Patent Publication Number: US-6668495-B1

Title: Variable load capacity and aesthetically enhanced construction components for patio enclosures

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation-in-part of application Ser. No. 09/949,822, filed on Sep. 12, 2001 and entitled, VARIABLE LOAD CAPACITY CONSTRUCTION COMPONENTS FOR PATIO POOL ENCLOSURES, by the same inventor as the subject application now U.S. Pat. No. 6,601,362. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to screened patio enclosures utilizing construction components such as beams and posts/columns. More specifically, it relates to beams and posts/columns which have a variable load capacity and includes decorative inserts for the primary and secondary construction components. The invention finds particular use in the construction of screened porch and patio/pool enclosures to form the frame work for the subsequently added screening. As one can imagine, a variety of beam and post/column capacities are required depending on the size of the particular job, and aesthetically enhanced, would be a desirable feature in what has been until now, plain colored metal, typically white or bronze. 
     The popularity of all weather, almost invisible fiberglass screened porch and patio enclosures has been rapidly increasing throughout the country, especially in the south, southeast, southwest and lower west coastal areas of the country. These enclosures find their popularity in the fact that they are very effective in keeping insects out while allowing the sunlight and breezes in, which is conducive to eating or partying outdoors in peace, protected from flies, mosquitoes and other insects. 
     Furthermore, these enclosures prevent the accumulation of leaves and debris, thus reducing maintenance time and cost, create a safe play area for children and provide security from unauthorized entry to your patio/pool area by unsupervised children. In addition, they enhance the value of your property by providing more useful living space at a fraction of the cost of a room addition. 
     As one would expect, these enclosures come in a wide variety of sizes. Some enclose only porch areas, others pool and patio areas, while still others are sufficiently large to enclose the immediate exterior of a multi-level home with a balcony and also the patio and pool below. The construction of these enclosures utilize primary components, such as beams and posts/columns and secondary components such as purlins and other profiles which serve to brace and stabilize the beams and posts/columns when connected to each other. There are purlins, beams, posts and profiles that are commercially available in solid and hollow extruded forms. Conventional connectors, such as gusset plates, stud anchors, lags and self-tapping sheet metal screws are utilized in constructing an enclosure. The subject invention is concerned with the construction of the beams and posts/columns that are the primary structural members that carry the live loads of the enclosure and secondary members that provide additional support thereto with both the primary and secondary members having the capability of receiving exterior decorative inserts. 
     The enclosures are pre-measured, laid out, engineered and prefabricated in a shop in most instances. The wall panels are also pre-screened, however, the roof panels are screened on site. The entire pre-fabricated job is then assembled and erected and in most cases attached to the house structure. 
     As the projection from the fascia of the home to the back of the enclosure or patio area increases, so must the size of the beams and the uprights (posts/columns), depending on the height and span in order to carry the loads. By means of the present invention, applicant has developed a variable load system which can be used to incrementally increase the load carrying capacity of the beams and posts/columns depending on the design criteria of the job. Each of these components, i.e. the beam and post/column is comprised of a pair of U-shaped extruded aluminum members which are combined and secured to each other to form a hollow beam or post/column. These components have an inherent load capacity based upon the height, width and wall thickness of these members. The current way of increasing the structural strength of the load carrying beams and post/columns is to increase the overall dimensions of the beams and post/columns, resulting in a larger beam and posts/column. However, applicant has developed a unique U-shaped extruded profile which allows one to add additional material in the form of metallic inserts which increase the overall load carrying capacity of the beam or post/column while retaining the outside dimensions of the previously used beams and posts/columns. The newly designed members include provision for receiving metallic inserts in the interior wall portions of the U-shaped members for increasing their structural strength. The number of additional inserts can vary in number from one to four, depending upon the desired load carrying capacity requirements of the beam or post/column. 
     Additionally, applicant has provided a unique means for installing decorative inserts to the outside facing portions on the exterior of the beams and posts/columns to break-up the boredom of conventional bronze or white colored beams and posts/columns as is presently the case. These decorative inserts are available in a variety of colors which can be selected to match the window trim or interior decor of the pool/patio furnishings. In addition to a variety of colors, imitation wood grain, simulated stucco, and other surface finishes are also available. The subject matter of this application takes the decorative appeal of the enclosure to the next level by providing decorative inserts for the secondary members of the enclosure, i.e. the purlins, horizontal square members and base anchoring members that run along the floor. Thus, it can be seen that the subject invention provides almost limitless choices in outfitting one&#39;s screened enclosure. 
     DISCUSSION OF THE PRIOR ART 
     A search of the U.S. Patent Office files in the appropriate construction areas revealed the following patents: 
     U.S. Pat. No. 3,413,775—issued to Katz on Dec. 18, 1968 discloses a hollow building column  10  wherein tape members  22 ,  24  are utilized to secure substrates to the outer surface which have a decorative effect. 
     U.S. Pat. No. 3,745,734—issued to Davey et al on Jul. 17, 1983—discloses a joint structure for strip concealing members. 
     U.S. Pat. No. 5,904,022—issued to Zadak on May 18, 1999 discloses a post and beam construction which include grooves or recesses on the outer portions thereof for receiving cover members  16 ,  20 ,  22 . The disclosure relates to a particular post construction that includes channel members for linear adjustment relative to the beams and further includes decorative covers is to improve the aesthetic appearance of the post and beam. 
     U.S. Pat. No. 3,416,282—issued to Daugherty on Dec. 17, 1968; U.S. Pat. No. 4,843,783—issued to Taravella on Jul. 4, 1988; and U.S. Pat. No. 5,088,253—issued to Autkeier on Feb. 8, 1992—These three patents disclose the use of trim strips which are received in grooves and used primarily for decorative purposes. 
     U.S. Pat. No. 5,203,130 issued to Freelove on Apr. 20, 1993 
     U.S. Pat. No. 5,737,878 issued o Rauleron et al on Apr. 14, 1998 
     U.S. Pat. No. 5,775,045 issued to Hill on Jul. 7, 1999 
     Each of these three patents disclose U-shaped members which are positioned over a door frame of jamb and serve as guards or shields to protect the frames against damage by wheelchairs, equipment and the like impacting upon them. 
     Although these patents disclose the use of decorative inserts on various building components including a post and beam, none disclose the use of U-shaped members which form a hollow beam wherein the inner walls of the beam or post/column receive metallic inserts to increase the structural strength thereof. Applicant&#39;s beams, secondary members and posts/columns further includes means for receiving decorative inserts to improve their appearance. It is urged that none of the above cited patents taken alone or in combinations thereof are anticipatory of the claimed subject matter hereinafter. 
     SUMMARY OF THE INVENTION 
     From the foregoing discussion it can readily be seen that applicant has provided a unique beam and post/column design that allows one to create a beam and post/column that will be job specific and aesthetically pleasing to one&#39;s eyes. Once the calculations have been made as to the particular job site, the fabricator can readily determine the number of metallic inserts required to satisfy the structural load requirements. With this system, the inventory of beams and posts/columns required by the fabricator is reduced to a minimum since the structural requirements can readily be satisfied by the addition of one or more stock metallic inserts, up to a maximum of four to vary the load capacity. Further, the provision of secondary members wherein decorative inserts are added, takes the enclosure&#39;s appearance to the next level. 
     Additionally, the subject invention provides for a wide selection of decorative inserts which can be readily installed without the need for special tools, clips or other hardware to the inner face portions of the posts/columns, beams and secondary members such as the purlins and base members that are anchored to the floor. After selection of the desired decorative style, one only needs to cut the vinyl or aluminum strip to its desired length and slide it into the channels, which are integrally formed on the exterior faces of the beams, posts/columns and secondary members. 
     OBJECTS OF THE INVENTION 
     An object of the invention is to provide a patio/pool enclosure which utilizes unique beam and post/column components in its construction. 
     A further object of the invention is to provide a screened enclosure that includes post/column components and secondary members that are provided with decorative inserts therein. 
     Another object of the invention is to provide a construction beam and post/column which includes means for varying its structural load capacity. 
     A further object of the invention is to provide a novel beam and post/column which reduces the inventory size required by a manufacturer. 
     Still another object of the invention is to provide a unique beam and post/column which can be incrementally strengthened through the selective addition of metallic inserts into the beam and post/column, 
     Yet another object of the invention is to provide a patio and pool enclosure which can be pre-assembled into panels for subsequent installation at the job site. 
     Another object of the invention is to provide a unique patio enclosure with construction beams and posts/columns that include integrally formed channels for receiving screening fabric and decorative inserts. 
     Yet another object of the invention is to provide a screened patio or patio/pool enclosure that becomes an integral outdoor extension of the home thus providing insect-free enjoyment to the homeowner. 
     A still further object of the invention is to provide the secondary support members with means for receiving screening fabric and decorative inserts to further enhance the overall aesthetic appearance of the enclosure. 
    
    
     These and other objects of the invention will become more apparent hereinafter. The instant invention will now be described with particular reference to the accompanying drawings that form a part of this specification wherein like reference characters designate the corresponding parts in the several views. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a screened patio and pool enclosure showing the novel beams and posts/columns with their secondary members in position for supporting the enclosure structure. 
     FIG. 2 is an illustration of a first embodiment of the novel U-shaped component used for the insertion of plural decorative and metallic inserts. 
     FIG. 3 illustrates the two U-shaped components joined together to form the hollow beam and post/column. 
     FIG. 4 is sectional view taken along the plane  4 — 4  of FIG. 1 illustrating the first embodiment of the novel beam and post/column with the metallic and decorative inserts placed therein. 
     FIG. 5 illustrates the second embodiment of the novel U-shaped components joined together and illustrating their condition prior to insertion of any decorative or metallic reinforcement inserts therein. 
     FIG. 6 illustrates a sectional view taken along the plane  6 — 6  of FIG. 1, illustrating the second embodiment wherein a single decorative insert is utilized on two sides of the beam and post/column. 
     FIG. 7 is an exploded view of the unique beam and post/column illustrating the first embodiment and the manner of inserting the decorative and metallic inserts. 
     FIG. 8 is a sectional view, taken along the plane  8 — 8  of FIG. 1, illustrating a novel square secondary horizontal member that is provided with recesses for receiving screening fabric and a decorative pinstripe inserted in the opposite side thereof. 
     FIG. 9 is a sectional view of the secondary member of FIG. 8, illustrating the secondary member per se, with the vinyl pinstripe and screening fabric receiving grooves/recesses therein. 
     FIG. 10 is an illustration of the decorative insert, per se, that is used in conjunction with the square secondary member profile of FIG.  9 . 
     FIG. 11 is a cross sectional view, taken along the plane  11 — 11  of FIG. 1, illustrating another secondary member, a base anchor member for securing the lowermost panel of screening. 
     FIG. 12 is a cross-section of the base anchor member of FIG. 11 without the vinyl pinstripe mounted therein. 
     FIG. 13 is a cross-sectional view of the pinstripe, per se, illustrated in FIG.  11 . 
     FIG. 14 is an enlarged perspective view of a square secondary member illustrating the pinstripe vinyl insert partially inserted therein. 
     FIG. 15 is an enlarged perspective view of the base anchor member with the pinstripe vinyl insert partially inserted therein. 
    
    
     DETAILED DESCRIPTION OF THE DRAWINGS 
     Referring to FIG. 1, there is illustrated a perspective view of a screened pool and patio enclosure  200  utilizing the novel beam and posts/column construction members of the subject invention to enclose a patio  50  and pool  75 . There is shown a plurality of screening panels  100  which include fiberglass screening attached in the usual manner to the beams  10  and post/columns  25  with a plurality of purlins  30  interconnecting beams  10  and posts/columns  25  to provide stability and lateral support to the enclosure  200 . Purlins  30  are commercially available aluminum components available in either hollow or solid form measuring approximately 1×2 inches and 2×2 inches in cross-section. As shown, beams  10  are the diagonal and horizontal upper structural members while the posts/columns  25  provide the vertical support to enclosure  200 . Beams and posts/columns are available in a variety of sizes ranging from 2×4 through 2×10 inches. The terms post/column refers to the vertical supports  25  which are sometimes referred to as “posts” and of columns”. However, it is intended that the terms “posts” and to columns” are, in fact, the same component and can be used interchangeably. Also shown are base anchor members  31  that are anchored to the patio deck  50 . Base members  31  extend the full perimeter of the enclosure and serve to provide attachment means for the lowermost screen panels  100  where it meets the deck  50 . 
     Turning now to FIG. 2, there is shown the two U-shaped components  15 , which when united, form the hollow beams  10  and posts/columns  25 . The beams  10  and posts/columns  25  are constructed of two U-shaped extruded aluminum components  15  which are identical to each other. In FIG. 2, the lower U-shaped component  15  is merely rotated 180 degrees relative to the upper U-shaped component  15 . Each U-shaped component  15  comprises a horizontal mid-portion  16  with a pair of legs  17  and  18  extending downward from opposite ends thereof a short distance. Leg  17  is provided with inside ridges  19  while leg  18  has outer ridges  20  thereon. Centrally located on the outer surface of mid-portion  16  is divider  21 . Divider  21  includes a pair of oppositely disposed recesses  22  which cooperate with recesses  23  on the opposite ends of mid-portion  16  to receive decorative inserts, not shown in this view. U-shaped components  15  also include two pair of oppositely disposed recesses  24 ,  24 A at the inner corners thereof for receiving metallic inserts therein. Additionally, each U-shaped component  15  is provided with a pair of spline grooves  24 S. Spline grooves  24 S receive the screening fabric and is retained therein by a flexible vinyl or rubber-like retaining strip that is forced into spline grooves  24 S over the screening fabric. 
     FIG. 3 illustrates the U-shaped members  15  of FIG. 2 in their mated condition, this is accomplished by merely sliding legs  17  and  18  of one U-shaped member  15  over legs  17  and  18  of the other U-shaped member  15 , as shown, inner and outer ridges  19 ,  20  cooperate to securely hold U-shaped components  15  firmly together to form a hollow beam or post/column. A plurality of self-tapping screws are inserted at spaced intervals from the outside through and into legs  17  and  18  to insure structural integrity of the unit. 
     Referring now to FIG. 4, there is shown a sectional view taken along the plane  4 — 4  of FIG. 1, illustrating a completed post/column  25  with a pair of decorative inserts  26  installed on each mid portion  16 . Additionally, metallic inserts  27  have been installed in recesses  24  with additional metallic inserts  28  installed in recesses  24 A. Inserts  27  and  28  are made of aluminum bar stock material with inserts  27  shown thicker than inserts  28  The specific dimensions of these members may vary as required for a particular job. 
     Referring now to FIG. 5, there is shown another embodiment of the novel beam and post/column construction. This embodiment is identical to the first embodiment shown in FIG. 3, with one exception, divider  21  has been deleted. Without divider  21  a single decorative insert, extending the full width of mid-portion  16  can be inserted therein, thus giving the homeowner an additional choice as to whether a single or double decorative insert should be used, 
     FIG. 6 is a sectional view taken along the plane  6 — 6  of FIG. 1, illustrating the assembled beam  10  with the four metallic inserts  27 , 27  and  28 , 28  inserted into their respective recesses for added structural strength. Additionally, a pair of decorative inserts have been placed in their respective recesses  23 . The decorative variations of FIGS. 4 and 6 may be reversed or optionally, the decorative inserts of both the beam and post/column may be comprised of a single decorative insert  26  as in FIG. 6 or alternatively, both the beam and post/column may comprise plural decorative inserts as shown in FIG.  4 . 
     Turning now to FIG. 7, there is illustrated an exploded view of the FIG. 4 embodiment showing the metallic inserts  27 , 28 , which are preferably made of aluminum, prior to insertion. Decorative inserts  26 , with a simulated wood grain finish thereon are shown in alignment with recesses  22  and  23  about to be inserted therein. Additionally the inserts are shown in their relative positions prior to insertion into their respective recesses. 
     Referring to FIG. 8, there is shown a cross-sectional view, taken along the plane  8 — 8  of FIG. 1, illustrating the purlin or horizontal support member  30 . Purlin  30  is a secondary member of extruded aluminum having a hollow square configuration with a first pair of oppositely disposed recesses or grooves  24 S for receiving the screening fabric therein. At the opposite side is a second pair of oppositely disposed grooves or recesses  35  with decorative pinstripe insert  34  mounted therein. Located internally, within the hollow portion thereof, are a plurality of screw bosses  32  that are used for receiving screws, for example, where the end abuts a vertical post/column. As indicated above, insert  34  may be vinyl, aluminum or other suitable flexible material. 
     Referring to FIG. 9, there is shown a cross-section of horizontal support member  30 , per se, that is used for lateral support between the vertical posts/columns  25  and beams  10 . As indicated, oppositely disposed recesses  35  include an inwardly turned portion for receiving retaining legs  37  of decorative insert member  34 . 
     Referring to FIG. 10, there is shown decorative pinstripe insert  34 , per se, that is available in a variety of colors to suit the taste of the homeowner. As shown, pinstripe insert  34  is an extruded flexible arcuate member with a pair of retaining legs  37  at the ends thereof that are received in grooves or recesses  35 . Inserts  34  are merely squeezed at opposite ends  37 , and released into recesses  35  where they are retained due to their flexibility. Decorative inserts  34  can be made of extruded vinyl, aluminum or other suitable flexible material. 
     Referring now to FIG. 11, there is shown a cross-sectional view, taken along the plane  11 — 11  of FIG. 11, illustrating another secondary member  31  that runs along the floor and supports the lowermost panel of screening fabric  100  and also provides lateral support to adjacent post/columns  25 . As shown, secondary member  31  is anchored to the floor by lag bolt  38  that is inserted through mid-portion  36  of secondary member  31  to anchor member  31  to the floor. 
     FIG. 12 is an illustration of secondary member  31 , per se, as shown, it is an aluminum extruded member with oppositely disposed recesses  35  for receiving decorative insert  34  and a screening retaining groove  24 S, both of which are formed in the extrusion process. It further includes a mid-portion  36  and a pair of spaced depending legs  39  with inwardly turned ends  40  for engagement with a supporting surface. 
     FIG. 13 is an illustration of pinstripe insert  34  per se. As shown, it has an arcuate portion terminating in a pair of retaining legs  37  for engagement with recesses  35 . 
     FIG. 14 is an enlarged perspective view showing the same structure of FIG. 8, illustrating the manner of insertion of decorative insert member  34  into secondary member  30 . 
     FIG. 15 is an enlarged perspective view showing the same structure of FIG. 11, illustrating the manner of inserting decorative insert  34  into secondary anchor member  31 . 
     By way of review, it is pointed out that applicant has provided a unique hollow beam and post/column construction that includes means for varying its structural load capacity by the insertion of additional load carrying members. As indicated earlier, these load carrying inserts are common aluminum flat bar stock material that are received in the interior of the beam  10  and post/column  25 . The number of inserts varies, depending upon the load requirements of the particular job. Additionally, applicant has provided a beam and post/column construction that allows receiving a variety of decorative inserts, thus adding to the interior beauty of the enclosure. Finally, applicant has provided a means for further improving the aesthetic appearance of the enclosure by providing decorative inserts for the secondary members, thus raising the appearance appeal to the next level. 
     While the invention has been described in its preferred embodiments, it is to be understood that the words used herein are words of description rather than words of limitation and that changes may be made within the purview of the appended claims without departing from the full scope or spirit of the invention.