Corner Connector

This application claims priority to and the benefit of U.S. patent application Ser. No. 18/619,059 filed on 27 Mar. 2024.

The disclosure relates generally to construction of building structures, and more particularly to connectors used to couple structural members to each other in the construction of such building structures.

Connection brackets function to simplify and strengthen the union of orthogonal and non-orthogonal members of various structures, such outdoor decks, pavilions, gazebos, pergolas, or other structures useful for providing shade, cover, or privacy. Most commonly, these connection brackets are made of metal and the members themselves are most commonly made of dimensional lumber.

In U.S. Pat. No. 949,394, Daly describes a device comprising a plurality of three-sided tubes orthogonally oriented to each other and welded into a unitary assembly. In U.S. Pat. No. 2,931, 129, Boniface teaches to weld tubes in various configurations to form a unitary bracket that accepts elongate dimensional lumber. It is proposed by Boniface that construction of framed shed-like structures is facilitated by such a plurality of arranged unitary brackets. In U.S. Pat. No. 4,076,431, Burvall teaches how to build framed structures with a sloped roof and common ridge using universal connecting brackets. These structures being coverable with canvas or other similar fabric to provide protection against rain or snow. In U.S. Pat. No. 10,858,819, Styrc teaches to weld the terminal ends of a plurality of metal tubes oriented in a common plane against a central orthogonal tube to create a unitary assembly into which posts (generally dimensional lumber) are fitted.

Devices disclosed in the prior art can be used for construction of modular structures for providing shade, cover, or privacy, by arranging unitary connectors in a desired manner and coupling the resulting arrangement of unitary connectors to each other using structural members, such as dimensional lumber.

The unitary connectors are commonly welded as a finished good and occupy a significant volume of space. Many of these modular assemblies are quite large and must be shipped in large boxes with low weight to volume ratios which generally increases shipping costs. A variety of unitary connector types need to be stocked by sellers to accommodate the variety of connection types, e.g. a four-corner connection, or an angled roof truss connection. Users, such as contractors and builders, need to carefully plan to determine the types of connectors needed in a particular construction. Variants may need to be included to account for unexpected situations arising during constructions. For large constructions, specialized delivery to the construction site may be needed, increasing costs and delays in construction.

Generally, once a structure is built using connectors, it is not particularly amenable to modification. For example, in order to add a horizontal post to a pre-existing vertical post, the structure may need to be dismantled in order to replace the connector with a connector accommodating the additional horizontal post.

In some cases, unitary connectors, partially modular connectors, partially assembled modular connectors are desirable. For example, modular components may be used to partially construct a partially modular connector, which may then be sold to an end user.

In many cases, structure performance of a connector is an important consideration. Due to limited access to advanced tools and the need to reduce working time, modular connectors are made to be easy to assemble, e.g. end users are generally not willing to weld components to form a connector due at least to the time required and the need for welding equipment. Such ease may come at the cost of structural performance and undesirable geometry of connectors. For example, fully modular connectors may end up with greater gaps and protrusions than a pre-constructed connectors. Such gaps and protrusions may interfere with user operation after construction. For example, modular connectors may have relatively low rigidity.

Improvement is desired.

It is found that problems discussed herein may be solved by using a modular connector that may be readily assembled and/or reconfigured into different configurations. For outdoor structures like pergolas, pavilions, or gazebos the most common assembly (or structure) is a three-post corner assembly comprising a vertical post (or member) and two horizontal orthogonal posts (or members). Other assemblies include a vertical post with two, four, or five horizontal orthogonal posts or two non-orthogonal posts. For such a modular connector, it is desirable to achieve a large number of configurations of the modular connectors using as a few unique parts as possible so as to allow building of a large variety of structures.

Advantageously greater design flexibility may be achieved, including the ability to add on to an existing structure without having to dismantle and rebuild a structure. For example, a user that initially installed a four-post pergola structure using three-post corner connection assemblies may later decide to extend the length of the structure. The modular connector disclosed herein may permit horizontal sleeves to be easily added to the three-post assemblies converting them to four-post connection assemblies with a pleasing aesthetic appearance. For example, a weld-free appearance may be readily achieved.

It is found partially modular connectors may provide similar advantages. It is found that a pre-constructed corner connector, comprising three sleeves and comprising modular flexibility to attach a fourth sleeve, may be achieved by the use of plurality of interconnecting or interleaving angle brackets to form one side of the corner connector and a sheath to form an opposing side of the corner connector. Projections extending from the angle brackets may overlap or abut each other to mitigate movement, which may advantageously improve rigidity of the constructed corner connector. Such overlapping projections may extend in a plurality of non-parallel direction to mitigate movement in two or three non-parallel directions. Additional rigidity may be achieved by welding of edges formed between angle brackets. Advantageously, a substantially continuous, i.e. lacking gaps or protrusions interfering with user operation, rigid, readily deployable three-sleeved corner connector that is flexibly and modularly expandable to a four-sleeved corner connector may be achieved.

Accordingly, in some aspect(s) herein, there is disclosed a corner connector to connect a first frame member, a second frame member, and a third frame member to each other to form a tubular corner of a structure. The corner connector comprises a first angle bracket directly attached to the first frame member, including a first projection and a first bottom slot formed on respective opposite arms of the first angle bracket; a second angle bracket directly attached to the second frame member proximal and non-parallel to the first frame member, including a second projection and a second bottom slot formed on respective opposite arms of the second angle bracket, a side slot dimensioned according to the first projection to securably receive the first projection therethrough into an interior of the tubular corner to couple the first angle bracket to the second angle bracket and to define a first end of the tubular corner; a third angle bracket directly attached to the third frame member proximal and non-parallel to each of the first and second frame members, including a plurality of projections dimensioned according to the first bottom slot and the second bottom slot, the plurality of projections being securably received through the first bottom slot and the second bottom slot into the interior to overlap the first projection and the second projection to improve rigidity of the corner connector by obstructing the first and the second projections to mitigate movement of the first and the second angle brackets; and a rigid sheath attached to and extending opposite to the first, the second, and the third angle brackets to form a second end of the tubular corner and to form first, second, and third sleeves for respectively receiving the first, the second, and the third frame members.

Implementations may include one or more of the following features. The first end of the tubular corner includes an inner spine of the tubular corner and the second end of the tubular corner includes an outer spine of the tubular corner. Overlapping of the first and the second projections mitigates movement of the first and the second angle brackets along a first direction, the first angle bracket includes a first bottom projection, the second angle bracket includes a second bottom projection overlapping the first bottom projection in the interior to mitigate movement of the first and the second angle brackets along a second direction non-parallel to the first direction. The first bottom projection is fastened to the second bottom projection. Each of the first projection, the second projection, the first bottom projection, and the second bottom projection is planar tabular-shaped. The first projection, the second projection, and the second bottom projection are mutually orthogonal planar plates. At least one of the first projection, the second projection, the first bottom projection, and the second bottom projection extends towards one of the first frame member, the second frame member, and the third frame member to cause abutment therewith to form a gap adjacent thereto in the interior. The sheath defines a plurality of slots suitable to receive a corresponding plurality of tabs of a fourth sleeve to couple the fourth sleeve to the corner connector. The sheath is welded to the first angle bracket, the second angle bracket, and the third angle bracket at outer edges of the corner connector. The sheath comprises three mutually orthogonal plates. The first frame member, the second frame member, and the third frame member are mutually orthogonal. The first angle bracket includes a first one or more apertures to allow fastening therethrough of the first frame member to the first angle bracket, the second angle bracket includes a second one or more apertures to allow fastening therethrough of the second frame member to the second angle bracket, and the third angle bracket includes a third one or more apertures to allow fastening therethrough of the third frame member to the third angle bracket. The plurality of projections are fastened to each of the first projection and the second projection.

Accordingly, in some aspect(s) herein, there is disclosed a structure. The structure comprises the corner connector described above, and the first frame member, the second frame member, and the third frame member.

Accordingly, in some aspect(s) herein, there is disclosed a method of constructing a corner connector to connect a first frame member, a second frame member, and a third frame member to each other to form a tubular corner of a structure.

Implementations may include one or more of the following features and/or steps. Receiving a first projection of a first angle bracket through a side slot of a second angle bracket to position the first projection inside the second angle bracket, to position a second projection of the second angle bracket inside the first angle bracket, and to secure the first angle bracket to the second angle bracket. Receiving a plurality of projections of a third angle bracket through a first bottom slot of the first angle bracket and a second bottom slot of the second angle bracket to secure the third angle bracket to the first angle bracket and the second angle bracket, the first bottom slot and the first projection being formed on opposite arms of the first angle bracket, the second bottom slot and the second projection being formed on opposite arms of the second angle bracket. Overlapping the plurality of projections against the first projection of the first angle bracket and a second projection of the second angle bracket to obstruct movement of the first angle bracket and the second angle bracket while the third angle bracket is secured to the first angle bracket and the second angle bracket. Attaching a rigid sheath to the first angle bracket to form a first sleeve suitable to receive the first frame member. Attaching the sheath to the second angle bracket to form a second sleeve suitable to receive the second frame member. Attaching the sheath to the third angle bracket to form a third sleeve suitable to receive the third frame member. Fastening the plurality of projections to each of the first projection and the second projection. Each of the first angle bracket, second angle bracket, third angle bracket, and sheath is of unitary construction. Attaching the sheath to the first angle bracket includes continuously joining the sheath to the first angle bracket to unitarily construct the first sleeve. Attaching the sheath to the second angle bracket includes continuously joining the sheath to the second angle bracket to unitarily construct the second sleeve. Attaching the sheath to the third angle bracket includes continuously joining the sheath to the third angle bracket to unitarily construct the third sleeve. Each of the first angle bracket, second angle bracket, third angle bracket, and sheath is composed of sheet metal. The sheath comprises a side sheath that defines an outer spine of the corner connector and a planar top sheath. Attaching the side sheath to the top sheath. Overlapping of the first and the second projections mitigates movement of the first and the second angle brackets along a first direction. Overlapping a first bottom projection of the first angle bracket and a second bottom projection of the second angle bracket inside the corner connector while the first angle bracket is secured to the second angle bracket to mitigate movement of the first and the second angle brackets along a second direction non-parallel to the first direction. Fastening the first bottom projection to the second bottom projection.

Accordingly, in some aspect(s) herein, there is disclosed a modular connector for coupling a first frame member to a second frame member at a predetermined angle. The modular connector also includes a first sleeve defining a first longitudinal axis and a first socket suitable to receive therein the first frame member, the first sleeve having an axially extending outer face, the outer face defining a plurality of slots thereon; and a second sleeve defining a second longitudinal axis, a terminal end along the second longitudinal axis, and a second socket suitable to receive therein the second frame member, the second sleeve including: a plurality of tabs extending away from the second socket from the terminal end, the plurality of tabs being receivable in the plurality of slots to position the second sleeve relative to the first sleeve, and an end plate extending from the terminal end towards the second socket to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is engaged with the plurality of slots to allow removable coupling of the first sleeve to the second sleeve, the end plate being angled relative to the second longitudinal axis to position the first frame member at the predetermined angle relative to the second frame member when the end plate is fastened in abutment to the outer face.

Implementations may include one or more of the following features. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners. Each of the first plurality of apertures is axially spaced apart from the plurality of slots and opens to the first socket to allow the fasteners to extend into the first socket via the first plurality of apertures to fasten the second sleeve to the first frame member. Each of the plurality of tabs is substantially non-parallel to the end plate. The plurality of tabs and the end plate are positioned at opposite lateral sides of the second sleeve. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the end plate. The first sleeve includes a plurality of grooves extending from the outer face into the first socket to cause an interference fit between the first frame member and the first sleeve. Each of the plurality of grooves is suitable to receive a corresponding fastener to allow fastening of the first sleeve to the first frame member. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners, the first plurality of apertures being axially spaced apart from the plurality of slots, a groove of the plurality of grooves being positioned axially in-between the first plurality of apertures and the plurality of slots. Each tab of the plurality of tabs is interlockable with a corresponding slot of the plurality of slots. The first sleeve includes a stiffener extending at least partially across the first socket, and being spaced apart from the plurality of slots to prevent interference with the first frame member. The first sleeve defines a quadrilateral cross-section, the stiffener being triangularly shaped and extending across two sides of the quadrilateral cross-section. The end plate is a first end plate, the second sleeve including a second end plate extending from the terminal end towards the second socket and opposite to the first end plate to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is received in the plurality of slots. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the first end plate, the second end plate being positioned between the two spaced-apart tabs.

Accordingly, in some aspect(s) herein, there is disclosed a structure. The structure also includes a first member, a second member, and a modular connector for coupling a first frame member to a second frame member at a predetermined angle. The modular connector also includes a first sleeve defining a first longitudinal axis and a first socket suitable to receive therein the first frame member, the first sleeve having an axially extending outer face, the outer face defining a plurality of slots thereon; and a second sleeve defining a second longitudinal axis, a terminal end along the second longitudinal axis, and a second socket suitable to receive therein the second frame member, the second sleeve including: a plurality of tabs extending away from the second socket from the terminal end, the plurality of tabs being receivable in the plurality of slots to position the second sleeve relative to the first sleeve, and an end plate extending from the terminal end towards the second socket to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is engaged with the plurality of slots to allow removable coupling of the first sleeve to the second sleeve, the end plate being angled relative to the second longitudinal axis to position the first frame member at the predetermined angle relative to the second frame member when the end plate is fastened in abutment to the outer face. The first frame member is the first member and the second frame member is the second member, the first member being received in the first sleeve, the second member being received in the second sleeve. The structure also includes a plurality of fasteners at least partially passing through the end plate, the outer face of the first sleeve, and the first member to cause frictional engagement therebetween to fasten the first sleeve, the second sleeve, and the first member to each other.

Implementations may include one or more of the following features. Each of the plurality of fasteners is received in a corresponding one of a plurality of apertures defined in each of the end plate and the outer face. The first sleeve includes a first plurality of grooves extending from the outer face into the first socket to frictionally engage with the first member, the second sleeve including a second plurality of grooves extending into the second socket to frictionally engage with the second member, each groove of the first and second plurality of grooves receiving a corresponding fastener of the plurality of fasteners. Each of the plurality of fasteners is received in a corresponding one of a plurality of apertures defined in each of the end plate and the outer face, and a groove of the first plurality of grooves being spaced-apart from and positioned axially in-between the plurality of apertures and the plurality of slots.

Accordingly, in some aspect(s) herein, there is disclosed a sleeve of a modular connector for coupling a first frame member to a second frame member at a predetermined angle. The sleeve also includes and a plurality of slots defined on an axially extending outer face of the common sleeve, the sleeve being axially elongated and defining: an axially terminal end; a second socket suitable to engageably receive therein the second frame member; a plurality of tabs extending away from the second socket from the axially terminal end and receivable in the plurality of slots to position the sleeve relative to the common sleeve; and an end plate extending from the axially terminal end towards the second socket to abut and fasten to the outer face of the common sleeve when each of the plurality of tabs is received in the plurality of slots to allow removable coupling of the sleeve to the common sleeve, the end plate being angled to allow the first frame member to be positioned at the predetermined angle relative to the second frame member when the end plate is fastened in abutment to the outer face.

Implementations may include one or more of the following features. The sleeve may include a plurality of grooves extending laterally inwardly towards the second socket to cause an interference fit between the sleeve and the second frame member when the second frame member is received in the second socket. Each of the plurality of grooves defines an aperture for receiving a corresponding fastener to allow fastening of the sleeve to the second frame member, the sleeve may include a plurality of apertures suitable to receive a plurality of fasteners to allow engagement of the sleeve with the common sleeve and the first frame member via the fasteners. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners. Each of the first plurality of apertures is axially spaced apart from the plurality of slots and opens to the first socket to allow the fasteners to extend into the first socket via the first plurality of apertures to fasten the second sleeve to the first frame member. Each of the plurality of tabs is substantially non-parallel to the end plate. The plurality of tabs and the end plate are positioned at opposite lateral sides of the second sleeve. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the end plate. The first sleeve includes a plurality of grooves extending from the outer face into the first socket to cause an interference fit between the first frame member and the first sleeve. Each of the plurality of grooves is suitable to receive a corresponding fastener to allow fastening of the first sleeve to the first frame member. A first plurality of apertures is defined on the outer face and is complementary to a second plurality of apertures of the end plate, the first and second plurality of apertures being suitable to receive fasteners to allow engagement of the first sleeve with the second sleeve via the fasteners, the first plurality of apertures being axially spaced apart from the plurality of slots, a groove of the plurality of grooves being positioned axially in-between the first plurality of apertures and the plurality of slots. Each tab of the plurality of tabs is interlockable with a corresponding slot of the plurality of slots. The first sleeve includes a stiffener extending at least partially across the first socket, and being spaced apart from the plurality of slots to prevent interference with the first frame member. The first sleeve defines a quadrilateral cross-section, the stiffener being triangularly shaped and extending across two sides of the quadrilateral cross-section. The end plate is a first end plate, the second sleeve including a second end plate extending from the terminal end towards the second socket and opposite to the first end plate to abut and fasten to the outer face of the first sleeve when each of the plurality of tabs is received in the plurality of slots. The plurality of tabs includes two spaced-apart tabs positioned at a common side of the second sleeve opposite to the first end plate, the second end plate being positioned between the two spaced-apart tabs.

Embodiments can include combinations of the above features. It is understood that one or more sleeves may be sold in packages or in kits.

Further details of these and other aspects of the subject matter of this application will be apparent from the detailed description included below and the drawings.

Aspects of various embodiments are now described in relation to the figures.

is a perspective view of a modular connector, in accordance with an embodiment.

The modular connector comprises a primary sleeve(also referred to as a common sleeve or first sleeve), and secondary sleevesA,B,C.

The modular connectoris suitable for coupling a primary frame member(also referred to herein as primary member) to a secondary frame member(also referred to herein as secondary member) at a predetermined angle, as shown inand as further described herein.

are various views of an embodiment of the primary sleeve.is a perspective view,is a front perspective view,is a side elevation view of the primary sleeve.

The primary sleeveis elongated along a primary axis(or first axis) so as to define a primary socket(or first socket).

The primary socketis suitable to receive the primary member. The primary socketis suitable to engage with the primary member, e.g. the primary socketmay be configured to frictionally engage with the primary member.

The primary sleevemay define one or more outer faces. The outer facesmay extend axially along the primary axis(axially extending outer faces). A plurality of slotsmay be formed on each outer face. The primary sleevemay define a plurality of sides. The primary sleevemay define four (lateral) sides, as shown in. It is understood that the primary sleevemay define more or less than four sides.

In various embodiments, the size and the shape of the primary sleevemay be similar to the size and shape of the primary frame memberthat is to be received in the primary sleeve.

A plurality of aperturesmay be formed on the outer faceto open to the primary socketto allow fasteners to pass therethrough to the primary frame member. Each of the first plurality of aperturesmay be axially spaced apart from the plurality of slots.

The primary sleevemay include a plurality of groovesextending from the outer faceinto the primary socketto cause an interference fit between the primary frame memberand the primary sleeve, e.g. by biting into the primary member.

In various embodiments, the groovesmay be circular or non-circular depressions. In some embodiments, the groovesmay be elongated.

Each of the plurality of grooves is suitable to receive a corresponding fastener(only four are shown infor illustrative purposes) to allow fastening of the primary sleeveto the primary frame member. In various embodiments, apertures may be provided in one or more of the plurality of groovesto allow passage therethrough of a corresponding one of the fastenersto fasten the primary sleeveto the primary member. It was found to be particularly effective to fasten the primary sleeveto the primary frame memberat the locations where the groovesbite into (or press against) the primary sleeve.

As shown in, in some embodiments, at least one grooveof the plurality of groovesis positioned axially in-between the plurality of aperturesand the plurality of slots. Advantageously, positioning of the at least one groovein-between the plurality of aperturesand the plurality of slotsmay allow concealing of fasteners engaged with members via the at least one grooveonce secondary sleeves is attached to the primary sleeveadjacent to the at least one groove.

Two or more additional groovesmay be provided. For example, such groovesmay be axially spaced apart from each other by an offset. In various embodiments, the grooves may be spaced apart from one terminal end by a distanceof about 1 inch and spaced apart from another terminal end by a distanceof about 0.25 inch. Advantageously, offsetting grooves may help mitigate interference between fasteners that are driven through opposite sides, i.e. through grooves on opposite sides of (primary or secondary) sleeves. Advantageously, at least two grooves are provided to center and hold the member fixed in-placed via fasteners passing therethrough.

are various views of an embodiment of a secondary sleeve, e.g. similar to one or more of the secondary sleevesA,B,B shown in.

is a rear perspective view.is a cross-sectional view, in perspective, through the lineB-B in.is a top elevation view.is a side elevation view.is a perspective view.

The secondary sleeveis elongated along a secondary axisto define a terminal endalong the secondary axisand a secondary socket.

The secondary socketis suitable to receive the secondary frame member. The secondary socketmay be suitable to engage with the secondary member, e.g. the secondary socketmay be configured to frictionally engage with the secondary member.

The secondary sleeveincludes an end plateextending from about the axially terminal endtowards the secondary socket. The end plateextends inwardly from an outer end of the secondary sleevein a lateral direction (laterally inwardly) to allow abutting and fastening of the end plateto the outer faceof the primary sleevewithout needing an external fastening connection.

The end platemay be angled relative to the secondary axisto angle the primary frame memberat the predetermined anglerelative to the secondary frame member(see angleshown in) when the end plateis fastened in abutment to the outer face.

The secondary sleevemay define a plurality of sides. The secondary sleevemay define four (lateral) sides, as shown in. It is understood that the secondary sleevemay define more or less than four sides.

The secondary sleeveincludes a plurality of tabsextending away from the secondary socketfrom about the terminal end. In various embodiments, the plurality of tabsmay include two spaced-apart tabspositioned at a common one of the sidesof the secondary sleeveopposite to the end plate.

The plurality of tabsare receivable in the plurality of slotsand may be complementary thereto. The plurality of tabsmay be complementarily receivable in the plurality of slotsto position the secondary sleeverelative to the primary sleeve. In some embodiments, each tabof the plurality of tabsmay be interlockable with a corresponding slotof the plurality of slots.