Abstract:
A corner bracket assembly for use in an associated movable frame assembly is provided. The corner bracket assembly includes a first housing piece having upstanding coupling pins. A second housing piece has receiving pockets for connecting engagement with the coupling pins and defining a cavity therebetween. A roller assembly is received within the cavity. The roller assembly includes a roller housing, a threaded engaging portion defined in the roller housing, and a roller rotatably mounted within the roller housing. A threaded fastener is rotatably mounted between the first and second housing pieces and is in threaded engagement with the roller assembly. A track is defined between the first and second housing pieces and the roller assembly for linearly adjusting a position of the roller assembly in relation to the first and second housing pieces.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a corner bracket assembly. More particularly, the invention relates to a corner bracket assembly for use with an associated frame assembly and will be described with particular reference thereto. However, it is to be appreciated that the present invention may also be amenable for other applications. 
     It is well known that corner bracket assemblies are used to connect a plurality of elongated frame elements to form a frame assembly of a door sash, window sash, panel, or the like. It is also well known to use rollers with such frame assemblies. Typically, the rollers or roller assemblies are separate from the corner bracket assemblies and are installed into the corner bracket or into the adjacent attached frame member. The rollers are capable of being slidably supported within a track on an associated fixed door frame, window frame, panel frame, or the like. Normally, the rollers are adjustable to accommodate varying fixed frames and to simplify installation of the frame assembly into a fixed frame, as well as removal therefrom. Most known corner brackets do not have the adjustable roller assembly integrated into the design of the corner bracket. The one known assembly which does, does not positively regulate a movement of the bracket assembly via a manually movable member. The known corner brackets also are not as sturdy as desirable. Furthermore, it is desirable to provide corner bracket assemblies having adjustable rollers wherein the strength and integrity of the corner bracket assembly is maintained. 
     The present invention provides a new and improved corner bracket assembly that overcomes the foregoing difficulties and others and provides the aforementioned advantageous features. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention, a new and improved corner bracket assembly for use in an associated frame assembly is provided. 
     More particularly in accordance with this aspect of the invention, the corner bracket assembly comprises a body, a first leg, and a second leg. The first leg extends from the body and is adapted to be connected to a first frame member of the associated frame assembly. The second leg extends from the body in a direction approximately normal to the first leg and is adapted to be connected to a second frame member of the associated frame assembly. The corner bracket assembly further comprises a roller assembly adjustably secured within at least one of the body, the first leg, and the second leg. The roller assembly is capable of protruding outward a selected distance relative to at least one of the body, the first leg, and the second leg. The roller assembly comprises a roller housing slidably mounted in at least one of the body, the first leg and the second leg. A roller element is rotatably mounted in the roller housing. A threaded member is defined within the roller housing. A fastener has a threaded portion engaged in the threaded member and a head portion extending away from the roller housing. 
     According to another aspect of the present invention, a new and improved corner fastener is provided for use in forming an associated frame assembly by interconnecting at a predetermined angle elongated tubular members of the associated frame assembly. The tubular members have a hollow internal space of a predetermined cross-sectional area. 
     More particularly in accordance with this aspect of the invention, the corner fastener comprises a pair of legs oriented at such predetermined angle with respect to each other and connected to a junction member. Each of the legs is adapted for disposition within the interior of a respective one of the associated elongated tubular members and is of such a cross-sectional area as to substantially and securely fill the internal space of the elongated tubular members. The junction member is of such configuration as to be contiguous with the outer walls of the tubular members. An adjustable roller device is slidably mounted in the junction member in order to move along a track defined between the junction member and the roller device. The roller device is selectively moveable to positions between a first protruding position and a second retracted position. 
     According to still another aspect of the present invention, a corner bracket assembly for use in an associated movable frame assembly is provided. 
     More particularly in accordance with this aspect of the invention, the corner bracket assembly comprises a first housing piece having upstanding coupling pins. A second housing piece has receiving pockets for connecting engagement with the coupling pins and defining a cavity therebetween. A roller assembly is received within the cavity. The roller assembly includes a roller housing, a threaded engaging portion defined in the roller housing, and a roller rotatably mounted within the roller housing. A threaded fastener is rotatably mounted between the first and second housing pieces and is in threaded engagement with the roller assembly. A track is defined between the first and second housing pieces and the roller assembly for linearly adjusting a position of the roller assembly in relation to the first and second housing pieces. 
     According to another aspect of the invention, a new and improved corner roller arrangement is provided for each of the corners of a sliding panel of the type including a pair of parallel, elongated spaced side members defining the length of the panel and top and bottom members defining the width of the panel. 
     More particularly in accordance with this aspect of the invention, the corner roller arrangement comprises a corner member including a frame, and corner keys integral therewith. The corner keys fit into the side, top and bottom panel members whereby the panel members abut the corner member frame for providing a rigid panel frame. The corner member frame has a first side and a second side. The first and second sides are in substantially parallel spaced relation. A roller housing rotatably supports a roller and is displaceably disposed within the corner member frame between the first and second corner member frame sides. The roller housing is selectively moveable to positions between a first protruding position and a second recessed position along a track defined by engaging components of at least one of the roller housing, the first side, and the second side. 
     According to another aspect of the invention, a new and improved a corner bracket and roller assembly for a sliding panel is provided. 
     More particularly in accordance with this aspect of the invention, the corner bracket and roller assembly comprises a corner bracket having integral first and second arms extending at approximately right angles and adapted for insertion into associated frame members of an associated panel. The first arm has an aperture in the bottom edge thereof. A roller assembly is disposed within the corner bracket. The roller assembly comprises a housing, a roller, and an adjusting means for moving the roller assembly along a linear path relative to the corner bracket. The roller is rotatably secured within the housing. The path includes a first position wherein the roller assembly protrudes through the aperture and a second position wherein the roller assembly recedes within the aperture. The path is defined by at least one groove and rib engagement. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention may take physical form in certain parts and arrangements of parts, preferred embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: 
     FIG. 1 is a perspective view of a corner bracket assembly according to the present invention as used with elongated frame members of a door or window and a track along which the panel slides; 
     FIG. 2 is a perspective view of the corner bracket assembly of FIG. 1 connected to elongated frame members, wherein a second housing piece is shown removed; 
     FIG. 3 is an exploded perspective view of the corner bracket assembly and elongated frame members of FIG. 2; 
     FIG. 4 is an enlarged perspective view of a portion of the corner bracket assembly of FIG. 3; 
     FIG. 5 is a perspective view of a second housing piece of the corner bracket assembly of FIG. 3 showing a cavity side thereof; 
     FIG. 6 is a perspective view of a first housing piece of the corner bracket assembly of FIG. 3 showing a cavity side thereof; 
     FIG. 7 is a perspective view of a first roller housing piece of the bracket assembly of FIG. 3 showing a cavity side thereof; 
     FIG. 8 is a perspective view of the first roller housing piece of FIG. 7 showing a grooved side thereof; 
     FIG. 9 is a perspective view of a second roller housing piece of the bracket assembly of FIG. 3 showing a cavity side thereof; 
     FIG. 10 is a perspective view of the second roller housing piece of FIG. 9 showing a grooved side thereof; 
     FIG. 11 is a perspective view of the corner bracket assembly of FIG. 1 showing window pane supports thereon; and 
     FIG. 12 is a perspective view of a corner bracket assembly according to a second preferred embodiment showing insulated window pane supports thereon. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to the drawings wherein the showings are for purposes of illustrating the preferred embodiments of the invention only and not for purposes of limiting the same, FIG. 1 shows a corner bracket assembly  10  comprising a first housing piece  12  and a second, opposing housing piece  14  which together form a housing  15 . With reference to FIG. 6, the first housing piece  12  comprises a body portion  16 , a first leg portion  18 , and a second leg portion  20 . The body portion  16  is generally rectangular-shaped. The first leg portion  18  extends from a first side  22  of the body portion  16 . The second leg portion  20  extends from a second side  24  of the body portion  16  in a direction approximately normal relative to the first leg portion  18 . A plurality of coupling pins  26  extend from a cavity side of the first housing piece  12 . Each of the plurality of coupling pins  26  includes a tail  28  (FIG. 4) at a distal end thereof. Additionally, a plurality of first housing walls  30  extend from a perimeter edge  32  of the cavity side. 
     With reference to FIG. 5, the second housing piece  14  comprises a body portion  34 , a first leg portion  36 , and a second leg portion  38 , similar to the first housing piece  12 . Again, the body portion  34  is generally rectangular-shaped. The first leg portion  36  extends from a first side  40  of the body portion  34 . The second leg portion  38  extends from a second side  42  of the body portion  34  in a direction approximately normal relative to the first leg portion  36 . A plurality of coupling pockets  44  are defined within the second housing piece  14 . A counterbored edge  46  (FIG. 2) is provided around each of the plurality of coupling pockets  44  on an outward side of the second housing piece  14  opposite from the cavity side. Additionally, a plurality of second housing walls  48  extend from a perimeter edge  50  of the cavity side. 
     With reference to FIG. 1, the first housing piece  12  connects to the second housing piece  14 . More specifically, the plurality of first housing walls  30  abuttingly engage the plurality of second housing walls  48 . To provide structural integrity and securely connect the housing pieces  12 , 14  together, the plurality of coupling pins  26  (FIG. 6) are received through the plurality of coupling pockets  44  (FIG.  5 ). The tails  28  (FIG. 4) of the plurality of coupling pins  26  are staked to the counterbored edges  46  (FIG. 2) of the second housing piece  14  to thereby securely connect the first and second housing pieces  12 ,  14  together. When connected together, the housing pieces  12 ,  14  define a cavity therebetween. 
     With reference again to FIG. 6, a pair of spaced first ridges  52  is disposed on the cavity side of the first housing piece  12 . Each of the first ridges  52  is angled relative to the second side  24  of the body portion  16  as shown. Additionally, the first ridges  52  are substantially parallel to one another. A pair of spaced second ridges  54  is disposed on the cavity side of the second housing piece  14 , as shown in FIG.  5 . Like the first ridges  52 , each of the second ridges  54  is angled relative to the second side  42  of the body portion  34  of the second housing piece  14  and the second ridges  42  are substantially parallel to one another. 
     With reference to FIG. 4, a lower bolt support  60  extends from the cavity side of the first housing piece  12 . The lower bolt support  60  includes a radial notch  62  (FIG. 6) for supporting a shaft  63  of a bolt  64 . A first upper bolt support  66  also extends from the cavity side of the first housing piece  12 . The upper bolt support  66  includes a radial notch  68  (FIG. 6) for supporting the shaft  63  near a head portion  70  of the bolt  64 . The first upper bolt support  66  and the lower bolt support  60  are oriented parallel to one another and position an axis  71  of the bolt  64  at an angle substantially parallel to the angle of the first and second ridges  52  and  54 . 
     A first bolt head positioning wall  72  is defined by one of the plurality of first housing walls  30 . The bolt head positioning wall  72  includes a radial notch  74  for providing access to a cross-slot  76  defined within the head portion  70  of the bolt  64 . Of course, the cross-slot  76  and/or the head portion  70  could be alternatively configured to allow adjustment of the bolt  64  by any of various known methods. For example, the cross-slot  76  could be replaced with a flat-head slot, hex-head slot, etc. Alternatively, the bolt head portion  70  could be replaced with a hex-headed bolt head, a knurled bolt head for toolless rotation, etc. Besides providing access to the bolt  64 , the bolt head positioning wall  72 , in conjunction with the first upper bolt support  66  and/or the lower bolt support  60 , restricts lateral and longitudinal movement of the bolt  64  relative to the first housing piece  12 . Only rotational movement is allowed. 
     With reference to FIG. 5, a second upper bolt support  78  extends from the cavity side of the second housing piece  14 . The second upper bolt support  78  includes a radial notch  80  for supporting the bolt  64  (FIG. 4) near the head portion  70  thereof. The second upper bolt support  78  is positioned on the cavity side such that when the housing pieces  12 ,  14  are connected together, the second upper bolt support  78  contacts the first upper bolt support  66  and traps the bolt  64  therebetween within the radial notches  68 , 80 . A second bolt head positioning wall  82  is defined by one of the plurality of second housing walls  48 . Like the first bolt head positioning wall  72 , the second bolt head positioning wall  82  includes a radial notch  84  for providing access to the cross-slot  76 . Similar to the first housing piece  12 , the second bolt head positioning wall  82 , in conjunction with the second upper bolt support  78 , restricts lateral and longitudinal movement of the bolt  64  relative to the second housing piece  14 . On the second housing piece  14 , a pair of notches  86  are disposed on respective channel walls  88 . The pair of notches  86 , the second upper bolt support  78 , and the second bolt head positioning wall  82  maintain the position of the bolt  64  in conjunction with the first housing piece supports  60 ,  66 ,  72 . More particularly, all the supports  60 ,  66 ,  72 ,  78 ,  82 ,  86  align the axis of the bolt  64  with the angle of the first and second pairs of ridges  52 ,  54 . 
     With reference to FIG. 3, a roller assembly  90  is slidably supported in the housing  15 . The roller assembly  90  comprises a first roller housing piece  92 , a second roller housing piece  94 , and a roller  96 . With reference to FIG. 7, the first roller housing piece  92  includes a body  97  having a plurality of roller housing walls  98  extending from a perimeter edge  100  of a cavity side thereof. Also, a plurality of coupling pins  102  extend from the cavity side of the body, each having a tail  103 . A first axle opening  104  is disposed in a middle portion of the first roller housing piece  92  for receiving one end of an axle  106  (FIG. 3) of the roller  96 . At a first end of the first roller housing piece  92 , a first nut support member  108  is defined. The nut support member  108  is defined by a set of walls extending from the body  97 . Two of these walls are transverse walls  110  and the other two are portions of the housing walls  98 . Each of the traverse walls  110  has a radial notch  112  defined therein. Between the notched walls  110  and the opposed portions of the housing walls  98 , a first nut pocket  114  is defined. Adjacent a second end of the first roller housing piece  92 , a roller edge portion  116  of the perimeter edge  100  is disposed whereon no roller housing wall  98  is provided. With reference to FIG. 8, a pair of first grooves  118  is located within an outward side of the first roller housing piece body  97  wherein the outward side is opposite the cavity side. 
     With reference to FIG. 9, the second roller housing piece  94  has a body  119  which is generally planar as it does not have any walls extending from its perimeter edge  120 . A plurality of pin pockets  122  are disposed in the second roller housing piece  94  that are capable of receiving the coupling pins  102  of the first roller housing piece  92 . Each pin pocket  122  includes a counterbored edge  123  (FIG. 10) on an opposite side of the second roller housing piece  94 . A second axle opening  124  is disposed in a middle portion of the second roller housing piece  94  for receiving the other of the axle  106  of the roller  96 . At a first end of the second roller housing piece  94 , a second nut support member  128  is provided. The second nut support member  128  comprises a pair of substantially parallel walls  130 , each having a radial notch  132  defined therein. A pair of stub walls  133  connect the extension walls  130 . A second nut pocket  134  is defined between the extension walls  130  and the stub walls  133 . The extension walls  130  are capable of interconnecting within the notched walls  110  of the first roller housing piece  92 . With reference to FIG. 10, a pair of second grooves  126  is defined within an outward side of the second roller housing piece  94 . 
     To assemble the roller assembly  90 , the second roller housing piece  94  is connected to the first roller housing piece  92  with a nut  136  (FIG. 4) and the roller  96  sandwiched therebetween. More particularly, with reference to FIG. 4, one end of the axle  106  of the roller  96  is positioned in the first axle opening  104  (FIG. 7) of the first roller housing piece  92 . The nut  136  is received in the nut pocket  114  of the first roller housing piece  92  between the notched walls  110 . The second roller housing piece  94  (FIG. 10) is connected to the first roller housing piece  94  by aligning the pin members  102  with the pin receiving recesses  122  (FIG.  10 ), the other of the axial support members  106  with the second axle opening  124  (FIG. 10) of the second roller housing piece  94 , and the extension walls  132  (FIG. 9) with the notched walls  110 . The tails  103  of the pin members  102  are staked such that the pin members  102  are securely connected to the counterbored edges  123  of the second roller housing piece  94 . In this arrangement, the nut  136  and the roller  106  are secured in the roller assembly  90 . With additional reference to FIG. 2, the position of the first and second axle openings  104 ,  124  causes the roller  106  to extend outwardly from the first and second roller housing pieces  92 , 94  adjacent the roller edge portion  116  of the first roller housing piece  92 . The grooves  118 , 126  of the roller housing pieces  92 , 94  are parallel to one another and are aligned on the outward sides of the roller housing assembly  90 . 
     To assemble the housing  15 , the bolt  64  is positioned within the upper and lower bolt supports  60 ,  66  of the first housing piece  12  with the head portion  70  positioned between the upper bolt support  66  and the first bolt head positioning wall  72 . The second housing piece  14  is connected to the first housing piece  12 . More particularly, the coupling pockets  44  of the second housing piece  14  are aligned with the coupling pins  26  of the first housing piece  12 . The tails  28  of the coupling pins  26  are staked such that the coupling pins  26  are securely connected to the counterbored edges  46  (FIG. 2) of the second housing piece  14  thereby forming the housing  15 . 
     The roller assembly  90  can then be installed in the housing  15 . More particularly, the grooves  118 , 126  of the roller assembly are aligned with the ridges  52 ,  54  of the housing  15  during which the roller  96  is positioned away from the housing  15 . The alignment of the grooves  118 ,  126  with the ridges  52 ,  54  causes the bolt  64  to be aligned with a bolt recess created by the outermost radial notches  112 ,  132  of the roller housing assembly  90 . The bolt  64  can be rotated to threadingly engage the nut  136  thereby securing the roller housing assembly within the housing  15 . In an alternative embodiment, the corner bracket assembly  10  can be assembled without the roller assembly  90  and used alone as a simple corner bracket where the roller feature is not desired, such as the top corners of a window sash. Of course, a corner bracket assembly  10  with the roller assembly  90  may be used on the same sash or panel as a corner bracket assembly  10  without the roller assembly. For example, a pair of corner brackets  10  with roller assemblies  90  could be used on bottom corners of a sash while a pair of corner brackets  10  without roller assemblies  90  could be used on top corners of the sash. 
     To adjust the roller  96  of the corner bracket assembly  10 , the bolt  64  is rotated in a first direction thereby extending the roller  96  outward relative to the housing pieces  12 ,  14  and in a second, reverse direction to retract the roller  96  inward relative to the housing pieces  12 ,  14 . The angle of the bolt  64  in the corner bracket assembly  10  ergonomically positions the bolt  64  for adjustment. More particularly, rotation of the bolt  64  in the first direction causes the roller assembly  90  to move in a direction of the axis  71  of the bolt  64  as a threaded portion  138  (FIG. 4) of the bolt  64  acts against the nut  136 . The roller  96  is allowed to protrude outward from the first and second housing pieces  12 ,  14  because none of the plurality of walls  30 ,  48  obstruct movement of the roller assembly  90 . The roller assembly  90  is guided during movement by a track comprised of the ridges  52 ,  54  of the first and second housing pieces  12 ,  14  engaged with the grooves  118 ,  126  of the first and second roller housing pieces  92 ,  94 . Thus, the roller assembly  90  slidably moves along the track. 
     When the bolt  64  is rotated in the first direction, the roller housing assembly  90  moves outwardly, relative to the housing  15 . Additionally, the track provides improved strength characteristics to the corner bracket assembly  10  because the groove and ridge engagement defines a rigid structure capable of resisting an upward force applied to the roller  96 , particularly when the upward force applied is parallel to the first leg portions  18 ,  36 . In a similar manner, rotation of the bolt  64  in the second, reverse direction causes the roller housing assembly  90  to retract into the cavity of the housing pieces  12 ,  14  along the track. As best shown in FIG. 1, the cross-slot  76  of the bolt  64  remains accessible for adjustment of the roller assembly  90 . 
     With reference to FIGS. 2 and 3, the corner bracket assembly  10  can be used with a frame assembly comprising a plurality of elongated members  140  and at least one pane of glass (not shown) or a screen. The frame assembly can be that of a door, window, panel or the like. The elongated members  140  generally have an internal cross-section that interconnects with the exterior cross-sections of the leg portions  18 ,  20 ,  36 ,  38  of the corner bracket assembly  10 . With additional reference to FIG. 11, flanges  160  protrude from the corner bracket assembly  10  for engaging flange receiving grooves  162  (FIG. 3) on the elongated members  140 . As shown in FIG. 11, portions of the first and second housing walls  30 ,  48  form pane supports  164 . The pane supports  164  extend inwardly toward one another and are adapted to receive and support the at least one pane of glass. In FIG. 11 the supports  164  are meant to hold an uninsulated double glass construction. With reference again to FIG. 1, the roller  96  is mounted in a track  146  that lies beneath the door, window or similar panel. 
     With reference again to FIG. 6, the first housing piece  12  also comprises a plurality of spaced ribs  150 . The ribs define a path for accommodating a locking bar (not illustrated) of the door or window. The locking bar extends out the bottom of the bracket assembly  10  through an aperture  152  (FIG. 1) defined therein. Suitable apertures such as at  154  (FIG. 1) are defined in the second housing piece for accommodating fasteners (not illustrated) for allowing the bracket assembly to be secured to the frame members  140 . A staked opening is illustrated at  156 . An indentation  158  is defined in the side wall of the bracket to allow access to the head portion  70  of the bolt or similar fastener that regulates the positioning of the housing for the roller  96 . 
     With reference to FIG. 12, a corner bracket assembly  200  is shown according to a second preferred embodiment of the present invention. In most aspects, the corner bracket assembly  200  is similar to the corner bracket assembly  10 . However, the corner bracket assembly  200  is for use with an insulated glass construction wherein two more widely separated panes of glass (not shown) are held in place between a plurality of elongated members (not shown) and a plurality of other corner bracket assemblies  200 . A layer of gas, such as argon gas, is used to separate the panes of glass and provide an insulating function. The elongated members used in such an insulated glass application do not have flange receiving grooves  162  so the corner bracket assembly  200  is without flanges  160 . Further, the pane supports  164  are replaced by opposing sets of pane supports  202  for the insulated pane construction. Each set of insulated pane supports  202  supports one of the two panes of glass used in the insulated pane construction. 
     The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they are within the scope of the appended claims or the equivalents thereof.