EP4638973A1

EP4638973A1 - A corner connector

Info

Publication number: EP4638973A1
Application number: EP23833868.5A
Authority: EP
Inventors: Tom Fletcher
Original assignee: Haefele UK Ltd
Current assignee: Haefele UK Ltd
Priority date: 2022-12-20
Filing date: 2023-12-20
Publication date: 2025-10-29
Also published as: GB202219252D0; GB2625554B; GB2625554A; WO2024134201A1

Abstract

A corner connector is provided for a frame assembly. The corner connector has a connector body with three connector walls aligned along mutually perpendicular planes relative to one another and connected along adjacent edges thereof. A first end cap mounting arrangement is configured to engage with a second end cap mounting arrangement of an end cap for mounting said end cap to the corner connector. First and second connector walls define a first free edge extending at least partially between the second and third connector walls and a second free edge extending at least partially between the first and third connector walls. Each of the connector walls define first, second and third external edges at the intersections therebetween. The first and second free edges and/or a first external connector edge comprises a recess, channel or groove thereon.

Description

A Corner Connector

FIELD

The present teachings relate to a corner connector for a frame assembly; an end cap for a frame; a frame assembly; and a kit of parts.

The present patent application claims priority of UK patent application No. 2219252.0 filed December 20, 2022. The content of UK patent application No. 2219252.0 is incorporated by reference and for all purposes.

BACKGROUND

Frame assemblies are often formed by connecting a series of frame members with a corner connector at each corner of the frame. Such frame assemblies may be used, for example, for a display unit or a table. The frame assemblies are commonly metallic frame assemblies, however polymeric frame members may also be used. It is known to assemble the frame by attaching elongate profiled beams to the corner connectors to create a rectangular frame. It is also known to attach an end cap at each of the corners to form a cover over the corner connector and improve the overall aesthetics of the frame. Typically, the end cap is a substantially cuboidal body defining an internal volume, and most of the internal volume is occupied by engagement feature for mounting the end cap to the corner connector and mounting the corner connector to the frame members. In these known frame assemblies, it can be difficult to pass cables, for example electrical cables, between adjacent elongate profiled beams.

The present teachings seek to overcome or at least mitigate one or more problems associated with the prior art.

SUMMARY

The present teachings provide a corner connector and an end cap according to the appended claims.

A first aspect of the teachings provides a corner connector for a frame assembly comprising three elongate profiled beams defining first ends thereof, a corner connector and an end cap, the corner connector comprising: a connector body comprising first, second and third connector walls aligned along mutually perpendicular planes relative to one another and connected along adjacent edges thereof; and a first end cap mounting arrangement configured to engage with a second end cap mounting arrangement of an end cap for mounting said end cap to the corner connector, wherein the first, second, and third connector walls each comprise a beam mounting arrangement configured to mount a first end of a respective elongate profiled beam to the connector body, wherein the first and second connector walls define a first free edge extending at least partially between the second and third connector walls and a second free edge extending at least partially between the first and third connector walls, respectively. The first and second free edges each comprise a recess, channel or groove thereon and/or the first external edge comprises a recess, channel or groove thereon.

Advantageously, the arrangement of the connector body with the profiled beams provides a compact and secure connection of the first and second profiled beams. The end cap mounting arrangement and the beam mounting arrangement improve ease of assembly whilst creating a compact connector. The recess, channel or groove on the first and second free edges and/or on the first external edge creates space between the respective connector wall and the profiled beam which and enables wiring to extend through the corner connector between two beams mounted to the connector.

The first and second free edges may each comprise a pair of spaced apart recesses, channels or grooves thereon.

Advantageously, providing the second recess, channel or groove creates additional space for additional cable routing.

The third connector wall may define a third free edge extending at least partially between the first and second connector walls, said third free edge comprising a recess, channel or groove thereon.

Advantageously, providing the recess, channel or groove creates additional space for cable routing, and creates space for wiring to extend from the third profiled beam through the corner connector.

The third free edge of the third connector wall may comprise a pair of spaced apart recesses, channels or grooves thereon. Advantageously, providing the second recess, channel or groove creates additional space for additional cable routing.

Each of the first, second and third connector walls may define a substantially planar external beam mounting face configured to abut against a respective first end of a profiled beam.

Advantageously, the planar beam mounting faces correspond to the planar first ends of the profiled beams, which simplifies the assembly of the corner connector to the profiled beam.

The first end cap mounting arrangement may comprise an aperture or recess on a connector wall configured to receive the second end cap mounting arrangement of the end cap.

Advantageously, the end cap mounting arrangement helps to ensure the correct positioning of the connector body relative to the end cap and holds the parts in place whilst the end cap is secured.

Advantageously, the female and projecting mounting arrangements help to ensure the end cap engages into position, and allows the user to insert and remove the end cap multiple times.

The female mounting member may be configured to provide a push-fit connection to the second end cap mounting arrangement of the end cap.

The aperture or recess may comprise at least one angled or tapered surface configured and arranged to retain the second end cap mounting arrangement of the end cap in the aperture or recess, in use.

Advantageously, the taper ensures the end cap engages into position and enables the end cap to be releasably mountable to the corner connector.

Each beam mounting arrangement may comprise a bore extending through a respective one of the first, second, and third connector walls.

Advantageously, the bore helps to fixedly secure the connector to the profiled beam, thereby improving the durability of the connection and helping to prevent the profiled beams from rotating relative to one another. Each bore may be located on a recessed region of an internal face of the respective connector wall.

Advantageously, the recessed section reduces the thickness of the connector walls around the bore, thereby creating additional space for cable routing.

The first, second and third connector walls may each define a thickness at the respective free edge thereof, and each free edge may comprise a region having a reduced thickness relative to the remainder of the free edge.

Advantageously, the region of reduced thickness at the edges of the walls creates additional space for cable routing.

Each recessed region may extend to the respective free edge to define the region of reduced thickness.

Advantageously, the recessed region extending to the free edge creates additional space at the first end of the profiled beams for wire routing.

The first, second and third connector walls may be configured and arranged to define three concurrent external connector edges at the intersections therebetween.

Each external connector edge may be substantially linear. Substantially linear in this context may include that the external connector edge has at least one linear portion or several colinear portions that constitute more than 80 percent of the length of the external connector edge.

The corner connector may comprise an alignment arrangement configured to align the corner connector with a first end of a profiled beam, in use.

Advantageously, the alignment feature helps to correctly align the corner connector with respect to the profiled beams, thereby simplifying the assembly process. The spacing between the beam mounting arrangement and the first and second edges aligns with the hollow profiles of the profiled beams.

The alignment arrangement may be spaced apart from the external edges defined between the first, second, and third connector walls. The alignment arrangement may comprise at least one alignment member projecting from an external beam mounting face of each of the first, second and third connector walls.

Additionally, this arrangement provides alignment of the first, second and third connector walls, thereby providing alignment in multiple directions and simplifying the manufacturing process.

Each alignment member may comprise at least one tapered or chamfered edge configured and arranged to align the corner connector with a first end of a respective profiled beam.

Advantageously, extended lugs ensure the corner connector fits easily and securely into position. This shape of lug enhances stability and stops adjacent profiled beams being able to rotate. The chamfer helps to aid positioning and are an exact fit to the internal routing of the profiled beam.

The corner connector may comprise or be formed from a polymeric material.

The polymeric material may be nylon.

Advantageously, a polymer is relatively low cost and readily available, thereby lowering manufacturing costs and complexity. Polymers are also relatively lightweight.

The polymeric material may comprise a reinforcement arrangement configured to increase the strength of the corner connector.

The reinforcement arrangement may comprise reinforcing glass fibres.

The corner connector may comprise, or be formed from, a metal or metallic alloy. The metal may be zinc. The corner connector may comprise or be formed from a zinc alloy. The zinc alloy may include any one, or any combination of, aluminium, copper and magnesium. Particularly, the zinc alloy may be an alloy of a zinc, aluminium, copper and magnesium or an alloy of a zinc, aluminium, and copper.

The adjacent edges of the first, second and third connector walls may meet at a common point. Advantageously, the reinforcing arrangement improves the strength properties of the corner connector, thereby reducing the likelihood of the corner connector failing and increasing the weight limit of the frame assembly.

A second aspect of the present teachings provides an end cap for a frame assembly comprising three elongate profiled beams defining fist ends thereof, a corner connector and an end cap, the end cap comprising: an end cap body comprising first, second and third cap walls aligned along mutually perpendicular planes relative to one another and connected along adjacent edges thereof; a second end cap mounting arrangement projecting from an internal face of the body to define an elongate length terminating at a distal end configured and arranged to engage a first end cap mounting arrangement of a corner connector for mounting the end cap to said corner connector; and at least one reinforcing rib extending between the end cap body and the second end cap mounting arrangement, wherein the at least one reinforcing rib terminates at a position away from the distal end of the projecting second end cap mounting arrangement.

Advantageously, the arrangement of the body with the profiled beams provides a compact and secure connection of the profiled beams. The end cap mounting arrangement improves ease of assembly whilst creating a compact bracket and creating the required space for cable routing. The ribs increase the structural strength of the end cap. The length of the ribs helps to create the required space for cable routing compared, for example, to a flange extending along the majority of the projecting second end cap mounting arrangement.

The at least one reinforcing rib may comprise a free edge extending at least partially between the body and the projection, said free edge comprising a recess, channel or groove thereon.

Advantageously, the spacing provided by the recess, channel or groove creates spacing and enables for wiring to extend around the frame assembly, for example to provide lighting around the frame assembly, thereby improving the overall aesthetics of the frame assembly.

The at least one reinforcing rib may comprise three reinforcing ribs.

Advantageously, the arrangement of three ribs provides the required support for the projecting second end cap mounting arrangement, whilst the recess, channel or groove provides the required spacing for cable routing. The three reinforcing ribs may be equally spaced around the second end cap mounting arrangement.

Advantageously, the spacing between the ribs provides support at different locations about the projecting second end cap mounting arrangement.

The at least one reinforcing rib may terminate at a position remote from the distal end of the second end cap mounting arrangement.

The at least one reinforcing rib may terminate at a position away from the distal end that is greater than a quarter of the elongate length of the second end cap mounting arrangement, for example greater than half of the elongate length of the second end cap mounting arrangement.

Advantageously, the location and length of the ribs helps to create the required space for cable routing compared, for example, to a flange extending along the majority of the projecting second end cap mounting arrangement.

The distal end of the second end cap mounting arrangement may comprise a resiliently deformable or deflectable portion.

Advantageously, this helps the removal and reattachment or the end cap to the corner connector.

The distal end of the second end cap mounting arrangement may comprise a tapered or angled surface configured and arranged to engage with the first end cap mounting arrangement of the corner connector.

Advantageously, the tapered surface corresponds to the tapered surface of the first end cap mounting arrangement.

At least one of the first, second and third end cap walls may comprise a frangible or weakened region.

Advantageously, the frangible or weaken region creates a position of exit for the cable and allows the cable system to be connected to an external power source. It is only necessary to remove the frangible or weakened region for applications where the corner connector benefits from having a position of exit for the cable. Otherwise, the frangible or weakened region can remain attached to the first, second and/or third connector wall. This helps to reduce unnecessary gaps, and improves the overall aesthetics of the corner. The first, second and third cap walls may be configured and arranged to define three concurrent external end cap edges at the intersections therebetween.

Each external end cap edge may be substantially linear.

The end cap may comprise a polymeric material.

The polymeric material may be nylon.

The adjacent edges of the first, second and third cap walls may meet at a common point.

A third aspect of the present teachings provides a frame assembly comprising: a corner connector according to the first aspect; first, second, and third elongate profiled beams defining first ends thereof, said first ends mounted to the first, second, and third connector walls, respectively; and an end cap according to the second aspect mounted, e.g. releasably mounted, to the corner connector.

A fourth aspect of the present teachings provides a kit of parts comprising: a corner connector according to the first aspect; and an end cap according to the second aspect.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will now be described with reference to the accompanying drawings, in which:

Figure 1 is an exploded isometric view of a frame assembly according to an embodiment of the present teachings;

Figure 2 is an isometric view of a corner of the frame assembly of Figure 1;

Figure 3 is a first isometric view of a corner connector of the frame assembly of Figure 1;

Figure 4 is a second isometric view of the corner connector of Figure 3;

Figure 5 is an isometric view of an end cap of the frame assembly of Figure 1;

Figure 6 is an isometric view of a corner connector of the frame assembly of Figure 1; Figure 7 is a side view of the corner connector of Figure 6; and

Figure 8 is an isometric view of a corner connector of the frame assembly of Figure 1.

DETAILED DESCRIPTION OF EMBODIMENT(S)

Referring firstly to Figure 1, a frame assembly generally indicated at 10 is shown. The frame assembly 10 is suitable for a range of applications, for example as a display unit or as a table. The frame assembly 10 is made up of a series of elongate profiled beams 12a-l. The elongate profiled beams 12a-l each define opposing ends thereof (i.e. each beam defines a first end and a second end). In the illustrated embodiment, the twelve profiled beams make up a substantially rectangular frame assembly 10. The substantially rectangular frame assembly 10 includes eight corner assemblies 14. It shall be appreciated that in alternative embodiments, any number of profiled beams may be used to construct the frame assembly 10 depending on the required shape and/or size of the frame assembly 10. The frame assembly 10 may support a pane or panel (not shown), such as a pane of glass, a panel of wood, aluminium or another suitable material. The frame assembly 10 is a metallic frame, i.e. a frame having profiled beams 12a-l that are at least in part metallic. A metallic frame as described here may include features or components of some non-metallic or composite material, such as polymer material. In particular, the frame may comprise non-metallic materials at the corner assemblies 14-d. In alternative embodiments, the frame assembly 10 may be a polymeric frame assembly. Each corner assembly 14 includes a corner connector 16. Each corner connector 16 has three profiled beams 12a-l mounted thereto. An end cap (not shown) is mounted to the corner connector 16 so as to cover the corner assembly.

Referring to Figure 2, the profiled beams 12a-l each include at least one hollow profile 13 extending along an elongate length of each of the profiled beams 12a-l. Put another way, the profiled beams 12a-l each define a recess or channel extending along the elongate length thereof. In this embodiment, each profiled beam 12a-l includes two hollow profiles 13. It shall be appreciated that in alternative embodiments, any suitable number of hollow profiles may be used. In the arrangement shown, the frame assembly 10 is provided with a lighting system. As illustrated in Figure 2, the lighting system may include LED strips located in a hollow profile 13 of an elongate beam 12a-l. In order to power the lighting system, cabling is routed inside the profiled beams 12a-l and through the corner assemblies 14 to extend between adjacent profiled beams. It shall be appreciated that although in this embodiment a lighting system is provided, the cabling may be used to power any suitable device.

It shall be appreciated that in this embodiment, each corner assembly 14 are of substantially the same configuration. Therefore for reasons of conciseness and brevity, only a single corner assembly 14 will be described hereafter. Three profiled beams 12a-c are mounted to the corner connector 16. The corner connector 16 connect the profiled beams 12 at the corner 14.

Referring to Figures 3 and 4, the corner connector 16 is illustrated in more detail.

The corner connector 16 includes a connector body 20. The connector body 20 includes a polymeric material. In this embodiment, the polymeric material is nylon, however any suitable polymer may be used. The polymeric material may include a reinforcement arrangement configured to increase the strength of the corner connector 16. The reinforcement arrangement may include glass fibres, by way of example.

In some embodiments, the corner connector 16 may include, or be formed from, a metal or metallic alloy. In some embodiments, the metal may be zinc. In other embodiments, the corner connector 16 may be formed from a zinc alloy. The zinc alloy may include any one, or any combination of, aluminium, copper and magnesium. In one embodiment, the corner connector 16 is formed from an alloy of a zinc, aluminium, copper and magnesium. In another embodiment, the corner connector 16 is formed from an alloy of a zinc, aluminium, and copper.

The connector body 20 includes first, second and third connector walls 26a-c arranged transverse relative to each other and connected along adjacent edges 28a-c thereof. In some embodiments, the first, second and third connector walls 26a-c are arranged so as to be perpendicular to each other, but in other embodiments the walls 26a-c may be arranged at different angles to each other. The first, second and third connector walls 26a-c are configured and arranged to define three external edges 28a-c at the intersections therebetween. Each external edge 28a-c is substantially linear. The three external edges 28a-c meet at a corner. Put another way, the first, second and third connector walls 26 are configured and arranged to define three concurrent external connector edges 28a-c at the intersections therebetween. In the present embodiment, the connector walls 26a-c are of substantially the same configuration. Therefore, only the first connector wall 26a and the associated features are labelled in Figures 3 and 4. It shall be appreciated that in alternative embodiments, the features of the first, second and/or third connector wall may differ.

Each of the first, second and third connector walls 26a-c include an external beam mounting face 30 and an internal, e.g. end cap mounting, face 32. The external edges 28a-c are located on the external beam mounting faces 30. The external beam mounting faces 30 abut against the first ends of the first, second and third profiled beams 12 respectively. The first ends of each of the first second and third profiled beams 12 are substantially planar. The external beam mounting faces 30 of the first second and third connector walls 26a-c are substantially planar. The corresponding planar surfaces of the ends of the profiled beams 12 and the external beam mounting faces 30 improves assembly of the corner assembly 14 and creates a compact corner assembly 14.

The first and second connector walls 26a, 26b define a free edge 34a, 34b extending at least partially between the second and third connector walls 26b, 26c and the first and third connector walls 26a, 26c respectively. Each of the first, second and third free edges 34a-c includes a recess, channel or groove thereon 36a. In this embodiment, the third connector wall 26c also defines a free edge extending at least partially between the first and second connector walls 26a, 26b and including a recess, channel or groove thereon. In the embodiment, the free edges 34a-c extend between the other two connector walls.

The free edges 34a-c comprise a substantially arcuate profile extending between the respective other two connector walls 26a-c. The recess 36a in this embodiment is a deviation in profile of the arcuate free edge 34a-c. In alternative embodiment, any suitable shape of recess, channel or groove may be provided, such as a rectangular channel or a V-shaped groove. In this embodiment, each free edge 34a-c further defines a second recess, groove or channel 36b thereon. The second recesses 36b are of substantially the same configuration to the first recesses 36a. It shall be appreciated that in alternative embodiments, the second recesses 36b may be omitted The first recesses 36a and the second recesses 36b are located symmetrically on the free edges 34a-c. Put another way, the first recesses 36a are spaced apart from the respective first, second and third edges 28a-c the same distance as the second recesses 36b from the respective first, second and third edges 28a-c.

The recesses 36a, 36b align with the hollow profiles 13 of the profiled beams so as to create a space between the free edge 34a-c and the end of the hollow profile 13 to enable wiring to pass therebetween to extend around the frame assembly. The first and second walls 26a, 26b each define a thickness at the respective free edge 34a, 34b thereof, and each free edge 34a, 34b includes a region having a reduced thickness relative to the remainder of the free edge 34a, 34b. As illustrated in Figure 4, in this embodiment the region of thinner thickness on the first connector wall 26a extends partially over each of the recesses 36a, 36b. The region of thinner thickness of the second and third connector walls 26b, 26c extends over one of the recesses. It shall be appreciated that the region of thinner thickness may extend over any portion of the free edges.

The corner connector includes a first end cap mounting arrangement 22 configured to engage with a second end cap mounting arrangement of an end cap for mounting said end cap to the corner connector. The first end cap mounting arrangement 22 is configured to engage with a second end cap mounting arrangement 50 of the end cap 18 for mounting the end cap 18 to the corner connector 16.

In this embodiment, the first end cap mounting arrangement 22 includes a female mounting arrangement 22 configured to engage with the second end cap mounting arrangement 50 of the end cap 18. The female mounting arrangement 22 includes an aperture or recess on one of the first, second or third connector walls 26a-c. In this embodiment, an aperture 22 is provided.

The aperture 22 extends through the entirety of the first connector wall 26a. It shall be appreciated that in alternative embodiments, the first end cap mounting arrangement 22 may be located on any of the first, second or third connector walls 26a-c. The female mounting arrangement 22 includes at least one tapered surface 23. The tapered surface 23 corresponds to the shape of the second end cap mounting arrangement 50, as will be described in more detail below. The tapered surface 23 extends from the end cap mounting face 32 to the external beam mounting face 30 such that the cross-section area of the aperture 22 increase from the end cap mounting face 32 to the external beam mounting face 30. It will be appreciated that the female mounting member is configured to provide a push-fit connection to the second end cap mounting arrangement of the end cap. The corner connector includes a beam mounting arrangement 24. The beam mounting arrangement 24 is configured to mount the first end of the respective elongate profiled beam 12 to the connector body 20. Put another way, the first, second, and third connector walls 26a-c each comprise a beam mounting arrangement configured to mount a first end of a respective elongate profiled beam to the connector body. Each beam mounting arrangement 24 includes a bore 24 extending through each of the first, second and third connector walls 26a-c. The bores 24 are each located equidistant between the respective first, second and third external edges 28a-c.

When the corner connector 16 is in an assembled state, a fastener 40 is located in each of the bores 24. The bores 24 fixedly secure the corner connector 16 to the profiled beam, thereby improving the durability of the connection and helping to prevent the profiled beams 12a-c from rotating relative to one another. It shall be appreciated that in embodiments with only first and second profiled beams 12a, 12b, a bore may be provided on only two of the connector walls 26a, 26b.

The bores 24 are located on a recessed region 38 of an internal face of the corner connector, i.e. the end cap mounting face 32 of the respective first, second and/or third connector wall 26a-c. The recessed region 38 extends in the direction parallel to a respective longitudinal axis of the respective profiled beam 12a-c. The recessed region 38 on the internal face of the respective connector wall 26a-c extends to the free edge 34a-c to define the region of thinner thickness of the free edge 34a-c. In this embodiment, the bores 24 are located on the planar cap mounting faces 32 of the connector walls 26a-c. Put another way, the bores 24 are not countersunk. This helps to overcome any issues when the corner connector 16 is being mounted to the profiled beams 12a-c.

In this embodiment, the corner connector 16 includes an alignment arrangement 46a, 46b configured to align the profiled beams 12a-c with respect to the corner connector 16 in a direction perpendicular to the respective longitudinal axis of the profiled beams 12a-c. It shall be appreciated that in alternative embodiments, the alignment arrangement 46a, 46b may be omitted. An entirety of the alignment arrangement 46a, 46b is spaced apart from the first, second and/or third intersecting (or external) edge 28a-c such that a space is defined between the alignment arrangement 46a, 46b and the first, second and/or third external edges 28a-c. The spacing creates additional space within the corner connector 16 for cable routing. In the embodiment of Figures 1 to 4, the alignment arrangement 46a, 46b includes one or more alignment members 46a, 46b, in this embodiment six alignment members 46a, 46b. The alignment members 46a, 46b are located on all of the first, second and third connector walls 26a-c. The alignment members 46a, 46b projecting from an external beam mounting face of each of the first, second and third connector walls. As illustrated in Figure 3, the alignment members 46a, 46b are arranged in pairs on all of the first, second and third connector walls 26a, 26b. In alternative embodiments, any suitable number of alignment members may b provided on each connect wall, such as one, three, four or more alignment members.

For each of the first, second and third connector walls 26a-c, one of the alignment members 46a is located adjacent the first recess 36a and one of the alignment members 46b is located adjacent the second recess 36b. Each of the alignment members 46a, 46b are located equidistant from the closest external edge 28a-c. The location of the alignment members 46a, 46b and the spacing from the external edges 28a-c axially aligns with the hollow profiles 13 of the profiled beams 12a-c such that the hollow profiles 13 are correctly alignment with respect to the corner connector 16.

The one or more alignment members 46a, 46b are lugs 46a, 46b projecting from the external beam mounting face of the respective connector wall 26a-c. Each lug 46a, 46b defines a width configured to extend in a direction perpendicular to the respective longitudinal axis of each of the profiled beams 12a-c with which it engages, and a length configured to extend in a direction parallel to the respective longitudinal axis of the profiled beam with which it engages. The length of the lug 46a, 46b is greater than the width of the lug 46a, 46b. This shape of lug enhances stability and stops adjacent profiled beams 12a-c being able to rotate.

In this embodiment, each alignment member, e.g. lug, includes a tapered or chamfered edge 48a, 48b configured to align the corner connector with a respective profiled beam 12a-c in the direction perpendicular to the longitudinal axes of the profiled beams 12a-c. The chamfer 48a, 48b helps to aid positioning of the profiled beams 12a-c and the shape corresponds to the hollow profiles of the profiled beams 12a-c. It shall be appreciated that in alternative embodiments, the shape of the alignment members 46a, 46b may be modified depending on the shape of the hollow profiles. Similarly, the location and number of alignment members 46a, 46b may vary depending on how many hollow profiles are provided and the location of the hollow profiles.

Referring to Figure 5, an end cap 18 of the frame assembly 10 is illustrated.

The end cap 18 includes an end cap body 50. The end cap body 50 includes a polymeric material. In this embodiment, the polymeric material is nylon, however any suitable polymer or material may be used. The polymeric material may include a reinforcement arrangement configured to increase the strength of the end cap 18. The reinforcement arrangement may include glass fibres, by way of example.

In some embodiments, the end cap 18 may include, or be formed from, a metal or metallic alloy. In some embodiments, the metal may be zinc. In other embodiments, the end cap 18 may be formed from a zinc alloy. The zinc alloy may include any one, or any combination of, aluminium, copper and magnesium. In one embodiment, the end cap 18 is formed from an alloy of a zinc, aluminium, copper and magnesium. In another embodiment, the end cap 18 is formed from an alloy of a zinc, aluminium, and copper.

The end cap body 50 includes first, second and third end cap walls 54a-c arranged transverse, e.g. substantially perpendicularly, to each other and connected long adjacent edges 56a-c thereof. The adjacent edges 56a-c are substantially linear. The three external edges meet at a corner. Put another way, the first, second and third connector walls 26a-c are configured and arranged to define three concurrent external connector edges 28a-c at the intersections therebetween.

The first, second and third end cap walls 54a-c are substantially rectangular. This creates a substantially cuboidal end cap 18 which when mounting to the corner connector creates a corner with improved aesthetics. The body 50 includes a hollow internal volume defined by the first, second and third end cap walls 54a-c The first, second and third end cap walls 54a-c are substantially planar. In this embodiment, the first, second and third connector walls 54a-c are of substantially the same configuration, however it shall be appreciated that in alternative embodiments, the features of the first, second and third end cap walls 54a-c may differ from one another.

The end cap 18 includes a second end cap mounting arrangement 52 projecting from an internal face of the body 50 to define an elongate length terminating at a distal end configured and arranged to engage a first end cap mounting arrangement of a corner connector for mounting the end cap to said corner connector. It shall be appreciated that in alternative embodiments, the configuration of the first and second end cap mounting arrangements 22, 52 may be reversed such that the first end cap mounting arrangement is a projecting first end cap mounting arrangement and the second end cap mounting arrangement is a female second end cap mounting arrangement.

The end cap 18 includes at least one reinforcing rib 58 extending between the end cap body and the second end cap mounting arrangement. In some embodiments, three reinforcing ribs 58a-c are provided. The three reinforcing ribs are equally spaced around the second end cap mounting arrangement. Each of the first, second and third reinforcing ribs 58a-c extends between the respective first second or third connector walls 54a-c and the projecting second end cap mounting arrangement 52. It shall be appreciated that in alternative embodiments, any suitable number of reinforcing ribs may be provided, for example one, two, four or more reinforcing ribs may be provided.

The reinforcing ribs 58a-c each include a free edge 60a-c extending at least partially between the end cap body 50 and the projecting second end cap mounting arrangement 52. The or each reinforcing rib terminates at a position away from the distal end of the projecting second end cap mounting arrangement. Each reinforcing rib terminates at a position remote from the distal end of the second end cap mounting arrangement. Each reinforcing rib terminates at a position away from the distal end that is greater than a quarter of the elongate length of the second end cap mounting arrangement, for example greater than half of the elongate length of the second end cap mounting arrangement. This helps to maximise the space for cabling whilst providing reinforcement to the projecting second end cap mounting arrangement 52.

The free edges 60a-c each include a recess, channel or groove thereon 62a-c. In this embodiment, a recess 62a-c is provided, and the spacing provided by the recess 62a-c enables for wiring to extend around the frame assembly 10. The recess 62a-c includes a deviation in profile. It shall be appreciated that in alternative embodiments, the recess, channel or groove may include any suitable shape for receiving a wire therein. The recess 62a-c may extend along any proportion of the free edge 60a-c. In the embodiment of Figure 5, the recess 62a-c extends along the entirety of the free edge 60a-c. The first, second and third reinforcing ribs 58a-c are spaced around the projecting second end cap mounting arrangement 52. In the embodiment of Figure 5, the first, second and third ribs 58a-c are equidistant about the projecting second end cap mounting arrangement 52. This provides stability to the projecting second end cap arrangement 52 during assembly and in use.

The projecting second end cap mounting arrangement 52 extends within the internal volume defined by the end cap body 50. The projecting second end cap mounting arrangement 52 is a column 52. The projecting second end cap mounting arrangement 52 of this embodiment is substantially linear. The projecting second end cap mounting arrangement 52 defines an elongate length and a distal end 64 remote from the end cap body 50.

The distal end of the second end cap mounting arrangement may include a tapered or angled surface configured and arranged to engage with the first end cap mounting arrangement of the corner connector. In some arrangements, the distal end 64 of the projecting second end cap mounting arrangement 52 is resiliently deformable or deflectable. The resiliently deformable portion is configured to deform when the end cap 18 is mounted to the corner connector 16. This aids the removal and reattachment of the end cap 18 to the corner connector 16. The resiliently deformable end 64 includes a tapered surface 65 configured to engage with the first end cap mounting arrangement 22. The tapered surface 65 of the projecting second end cap mounting arrangement 52 corresponds to the tapered surface 23 of the first end cap mounting arrangement 22, therefore helping to create a secure connection between the corner connector 16 and the end cap 18. It shall be appreciated that the shape of the end cap 18 may take any suitable form.

In the embodiment of Figure 5, the distal end 64 of the projecting second end cap mounting arrangement 52 is a bulbous end 64. A cross-section area of the projecting second end cap mounting arrangement 52 therefore increases towards the distal end 64. In the embodiment of Figure 5, the bulbous end 64 includes splices for improving the precision of location of the projecting second end cap mounting arrangement 52 and, in combination with the bulbous end 64, enables the end cap 18 to pull into the corner connector 16 and reduces gaps or movement when the end cap 18 is in position.

It shall be appreciated that in alternative embodiments, any suitable engagement arrangement may be used to mount the end cap 16 to the corner connector. The end cap 18 also includes at least one frangible or weakened region 66a-f. In the embodiment of Figure 5, two frangible regions 66a-f are provided on each of the first, second and third end cap walls 54a-c. It shall be appreciated that on alternative embodiments, any suitable number of frangible or weakened regions may be provided at any location on the connector walls 54a-c, or the frangible or weakened regions may be omitted.

The frangible regions 66a-f may be removed from the end cap body 50 when the user applies a force to the frangible regions 66a-f. When the frangible regions 66a- f are removed, openings may be provided in the end cap walls 54a-c. The openings are advantageous because they enable cabling to exit the corner assembly 14 and connect, for example, to an external source of power. However, such openings may not be required on all of the connector walls 54a-c, nor at all of the corner assemblies 14. Providing removeable frangible regions 66a-f therefore prevents unnecessary openings into which debris may enter the corner assembly 14, and improves the aesthetics of the corner assembly 14.

A method of assembling the corner assembly 14 shall be described hereafter. The first, second and third profiled beams 12a-c are located on the first, second and third connector walls 26a-c respectively such that the alignment members 48a, 48b are located within the respective hollow profile 13 of the profiled beams 12a-c. The fasteners 40 are screwed into the bores 24 such that a thread is formed on the bores 24. The fasteners 40 are screwed to fixedly secure the corner connector 16 to the profiled beams 12a-c.

The cabling is routed around the frame assembly 10 according to the requirements of the frame assembly 10 prior to mounting the end cap 18 to the corner connector 16. The end cap 16 is provided, and the frangible regions 66a-f may be removed depending on the application of the end cap 16. The projecting second end cap mounting arrangement 52 is located in the first end cap mounting arrangement 22 and pushed in such that the bulbous end 64 engages with the tapered surface 23. This removably fastens the end cap 16 to the corner connector 18.

Referring now to Figures 6 and 7, there is provided an alternative embodiment of a corner connector 16 according to the present teachings. It shall be appreciated that the teachings of Figures 6 and 7 may be combined with the corner connector 16 of Figures 1 to 5, and vice versa. Only differences between the embodiments of Figures 3 and 4 and of Figures 6 and 7 are discussed. In this embodiment, the connector walls 26a-c include a reinforcement arrangement 29a-c configured to increase the structural strength of the corner connector 16. The reinforcement arrangement 29a-c may be located at the intersections between the side walls 26a-c. The reinforcement arrangement 29a-c comprises reinforcing ribs 29a-c extending along the length of the respective intersecting internal edges of the corner connector 16. Each rib 29a-c extends between respective adjacent connector walls 26a-c. Each rib 29a-c may be substantially planar, for example to define a substantially flat angled rib wall extending between adjacent side walls 26a-c. The rib 29a-c defines an acute angle with each of the respective adjacent connector walls 26a-c. The acute angle may be in the range 15° to 75°, for example in the range 30° to 60°, optionally 45°. In alternative embodiments, each rib may define a substantially curved surface. Although in the embodiment of Figures 6 and 7 a reinforcing rib 29a-c is provided on each of the external edges 28a-c, it shall be appreciated that in some embodiments, only one or two of the external edges 28a-c may include a rib 29a- c, or the ribs 29a-c may be omitted.

As discussed above in relation to Figures 3 and 4, the corner connector 16 may include alignment features 46a, 46b having a respective tapered or chamfered edge 48a, 48b. As illustrated in Figure 7, each alignment feature 46a, 46b may include a second tapered or chamfered portion. Each alignment feature 46a, 46b may include further chamfered or tapered edge 49a, 49b configured to align the corner connector 16 with a respective profiled beam 12a-c. Put another way, each alignment feature 46a, 46b may taper in a direction towards the respective chamfered edge 48a, 48b. The second chamfered surface 49a, 49b helps to aid positioning of the profile beams 12a-c, and the shape corresponds to the hollow profiles of the profiled beam 12a-c. It shall be appreciated that in some embodiments, the second chamfered surface 49a, 49b may be omitted, any alternative shape of alignment feature may be used. Particularly, the second chamfered surface 49a, 49b is formed in a way that the alignment features 46a, 46b may taper in a direction away from the respective connector wall 26a-c.

Referring now to Figure 8, there is provided an alternative embodiment of a corner connector 16 according to the present teachings. It shall be appreciated that the teachings of Figure 8 may be combined with the corner connector of Figures 1 to 5 and/or with the corner connector of Figures 6 and 7, and vice versa. Only differences between the embodiment of Figure 8 and the embodiment of Figures 3 and 4 are discussed. In this embodiment, one or more of the external edges 28a-c may include a recess, channel or groove 37a-c located thereon. The recess, channel or groove 37a-c on the external edge 28a-c creates space between the respective connector wall 26a- c and the profiled beam which enables wiring to extend through the corner connector 16 between two beams 12a-c mounted to the corner connector 16. The recess, channel or groove 37a-c may be included in addition or as an alternative to the recess, groove or channel 36a, 36b of the free edge 34a-c. In the illustrated embodiment, the external edges 28a-c are provided with a channel or aperture 37a-c that extends through each of the connector walls 26a-c, for example through the external edge 28a-c of each of the connector walls 26a-c. In some embodiments, the channel or aperture 37a-c may be arranged at or adjacent to the respective external edge 28a-c. The channel 37a-c may be any suitable shape, for example substantially rectangular in cross-section, substantially curved, oval, circular etc. In embodiments including the reinforcing ribs 29a-c (see Figures 6 and 7), the channel 37a-c of the respective external edge 28a-c may extend at least partially through the respective reinforcing rib 29a-c. In some embodiments, the external edges 28a-c may include more than one recess, channel or groove 37a-c. It shall be appreciated that any combination of recesses, channels or grooves may be used on any one or any combination of the free edges 34a-c and the external edges 28a-c.

Although not illustrated, in some embodiments, the corner connector may define a channel extending through a portion of the corner connector 16 for enabling wiring to pass therethrough. The internal channel may extend between a pair of recesses, channels or grooves 37a-c located on the external edges of the corner connector 16. Particularly, the internal channel may extend between a recess, channel or groove 37a on the first external edge 28a to a recess, channel or groove 37b on the second external edge 28b. This internal channel may particularly extend through the corner of the corner connector 16 formed by the intersection of the first, second and third connector walls 26a-c.

Although the teachings have been described above with reference to one or more preferred embodiments, it will be appreciated that various changes or modifications may be made without departing from the scope as defined in the appended claims.

Claims

1. A corner connector (16) for a frame assembly (10) comprising three elongate profiled beams (12a-c) defining first ends thereof, a corner connector (16) and an end cap (18), the corner connector (16) comprising: a connector body (20) comprising first, second and third connector walls (26a-c) aligned along mutually perpendicular planes relative to one another and connected along adjacent edges (28a-c) thereof; and a first end cap mounting arrangement (22) configured to engage with a second end cap mounting arrangement (52) of an end cap (18) for mounting said end cap (18) to the corner connector (16), wherein the first, second, and third connector walls (26a-c) each comprise a beam mounting arrangement (24) configured to mount a first end of a respective elongate profiled beam (12a-c) to the connector body (20), wherein the first and second connector walls (26a-c) define a first free edge (34a) extending at least partially between the second and third connector walls (26b, 26c) and a second free edge (34b) extending at least partially between the first and third connector walls (26a, 26c), respectively, wherein each of the connector walls (26a-c) define first, second and third external edges (28a-c) at the intersections therebetween, and wherein the first and second free edges (34a, 34b) each comprise a recess, channel or groove (36, 37) thereon and/or a first external connector edge (28a) comprises a recess, channel or groove (36, 37) thereon.

2. The corner connector (16) according to claim 1, wherein the first and second free edges (34a, 34b) each comprise a pair of spaced apart recesses (36a, 36b), channels or grooves thereon.

3. The corner connector (16) according to claim 1 or claim 2, wherein the third connector wall (26c) defines a third free edge (34c) extending at least partially between the first and second connector walls (26b, 26c), said third free edge (34c) comprising a recess, channel or groove (36) thereon, optionally wherein the third free edge (34c) of the third connector wall (26c) comprises a pair of spaced apart recesses (36a, 36b), channels or grooves thereon.

4. The corner connector (16) according to any preceding claim, wherein each of the first, second and third connector walls (26a-c) defines a substantially planar external beam mounting face (30) configured to abut against a respective first end of a profiled beam (12a-c).

5. The corner connector (16) according to any preceding claim, wherein the first end cap mounting arrangement (22) comprises an aperture (22) or recess on a connector wall (26a-c) configured to receive the second end cap mounting arrangement (52) of the end cap (18).

6. The corner connector (16) according to claim 5, wherein a female mounting member (22) is configured to provide a push-fit connection to the second end cap mounting arrangement (52) of the end cap (18).

7. The corner connector (16) according to claim 6, wherein the aperture (22) or recess comprises at least one angled or tapered surface configured and arranged to retain the second end cap mounting arrangement (52) of the end cap (18) in the aperture (22) or recess, in use.

8. The corner connector (16) according to any preceding claim, wherein each beam mounting arrangement (24) comprises a bore (24) extending through a respective one of the first, second, and third connector walls (26a-c).

9. The corner connector (16) according to claim 8, wherein each bore (24) is located on a recessed region (38) of an internal face of the respective connector wall (26a-c).

10. The corner connector (16) according to any preceding claim, wherein the first, second and third connector walls (26a-c) each define a thickness at the respective free edge (34a-c) thereof, and wherein each free edge (34a-c) comprises a region having a reduced thickness relative to the remainder of the free edge (34a-c).

11. The corner connector (16) according to claim 10 when dependent on claim 9, wherein each recessed region extends to the respective free edge (34a- c) to define the region of reduced thickness.

12. The corner connector (16) according to any preceding claim, wherein the adjacent edges (28a-c) of the first, second and third connector walls (26a- c) meet at a common point.

13. The corner connector (16) according to claim 12, wherein each external connector edge (28a-c) is substantially linear.

14. The corner connector (16) according to any preceding claim, comprising an alignment arrangement (46a, 46b) configured to align the corner connector (16) with a first end of a profiled beam (12a-c), in use, optionally wherein the alignment arrangement (46a, 46b) comprises at least one alignment member (48a, 48b) projecting from an external beam mounting face (30) of each of the first, second and third connector walls (26a-c).

15. The corner connector (16) according to claim 14, wherein each alignment member (46a, 46b) comprises at least one tapered or chamfered edge (48a, 48b) configured and arranged to align the corner connector (16) with a first end of a respective profiled beam (12a-c).

16. The corner connector (16) according to any preceding claim, wherein the first external edge (28a) comprises a channel (37) extending therethrough.

17. The corner connector (16) according to any preceding claim, wherein the corner connector (16) comprises a reinforcement arrangement (29) configured to provide structural reinforcement to the corner connector (16).

18. The corner connector (16) according to claim 17, wherein the reinforcement arrangement (29) comprises at least one reinforcing rib (29a-c), optionally wherein the reinforcing rib (29a-c) extends along a length of the respective first, second or third external edge (28a-c).

19. The corner connector (16) according to any preceding claim, wherein the corner connector (16) includes, or is formed from, a metal or metallic alloy and/or a polymeric material, optionally wherein the corner connector (16) is formed from a zinc alloy and/or nylon.

20. An end cap (18) for a frame assembly (10) comprising three elongate profiled beams (12a-c) defining fist ends thereof, a corner connector (16) and an end cap (18), the end cap (18) comprising: an end cap body (50) comprising first, second and third cap walls (54a-c) aligned along mutually perpendicular planes relative to one another and connected along adjacent edges (56a-c) thereof; a second end cap mounting arrangement (52) projecting from an internal face of the body (50) to define an elongate length terminating at a distal end (64) configured and arranged to engage a first end cap mounting arrangement (22) of a corner connector (16) for mounting the end cap (18) to said corner connector (16); and at least one reinforcing rib (58a-c) extending between the end cap body and the second end cap mounting arrangement (52), wherein the at least one reinforcing rib (58a-c) terminates at a position away from the distal end (64) of the projecting second end cap mounting arrangement (52).

21. The end cap (18) according to claim 20, wherein the at least one reinforcing rib (58a-c) comprises a free edge (60a-c) extending at least partially between the body (50) and the projection, said free edge (60a-c) comprising a recess, channel or groove (62a-c) thereon.

22. The end cap (18) according to claim 20 or claim 21, wherein the at least one reinforcing rib (58a-c) comprises three reinforcing ribs (58a-c) equally spaced around the second end cap mounting arrangement (52).

23. The end cap (18) according to any one of claims 20 to 22, wherein the at least one reinforcing rib (58a-c) terminates at a position remote from the distal end (64) of the second end cap mounting arrangement (52).

24. The end cap (18) according to claim 23, wherein the at least one reinforcing rib (58a-c) terminates at a position away from the distal end (64) that is greater than a quarter of the elongate length of the second end cap mounting arrangement (52), for example greater than half of the elongate length of the second end cap mounting arrangement (52).

25. The end cap (18) according to any one of claims 20 to 24, wherein the distal end (64) of the second end cap mounting arrangement (52) comprises a resiliently deformable or deflectable portion.

26. The end cap (18) according to any one of claims 20 to 25, wherein the distal end (64) of the second end cap mounting arrangement (52) comprises a tapered or angled surface configured and arranged to engage with the first end cap mounting arrangement (22) of the corner connector (16).

27. The end cap (18) according to any one of claims 20 to 26, wherein at least one of the first, second and third end cap walls (54a-c) comprises a frangible or weakened region (66a-f).

28. The end cap (18) according to any one of claims 20 to 27 , wherein the first, second and third cap walls (54a-c) are configured and arranged to define three concurrent external end cap edges at the intersections therebetween, optionally wherein the adjacent edges of the first, second and third cap walls (54a-c) meet at a common point.

29. A frame assembly (10) comprising: a corner connector (16) according to any one of claim 1 to claim 19; first, second, and third elongate profiled beams (12a-c) defining first ends thereof, said first ends mounted to the first, second, and third connector walls (26a-c), respectively; and an end cap (18) according to any one of claims 20 to 28 mounted, e.g. releasably mounted, to the corner connector(16).