Abstract:
The present invention relates to a structural component interconnect assembly. The structural component interconnect assembly includes a first component adapted for interconnection with a second component. A connection component is adapted for securing the first component and the second component together in a secured interconnection. The connection component includes at least two flanges spaced from each other by a first distance. The first component includes a mating surface having at least two slots formed therein and spaced one from another by the first distance. The second component includes a first surface and a second surface spaced one from the other by a distance on the order of the first distance. Engagement of the at least two flanges, via the at least two slots, with the first surface and the second surface secures the first component to the second component.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/434,433, filed Mar. 29, 2012. U.S. patent application Ser. No. 13/434,433 claims priority from U.S. Provisional Patent Application No. 61/469,504, filed Mar. 30, 2011. U.S. patent application Ser. No. 13/434,433 and U.S. Provisional Patent Application No. 61/469,504 are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to structural interconnections and more particularly, but not by way of limitation, to methods and systems for securing structural components such as, for example, doors and door frames. 
         [0004]    2. History of the Related Art 
         [0005]    When joining two or more structural members such as, for example, doors and door frames through processes such as, for example, welding, gluing, brazing, soldering, chemical bonding, and the like, it is common to secure the two or more structural members in a desired configuration so as to prevent incidental movement. Securing the two or more structural members often includes utilizing a specialized tool commonly known as a “jig” or a “fixture.” The jig, for example, holds the two or more structural members in the desired configuration and prevents undesired incidental movement. In most cases, the jig is removed immediately after use and provides no added structural support. By way of example, in the case of doors and door frames, the jig often utilizes at least one screw that is placed through a horizontal member and into at least one vertical member thereby securing the horizontal member and the at least one vertical member. 
         [0006]    The use of screws when securing components to be welded is not without problems. First, screws often require threaded holes to be formed in each component through which the screws pass. Often times, this is a two-step process of drilling a hole and, subsequently, tapping the drilled hole. The process of forming threaded holes adds costs to a structural assembly in the form of increased labor and material expense. Second, screws do not entirely eliminate movement between the horizontal member and the at least one vertical member. Furthermore, in many cases, the jig is often removed after securement and adds no additional support to the structural assembly. 
       SUMMARY 
       [0007]    The present invention relates to structural interconnections and more particularly, but not by way of limitation, to methods and systems for securing structural components during assembly. One aspect of the present invention relates to a structural component interconnect assembly. The structural component interconnect assembly includes a first component adapted for interconnection with a second component. A connection component is adapted for securing the first component and the second component together in a secured interconnection. The connection component includes at least two flanges spaced from each other by a first distance. The first component includes a mating surface having at least two slots formed therein and spaced one from another by the first distance. The second component includes a first surface and a second surface spaced one from the other by a distance on the order of the first distance. Engagement of the at least two flanges, via the at least two slots, with the first surface and the second surface secures the first component to the second component. 
         [0008]    Another aspect of the present invention relates to a method for assembling structural components. The method includes providing a first component having a first surface and a second surface and providing a connection component having at least two flanges. The method further includes coupling the connection component with a second component such that the at least two flanges protrude from the second component, inserting the at least two flanges between the first surface and the second surface, and securing the first component to the second component via friction between the first component and the connection component. 
         [0009]    Another aspect of the present invention relates to a structural component interconnect assembly. The structural component interconnect assembly includes a first component having a first surface and a second surface. The first surface and the second surface together define an interior gap. The structural component interconnect assembly further includes a connection component having at least two flanges. An exterior face of the at least two flanges is spaced from each other by a distance approximately equal to a distance between the first surface and the second surface. A second component is operable to receive the connection component such that the at least two flanges protrude outwardly from the second member. Upon insertion into the interior gap, the at least two flanges engage the first surface and the second surface thereby securing the first component to the second component. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    A more complete understanding of the method and system of the present invention may be obtained by reference to the following Detailed Description when taken in conjunction with the accompanying drawings wherein: 
           [0011]      FIG. 1  is an exploded perspective view of a structural assembly according to an exemplary embodiment; 
           [0012]      FIG. 2  is a side view of a connection component according to an exemplary embodiment; 
           [0013]      FIG. 3  is a detailed side view of the connection component of  FIG. 2  according to an exemplary embodiment; 
           [0014]      FIG. 4  is a cross-sectional view of the structural assembly having the connection component installed therein according to an exemplary embodiment; 
           [0015]      FIG. 5  is an end view of a first component showing placement of the connection component therein according to an exemplary embodiment; and 
           [0016]      FIG. 6  is a flow diagram of a process for forming a structural assembly according to an exemplary embodiment. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Various embodiments of the present invention will now be described more fully with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. 
         [0018]    As used herein, the term “interference fit” refers to joining two mating parts via friction. The two mating parts being held together via friction is greatly increased by compression of one part against the other. A magnitude of friction resulting from the compression depends upon tensile and compressive strengths of materials from which two mating parts are constructed. Common examples of an interference fit include, for example, fitting of shafts into bearings, assembly of various pipe fittings, and the like. An interference fit may be created via, for example, force or thermal expansion. 
         [0019]    An interference fit created by force (also commonly known as a “press fit” or a “friction fit”) is achieved via tools that are operable to press the two mating parts together with large amounts of force. The tools may range in size and complexity from large hydraulic presses, capable of delivering several tons of force, to small hand-operated mechanical presses. 
         [0020]    An interference fit created by thermal expansion relies on the principle that most materials expand when heated and contract when cooled. Enveloping parts such as, for example, a bearing, are heated, assembled into position while hot, and then allowed to cool and contract back to normal size. When creating an interference fit via, for example, thermal expansion, care must be taken not to alter mechanical properties of the two mating parts. For example, hardness of metallic components is particularly susceptible to change due to repeated heating and cooling. 
         [0021]      FIG. 1  is an exploded assembly view of a structural assembly according to an exemplary embodiment. An assembly  100  includes a first component  102 , a second component  104 , and a connection component  106 . The first component  102  includes a left side  103  and a right side  105  connected by a first surface  116  and a second surface  117 . The first surface  116  and the second surface  117  define an interior gap  108  having a height (h). An access port  114  is formed in the first surface  116  of the first component  102  and a second access port  115  (shown in  FIG. 5 ) is formed in the second surface  117 . 
         [0022]    The second component  104  includes a left side  107 , a right side  109 , a rear face  121 , and an interior face  112 . The left side  107 , the right side  109 , the rear face  121 , and the interior face  112  define an interior region  113  within the second component  104 . A first slot  110 ( 1 ) and a second slot  110 ( 2 ) formed on an interior face  112 . The first slot  110 ( 1 ) includes an upper edge  111 ( 1 ) and a lower edge  119 ( 1 ). The second slot  110 ( 2 ) includes an upper edge  111 ( 2 ) and a lower edge  119 ( 2 ). The upper edge  111 ( 1 ) of the first slot  110 ( 1 ) and the lower edge  119 ( 2 ) of the second slot are separated from each other by a distance generally equal to the height (h) of the interior gap  108 . In other embodiments, components utilizing principles of the invention may include a single slot of a height generally equal to the height (h) of the interior gap. The first slot  110 ( 1 ) and the second slot  110 ( 2 ) include generally-vertical end regions  101 . The generally-vertical end regions  101  ensure that the first slot  110 ( 1 ) and the second slot  110 ( 2 ) have may accommodate a rectangular shaped member therethrough. 
         [0023]    The connection component  106  includes a base  202 , a first flange  204 ( 1 ), and a second flange  204 ( 2 ). In a typical embodiment, the first component  102  and the second component  104  are constructed from a material that is light weight and sturdy such as, for example, extruded aluminum, plastic, or other appropriate material. The connection component  106  is constructed from, for example, aluminum or plastic; however, any material appropriate for such purpose may be used. In a typical embodiment, the connection component  106  is constructed from the same material as the first component  102  and the second component  104  to avoid differing coefficients of thermal expansion. Intense heating common during welding often creates a high temperature differential that induces different rates of thermal expansion in different materials. Damage to the structural assembly  100  could result if the connection component  106  is constructed from a different material than the first component  102  or the second component  104 . 
         [0024]      FIG. 2  is a side view of a connection component according to an exemplary embodiment. The connection component  106  includes a base  202 , a first flange  204 ( 1 ), and a second flange  204 ( 2 ). The embodiment shown in  FIG. 2  illustrates the first flange and the second flange  204 ( 1 ) and  204 ( 2 ); however, in various alternative embodiments, any number of flanges could be utilized. The first flange  204 ( 1 ) and the second flange  204 ( 2 ) extend generally orthogonally from the base  202 ; however, in various alternative embodiments, flanges utilizing principles of the invention may be oriented at any angle relative to each other or the base  202 . In a typical embodiment, the first flange  204 ( 1 ) and the second flange  204 ( 2 ) extend from the same side of the base  202 ; however, in alternative embodiments, flanges utilizing principals of the invention may be present on both sides of the base  202 . The first flange  204 ( 1 ) includes a top surface  205 ( 1 ) and a bottom surface  207 ( 1 ). The second flange  204 ( 2 ) includes a top surface  205 ( 2 ) and a bottom surface  207 ( 2 ). The top surface  205 ( 1 ) of the first flange  204 ( 1 ) and the bottom surface  207 ( 2 ) of the second flange  204 ( 2 ) are separated from each other by a distance generally equal to the height (h) of the interior gap  108  (illustrated in  FIG. 1 ). 
         [0025]      FIG. 3  is a detailed side view of the connection component of  FIG. 2  according to an exemplary embodiment. The first flange  204 ( 1 ) includes the top surface  205 ( 1 ) and the bottom surface  207 ( 1 ). The first flange  204 ( 1 ) is tapered such that a first region  302 , disposed adjacent to the base  202 , is thicker than a second region  303  (shown in  FIG. 2 ) disposed distal to the base  202 . At least one serration  304  extends from the top surface  205 ( 1 ) in the first region  302 . As will be described in more detail hereinbelow, the at least one serration  304  increases friction between the top surface  205 ( 1 ) of the first flange  204 ( 1 ) and a surface engaged with the top surface  205 ( 1 ) of the first flange  204 ( 1 ). In various embodiments, the at least one serration  304  extends from either the top surface  205 ( 1 ) or the bottom surface  207 ( 1 ) in the first region  302 . In various alternative embodiments, the at least one serration  304  may include a plurality of serrations extending from both the top surface  205 ( 1 ) and the bottom surface  207 ( 1 ) in the first region  302 . In other embodiments, flanges utilizing principles of the invention may include serrations of different profile shapes such as, for example, curved or triangular. In other embodiments, the at least one serration  304  may be omitted. By way of example, the first flange  204 ( 1 ) is depicted in  FIG. 3 ; however, one skilled in the art will recognize that the second flange  204 ( 2 ) is similar in terms of construction and operation to the first flange  204 ( 1 ). 
         [0026]      FIG. 4  is a cross-sectional view of a structural assembly having a connection component installed therein according to an exemplary embodiment. In a typical embodiment, the connection component  106  is placed inside the interior region  113  of the second component  104 . The first flange  204 ( 1 ) is inserted through the first slot  110 ( 1 ) and the second flange  204 ( 2 ) is inserted through the second slot  110 ( 2 ). After insertion, the first flange  204 ( 1 ) and the second flange  204 ( 2 ) protrude outwardly from the interior face  112  of the second component  104  in a generally orthogonal orientation. However, in various alternative embodiments, flanges utilizing principles of the invention may be arranged at any angle with respect to the second component  104 . Such alternative embodiments accommodate coupling of the first component  102  and the second component  104  at a variety of angles including, for example, acute, right, or obtuse angles. In various alternative embodiments, the first component  102  and the second component  104  may be mitered to facilitate connection. 
         [0027]    Still referring to  FIG. 4 , the first slot  110 ( 1 ) and the second slot  110 ( 2 ) are of a width (w). In a typical embodiment, the width (w) is sufficiently sized to allow one of the first flange  204 ( 1 ) or the second flange  204 ( 2 ) to pass therethrough. In other embodiments, the width (w) slightly smaller than the first region  302  of the first flange  204 ( 1 ) and the second flange  204 ( 2 ) thus creating an interference fit between the first and second slots  110 ( 1 )-( 2 ) and the first region  302  of the first flange  204 ( 1 ) and the second flange  204 ( 2 ). Such an interference fit provides that, once assembled, the connection component  106  may not be easily disengaged from the second component  104 . In various embodiments, the at least one of serration  304  further increases friction between each of the first and second slots  110 ( 1 )-( 2 ) and the first region  302 . 
         [0028]    Referring still to  FIG. 4 , during assembly, tapering of the first and second flanges  204 ( 1 )-( 2 ) provides several advantages. First, the first and second tapered flanges  204 ( 1 )-( 2 ) acts to distribute a compressive force around a perimeter of the first and second slots  110 ( 1 )-( 2 ). Second, the first and second tapered flanges  204 ( 1 )-( 2 ) act as a leading edge and facilitate alignment of the first and second flanges  204 ( 1 )-( 2 ) with the first and second slots  110 ( 1 )-( 2 ), respectively. Furthermore, the first and second tapered flanges  204 ( 1 )-( 2 ) reduces a magnitude of force required to assemble the connection component  106  with the second component  104  or the first component  102 . Finally, the first and second tapered flanges  204 ( 1 )-( 2 ) accurately aligns the connection component  106  within the interior gap  108 . In this manner, the first and second flanges  204 ( 1 )-( 2 ) are self-aligning. 
         [0029]      FIG. 5  is an end view of a first component showing placement of the connection component therein according to an exemplary embodiment. Referring now to  FIGS. 4 and 5 , the first and second flanges  204 ( 1 )-( 2 ) are arranged such that the top surface  205 ( 1 ) of the first flange  204 ( 1 ) and the bottom surface  207 ( 2 ) of the second flange  204 ( 2 ) are spaced from each other by a distance generally equal to the height (h) of the interior gap  108 . In a typical embodiment, the first and second flanges  204 ( 1 )-( 2 ) are received within the interior gap  108 . Upon installation, the first flange  204 ( 1 ) engages an interior face of the first surface  116  of the first component  102  while the second flange  204 ( 2 ) engages an interior face of the second surface  117 . Spacing between the first and second flanges  204 ( 1 )-( 2 ) is such that engagement of the first surface  116  and the second surface  117  compresses the first and second flanges  204  ( 1 )-( 2 ) in a direction towards each other. Compression of the first and second flanges  204 ( 1 )-( 2 ) greatly increases friction between the first flange  204 ( 1 ) and the first surface  116  and greatly increases friction between the second flange  204 ( 2 ) and the second surface  117  thereby creating an interference fit between the connection component  106  and the first component  102 . Such an interference fit prevents the first component  102  from being disengaged from either the connection component  106  or the second component  104 . In this manner, the connection component  106  imparts additional structural integrity to the assembly  100 . 
         [0030]    Still referring to  FIGS. 4 and 5 , in various embodiments, the at least one serration  304  further increases friction between the first flange  204 ( 1 ) and the first surface  116  and further increases friction between the second flange  204 ( 2 ) and the second surface  117 . Once the first component  102  and the connection component  106  are operatively engaged, the access port  114  provides access for the first component  102  to be secured to the connection component  106  through a process such as, for example, welding, gluing, brazing, soldering, chemical bonding, or other similar process. In various embodiments, a second access port  115  may be formed through the second surface  117 . The second access port  115  provides access to the second flange  204 ( 2 ). In various alternative embodiments, an interference fit is not present between the connection component  106  and the first component  102 . In such embodiments, the connection component  106  is secured to the first component by a process such as, for example, welding, gluing, brazing, soldering, chemical bonding, or other similar process applied via the first access port  114  and the second access port  115 . 
         [0031]    Still referring to  FIGS. 4 and 5 , in a typical embodiment, assembly of the structural components using the connection component  106 , the second component  104 , and the first component  102  may be achieved by hand. In various other embodiments, tools such as, for example, mechanical or hydraulic presses may be used to assist assembly of the structural components using the connection component  106  in conjunction with the second component  104  and the first component  102 . In other embodiments, the structural components such as, for example, the first component  102 , the second component  104 , and the connection component  106  may be drawn together using a removable fastening system. 
         [0032]      FIG. 6  is a flow diagram of a process for forming a structural assembly according to an exemplary embodiment. A process  600  begins at step  602 . At step  604 , the second component  104  is formed having slots for the connection component  106  to pass therethrough. At step  606 , the first component  102  is formed with the interior gap  108  therein. At step  608 , the connection component  106  is formed with the first flange  204 ( 1 ) and the second flange  204 ( 2 ). At step  610 , the connection component  106  is inserted into the second component  104  such that the first flange  204 ( 1 ) and the second flange  204 ( 2 ) engage the first slot  110 ( 1 ) and the second slot  110 ( 2 ), respectively. At step  612 , an interference fit is created between the connection component  106  and the second component  104 . At step  614 , the first flange  204 ( 1 ) and the second flange  204 ( 2 ) are inserted into the interior gap  108  of the first component  102 . At step  616 , in some embodiments, an interference fit is formed between the connection component  106  and the first component  102 . In some embodiments, step  616  may be omitted and no interference fit is formed between the connection component  106  and the first component  102 . At step  618 , the first component  102  is secured into place through a process such as, for example, welding, gluing, brazing, soldering, chemical bonding, or any other similar process. The process ends at step  620 . 
         [0033]    The advantages of the embodiments disclosed herein will be apparent to those skilled in the art. First, the assembly  100  as shown and described herein eliminates any need for installation of screws or other fasteners prior to securement thereby reducing overall material and labor costs associated with structural assemblies. Second, the interference fit present between the connection component  106  and the first component  102  substantially reduces incidental movement or “play” of the first component  102  relative to the second component  104 . Furthermore, the interaction of the first and second flanges  204 ( 1 )-( 2 ) with the first surface  116  and the second surface  117  lends additional structural support to the assembly  100 . 
         [0034]    Although various embodiments of the method and system of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions without departing from the spirit of the invention as set forth herein. For example, although the interference fit associated with the connection component  106  has been described herein as being created via force, one skilled in the art will recognize that the interference fit of the present invention could also be created through thermal expansion. In addition, the first and second flanges  204 ( 1 )-( 2 ) have been shown and described herein as being arranged in a generally vertically-spaced relationship with respect to each other. However, one skilled in the art will recognize that flanges utilizing principles of the invention may, in various embodiments, be arranged in a horizontally-spaced relationship with respect to each other. In other embodiments, a combination of horizontal and vertical flanges may be utilized. Next, in some embodiments, flanges utilizing principles of the invention may be curved to allowing joining of curved structural members. Finally, the connection component  106  is shown and described as being located in an interior region  113  of a second component  104 . However, one skilled in the art will recognize that, in various embodiments, the connection component  106  may have flanges present on either side of the base  202 . Such an arrangement allows placement of the connection component  106  directly on the interior surface  112  of the second component  104 . The embodiments described herein should be taken as illustrative only.