Abstract:
A column cap connector for mounting and securing a beam to a post of a building including a central web portion and upwardly extending walls disposed along longitudinal edges thereof, wherein a lower portion of the beam fits within the walls, downwardly extending legs formed from the seat and alternatively from the seat and the walls of the connector attach the connector to the post with projecting tabs attached to the seat to support the connector on the post.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention provides an improved steel connector for joining a post to a beam, typically known as a column cap or a post cap. Typically, the joist and beam lie in a common plane with the end of the post abutting the bottom face of the beam or being in close proximity thereto. The use of the connector helps the connection to resist gravity, lateral and uplift loads. 
         [0002]    Column caps and post caps are well known in the art. U.S. Pat. No. 963,585, granted to J. A. Kimball in 1910 teaches a sheet-metal, channel-shaped connector where legs for connecting to the post are bent down from the seat and then bent back on themselves 180 degrees to reach up and grab the sides of the beam. U.S. Pat. No. 1,848,085, granted to L. A. Eisenschmidt in 1932, also teaches a channel-shaped connector made from sheet-metal. In this patent the legs that grab the post are bent from the seat at its sides and the walls of the channel are bent up from the front and back edges of the seat. U.S. Pat. No. 2,084,758, granted to A. R. Anderson in 1937, also teaches a channel-shaped connector. In this case the legs for attaching the connector to the post are formed from portions that would otherwise be the walls of the channel and are bent down from the seat of the channel to grasp the post. This patent also teaches an extension on one of the sides of the channel that further strengthens the connection between the post and the beam. US Design Pat. D256,663, granted to Tyrell T. Gilb in 1980, also teaches a channel-shaped connector where legs for attaching to the post are formed from the walls of the channel and are bent down from the seat of the channel to grasp the post. U.S. Pat. No. 5,488,810, granted to Jim W. Horton in 1996, teaches a sheet-metal, channel-shaped connector where the legs for attaching the connector to the post are cut from the seat and extend downwardly from the walls of the channel. 
         [0003]    The present invention improves upon the prior art devices by maximizing the material used to make the connection to the post through the legs while not comprising the integrity of the seat or web of the connector, and being easy to install. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention provides a connection between angularly joined supported and supporting members by means of a connector. Selected embodiment of the present invention improve on the prior art column caps by providing one or more projecting tabs to hold the column cap connector on the top of the post or supporting member, at least during installation, while still creating sufficient material for the legs to attach the column cap to the post or supporting member. 
         [0005]    The connector of the present invention has a channel length with a central web portion and upstanding spaced and substantially parallel side walls to cradle a supported member such as truss or beam and depending legs to attach the connector to the supporting member, such as a post. The attachment legs are formed from the material of the web. The projecting tabs that support the connector on the top of the post can be formed from the web or seat of the connector or they can project from the side walls of the connector. The projecting tabs can remain in place interfacing with both the end face of the supporting post and the bottom surface of the supported member, or they can be designed to bend, such that during installation, when the connector is placed on the post and before it is connected to the post with fasteners the projecting tabs interface with the end face of the supporting member and hold the connector at the proper level, but when the supported member is received by the connector, the projecting tabs are bent out of the way, such that the supported member sits directly on the supporting member. 
         [0006]    In one preferred embodiment attachment legs are provided that are formed from both the seat or web of the channel and the opposed side wall thus increasing the attachment length of the lengths. The legs extend farther down from the top of the post, distributing the fasteners entering along the length of the post and away from the end of the post which helps to prevent splitting of the post. 
         [0007]    In one preferred embodiment, the attachment legs are wider where they attach to the side walls of the connector so as to increase the strength of the connector at this junction. In another preferred embodiment, the attachment legs are twisted so that two distinct surfaces of each attachment leg interface with two surfaces of the post, and fasteners are driven in the sides of the post beneath the extending portions of the beam. 
         [0008]    Preferably, the connector of the present invention is formed from a flat blank of sheet steel which is cut, punched, and folded to form the final shape of the connector without welding or connecting additional pieces to the connector. In one preferred embodiment, the attachment legs are formed with alternating widening and narrowing portions so as to provide for the spacing of the fasteners that connect the attachment legs to the supporting member. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0009]      FIG. 1  is a perspective view of the connection of the present invention using one form of the connector. 
           [0010]      FIG. 2  is an exploded perspective view of the connection of the present invention shown in  FIG. 1 . 
           [0011]      FIG. 3  is a perspective view the connector shown in  FIG. 1 . 
           [0012]      FIG. 4  is a front elevation view of the connector of  FIG. 1 . 
           [0013]      FIG. 5  is a side elevation view of the connector of  FIG. 1 . 
           [0014]      FIG. 6  is a top plan view of the connector of  FIG. 1 . 
           [0015]      FIG. 7  is a plan view of the sheet metal blank of the connector of  FIG. 1 . 
           [0016]      FIG. 8  is a top perspective view of the connector and post of  FIG. 1 . 
           [0017]      FIG. 9  is a top plan view of the connector and post of  FIG. 1 . 
           [0018]      FIG. 10  is a perspective view of an alternate connector of the present invention. 
           [0019]      FIG. 11  is a front elevation view of the connector of  FIG. 10 . 
           [0020]      FIG. 12  is a side elevation view of the connector of  FIG. 10 . 
           [0021]      FIG. 13  is a top plan view of the connector of  FIG. 10 . 
           [0022]      FIG. 14  is a plan view of the sheet metal blank of the connector of  FIG. 10 . 
           [0023]      FIG. 15  is a top plan view of the connector and post of  FIG. 10 . 
           [0024]      FIG. 16  is a perspective view of an alternate connector of the present invention. 
           [0025]      FIG. 17  is an exploded perspective view of a connection made with the connector shown in  FIG. 16 . 
           [0026]      FIG. 18  is a front elevation view of the connector of  FIG. 16 . 
           [0027]      FIG. 19  is a side elevation view of the connector of  FIG. 16 . 
           [0028]      FIG. 20  is a top plan view of the connector of  FIG. 16 . 
           [0029]      FIG. 21  is a plan view of the sheet metal blank of the connector of  FIG. 16 . 
           [0030]      FIG. 22  is a top plan view of the connector and post of  FIG. 16 . 
           [0031]      FIG. 23  is a perspective view of an alternate connector of the present invention. 
           [0032]      FIG. 24  is a front elevation view of the connector of  FIG. 23 . 
           [0033]      FIG. 25  is a side elevation view of the connector of  FIG. 23 . 
           [0034]      FIG. 26  is a top plan view of the connector of  FIG. 23 . 
           [0035]      FIG. 27  is a plan view of the sheet metal blank of the connector of  FIG. 23 . 
           [0036]      FIG. 28  is a top plan view of the connector and post of  FIG. 23 . 
           [0037]      FIG. 29  is a perspective view of an alternate connector of the present invention. 
           [0038]      FIG. 30  is a front elevation view of the connection of the present invention made with the connector of  FIG. 29 . 
           [0039]      FIG. 31  is a front elevation view of the connector of  FIG. 29 . 
           [0040]      FIG. 32  is a side elevation view of the connector of  FIG. 29 . 
           [0041]      FIG. 33  is a top plan view of the connector of  FIG. 29 . 
           [0042]      FIG. 34  is a plan view of the sheet metal blank of the connector of  FIG. 29 . 
           [0043]      FIG. 35  is a top plan view of the connector and post of  FIG. 29 . 
           [0044]      FIG. 36  is a perspective view of an alternate connector of the present invention. 
           [0045]      FIG. 37  is a front elevation view of the connection of the present invention made with the connector of  FIG. 36 . 
           [0046]      FIG. 38  is a front elevation view of the connector of  FIG. 36 . 
           [0047]      FIG. 39  is a side elevation view of the connector of  FIG. 36 . 
           [0048]      FIG. 40  is a top plan view of the connector of  FIG. 36 . 
           [0049]      FIG. 41  is a plan view of the sheet metal blank of the connector of  FIG. 36 . 
           [0050]      FIG. 42  is a top plan view of the connector and post of  FIG. 36 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0051]    As shown in  FIGS. 1, 2, 17, 30 and 37 , the present invention is an improved connection  1  between a supported member  100 , preferably a beam, and a supporting member  200 , preferably a post, made with a connector  2 , with the supporting member  200  in abutting relation or near abutting relation to the supported member  100 , and preferably, in some embodiments, with portions of the connector  2  disposed between the supported member  100  and the supporting member  200 . 
         [0052]    As shown in  FIGS. 2, 4, 5 and 6 , the connector  2  has a first end  3  and a second end  4 , and a web or seat  5 . In the preferred embodiments, the web  5  is interrupted. The web  5  has first and second longitudinally extending edges  6  and  56  with first and second walls  7  and  57  secured to the respective edges  6  and  56 . The first and second walls  7  and  57  have outer surfaces  8  and  58  facing away from the web  5 , and inner surfaces  9  and  59  facing toward each other and inwardly toward the web  5 . The walls  7  and  57  extend longitudinally along the first and second edges  6  and  56  and extend upwardly from the web  5  to support and stabilize the beam  100 . The first wall has a top edge  36 , and the second wall has a top edge  86 . 
         [0053]    As shown in  FIG. 1 , the connector  2  is adapted to receive a beam  100  on or above the web  5  and between the walls  7  and  57 . As shown in  FIGS. 8, 9, 15, 28 and 28 , in selected embodiments, preferably portions of the web or seat  5  are designed to rest on the substantially planar end face  251  of the post  200 . End face  251  of post  200  is defined by edges  252 . The central web  5  is preferably disposed beneath and in supporting relation to the beam  100 . 
         [0054]    As shown in  FIG. 1 , the beam  100  preferably has a substantially planar bottom surface  101  that interfaces with portions of the web  5  of the connector  2  and the beam has first and second side surfaces  107  and  157  that are substantially planar and preferably interface with the inner surfaces  9  and  59  of the walls  7  and  57 . 
         [0055]    In all of the embodiments of the invention, the connector  2  has one or more central apertures  18  in the web  5 . As shown in  FIGS. 6, 8, 15, 20, 22, 26, 28, 33, 35, 40 and 42 , web  5  has a first central edge  23  that borders a central aperture  18  and lies nearer to the first end  3  of the connector  2  than the second end  4  of the connector  2 . The web  5  also has a second central edge  24  that borders a central aperture  18  and lies nearer to the second end  4  of the connector  2  than the first end  3  of the connector  2 . 
         [0056]    As shown in  FIGS. 3, 4, 5 and 6 , in all of the embodiments, the connector  2  also has first and second attachment legs  21  and  71 . The first and second attachment legs  21  and  71  are formed from material removed from the web  5  to create the one or more central apertures  18 . The leg  21  has an outer face  38  that preferably extends from the outer surface  8  of the first wall  7 . The leg  21  projects from, is integrally joined to, and is preferably at least partially co-planar with the first wall  7 . The second attachment leg  71  is also formed from material removed from the web  5  to create the central aperture  18 . The attachment leg  71  has an outer face  88  that preferably extends from the outer surface  58  of the second wall  57 . The second leg  71  projects from, is integrally joined to, and is, preferably, at least partially co-planar with the second wall  57 . 
         [0057]    As shown in  FIGS. 1, 5 and 9 , the attachment leg  21  also has inner face  39  that preferably extends from the inner surface  9  of the first wall  7 , and the attachment leg  71  also has an inner face  89  that preferably extends from the inner surface  59  of the second wall  57 . The post  200  is preferably formed with opposed planar side surfaces  207  and  257 , portions of which are in registration with the inner faces  39  and  89  of the legs  21  and  71  when the connection  1  is made. 
         [0058]    As shown in  FIGS. 6, 8, 9, 13, 15, 20, 22, 26 and 28 , and in select embodiments of the invention, along the first edge  23  of the web  5  that borders central aperture  18  and between the longitudinally extending edges  6  and  56  of the web  5  the first central edge  23  is provided with one or more projecting tabs  31  that overlie the end  251  of the post  200  when the connector  2  is attached to the post  200 . Projecting tabs  31  along first central edge  23  extend toward second end  4  of the connector  2 . Similarly, along the second central edge  24  of the web  5  that borders the central aperture  18  and between the longitudinally extending edges  6  and  56  of the web  5  the second central edge  24  is provided with one or more projecting tabs  31  that overlie the end  251  of the post  200  when the connector  2  is attached to the post  200 . Projecting tabs  31  along second central edge  24  extend toward first end  3  of the connector  2 . Projecting tabs  31  prevent the connector  2  from slipping down the post  200  during installation. The use of projecting tabs  31  in the web  5  also allows more material to be used to make the connection between the attachment legs  21  and  71  and the first and second walls  7  and  57 . 
         [0059]    As shown in  FIGS. 1-15 and 29-42 , in select embodiments of the invention, the central aperture or apertures  18  traverse both the first and second longitudinally extending edges  6  and  56  of the web  5 , or one of the first and second longitudinally extending edges  6  and  56 , to enter the first and second walls  7  and  57 , forming notches  67  and  97  in the respective walls. Notch  67  in first wall  7  creates a first end portion  65  and a second end portion  68  in first wall  7  with the notch  67  between them. The first and second end portions  65  and  68  are connected by a bridge portion  66  that lies above the notch  67 . Bridge portion  66  is spaced substantially away from longitudinal edge  6 . Notch  97  in second wall  57  creates a first wall portion  95  and a second wall portion  98  that are separated by the notch  97  and connected by a bridge portion  96  that lies above the notch  97 . Bridge portion  96  is spaced substantially away from longitudinal edge  56 . As shown in  FIGS. 3, 10 and 29 , the central edge  23  of the web  5  continues to an upper portion  20  in the first wall  7  or second wall  57 , and the central edge  24  of the web  5  continues to an upper portion  70  in the second wall  57  or the first wall  7 . In these embodiments, the first and second legs  21  and  71  have extended portions or leg extensions  22  and  72  respectively made from material from the first or second walls  7  and  57  which extends the central aperture or apertures  18 . 
         [0060]    As best shown in  FIGS. 4, 6, 7 and 8 , in certain embodiments of the invention, along the first central edge  23  that borders the web  5  and between the longitudinally extending edges  6  and  56  of the web  5  the first central edge  23  angles away from second end  4  and toward first end  3  of the connector  2  where attachment leg  21  connects to first end portion  65  of first wall  7 . Similarly, along the second central edge  24  that borders the web  5  and between the longitudinally extending edges  6  and  56  of the web  5  the second central edge  24  angles away from first end  3  and toward second end  4  of the connector  2  where attachment leg  21  connects to first end portion  95  of second wall  57 . This angling of first and second central edges  23  and  24  where the attachment legs  21  and  71  join to the first and second wall  7  and  57  allows the attachment legs  21  and  71  to be wider and thus stronger. Preferably, the angling of the first and second central edges  23  and  24  is only for a portion of the first and second central edges  23  and  24  between the longitudinally extending edges  6  and  56  so as to not remove too much material from the web  5 . Angling of central edges  23  and  24  creates angled sides  33  and  34  of attachment legs  21  and  71 . 
         [0061]    As shown in  FIGS. 7, 14, 21, 27, 34 and 41  the connector  2  is preferably cut from a flat sheet metal blank. Fastener openings  30  are drilled or punched through the first and second wall portions  7  and  57 . When the first and second wall portions  7  and  57  are bent up along the first and longitudinally extending parallel edges  6  and  56  of the channel length  2 , the first and second attachment legs  21  and  71  are simultaneously bent down, enlarging the one or more central apertures  18 . 
         [0062]    As shown in  FIGS. 7 and 14 , the blanks between legs  21  and  71  and between leg extensions  22  and  72  can be cut in a wavering patterns so at to make alternating and corresponding narrowing and widening portions in the attachment legs  21  and  71  and leg extension  22  and  72 . This allows for the spacing of fasteners  37  so as to prevent splitting of post  200 . The fasteners  37  used are preferably nails, as shown in  FIG. 17 , or self-drilling and self-cutting threaded fasteners  37  as shown in  FIG. 2 . The fasteners  37  are also driven through the side walls  7  and  57  of the connector  2  into the supported member  100 . 
         [0063]    As shown in  FIG. 1 , the purpose of the connector  2  is to adequately position and secure a beam  100  in an anchored relation to a post  200 . The post  200  is preferably formed from wood, but another form of building material or, in fact, any other material which is strong enough and to which the legs can be connected, as by welding, fastening or adhesively bonding is possible. Preferably, the connector  2  is made from cold-formed sheet steel. 
         [0064]    As shown in  FIGS. 30, 35, 36 and 42 , the projecting tabs  31  that are able to interface with the end face  351  of the supporting member  200  can be provided along the first longitudinally extending edge  6  of the connector  2  and along the second longitudinally extending edge  56  of the connector  2 . As shown in  FIG. 37 , in the embodiment shown in  FIGS. 36-42 , the one or more projecting tabs  31  that are able to interface with the end face  251  of the supporting member  200  can be moved out of interfacing engagement with the end face  251  of the supporting member  200  when the supported member  100  is received by the connector  2 , such that the bottom surface  101  of the supported member  100  rests directly on the end face  251  of the supporting member  200 . Preferably the projecting tabs  31  are cut and bent from the first and second side walls  7  and  57 , and the edges of the projecting tabs  31  interface with the end face  251  of the supporting member. When the supported member is inserted between first and second side walls  6  and  56 , during the formation of the connection, and the supported member  100  is set on the web  5 , the first and second side surfaces  107  and  157  of the supported member  100  push the projecting tabs  31  out of interfacing engagement with the end face  251  of the supported member  200 . 
         [0065]    As shown in  FIGS. 29-33 , the first and second attachment legs  21  and  71  can be formed with upper planar portions  27  and  77  and lower angled portions  28  and  78 . The lower angled portions  77  and  78  preferably wrap around the supporting member  200 , and are preferably set orthogonally to the upper planar portions  27  and  28 . The upper planar portion  27  of the first attachment leg  21  projects from, is integrally joined to, and is preferably co-planar with the first wall  7 . The upper planar portion  77  of the second attachment leg  71  projects from, is integrally joined to, and is, preferably, at least partially co-planar with the second wall  57 . The post  200  is preferably formed with first and second opposed planar side surfaces  207  and  257 , portions of which are in registration with the inner faces  39  and  89  of the upper planar portions  27  and  77  of the first and second attachment legs  21  and  71  when the connection  1  is made. First and second opposed planar side surfaces  207  and  257  of the supporting member  200  are preferably in parallel relation to the first and second side walls  7  and  57  of the connector  2  and the first and second side surfaces  107  and  157  of the supported member  100 . The supporting member or post  200  is also preferably formed with third and fourth opposed planar side surfaces  277  and  287  which are orthogonally disposed with respect to the first and second opposed planar side surfaces  207  and  257 . Portions of third and fourth opposed planar side surfaces  277  and  287  are in registration with the inner faces  39  and  89  of the lower angled portions  28  and  78  of the first and second attachment legs  21  and  71 , respectively, when the connection is made. As shown in  FIG. 30 , preferably the lower angled portions  28  and  78  of the first and second attachment legs  21  and  71  are connected to the third and fourth opposed planar side surfaces  277  and  287  with fasteners  37 . 
         [0066]    As is also shown in  FIGS. 33, 34 and 35 , the projecting tabs  31  from the longitudinally extending edges  6  and  56  can extend towards and be integrally connected to each other.