Rod connector system and methods of use

A rod connector is provided including a disc portion, a first shaft portion and a second shaft portion. The disc portion has a first side configured to engage a first rod and a second side configured to engage a second rod. The first shaft portion extends from the first side of the disc portion and includes threads along at least a portion of the length thereof for engaging threads of the first rod to draw the first rod into engagement with the disc portion. The second shaft portion extends from the second side of the disc portion and includes threads along at least a portion of the length thereof for engaging threads of the second rod to draw the second rod into engagement with the disc portion.

FIELD

This disclosure relates to connectors and, in particular, to connectors for joining rods together.

BACKGROUND

Many homeowners place curtain rods above windows to enable curtains to be drawn open or closed over the window to selectively control the amount of light entering a room from outside the home. Curtains may also be drawn closed to inhibit those outside of the home from viewing inside the home through the window. Curtain rods are also often used with showers to hang a shower curtain along an opening to a shower to prevent water from exiting the shower.

Since the curtain rods must span the width of a window or the length of a shower, the curtain rods can be very long. Even where telescoping rods are used, the length of each rod may be very long. As a result, the curtain rods are placed in long boxes for sale, storage, and transportation. Long boxes are more costly to produce, to transport, and to store in a warehouse and consume too much display space in retail stores.

Further, connections can also provide a rough transition between tubes. In many instances, curtains are suspended from the rods using loops and hooks. The loops and hooks have to slide along the rods to open and close the curtain. When there is a rough transition between the rods, the loops and hooks tend to hang up on the transitions as they slide along the rods.

DETAILED DESCRIPTION

A rod connector is provided for coaxially connecting two rods together. The rods may be curtain rods for supporting curtains over a window or shower rods for supporting a shower curtain. The rod connector also may be used, for example, to connect rods used to support a shower caddy, rods of a storage support, and rods of a closet pole (e.g., for hanging clothes). Those having skill in the art will readily appreciate other applications where the rod connector may be used to join two rods together to increase the overall combined rod length. Use of the rod connector enables two rods to be joined together to form a rod having an increased length and smooth transition from one rod to the other. The two rods may be separate when packaged enabling a box having a shorter length to be used which reduces the costs of the box and costs associated with shipping and storing the packaged rod system. The end user or installer may join the two rods together using the rod connector to provide a rod having a desired length, e.g., a length that spans the width of a window or the length of a shower.

The rod connector includes a disc portion that is positioned between the ends of the two rods to be connected. The disc portion has a first side configured to engage a first rod and a second side configured to engage a second rod. A first shaft portion extends from the first side of the disc portion for connection with a first rod. The first shaft portion includes threads along at least a portion of the length thereof for engaging threads within the first rod to draw the first rod into engagement with the disc portion. A second shaft portion extends from the second side of the disc portion for connection with a second rod. The second shaft portion includes threads along at least a portion of the length thereof for engaging threads within the second rod to draw the second rod into engagement with the disc portion. The first and second rods are connected to one another when the first and second rods are threaded on to the first shaft portion and second shaft portion, respectively, such that the first and second rods engage the disc portion. The disc portion creates a smooth transition from one rod to another.

With respect toFIG.1-5, a rod connector100is shown according to a first embodiment. The rod connector100includes a connecting disc102and a stud104. The connecting disc102includes a disc portion106having a central opening108through which the stud104passes through the connecting disc102. The stud104includes threads110disposed thereon for attachment to the rods112,114as described in further detail below. The stud104may be formed of a metal (e.g., steel). As one example, the stud104has a diameter of 0.25 inches with20threads per inch.

The central opening108of the connecting disc102may be sized to slide over the threads of the stud104along the length of the stud104. The central opening108may be sized such that the central opening108is slightly larger than the threads110of the stud104so that the connecting disc102is maintained on the stud104by a friction fit connection. The connecting disc102may be positioned at a middle point of the stud104such that a first portion104A of the stud104extends from the connecting disc102in a first direction and a second portion104B of the stud104extends from the connecting disc102in a second direction opposite the first direction. As one example, the central opening108may have a diameter of 0.25 inches.

The connecting disc102includes a collar116about the central opening108on both sides of the connecting disc102. The collars116increases the length of the central opening108through which the stud104passes through the connecting disc102. The collars116may aid to stabilize the connecting disc102and maintain the connecting disc102in a position substantially perpendicular to the length of the stud104. The collars116further increases the portion of the connecting disc102that engages the stud104providing for increased frictional resistance between the connecting disc102and the stud104.

In some forms, the central opening108of the connecting disc102may include complementary threads for engaging the threads110of the stud104to maintain the connecting disc102on the stud104. The stud104may be threaded into the connecting disc102until the connecting disc102is at the desired position along the stud104.

The disc portion106extends radially outward from the collar116to a radial outer edge or outer rim118. The disc portion106is substantially planar and forms a surface for the ends of tubes or rods112,114(seeFIG.5) to contact or abut when connected by the rod connector100. The outer rim118forms a flange120about the peripheral edge of the disc portion106on both sides of the connecting disc102. Each flange120extends substantially parallel to the length of the stud104to form recessed portions for receiving the rods112,114therein.

In some embodiments, such as the embodiment inFIG.11, the flanges120form a face against which the end of the rods112,114engage. For instance, an outer portion of the flanges120may have an increased radial thickness to provide a face120A having a larger surface area for the ends of the rods112,114to engage when drawn toward the connecting disc102. In some forms, the flanges120form a surface extending radially inward a substantial or the entire distance to the collars116. In other forms, the outer diameter of the flange120may have the same outer diameter of the rods112,114so that the transition between the rods112,114over the flanges120of the connecting disc102is smooth. In further forms, the diameter of the flange120may be smaller or larger than the outer diameter of the rods112,114.

The radial outer surface of the outer rim118is rounded or arcuate to create a smooth transition from the first rod112over the connecting disc102and to the second rod114. This smooth transitional surface permits or facilitates curtains and/or curtain rings or hooks which support a curtain to pass from the first rod112to the second rod114, and vice versa, without catching on an end of a rod or the connector100as the curtains/curtain rings are drawn to one side or the other of the length of the rods112,114. The connecting disc102may be formed of a plastic material, such as acrylonitrile butadiene styrene (ABS). In other embodiments, the connecting disc102is formed of a metal material (e.g., steel, zinc, or aluminum). As one example, the outer diameter of the outer rim118is 0.905 inches and the inner diameter formed by the flange120is 0.875 inches.

With respect toFIG.5, the rod connector100is shown attaching two rods112,114coaxially to one another. As shown, the rods112,114include attachment members or attachment plates122,124positioned at the end of the rods112,114. Each attachment plate122,124includes a threaded hole (not shown). The attachment plate122is secured in the end of the rod using welding, indentations or any conventional methods. The first portion104A of the stud104is threaded into the threaded hole of the attachment plate122until the end face112A of the rod112is brought into contact with the disc portion106of the connecting disc102and within the flange120. Likewise, the second portion104B of the stud104is threaded into the threaded hole of the attachment plate124until the end face114A of the rod114is brought into contact with the disc portion106and within the flange120.

The outer diameter of the rods112,114may be adjacent and in contact with the radially inner surface of the flange120. For example, the rods112,114may be ⅞ inch rods configured to be received within the flange120. The flange120spans the gap between the connecting disc102and the rods112,114. As discussed above, due to the rounded or curved shape of the outer rim118of the connecting disc102, the outer rim118creates a ramped or smooth transitional surface from the first rod112to the second rod114when the rods112,114are connected by the rod connector100to permit curtains or curtain rings to pass over the connection interface of the rods112,114with ease.

By use of the rod connector100, a curtain rod system may include two shorter rods that are easily joined together by the rod connector100to form a longer rod upon assembly by the installer or end user. The curtain rod system with shorter rods may be contained, transported, stored, and displayed in a smaller box which reduces the costs of the box, the cost to transport the system, the cost to store the system, and the cost to display the system, all without compromising the functionality and utility of the curtain rod system.

With respect toFIGS.6-10, a rod connector system according to a second embodiment is shown including a rod connector200and attachment members or insert plugs202. In this second embodiment, the insert plugs202are positioned within the end of two rods that are to be connected to one another. The rod connector200may thread into the insert plugs202within each rod to coaxially connect the rods together.

With respect toFIGS.6and7, the rod connector200includes a disc portion204positioned along a shaft206. A first end206A of the shaft206may extend from the disc portion204in a first direction and a second end206B of the shaft206may extend from the disc portion204in a second direction opposite the first direction. As one example, the rod connector200may have length of 2.188 inches.

In some forms, the rod connector200is a single piece with the shaft206formed integrally or unitarily with the disc portion204. For example, the rod connector200may be a molded or cast component. The rod connector200may be formed of a plastic or a metal material (e.g., zinc). In other forms, the disc portion204includes a central opening through which the shaft206extends similar to that described above with regard to the first embodiment.

Each end206A,206B of the shaft206include threads207for engaging the insert plugs202to secure two rods222,224(seeFIG.10) together as described in further detail below. The threads207may extend along the entire length of the ends206A,206B of the shaft206or along a portion of the length of the ends206A,206B of the shaft206as shown.

The disc portion204may include a cylindrical body208coaxially aligned with the shaft206. The disc portion204may include a ridge210extending annularly about the body208and defining a first portion208A and a second portion208B of the body208. The cylindrical body208may have a diameter configured to be received within the end of the rods222,224when the rod connector200connects the two rods together, with the ridge210having a diameter that is larger than the internal diameter of the rods222,224. Thus, when connecting two rods together, the rods may extend over the body208and abut the ridge210. As one example, the outer diameter of the cylindrical body208has a diameter of 0.6 inches and the outer diameter of the ridge210has an outer diameter of 0.65 inches. The ridge210creates a smooth transition between the two rods.

With respect toFIGS.8-9, the insert plugs202have a substantially cylindrical body211having an outer diameter sized to be positioned within an end of a rod222,224and be held within the rod222,224by a friction fit. The outer diameter of the insert plugs202may be the same size or slightly smaller than the internal diameter of the rods. The insert plugs202may be sized such that insertion into the rods222,224requires substantial force such that the insert plugs202are not able to move substantially when the rod connector100is used to connect the two rods222,224together. For example, the insert plug202may be held in place by a frictional force that is greater than the forces expected to be applied to the insert plug202under normal use and application of the rod connector system to prevent the insert plug202from moving substantially within the rod. Alternatively, indentations of the rod may be dug into the body211to hold the insert plug202in place.

The insert plugs202include an internal surface212that defines a central opening214for receiving the shaft206of the rod connector200. The insert plugs202include internal threads216along a portion or the entire length of the internal surface212for receiving and engaging the threads207of the rod connector200.

The insert plugs202may be formed of a plastic such as acetal. In one example, the outer diameter of the insert plug202is 0.6 inches and the insert plug202has a length of 0.8 inches.

In use, and with respect toFIG.10, one insert plug202is positioned within an end of a first rod222and a second insert plug202is positioned within an end of a second rod224. The threads207of each end206A,206B of the shaft206of the rod connector200may be threaded into the threads216of the insert plug202. The rods222,224may be threaded on to the rod connector200simultaneously or one rod222,224at a time. The rods222,224may be rotated until the respective ends222A,224A of the rod abut or contact the ridge210of the disc portion204. The outer diameter of the rods222,224may be the same or smaller than the outer diameter of the ridge210such that the rods222,224are not able to pass beyond the ridge210. The ridge210thus aids to prevent an installer from overtightening the rods222,224on the rod connector200, which aids in limiting the force applied by the rod connector200to the insert plugs202held in place by a friction fit. In one example, the rods222,224have an outer diameter of 0.63 inches.

When the rods222,224are connected via the rod connector200, the first and second portions of the body208A,208B of the disc portion204may be within the ends of the rods222,224. The outer diameter of the body208may have a diameter that is the same or slightly smaller than the internal diameter of the rods222,224such that the body208engages the rods222,224and aids to maintain the rods222,224in coaxial alignment with one another. The ridge210of the disc portion204may function similar to the outer rim118of the first embodiment, filling the gap between the rods222,224such that a curtain and or curtain hook may slide over the connection point without hooking or snagging the rods222,224or rod connector200. In some forms, the outer edge of the ridge210is rounded or has an arcuate cross-section to form a smooth transitional surface to facilitate movement of a curtain or curtain hook across the connection interface of the rods222,224. In some forms, the ridge210includes flanges extending over the ends of the rods222,224similar to the flange120of the connecting disc102of the first embodiment.

Uses of singular terms such as “a,” “an,” are intended to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms. It is intended that the phrase “at least one of” as used herein be interpreted in the disjunctive sense. For example, the phrase “at least one of A and B” is intended to encompass A, B, or both A and B.

While there have been illustrated and described particular embodiments of the present invention, those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above-described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.