Patent Publication Number: US-9422711-B1

Title: Screen support assembly with wide lateral support efficiency

Description:
FIELD OF THE INVENTION 
     The present invention is generally directed to a support assembly, and in particular, a screen support assembly with a wide lateral support efficiency in that with the construction of the various embodiments of the present invention, horizontal or lateral beams may extend large distances from the vertical supports, allowing for large or wide open screen portions between vertical supports. 
     BACKGROUND OF THE INVENTION 
     Screen enclosures for patios, pool areas, porches, etc. are well known in the art and are installed on many homes, buildings, and apartments throughout the United States and the World. Such screen enclosures are often constructed by installing closely spaced vertical posts or beams with horizontal beams spanning between them. Screen material, often in square or rectangular panels, will then fill the open spaces between the vertical posts and horizontal beams. 
     The problem, however, is that the vertical posts often obstruct views and scenery for those individuals positioned within the enclosure and who wish to gaze or look out through the screen and beyond the enclosure. This is particularly true for many luxurious homes and buildings that overlook bodies of water, such as lakes, oceans, etc. or golf courses, pastures, mountains, etc. While the screened enclosure may be beneficial in protecting the enclosed area from many of the outside elements, wildlife, and insects, it also obstructs the once stunning view of the outside scenery. 
     Accordingly, there is a need in the art for a new screen enclosure or support assembly that includes a high degree of lateral strength and structural integrity between the joints where the vertical and horizontal or lateral beams meet. The high strength and integrity of the proposed screen enclosure and support assembly must support horizontal beams that can span great distances (e.g., greater than thirty feet) between vertical posts, thereby creating a wide open viewing panel that is not obstructed by intermediate vertical support posts. 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention is generally directed to a support assembly which includes a high degree of lateral strength and integrity in order to allow for lateral beams to span great distances between vertical supports. This provides wide open spaces or screened panels that create unobstructed or less obstructed views there through. 
     In particular, the support assembly of at least one embodiment includes a beam support bracket having at least one laterally disposed elongated portion that is slidingly or telescopically engaged with a corresponding lateral beam. For instance, the elongated portion of the beam support bracket is defined by spaced apart first and second extension members or plates connected to one another via internal support webbing or spacer plates. The extension members each include oppositely disposed edges, such as, but not limited to, upper and lower edges, which will mate with corresponding ledges or protrusions disposed within the lateral beam, for example, at or near inside corners thereof. 
     Specifically, the lateral beam(s) may include rectangular shaped tubes manufactured out of extruded aluminum or other materials capable of facilitating the implementation of the present invention. The beam(s) include an internal receiving portion with reinforced corners or surface protrusions which define channels through which the extension members of the beam support bracket are slidingly or telescopically engaged. 
     For instance, the elongated portion of the beam support bracket may be disposed within the internal receiving portion of the lateral beam such that the oppositely disposed edges of each of the extension members correspondingly mate with the reinforced corners on the inside of the lateral beam. The mating engagement between the bracket and the beam restrict side-to-side, up and down and rotational movement there between. 
     Further embodiments may also include a support post with an internal receiving portion similar to that of the lateral beam. Specifically, the support post may include reinforced corners on the inside thereof in order to define channels through which a downwardly directed portion of the support beam will fit or engage. Certain embodiments of the support post are constructed from an extruded aluminum, similar to the lateral beams, although other materials and methods of construction may be implemented. 
     The lateral beams and the support post may further include screen retention assemblies, such as spline grooves, within which a screen panel and retention spline may be inserted for attaching screen material thereto. Other screen retention assemblies may be implemented or incorporated within the full spirit and scope of the present invention. 
     Further, it should also be noted that the screen or support assembly of certain embodiments of the present invention may be constructed to withstand high velocity winds, including hurricane force winds. Thus, certain embodiments may be constructed to pass stringent wind velocity standards and tests that may be found or implemented in many parts of the United States, including Florida, and Worldwide. 
     These and other objects, features and advantages of the present invention will become more apparent when the drawings as well as the detailed description are taken into consideration. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the support assembly of at least one embodiment of the present invention installed on home or other structure. 
         FIG. 2A  is an exploded view of the support assembly as disclosed in accordance with at least one embodiment of the present invention. 
         FIG. 2B  is a perspective view of the support assembly illustrated in  FIG. 2A . 
         FIG. 3A  is a perspective view of a lateral beam as disclosed in accordance with at least one embodiment of the present invention. 
         FIG. 3B  is a partial perspective end view of the lateral beam illustrated in  FIG. 3A . 
         FIG. 4A  is a partially exploded and cut-away view of the beam support bracket and lateral beams as disclosed in accordance with at least one embodiment of the present invention. 
         FIG. 4B  is a cut-away view of  FIG. 4A  along line  4 B- 4 B as illustrated therein. 
         FIG. 5  is a partial end view of the support post as disclosed in accordance with at least one embodiment of the present invention. 
         FIG. 5A  is a cut away view of the interconnected support post and beam support bracket as disclosed in accordance with at least one embodiment of the present invention. 
         FIG. 6  is a perspective view of the support boot as disclosed in accordance with at least one embodiment of the present invention. 
         FIG. 6A  is a cut-away view of the interconnected support boot and support post along line  6 A- 6 A illustrated in  FIG. 2A . 
         FIG. 7  is a perspective view of another beam support bracket and intermediate lateral beam as disclosed in accordance with at least one embodiment of the present invention. 
     
    
    
     Like reference numerals refer to like parts throughout the several views of the drawings provided herein. 
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in the accompanying drawings, and with particular reference to  FIG. 1 , the present invention is directed to a support assembly, as generally shown by reference character  10 . Particularly, in the exemplary embodiment illustrated in  FIG. 1 , the support assembly  10  is structured to support one or more screen panels  5  as is shown installed on the rear portion of a structure  1 , such as a home. The screened or other enclosure may enclose a pool, patio, or other area. However, while many implementations of the support assembly  10  of the present invention may be used to support or construct screen enclosures on homes, businesses or other structures  1 , as generally illustrated in  FIG. 1 , for example, other embodiments may be used for other various support assembly applications. 
     In any event, as provided herein, the support assembly  10  of the various embodiments of the present invention provides significant lateral or horizontal strength and integrity allowing for the construction of or implementation of wide open screen panels or other areas, for example, as generally represented by reference character  7  in  FIG. 1 . Particularly, the large or wide open screen panels may be configured such that vertical support members  30 , which support the horizontal or lateral beams  20 , may be positioned great distances from one another, including, for example, up to approximately thirty-five (35) feet. Such a configuration, made possible by the lateral strength and integrity between the horizontal or lateral beams  20  and the vertical support posts  20 , creates large, wide and quite visually stunning, viewing panels unobstructed by vertical support posts  30 . 
     For instance, referring now to  FIGS. 2A and 2B , the support assembly  10  includes a beam support bracket  40 , at least one lateral beam  20 , and a substantially vertically oriented support post  30 . As described herein, the lateral beam(s)  20  are slidingly engaged with or otherwise over elongated portions  41  of the beam support bracket  40 . It should be noted, however, that a reverse configuration may be implemented wherein the beam support bracket  40  is configured to slide over the lateral beam(s)  20 . Similarly, a downward portion  50  of the beam support bracket  40  is slidingly engaged within an end of the support post  30 , such as an upper end, although, again, a reverse embodiment may be implemented wherein the support post slides within the downward portion  50 . 
     It should also be noted that while  FIGS. 2A and 2B  illustrate a “T” shaped beam support bracket, other shapes may be contemplated within the full spirit and scope of the present invention in order to install or construct a support assembly  10 , for example, as shown in  FIG. 1 . For instance, the beam support assembly  40  may comprise a corner or “L” shape, or other configurations which may facilitate support angles, etc. Accordingly, a single beam support bracket  40  may support or engage with one, two or more lateral beams  20 . 
     Still referring to  FIG. 2A , the beam support bracket  40  of at least one embodiment of the present invention includes laterally spaced first and second extension members  42 ,  44  which define the elongated portion  41  that is slidingly engaged or disposed within a corresponding lateral beam  20 . Each of the extension members  42 ,  44  include oppositely disposed edges, such as, but not limited to, upper edges  42 A,  44 A and lower edges  42 B,  44 B that will correspondingly mate with cooperatively constructed and disposed portions within the lateral beam(s)  20 , as described herein. 
     Further, in at least one exemplary embodiment of the present invention, the beam support bracket  40  is constructed by securing a plurality of spacer plates  45  between the two laterally spaced extension members  42 ,  44  in order to space the extension members  42 ,  44  a proper distance from one another to correspondingly and slidingly fit within the lateral beam  20 . Accordingly, the extension members  42 ,  44  may comprise separately structured metal, aluminum or other like plates laterally spaced from one another via at least one, but more practically, a plurality of spacer plates  45 . For instance, in the “T” shaped construction illustrated in  FIG. 2A , the beam support bracket  40  may comprise two (2) “T” shaped plates laterally spaced from one another via one or more spacers  45 . The “T” shape creates two elongated portions  41  extending from the downward portion  50 , although, as noted above, other shapes and brackets can be implemented. The spacer plates  45  may thus be welded, screwed, glued, adhered, or otherwise connected to the inside surface of the plates or extension members  42 ,  44 . Other ways of manufacturing or constructing the beam support bracket  40  may be contemplated within the full spirit and scope of the various embodiments disclosed herein. 
     Referring now to  FIGS. 3A and 3B , an exemplary embodiment of the lateral beam  20  is shown. For instance, the lateral beam  20  may be connected to a support bracket  40  on each end  21 ,  29 . Due to the significant strength and integrity of the interconnections between the lateral beam  20  and the support brackets  40 , the lateral beam  20  may, in some instances, span a distance of approximately thirty-five (35) feet between the support brackets  40  or vertical supports  20 . Of course, other distances, whether longer or shorter may be implemented in order to construct the support assembly  10 , for example, as shown in  FIG. 1 . Further, the lateral beams  20  may include screen retention assemblies  60 , such as retention channels configured to receive a portion of a screen panel and a corresponding spline member therein. Other screen retentions assemblies now known or later developed in the art are contemplated in order to secure a screen panel to the lateral beam  20 . 
     Furthermore, the lateral beams  20  of the various embodiments of the present invention may be constructed by way of metal or aluminum extrusion techniques in that the lateral beam(s)  20  may be extruded pieces of aluminum or other metal. For example, in one illustrative embodiments, the lateral beams  20  may comprise 60-63 T6 extruded aluminum, although other materials may be implemented in order to facilitate the practice of the present invention in the intended manner. In addition, the lateral beam(s)  20  of at least one exemplary embodiment may comprise a rectangular tube comprising a width of six (6) inches, a height of eight (8) inches and a thickness of 0.19 inches. Other dimensions and configuration may be implemented within the scope of the present invention. 
     Still referring to  FIGS. 3A and 3B , the lateral beam  20  includes an internal receiving portion  25  with first and second surface protrusion pairs or reinforced corner portions, wherein the first surface protrusion pair may be defined by a first upper surface protrusion  22 A and a first lower surface protrusion  22 B, and the second surface protrusion pair defined by a second upper surface protrusion  24 A and a second lower surface protrusion  24 B. For instance, the surface protrusions  22 A,  22 B,  24 A,  24 B of the various embodiments comprise cooperatively structured surfaces or ledges that will correspondingly mate or fit with the upper and lower edges  42 A,  42 B,  44 A,  44 B of the first and second extension members  42 ,  44  of the beam support bracket  40 . In the embodiments shown, the upper and lower edges  42 A,  42 B,  44 A,  44 B and the surface protrusions  22 A,  22 B,  24 A,  24 B comprise generally corresponding flat surfaces, although it should be noted that other surface configurations such as curved surfaces, locking surfaces, tongue and groove, etc. may be contemplated. 
     Furthermore, as shown in  FIGS. 3A and 3B , the surface protrusions  22 A,  22 B,  24 A,  24 B are disposed in the inside corners of the internal receiving portion  25  of the lateral beam  20 , thereby providing reinforced corner portions. Particularly, the first surface protrusions  22 A and  22 B are disposed on adjacent corners and in some implementations, vertically aligned corners such that the first surface protrusions  22 A and  22 B will mate with the first upper and lower edges  42 A,  42 B of the first extension member  42 . Similarly, the second surface protrusions  24 A and  24 B are disposed on a different set of adjacent corners within the lateral beam  20  and in some implementations, vertically aligned corners such that the second surface protrusions  24 A and  24 B will mate with the second upper and lower edges  44 A,  44 B of the second extension member  44  of the beam support bracket  40 . 
     In addition, and still referring to  FIGS. 3A and 3B , the internal receiving portion  25  of the lateral beam  20  includes internal lateral surfaces, such as a first internal lateral surface  22 C and a second internal lateral surface  24 C. The first internal lateral surface  22 C is disposed between the first upper surface protrusion  22 A and the first lower surface protrusion  22 B, and similarly, the second internal lateral surface  24 C is disposed between the second upper surface protrusion  24 A and the second lower surface protrusion  24 B. In this manner, the external lateral surfaces  42 C and  44 C of the elongated portions  42 ,  44  of the support bracket  40  will correspondingly mate with the internal lateral surfaces  22 C,  24 C of the lateral beam  20 . 
     Accordingly, the first surface protrusion pair  22 A,  22 B and the connecting internal surface  22 C define a first side channel within which the first extension member  42  of the beam support bracket  40  will slide. Similarly, the second surface protrusion pair  24 A,  24 B and the connecting internal surface  24 C define a second channel within which the second extension member  44  of the beam support bracket will slide. 
     Furthermore,  FIGS. 4A and 4B  illustrate exemplary embodiments wherein the lateral beam(s)  20  is slidingly or telescopically engaged with or onto the beam support bracket  40 . Particularly,  FIG. 4B  is a cross-sectional view taken along line  4 B- 4 B shown in  FIG. 4A . For instance, the elongated portion  41  of the beam support bracket  40  is disposed within the internal portion  25  of the lateral beam  20  in a manner such that the oppositely disposed or upper and lower edges  42 A,  42 B of the first extension member  42  correspondingly mate with the first surface protrusion pair (for example, defined by the first upper surface protrusion  22 A and first lower surface protrusion  22 B in one embodiment) and the oppositely disposed edges or upper and lower edges  44 A,  44 B of the second extension member  44  of the same elongated portion  41  correspondingly mate with the second surface protrusion pair (for example, defined by the second upper surface protrusion  44 A and the second lower surface protrusion  44 B of one embodiment). In addition, the external lateral surfaces  42 C and  44 C of the elongated portions  42 ,  44  of the support bracket  40  are correspondingly aligned or mated with the internal lateral surfaces  22 C,  24 C of the lateral beam  20 . The lateral beam  20  may be secured to the beam support bracket  40  by way of securing one or more bolts, screws, or other like securing mechanisms through correspondingly positioned and aligned holes, as generally represented as  15 . Depending on the particular beam support bracket  40 , a cap  45 C may be secured to a top portion of the bracket  40 , such as, for example, between adjacent lateral beams  40 , as shown in  FIG. 4A . 
     In this regard, the lateral beam  20  is secured into place on the beam support bracket  20  and is prevented from twisting, rotating, or otherwise moving relative to the beam support bracket  40 . Particularly, the mating engagement between the various edges  42 A,  42 B,  44 A,  44 B and the corresponding protrusions  22 A,  22 B,  24 A,  24 B, as well as the mating alignment or engagement between the surfaces  42 C,  44 C and  22 C,  24 C restrict movement between the lateral beam  20  and the beam support bracket  40 . In addition, the spacer plates or spacers  45  secured between the two extension members  42 ,  44  maintain the appropriate spacing between the extension members  42 ,  44  and thereby further restrict or contribute to the movement restriction between the lateral beam  20  and the beam support bracket  40 . 
     Referring again to  FIG. 2A , in at least one embodiment, the beam support bracket  40  further comprises a downward portion  50  defined by the laterally spaced first and second extension members  42 ,  44 , for example. The downward portion  50  is structured to slidingly or telescopically fit or engage within a support post  30 , in a similar manner as the elongated portion(s)  41  slidingly fit or engage within the lateral beams  20 . For example, as shown in  FIGS. 5 and 5A , the support post  30  includes an internal receiving portion  35  with a first surface protrusion pair  32 A,  32 B and a second surface protrusion pair  34 A,  34 B, each defining a first channel and a second channel, respectively. 
     The downward portion  50  of the beam support bracket  40  includes corresponding edges  52 A,  52 B and  54 A,  54 B which correspondingly mate with the first and second channels defined by the surface protrusion portions  32 A,  32 B and  34 A,  34 B, as shown in  FIG. 5A . Thus, the mating engagement between the edges  52 A,  52 B,  54 A,  54 B of the downward portion  50  and the surface protrusion portions  32 A,  32 B,  34 A,  34 B disposed in the internal receiving portion  35  of the support post  30  is structured to restrict movement, such as lateral, rotational or twisting movement between the beam support bracket  40  and the support post  30 . In additional, the spacers  45  which, as above, are structured to maintain a corresponding spacing between the extension members  42 ,  44 , may also restrict movement or contribute to the movement restriction between the beam support bracket  40  and the support post  30 . Of course, screws, bolts or other securing mechanisms may be secured through or between the support post  30  and the beam support bracket  20 , for example, through correspondingly aligned holes  15 , which also contribute to the secure engagement and movement restriction relation between the support post  30  and the beam support bracket  20 . 
     It should also be noted that, as illustrated in  FIG. 5A , for example, the support post  50  may include a plurality of screen retention assemblies  60  for securely retaining a screen panel  5  therein. As an example, the screen retention assembly  60  may include a channel for securely retaining a portion of the screen panel  5  therein, along with a flexible or other spline for retaining the screen portion therein. Other screen retention assemblies may be incorporated within the full spirit and scope of the present invention. 
     In addition, the support post  30  of at least one embodiment of the present invention may include one or more upper flanges  36  extending upward beyond the interior portion  35 . Accordingly, the flange(s)  36  of at least one embodiment, may extend in an at least partially overlapping relation with an external surface of the beam support bracket  40 , as generally illustrated in  FIG. 2A . Corresponding holes and bolts, screws or other securing mechanisms may be implemented to keep the flanges secured to the beam support bracket. 
     Furthermore, the support post(s)  30  of the various embodiments of the present invention may be constructed by way of metal or aluminum extrusion techniques in that the support posts(s)  30  may be a single piece of extruded aluminum or other metal. For example, in one illustrative embodiments, the support post(s)  30  may comprise 60-63 T6 extruded aluminum, although other materials may be implemented in order to facilitate the practice of the present invention in the intended manner. In addition, the support post(s)  30  of at least one exemplary embodiment may comprise a rectangular or square tube comprising a width of six (6) inches, a height of six (6) inches and a thickness of 0.25 inches. Other dimensions and configuration may be implemented within the scope of the present invention. 
     Additional features of certain embodiments of the present invention include a support boot  70  slidingly or telescopically engaged to or within a lower end of the support post  30 . For example, as shown in  FIGS. 6 and 6A , the support boot  70  of at least one embodiment comprises a generally upright portion  76  and a base  78 . The base  78  may be flanged outward from the upright portion  76  in order to provide additional stability or support. The base  78  may be secured to a floor, concrete slab, ground, or other surface. 
     Further, still referring to  FIGS. 6 and 6A , the upright portion of the boot  70  may include surface indents or external receiving corner portions  72 A,  72 B,  74 A,  74 B which correspond to the surface protrusions  32 A,  32 B,  34 A,  34 B disposed on the inside of the support post  30 , as described herein. In this manner, the surface protrusions  32 A,  32 B,  34 A,  34 B of the support post  30  will correspondingly mate with the surface indents  72 A,  72 B,  74 A,  74 B on the boot  70 , proving a secure mating engagement there between. As before, the surface protrusions  32 A,  32 B,  34 A,  34 B and the surface indents  72 A,  72 B,  74 A,  74 B may be disposed on the corners of the corresponding element, as illustrated. While the surface protrusions  32 A,  32 B,  34 A,  34 B and the surface indents  72 A,  72 B,  74 A,  74 B are shown as comprising generally flat 90 degree surfaces, it is contemplated that any surface shapes may be implemented such that the surface protrusions  32 A,  32 B,  34 A,  34 B and the surface indents  72 A,  72 B,  74 A,  74 B correspondingly mate with one another and provide a secure interconnection. 
     Referring now to  FIG. 7 , yet another embodiment of the beam support bracket  40  is shown. Particularly, instead of being secured to a vertically oriented support post, the beam support bracket  40  may be secured to the structured  1 , itself, such as a tie-beam, wall, post, pillar, etc. For instance, the beam support bracket  40  may include a base  43  secured to the structure  1 , wherein the extension members  42 ,  44  extend outwardly there from. The lateral beam  20  may therefore slidingly engage with the beam support bracket  40  or extension members  42 ,  44 , in the manner described herein. Other embodiments may include an intermediate beam  20 ′ configured similarly to the lateral beam  20  in that the intermediate beam  20 ′ can be slidingly engaged with the beam support bracket  40  in the same manner the lateral beam  20  can be secured, as described herein. As shown in  FIG. 7 , the lateral beam  20  may then be secured to the intermediate beam  20 ′, for example, by providing bolts, screws, or other securing devices there between (not shown). The outer end  20  of the lateral beam  20  may then be slidingly engaged with another beam support bracket  40  to assemble the support assembly of the present invention. 
     This written description provides an illustrative explanation and/or account of the present invention. It may be possible to deliver equivalent benefits and insights using variations of the sequence, steps, specific embodiments and methods, without departing from the inventive concept. This description and these drawings, therefore, are to be regarded as illustrative and not restrictive. 
     Now that the invention has been described,