Full Moment Connection Collar Systems

This application is a continuation of U.S. patent application Ser. No. 18/483,438 filed Oct. 9, 2023, and issued as U.S. Pat. No. 12,203,261 on Jan. 21, 2025, which is a continuation of U.S. patent application Ser. No. 17/589,742, filed Jan. 31, 2022, and issued as U.S. Pat. No. 11,781,308 on Oct. 10, 2023, which is a continuation of U.S. patent application Ser. No. 16/270,571, filed Feb. 7, 2019, and issued as U.S. Pat. No. 11,236,501 on Feb. 1, 2022, which claims priority from U.S. Provisional Patent Application Ser. No. 62/628,807, filed Feb. 9, 2018, the entireties of which are hereby incorporated by reference for all purposes. U.S. Pat. No. 7,941,985 B2 is also incorporated by reference herein, in its entirety, for all purposes.

Steel frame building construction requires connection of beams and columns, and moment resisting connections are needed for continuous frames. Full moment connection systems such as collar mounts offer valuable improvements over on-site welding techniques. Welding can be done off-site in controlled conditions, frame members are seated in the proper spatial orientation when connected by a collar, and on-site construction may be carried out more quickly, safely, and efficiently.

U.S. Pat. No. 7,941,985 B2 discloses an exemplary full moment collar mount, described as a halo/spider connection. Where a beam and a column connect, a collar flange assembly is welded to the end of the beam. Two collar corners are welded to corners on either side of a face of the column. To connect, the beam is lowered so that the flange assembly is received between the collar corners, which form a tapered channel. Connections on all faces of the column together form a full moment collar.

The present disclosure provides systems, apparatuses, and methods relating to full moment connections. In some examples, a full moment column collar may include four collar flange assemblies and four collar corner assemblies. Each collar flange assembly may include an upper transverse element and a lower transverse element, connected by a bridging member. Each collar corner assembly may include first and second expanses defining a corner and a standoff portion extending from the corner, the standoff portion having a distal T-shaped structure. Each collar corner assembly may be configured to connect two adjacent collar flange assemblies, and each collar corner assembly may have a multi-axis alignment structure extending from a bottom end portion for vertically positioning a lower transverse element of a respective collar flange assembly.

In some examples, a method of manufacturing a full moment column collar may include molding a collar flange blank. The method may further include machining a beam docking structure in the collar flange blank, corresponding to a selected I-beam flange dimension. The beam docking structure may include a seat configured to contact and I-beam flange.

In some examples, a method of manufacturing a full moment column collar may include molding a collar corner blank having first and second expanses defining a corner and a standoff extending from the corner. The standoff may have a distal T-shaped structure. The method may further include machining a stop surface on the collar corner blank, configured to contact a surface on a collar flange assembly.

Features, functions, and advantages may be achieved independently in various examples of the present disclosure, or may be combined in yet other examples, further details of which can be seen with reference to the following description and drawings.

Various aspects and examples of a full-moment connection collar system, as well as related methods, are described below and illustrated in the associated drawings. Unless otherwise specified, a connection system in accordance with the present teachings, and/or its various components may, but are not required to, contain at least one of the structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein. Furthermore, unless specifically excluded, the process steps, structures, components, functionalities, and/or variations described, illustrated, and/or incorporated herein in connection with the present teachings may be included in other similar devices and methods, including being interchangeable between disclosed examples. The following description of various examples is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. Additionally, the advantages provided by the examples described below are illustrative in nature and not all examples provide the same advantages or the same degree of advantages.

This Detailed Description includes the following sections, which follow immediately below: (1) Overview; (2) Examples, Components, and Alternatives; (3) Illustrative Combinations and Additional Examples; (4) Advantages, Features, and Benefits; and (5) Conclusion. The Examples, Components, and Alternatives section is further divided into subsections A to C, each of which is labeled accordingly.

In general, a full-moment collar connection system may connect one or more lateral members to a vertical member. For instance, the full moment collar connection system may connect a square box column and four I-beams. The connection system may also be configured to connect other types of structural members.

The connection system includes a collar, which surrounds a portion of the vertical member. The collar may include a first plurality of components and a second plurality components. The first plurality of components may be fixed to the vertical member, and may be referred to as standoffs, column-connectors, and/or collar corner assemblies. One or more of the second plurality of components may each be fixed to a corresponding lateral member, and the components may be referred to as spans, beam-connectors, and/or collar flange assemblies.

Components of the first and second pluralities may be fastened together, for instance may be bolted together. The components of the collar may be configured to connect in a precise spatial configuration. Correct spatial configuration of the collar may allow precise and accurate orientation of the lateral members relative to each other and relative to the vertical member. Such orientation may be important to successful building of larger structures, such as a building frame. By locating the collar components relative to one another, a desired spatial configuration of the collar may be achieved largely independently of variations in the specifications of the lateral members and vertical member.

Components of the collar may be manufactured by molding a blank and machining selected features. Molding of the blanks may limit production cost, allowing precise machining to be used only for those features important to achieving the desired spatial configuration. Such manufacturing may also allow storage of a standard blank, and on-demand machining according to the dimensions of a selected lateral member.

The following sections describe selected aspects of exemplary full-moment connection collars as well as related systems and/or methods. The examples in these sections are intended for illustration and should not be interpreted as limiting the entire scope of the present disclosure. Each section may include one or more distinct examples, and/or contextual or related information, function, and/or structure.

As shown in, this section describes an illustrative collar. Collaris an example of a full-moment collar connection system, as described above. In, collaris shown connecting a square box columnand four I-beamsof a building frame. The location of the connection on the column may be referred to as a node. In some examples, one column may include multiple nodes, each connected to one or more beams by a collar.

As shown in, collarconnects beamsto columnsuch that opposing beams are parallel and adjacent beams are orthogonal, with all the beams orthogonal to the column. In some examples, the beams may be substantially orthogonal within some angular tolerance or may form other angles with adjacent beams and/or with the column. Precise location and orientation of the beams relative to the column is achieved by engagement between components of the collar.

Columnincludes four sides or facesand four corners. Each beamis mounted proximate a corresponding faceof the column. Each beamincludes a webspanning between upper and lower beam flanges. Webhas a thicknessand a height, which is typically referred to as a beam depth of beam. Upper and lower beam flangeseach have a width. Beam depth, web thickness, and flange widthmay all vary with beam weight and size. Collarmay be configured according to the dimensions of columnand beams. Collarmay be configured to connect four beams of matching dimensions, or beams of differing dimensions.

Collarincludes equal numbers of flange assembliesand corner assemblies. In the present example, for a column with four faces, the collar includes four flange assemblies and four corner assemblies. The flange assemblies and corner assemblies alternate, such that each corner assembly engages two flange assemblies, and similarly each flange assembly engages two corner assemblies. Each corner assemblyis welded to one of cornersof column. In the present example, each flange assemblyis welded to one of beams. In some examples, fewer than four beams may be connected to the column and up to three flange assemblies may remain un-welded to a beam. In some examples, other structures or structural members may be connected to one or more flange assemblies. For instance, a converter for a gravity catch connection may be welded to a flange assembly.

As shown in, flange assemblies and corner assemblies are fastened together by horizontal boltsextending through corresponding holes in the assemblies. Each boltextends through two flange assemblies and a corner assembly. Each corner assembly is fastened by only four bolts, and collaris fastened by a total of only sixteen bolts.

Collarincludes a gravity stop feature, such that a beam with a mounted flange assembly can be lowered into engagement with two corner assemblies on the column and can be supported by the gravity stop feature while the assemblies are bolted together. The gravity stop may also be referred to as an alignment guide, and may be configured to guide a flange assembly to a precise vertical and horizontal position. For example, the gravity stop may include curved or sloped surfaces. The gravity stop may also help to correctly position each adjacent flange assembly and corner assembly relative to one another, align corresponding holes in the assemblies, and position each assembly relative to the collar as a whole.

Each assembly may comprise multiple components, welded together. Each component may be produced from a molded blank. For instance, blanks may be cast, forged, extruded, or additively manufactured. Selected features may be machined into the blank to form an assembly component. The features selected may be those responsible for determining spatial location and orientation of the assembly when connected in collar. For instance, bolt holes and engaging features may be selected to assure precise engagement. The machined surfaces of the selected features may be referred to as datum surfaces.

is a more detailed view of a corner assembly. Corner assemblyincludes a column mating portionhaving first and second expanses. The expanses extend the length of the assembly and define a corner or intersection. The expanses, which may also be referred to as feet, form an interior angle at the intersection, which corresponds to column(See). In the present example columnhas a square cross-section, and the interior angle is a right angle.

Each footis configured for mounting on a face of the column, such that the corner assembly spans a corner of the column. A standoffextends from intersection, oriented generally parallel to a bisector of the interior angle of the feet. A standoff-facing side of each footmay be a primary datum surfaceof corner assembly. Each side surface of the standoff may also be a datum surface. Standoffalso includes a T-shaped structure, distal from intersection.

In the present example, corner assemblyis comprised of a top section, a middle section, and a bottom section. Each section may be machined from a separate blank. Sections,, andare welded together to form the corner assembly.

Top sectionand bottom sectionare generally matching, but mirrored. Each includes two bolt holes, an outer bolt holeand an inner bolt hole. The bolt holes are located to correspond to holes in the flange assemblies.

Outer bolt holeand inner bolt holeof top sectionand bottom sectionextend through standoff. Each of the top and bottom sections includes an inner portion of standoffthat is adjacent to middle sectionand an outer portion of the standoff that is distant from the middle section. Each outer bolt holeis disposed in the outer portion, proximal to intersection. Each inner bolt holeis disposed in the inner portion, and in the present example is distal from intersection. Holes,may be described as aligned along a line oblique to an elongate axis BB of the corner assembly.

The location of outer bolt holemay reduce the mechanical advantage of bending loads from beams connected to the collar, as described further with reference to flange assemblyand. Such placement thereby allows use of only two bolts at each top and bottom section, simplifying connection of the collar while maintaining connection strength.

Along top sectionand bottom section, the height of standoffmay vary. That is, the distance between T-shaped structureand intersectionmay vary. A channel formed between a footand T-shaped structureof the standoff may therefore taper over the length of corner assembly. Note that in, the taper is difficult to distinguish due to the small taper angle. T-shaped structureis more clearly shown in.

Top sectionand bottom sectionare a standard size, but middle sectionis selectable from a range of sizes. In the present example, middle sectionis composed of multiple identical pieces, welded together. The number of pieces included in the middle section can be varied according to a desired length of corner assembly. The length of corner assemblymay be selected to correspond to a selected flange assembly size or beam depth. In examples for which a minimum size of corner assemblyis desired, middle sectionmay be omitted.

As shown in more detail in, each footof bottom sectionincludes a multi-axis alignment structureat a bottom end. The structure is distal from intersectionon foot. Alignment structureis configured to position a flange assembly along two axes, a vertical and a horizontal axis. For example, the alignment structure may position the flange assembly with respect to axes AA and BB, shown in. For another example, the alignment structure may position the flange assembly along a column axis and a beam axis, as defined by columnand an adjacent beam, shown in.

Referring again to, alignment structureis configured to act as a gravity stop, to support a flange assembly, and to precisely position the assembly in a vertical or Z-axis direction. Secondly, the alignment structure is configured to act as a guide, to engage a flange assembly, and to precisely position the assembly in a horizontal or X-axis direction. The channel defined between footand t-shaped structureis similarly configured to precisely locate an engaged flange assembly in a horizontal or lateral plane.

The alignment and guide functions of alignment structureare discussed in greater detail with reference to, below.

Structurehas a planar top facethat precisely locates a supported flange assembly along the vertical or column axis. Structurealso includes a curved upper surfaceor guiding shoulder configured to engage a complementary bottom surface of a flange assembly. Upper surfacemay be described as a graduated surface descending from planar top face. Alignment structuremay also be described as having a planar horizontal faceconnect to a vertical planar face by a sloping and/or sloped face. The sloped face may be planar or curved as in the present example. Preferably the sloped face may have an average slope in a range of approximately 15 to 45 degrees.

Alignment structuremay be configured for effective load transfer to foot. For example, the structure may be of sufficient size and/or sufficient cross-sectional dimension to withstand loads applied by a flange assembly. Alignment structureis molded as part of the blank for bottom section, which may confer additional structural strength. Planar top faceand curved upper surfacemay each be machined from the molded structure.

Corner assemblyis configured to limit weight by omitting material unnecessary to structural strength. For this reason, top sectionand bottom sectionhave curved outer profiles and include recesses in standoff. Similarly, feetinclude cutouts at the edge to reduce material. As noted below, such shaping may improve a strength to weight ratio of the collar.

is a schematic diagram showing production of top sectionand bottom sectionof corner assembly. A collar corner blankis molded for each section, including column mating portionand standoff. Blankdiffers for top sectionand bottom section, as bottom sectionincludes alignment structure.

Datum surfaces of each blank are machined to achieve precise engagement with other components of the corner assembly, the collar, and/or the column. Datum surfaces shown ininclude bolt holes,, planar surfaceand curved surfaceof alignment structure, foot surfaces, and standoff surfaces. In some examples, additional datum surfaces may be machined, such an inner column-facing surface each foot. Specific sizes and measurements according to which the machining is performed may vary according to the size of beam and/or column.

Non-datum surfaces and/or features may also be machined, to conform to a more rigorous specification than was used in the molding process, to add features that differ between the top and bottom sections, and/or as needed to produce a desired top or bottom section. For example, as shown in, an inner surface of t-shaped structuremay be machined to a desired smoothness and/or weld prep recesses may be machined into an edge adjacent middle section.

shows a flange assembly, which includes upper and lower transverse elements connected by a bridging component. These may be referred to as a top flangeand a bottom flange, connected by an insert. The top and bottom flanges are generally matching, but mirrored. Insertmay be a rectangular bar or other elongate member, with a length chosen according to a desired size of flange assembly. The flange assembly may be sized to match a depth and weight of an I-beam or other structural member.

As shown for bottom flangein, each of the top and bottom flanges include a main body portionwith first and second end portionsand a central span. End portionsextend generally parallel with central span. Angled wing portionsextend from the first and second end portions. Beam-facing sideof each end portions is a primary datum surface. Each surfacemay contact a datum surface on a corresponding corner assembly in the assembled collar. Beam facing sideof each wing portionmay also be a datum surface

Referring again to, on each flange a brace or crosspieceextends generally perpendicularly from main body portionand wing portions. Each wing portionhas an outside portion and an inside portion, divided by crosspiece. The outside portion includes an outer bolt holeand the inside portion includes an inner bolt hole. In the present example, outer bolt holeis proximal to a central axis BB of the flange assembly, while inner bolt holeis distal from the central axis. Holes,may also be described as aligned along a line oblique to a central axis BB. Central axis BB may be parallel to insertand may bisect central span.

In the assembled collar, bolts extending through the inner and outer bolt holes transfer loads between components of the collar, in particular bending loads from attached beams. A larger proportion of loads may be applied to bolts in the outside portion of each flange. The distance of each bolt from a central axis of the beam may determine the moment arm and consequently the mechanical advantage. Decreasing the number of bolts in each wing portion can result in breaking of the collar, if the mechanical advantage is too great.

Accordingly, outer bolt holeis located to minimize the moment arm. As shown in, the outer bolt hole is disposed immediately adjacent end portionof main body portion. In the present example, inner bolt holeis disposed proximate a distal edgeof wing portion. Such positioning of the inner bolt hole may allow access for tools used to install and tighten bolts. For some tools and/or bolts, insertmay interfere when inner bolt holeis closer to central axis BB. In some examples, fasteners may be used which allow inner bolt holeto be disposed in vertical alignment with outer bolt hole, immediately adjacent end portion.

Such locations of bolt holes,may allow use of only two bolts at each wing portion, simplifying collar connection while maintaining connection strength. Fewer bolts may result in less machining time for bolt holes, reduced material cost for bolts, and improved installation times. In some examples,bolt holes may be included (as in example C described below), the number of holes in different wing portions may vary, and/or other numbers of holes in other configurations may be used to achieve a desired load transference.

Top flangeand bottom flangeare configured to limit weight by omitting material unnecessary to structural strength. Along with the weight reducing shapes of the collar corner assemblies, this may improve a strength to weight ratio of the collar. For example, a collar may achieve a ratio of between 5,000 and 9,000 pounds of force per pound of mass (or between 2,200 and 4,000 kilograms of force per kilogram of mass). For this reason, wing portionsand crosspiecehave curved profiles, and cutouts such as recesses. The outside portion of each wingis smaller than the inside portion, with a cut-off corner having a diagonal border distal from central span.

As shown for bottom flangein, end portionsof main body portionnarrow from wing portionsto central span. Central spanmay be described as having a heightthat is less than a heightof wing portions. The top and bottom flanges may also be described as asymmetrical about crosspiece, and/or as having a butterfly shape. The rounded profiles of the flanges may also facilitate easy assembly of the collar beam mount, guiding a slightly misaligned flange assembly into correct alignment.

When assembled into full moment collaras shown in, column facing sideof central spanis proximate faceof columnbut spaced from the column. Each beamis mounted to a flange assembly, with flangesof the beam contacting beam facing sideof crosspieceof top flangeand bottom flange, and webof the beam contacting insertof the flange assembly.

Contact between an upper flangeof beamand crosspieceof top flangeis shown in more detail in, with the beam depicted as transparent. Contact between the beam and bottom flangeis similar but mirrored, so the following description may apply for the described features on both top and bottom flanges. Crosspieceof top flangeincludes a beam docking structureon the outer face at beam facing side, configured to receive an end portion of beam.

Docking structureincludes a recess in an outer side of crosspiece, which is defined by a planar seatand an inclined wall. Seatis configured to support a portion of upper beam flange. A protrusionextends out from beam facing sideof crosspiece, proximate a central portion of seat. A slotin protrusionis configured to receive an end portion of webof beam.

Seatand slotof docking structuremay support and stabilize the end portion of beamduring welding to the flange assembly. Such stability may simplify and improve safety of welding. Docking structureis also shaped to accommodate fill material used in welding beamto top flange. Such fill material may be contained between the beam end and inclined wall.