Connector assembly for food preparation equipment and method of assembly

A connector assembly for joining a horizontal member and a vertical member without the formation of substantial exposed gaps. The assembly includes a base with a saddle surface at one end and an abutment flange at the other end. The base has an aperture between the ends and a slot communicating with the aperture. A locking collar has a bore receiving the base and an inwardly directed annular lip at a first end of the collar. The collar also includes an internal screw thread and an abutment for engaging the flange of the base. Also the assembly includes a locking insert with a body for reception in the base. The insert has extending arms at one end terminating in screw threads and at the other end a holding flange for retaining the horizontal member. A method of using the connector assembly is also disclosed.

This invention relates to connector assemblies and, more specifically, to a 
connector assembly for joining a vertical leg and a horizontal support in 
a food preparation table without the formation of substantial crevices or 
cracks. 
BACKGROUND OF THE INVENTION 
The National Sanitation Foundation (NSF), a body recognized by the food 
service supply industry, has promulgated various regulations with respect 
to the materials used in and the design of food service furniture such as 
food preparation tables. The construction materials currently approved by 
NSF for use in such furniture are stainless steel, zinc coated steel and 
polyamide 11 nylon over galvanized steel. NSF also requires that there be 
nothing in the furniture of a nature to cause a gap over 1/32". Food could 
collect in such a gap resulting in the growth of bacteria. 
Various connector assemblies are known for joining a horizontal brace to a 
vertical leg in furniture or the like. However, these assemblies are not 
suitable for food service furniture because they result in the formation 
of cracks or crevices, or because certain components must be cemented 
together. For further information regarding the structure and operation of 
such connector assemblies, reference may be made to U.S. Pat. Nos. 
4,386,870; 4,150,907 and 3,891,334. A knock-down work table for use in the 
food service industry is the subject of U.S. Pat. No. 4,444,125. 
SUMMARY OF THE INVENTION 
Among the several aspects and features of the subject invention is the 
provision of an improved connector assembly. The use of the connector 
assembly does not result in the formation of an substantial exposed gaps 
cracks or crevices, and the only preparation required for the vertical leg 
is drilling a hole and forming inwardly extending protuberances in the 
horizontal brace. The connector assembly also extends over areas of cut 
metal in the leg and brace to resist corrosion. The connector assembly of 
the present invention is easy to install, is reliable in use, has long 
service life, and is easy and economical to manufacture. Other aspects and 
features of the method of the present invention will be, in part, apparent 
and, in part, pointed out hereinafter in the following specification and 
in the accompanying drawings. 
Briefly, the connector assembly of the present invention includes a base 
having at one end a saddle surface for engaging the outside surface of the 
vertical member and at the other an abutment flange. An aperture extends 
between the ends and a slot is provided communicating with the aperture. A 
locking collar defines a bore for receiving the base with a first end 
defining an opening having a diameter slightly greater than the diameter 
of the outside surface of the base. The collar has a second end with an 
inside diameter slightly greater than the outside diameter of the 
horizontal brace, and an internal screw thread is provided between the 
collar ends. The collar also has an abutment for engaging the abutment 
flange. The assembly also includes a locking insert having a body sized 
for reception in the base aperture with a leading end and a trailing end. 
The insert has an outward extension adjacent the leading end for reception 
in the slot in the base with a thread on the outside surface of the 
extension. A holding flange for bearing on the protuberances extends from 
the body adjacent the trailing end. 
As a method, the present invention includes the following steps: 
(a) the base is inserted through the collar with the saddle surface 
extending beyond the collar first end; 
(b) the base is fastened to the vertical leg with the saddle surface 
engaging the outside surface of the leg; 
(c) the insert is positioned in the horizontal member with the holding 
flange behind the protuberances and the leading end of the insert 
extending beyond the brace leading end; 
(d) the insert body is positioned inside the base aperture with the 
extension projecting through the slot; and 
(e) the collar is threaded onto the extension until the protuberances 
engage the holding flange and the abutment flange engages the brace end.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to the drawings, a connector assembly of the present 
invention for joining a horizontal brace 16 to a vertical leg 18 in, for 
example, a food preparation table 19, is generally indicated in FIGS. 1--3 
by reference numeral 20. The connector assembly 20 includes a generally 
cylindrical base 22 held to the vertical leg 18 by a fastener assembly, a 
locking insert 26 retained by the horizontal brace 16 and extending 
therefrom, and a locking collar 28 which is retained by the base and is 
threadably connected to the insert 26. The assembly 20 is particularly 
adapted for use with legs and braces formed of polyamide 11 nylon coated 
galvanized tubing which, as shown in the drawings, are preferably 
cylindrical. As will be explained in more detail below, to mount the 
assembly 20, a hole 30 must be drilled in the wall of the leg 18 and 
inwardly extending protuberances 32 must be formed in the horizontal brace 
which may result in separation of the metal. Besides avoiding the 
formation of substantial openings, the connector assembly 20 fully covers 
areas of cut metal in the leg and brace to resist corrosion. 
The fastener assembly includes a deformable nut 34, and a bolt 36 
preferable of zinc plated steel. The base 22, locking insert 26 and 
locking collar 28 are preferably formed of nylon or other high strength 
plastic material, as will be appreciated by those of skill in the art. 
More specifically, the base 22 has a generally cylindrical outside surface 
38 and a saddle surface 40 at one end for engaging the outside surface of 
vertical leg 18. As best shown in FIG. 6, the saddle surface 40 defines a 
portion of a cylindrical surface having substantially the same diameter as 
the outside diameter of the leg 18 so that the body and leg may enter into 
substantially full surface engagement. An outwardly extending abutment 
flange 42 is provided at the other end of the base for engagement by both 
the collar 28 and the leading end 44 of the brace. The base has an 
aperture 46 extending between its ends and intersecting an interior ledge 
48 (for engaging the head of the bolt 36). The aperture 46 has an enlarged 
portion 50 for receiving the insert 26, and a pair of diametrically 
opposed slots 52 extending from the other end of the base and 
communicating with aperture portion 50 to permit extension of components 
of the insert 26 radially outwardly of the base 22. 
The locking collar 28, which may have a hexagonal outer surface 53 to 
permit tightening with a wrench, defines a bore 54 for receiving the base 
22, and has a first end 56 with an inwardly directed annular lip 58 
extending into the bore. The lip 58 defines an opening having a diameter 
substantially equal to but slightly greater than the diameter of the base 
outside surface 38. That is, with the base received by the collar, no gap 
between the two at the first end 56 of the collar is formed greater than 
1/32 of an inch. The collar 28 has a second end 60 defining the 
cylindrical bore 54 which has a diameter substantially equal to but 
slightly greater than the outside diameter of the horizontal brace 22 so 
that when the collar second end 60 receives the horizontal brace 16, no 
gap greater than 1/32 of an inch is formed. An internal screw thread 62 is 
provide extending into the bore 54 between the lip 58 and the second end 
60, with an annular abutment 64 adjacent the trailing end of the thread 
for engaging the base flange 42 to prevent complete passage of the base 
through the collar. 
Referring to FIGS. 8-10, the locking insert 26 includes a body 66 sized for 
reception in the enlarged aperture portion 50 in the base 22. The insert 
has a leading end 68 and a trailing end 70 with a pair of diametrically 
opposed arms 72, terminating with screw threads 74 which are threadably 
engageable with the collar screw thread 62. The arms 72 extend through 
corresponding slots 52 when the insert body 66 is received in aperture 
portion 50. An annular holding flange 76 is provided extending radially 
outwardly from trailing end 70 for bearing on the protuberances 32 formed 
in the horizontal brace 16. The flange 76 is sized to fit inside the brace 
and is split, having open areas 78 to permit its insertion through the 
brace end 44 beyond the protuberances 32. By rotating the insert 26 with 
respect to the brace, components of the flange 76 are brought into 
alignment with the protuberances to preclude withdrawal of the insert from 
the brace. 
The protuberances 32 can be formed in the brace by any convenient means, as 
will be apparent to one of skill in the art. One preferred method of 
formation involves placement of relatively short, transverse saw cuts 80 
on diametrically opposed areas of the brace about 1/4 inch from end 44. 
Striking the area between a cut 80 and the end 44 results in formation on 
a dimple or protuberance 32. 
Operation of the connector assembly 20 of the present invention is as 
follows. After the hole 30 is drilled in the horizontal leg 18, the insert 
end 82 of the deformable nut 34 is placed through the hole, until the rim 
84 of the deformable nut bears upon the outside surface of the vertical 
leg 18. The base 22 is inserted through the locking collar 28 until the 
saddle surface 40 extends beyond the lip 58. After inserting the threaded 
shaft of the bolt 36 through the aperture 46 in the base and into the 
insert end 82 of the nut 34, the bolt is tightened until the bolt head 
bears upon the internal ledge 48 in the base 22. Further tightening of the 
bolt 36 draws the deformable nut insert end 82 rearwardly causing it to 
expand to a size greater than the hole 30 thereby firmly affixing the base 
to the vertical leg. 
The locking insert 26 is aligned with the protuberances 32 of the 
horizontal brace 16 so that the insert 26 can be moved inside the brace 
without any interference from the protuberances. After the holding flange 
76 is positioned behind the protuberances, the insert is rotated about 90 
degrees so that the holding flange 76 is aligned with the protuberances. 
Preferably the arms 72 have a greater extension than the inside diameter 
of the brace so that the arms cannot be moved inside of the brace. Next 
the insert body 66 is moved inside of the enlarged portion 50 of aperture 
46 with the arms 72 received in the base slots 52 and extending beyond the 
base outside surface 38. Upon advancing the collar 28 toward the insert 
and threading the screw thread 62 onto the arms 72, the insert is pulled 
towards the collar. This tightening continues until the leading end of the 
base abutment flange 42 is engaged by the abutment 64 in the collar and 
the brace end 44 engages the trailing end of the base abutment flange 42. 
The protuberances 32 are then in engagement with the holding flange 76 of 
the insert. Firm tightening of the collar 28 causes the end portion of the 
brace to be compressed slightly between the flanges 76 and 42, as shown in 
FIGS. 3 and 4. 
Alternately collar 28, base 22, and insert 26 can be shipped partially 
assembled with threads of the arms 72 partially engaged with the threads 
62 of collar 28. 
It will be appreciated that the use of the connector assembly does not 
result in the formation of any gaps over 1/32 of an inch. Thus, the 
connector assembly of the present invention is particularly adapted for 
use in furniture used in the food service industry. 
In view of the above, it will be seen that the several objects of the 
invention are achieved and other advantageous results attained. 
As various changes could be made without departing from the scope of the 
invention, it is intended that all matter contained in the above 
description or shown in the accompanying drawings shall be interpreted as 
illustrative and not in a limiting sense.