Support bracket and assembly formed of connected structural members

A structural support apparatus comprises a connection bracket comprising, a generally flat, rigid member having opposing generally flat faces and a thickness extending between the flat faces. The rigid member is attachable to a support member. An arm extends from an end of the rigid member and a finger extends from the arm and is receivable in a hollow channel formed in an attachable member of rigid material. The hollow channel is complementary in configuration to at least one of the finger and the arm and a selected recess configuration is formed between the finger, the arm and the end of the rigid member. The recess accommodates one or more lip portions of the attachable member when either the arm or the finger, are received within the hollow channel.

TECHNICAL FIELD

A system concerns a bracket and assembly of wooden, composite, plastic, metal or other beams, planks, boards and their attachment, connection and support in the form of support structures.

BACKGROUND

The assembly of solid elongated wooden or plastic or carbon fiber planks or beams typically requires adapting the beams to include complex channels bored within the body of the beams and unsightly nails, tacks screws and the like inserted through the top surfaces of the beams in order to fasten or attach the beams to an underside set of support beams.

SUMMARY

A structural support apparatus comprises a connection bracket comprising, a generally flat, rigid member having opposing generally flat faces and a thickness extending between the flat faces. The rigid member is attachable to a support member. An arm extends from an end of the rigid member and a finger extends from the arm and is receivable in a hollow channel formed in an attachable member of rigid material. The hollow channel is complementary in configuration to at least one of the finger and the arm and a selected recess configuration is formed between the finger, the arm and the end of the rigid member. The recess accommodates one or more lip portions of the attachable member when either the arm or the finger, are received within the hollow channel.

In a feature, the attachable member comprises a solid body of rigid material formed as a generally rectangular parallelepiped having top and bottom with opposing side and opposing end faces having a selected length, width and thickness respectively. The connection bracket is attachable to a beam of rigid material. The connection bracket is movable within the hollow channel to position the beam with respect to the attachable member and in response to attachment of the connection bracket to the beam, the beam is rigidly attached to the attachable member by pressure of the lip portions of the attachable member on the arm and the finger. The beam comprises a solid body having generally flat top and bottom faces and a thickness extending between the top and bottom faces. One of the opposing generally flat faces of the connection bracket is preferably matable against and attachable to one or the other of the generally flat top and bottom faces of the beam while the arm and the finger of the bracket are received within one or more hollow channels of the attachable member.

In another feature, the attachable member and the connection bracket comprise at least one of, (a) metal, (b) wood, (c) plastic, (d) composite material and (e) glass fiber. One or more generally rectangular hollow channels are formed within the thickness of the channel extending along the attachable member length. The one or more hollow channels are disposed within the solid body of rigid material of which the attachable member is comprised. The apparatus can include at least two attachable members each having a generally rectangular channel formed within the thickness of each of the at least two attachable members. The rectangular channels form a lengthwise lip in each of the two attachable members that are each receivable within one or the other of the pair of recesses formed by the arm and the fingers of the bracket. The rectangular channel forms a lengthwise lip receivable within the recess. The attachable member includes a generally T-shaped channel disposed within the thickness of the body of the attachable member. The generally T-shaped channel is complementary in configuration to recesses formed by the arm and the finger of the bracket such that the arm and the finger of the bracket fit within the generally T-shaped channel.

In a further feature, the arm and the finger and the hollow channel are configured such that the lip portions fit snugly within the recess and the arm is angled with a non-zero angle relative to a plane of the rigid member. The finger is at a non-zero angle of rotation with respect to a plane of the arm or of the rigid member. The arm extends longitudinally from the end of the rigid member and a pair of fingers extend in a flange configuration from the end of the arm. The arm and the fingers form a generally T-shaped extension member and a pair of opposing recesses are formed between the pair of fingers, the arm and the end of the rigid member.

In another feature, the bracket includes one or more clips extending laterally in one direction from at least one of the generally flat faces of the bracket. The one or more clips have a sharp terminal edge that can puncture and extend through a face of a beam and extend into the solid body of the beam upon application of a laterally directed force against a face of the bracket opposing the lateral direction of extension of the one or more clips. In response to insertion of a clip into the body of the beam, the bracket is forced to travel along its longitude by forcible interaction between a surface of the clip and the body of the beam. A lengthwise lip in each of the channels in two attachable members are each receivable within one or the other of the pair of recesses formed by the arm and the fingers of the bracket.

In an additional feature a kit comprises the connection bracket and a machining tool for use in machining rigid material comprising the attachable member to provide the hollow channel complementary in configuration to at least one of the finger and the arm and the selected recess configuration.

DETAILED DESCRIPTION

A structural support connection bracket comprises, a generally flat, rigid member with an arm extending from the end of the rigid member and a finger extending from the arm with the finger being receivable in a hollow channel formed in an attachable member of rigid material.FIG. 1shows an assembly10employing a connection bracket50and forming a structural support apparatus such as an outdoor deck, shelves, flooring, for example, comprised of at least one elongated attachable member (plank)20that is comprised of a solid body of rigid material such as wood or plastic. Individual attachable member20is formed as a generally rectangular parallelepiped30having top32and bottom34(FIG. 2) and opposing sides36a,36bas well as opposing end38faces. Member20has a selected length L1, width W1and thickness TH1. The beam40has generally flat opposing or parallel top42and bottom44faces and a thickness TH2extending between the top bottom faces42,44. The attachable member and beam comprise at least one of, (a) metal, (b) wood, (c) plastic, (d) composite material and (e) glass fiber. The connection bracket comprise at least one of, (i) metal, (ii) plastic and (iii) composite material.

As shown inFIG. 1, one of the faces52,54(FIG. 3, 4) of a bracket can be placed in matable engagement with a face42,44of a beam40and attached to the beam by conventional attachment means such as a nail or screw120driven through the thickness TH3(FIG. 4) of a bracket into the body of the beam40holding the two components50,40together to form the assembly shown inFIG. 1.

A connection bracket50comprises a generally flat, rigid metal plate member having opposing generally flat longitudinal faces52,54,FIG. 4, and a thickness TH3extending between the flat longitudinal faces52,54, the plate member50having a longitudinal terminal end56(FIG. 3) from which extends an arm60having a selected arm configuration from which extends a finger70,72having a selected finger configuration. The fingers70,72and the arm are adapted, formed and arranged to form a recess80having a selected recess configuration formed between the finger, the arm and the terminal end.

The attachable member20has one or more hollow channels90,92(FIG. 2A, 2B) disposed within the solid body of rigid material of which the attachable member20is comprised. The one or more channels90,92are adapted and configured to be complementary in configuration to the configuration of one or the other or both of the selected configurations of the arm60, the fingers70,72and the recesses80. Thereby, one or the other or both of the finger70,72and the arm60of the bracket50is receivable within the one or more hollow channels90,92. The channels form one or more lip portions27a,27b,29a,29bin the solid body of the attachable member20such that the lip portions27a,27b,29a,29bare received within the recess80of the connection bracket50when either the arm60or the finger70,72are received within the channel90,92.

One of the opposing generally flat longitudinal faces52,54of the connection bracket50is preferably matable against, and attachable to, one or the other of the generally flat top and bottom faces42,44of the support beam40while the arm60and the finger70,72of the bracket50are received within the one or more hollow channels90,92of the attachable member20. The arm60and finger70,72of the bracket50and the one or more hollow channels90,92of the attachable member20are preferably adapted, configured and arranged such that the lip portions27a,27b,29a,29bformed in the solid body of the attachable member20fit snugly within the recess80formed by the arm60and the finger70,72and the longitudinal terminal end56of the bracket50.

The arm60typically extends longitudinally LA (FIG. 3) away from the terminal end56of the bracket and a pair of fingers70,72extend in a flange configuration from a longitudinal terminal end62of the arm60. The arm60and the fingers70,72form a generally T-shaped extension member75from the longitudinal terminal end56of the bracket50, a pair of opposing recesses80are formed between the pair of fingers70,72, the arm60and the longitudinal terminal end56of the bracket50.

The bracket50preferably includes one or more clips100extending laterally LO (FIG. 4) in one direction outwardly from at least one of the generally flat faces52,54of the bracket50. The one or more clips100being adapted, configured and arranged to have a sharp terminal edge102that can puncture and extend through a face42,44of the support beam40and extend into the solid body of the support beam40upon application of a manually applied laterally directed force F against a face54,FIG. 4, of the bracket50that laterally opposes the lateral direction of extension LO of the one or more clips100. The one or more clips100are typically adapted, configured and arranged such that upon extension of a clip into the body of the support beam40, the bracket50is forced to travel along its longitude LA by forcible interaction between a surface of the clip100and the body of the support beam40.

The attachable member20typically has a generally rectangular channel92formed within the thickness of the channel extending along the attachable member length L1,FIG. 2B,FIG. 2A. The rectangular channel92forms a lengthwise lip29aor29breceivable within the recess80formed by the arm60, the finger70,72and the longitudinal terminal end56of the bracket50. The apparatus10can include at least two attachable members20,FIG. 1,FIG. 2Beach having a generally rectangular channel92formed within the thickness of each of the at least two attachable members20,20a(FIG. 2B). The rectangular channels92form a lengthwise lip29a,29bin each of the two attachable members20,20athat are each receivable within one or the other of the pair of recesses80formed by the arm60and the fingers70,72of the bracket50.

The attachable member20includes a generally T-shaped channel90(FIG. 2A) disposed within the thickness of the body of the attachable member and extending the length L1of the attachable member,FIGS. 1, 2A. The generally T-shaped channel90is complementary in configuration to the recesses80formed by the arms60and the fingers70,72of the bracket50such that the generally T-shaped extension member75of the bracket50fits within the generally T-shaped channel90within the body of the attachable member20.

As shown inFIG. 5the clips100are configured to have a surface104that is arranged along a planar direction A that is oriented at an acute angle AA to the longitudinal axis LA of the bracket50. This angled orientation of the surface104as surface104is bored into engagement with the body of support beam40by force F, causes the bracket to travel longitudinally LA upon application of force F. As shown inFIG. 5, the clips having a laterally extending LO sharp distal edge102that can be driven into the body of the support beam on application of force F serving to assist in attaching the bracket to the beam40.

FIG. 6shows a connection bracket embodiment in views601,603,605and607presenting a generally flat, rigid member having opposing generally flat faces and a thickness extending between the flat faces where the rigid member is attachable to a support member. An arm extends from an end of the rigid member and a sharp edged finger extends from the arm and is receivable in a hollow channel formed in an attachable member of rigid material. The arm is in the same plane as the rigid member. Upon insertion of a screw through the bracket into a beam, the bracket is forced longitudinally so that the sharp edged finger engages with the hollow channel of the attached member. The hollow channel is complementary in configuration to at least one of the finger and the arm and a selected recess configuration is formed between the finger, the arm and the end of the rigid member. View601shows a rotated view of the bracket, view603shows the bracket side profile and view605shows the bracket planar view indicating a curved lower edge offering enhanced aesthetic appeal for furniture type use, for example. Two screw holes through the bracket are also shown in the planar view with one or more of the holes providing an angled guide for forcing the bracket towards an attachable member upon insertion of the screw through the bracket into a beam. View607shows the first bracket top view from the finger end.

FIG. 7shows another connection bracket embodiment in views609,613,615and630. View630shows a rotated view of the bracket, View609shows a side profile of the bracket and view613shows the bracket planar view. View609shows a rotated arm and finger element611. At least one of the arm and finger elements are rotated with respect to the rigid member. The rotated arm and finger element611advantageously enables attaching a member to the bracket in a non-perpendicular arrangement. The angle of rotation may lie in the range 0-90 degrees. View615shows the bracket top view from the rotated finger end.

FIG. 8shows a further connection bracket embodiment in views701,703,720and722. View701shows a rotated view of the bracket, View703shows the bracket side profile illustrating sharp edged fingers705that oppose each other and engage with a hollow channel of an attached member to resist movement as further illustrated in fingers717of end view722. Upon insertion of screw707through the bracket into a beam until the screw head is flush with the adjacent bracket protrusion as shown in view703, the bracket is forced longitudinally so that the sharp edged fingers engage with the hollow channel of the attached member. Additional protrusions709(one to four or more, for example, with the number adaptively selected in response to type of materials used) dig into the beam to position the bracket for installation and provide a further force in a longitudinal direction through the bracket to the attached member. The protrusions709are advantageously angled in an embodiment to provide longitudinal force along the bracket in the direction of the attached member. Planar view720of the bracket shows two screw holes with hole713comprising an elongated hole available for a second screw if the material requires it.

FIG. 9shows another connection bracket embodiment in views715,719,724and731. View731shows a rotated view of the bracket, View724shows a side profile of the bracket presenting an angled arm and finger arrangement711further illustrated in end view719. The angle provides pre-tensioning of the bracket within a hollow channel of an attached member and enhances resistance between channel and finger-arm and also advantageously provides angular installation of a beam with respect to an attached member. Planar view715of the bracket again shows two screw holes as previously described. In one embodiment, he arm is angled with a non-zero angle relative to a plane of the rigid member. In a further embodiment, the finger is at a non-zero angle of rotation with respect to a plane of the arm or of the rigid member.

FIG. 10shows additional views903and906of a bracket assembly. Specifically, view903shows four brackets attached to a beam with the bracket arm and finger elements being incorporated in hollow channels of attached members. View906shows three beams coupled to three attached members with each beam being incorporated in hollow channels of attached members using six brackets.

A structural support connection bracket comprises an arm extending from the end of a rigid member and a finger extending from the arm with the finger being receivable in a hollow channel formed in an attachable member of rigid material. The bracket advantageously enables quick secure, flexible assembly of a wide variety of structures, including, flooring, shelves, walls, cupboards, furniture and many more structures. Those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific bracket embodiments and examples herein.