Abstract:
A mechanical framework ( 168, 187 ) is formed with a basic tube nut ( 1, 63 ) and channel tube ( 124, 137 ) geometry. A threaded faster ( 170 ) is used to attach the elements. Orthogonal elements can be strengthened by an angle bracket ( 163 ) and nut plate ( 168 ). The edges ( 126 ) of the channel tube ( 124 ) are scalloped by a series of indentations ( 129, 130 ) which engage the fastener ( 170 ) and resist rotation of the tube nut ( 1, 63 ) within the channel tube ( 124, 137 ). Additional tube nuts ( 82, 100 ) provide an additional single flange ( 87 ) and pair of flanges ( 101, 102 ) respectively. The tube nut ( 1, 63 ) includes a turret ( 2 ) that fits between guide rails ( 152, 153 ) so as to form a continuous planar surface when mounted within the channel tube ( 124, 137 ).

Description:
[0001]    This patent application derives priority from provisional patent application Ser. No. 62/133,452, filed on Mar. 15, 2015. 
     
    
     TECHNICAL FIELD 
       [0002]    The present invention pertains generally to the field of fasteners, and more particularly to generic structural members that may be easily formed into desired objects with a generic fastener. 
       DESCRIPTION OF RELATED TECHNOLOGY 
       [0003]    A mechanical framework is the basic structural element of many common items such as a table, wall, desk, shelf or partition. These items have been well known for centuries, and the variety of designs, construction methods, materials and dimensions is vast. In an industrial setting, the workspace presents a large number of nonstandard floor layouts and tasks to be accomplished, and so necessarily no single collection of tools, storage bins, work surfaces and shop layouts can possibly satisfy every possible production environment. 
         [0004]    In other words, a desk or shelf, for example, may be needed to fit into a specific space in a room, and that desk or shelf must therefore have certain dimensions. The dimensions needed may not be available in any existing product, thereby requiring the construction of a specific desk or shelf having a custom shape and size. Frequently the shelf or desk may be needed only temporarily, or may need to be relocated to a different location having different space requirements. In that case, the shelf or desk must either be replaced, or must be resized in some convenient manner. 
         [0005]    Typically, a desk or shelf of some standard size is used in the workplace, resulting in wasted space or other inconvenience because that is a more economical solution than constructing custom furnishings to accommodate each specific situation as it arises. Many attempts have been made in the past to create some sort of universal or modular construction system that will permit frameworks of various shapes and sizes to be readily constructed and reconstructed as needed. 
         [0006]    For example, U.S. Pat. No. 576,939, entitled “Adjustable Shelf Bracket”, utilizes a standard channel having a predetermined known shape to permit the relocation of a bracket element. U.S. Pat. No. 2,345,650 entitled “Skeletonized Structure” uses a channel that accommodates a biased nut to permit infinite repositioning of the nut within the channel. The biased nut is retained by two tabs formed as a part of the channel U.S. Pat. No. 4,278,361 entitled “Channel Interconnection Apparatus” discloses a dimpled nut that interacts with a serrated channel, the nut engaging a screw that passes through holes placed in between the serrations. 
         [0007]    The need remains for a simple generic channel and nut assembly that may be easily manufactured, and readily configured and reconfigured in the field to create frameworks having any desired geometry or dimensions. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is an isometric view of a tube nut constructed according to the principles of the present invention; 
           [0009]      FIG. 2  is a top plan view of the tube nut illustrated in  FIG. 1 ; 
           [0010]      FIG. 3  is a side elevation view of the tube nut illustrated in  FIG. 1 ;  FIG. 4  is an end elevation view of tube nut illustrated in  FIG. 1 ; 
           [0011]      FIG. 5  is an isometric view of a second embodiment of a tube nut constructed according to the principles of the present invention; 
           [0012]      FIG. 6  is a top plan view of the tube nut illustrated in  FIG. 5 ; 
           [0013]      FIG. 7  is an end elevation view of tube nut illustrated in  FIG. 5 ; 
           [0014]      FIG. 8  is an end elevation view of tube nut illustrated in  FIG. 5 ; 
           [0015]      FIG. 9  an isometric view of a third embodiment of a tube nut constructed according to the principles of the present invention; 
           [0016]      FIG. 10  an isometric view of a fourth embodiment of a tube nut constructed according to the principles of the present invention; 
           [0017]      FIG. 11  an isometric view of a fifth embodiment of a tube nut constructed according to the principles of the present invention; 
           [0018]      FIG. 12  is an isometric view of a channel tube constructed according to the principles of the present invention shown with the tube nut of  FIG. 9  mounted therein; 
           [0019]      FIG. 13  is an isometric view of a second embodiment of a channel tube including a pair of flanges constructed according to the principles of the present invention; 
           [0020]      FIG. 14  is an isometric view of a third embodiment of a channel tube constructed according to the principles of the present invention; 
           [0021]      FIG. 15  is an isometric view of a fourth embodiment of a channel tube including two pairs of flanges constructed according to the principles of the present invention; 
           [0022]      FIG. 16  is an isometric view of a framework joint constructed according to the principles of the present invention; 
           [0023]      FIG. 17  is an end view of the tube nut depicted in  FIG. 4  shown mounted within a channel tube depicted in  FIG. 15 ; 
           [0024]      FIG. 18  is a side elevation of a fastener constructed according to the principles of the present invention; 
           [0025]      FIG. 19  is a cross sectional view taken along line  19 - 19  of  FIG. 17 ; 
           [0026]      FIG. 20  is a detailed view of the region  20  depicted in  FIG. 17 ; 
           [0027]      FIG. 21  a side elevation channel and tube nut assembly depicted in  FIG. 12 ; 
           [0028]      FIG. 22  is a detailed view of the region  22  depicted in  FIG. 16 ; 
           [0029]      FIG. 23  is an isometric view of an exemplary framework constructed according to the principles of the present invention; 
           [0030]      FIG. 24  is an isometric view of an assembly including a trim board fastened to a channel constructed according to the principles of the present invention; 
           [0031]      FIG. 25  is an end elevation view of the assembly depicted in  FIG. 24 ; 
           [0032]      FIG. 26  is an isometric view of showing the combination of an angle bracket and fasteners constructed according to the principles of the present invention; 
           [0033]      FIG. 27  is a partial sectional view taken along lines  27 - 27  of  FIG. 26  with the addition of the channel tube sidewall and the channel nut; and 
           [0034]      FIG. 28  is a second exemplary isometric view of a framework constructed according to the principles of the present invention. 
       
    
    
     SUMMARY OF THE INVENTION 
       [0035]    The present invention addresses frame construction, accessory mounting and unitized manufacturing. The present invention discloses a simpler standardized way to construct a mechanical frame work that can fit many applications including tables, enclosures, shelving, desks, benches, stands, continuous counter tops and cabinets, sporting enclosures, trailer enclosures, general enclosures, barriers, wall racking, and nonbearing walls. The present invention includes components that allow the end user to select an existing frame design or to select components that create a unique design. The present invention permits the end user to alter existing frame work, adding, subtracting or rearranging features as necessary. 
         [0036]    Commercially available materials and hardware may be readily added to the unitized platform of the present invention. The present invention includes a channel tube constructed of sheet metal and shaped as a four sided tube with a channel opening. The corresponding connector is a channel nut that fits the inside cross sectional shape in a precise fashion along with fasteners applied from the outside of the channel. The channel and fasteners of the present invention provide a uniform method of making frame work based on an equal unit of measure (EUM) for the length, width and height of a mechanical frame such as, for example a 1″×1″×1″ channel. Because of this novel approach to framing, engineering values can be systematically assigned to the framing structures and their components to simplify frame design and manufacture. 
         [0037]    The assembly of the channel nut and the fastener can create the strength of a welded joint. The fastener of the present invention combines a clamping surface and a locating shoulder that engages both the channel nut and channel itself, thereby transferring the shear load from the channel members through the fitment of the mating hole surfaces to the locating shoulder and finally to the mating socket on the tube nut. 
         [0038]    The present invention includes a variety of channel tubes with the same standard patterns of spaced apart holes which can be used as both vertical and horizontal channels. Other structural members can be formed to include flanges for creating connection surfaces at the ends of the channel tube. 
         [0039]    Construction of the framework is dependent on the pattern and spacing of holes which allows for standard increments of frame fitment and sizing. This provides a standardized way to attach other components properly to the frame work without having to add additional holes. The present invention results in reduced planning and lead time while requiring less material, skill and labor to create the desired object were it to be made by conventional means such as wood framing, welded members or other fastened joint designs. 
         [0040]    The present invention simplifies the construction of common frame work applications by reducing the need for saws, drills, hammers, nails, welders, and various other tools, as well as reducing the skills and knowledge needed to construct various sizes of unitized frames to within a value of for example, one cubic inch. The present system promotes the use of a single fastener type further simplifying construction effort, efficiency and quality. 
         [0041]    A selection of channels and fasteners constructed according to the principles of the present invention permits erection of a framework with only a rotary driver and a single bit. Typically, the corner frame joint of the present channel tube construction is supported by the channel nut which provides a common connection region for all frame members at the joint. The specialized fastener and channel hole pattern of the present invention support joining up to six channels at a single joint. 
         [0042]    The rigidity and strength of the joint area of the channel tube is stronger than the channel itself, which greatly enhances the rigidity of the overall frame work while retaining a simple method of construction. Construction of the channel members is of a relatively light or thin gage of material which nonetheless produces a rigid frame work with relatively less material and energy expended in creating the channel members themselves. 
         [0043]    The pattern and spacing of holes, as well as the fastener size used in the channel tube and channel nut permits the fastener and nut to be placed so that the channel side of the channel tube has a pattern of holes that is substantially identical to the pattern holes present on the other sides of the channel. The pattern and spacing of holes in the channel tube allows for standardized components to be made in a unitized system that are compatible to the applied standard increment of channel tube hole spacing. The consistent pattern of holes matches on all sides of the channel tube to permit the mounting of an accessory to the frame work anywhere along the length of the channel without regard to frame work orientation. 
         [0044]    The channel tube wall thickness, channel nut thickness, and fastener size are scalable to create different outside dimensions of channel tube to accommodate the strength required to fit a variety of mechanical applications. The perforation of the channel tube and channel nut pattern can be performed along the entire length of the tube or placed in selected locations where the channel nuts and tubes are required for a particular structure. Utilizing the channel tube in this fashion allows for custom design of a framework when encountering nonstandard or customer specific requests for the channel tube and channel nut system of the present invention. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0045]    Referring generally to  FIGS. 1-4 , the channel nut  1  of the present invention is formed generally as a substantially rectangular solid having rounded corners, such as outer corners  18  and  19  as well as a corresponding inner corner  32 . Each of the corners  19 ,  20  have an outer radius  33  of approximately 0.19 inch and an inner radius  31  of approximately 0.13 inch. The channel nut includes an interior channel having a floor  22  and a ceiling or upper surface  28 . The outer width  35  of the channel  1  is approximately 1.89 inches while the wall thickness  34  is approximately 0.250 inch. The channel nut  1  is substantially rectangular except for a top shelf or turret  2  which extends outwardly from the planar surfaces  21  and  22 . Four symmetrically places beveled bores  4 ,  5 ,  6  and  7  are formed orthogonally through the plane defined by turret  2 . The channel nut  1  includes a substantially planar end surface  8 . The turret  2  includes a radiused corner  9  which joins a substantially vertical wall  10 , the wall  10  transitioning to the planar surface  20  via a filleted corner  11 . The height  30  of the turret  2  is approximately 0.100 inch. The length  25  of the turret  2  is approximately 1.97 inches. The channel nut  1  includes two opposite sidewalls, such as sidewall  3 , which contains four beveled bores  12 ,  13 ,  14  and  15 . The bores  12 - 15  are arranged in a pattern and spacing that is substantially identical to the pattern of bores  4 - 7  formed within the turret  2 . Similar bores arranged in a similar pattern appear on each surface of the turret  2 , such as bore  16  and bore  17  visible in  FIG. 1 . The diameter of each bores is approximately 0.201 inch. The longitudinal distance  24  between adjacent bores  12  and  13 , or bores  5  and  7 , for example, is approximately one inch. The turret  2  includes a longitudinal axis  39 . The center of each bore  2 ,  6  and  5 ,  7  are each spaced a distance  23  from the axis  39  by a distance of 0.375 inch, resulting in a total bore spacing  27  of 0.750 inch. Sidewall  3  has a parallel longitudinal axis  38 . The center of each bore  12 ,  13  and  14 ,  15  is spaced a distance  36  from the axis  38  by a distance of 0.396 inch, resulting in a total bore spacing  37  of 0.750 inch. The total width  40  of the channel nut  1  is approximately 1.935 inches. 
         [0046]    Referring also to  FIGS. 5-8 , a second embodiment of a channel nut  41  is formed as a rectangular solid including an upper bench  42  having a planar surface  60 . The upper bench  42  includes two threaded bores  43  and  44  which are separated by a distance  57  of approximately 0.500 inch, or a distance  58  of approximately 0.25 inch from the longitudinal axis  59 . The rectangular solid includes two opposing sidewalls, such as sidewall  61  which includes threaded bores  47  and  48 , also separated by a distance  54  of approximately 0.500 inch, or a distance  53  of 0.250 inch from the longitudinal axis  51 . The remaining sidewalls each contain a pair of threaded bores, such as bores  45 ,  46  and bores  49 ,  50 . The length  56  of channel nut  41  is approximately  0 . 94  inch, causing the centerline of each bore  47  and  48  to be displaced from the edge of channel nut  41  by a distance  55  of approximately 0.469 inch. 
         [0047]    Referring also to  FIG. 9 , a third embodiment of a channel nut  63  is shown including four bores  64 ,  65 ,  66  and  67  which are formed orthogonally through the planar surface  69  of the upper shelf  70 . The opposite sidewalls  71  and  72  support the upper shelf  70 , with each sidewall including a plurality of bores, such as bores  73 ,  74 ,  75  and  76 , which are arranged in a pattern that is substantially similar to the orientation and spacing of bores  64 - 67 . The opposite sidewall includes a threaded bore  176  that is aligned with bore  75 . The upper shelf  70  includes an edge  68 , through which each of the bores  64 - 67  pass, with approximately half of each bored  64 - 67  passing through the planar surface  69 . An enlarged bore  77  is formed through upper shelf  70  and is substantially aligned with a similar enlarged bore  80  formed in the bottom surface  81  of the channel nut  69 . Similarly, a substantially identical bore  78  passes through the sidewall  71  and is aligned with a matching bore  79  formed in sidewall  72 . The threaded bore  178  in the bottom surface  81  is aligned with the bore  65  that passes through the upper shelf  70 . 
         [0048]    A fourth embodiment of a channel nut  82  is depicted in  FIG. 10 , which includes a top shelf  83  residing above opposite sidewalls  84  and  85 , as well as bottom wall  86 . Integrally formed with the top shelf or bench  83  is a flanged bracket  87  that is formed to include a planar base  88  that transitions through fillet  89  to an orthogonal flange  90 . The outer planar surface  91  of the orthogonal flange  90  is substantially coplanar with the outer surface  92  of the sidewall  84 . A pair of bores  93  and  94  is formed through the orthogonal flange  91  and are spaced apart by the distance  24 , which is equal to the spacing between the sidewall bore pairs  96 ,  97  and  98 ,  99 . 
         [0049]    Referring also to  FIG. 11 , a channel nut  100  containing a pair of orthogonal, upwardly extending flanges  101  and  102  is depicted. The flanges  101 ,  102  are integrally formed with an enlarged upper shelf region  103  which resides on the top surface  104  of channel nut  100 . Flange  101  contains two bores  105  and  106 , each of which is aligned with a substantially identical bore  108  and  109 , respectively, formed in flange  102 . 
         [0050]    As best seen in  FIGS. 13, 14 and 15  the present invention includes a series of channels or channel tubes that, when combined with the previously described channel nuts, can be used to create a variety of useful articles.  FIG. 13  depicts an open channel  110  having three sidewalls  111 ,  112  and  113 . The sidewall  111  is formed to include a lower, extended orthogonal edge  114 , which creates a surface or platform  115 . Similarly, the opposite sidewall  113  is formed to include a lower, extended orthogonal edge  116  which creates a platform or rail  117 . Together the two platforms or surfaces  115  and  117  are useful in retaining the aforementioned channel nuts within the open channel  110  when the channel nuts are slidably repositioned. The surface  115  includes an inner edge  118  which is scalloped or perforated by semicircular indentations  119  and  120 , for example, which are spaced apart by distance  24  that is equal to the distance  24  between bore holes formed within the channel nuts. In particular, the bores  65 - 67  of channel nut  63  correspond to the semicircular geometry of the scallops  119  and  120 . The channel  110  includes two end flanges  190  and  121  which are useful for interconnecting the channel tube  110  to other similarly configured channels. In particular, the channel nut  63  can be positioned so that bores  64  and  65  overlay the flange bores  122  and  123 , respectively, so that the remaining channel nut bores  66  and  67  are free to mate with another channel tube or similarly configured accessory. 
         [0051]      FIG. 15  depicts a similar channel tube  124  in which each edge  125  and  126  is seen to include a plurality of scalloped indentations, such as indentations  127 ,  128 ,  129  and  130 , for example. Channel tube  124  is also seen to include a flange  131  and  132  terminating each end of sidewall  133  and a substantially identical pair of flanges  134  and  135  terminating each end of sidewall  136 . An alternate channel tube  137  is depicted in  FIG. 14 , which includes sidewalls  138 ,  139  and  140 . Edges or guides  150  and  151  form a support for the insertion of a tube nut  63 . A plurality of bores, such as bores  141 ,  142  and  143  appear on each of the sidewalls in a spaced apart pattern that maintains the bore separation distance  24  appearing on channel nut  63 , for example. Additionally, a plurality of substantially rectangular slots  144 ,  145  and  146 , for example, are formed along the centerline  147  of each sidewall. The slots  144 - 147  are useful in anchoring the distal end of a fastener passing through the bores  77  and  80  of channel nut  63 , for example, or for engaging a hook, tab or other protrusion that may be present on an accessory to be attached to the channel tube  137 . The flange  132  includes a pair of bore holed  176  and  178 . 
         [0052]    The combination of channel nut  63  and channel tube  137  to create a rigid framework can be more fully appreciated by reference to  FIGS. 12, 16, 21, 22 and 26 .  FIG. 12  depicts a channel tube  137  in two channel nuts  63  have been placed. Prior to affixing any fasteners, the channel nuts  63  may be moved to by sliding with the channel tube  137  to any position at which the scalloped indentations  148 ,  149  align with the bores  64  and  65  of the nut  63 . The planar surface  69  of the top shelf  79  fits between the edges  150  and  151  of the channel  137  such that a single, substantially continuous, flush planar surface is extends between edge surface  152  and the opposite edge surface  153 .  FIG. 21  depicts the dimensional characteristics of the channel and tube interaction. The distance  24  between adjacent bores can be considered a single equal unit of measure (EUM). The diameter  154  of each bore  155  is equal to 0.28 EUM, while the distance  156  between the edge  157  of channel  137  and the centerline  158  of the last bore  159  is 0.50 EUM. The width  160  of channel nut  63  is one EUM, while the width  161  of channel tube  137  is two EUMs. The overall length  162  of the channel tube  137  is an integral multiple of one EUM. 
         [0053]    More complex joints may require the use of angle bracket to provide additional rigidity and absolute strength.  FIG. 26  depicts an orthogonal angle bracket  163  as well as a plurality of threaded fasteners  164 ,  165 ,  166  and  167 . Two separate threaded nut plates  168  and  169  are places within the channel tube  137  and aligned with the threaded fasteners  164 - 167  to permit tightening the fasteners by use of a single tool that is exterior to the channel tube  137 .  FIGS. 16 and 22  depict a section of a completed framework in which the angle brackets  163  are utilized. Using two of the channel tubes  124  with flanges  132 ,  135 ,  134  and  131  as discussed earlier with reference to  FIG. 15 , multiple angle brackets  163  may be used to create a single joint supporting extensions in six different directions by means of a single tube nut  63 . One of the nut plates  169  is visible inside the channel  110 . As best seen in  FIG. 27 , the 
         [0054]    Referring to  FIGS. 17, 18, 19 and 20 , the interaction of the fastener  170  with the tube nut  63  may be better understood. The fastener  170  includes a head  171 , a solid shank  172  and a tapered thread portion  173 . In the typical application depicted in  FIG. 17 , the fastener  170  is inserted through a bore the flange  135  which is part of the channel tube  124 , through a hole  175  (visible in  FIG. 12 ) in a channel  137  which does not have a flange, and finally through the threaded bore  75  in the channel nut  63 . As seen in  FIG. 19 , the tapered thread  173  of the fastener  170  is inserted into the threaded bore  176  of the channel nut  63 . The solid shank  172  transfers any shear force transmitted by either the flange  132  or the sidewall  138  of channel  137  through the fastener  170  and to the tube nut  63 .  FIG. 20  depicts the solid shank portion  172  of the threaded fastener  170  resting on the scalloped edge  149  of the channel tube  137  depicted in  FIG. 12 .  FIG. 27  depicts the installed angle bracket  63  and tube nut  168 . The solid shank portion  177  of the fastener  165  abuts the angle bracket  163  and the sidewall  136  of the channel tube. The threaded portion  178  of the fastener  165  engages the nut plate  168 , thereby creating a strong joint that is displaced from the tube nut  63 . 
         [0055]    Practical examples of the system described herein are depicted in  FIGS. 23, 24, 25 and 28 . A cubical framework  179  is shown in  FIG. 23 . Channels  124  and  137  are utilized along with angle brackets  163  to create a table or bench. Panels  180 ,  181  and  182  are used to conceal the framework  179  and present a continuous, smooth working surface.  FIGS. 24 and 25  depict a trim board  183  that is applied to a channel  137 . An extension bit  184  permits access to interior fasteners  185  and  186  via an aligned bore  191  on the outer sidewall  192 .  FIG. 28  depicts a custom shaped framework  187  that includes various additional elements  188  and  189  that are readily utilized by imitating the bore pattern found on the channels  124  and  137 . Anchor points for additional elements are provided by the extension of the tube nuts  63 . In this manner a very wide variety of framework can be constructed with a very few elements and tools. While the system and components have been described to disclose the preferred embodiments of the present invention, those skilled in this field of endeavor will appreciate that many obvious modifications may be made to specific dimensions and shapes while still remaining within the scope of the invention.