Channel strut fasteners

Provided herein is a fastener that may be used to secure objects to a channel strut or attach a channel strut to a structure. In an arrangement, the fastener is a fastener block configured for disposition within the interior of a channel strut. The fastener block has a body that includes at least one aperture, which may be threaded, extending through the fastener block between upper and lower surfaces. A fastener receptacle may be formed around the aperture. A standard nut or bolt may be inserted into the fastener receptacle.

FIELD

The present disclosure generally relates to fasteners for channel strut framing. More specifically, a fastener arrangement is provided that allows for using standard SAE and/or metric hardware (e.g., nuts and bolts) to fastens objects to channel strut framing.

BACKGROUND

One type of channel framing is called strut channel or channel strut (used herein interchangeably), which is commonly used in the construction and electrical industries for structural support, often for supporting wiring, plumbing, or mechanical components such as air conditioning or ventilation systems. Strut channel may be utilized in numerous other industries and applications. Strut channel is usually formed from metal sheet, folded over to define an open channel with inward-curving lips to provide additional stiffness and as a location to mount interconnecting components. A fastener nut may be inserted into the interior of the channel (e.g., behind the inward curving lips) for use in securing a part to the open channel side of the strut channel. The side of the strut channel opposite the open channel and/or the sidewalls of the channel may further include repeating apertures or slots to facilitate interconnection or fastening the strut to underlying building structures.

Strut channel is standardized allowing struts and components from different manufacturers to be compatible. Basic strut channel comes in the open box section, 1⅝ by 1⅝ inch square cross section. A half-height (1⅝ inch wide, 13/16 inch tall) cross section version is also available. A deep channel 2 7/16 inches tall and 1⅝ inch wide is also manufactured. Additionally, a half-width ( 13/16 inch wide) version is also available.

In any arrangement, the inwards-facing lips on the open side of strut channel are routinely used to mount specialized nuts, braces, connecting angles, and other types of interconnection mechanisms or devices to join lengths of strut channel together or connect pipes, wire, other structures, threaded rod, bolts, or walls into a strut channel structural system.

SUMMARY

Provided herein is a fastener that may be used to secure objects to a channel strut. In various arrangements, the fastener is configured to engage and hold a threaded fastener such as nut or a bolt. By way of example only, the fastener may engage standard hex head nuts or hex head bolts. Once engaged with the fastener, the nut or bolt is prevented from rotating. Accordingly, the fastener may then be positioned within a strut and a mating bolt or nut may be affixed to the nut or bolt engaged with the fastener.

In an arrangement, the fastener is a fastener body or block configured for disposition within the interior of a channel strut. At least one aperture extends through the fastener block (e.g., body) between an upper and a lower surface. At least one fastener receptacle is disposed around the aperture on the upper and/or bottom surface. In various arrangements, the fastener receptacle may be a protrusion that at least partially extends above the upper surface of the fastener block/body. In such an arrangement, the protrusion may have a recessed interior sized to receive a nut or a bolt head (e.g., hexagon recess). In another arrangement, the fastener receptacle may be formed as a recess below the upper surface of the block. In any arrangement, a correspondingly shaped nut or bolt may be inserted into the fastener receptacle. In a further arrangement, the aperture may be threaded. Once the fastener block is disposed within a strut channel, the fastener block may be rotated to engage opposing inside lip surfaces of the strut channel. Rounded corners (e.g., diagonally opposed corners) of the fastener block allow the block to rotate between the lip surfaces until opposing side engagement surface engage with the opposing lip surfaces. In an arrangement, the fastener block/body includes a recessed slot formed in it upper and/or lower surfaces. The elongated recess allows engaging the block with, for example, a flat screwdriver to rotate the block within the channel. Other configurations of the recessed slot are possible. Once so rotated, the fastener block is secured between the opposing lips of the strut channel. Further, upper and lower protrusions extending over upper and lower edges of the opposing side engagement surfaces may extend over and blow the lips of the strut channel, when installed. A user may then engage a nut or bolt with a mating fastener disposed within the fastener recess or engage a bolt with the threaded aperture. In an arrangement, the fastener recess is configured to engage a fastener (e.g., nut or bolt) of a first size while a threaded aperture is configured to engage a threaded fastener (e.g., bolt) of a second different size.

In another arrangement, the fastener block includes first and second fastener receptacles on opposing surfaces (e.g., upper and lower surfaces of the fastener block). In such an arrangement, fastener receptacles on the upper and lower surfaces may have different cross-dimensions permitting the fastener block to engage differently sized nuts or bolts. In another arrangement, the fastener block may include two or more concentric or nested fastener receptacles. In one arrangement, a second fastener receptacle (e.g., recess) may be formed in the bottom surface of a first fastener receptacle. In such an arrangement, the second receptacle may be smaller than the first receptacle. Accordingly, the second receptacle may engage nut or bolts of a different size (i.e., smaller) that the first receptacle. In a further arrangement, the fastener block may include a third receptacle (e.g., recess) formed in the bottom surface of the second receptacle. In such an arrangement, the fastener block may be configured for use with multiple different sized fasteners including, for example, standard and metric nuts and bolts.

In an arrangement, a fastener block is configured for use as a nut configured to engage and maintain its position within the interior of a channel strut. At least one threaded aperture extends through the fastener block (e.g., body) between an upper and a lower surface. Rounded corners (e.g., diagonally opposed corners) of the fastener block allow the block to rotate between the lip surfaces until opposing side engagement surface engage with the opposing lip surfaces. In an arrangement, the fastener block/body includes a recessed slot formed in it upper and/or lower surfaces to allow rotating the block/body. In such an arrangement, the fastener block may omit a receptacle disposed about the threaded aperture.

In an arrangement, the fastener block may be non-conductive (e.g., polymeric). Such a non-conductive fastener block may prevent galvanic corrosion (e.g., dielectric contact) between a metal channel strut and a metal fastener. Additionally, a polymeric fastener block (e.g., plastic) may be light weight as well as non-corrosive in many environments (e.g., salt air, chemical laden air, moisture laden air, etc.).

DETAILED DESCRIPTION

Reference will now be made to the accompanying drawings, which at least assist in illustrating the various pertinent features of the presented inventions. The following description is presented for purposes of illustration and description and is not intended to limit the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described herein are further intended to explain the best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions.

FIG.1Ais a perspective view of a section of a channel strut100andFIG.1Bis a cross-sectional view of the strut100. As shown, the strut100has three sidewall surfaces and a generally open side surface. More specifically, the strut100may include a closed or bottom-end102(which may have various apertures formed therein), a first side-wall surface104aand a second sidewall surface104b(collectively, sidewalls104). Disposed on the free ends of the sidewalls104are a first flange106aand a second flange106b, respectively, (collectively, flanges106). The first flange106a, may include a first inwardly projecting portion108aand a first upwardly projecting portion110a(e.g., lip). Likewise, the second flange106bmay include a second inwardly projecting portion108band a second upwardly projecting portion110b(e.g., lip). Collectively, the inward and upward projections of the flanges106define inwardly curving lips on the open side of the channel strut. Such flanges/lips provide additional stiffness to the strut channel as well as a location to mount interconnecting components. As shown inFIG.1B, the side of the strut100opposite the end-surface102has an opening112between the facing or inside surfaces of the flanges106. The opening112has a width of d1between the first upwardly projection portion110aand the second upwardly projecting portion1108b. Further, the channel strut100has a channel width of d2from the inner surface of the first sidewall104ato the inner surface of the second sidewall104b.

As illustrated inFIG.2A, a fastener block120, in accordance with some aspects of the present disclosure, may be disposed through the opening112in the strut channel100. The fastener block120may then be positioned (e.g., rotated) to extend across the top surfaces of the upward projections110aand110band between the inside surfaces of the sidewalls104. Once the fastener block120is positioned across the opening112, a fastener such as a bolt162may engage a nut (not shown) engaged with the fastener block120to secure and object164against the surface of the channel strut100. The fastener block may be utilized in various different ways. No limitation should be inferred.

As noted above, prior strut channel fasteners are formed as specialized fastener nuts or specialized fastener bolts configured to engage with the strut channel. Such prior fasteners have a predetermined nut or bolt diameter. In these arrangements, a specialized fastener nut that engages with the strut may receive a standard bolt and a specialized fastener bolt that engages with the strut may engage a standard nut. However, such prior fastening systems cannot be utilized with both standard nuts and bolts (e.g., SAE and metric). If a user wants to utilize different sized fastener hardware, the user needs to have a different sized specialized fastener. That is, such prior art specialized fasteners cannot accommodate differently sized fastener hardware (e.g., nuts, bolts, thread types etc.).

FIGS.3A and3Billustrate top and bottom perspective views of a fastener block120in accordance with some aspects of the present disclosure.FIGS.4A-4Cillustrate top, side and bottom views of the fastener block120. In the illustrated embodiment, the fastener block120is roughly defined as a rectangular prismatic body having an upper surface122, a lower surface124, and four side surfaces extending between the upper surface122and the lower surface124. Specifically, the body of the fastener block120includes opposing side surfaces126a,126b, a front side surface128aand a rear side surface128b. In the embodiment illustrated inFIG.3A-4C, the fastener block120incudes a plurality of fastener receptacles, which in the illustrated embodiment are recesses140a-d(hereafter140unless specifically referenced) formed into its upper and lower surfaces. The fastener recesses140each extend partway into the body of the fastener block120.

Upper and lower pairs of channels150a,150bare formed into the upper and lower surfaces of the fastener block120and extend between the front and rear side surfaces128of the fastener block120. The upper or lower pairs of channels are configured to engage with the first upwardly projecting portion110a(e.g., first lip) and the second upwardly projecting portion110b(e.g., second lip) of the channel strut100when the fastener block120is disposed therein. This is best illustrated inFIGS.2A and2C, which show the lower pair of channels150bengaging the upwardly projection portion of the channel flanges/lips110. As will be appreciated, the fastener block is resistant to rotating/turning when the channels are fully engaged with the channel flanges/lips.

Referring toFIG.3A, the illustrated embodiment of the fastener block120includes two fastener receptacles or recesses140aand140b, which are recessed into the upper surface122. Each fastener recess140aand140bsurrounds an aperture144aand144b, respectively, which passes through the body of the fastener block120. In the illustrated embodiment, these recesses140are hexagonal-shaped recesses, which are sized to receive correspondingly sized hexagonal fasteners. That is, each recess may be sized to receive a hexagonal nut or a hexagonal head of a bolt. In this specific embodiment, the first recess140ais sized to receive a 5/16 inch hexagonal nut or bolt while the second recess140bis sized to receive a ¼ inch hexagonal nut or bolt. The sidewalls of the recess may be substantially parallel to a centerline axis of the aperture. Alternatively, the sidewalls my taper such that the recess is slightly narrower at the bottom edge of the recess comparted to the top edge of the recess. Such tapering may provide a compression fit with an inserted fastener (e.g., nut or bolt) to hold the fastener within the recess. In various embodiments, the block may include surface indicia showing the size of the fastener recesses. As further illustrated inFIG.3B, the fastener block120includes two additional fastener recesses140cand140dthat are recessed into its lower surface124. Each of the lower fastener recesses140cand140dare likewise disposed around one of the apertures144aand144b. In this regard, first and second opposing fastener receptacles may be disposed around both an upper and lower end of each aperture. In the illustrated embodiment, the lower fastener receptacles may have dimensions that are different than the dimensions of the upper fastener receptacles, which may themselves be different. By way of example, the third recess140cis sized to receive an 8 mm hexagonal nut or bolt while the fourth recess140cis sized to receive a 6 mm hexagonal nut or bolt. In this regard, a single fastener block120may be utilized with a variety of differently sized hardware.

FIGS.5A-5Cillustrate another embodiment of a fastener block120a. This embodiment of the fastener block120ashares many of the same attributes as the fastener block120described in relation toFIGS.3A-4Cand like reference numeral are utilized to refer to like elements. As shown, this embodiment the fastener block120aincludes a single aperture144that extends through the block between its upper surface122and its lower surface124. Likewise, the fastener block120aincludes a single upper hexagonal fastener receptacle141that is recessed into the upper surface122and a single lower hexagonal fastener receptacle that is recessed into the lower surface124. In such an embodiment, the fastener block may allow use with two differently sized standard hexagonal bolts and/or nuts.

Though previously discussed as utilizing hexagonal fastener recesses, it will be appreciated that the fastener block of the present disclosure is not limited any specific receptacle configuration. That is, the fastener receptacle(s) may have any appropriate shape to match any corresponding fastener.FIGS.6A-6Cillustrates three nonlimiting embodiments of fastener blocks120b,120cand120d, respectively, which utilize various differently shaped fastener recesses in their top and/or bottom surfaces. By way of example, the fastener block120bofFIG.6Autilizes a four-pointed star fastener recess145, the fastener block120cofFIG.6Butilizes a diamond-shaped fastener recess and the fastener block120dofFIG.6Cutilizes a multi-pointed star-shaped fastener recess149. Other variations are possible. Of further note, the shape of the fastener receptacles may vary between the top surface and the bottom surface. What is important is that the fastener receptacle be configured to at least partially engage a fastener (e.g., nut or bolt head) and prevent the fastener from turning while being engaged by a matching fastener.

The disclosed fastener blocks may be utilized to position either a standard nut or a standard bolt within a strut channel to allow for attachment thereto. As illustrated inFIG.7A, the fastener block120is shown with a standard hexagonal nut160disposed within the fastener recess140within its top surface. In the illustrated embodiment, the depth of the fastener recess140is equal to the thickness of the nut160. However, this is not a requirement. Once the hexagonal nut160is disposed within the fastener recess140, and the fastener block120engages a strut channel (not shown), a bolt may extend through the fastener block aperture144to engage the nut160.FIG.7Billustrates a configuration where the fastener block120receives the bolt162, which extends through the central aperture of the fastener block until the hexagonal head of the bolt is received within the fastener recess140. Once the fastener block is engaged with a strut channel (not shown), the hexagonal nut may engage the threads on the distal end of the supported bolt162.

As mentioned above with respect toFIGS.2A-2C, a fastener block120may be inserted into the open channel of the strut100and rotated to secure the fastener within the strut100.FIG.8illustrates a fastener block disposed between the sidewalls104of a strut channel100. For clarity, the flanges/lips are removed though the inside edges of the flanges are shown in phantom to illustrate the width d1of the channel opening112. In an embodiment, fastener100has a width ‘w’ that is narrow enough to be inserted into the channel opening112. For example, as illustrated in the top position (e.g., position1) inFIG.8, the fastener width w is less than opening width d1of the strut channel112. In this example, width w extends between the front and rear side surfaces128aand128b. Once the fastener block120is inserted into the strut100, the fastener block120may be rotated as shown in the middle position (e.g., position2) ofFIG.8. Once rotated and the block is held by the compression exhibited on the block by the strut. This is beneficial as it inhibits bolts and nuts from moving when trying to attach objects to a strut. The compression can be varied by the size of the fastener block in relation to the inside strut dimension. This is helpful in “blind” fastening of panels, and other items where it is desirable that the bolt or nut not wander or move (e.g., slide along the strut). In the illustrated embodiment, the fastener block120includes opposite rounded side-surface corners130aand130b. A first rounded corner130aextends between the front side surface128aand the second opposing side surface126b. The second rounded corner130bextends between the first opposing side surface126aand the rearward surface128b. The rounded corners130a,130ballow the fastener block120to be rotated from the middle position to the bottom position (e.g., position3) inFIG.8. That is, if a distance measured from the first rounded corner130ato the second rounded corner130bis less than the width d2of the strut channel, the fastener block130may rotate about an axis normal to its top and/or bottom surfaces while disposed within the channel. That is, the rounded corners and/or opposing corners having a maximum length therebetween that is less than the length of the channel width allow turning the fastener block.

The ability to rotate the fastener block about an axis normal to its upper surface limits an overall length of a fastener block and, therefore, the number of fastener recesses that the fastener block may contain. However, it will be appreciated that the fastener block may be rotated about an axis that is perpendicular to an axis normal to the top and/or bottom surface of the fastener block. This is illustrated inFIGS.9A-9C. As shown, the fastener block120may be inserted into the opening112of the strut channel100as long as the thickness (e.g., between the top and bottom surfaces122,124) of the fastener block120is less than the width of the opening. SeeFIG.9A. Once within the strut channel, the fastener block may be rotated around its long axis (i.e., normal to the paper; seeFIG.9B) to align the channels150with the lips110of the channel opening. The fastener block may then be pulled into engagement with the lips110. SeeFIG.9C.

FIG.10illustrates top, side and bottom views of one embodiment of a fastener block220having a length that prevents rotation within a channel strut about an axis normal to its top surface. This embodiment of the fastener block220shares many of the same attributes as the fastener block120described in relation toFIGS.3A-4Cand like reference numeral are utilized to refer to like elements. This embodiment of the fastener block includes a set of three fastener recesses240a-240con its top surface122and a set of three fastener recesses240d-240fon its bottom surface124. The six total fastener recesses240a-fare disposed on opposing sides of three apertures244a-cthat pass through the body of the fastener block between its upper and lower surfaces. In this embodiment, each of the fastener recesses may be aligned with center of the fastener block (e.g., midway between the channels150) such that an object attached to a channel strut may be aligned with a center of the channel opening. In addition, the six fastener recesses240a-fmay each be different sized allowing a single fastener block to be utilized with standard nuts and bolts having at least six different cross-dimensions (e.g., diameters). When taking into account thread pitches and counts, multiple configurations are possible with a single fastening block greatly minimizing the number of parts required. Other configurations are possible.

FIGS.11A-11Dillustrate yet another version of a fastener block320. This embodiment of the fastener block320is configured for receipt within a half channel300and may require insertion through an end surface of the channel. The fastener block includes six differently sized fastener recesses340a-f(only three shown) disposed within the upper and lower surfaces122,124of the fastener block320. As with the previous fastener blocks, the upper and lower surfaces include channels150that are configured to engage the lips of a strut channel.

One difficulty in positioning a fastener block within a strut channel is that the fastener block may move along the channel. This is especially problematic when the strut is vertically positioned. That is, a fastener block disposed within the channel tends to fall to the bottom of the strut. A user is required to hold the fastener block in place. To facilitate maintaining the position of a fastener block in a desired position once inserted into a strut channel, the embodiment illustrated inFIGS.11A-11Dincludes a number of small protrusions170formed on the fastener block's side surfaces126a,126b, which are positioned between opposing sidewalls302and304of the strut channel. As defined above, the channel width of the strut channel between the inside surfaces of the opposing sidewalls may be defined as having a distance or width of ‘d2’. This width d2is wider than a distance between the opposing side surfaces126aand126bof the fastener block to allow the fastener block to be positioned therebetween. However, a width or distance ‘d3’ between the outside surfaces of opposing protrusions170a,170b(seeFIG.11C) is greater than the channel width d2. In this regard, the opposing protrusions engage the opposing inside surfaces of the channel300when the fastener block is disposed therein. SeeFIG.11D. This engagement provides sufficient friction to hold the fastener block320in a desired location within the strut channel300. Though discussed in relation to the embodiment ofFIGS.11A-11D, it will be appreciated that such protrusions may be incorporated with any of the fastener blocks disclosed herein.

The protrusions170are preferably formed of a malleable material such that they may deform to allow a fastener block to be positioned within a strut channel. In one embodiment, the protrusions are integrally formed with the fastener block. In such an arrangement, the fastener block and the protrusions may be formed in, without limitation, a 3-D printing process or a molding process (e.g., injection molding). In one embodiment, the fastener block and, if included, the protrusions are formed of a polymeric material. In another embodiment, the fastener block and, if included, the protrusions are formed from a metallic material. The fastener block may be made of any material that provides sufficient structural rigidity.

Additional features may be incorporated into the fastener blocks to maintain the fastener blocks in a desired location within a strut channel. Referring toFIG.4B, it will be noted that each of the channels150formed within the body of the fastener block may have sidewalls153a,153bthat are angled or tapered to a bottom surface155. The width of the bottom surface ‘w1’ may be narrower that the width ‘w2’ of the upper end of upwardly projecting portion110bor lip of the flanges. SeeFIG.1B. (e.g., lip). More specifically, the sidewalls may taper from an opening that is wider than the upper end of the lip to the bottom surface of the channel. In this regard, the upper end of the projection portion/lip may wedge into the channel150when a user applies a compressive force between the fastener block and the strut channel.

FIG.12illustrates a yet further embodiment of a fastener block420. This fastener block again has a pair of upper channels150aand fastener recesses formed into its upper surface. The fastener block may additionally include a pair of lower channels150band fastener recesses formed in its lower surface124. To provide additional frictional contact between the fastener block and the lips of a strut channel, the channels150may include one or more deflectable protrusions or partial webs180that extend from the sidewall surfaces153a,153bof the channels150. These partial webs may deflect and provide a frictional fit between the channel lips and the fastener block when the fastener block is compressed against the channel lips. As with the protrusions formed on the side surfaces of the fasteners, the partial webs are preferably formed of a malleable material such that they may deform to allow a fastener block to be fixedly positioned within a strut channel.

An additional problem that may be encountered when utilizing the fastener block is maintaining either a nut or bolt within a fastener recess during installation. That is, the nut or bolt may fall out of the fastener receptacle (e.g., recess). To provide a frictional fit between the fastener receptacle and an inserted fastener (e.g., nut or bolt head), the fastener recesses may include a protruding ridge that extends from a sidewall of the fastener recess into the open interior of the recess. This is illustrated inFIG.3Awhich shows a ridge190disposed on the sidewall of the first fastener recess140a. As shown, this embodiment of the ridge190is generally triangular-shaped and extends from the top surface122of the fastener block to the bottom of the first fastener recess. The ridge may provide a location within the fastener recess that has a cross-dimension that is slightly smaller than a corresponding cross-dimension of a fastener that will be disposed within the recess. Accordingly, if the ridge is formed of a malleable material, it may deform when a fastener is pressed into the recess and thereby provide a frictional fit with the inserted fastener. Such a ridge or other protrusion may be integrally formed with the fastener block.

Additional variations exist for the fastener blocks.FIG.13illustrate a further embodiment of a fastener block520. As illustrated, the fastener block is configured for use in a shallow strut channel100. In such an arrangement, there may not be enough space to utilize a dual sided fastener block that may receive two or more differently sized fasteners. In such an arrangement, a single sided fastener block may be utilized having a fastener recess140on a top surface122that surround an aperture144passing through the fastener block. Two channels150may be formed on the lower surface of the fastener block for engaging the lips of the strut channel. Though not permitting use of multiple sized fasteners, this embodiment still allows use of standard nuts and bolts.

FIG.14Aillustrate another embodiment of a fastener block620. As illustrated, the fastener block620includes a body142having an upper surface122, a lower surface, two side surfaces126a,126b, a front side surface128aand a rear side surface128b. The fastener block620includes a first fastener receptacle146aformed on its upper surface122and disposed about an aperture144that passes through the fastener block between the upper and lower surfaces. More specifically, the first fastener receptacle146ais a wall or projection that extends/projects above the upper surface122of the block620. As illustrated, the first fastener receptacle146ais a continuous wall having a closed geometric shape (e.g., hexagonal shape) with an open or recessed interior. The recessed interior of the first fastener receptacle146ais configured to receive a head of a bolt or a nut as variously described above. Optionally, the fastener block60may include a second fastener receptacle146bformed about the aperture144. As illustrated, the second fastener receptacle146bis a smaller receptacle formed as a recess in the bottom of the first fastener receptacle146a. That is, the first and second fastener receptacles146a,146bare nested (e.g., generally concentric). The nesting of the receptacles allows the fastener block620to engage differently sized fasteners (e.g., nuts and bolts) relative to a single aperture144. Though illustrated as having two nested receptacles, it will be appreciated that the block620could have three or even four nested receptacle with each lower receptacle being smaller than the upper receptacle(s). Additionally, one or more receptacles could be tapered to engage with different sized fasteners. That is, an upper portion of the receptacle could engage with larger nuts/bolts while a lower portion of the receptacle could engage with smaller nuts/bolts. Further, it will be appreciated that the nested receptacles may each be recessed below the upper surface of the fastener block. For instance, the recesses described above in relation toFIGS.3A-13could have an additional receptacle(s) formed in the bottom of some or all of the described recesses. Of note, the embodiment illustrated inFIG.14Adoes not include the recessed channels described above. However, it will be appreciated that the fastener block620could include such recessed channels.

FIG.14Billustrates a variation of the fastener block ofFIG.14A. As illustrated, the fastener block620aofFIG.14Bshares numerous common features with the embodiment ofFIG.14Aand common reference numbers refer to common elements. In the illustrated embodiment, the first fastener receptacle146ais defined by separate walls or projections147that extend above the top surface122of the fastener block. This is, rather than having a continuous projection with an open interior that is sized to receive a fastener, the separate projections147collectively define an interior area (e.g., receptacle146a) as partially illustrated by phantom lines, that is sized to receive a fastener (e.g., nut or bolt). When a fastener is positioned between the projections147, the projections147aprevent the fastener from turning.

FIG.14Cillustrates a variation of the fastener block ofFIG.14A. As illustrated, the fastener block620cofFIG.14Cshares numerous common features with the embodiment ofFIG.14Aand common reference numbers refer to common elements. In the illustrated embodiment, the fastener block has a single receptacle146athat is configured to engage differently sized fasteners (e.g., nut and bolts). In this embodiment, the interior walls of the receptacle146ataper. In this regard, a cross-dimension d1at the upper edge of the receptacle146ais larger than a corresponding cross-dimension d2at the lower edge of the receptacle146b. This allows inserting different sized nuts or bolts into the receptacle. A nut or bolt extends into the receptacle146ato the point that the tapering sidewalls have a smaller cross-dimension than the cross-dimension of the nut or bolt.

FIG.15illustrates a further embodiment of the fastener block620. In this embodiment, the block may have an upper receptacle146aformed about an aperture (not shown) on the upper surface of the block and a lower receptacle146cformed about the aperture on the lower surface124of the block. As with the embodiment ofFIG.14, either or both of the receptacle146a,146cmay include one or more additional nested receptacle formed therein.

FIGS.16A and16Billustrate a further embodiment of a fastener block720. As illustrated, the block720includes at least a first fastener receptacle144disposed about an aperture144that extends through the block720between its upper and lower surfaces. In this embodiment, the block720includes side channels152formed into opposing side surfaces. These channels152are sized to receive the flanges106of a channel strut100when the block720is disposed within the strut as best illustrated inFIG.16B. The block720includes two rounded corners130(diagonally opposing corners) that allow the block to rotate within the channel to position the strut flanges106within the channels152. This is substantially similar to the insertion process described inFIG.8. However, once rotated into position, rather than being disposed entirely within the strut, the block720traps the flanges106between upper and lower surfaces of the channels152. In this regard, the lower surfaces of the channels152or flanges182are disposed on an outside surface of the strut100when the fastener block720is positioned.

FIG.17illustrates another embodiment of a fastener block820. The illustrated fastener block820shares many attributes with the fastener blocks discussed above. In contrast to the previously described fastener blocks, the illustrate fastener block820lacks a fastener receptacle that receives and prevents rotation of a fastener. Rather, the fastener block820is configured to be engaged by a screw (e.g., pointed, self-tapping etc.). The screw may be driven into the body of the block once the block is positioned with a strut. To facilitate engagement with such a screw, the block820may be made of a soft material (e.g., polymer). Further, the block820may include a slot192and/or aperture(s)194that extend partially or entirely through the block. These opening provide location for a screw to engage the block820.

FIGS.18A and18Billustrate fastener blocks120aand720, which have been previously described, as modified to include positioning tabs158. As illustrated, various tabs158may be formed on the upper or lower surfaces of the fastener blocks. The158allow a user to more easily position the fastener block within a strut channel. The tabs158are particularly useful for rotating the fastener blocks when disposed within a strut channel. Such tabs may be incorporated onto any embodiment of the fastener blocks. Further, it will be appreciated that the tabs are not limited to the illustrated design. Any protrusion that allows a user to grasp the fastener may be utilized.

FIGS.19A-Cillustrates a fastener block120asubstantially similar to that described in relation toFIGS.5a-5cwith the addition of deflectable protrusions132a,132b(hereafter132unless specifically references) formed on the opposing side surfaces126a,126b, respectively. The deflectable protrusions132(e.g., spring tabs) are configured to compress inward during installation within a channel strut as illustrated in the cross-sectional view ofFIG.19B. The protrusions provide an outward retaining force once positioned to hold the fastener block at a desired position within a channel strut. As illustrated, the illustrated deflectable protrusions132are formed similar to a leaf spring having both ends attached to a side of the fastener block120a. However, it will be appreciated that other spring type protrusions (e.g., cantilevered) may be utilized as well. What is important is that the protrusions elastically/resiliently deflect to allow installation and subsequently apply a restraining force for the block.

FIGS.20A and20Billustrate top and bottom perspective views of another embodiment of a fastener block920in accordance with some aspects of the present disclosure. In the illustrated embodiment, the fastener block920has a body having an upper surface922, a lower surface924, and side surfaces extending between the upper surface922and the lower surface924. Specifically, the body of the fastener block920includes a front surface928a, a rear surface928band two opposing side engagement surfaces926a,926b(hereafter926unless specifically referenced). The opposing side engagement surfaces926are substantially parallel to one another. The opposing side engagement surfaces are configured to be disposed between opposing lips110a,110bof a channel strut. See, e.g.,FIG.22A. As illustrated inFIGS.20A and20B, the opposing side engagement surfaces each connect to one of the front surface928aor rear surface928bvia an arcuate sidewall. Specifically, in the illustrated embodiment, the first side engagement surface926aconnects to the rear surface928bvia a first arcuate sidewall930aand the second side engagement surface926bconnects to the front surface928avia a second arcuate sidewall930b. The arcuate sidewalls930a,930b, which are disposed on diagonally opposing corners of the fastener block920allow rotating the fastener block between the opposing lips110a,110bof a channel strut until the side engagement surfaces contact the opposing lips110a,110bof the channel strut, as is more fully discussed herein.

To better secure the fastener block920between the opposing lips of a channel strut, the fastener block includes lips or protrusions that extend over an upper edge of each side engagement surface and lips or protrusions that extend below a lower edge of each side engagement surface. As best illustrated inFIG.20A, first and second upper protrusions932a,932bextend outward from the upper surface922to a location laterally beyond top edges of generally parallel side engagement surfaces926. Likewise, first and second lower protrusions934a,934bextend outward from the fastener block920to a location laterally beyond bottom edges of generally parallel side engagement surfaces926. When disposed between opposing lips110a,110bof a strut channel, these projections932,934are disposed above and below the strut channel lips. See, e.g.,FIG.22A.

As illustrated inFIGS.20A and20B, the fastener block920includes an aperture944that extends through the body of the fastener block between the upper surface922and the lower surface924. In the embodiment illustrated inFIGS.20A and20B, the fastener block920incudes a single fastener receptacle940recessed about the aperture944into the lower surface924. As illustrated, the fastener receptacle940is a hexagonal recess configured to receive a hexagonal nut or bolt. However, it will be appreciated that the receptacle may have other shapes and/or extend above the lower surface. Further, it will be appreciated that this embodiment of the fastener block920may include multiple fastener receptacles as various discussed above. In one embodiment, the aperture944is threaded such that the fastener block itself may be utilized as a nut for a bolt. In an embodiment having a threaded aperture, the fastener block920may optionally omit the fastener receptacle940and simply be utilized as a nut configured to engage a channel strut. In such an embodiment, the fastener block may include two or more threaded apertures. When utilizing two or more threaded apertures, the tread dimensions of the different apertures may be different. In another embodiment, the fastener block920may utilize both a threaded aperture944and a fastener receptacle940where the aperture and receptacle are configured to engage different sized fasteners. By way of example, the aperture may be threaded to engage ⅜ inch threads (e.g., 16 or 20) while the receptacle could be sized to engage a 5/16 bolt head or nut. Similarly, the aperture944could be threaded for 5/16 inch while the receptacle is sized to engage ¼ inch bolts heads or nuts. That is, the aperture may be configured to engage a bolt with a first thread dimension while the receptacle(s) is configured to engage bolt heads or nuts with a second different thread dimension. Many combinations are possible.

To facilitate turning the fastener block920within a strut channel, the fastener block may additionally include an elongated slot950recessed into its upper and/or lower surfaces. Such an elongated slot provides an engagement surface that allows utilizing, for example, a flat screwdriver to turn the fastener block during installation. Other engagement surfaces and/or elements may be utilized.

FIGS.21and22Aillustrate the insertion of the fastener block920between the opposing lips110a,110bof a strut channel100. Initially, the fastener block920is disposed between the opposing lips110a,110bsuch that the front/forward surface928aand rear/rearward surface928bare disposed adjacent to the opposing lips110a,110b(upper fastener block920aas illustrated inFIG.21). To allow such positioning, the front surface928aand rear surface928bare spaced a distance apart that is less than a distance between the upright surfaces of the opposing lips110a,110b. At this time, a user may insert a tool952(e.g., screwdriver) into the elongated slot950and begin rotating the fastener block920about an axis that is substantially aligned with an axis the aperture944(middle fastener block920bas illustrated inFIG.21). While rotating, the arcuate surfaces930a,930bengage the upright surfaces of the lips110a,110b. Further, the lower projections934a,934bextending over the side engagement surfaces926a,926b(seeFIG.22A) rotate to a position under the lips110a,110bwhile the upper projections932a,932brotate to a position above the lips110a,110b. Once fully rotated (bottom fastener block920cas illustrated inFIG.21), the side engagement surfaces926a,926bare juxtaposed between the opposing inside surfaces of the lips110a,110bwhile the upper and lower projections932,934prevent the fastener block from moving into and out of the struct channel100. Further, it will be appreciated that by selecting a distance or spacing between the side engagement surfaces926a,926bto be equal to or slightly greater than the distance between the opposing inside/upright surfaces of the lips100a,110be, the fastener block920may be wedged within the strut channel. That is, the fastener block920is held by the compression exhibited on the block by the opposing lips of the strut. The compression can be varied by the size of the fastener block in relation to the inside strut dimension. When compressed between the lips of the strut, the fastener block may maintain its position even if installed on a vertically aligned strut channel. Once positioned, fastener block920may be utilized to bolt an object960to the strut channel.

The presented fasteners provide a number of benefits over prior strut fasteners. In various embodiments, the fasteners may be made of non-reactive materials (e.g., polymeric materials) that isolate potentially dissimilar materials (e.g., strut channel and bolt) to prevent, for example, galling, corrosion, and other negative effects that arise if the components are incompatible. The disclosed fasteners may also provide electrical isolation. The fasteners also allow use of standard nuts and bolts of varying sizes thereby eliminating the use of a wide variety of differently sized diameter and thread configurations of prior specialized fasteners. Further, standard or metric nuts and bolts may be utilized interchangeably with a single fastener. Prior fasteners attempt to use springs, wings, threading of components, etc., to hold the fastener in place during application. Such methods do not fully solve the issue of the product moving within the channel during installation and or attachment. That is, current methods do not adequately hold the fastener prior, and during installation, in positioning incrementally, and tightening of the fastener. The use of the malleable protrusions or spring-type protrusions on one or more outer surfaces of the presented fasteners provide a secure fit between the fastener and the strut channel during the application process.

The foregoing description has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventions and/or aspects of the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. Further any feature illustrated in any one embodiment may be incorporated into any other embodiment. That is, different aspects of the different embodiments may be utilized in different combinations. The embodiments described hereinabove are further intended to explain best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.