Connection of side panels of staircase box

Abstract

A connector that allows a supported member to be connected to a supporting member, where the supported member can be part of an existing member such as a box, and the connector has a front member and a rear member connected by a seat member.

Description

[Technical field]

[0001] The present invention relates to connectors for joining structural members and connections made thereby. More particularly, the invention has particular application as a simple, inexpensive hanger for strengthening connections between headers and rungs, and as a mechanism for joining prefabricated members, such as stair boxes, to supporting headers. [Background technology]

[0002] U.S. Patent No. 7,024,833, issued in 2006 and invented by John Rice, teaches a simple hanger for connecting cross planks to spaced foam molded walls.

[0003] U.S. Patent No. 7,631,463, issued in 2009 and invented by Greg Greenlee et al., teaches a staircase stringer hanger for attaching angled staircase stringers to rungs.

[0004] U.S. Patent No. 7,958,690, granted in 2011 and invented by William F. Lee et al., teaches a connector having gussets for angled fastener openings in the connector.

[0005] The present invention is a connector and a connection made therewith that allows for the quick attachment of prefabricated components such as staircase boxes or other types of boxes to a header. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Patent No. 7,024,833 [Patent Document 2] U.S. Patent No. 7,631,463 [Patent Document 3] U.S. Patent No. 7,958,690 Summary of the Invention [Means for solving the problem]

[0007] The present invention provides a connector that allows for easy attachment of rungs to headers, and in particular to rungs that are part of prefabricated components such as stair boxes.

[0008] The present invention provides a connector capable of supporting a supported member by a supporting member. The connector is preferably U-shaped, with a front member and a rear member connected to each other at their lower edges by a seat member, and the front member and the rear member extending upwardly from the seat member. Preferably, an angled fastener is used to attach the connector to the supported member and the supporting member. An additional fastener is used to attach the rear member of the connector to the supporting member.

[0009] In a preferred form of the invention, the angled fasteners are driven through the front member in an upward direction such that the fasteners first pass into and into the supported member and then into the support member. Preferably, at least two angled fasteners are driven through the front member and into the support member near the top of the rear member to clamp the top of the rear member.

[0010] The front and rear members have generally flat portions. The seat member is generally flat. The rear member preferably extends above the seat member significantly higher than the front member. When the connector is attached to the support member, the front and rear members extend generally vertically and the seat member extends horizontally.

[0011] The front member is preferably a generally rectangular member having the same width as the seat member.

[0012] The rear member preferably has a lower portion, a middle portion disposed upwardly from the seat member and above the lower portion, and an upper portion disposed above the middle portion. The lower portion of the rear member is preferably the same width as the seat member. The upper portion of the rear member is preferably significantly narrower than the seat member and the front member. The middle portion of the rear member extends between the lower portion and the upper portion and narrows in width from the lower portion to the upper portion. Preferably, the lower end of the upper portion of the rear member, which is the interface between the middle portion and the upper portion, is disposed above the seat member at a distance similar to and just above the height of the upper edge of the front member.

[0013] The forward member is preferably formed with an upper and lower portion. The upper portion of the forward member is preferably formed as an overhanging lip flange and the lower portion is formed as a generally flat member. The overhanging lip flange has an upper edge.

[0014] The upper edge of the lower portion of the forward member is connected to an overhanging lip flange that extends outwardly and further away from the rear member than the generally flat lower portion of the forward member. The overhanging lip flange is preferably a flat member that extends outwardly, preferably at a 45 degree angle, relative to the generally flat lower portion of the forward member. The overhanging lip flange is attached to the lower portion of the forward member at a fold line at the upper edge of the lower portion of the forward member.

[0015] Preferably, an opening is provided in the front member and an opening is also provided in the rear member.

[0016] The interface between the overhanging lip flange and the lower portion of the forward member includes one or more gusset members extending between the overhanging lip flange and the lower portion of the forward member. The one or more gusset members have generally planar fastener receiving members extending outwardly and away from the generally planar lower portion of the forward member at an angle of about 22.5 degrees. Openings for receiving fasteners are preferably formed in each fastener receiving member.

[0017] The fastener receiving member of the gusset is preferably formed as a rectangular member having a top edge, a bottom edge, a right edge, and a left edge, the top edge of the fastener receiving member being connected to the overhanging lip flange and the bottom edge of the fastener receiving member being connected to the lower portion of the front member.

[0018] The gusset or gussets are preferably formed with triangular left and right ends that respectively connect the left and right edges of the generally planar fastener receiving member to the overhanging lip flange and front member.

[0019] The front member, rear member and seat member are preferably formed from metal and integrally joined together by bending steel sheets to create the three dimensional shape of the U-shaped connector.

[0020] The box is preferably formed with a cross plate, an opposite end plate and a side edge plate arranged on the periphery of the box. The box is provided with a bottom plate connected to the cross plate, the opposite end plate and the side edge plate. In the case of the stair box, the side edge plate is made of a stair stringer. The stair stringer is preferably formed with a straight bottom surface and the opposite top surface is notched to form a horizontal surface that will act as the tread support surface and a vertical surface that will form the riser surface between the tread surfaces. At the upper end of the stair stringer, the stringer is cut to form a vertically facing surface that will interlock or closely adjoin the cross plate. At the lower end of the stair stringer, the stringer is cut to form a downwardly facing horizontal surface that can support the stair box. [Brief description of the drawings]

[0021] [Figure 1] FIG. 2 is a perspective view of the connector of the present invention. [Diagram 2] FIG. 2 is a front view of the connector of FIG. [Diagram 3] FIG. 2 is a rear view of the connector of FIG. 1. [Figure 4] FIG. 2 is a right side view of the connector of FIG. 1. [Diagram 5] FIG. 2 is a left side view of the connector of FIG. 1. [Figure 6] FIG. 2 is a top view of the connector of FIG. 1. [Figure 7] FIG. 2 is a bottom view of the connector of FIG. 1. [Figure 8] FIG. 13 is a right side view of the connection of the present invention having an additional fastener connecting the cross plate to the header, not shown. [Figure 9] FIG. 9 is a close-up right side view of the connector of the present invention taken along the line of view indicated in FIG. 8. [Figure 10] FIG. 13 is a right side view of the connection of the present invention with an additional fastener connecting the cross plate to the header shown. [Figure 11] FIG. 2 is a bottom perspective view of the connector of the present invention. [Figure 12] FIG. 2 is a bottom perspective view of the connector of the present invention illustrating the entire staircase box. [Figure 13] FIG. 13 is a top perspective view illustrating the stair box just before being installed into the connector that has been previously attached to the header. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] 1 and 4 of the drawings, the connector or hanger 1 of the present invention is designed to attach a supported member 2 to a supporting member 3. The hanger 1 has a front member 4 and a rear member 5. The front member is formed with a lower portion 6 and an upper portion 7. A seat member 8 connects the front member 4 and the rear member 5 to create a U-shaped connector 1.

[0023] As shown in FIG. 1, the seat member 8 is an integral part of the front member 4 and the rear member 5 of the suspension device 1. The seat member 8 is preferably connected to the front member 4 and the rear member 5 at their lower ends. Preferably, the seat member 8 is a generally flat member. The seat member 8 is preferably connected to the members 4, 5 along parallel seat front fold lines 9 and seat rear fold lines 10. The seat member 8 is integrally connected to the front member 4 and the rear member 5 along the seat front fold line 9 and the seat rear fold line 10. The front member 4 and the rear member 5 extend upwardly from the seat front fold line 9 and the seat rear fold line 10, respectively. The front member 4 and the rear member 5 have generally flat portions. The seat member 8 is generally flat. The rear member 5 preferably extends above the seat member 8 significantly higher than the front member 4. When the connector 1 is mounted on the support member 3, the front member 4 and the rear member 5 extend generally vertically, and the seat member 8 extends horizontally.

[0024] The front member 4 is preferably a generally rectangular member that is the same width as the seat member 8 .

[0025] The rear member preferably has a lower portion 11, a middle portion 12 disposed above and in a direction upward from the seat member 8, and an upper portion 13 disposed above the middle portion 12. The lower portion 11 of the rear member 4 is preferably the same width as the seat member 8. The upper portion 13 of the rear member 4 is preferably significantly narrower than the seat member 8 and the front member 5. The middle portion 12 of the rear member 4 extends between the lower portion 11 and the upper portion 13, narrowing in width from the lower portion 11 to the upper portion 13. Preferably, the lower end 14 of the upper portion 13 of the rear member 5, which is the interface between the middle portion 12 and the upper portion 13, is disposed above the seat member 8 at a distance similar to and just above the height of the upper edge of the front member 5.

[0026] Preferably, angled fasteners 15 are used to connect the connector 1 to the supported member 2 and the support member 3. As shown in Figure 12, the angled fasteners 15 driven through the front member 4 can be driven in an upward direction, first passing into and through the supported member 2 and then into the support member 3. Preferably, at least two angled fasteners 15 are driven through the front member 4 and into the support member 3 near the top 13 of the rear member 4 to clamp the top 13 of the rear member 4.

[0027] The angled fastener 15 is preferably formed with a shaft 16 having an end portion 17 and a middle portion 18. The end portion 17 of the fastener 15 shaft 16 is embedded in the supporting member 3 and the middle portion 18 of the fastener 15 shaft 16 is embedded in the supported member 2. The fastener 15 shown is a screw, however nails and other similar fasteners may be used.

[0028] Connector 1 is preferably formed with fastener openings 19 to aid the user in aligning and driving the angled fasteners that perform the installation.

[0029] Preferably, additional fasteners 20 attach the rear member 5 of the connector 1 to the support member 3. Preferably, the rear member 5 of the connector 1 is formed with openings 21 for these fasteners 20, which are preferably nails.

[0030] As shown in Figures 8, 11 and 12, the supported member 2 is formed with a front side 22 and a rear side 23 that are parallel to each other and spaced apart a first selected distance 24. The supported member 2 also has an end surface 25 that intersects with the front side 22 and the rear side 23 of the supported member 2 at a front side edge 26 and a rear side edge 27 of the end surface 25. As shown in Figure 8, the supported member 2 can be formed with a left side 22, a right side 23, and a top surface 28 and a bottom surface 29 that intersect with the end surface 25. As shown in Figure 8, the support member 3 has a mounting surface 30 and a top surface 31 that intersects with the mounting surface 30 at an upper edge 32 of the mounting surface 30. As shown in Figure 8, the mounting surface 30 is disposed generally vertically and the top surface 31 of the support member 3 is disposed generally horizontally.

[0031] As shown, the connector 1 is formed with a front member 4 and a rear member 5. The front member 4 and the rear member 5 are substantially planar members that are generally parallel to one another. The front member 4 and the rear member 5 are spaced apart from one another by a sufficient distance to closely receive the supported member 2 therebetween. The front member 4 is in surface contact with a front side 22 of the supported member, and the rear member 5 is in surface contact with a rear side 23 of the supported member 2. The front member 4 and the rear member 5 are each connected to a seat member 8, and the front member 4 and the rear member 5 are connected to one another only via the seat member 8. The seat member 8 is sufficiently rigid to hold the front member 4 and the rear member 5 in a spaced apart relationship.

[0032] The connector 1 is preferably cut and formed from thin steel sheet using automated machinery.

[0033] The front member 4 is formed having an upper portion 7 and a lower portion 6. The upper portion 7 of the front member is preferably formed as an overhanging lip flange and the lower portion 6 is formed as a generally flat member. The overhanging lip flange has an upper edge 33.

[0034] The upper edge 34 of the lower portion 6 of the front member 4 is connected to an overhanging lip flange 7 that extends outwardly, further away from the rear member 5 than the generally flat lower portion 6 of the front member 4. The overhanging lip flange 7 is preferably a flat member that extends preferably at a 45 degree angle outwardly relative to the generally flat lower portion 6 of the front member 4. The overhanging lip flange 7 is attached to the lower portion 6 of the front member 4 at a fold line along the upper edge 34 of the lower portion 6 of the front member 4.

[0035] Preferably, fastener openings 19 are provided in the front member 4 and additional fastener openings 20 are also provided in the rear member 5 .

[0036] The interface between the overhanging lip flange 7 and the lower portion 6 of the front member 4 includes one or more gusset members 35 extending between the overhanging lip flange 7 and the lower portion 6 of the front member 4. The one or more gusset members 35 have generally planar fastener receiving members 36 that extend outwardly and away from the generally planar lower portion 6 of the front member 4 at an angle of approximately 22.5 degrees. An opening 19 for receiving an angled fastener 15 is preferably formed in each fastener receiving member 36.

[0037] The fastener receiving member 36 of the gusset member 35 is preferably formed as a rectangular member having an upper edge 37, a lower edge 38, a left edge 39, and a right edge 40. The upper edge 37 of the fastener receiving member 36 is connected to the overhanging lip flange 6 and the lower edge 38 of the fastener receiving member 36 is connected to the lower portion 6 of the front member 4.

[0038] The one or more gusset members 35 are preferably formed with triangular left and right ends 41, 42 that respectively connect the left and right edges 39, 40 of the generally planar fastener receiving member 36 to the overhanging lip flange 7 and the lower portion 6 of the front member 4. The rear member 5 is formed with an upper edge 43 and the upper portion 13 is formed with left and right outer edges 44, 45. The lower portion 6 of the front member 4 is preferably formed with left and right outer edges 46, 47.

[0039] The seat member 8 is preferably 5 inches wide. The rear member 5 is preferably 7+3 / 16 inches high, with the front member being almost 2 inches high. The space between the front member 4 and rear member 5 is preferably 1+7 / 8 inches wide. Six additional fastener openings 21 are preferably formed in the top 7 of the rear member 5 with the tallest fastener opening 0.5 inches below the top edge 43 of the rear member 5. The top 7 of the rear member 5 is preferably 2.75 inches wide. The left and right angled fastener openings 19 are preferably formed in the front member 4 0.5" to 1" from the left and right outer edges 46 and 47 of the lower portion 6 of the front member 4, and more specifically 0.813" from the center. The left and right angled fastener openings 19 are preferably formed in the front member 4 0.125" to 0.5" from the left and right outer edges 44 and 45 of the upper portion 13 of the rear member 5, and more specifically 0.313" from the center. The lower portion 6 of the front member 4 is preferably 1.5" high, and the overhanging lip flange extends approximately 0.5" from the upper edge 34 of the lower portion 6 of the front member 4. The angled fasteners 15 are preferably 3.5 inch long 025 inch diameter SDS screws manufactured by Simpson Strong-Tie Company, Inc. The angled fasteners 15 enter the supported member 2 and the support member 3 at an angle of 22.5 degrees relative to the front side 22 of the supported member 2 and the mounting surface 30 of the support member 3. The six additional fasteners 20 which pass through the rear member 5 and into the support member 3 are preferably ten or twelve penny size nails and the fastener openings 21 which receive them are of a similar diameter as the nails.

[0040] 8 and 11, the supported member or rung 2 is preferably a custom wood plank such as laminated plywood that is 1.75 inches wide by 9.6 inches high by 4' 3 inches wide, and two connectors 1 are used to attach the rung or supported member 2 to a header or support member 3. The support member or header 3 is also a custom wood piece that is 3.5 inches wide by 16 inches high.

[0041] The box section 48 is preferably formed with a cross plate 2, an opposite end plate 49, and side edge plates or stringers 50 arranged around the periphery of the box. Preferably, the cross plates 2 are connected to the opposing side edge plates 50, and the end plates 49 are also connected to the opposing side edge plates 50. The box section 48 is provided with a sole plate 51 connected to one or more of the cross plates 2, the opposite end plate 49, and the side edge plates 50. In the case of the stair box section 48, the side edge plates are made of stair stringers 50. As shown in Figures 8, 12 and 13, additional members or stringers 52 are placed between the outer stair stringers 50 to provide additional support. If the box section 48 were a flat member, the side edge plates 50 and the one or more additional members 52 would be normal straight joists. As shown in Figure 12, the staircase vertical members 50, 52 are preferably formed with a straight bottom surface 53, while the top surface 54 is notched to form a horizontal surface 55 which will act as a tread support surface, and a vertical surface 56 which will form a riser surface between the tread surfaces 55. As shown in Figure 12, treads 57 and risers 58 are provided. At the upper ends of the staircase vertical members 50, 52, the vertical members are cut to form a vertical rear surface 59 which will mate with or closely abut the rungs 2. At the lower ends of the staircase vertical members 50, 52, the vertical members are cut to form a downwardly facing horizontal surface 60 which can support the staircase box 48.

[0042] As shown in FIG. 8, the header 3 is significantly higher than the cross plate 2 .

[0043] As shown in Figures 8 and 12, the upper ends of the staircase stringers 50, 52 are connected to the rungs 2 by batten connectors 61. Preferably, the batten connectors 61 each have a back plate 62 that will mate with or closely abut the rear face 59 of the staircase stringers 50, 52. Fasteners are driven through the back plate 62 into the rungs 2. Connected to the back plate 62 are support plates 63 that mate with the bottom faces 53 of the staircase stringers 50, 52. Support fasteners 64, which may be nails, are driven through the support plates 63 into the bottom faces 53 of the stringers 50, 52. The batten connectors 61 may have an additional flange 65 connected to the back plate 62 and the support plate 63 that receives a connecting fastener 66, which may be a nail, further connecting the batten connectors 61 to the staircase stringers 50, 52.

[0044] 10, additional rung fasteners 67, preferably Simpson Strong-Drive SDS screws, are driven through supported member 2 into support member 3 at spaced intervals along the length of supported member 2. These rung fasteners 67 do not pass through connector 1.

[0045] 13, to effect the connection between the box 48 and the header 3, the first connector or connectors 1 are attached to the header 3 with additional fasteners 20 driven through the rear member 5 and into the header 3. Once the connector 1 is in place, the box 48 is lowered into place.

[0046] Preferably, the box section 48 is almost completely formed when lowered into place. The rungs 2, opposite end plates 49 and side edge plates or uprights 50 are all connected in a manner that secures them in place, and most of the box sections 48 are provided with rungs 51. Any additional members or uprights 52 are also attached to the box sections. According to a preferred method of installation, one or more top treads 57 and risers 58 are not attached to the stair box section 48 prior to installation. The box panel is then lowered into place with the rungs 2 received between the front member 4 and rear member 5, and the seat member 8 supporting the bottom surface 29 of the rungs 2. The installation tool then reaches through the uprights 50, 52 and drives the angled fasteners 15 through the front member 4 of the connector 1, through the supported member 2, and into the support member 3, preferably at a preferred upward angle of 22.5 degrees. Preferably, two angled fasteners 15 are used for each connector 1. For a typical stair box 48, two such connectors 1 would be used. An installation tool then drives a number of interlocking fasteners 66 through the rungs 2 and into the header 3. The missing tread or treads 57 and risers 58 are then attached to the uprights 50, 52. The bottom end of the stair box 48 may also be connected to a support member at its bottom end.

Claims

1. a. A supported member having a front surface and a rear surface that are substantially parallel to each other and spaced apart by a first selected distance, and also having an end surface that intersects the rear surface and the front surface of the supported member with its own front and rear side edges, and also having an upper surface and a bottom surface that intersect the front surface, the rear surface, and the end surface, b. A support member having a mounting surface, wherein the rear side surface of the supported member is in close proximity to the mounting surface, and the rear side surface of the supported member is in contact with or in close coordination with the mounting surface of the support member, c. A connector having a front member and a rear member connected to each other at their respective lower edges by a seating member, wherein the front member and the rear member extend upward from the seating member, the seating member supports the bottom surface of the supported member, the front member of the connector is in close proximity to the front side surface of the supported member, the rear member of the connector is in close proximity to the rear side surface of the supported member, the front member is formed having an upper part and a lower part, the rear member is formed having an upper part, a middle part and a lower part, the front member and the rear member have generally flat portions, and the seating member is generally flat. Furthermore, the rear member extends above the seating surface member and is significantly higher than the front member, and when the connector is attached to the support member, the front member and the rear member extend generally vertically, the seating surface member extends generally horizontally, the front member has substantially the same width as the seating surface member, the middle portion of the rear member is positioned above the lower portion in an upward direction from the seating surface member, the upper portion of the rear member is positioned above the middle portion, the lower portion of the rear member has substantially the same width as the seating surface member, and the upper portion of the rear member is narrower than the seating surface member and the front member, and the connector, d. At least two inclined fasteners that pass through the front member and the supported member of the connector and enter the support member to attach the connector and the supported member to the support member, wherein the at least two inclined fasteners that pass through the front member and the supported member of the connector and enter the support member are positioned at an acute upward angle with respect to the seating member and enter the support member near the upper part of the rear member without passing through the rear member and securing the upper part of the rear member, and A connecting portion between the supported member and the supporting member, comprising the above.

2. One or more additional fasteners pass through the rear member and enter the support member. The connecting portion according to claim 1.

3. The aforementioned front member is generally rectangular in shape. The connecting portion according to claim 1.

4. a. The intermediate portion of the rear member extends between the lower and upper parts, and its width narrows from the lower part to the upper part. The connecting portion according to claim 1.

5. The upper part of the rear member has a lower end, and the lower end of the upper part of the rear member, which is the contact surface between the intermediate part and the upper part, is positioned above the seating member at a distance equal to the height of the upper edge of the front member. The connecting portion according to claim 1.

6. The upper part of the front member is formed as an overhanging lip flange, the lower part of the front member is formed as a generally flat member, and the overhanging lip flange has an upper edge. The connecting portion according to claim 1.

7. The upper edge of the lower part of the front member is connected to the overhanging lip flange, and the overhanging lip flange extends outward, further away from the rear member than the generally flat lower part of the front member. The connecting portion according to claim 6.

8. The aforementioned protruding lip flange is a flat member that extends outward at a 45-degree angle to the generally flat lower part of the front member. The connecting portion according to claim 7.

9. The protruding lip flange is attached to the lower part of the front member at the bend line of the upper edge of the lower part of the front member. The connecting portion according to claim 8.

10. One or more fastening openings are provided in the front member. The connecting portion according to claim 9.

11. One or more gusset members are provided on the contact surface between the protruding lip flange and the lower part of the front member, extending between the protruding lip flange and the lower part of the front member. The connecting portion according to claim 10.

12. One or more of the gusset members have a generally flat fastener receiving member that extends outward at an angle of 22.5 degrees away from the generally flat lower part of the front member, and each fastener receiving member is formed to have at least one of the one or more fastener openings for receiving an inclined fastener. The connecting portion according to claim 11.

13. The fastener receiving member of the gusset is formed as a rectangular member having an upper edge, a lower edge, a right edge, and a left edge, the upper edge of the fastener receiving member is connected to the overhanging lip flange, and the lower edge of the fastener receiving member is connected to the lower part of the front member. The connecting portion according to claim 12.

14. One or more of the gussets are formed such that they have triangular left and right ends that connect the left and right edges of the generally flat fastener receiving member to the overhanging lip flange and the front member, respectively. The connecting portion according to claim 13.

15. The front member, the rear member, and the seating member are formed from metal, integrally joined together, and formed by bending steel plates to create the three-dimensional shape of the connector. The connecting portion according to claim 14.

16. a. The supported member is a horizontal plate, and the horizontal plate is part of a prefabricated member including additional members. b. The support member is a header. The connecting portion according to claim 1.

17. The aforementioned prefabricated component is a box section, which is formed having a horizontal board, a board at the opposite end, and a side edge board positioned around the periphery of the box section, and the box section is provided with a base plate material connected to the horizontal board, the board at the opposite end, and the side edge board. The connecting portion according to claim 16.

18. The box section is a staircase box section, and the side edge board is an inclined staircase vertical member formed with a notch on its own upper surface. The connecting portion according to claim 17.

19. The connecting portion according to claim 5, wherein the front member is a generally rectangular member.

20. a. The connecting portion according to claim 5, wherein the intermediate portion of the rear member extends between the lower part and the upper part, and its width narrows from the lower part to the upper part.

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