Static structures (e.g. – buildings) – Facer held by stiffener-type frame – Facer attached between exposed frame members
Reexamination Certificate
2000-04-05
2004-02-24
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Facer held by stiffener-type frame
Facer attached between exposed frame members
C403S230000, C403S231000, C403S403000, C403S205000, C052S528000, C052S584100, C052S712000, C052S714000, C052S655100, C052S656400, C052S749100, C052S633000, C052S650300, C052S653100, C052S273000, C411S402000, C411S403000, C411S404000, C411S531000, C411S533000
Reexamination Certificate
active
06694700
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates in general to the construction of building structures, and in particular to a fastener for attaching frame members of a patio enclosure.
Patio enclosures are typically constructed with a plurality of elongated beams or frame members which are fastened to one another to form a framework. The framework generally provides the structural integrity and shape of the patio enclosure. Panels, screens, windows, and doors are commonly inserted between various frame members to form an enclosed structure. The frame members can be oriented vertically, horizontally, or angled with respect to one another. Additionally, a roof structure can be installed over the patio enclosure.
The frame members are relatively narrow compared to their length. Frame members have been constructed out of many types of materials, such as wood, aluminum, and polymeric materials, such as vinyl. In recent times, frame members have been formed from multiple materials to form a composite frame member. A composite frame member generally has an inner core covered by an outer casing. The outer casing is made of a different material than the inner core. For example, the inner core can be a relatively rigid material, such as wood or aluminum, which provides rigidity and the structural integrity for the frame member. The outer casing or skin can be made of a suitable material having weather resistant properties and which is aesthetically pleasing, such as vinyl or other suitable polymeric materials. If vinyl or other polymeric materials are used for the outer casing, the outer casing can be manufactured using an extrusion process, and is preferably formed with a hollow interior. The inner core is inserted into the hollow interior of the outer casing to form a frame member having a relatively rigid structure and having exceptional wear properties for withstanding an outdoor environment.
Frame members are supplied in various cross-sectional shapes depending on their application and location in the patio enclosure. Commonly, the cross-sectional shape of frame members is generally square or rectangular. The frame members can include pairs of elongated relatively thin planar ribs extending along the length of one or more sides of the frame member. Typically, the ribs extend normal to a flat surface defined by the side of the frame member. The ribs form a track in which panels or widows can be inserted therebetween to secure the panel or window to the frame member. The ribs of adjacent frame members are dimensioned and oriented so that they are in alignment with each other and are generally coplanar to form a continuous track surrounding the periphery of the panel or window. If the frame member is formed by an extrusion process, the ribs can easily be formed integrally with the extruded outer casing.
Generally, the frame members are positioned and fastened together such that an end of one frame member abuts a side of another frame member. The frame members are commonly at right angles with respect to one another and form what is known in the art as a butt joint. It is known to fasten frame members by conventional angle brackets having a pair of relatively flat legs perpendicular to one another. The legs of the bracket are fastened to the adjacent sides of the adjoining frame members, such as by self-tapping screws.
It is also known to use an insert to assist in fastening frame members together. There is illustrated in
FIG. 1
, a joint, indicated generally at
100
, for use in a conventional known prior art patio enclosure. The joint
100
is formed by joining a first frame member
102
to a second frame member
104
with the aid of an insert
106
. The frame members
102
and
104
are similar in structure. The frame members
102
and
104
are composite frame members having a polymeric outer casing
108
and a rigid inner core
110
. The frame members
102
and
104
include outwardly extending ribs
112
to form tracks for retaining doors, windows, and panels of the patio enclosure. The insert
106
is generally U-shaped having a pair of spaced apart parallel legs
114
joined by a web
116
. The insert
106
and the inner cores
110
of the frame members
102
and
104
are formed of aluminum, a relatively rigid material.
To form the joint
100
, the web
116
of the insert
106
is fastened to a side surface
118
of the frame member
102
by a threaded fastener (not shown). The legs
114
of the insert
106
are then inserted into a bore
120
of the inner core
110
of the frame member
104
. The legs
114
of the insert
106
are then fastened to the side of the frame member
104
by threaded fasteners threaded through a side wall
121
of the frame member
104
.
To form a relatively secure joint, a structural end of the frame member
104
should be in abutment with the structural side of the frame member
102
. Since the outwardly extending ribs
112
of the frame members
102
and
104
are oriented so that they align with each other, the end of the frame member
104
will not abut the flat side surface
118
of the mating frame member
102
due to the interference from the ribs
112
. In other words, the end of the frame member
104
will abut the outer edges of the ribs
112
of the frame member
104
. Fastening the frame members
102
and
104
at this displacement position is undesirable because of the formation of a relatively weak joint due to the lack of direct contact of the structural members. To overcome this problem, portions of the frame members, such as the ribs
112
, from one or both of the frame members
102
and
104
are removed or cut out to form notches. For example, as shown in
FIG. 1
, notches
122
are formed in the ribs
112
of the frame member
104
. The length of the notch
122
corresponds to the width of the rib
112
extending from the side surface
118
. The notch
122
provides clearance for the ribs
112
of the end of the frame member
104
from interfering with the ribs
112
of the frame member
102
when the end of the frame member
104
is positioned adjacent the side surface
118
of the frame member
102
. A generally rectangular notch
124
is formed in the side surface
118
of the frame member
102
corresponding to the dimensions of the web
116
of the insert
106
. The notch
124
allows direct contact between the web
116
of the insert
106
and the inner core
110
of the frame member
103
. Since the surface area of the web
116
is relatively small, the insert
106
is mounted directly to the surface of the inner core
110
.
The appropriate portions (notches) of the frame members can be removed manually by hand tools or by power tools, such as routers or milling machines. Special cutting tools have been developed to cut an appropriate notch into the frame members. However, these cutting tools can be relatively expensive, especially if different configurations of notches must be machined corresponding to frame members having different cross-sections.
Although the removal of the portions of the frame members overcomes the problem of joining the structural portions of the frame members to form a butt joint, it is very time consuming and intricate. Commonly, the frame members are provided in relatively long lengths, such as 20 feet in length, and are cut to the appropriate size at the job site where the patio enclosure is being built. If the frame members are sized at the job site, the appropriate tools must be available to remove the appropriate portions of the frame embers to accommodate the butt joint. To avoid having the workers on the job site cutting the appropriate notches, it is known to cut the frame members at a manufacturing facility prior to assembly at the job site. However, any complications, such as inaccurate measurements or inventory errors, will complicate assembly of the patio enclosure because of non-mating frame members. Often, the workers must notch the frame members using hand tools regardless of having the premeasured and notched frame members.
REFERENCES:
patent: 3642310 (1972-02-01), Hudson
pa
MacMillan Sobanski & Todd LLC
Varner Steve
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