a perspective view of another embodiment of the bracket with a bendable bracket section, according to aspects of the present disclosure.

FIG. 9 is a perspective view of another embodiment of the bracket with returns, according to aspects of the present disclosure.

FIGS. 10A-10B are perspective views of another embodiment of the bracket with slots to facilitate bending of the bracket, according to aspects of the present disclosure.

FIGS. 11A-11B are perspective views of another embodiment of the bracket with a skewable bracket section, according to aspects of the present disclosure.

FIG. 12 is an exploded view of another embodiment of the framing assembly, according to aspects of the present disclosure.

FIGS. 13A-13B are various views of another embodiment of the bracket for the framing assembly, according to aspects of the present disclosure.

FIGS. 14A-14B are various views of another embodiment of the bracket for use with the framing assembly, according to aspects of the present disclosure.

FIG. 15 is a top plan view of another embodiment of the bracket for use with the framing assembly, according to aspects of the present disclosure.

FIG. 16 is a top plan view of another embodiment of the bracket for use with the framing assembly, according to aspects of the present disclosure.

FIG. 17A-17B are various views that illustrate greater detail regarding the implementation of inserts, according to aspects of the present disclosure.

FIGS. 18A-18E are side views of the bracket mechanically coupled to an end rail or joist, according to aspects of the present disclosure.

Corresponding reference characters indicate corresponding elements among the view of the drawings. The headings used in the figures do not limit the scope of the claims.

DETAILED DESCRIPTION

Aspects of the present disclosure involve a modular framing assembly comprising a plurality of framing components such as brackets, joists, end rails, inserts, and the like. The joists and end rails may each comprise a respective web or middle portion defined between opposing flanges. In some embodiments, returns extend from the opposing flanges of the joists and end rails such that the joists and end rails may define a generally C-shape configuration. The opposing flanges and the middle portion of each of the joists define a joist interior portion. The opposing flanges and middle portion of each of the end rails define an end rail interior portion. The brackets disclosed herein may be implemented to connect the end rails and the joists to form the framing assembly. In some embodiments, the brackets may include one or more bracket bends defining different bracket sections aligned along various orientations, such as a first bracket section in perpendicular orientation relative to a second bracket section. Contrary to conventional framing assemblies, the brackets disclosed herein mechanically connect components of the framing assembly from the interior side. More specifically, in some embodiments, the first bracket section or the second bracket section of each bracket may slidably engage within the joist interior portion defined by the joist as described herein. Similarly, the second bracket section or the first bracket section of each bracket may slidably engage within the end rail interior portion defined by the end rail as described herein. In some embodiments, the brackets may comprise first and second slots or notches to facilitate engagement with the flanges and returns of the end rails and joists respectively, and maintain the framing assembly in place during assembly.
The inserts of the framing assembly may be formed similar to the brackets and may be used to connect adjacent joists as well as connect adjacent end rails to extend the length or width of the framing assembly described herein. Utilizing the inserts as described herein, the joists and end rails may be fabricated with a reduced size which assists with the construction and transportation of the framing assembly. The inserts may further be utilized to cover the openings between the returns and flanges of the end rails and joists.
In one embodiment, the components of the framing assembly are mechanically coupled together and held in place by gravity and friction such that free hands may be used to mechanically fasten the components of the framing assembly together. For example, the brackets may be fabricated with a size slightly smaller than the size of the joists so that e.g. the first bracket section or second bracket section may fit snug within the joist interior portion of the joist or the end rail interior portion of the end rail. Because the components can be held in place and attached together with minimal or no amount of tools, the disclosed framing assembly is both easier and quicker to build.
According to aspects of the present disclosure, the framing assembly components, e.g., one or more of the plurality of joists, end rails, inserts, and brackets may be made from a metal such as steel, aluminum, plastic, fiberglass, carbon fiber, or other composite materials. In one particular embodiment, the aforementioned components may comprise steel. Steel framing is an ideal construction choice due to its various advantages over common lumber. For example, steel retains its rigidity, straightness and also resists warping. Steel is also stronger than lumber, lightweight, recyclable, and renewable and can be protected against the elements using galvanization and coatings. Further, steel is versatile as it can be bent and manipulated to different orientations and shapes depending on the particular application. The aforementioned components of the framing assembly may further have at least one coating for treating and/or preparing the components which may be applied prior to, during, and/or after assembly of the framing assembly.
In some embodiments, the brackets of the framing assembly may comprise flanges that are skewable. For example, the bracket flanges may have a predetermined degree of flex capability, and can temporarily bend inwards (or outwards) to allow the flanges of the brackets to fit inside e.g. interior portions of a joist or end rail. In some embodiments, the flanges of the brackets may further define angular slits to facilitate bending of the first or second bracket sections. In addition, the flanges of the brackets may be bent with respect to a bracket middle portion at predetermined angles corresponding to different sized joists or end rails. The brackets may further include flanges that can be bent at predetermined slotted locations so that the bracket and bracket flanges are suitable for engagement with a variety of different sized joists or end rails. The slotted locations may assist a builder of the framing assembly with the manipulation and bending of the skewable bracket flanges.
The disclosed framing assembly may be utilized for a variety of different applications. As one example, the framing assembly may be used for providing a deck and disposing a deck cover over the framing assembly. The framing assembly may further be utilized as part of a temporary or permanent pool cover. The framing assembly may further be utilized for more general construction applications such as building a wall, floor, or a roof.
Ultimately, the disclosed framing assembly may assist the average homeowner or handyman to be able to build a frame or framing assembly. The described framing assembly lowers the expertise level needed and time requirements for assembly to a level below a normal contracting expert such as a common handyman or even a novice homeowner. The disclosed framing assembly provides a reduced build time, is easier to use, more adaptable to different structures or applications, and provides a more accurate frame. The framing assembly may further involve smaller, more modular components and connectors which can be shipped more easily to and from different locations—in sharp contrast to the larger components implemented with conventional framing assemblies which are often required to be cut prior to shipping or require special shipping arrangements.
Referring to FIGS. 1 and 2, in some embodiments the framing assembly 100 may comprise a plurality of framing components that are mechanically coupled to one another to form the framing assembly 100 as disclosed herein. Specifically, the framing assembly 100 comprises framing components such as a plurality of brackets 102 that are used to mechanically couple other framing components, such as joists 104 and end rails 106 to manufacture the framing assembly 100. In some embodiments, the joists 104 extend from a first side 110 of the framing assembly 100 to a second side 112 of the framing assembly 100 and define an overall width of the framing assembly 100, while the end rails 106 extend from a third side 114 of the framing assembly 100 to a fourth side 116 of the framing assembly 100 and define an overall length of the framing assembly 100. The framing assembly 100 is not limited to the aforementioned framing components disclosed herein and additional framing components are contemplated to assemble the framing assembly 100.
Referring to FIGS. 3A-3B one embodiment of a bracket 102 may include a bracket bend 118 defined between a first bracket section 120 and a second bracket section 140. In the embodiment shown, the bracket bend 118 may define a substantially 90 degree bend such that the first bracket section 120 extends along a first axis X1 and the second bracket section 140 extends along a second axis X2 with the first axis X1 intersecting the second axis X2 orthogonally or at a substantially right angle. The bracket 102 further comprises a bracket peripheral end 150 defined by the first bracket section 120 and a bracket peripheral end 158 defined by the second bracket section 140.
The first bracket section 120 comprises a bracket middle portion 122 defining an interior surface 122 a and an exterior surface 122 b. As shown, opposing flanges 124 and 126 extend from the bracket middle portion 122 such that the bracket middle portion 122 and the opposing flanges 124 and 126 of the first bracket section 120 collectively define a generally U-shape configuration. As shown, the flange 124 is defined on a first side of the bracket middle portion 122 and defines an interior surface 124 a and an exterior surface 124 b. The flange 126 is defined on a second side of the bracket middle portion 122 opposite the flange 124 and the flange 126 defines an interior surface 126 a and an exterior surface 126 b. In some embodiments, the flanges 124 and 126 define a width in the range of 1 to 3 inches and the bracket middle portion 122 defines a length/height in the range of 3 to 9 inches. However, it should be understood that the dimensions of the bracket middle portion 122 and the flanges 124 and 126 of the first bracket section 120 may vary depending on the particular application of the bracket 102. The first bracket section 120 may further include at least one aperture 119 a configured to receive a securing member 121 a such as a screw or a bolt to facilitate anchoring of the bracket 102 to additional components of the framing assembly 100.
The second bracket section 140 may be fabricated similar to the first bracket section 120. As such, the second bracket section 140 comprises a bracket middle portion 142 defining an interior surface 142 a and an exterior surface 142 b. The second bracket section 140 comprises opposing flanges 144 and 146 that extend from the bracket middle portion 142 and collectively define a generally U-shaped configuration. The flange 144 is defined on a first side of the bracket middle portion 142 and defines an interior surface 144 a and an exterior surface 144 b. The flange 146 is defined on a second side of the bracket middle portion 142 opposite the flange 144 and the flange 146 defines an interior surface 146 a and an exterior surface 146 b as shown. As further shown in FIG. 3A, the flanges 144 and 146 of the second bracket section 140 align perpendicularly with the flanges 124 and 126 of the first bracket section 120 respectively.
In some embodiments, the flanges 144 and 146 define a width in the range of 1 to 3 inches and the bracket middle portion 142 defines a length/height in the range of 3 to 9 inches. However, it should be understood that the dimensions of the bracket middle portion 142 and the flanges 144 and 146 may vary depending on the particular application of the bracket 102. The second bracket section 140 may further define at least one aperture 119 b, configured to receive a securing member 121 b such as a screw or bolt to facilitate anchoring of the bracket 102 to additional components of the framing assembly 100.
The bracket 102 may further comprise one or more slots or notches to facilitate engagement of the bracket 102 to the joist 104 or end rail 106. In the example shown, the first bracket section 120 comprises a first slot 130 and a second slot 132. In some embodiments, the first and second slots 130 and 132 are defined on opposite sides of the bracket middle portion 122. The first slot 130 defines a first slot portion 130 a at a first side of the bracket middle portion 122. The first slot portion 130 a extends a predetermined distance from the intersection of the flange 124 and the bracket middle portion 122 towards the center of the bracket middle portion 122 and is defined a predetermined distance from the bracket bend 118 adjacent the flange 144. The first slot 130 further defines a second slot portion 130 b in communication with the first slot portion 130 a. The second slot portion 130 b is defined between the flange 124 and the flange 144. Specifically, the second slot portion 130 b is defined between an edge 124 c of the flange 124 and an edge 144 c of the flange 144. The first slot portion 130 a is in orthogonal relation relative to the second slot portion 130 b.
Similarly, the second slot 132 defines a third slot portion 132 a at a second side of the bracket middle portion 122 opposite the first slot 130. The third slot portion 132 a extends a predetermined distance from the intersection of the flange 126 and the bracket middle portion 122 towards the center of the bracket middle portion 122 and is defined a predetermined distance from the bracket bend 118 adjacent the flange 146. The second slot 132 further defines a fourth slot portion 132 b in communication with the third slot portion 132 a of the second slot 132. The fourth slot portion 132 b is defined between the second bracket flange 126 and the fourth bracket flange 146. Specifically, the fourth slot portion 132 b is defined between an edge 126 c of the flange 126 and an edge 146 c of the flange 146. The third slot portion 132 a is in orthogonal relation relative to the fourth slot portion 132 b.
The bracket 102 facilitates the interlocking and fastening of various components of the framing assembly 100 together as described herein. As such, the bracket 102 may be sized according to the specifications of other components of the framing assembly 100 and may be sized slightly smaller than the joists and end rails of the framing assembly 100. The bracket 102 may be made from a metal such as steel, aluminum, or the like. Alternatively, the bracket 102 may be made from a plastic or plastic composite material. Utilizing the bracket 102 as part of the framing assembly 100 increases the efficiency of building the framing assembly 100 while reducing the number of tools and resources typically used for conventional construction systems, as described herein. It should be understood that additional variations of the bracket 102 are contemplated. For example, the bracket 102 may be formed with the second bracket section 140 rotated 180 degrees such that the second bracket section 140 extends along the axis X2 but in a direction opposite to that shown in FIG. 3A. The bracket 102 may be formed such that either of the first bracket section 120 or the second bracket section 140 are flipped in this manner to accommodate varying specifications of the framing assembly 100 or for other applications. In some embodiments, a mirror orientation of the bracket 102 is contemplated. In one embodiment, 14 gauge steel may be used for the bracket 102 described herein. In some embodiments, the bracket 102 may be 6″ long and fit inside up-to-2½″ flanged joists, down to 1⅝″ and 18 gauge. Other sizes are contemplated, including but not limited to approximately 4″, 6″, 8″, and the like.
FIG. 3B illustrates a template 152 or stencil formed during an initial state of manufacturing of the bracket 102. The template 152 of the bracket 102 may comprise a substantially flat or planar sheet of metal or plastic composite material specifically designed so that the template 152 can be manipulated or bent to form the bracket 102 (although a similar template may be implemented to form other components of the framing assembly 100). In other words, the template 152 may define a flat configuration of the bracket 102. In some embodiments, bending lines 154A-1540 and bending line 156 may be etched or stamped into the template 152 to define the various components of the bracket 102. For example, the folding line 156 may define a divide (such as the bracket bend 118) between the first bracket section 120 and the second bracket section 140 of the bracket 102. Bending lines 154A-154B may define respective bends formed adjacent the flanges 124 and 126 of the first bracket section 120, and bending lines 154C-154D may define respective bends formed adjacent the flanges 144 and 146 of the second bracket section 140. Using the bending lines 154A-1540 and bending line 156, portions of the template 152 may be manipulated or bent according to the arrows A1-A4 shown to form the bracket 102 of FIG. 3A. The template 152 and the bracket 102 may be formed using stamping, punching, laser cutting, plastic molding, and the like although it should be understood the present disclosure is not limited to the aforementioned methods of manufacturing. It should further be understood that in some embodiments, the bracket 102 may be formed without first forming the flat configuration of the bracket 102 of FIG. 3B using, e.g., three-dimensional (3D) printing or similar methods.
The bracket 102 may be mechanically coupled to other components of the framing assembly 100 as described herein. FIG. 4A illustrates a portion of an end rail 106 which may be mechanically coupled to the bracket 102 as part of the framing assembly 100. The end rail 106 may comprise an elongated rigid member that forms a portion of a boundary or border of the framing assembly 100. In some embodiments, the end rail 106 may be made from a metal such as steel, aluminum, or the like. Alternatively, the end rail 106 may be made from a plastic or plastic composite material. The end rail 106 comprises an end rail middle portion 162 defining an interior surface 162 a and an exterior surface 162 b. As further shown, the end rail 106 further defines a peripheral end 170 and an opposite peripheral end 171. Adjacent the peripheral end 170 of the end rail 106, opposing flanges 164 and 166 extend from opposite sides of the end rail middle portion 162. Flanges 164 and 166 collectively define an interior surface 164 a and an exterior surface 164 b. Similarly, flanges 166 define an interior surface 166 a and an exterior surface 166 b.
In some embodiments, the end rail 106 may comprise opposing returns 165 and 167 extending from flanges 164 and 166 respectively, such that the end rail 106 defines a generally C-shape configuration in a side view. Similar to flanges 164 and 166 of the end rail 106, return 165 defines a return interior surface 165 a and a return exterior surface 165 b. In addition, return 167 defines a return interior surface 167 a and a return exterior surface 167 b. In some embodiments, the first and second slots 130 and 132 are sized to receive the returns 165 and 167 such that the returns 165 and 167 may slide through the first and second slots 130 and 132 respectively when engaging the bracket 102 to the end rail 106.
Flanges 164 and 166 and end rail middle portion 162 collectively define an end rail interior portion 168 for receiving the second bracket section 140. In other words, the end rail interior portion 168 comprises the space between the flanges 164 and 166 and end rail middle portion 162 which may be specially sized to receive the second bracket section 140 of the bracket 102.
Referring again to FIGS. 4A-4B, the end rail 106 and the bracket 102 may be oriented side by side to mechanically couple the two components to one another. During assembly, the end rail interior portion 168 of the end rail 106 may then slidably receive the second bracket section 140 of the bracket 102, i.e., the second bracket section 140 may be urged within the end rail interior portion 168, to mechanically couple, fasten, and/or attach the bracket 102 to the end rail 106. As shown in FIG. 4A, the bracket peripheral end 158 of the bracket 102 may be aligned with the peripheral end 170 of the end rail 106 along the axis X2. The flanges 144 and 146 of the second bracket section 140 of the bracket 102 may be substantially aligned with the flanges 164 and 166 of the end rail 106. Further, the slots 130 and 132 of the bracket 102 may be aligned with the returns 165 and 167 of the end rail 106.
Upon aligning the bracket 102 and end rail 106 as described herein, the second bracket section 140 of the bracket 102 may be urged towards the peripheral end 170 of the end rail 106 and into the end rail interior portion 168. The returns 165 and 167 of end rail 106 are then received through and slide within the first and second slots 130 and 132 respectively, of the bracket 102. Further, the exterior surface 142 b of the bracket middle portion 142 of the second bracket section 140 may slide over with the interior surface 162 a of the end rail 106, the flange exterior surface 144 b of the bracket 102 may slide below the flange interior surface 164 a of the end rail 106, and the flange exterior surface 146 b of the bracket 102 may slide over the flange interior surface 166 a of the end rail 106. The returns 165 and 167 being received within the first and second slots 130 and 132 of the bracket 102 facilitate a secure engagement of the second bracket section 140 of the bracket 102 within the end rail interior portion 168 of the end rail 106. In some embodiments, the aforementioned configuration comprises an assembled state with the second bracket section 140 simultaneously contacting the interior surface 162 a, the flange interior surface 164 a, and the flange interior surface 166 a to facilitate a snug engagement of the second bracket section 140 within the end rail interior portion 168.
As the second bracket section 140 is urged within the end rail interior portion 168, the flange 144 of second bracket section 140 passes within the end rail interior portion 168 below the interior surface 164 a of flange 164 of end rail 106. Similarly, the flange 146 of second bracket section 140 passes within the end rail interior portion 168 above interior surface 166 a of the flange 166 of the end rail 106. Where the end rail 106 includes returns 165 and 167 as shown, the returns 165 and 167 function as rails to slidably fasten the second bracket section 140 within a trough defined by the interior surfaces of the respective flanges 164 and 166 and the returns 165 and 167 of the end rail 106. In other words, the flanges 144 and 146 of the second bracket section 140 abut the returns 165 and 167 of the end rail 106 which restricts the second bracket section 140 from sliding out of the end rail interior portion 168 away from the interior surface 162 a of the end rail middle portion 162. In some embodiments, the returns 165 and 167 and/or the flanges 164 and 166 contact the interior surfaces of the first bracket section 120 that define the first and second slots 130 and 132. The returns 165 and 167 wrapping around the flanges 144 and 146 of the bracket 102 help to maintain the second bracket section 140 of the bracket 102 within the end rail interior portion 168.
In some embodiments, the second bracket section 140 may slidably pass within the end rail interior portion 168 to a predetermined portion along a length of the end rail 106. In other words, the first and second slots 130 and 132 of the bracket 102 receive the returns 165 and 167 such that the returns 165 and 167 slidably pass there through, and the end rail interior portion 168 receives the second bracket section 140 such that the bracket 102 may slidably pass within the end rail interior portion 168 and may be positioned anywhere along a length of the end rail 106 (as needed for the framing assembly 100) by continuing to urge the second bracket section 140 further within the end rail interior portion 168 towards the peripheral end 171 of the end rail 106 opposite the peripheral end 170.
Referring to FIGS. 5A-5B, the bracket 102 may also be mechanically coupled to at least one joist 104 of the framing assembly 100. Specifically, the first bracket section 120 of the bracket 102 may be mechanically coupled to the joist 104. Similar to the end rail 106, the joist 104 may comprise an elongated member and may be manufactured using a metal such as steel or a plastic composite material. The joist 104 may function as a cross beam and a plurality of joists similar to the joist 104 may be connected to respective end rails 106 to construct the framing assembly 100. The joist 104 may comprise a cross-sectional profile similar to that of the end rail 106 described above and may have a generally C-shaped configuration when viewed from a side view.
In some embodiments, the joist 104 comprises a joist middle portion 212. The joist middle portion 212 defines an exterior surface 212 b and an interior surface 212 a. Opposing flanges 214 and 216 extend from opposite sides of the joist middle portion 212, and opposing returns 218 and 220 extending from the flanges 214 and 216, respectively, of the joist 104 similar to the end rail 106. The joist middle portion 212, flanges 212 and 216, and returns 212 and 220 collectively define a joist interior portion 228.
The flange 214 may define a flange interior surface 214 a and a flange back exterior surface 214 b. The flange 216 may define a flange interior surface 216 a and a flange exterior surface 216 b. The return 218 may define a return interior surface 218 a and a return exterior surface 218 b. Similarly, the return 220 may define a return interior surface 220 a and a return exterior surface 220 b.
As shown, joist 104 may define a peripheral end 210 and a peripheral end 211. The peripheral end 210 of the joist 104 may be aligned with the bracket peripheral end 150 of the first bracket section 120. The first bracket section 120 may then be urged towards the peripheral end 210 of the joist 104 to slide the first bracket section 120 within the joist interior portion 228. Specifically, the exterior surface 122 b of the bracket middle portion 122 of first bracket section 120 slides over the interior surface 212 a of the joist middle portion 212. Further, as the first bracket section 120 is urged towards the peripheral end 210 and into the joist interior portion 228, the flange 124 of the first bracket section 120 passes within the joist interior portion 228 below the interior surface 214 a of the flange 214 of the joist 104. Similarly, the flange 126 of the first bracket section 120 passes within the joist interior portion 228 above the interior surface 216 a of the flange 216 of joist 104.
FIGS. 6A-6C show the bracket 102 being mechanically coupled to both the end rail 106 and the joist 104 as described in FIGS. 4A-4B and 5A-5B. These framing components may be coupled as shown to form part of the framing assembly 100. FIG. 6A in particular shows an initial step of aligning the second bracket section 140 with the end rail 106 as described in FIGS. 4A-4B as well as aligning the first bracket section 120 with the joist 104 as described in FIGS. 5A-5B.
FIG. 6B further shows one configuration for mechanically coupling the second bracket section 140 of the bracket 102 to the end rail 106. In this configuration, the end rail 106, the joist 104, and the bracket 102 collectively form a corner of the framing assembly 100. The securing member 121 a may be inserted through the aperture 119 a, and the securing member 121 b may be inserted through the aperture 119 b to maintain the orientation shown in FIG. 6B.
FIG. 6C illustrates another configuration of mechanically coupling the second bracket section 140 of the bracket 102 to the end rail 106. As shown, the second bracket section 140 may be aligned along a middle section of the end rail 106 anywhere between the peripheral end 170 and the peripheral end 171 of the end rail 106. More specifically, because the second bracket section 140 of the bracket 102 is formed with a size slightly less than the size of the end rail interior portion 168, the second bracket section 140 of the bracket 102 may slide within the end rail interior portion 168 to a predetermined position anywhere along a length of the end rail 106. The returns 165 and 167 of the end rail 106 pass through the first and second slots 130 and 132 of the bracket 102 respectively as the bracket 102 slides along the end rail 106. As such, the first and second slots 130 and 132 function as a track for the returns 165 and 167. In addition, the flanges 144 and 146 of the bracket 102 slide over the flanges 164 and 166 and the returns 165 and 167 within the end rail interior portion 168. In either case, the configurations of both FIG. 6B and FIG. 6C show the joist 104 and end rail 106 overlapping the first bracket section 120 and the second bracket section 140, respectively, such that the connecting component, the bracket 102, is implemented from an interior side of the joist 104 and the end rail 106 in contrast to an external connecting component such as a sleeve or track which is implemented from an external side of the joist 104.
FIGS. 6A-6C and the preceding figures demonstrate that the unique design of the bracket 102 provides various advantages for the framing assembly 100. For example, because the second bracket section 140 of the bracket 102 slidably engages within the end rail interior portion 168, with the first and second slots 130 and 132 of the bracket 102 slidably receiving the respective returns 165 and 167 of the end rail 106, the bracket 102 is slidably held in place and can be adjusted to a predetermined position along a length of the end rail 106. Connecting the bracket 102 to the end rail 106 such that at least a portion of the bracket 102 is housed within the end rail interior portion 168 is believed to be an advantageous departure from conventional frame assembly methods that mechanically couple framing components by fastening adjacent joists using connections that fit around the exterior of the joists, e.g. sleeves. By disposing at least a portion of the bracket 102 (such as the second bracket section 140) within the end rail interior portion 168, valuable space along the peripheral profile of a completed frame assembly 100 remains available for mounting of additional framing or construction components thereto, or other utility. Further, partially housing different sections of the bracket 102 (first bracket section 120 and second bracket section 140) within interior portions of the joist 104 and end rail 106 is advantageous for packaging of the framing assembly 100 (which may comprise a plurality of brackets, joists, end rails, and other components) within e.g. a shipping container.
The framing components of the framing assembly 100 may be temporarily mechanically coupled such that the framing assembly 100 can be disassembled for transport or modification. Yet in some embodiments, fastening components, such as screws, bolts, or the like may be employed to anchor at least a portion of the framing assembly components together. While the framing assembly 100 is shown with a rectangular shape, the present disclosure contemplates configuring the framing assembly 100 to comprise a variety of shapes depending on the particular application for the framing assembly 100. For example, the framing assembly 100 may be used as support structure and may cover a particular surface area for a deck, a pool cover, or the like. The surface area may be rectangular, square-shaped, or may have curved edges as in the case where the framing assembly 100 is utilized to cover a kidney-shaped pool. The components of the framing assembly 100 may be selected and formed to the particular size and dimensions of the particular surface area given.
Additional variations of the bracket 102 are contemplated for the framing assembly 100. For example, FIG. 7 illustrates another embodiment of a bracket 302 similar to the bracket 102. The bracket 302 may include a bracket bend 318 which is defined between a first bracket section 320 and a second bracket section 340. In the embodiment shown, the bracket bend 318 may define a substantially 90 degree bend such that the first bracket section 320 extends along the first axis X1 and the second bracket section 340 extends along the second axis X2 with the first axis X1 intersecting the second axis X2 orthogonally or at a substantially right angle. The bracket 302 further comprises a bracket peripheral end 350 defined by the first bracket section 320 and a bracket peripheral end 358 defined by the second bracket section 340.
The first bracket section 320 of the bracket 302 comprises a bracket middle portion 322 defining an interior surface 322 a and an exterior surface 322 b. As shown, opposing flanges 324 and 326 extend from the bracket middle portion 322 such that the bracket middle portion 322 and the opposing flanges 324 and 326 of the first bracket section 320 collectively define a generally U-shape configuration. The flange 324 defines an interior surface 324 a and an exterior surface 324 b. Similarly, the flange 326 defines an interior surface 326 a and an exterior surface 326 b. In some embodiments, the flanges 324 and 326 define a width in the range of 1 to 3 inches and the bracket middle portion 322 defines a length/height in the range of 3 to 9 inches. However, it should be understood that the dimensions of the bracket middle portion 322 and the flanges 324 and 326 may vary depending on the particular application of the bracket 302. The first bracket section 320 may further include at least one aperture 314 configured to receive a securing member 321 a such as a screw or a bolt to facilitate anchoring of the bracket 302 to additional components of the framing assembly 100.
The second bracket section 340 of the bracket 302 may be fabricated similar to the first bracket section 320. As such, the second bracket section 340 comprises a bracket middle portion 342 defining an interior surface 342 a and an exterior surface 342 b. The second bracket section 340 comprises opposing flanges 344 and 346 that extend from the bracket middle portion 342. Flange 344 defines an interior surface 344 a and an exterior surface 344 b. Similarly, flange 346 defines an interior surface 346 a and an exterior surface 346 b as shown. The flanges 344 and 346 of the second bracket section 340 align perpendicularly with the flanges 324 and 326 of the first bracket section 320.
In some embodiments, the flanges 344 and 346 define a width in the range of 1 to 3 inches and the bracket middle portion 342 defines a length/height in the range of 3 to 9 inches. However, it should be understood that the dimensions of the bracket middle portion 342 and the flanges 344 and 346 may vary depending on the particular application of the bracket 302. The second bracket section 340 may further define at least one aperture 316, configured to receive a securing member 321 b such as a screw or bolt to facilitate anchoring of the bracket 302 to additional components of the framing assembly 100.
The bracket 302 further comprises first and second slots 330 and 332 similar to the first and second slots 130 and 132. However as shown, the first and second slots 330 and 332 do not extend into the bracket middle portion 322 but instead terminate before the bracket middle portion 322 such that the bracket middle portion 322 is devoid of the slots 330 and 332.
In some embodiments, the bracket 302 of FIG. 7 may be implemented with the framing assembly 100 and coupled to an end rail 106. For example, the second bracket section 340 of the bracket 302 may be disposed within the end rail interior portion 168 similar to the steps described in FIGS. 4A-4B. In this configuration, the returns 165 and 167 of the end rail 106 may make contact with the bracket middle portion 322 of the first bracket section 320, due to the reduced size of the first and second slots 330 and 332 of the bracket 302. In other words, because the first and second slots 330 and 332 of the bracket 302 do not extend into the bracket middle portion 322 and do not receive the returns 165 and 167 there through, the returns 165 and 167 abut the bracket middle portion 322 when the second bracket section 340 is passed within the end rail interior portion 168.
The bracket 302 may be especially useful where it is desired to impede movement of the second bracket section 340 of the bracket 300 beyond the peripheral end 170 of the end rail 106. Specifically, with the bracket 300, the configuration of FIG. 6B may be maintained because the returns 165 and 167 make contact with the middle portion 322 once the second bracket section 340 of the bracket 300 is mechanically engaged within the end rail interior portion 168.
FIG. 8 shows another embodiment of a bracket 402 similar to the bracket 102 which may be implemented with the framing assembly 100 with the bracket 402 partially mechanically coupled to the end rail 106. The bracket 402 may define a bracket bend 418 between a first bracket section 420 and a second bracket section 440 of the bracket 402. In the embodiment shown, the bracket bend 418 may define a substantially 90 degree bend such that the first bracket section 420 is in orthogonal relation relative to the second bracket section 440.
The first bracket section 420 comprises a bend line 470. The bend line 470 defines a bend extending vertically through the first bracket section 420 such that the first bracket section 420 may bend laterally at the bend point 470 in the manner indicated by the arrow A10. As such, the first bracket section 420 may be skewable towards the interior surface 162 a of the end rail 106. It should be understood that in some embodiments the second bracket section 440 may be skewable or both the first bracket section 420 and the second bracket section 440 may be skewable. A skewable framing component as used herein generally defines a framing component where at least a portion of the framing component can be bent to a predetermined position and rigidly maintain that predetermined position after being bent.
FIG. 9 shows another embodiment of a bracket 502 which may be implemented with the framing assembly 100. As shown, the bracket 502 is similar to the bracket 102 and may be coupled to the joist 104. The bracket 502 may include a bracket bend 518 which defines a first bracket section 520 and a second bracket section 540. In the embodiment shown, the bracket bend 518 may define a substantially 90 degree bend such that the first bracket section 520 is in orthogonal relation relative to the second bracket section 540. The bracket 502 further comprises a bracket peripheral end 550 defined by the first bracket section 520 and a bracket peripheral end 558 defined by the second bracket section 540. The second bracket section 540 comprises opposing flanges 544 and 546. The first bracket section 520 overlays the joist middle portion 212.
The bracket 502 may further define returns 590 and 592 extending from the flanges 544 and 546, respectively. As shown, the return 544 of the bracket 502 abuts the flange 214 and the return 218 of the joist 104, and the return 592 of the bracket 502 abuts the flange 216 and the return 220 of the joist 104. Fabricating the bracket 502 with returns 590 and 592 as shown, either with the first bracket section 520 or the second bracket section 540 may allow the bracket 502 to be mechanically coupled more securely to the joist 104 or the end rail 106 of the framing assembly 100.
FIGS. 10A-10B show another embodiment of a bracket 602 similar to the bracket 102, for use with the framing assembly 100. The bracket 602 may include a bracket bend 618 defined between a first bracket section 620 and a second bracket section 640. In the embodiment shown, the bracket bend 618 may define a substantially 90 degree bend such that the first bracket section 620 is in orthogonal relation relative to the second bracket section 640. The first bracket section 620 comprises opposing flanges 624 and 626. The second bracket section 640 is mechanically coupled to the end rail 106 similar to the bracket 102 as shown.
The bracket 602 may differ from the bracket 102 in that the bracket 602 further comprises first and second angled slits 683 and 685, cuts, or cut-out portions that may be formed within the flanges 624 and 626 of the first bracket section 620. The lines 680 and 682 of FIG. 10A define respective cut out portions that may be used to form the first and second angled slits 683 and 685 of FIG. 10B. The first and second angled slits 683 and 685 facilitate the first bracket section 620 to be able to lay over the end rail 106 as may be needed for a particular application. The arrow A11 shown in FIG. 10B shown indicates a possible direction in which to manipulate the first bracket section 620 once the first and second angled slits 683 and 685 are formed.
FIGS. 11A-11B show another embodiment of a bracket 702 similar to the bracket 102 which may be implemented with the framing assembly 100. The bracket 702 may include a bracket bend 718 defined between a first bracket section 720 and a second bracket section 740. In the embodiment shown, the first bracket section 720 is in orthogonal relation relative to the second bracket section 740 in a first configuration.
The second bracket section 740 of the bracket 702 comprises opposing flanges 744 and 746. The second bracket section 740 may further define at least one aperture 719 b, configured to receive a securing member 721 b such as a screw or bolt to facilitate anchoring of the bracket 702 to additional framing components of the framing assembly 100.
The first bracket section 720 of the bracket 702 lacks flanges and comprises first and second slits 790 and 792 that oppose one another. The first and second slits 790 and 792, similar to the slots 130 and 132 of the bracket 102, extend a predetermined distance towards the center of the first bracket section 720. A twist arrow A12 is defined between the opposing slits 790 and 792. The first bracket section 720 can be twisted according to the twist arrow A12 in various directions so that the first bracket section 720 can be oriented as needed to connect with other components of the framing assembly 100. As one example, the bracket 702 may be implemented where a framing assembly involves joists 104 that need to be oriented upwards or at a particular angle. In such an example, the first bracket section 720 may be bent at the twist arrow A12 to orient the first bracket section 720 of the bracket 702 as needed. The first bracket section 720 may further include at least one aperture 719 a configured to receive a securing member such as a screw or a bolt to facilitate anchoring of the bracket 702 to additional components of the framing assembly 100.
FIG. 12 illustrates another embodiment of a framing assembly 1000 comprising components similar to the framing assembly 100. The framing assembly 1000 comprises a plurality of brackets 1002 to mechanically couple or connect together other components of the framing assembly 1000.
The framing assembly 1000 further comprises a plurality of end rails 1006. More particularly, the framing assembly 1000 may comprise a plurality of end rails 1006 a defining a first side 1010 of the framing assembly 1000 and a sole end rail 1006 b defining a second side 1012 of the framing assembly 1000 opposite the first side 1010. The end rail 1006 b may span a length of the framing assembly 1300 to define the second side 1012 of the framing assembly 1000. Adjacent end rails 1006 a may be coupled together side by side to define the first side 1010 of the framing assembly 1000. The end rails 1006 may comprise dimensions similar to the end rail 106 such that the end rails 1006 comprise a middle portion, flanges, and returns collectively defining an end rail interior portion 1068. In some embodiments, the end rails 1006 may define a generally C-shaped configuration as viewed from a side view.
The framing assembly 1000 further comprises a plurality of joists 1004 extending between the first side 1010 and the second side 1012 of the framing assembly 1000. In the example shown, the joists 1004 include a plurality of joists 1004 a and a plurality of joists 1004 b. The joists 1004 b may span from the first side 1010 of the framing assembly 1000 to the second side 1012 of the framing assembly 100 and a portion of the joists 1004 may define a third side 1014 of the framing assembly 1000 and a fourth side 1016 of the framing assembly 1000 opposite the third side 1014. The joists 1004 a may be shorter in length than the joists 1004 b and coupled together between the first side 1010 of the framing assembly 1000 to the second side 1012 of the framing assembly 1000. The joists 1004 a may be e.g. 1 to 3 feet in length which may facilitate easier packaging and transport of the framing assembly 1000. The joists 1004 may comprise dimensions similar to the joist 104 such that the joists 1004 comprise a middle portion, flanges, and returns collectively defining a joist interior portion 1228. Accordingly, the joists 1004 may define a generally C-shaped configuration as viewed from a side view.
The framing assembly 1000 may further comprise inserts 1005. Inserts 1005 may be utilized to mechanically couple together e.g. adjacent ones of the end rails 1006 a or the joists 1004. The inserts 1005 may define a generally U-shaped configuration and may frictionally fit within the end rail interior portion 1068 of the end rails 1006 or the joist interior portion 1228 of the joists 1004. The inserts 1005 may comprise a metal such as steel, or may also comprise a plastic or plastic composite material. In some embodiments the framing assembly 1000 may comprise a plurality of different inserts to mechanically couple together the joists 1004 a.
As further shown in FIG. 12, utilizing smaller framing components, such as the joists 1004 a, may allow the framing assembly 1000 to be configured with certain openings, such as the indicated opening 1030. The opening 1030 may define an access point or provide other utility when the framing assembly 1000 is used for a deck or cover. Utilizing smaller components provides flexibility for packaging and design of the framing assembly 1000 and also transport of the framing assembly 1000.
Further detail regarding the brackets 1002 may be described with reference to FIGS. 13A-13B. FIG. 13A comprises a front view of a bracket 1002, and FIG. 13B comprises a top view of the bracket 1002. The bracket 1002 may be slightly smaller than the joist 1004 and end rail 1006 so that the bracket 1002 may slidably engage within the end rail interior portion 1068 and the joist interior portion 1228 similar to the manner of mechanically coupling the bracket 102 to the end rail 106 or joist 104 as described herein. FIG. 13A shows the bracket 1002 defines an end bracket section 1410, a middle bracket section 1420, and an end bracket section 1430 such the middle bracket section 1420 is defined between the end bracket section 1410 and the end bracket section 1430. As shown, the height of the middle bracket section 1420 may be slightly less than the height of the end bracket section 1410 and the height of the end bracket section 1430. In some embodiments, any one or more of the middle bracket section 1420, end bracket section 1430 or end bracket section 1410 may be skewable such that portions of the bracket 1002 may be manipulated or bent to maintain additional different configurations. As such, the bracket 1002 may more flexibly engage with other components of the framing assembly 1000 as described herein. More specifically, the end bracket section 1410 may be bendable relative to the middle bracket section 1420, and the end bracket section 1430 may be bendable relative to the middle bracket section 1420.
As shown, the brackets 1002 comprise flanges 1406 and flanges 1404 that oppose one another. The flanges 1406 and 1404 are overlapped by the flanges of a joist 1004 or end rail 1006 when the bracket 1002 is connected to the same. In some embodiments, the flanges 1406 and the flanges 1404 may extend across an entire length of the bracket 1002 from the end bracket section 1410 to the end bracket section 1430, although the brackets 1002 are not limited in this regard.
In some embodiments, a screw hole 1402 may be formed through the end bracket section 1410 and configured to receive a securing member such as a screw or bolt. In some embodiments, e.g., when implementing the bracket 1002 with a reduced size, the screw hole 1402 may be the sole screw hole formed. This may be significant because conventional framing assemblies that are not so closely fitted may need multiple screws and clamping while a builder is placing the screws. In fact, a first person may be needed with both hands holding the joist and bracket in place during assembly with another person focusing on applying screws or other fasteners to complete the assembly. This requires additional time and personnel to construct the conventional framing assembly. Alternatively, in some embodiments, one or more or a plurality of securing members may be implemented to more permanently attach the bracket 1002 to other framing components.
Additional detail regarding implementation of the bracket 1002 may be explained with reference back to FIG. 12. As shown, a plurality of the brackets 1002 may be utilized to form the framing assembly 1000. For example, a bracket 1002 may be used to connect a joist 1004 b to an end rail 1006 a. Either of the end bracket section 1410 or the end bracket section 1430 of a bracket 1002 may be mechanically coupled to the joist interior portion 1228 of the joist 1004 b and the other end of the bracket 1002 may be mechanically coupled to the end rail interior portion 1068 of the end rail 1006 a. As further shown, the brackets 1002 may be used to connect the smaller joists 1004 a to the joists 1004 b, or to connect the end rails 1006 b or 1006 a to the joists 1004 a and the 1004 b, and the like.
FIG. 14A and FIG. 14B show another embodiment of a bracket 1502 similar to the bracket 1002. The bracket 1502 defines an end bracket section 1510, a middle bracket section 1520, and an end bracket section 1530 such the middle bracket section 1520 is defined between the end bracket section 1510 and the end bracket section 1530. As shown, the height of the middle bracket section 1520 may be slightly less than the height of the end bracket section 1510 and the height of the end bracket section 1530. The bracket 1502 may be skewable such that portions of the bracket 1502 may be manipulated or bent to maintain additional different configurations. For example, the end bracket section 1530 may be skewable towards the middle bracket section 1520, and the end bracket section 1510 may be skewable towards the middle bracket section 1520 as indicated by the arrows shown.
As further shown, the bracket 1502 may comprise flanges 1506 and flanges 1504 opposing one another. The flanges 1506 and the flanges 1504 may be defined on the end bracket section 1510 and the end bracket section 1530 respectively, with the middle bracket section 1520 being devoid of the flanges.
The bracket 1502 may be skewable or bendable. The end bracket section 1510 and the end bracket section 1530 may be shifted or bent towards one another to more easily engage the bracket 1502 within the framing assembly 1000. Specifically, the end bracket section 1510 may be bent in the direction D1, and the end bracket section 1530 may be bent in the direction D2.
In some embodiments, the bracket 1502 may be configured such that the end bracket section 1510 and the end bracket section 1530 are biased, or otherwise tend to return to an original position opposite the directions D1 and D2 shown. This tendency for the end bracket section 1510 and the end bracket section 1530 to return to an original orientation may facilitate a firm fit of the bracket 1502 within the end rail interior portion 1068 or the joist interior portion 1228 of the framing assembly 1000. The end bracket section 1510, the middle bracket section 1520, and the end bracket section 1530 may each define at least one hole 1502 or aperture to receive a securing member such as a bolt or screw.
FIG. 15 shows another embodiment of a bracket 1602 for use with the framing assembly 1000. The bracket 1602 defines a first bracket section 1610 and a second bracket section 1620 with a plurality of cutouts 1650 defined generally in the center of the bracket 1602 to facilitate bending of the first bracket section 1610 and the second bracket section 1620 as needed, so that the bracket 1602 can more easily engage within an interior portion of a joist or end rail.
FIG. 16 shows another embodiment of a bracket 1702. The bracket 1702 defines a first bracket section 1720 and a second bracket section 1740. The first bracket section 1720 of the bracket 1700 defines a bracket middle portion 1722 with opposing flanges 1724 and 1726 defined along opposing sides of the bracket middle portion 1722. Similarly, the second bracket section 1740 defines a bracket middle portion 1742 with opposing flanges 1744 and 1746 defined along opposing sides of the bracket middle portion 1742. A bracket bending line 1718 is defined between the first bracket section 1720 and the second bracket section 1740.
The bracket 1702 comprises tabs 1760 defining keyhole shapes. These tabs 1760 may be cut into a middle portion of each of the first bracket section 1720 and the second bracket section 1740 using a plasma burner, water jet, or CNC punch, or can otherwise be punched or cut into the metal of the bracket 1702. The tabs 1760 may replace screw holes and the tedious step of adding screws. The keyhole design may be advantageous because it has a narrow base that is relatively easy to bend when the installer pushes it through a hole in the joist. The larger head facilitates the bracket to stay affixed in place in an interior portion of a joist or end rail.
Any of the aforementioned brackets and additional embodiments may be implemented to mechanically couple together the end rails 1006 and the joists 1004 of the framing assembly 1000. In one embodiment, 14 gauge steel may be used for the brackets described herein. The brackets may be 6″ long and fit inside up-to-2½″ flanged joists, down to 1⅝″ and 18 gauge. Other sizes are contemplated, including but not limited to approximately 4″, 6″, 8″, and the like.
FIGS. 17A-17B illustrate greater detail regarding the inserts 1005 of FIG. 12, which may also be implemented for the framing assembly 1000. The insert 1005 comprises an insert middle portion 1806, and opposing flanges 1802 and 1804 extending orthogonally from the insert middle portion 1806 such that the insert 1005 defines a generally U-shape configuration when viewed from a side view. Unlike the bracket 102 or the bracket 1002, the insert 1005 may be devoid of a bend similar to the bracket bend 118. As shown, a first end 1880 of the insert 1005 may be mechanically coupled to a first end rail 1006, and a second end 1882 of the insert 1005 may be mechanically coupled to a second end rail 1006. Like the bracket 1002 and the bracket 102, the insert 1005 may be sized slightly smaller than the end rail 1006, so that the ends of the insert 1005 may slidably fit within the end rail interior portion 1068 of each adjacent end rail 1006.
When the insert 1005 is implemented to connect adjacent components of the framing assembly 1000 such as a first end rail 1006 and a second end rail 1006, the insert 1005 may be oriented within the end rail interior portion 1068 of both of the adjacent end rails such that the insert 1005 is hidden from view. In other words, inserts 1005 may, in some embodiments, be completely disposed with an interior portion 1228 of a joist 1004 or an end rail interior portion 1068 of an end rail 1006. Using inserts such as the inserts 1005, shorter end rails 1006 and joists 1004 may be combined at peripheral ends to form longer end rails or joists when needed during formation of the framing assembly 1000. In some embodiments, the insert middle portion 1806 may be oriented over the opening between the flanges of the end rail 1006 to cover the opening as needed.
As described herein, the components of the framing assembly 100 and framing assembly 1000 are mechanically coupled by orienting a first component side by side next to a second component, and slidably engaging the first component within an interior portion defined by the second component. For example, the components of the framing assembly 100, such as the different bracket sections of the bracket 102, end rails 106, and joists 104, may each be associated with a side profile. A side profile of each framing component generally defines certain dimensions of the component such as a shape and size of the framing component as measured from a side view. Each side profile may define an outer perimeter of the framing component as taken from a side view. Each side profile may further define a maximum height and a maximum width of the framing component taken from a side view. The maximum height and maximum width of a side profile for a framing component determines whether that framing component can be slidably connected to another framing component, and how such framing components relate to one another after being connected, as described herein.
FIGS. 18A-18E illustrate exemplary side profiles of bracket sections and joists or end rails, with certain portions of the components cut away from view. More specifically, FIG. 18A illustrates a side view of the second bracket section 140 of the bracket 102 of FIG. 3A housed within the end rail interior portion 168, as taken from the peripheral side 171 of the end rail 106 opposite the peripheral side 170 of the end rail 106, with the bracket middle portion 122 of the first bracket section 120 partially cut away from view. As shown, the second bracket section 140 of the bracket 102 comprises a side profile 1902, and the end rail 106 comprises a side profile 1904. The side profile 1902 of the second bracket section 140 of the bracket 102 is generally smaller than the side profile 1904 of the end rail 106. In other words, the maximum height of the side profile 1902 is less than the maximum height of the side profile 1904 such that the second bracket section 140 may slidably fit within the end rail interior portion 168. The flanges 144 and 146 and the bracket middle portion 142 of the second bracket section 140 fit within the end rail interior portion 168, and are overlapped by the end rail middle portion 162, the end rail flanges 164 and 166, and the end rail returns 165 and 167 as shown. Further, the returns 165 and 167 of the end rail 106 wrap around the flanges 144 and 146 of the second bracket section 140 within the first and second slots 130 and 132 respectively, to maintain the second bracket section 140 within the end rail interior portion 168.
In addition, the exterior surface 142 b of the bracket middle portion 142 of the second bracket section 140 is aligned flush along the interior surface 162 a of the end rail middle portion 162. The exterior surface 146 b of the flange 146 of the second bracket section 140 is aligned flush with the interior surface 166 a of the end rail flange 166. The exterior surface 144 b is aligned flush with the interior surface 164 a of the end rail flange 164. In some embodiments, the interior surface 165 a of the return 165 of the end rail 106 abuts the bracket flange 144, and the interior surface 167 a of the return 167 of the end rail 160 abuts the bracket flange 146.
As further shown, the maximum width of the side profile 1902 of the second bracket section 140 is less than the maximum width of the side profile 1904 of the end rail 106, i.e., the width of the flanges 144 and 146 of the bracket 102 is smaller than the width of the flanges 164 and 166 of the end rail 106 such that in some embodiments the second bracket section 140 is completely surrounded by the flanges 164 and 166 and returns 165 and 167 of the end rail 106.
FIG. 18B illustrates a side profile 1906 of the second bracket section 540 of the bracket 502 where the second bracket section 540 comprises returns 590 and 592 extending from the flanges 544 and 546. The returns 590 and 592 align with the returns 165 and 167 respectively of the end rail 106. The flanges 544 and 546 of the bracket 502 align with the flanges 164 and 166 of the end rail 106 respectively. The bracket middle portion 542 of the bracket 502 aligns with the end rail middle portion 162.
FIG. 18C illustrates the side profile 1902 of the second bracket section 140 of the bracket 102 but also illustrates a side profile 1908 of the end rail 106 where the end rail 106 is devoid of returns. As shown, the first bracket section 120 (partially cut away) is in communication with the second bracket section 140. The bracket middle portion 142 is aligned with the end rail middle portion 162, the flange 144 is aligned with the flange 164, and the flange 146 is aligned with the flange 166.
FIG. 18D illustrates that the components, such as the second bracket section 140, may comprise profiles with varying thicknesses. In particular, FIG. 18D illustrates an example where the bracket middle portion 142 of the bracket 102 comprises a side profile 1910 with an increased thickness. As shown, the first bracket section 120 (partially cut away) is in communication with the second bracket section 140. As further shown, the bracket middle portion 142 with an increased thickness is aligned with the end rail middle portion 162, the flange 144 is aligned with the flange 164, and the flange 146 is aligned with the flange 166. Returns 165 and 167 of the end rail 106 abut the flange 144 and flange 146.
FIG. 18E illustrates another side view of the second bracket section 140 of the bracket 102. FIG. 18E depicts the same components and dimensions as FIG. 18A but shows the second bracket section 140 from behind the back surface 122 b of the bracket 102. As such, the second bracket section 140 of FIG. 18E comprises the side profile 1902 and the end rail 106 comprises the side profile 1904.
In some embodiments, a height or width of the brackets, receiving joists, or end rails may decrease, increase or otherwise change along a length of such components such that e.g. the bracket sections 120 and 140 can frictionally engage within the interior portion of the corresponding joist 104 and end rail 106, respectively. For example, the end rail 106 may be formed such that a height of the end rail 106 (or joist 104) decreases in size at some point along a length of the end rail 106. Accordingly, where the second bracket section 140 of the bracket 102 is urged within the end rail interior portion 168 and passes along the length the end rail 106, as the height of the end rail 106 begins to decrease, friction between the second bracket section 140 and the interior surfaces of the end rail 106 increases and may facilitate a temporary snug fit between the components. In such an embodiment, the second bracket section 140 can be engaged within the end rail interior portion 168 to a particular location along a length of the end rail 106 without the need for securing (via e.g., screw or nail) the second bracket section 140 to the end rail 106. On the other hand, the height of the second bracket section 140 may increase along a length of the second bracket section 140 to achieve a similar result. Such embodiments may be particularly useful for temporary coupling of the bracket 102 to the end rail 106 and joist 104 such that the framing assembly 100 can be completed and disassembled with ease and reduced amount of tools and fasteners. Any one or more of the other brackets disclosed herein may be configured in this fashion.
With the framing assembly 100 or the framing assembly 1000, the brackets disclosed herein including the bracket 102 and the bracket 1002 and additional embodiments thereof interlock e.g. the joists 102/1002, and the end rails 106/1006 by slidably engaging bracket sections within an interior portion (e.g. 168, 228, 1068, or 1228) of an end rail or joist. As such, the joists and end rails are connected from the interior side, i.e., the interior portion, as opposed to being connected from the exterior side. In some embodiments, the external surfaces of a bracket section being mechanically coupled to a joist or end rail frictionally contact the interior surfaces of the joist or end rail to help hold the bracket section in place within the interior portion of the joist or end rail to which the bracket section is being coupled or engaged.
It is believed that the present disclosure and many of its attendant advantages should be understood by the foregoing description, and it should be apparent that various changes may be made in the form, construction, and arrangement of the components without departing from the disclosed subject matter or without sacrificing all of its material advantages. The form described is merely explanatory, and it is the intention of the following claims to encompass and include such changes.
While the present disclosure has been described with reference to various embodiments, it should be understood that these embodiments are illustrative and that the scope of the disclosure is not limited to such embodiments. Many variations, modifications, additions, and improvements are possible. More generally, embodiments in accordance with the present disclosure have been described in the context of particular implementations. Functionality may be separated or combined in blocks differently in various embodiments of the disclosure or described with different terminology. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure as defined in the claims that follow.

Claims

What is claimed is:

1. A method of manufacturing a framing assembly, comprising:

forming a framing component comprising:

a framing component middle portion, a first framing component flange defined along a first side of the framing component middle portion, a first return defined along the first framing component flange, a second framing component flange defined along a second side of the framing component middle portion opposite the first framing component flange, and a second return defined along the second framing component flange with the second return in opposite orientation relative to the first return,

wherein a framing component interior portion is defined collectively by the framing component middle portion, the first framing component flange, the second framing component flange, the first return, and the second return; and

forming a bracket comprising:

a first bracket section in communication with a second bracket section with a bracket bend defined between the first bracket section and the second bracket section, the first bracket section aligned in perpendicular relation relative to the second bracket section,

wherein the first bracket section comprises a first bracket middle portion, a first bracket flange defined along a first side of the first bracket middle portion, and a second bracket flange defined along a second side of the first bracket middle portion opposite the first bracket flange,

wherein the second bracket section comprises a second bracket middle portion, a third bracket flange defined along a first side of the second bracket middle portion, and a fourth bracket flange defined along a second side of the second bracket middle portion opposite the third bracket flange,

a first slot defined along the first side of the first bracket middle portion, and

a second slot defined along the second side of the first bracket middle portion opposite the first side,

engaging the second bracket section within the framing component interior portion such that the first slot receives the first return and the second slot of the framing component receives the second return.

2. The method of claim 1, wherein the first slot comprises a first slot portion defined along the first side of the first bracket middle portion, and a second slot portion in communication with the first slot portion, the second slot portion defined between the first bracket flange and the third bracket flange, and wherein the second slot comprises a third slot portion defined along the second side of the first bracket middle portion, and a fourth slot portion in communication with the third slot portion, the fourth slot portion defined between the second bracket flange and the fourth bracket flange.

3. The method of claim 2, wherein the first slot portion of the first slot is aligned in perpendicular relation relative to the second slot portion of the first slot, and wherein the third slot portion of the second slot is aligned in perpendicular relation relative to the fourth slot portion of the second slot.

4. The method of claim 2, wherein the second slot portion of the first slot is defined between a first bracket flange edge of the first bracket flange and a third bracket flange edge of the third bracket flange opposing the first bracket flange edge; and wherein the second slot portion of the second slot is defined between a second bracket flange edge of the second bracket flange and a fourth bracket flange edge of the fourth bracket flange opposing the second bracket flange edge.

5. The method of claim 1, wherein when the framing assembly is assembled the first return and the second return of the framing component wrap around the third bracket flange and the fourth bracket flange respectively of the bracket.

6. The method of claim 1, further comprising:

aligning a peripheral end of the second bracket section with a first peripheral end of the framing component; and

sliding the second bracket section within the framing component interior portion to a predetermined location along the framing component.

7. The method of claim 1, further comprising:

providing a joist, comprising:

a joist middle portion, a first joist flange defined along a first side of the joist middle portion, and a second joist flange defined along a second side of the joist middle portion opposite the first side collectively defining a joist interior portion, the joist defining a joist peripheral end;

aligning a peripheral end of the first bracket section towards the joist peripheral end; and

sliding the first bracket section within the joist interior portion,

wherein the framing component comprises an end rail.

8. The method of claim 7, further comprising:

orienting the first bracket section within the joist interior portion such that a top side of the joist peripheral end of the joist abuts the first framing component flange of the framing component and bottom side of the joist peripheral end of the joist opposite the top side abuts the second framing component flange of the framing component.

9. The method of claim 1, further comprising:

wherein when the framing assembly is assembled a plurality of interior surfaces defined respectively by the framing component middle portion, the first framing component flange, and the second framing component flange make contact with and overlay a plurality of exterior surfaces defined respectively by the second bracket middle portion, the third bracket flange, and the fourth bracket flange.

10. The method of claim 1, wherein a width of the second bracket middle portion is less than a width of the framing component middle portion.

11. The method of claim 1, further comprising:

forming the first bracket section along a first axis; and

forming the second bracket section along a second axis,

wherein the first axis and the second axis intersect at a 90 degree angle such that the first bracket section is in orthogonal relation relative to the second bracket section.

12. The method of claim 1, wherein the first bracket flange and the second bracket flange are bendable to maintain different orientations and fit within the framing component interior portion.

13. The method of claim 1, wherein the first bracket flange and the second bracket flange comprise first bracket returns and second bracket returns, respectively.

14. The method of claim 1, wherein a height of the second bracket section is less than a height of the framing component middle portion; and wherein a width of the third bracket flange and the fourth bracket flange is less than a width of the first framing component flange and the second framing component flange respectively.

15. A method of making a framing assembly, comprising:

forming a bracket defining a first bracket section and a second bracket section in perpendicular relation relative to the second bracket section;

forming a first slot defined at a first side of the first bracket section;

forming a second slot defined at a second side of the first bracket section opposite the first side; and

providing a framing component, the framing component comprising a framing component middle portion, opposing framing component flanges defined along opposite sides of the framing component middle portion, and opposing framing component returns extending from the opposing framing component flanges collectively defining a framing component interior portion; and

disposing the second bracket section within the framing component interior portion with the opposing framing component returns received within the first slot and second slot.

16. The method of claim 15, wherein the bracket defines a first bracket flange defined along a first side of the first bracket section.

17. The method of claim 15, wherein an angle is defined at an intersection of the first bracket flange and the first side of the first bracket section; and

bending the first bracket section relative to the first bracket flange to modify the angle.

18. The method of claim 15, wherein the second bracket section is aligned side by side with the framing component and a middle portion of the second bracket section slides over a middle portion of the framing component to dispose the second bracket section within the framing component interior portion.

19. A framing assembly, comprising:

a bracket, comprising:

a first bracket section and a second bracket section in communication with the first bracket section, the first bracket section aligned in perpendicular relation relative to the second bracket section;

a first slot defined at a first side of the first bracket section; and

a second slot defined at a second side of the first bracket section opposite the first side.

20. The framing assembly of claim 19, further comprising:

a framing component, the framing component comprising a framing component middle portion, opposing framing component flanges defined along the framing component middle portion, and opposing framing component returns extending from the opposing framing component flanges collectively defining a framing component interior portion,

wherein in an assembled state the second bracket section is disposed within the framing component interior portion.