Flexible connector and assembly for structural connection

A flexible corner connector is provided for use in holding frame members of a structure together. The flexible connector includes a first rigid end portion having threaded surfaces adapted for receiving a threaded nut. A second rigid end portion has an enlarged head at a distal end thereof. An elongated flexible member is attached to and extends between the first and second rigid end portions. A spike washer is engageable on the first rigid end portion. The first rigid end portion and spike washer are shaped and configured for mated engagement with one another to prevent rotation of the first rigid end portion. The spike washer has at least two projections outwardly extending for engagement into a frame member.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates generally to connectors and assemblies for 
the connection of frames and structures. More particularly, the invention 
pertains to a flexible connector for use in the connection of frame 
members at corners of a structure. 
2. Description of the Prior Art 
In the building and construction industries, the connection of frames or 
other members are commonly achieved through the use of screws, nails, 
bolts, or other similarly rigid connectors. At corners or other junction 
points where a plurality of elongated frame members meet along their 
length, each frame member is typically independently connected to an 
adjacent frame member to secure the members together. While this 
conventional form of construction produces a strong connection between 
adjoining members, it suffers in several regards. 
For example, this form of construction is fairly labor intensive which 
results in increased costs. Further, the rigid nature of each corner or 
junction using this procedure requires the builder to have meticulously 
planned and measured each portion of the structure so that when the final 
portions of structure are to be completed, the structure is appropriately 
sized to match the final members. 
When constructing the frame of a building such as a gazebo for example, one 
often begins construction of the walls separately and then connects each 
succeeding wall to one another until the last wall is connected to 
complete the geometric shape of the structure. However, any errors or 
inconsistencies in measurement or in construction for each prior wall are 
cumulatively added in the resulting structure, such that the final wall or 
segment may not appropriately fit when positioned into place. The lack of 
flexibility in the conventional connections between the walls does not aid 
in a providing any real solution relating to possible adjustments due to 
the connection's rather unyielding nature. 
As will be described in greater detail hereinafter, the flexible connector 
and corner connection of the present invention solves the aforementioned 
problems and employs a number of novel features that render it highly 
advantageous over the prior art. 
SUMMARY OF THE INVENTION 
Accordingly, it is an object of this invention to provide a connector for 
use in the connection of building or frame members. 
Another object of this invention is to provide a connector that would 
result in decreased labor costs in building construction. 
Another object of this invention is to provide a connector that is easy to 
use and well suited for use in building assembly kits that would be 
desirable for both home owners and businesses, as well as those requiring 
the use of knock-down type structures for trade shows and the like. 
Still another object of this invention is to provide a flexible connector 
that is adapted to bend around a corner, as well as connect members that 
are not perfectly lined up with one another. 
Yet another object of this invention is to provide an assembly in 
combination with the flexible connector that is adapted and well suited 
for removal and reassembly of a partial section or side of a structure or 
frame without the need or requirement of taking apart additional portions 
of the structure. The flexible connector allows one to "fish" the flexible 
connector through structural members while the members are in a curved or 
non-aligned position. 
To achieve the foregoing and other objectives, and in accordance with the 
purposes of the present invention a flexible connector is provided for use 
in holding at least two frame members together. The flexible connector 
includes a first rigid end portion having threaded surfaces adapted for 
receiving a threaded nut. A second rigid end portion has an enlarged head 
at a distal end thereof An elongated flexible member is attached to and 
extends between the first and second rigid end portions. A spike washer is 
provided having an aperture therethrough. The spike washer is engageable 
on the first rigid end portion. The first rigid end portion and aperture 
are shaped and configured for mated engagement to prevent rotation of the 
first rigid end portion during connection with the nut. The spike washer 
has at least two projections outwardly extending from an inner facing 
surface of the spike washer for fixed engagement into a frame member. 
In accordance with an aspect of the invention, a plurality of frame members 
oriented in side-by-side engagement with one another form a corner. A 
longitudinal axis of each of the plurality of frame members are parallel 
to one another. Each of the plurality of frame members have a hole 
extending therethrough perpendicular to each respective longitudinal axis. 
Each of the holes between adjacently engaging frame members are in 
overlapping adjacency with one another to allow the flexible corner 
connector to extend through the holes to secure the plurality of frame 
members in unitary assembly. 
Other objects, features and advantages of the invention will become more 
readily apparent upon reference to the following description when taken in 
conjunction with the accompanying drawings, which drawings illustrate 
several embodiments of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to the drawings, a flexible connector 10 is illustrated in 
FIG. 1. The flexible connector 10 includes a generally cylindrically 
shaped first rigid end portion 12. having threaded surfaces 14 for 
receiving a threaded nut 16. 
A second rigid end portion 18 has a generally cylindrically shaped body 20 
and an enlarged head 22 at a distal end 24 thereof An elongated flexible 
member 26 is connected to and extends between the first and second rigid 
end portions 12,18. Preferably, the flexible member 26 is formed of cable, 
such as stainless steel cable which is composed of wires twisted or laid 
together in a helical relation. Opposite ends 28 of the flexible member 
are preferably connected to respective end portions 12,18 by inserting the 
ends 28 into axial holes 30,31 of the respective end portions 12,18 and 
welding the ends 28 therein. However, it should be understood that other 
manners of attachment could be employed including crimping, threading, and 
other forms of welding. 
It is noteworthy that the elongated flexible member 26 has a diameter less 
than respective diameters of the first and second rigid end portions 12,18 
so that the elongated flexible member 26 has increased flexibility 
allowing the flexible member to bend about corners as later described. In 
the preferred embodiment illustrated in FIG. 1, the flexible member 10 has 
diameter of approximately one half the size of respective diameters of the 
first and second rigid end portions 12,18. 
A distal end 32 of the first rigid end portion 12 is rounded and has a 
convex annular surface 34 co-axial with a longitudinal axis 36 of the 
first rigid end portion 12. The rounded distal end 32 allows for improved 
installation of the connector 10 where the end 32 is threaded through a 
series of holes as later described. Each of the first and second rigid end 
portions 12,18 has a sloped annular surface 38,39 extending inwardly from 
each respective end portion 12,18 towards the elongated flexible member 
26. The sloped surfaces 38,39 thereby eliminate any edges on the end 
portion 12,18 between the flexible member 26 that would be susceptible to 
becoming caught or otherwise trapped against any protrusions or edges when 
the flexible member 26 is installed or removed from within holes 40 of 
frame members 42 (FIG. 2). 
Referring to FIG. 2, the enlarged head 22 has a flange 44 on an inwardly 
facing side 46 of the enlarged head 22 which is sized for flush engagement 
against a frame member 42. The enlarged head 22 in the preferred 
embodiment has a smooth convex annular outer surface 48 on an outwardly 
facing side 50 of the enlarged head 22 co-axial with a longitudinal axis 
52 of the second rigid end portion 18. 
Referring to FIGS. 2 and 3, a spike washer 54 is provided having an 
aperture 56 therethrough. The spike washer 54 is removably engageable on 
the first rigid end portion 12. The first rigid end portion 12 and 
aperture 56 are shaped and configured for mated or keyed engagement to 
prevent rotation the first rigid end portion 12 when the nut 16 is 
threadingly secured thereto. In the preferred embodiment, the aperture 56 
and a nut and washer receiving portion 58 of the first rigid end portion 
12 are generally D-shaped having a semi-circular portion and a flat 
portion which provide keyed surfaces for engagement. It should be 
understood that other types of keyed surfaces could be employed, however 
the D-shaped surfaces are preferred. 
The spike washer 54 has at least two projections 60 outwardly extending 
from an inner facing surface 62 of the spike washer 54, although it should 
be understood that even one projection 60 would function to some degree. 
Preferably, the spike washer 54 has three projections 60 annularly spaced 
apart from one another. Each projection 60 has a pointed end 62 for biting 
or pressing engagement into one of the frame member 42 when the nut 16 is 
tightened and therefore correspondingly holds the first rigid end portion 
12 in place. Preferably, the spike washer 54, end portions 12,18, and nut 
16 are formed of brass or other suitable metal. 
It is significant to note that engagement of the spike washer 54 into the 
frame member prevents axial rotation of the spike washer 54 about the 
first rigid end portion 12 as the nut 16 is tightened. Since the spike 
washer 54 is in keyed or mated engagement with the first rigid end portion 
12, the spike washer 54 accordingly holds the first rigid end portion 12 
in a fixed position while the nut 16 is turned. 
Referring to FIGS. 4A-4D, and 5, various corner connection assemblies 62 
are disclosed utilizing the flexible connector 10 to produce corners of 
varied degrees for use in structure 64 (FIG. 6). A plurality of frame 
members 42 are oriented in side-by-side pressing engagement with one 
another (FIGS. 5A and 5B). A longitudinal axis 66 of each of the plurality 
of frame members 42 are parallel to one another. Each of frame members 42 
has a hole 68 extending therethrough perpendicular to each respective 
longitudinal axis 66. Each of the holes 68 between adjacently engaging 
frame members 42 are in overlapping adjacency with one another to allow 
the flexible corner connector 10 to extend through the holes 68 to secure 
the plurality of frame members 42 in unitary assembly. 
Wedge shaped frame members 70, as illustrated in FIGS. 4B-4D, are provided 
to produce a desired angle. The members 70 have flat opposite sides 72 in 
angled relation to one another for side-by-side confronting engagement 
with flat surfaces 74 of other frame members 42 of said plurality of frame 
members (FIG. 4B). Accordingly, the hole 68 of the wedge shaped frame 
member 70 has a longitudinal axis in axially angled relationship with a 
longitudinal axis of the hole 68 of an immediately adjacent frame member 
42,70. As illustrated, the use of members 70 having a 22.5.degree. angle 
allows for the creation of corners of various angles as shown with the 
holes 68 of the frame members 42,70 being generally arcuately aligned. 
Similarly, the use of wedged shaped members 70 having angles of varied 
degree, such as 30.degree. and the like could be used. Further, the use of 
standardized members allows for decreased costs in producing the various 
frame members 42,70, especially where the frame members 42,70 are to be 
sold in kits with the flexible connectors 10. 
In some applications, combinations of different numbers of member 70 in a 
single assembly allow for the creation of corners with various angular 
relation without changes to any of the members 42, which in some cases may 
be a centermost member that is providing loading bearing strength to a 
structure 64. This also allows for the creation of standard geometric 
shapes of a structure 64 (FIG. 6), such as octagons and hexagons, or 
alternatively other polygon shapes. 
For proper alignment of the holes 68, the longitudinal axis of the hole 68 
of each of the frame members 42,70 is preferably perpendicular to one of 
the flat opposite sides. Further, each hole 68 of frame members 42,70 is 
greater than a diameter of the first rigid end portion 12 so the first 
rigid end portion 12 is relatively movable within each hole 68 with the 
longitudinal axis of the first rigid end portion 12 being positionable in 
angled relationship with the longitudinal axis of each hole 68 as the 
first rigid end portion 12 is extended through each hole 68. 
In FIG. 4C for example, where the first rigid end portion has a 3/8" 
diameter and is approximately 1.0" in length, the holes 68 of the frame 
members 42,70 have a diameter of 1/2" with a centermost frame member 42 
indicated by the numeral 71 having a diameter of 3/4". Typically, the 
centermost positioned member 71 provides support of vertical loads of the 
structure 64 and extends from ground level or below and up to other and 
secured with members 71 which are then functioning as roof rafters, as 
shown in FIG. 2. 
It is important to note that if the holes 68 were not oversized in this 
fashion, the first rigid end portion 12 would not be extendible through 
the holes in the segmented arcuate manner as shown. Further, the oversized 
feature of these holes also allows for some degree of flexibility and 
adjustability of the structure 64, as later described. 
Referring to FIG. 6, the building structure 64 is constructed with a 
plurality of upstanding corner connection assemblies 62 as previously 
described which are interconnected to one another by connecting members 
75. While each of the corner connection assemblies 62 form strong corners 
of the structure, they at the same time allow the corner to be slightly 
yielding or movable in each geometric plane. In FIG. 2, it should be noted 
that corner assembly 77 is produced for the connection of members 42, 
which in this embodiment function as roof rafters to hold roof panels of 
the structure 64 together, as also shown in combination with the corners 
or assemblies 62 in the polygonal structure 64 illustrated in FIG. 6. 
Further, in making standard geometrically shaped structures, as 
illustrated in FIG. 6, using members 75 that form large rectangular sides 
that extend between respective members 71, it is important to accommodate 
variation of the length of such sides or members 75 without changing the 
angle of the structure. The use of the split beam corner assembly 62 
provides a solution to this problem due to the flexibility of the corner 
62 as previously provided, as well as the slight movability of the wedge 
shaped members 70. 
As an additional feature of the corner connection assemblies 62 of the 
present invention, the various above described frame members are formed of 
extruded profiles made of a rigid foam or cellular PVC that can replace 
the use of wood. Pre-machined frame members including vertical posts, 
split beams, rafters, horizontal beams, vertical beams and the like 
commonly used in building construction can be supplied as building modules 
or kits that can be assembled with the flexible connector 10 for quick 
dismantling and re-assembly. The flexible connector 10 is provided in 
standardized lengths for use in such applications. 
Although the invention has been described by reference to some embodiments 
it is not intended that the novel device be limited thereby, but that 
modifications thereof are intended to be included as falling within the 
broad scope and spirit of the foregoing disclosure, the following claims 
and the appended drawings.