NZ529593A - A coupling - Google Patents

Abstract

A coupling for purlin to rafter or girt to upright. The coupling comprising a rafter/ upright member adapted for selective location along the rafter or upright. A purlin/girt fixture is connected to the rafter /upright member, the purlin/girt fixture being adapted for securing to or locating on the end of the purlin or girt. Flange means projecting from the end of the purlin/girt fixture enables the connection of the purlin/girt remote end to the rafter or upright.

Description

529 5 9 3 PATENTS FORM NO. 5 Fee No. 4: $250.00 PATENTS ACT 1953 COMPLETE SPECIFICATION A COUPLING WE ONESTEEL TRADING PTY LIMITED, an Australian company of Level 23, 1 York Street, Sydney, New South Wales 2000, AUSTRALIA hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: /nteffectual Property Office of NZ 17 NOV 2003 1 receded - 2 -A COUPLING.

Field of the Invention.

The present invention relates to a coupling, either for connecting a purlin to a rafter or for connecting a 5 girt to an upright.

Background to the Invention.

The coupling of the present invention represents an improvement over the purlin to rafter coupling as set 10 forth in Australian patent application No. 59520/00.

Summary of the Invention.

In a first aspect the present invention provides a coupling for a purlin to rafter or girt to upright, the 15 coupling comprising: - a rafter/upright member adapted for selective location along the rafter or upright; - a purlin/girt fixture connected to the rafter/upright member, the purlin/girt fixture being adapted for securing to or locating an end of the purlin or girt; and - flange means projecting from or near an end of the purlin/girt fixture, remote from the fixture connection to the rafter/upright member, the flange means enabling fastening of the purlin/girt fixture remote end to the rafter or upright.

Advantageously, by providing a flange means which enables fastening of the purlin/girt fixture remote end to the rafter or upright, the stability of the coupling to differential movement between a purlin and rafter or 30 between a girt and upright can be enhanced. In this regard, a stronger connection can be provided.

Preferably the flange means is one or two plate-like lugs respectively projecting laterally from one or opposing sides of the purlin/girt fixture remote end.

Preferably the or each plate-like lug has a fixing 5 hole defined therethrough, and through which a fastener can be introduced to fasten the purlin/girt fixture remote end to the rafter/upright member.

In one preferred variation a purlin/girt fixture is connected to the rafter/upright member on either side 10 thereof such that the coupling straddles the rafter/upright member. However, a single purlin/girt fixture can be provided (eg. for when the coupling is located at an end of a roof or wall).

Preferably the rafter/upright member is either a 15 saddle or a plate. Preferably both the saddle and plate have a portion which abuts an outer face of the rafter or upright. Optionally one or more fixing holes can be defined through the portion so that a respective fastener can be introduced to fasten the saddle or plate to the 2 0 rafter or upright outer face.

Preferably the saddle has one or two sidewalls which in use sit adjacent to respective sides of the rafter/upright member. Preferably the or each sidewall has one or more fixing holes defined therethrough, and through 25 each of which a fastener can be introduced to fasten the rafter/upright member to a respective side of the rafter or upright.

Preferably each saddle sidewall is spaced from the one or two plate-like lugs. In this regard, when the 3 0 coupling has two lugs and is viewed in side elevation, the coupling can have an I-shape.

Preferably the coupling is adapted such that, when the end of the purlin or girt is secured to or located in the purlin/girt fixture, respective outer surfaces of the rafter or upright and the purlin or girt are substantially flush.

Preferably the purlin/girt fixture is formed 5 integrally with the rafter/upright member.

Preferably the coupling is fabricated from a single metal sheet, preferably a steel sheet.

Preferably the purlin/girt fixture is formed as a shoe being shaped internally substantially complementary 10 to the end of the purlin or girt so that this end can be seated in the shoe for connection via the coupling to the rafter or upright.

In a second aspect the present invention provides a method for forming from a metal sheet a coupling as 15 defined in the first aspect, the method comprising the steps of: defining a plurality of cuts in the sheet; and bending portions of the sheet adjacent to the cuts so that the rafter/upright member, purlin/girt fixture and 20 flange means are defined.

Preferably the end of each cut is rounded to prevent sheet tearing thereat during bending.

Preferably fixing holes are defined in each of the rafter/upright member, purlin/girt fixture and flange 25 means prior to bending.

Preferably in the second aspect the sheet is a steel sheet.

Brief Description of the Drawings 3 0 Notwithstanding any other forms which may fall within the scope of the present invention, preferred forms of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 shows in views A, B, C and D plan, end, front and perspective views of a first coupling according to the present invention; Figures 2A to 2D show similar views to Figures 1A to 5 ID, but for a modified coupling to that of Figure 1; Figures 3A to 3D show similar views to Figures 1A to ID, but for an alternative coupling to that of Figure 1; Figures 4A to 4D show similar views to Figures 3A to 3D, but for a modified coupling to that of Figure 3; 10 Figures 5A to 5D show similar views to Figures 1A to ID but for a further alternative coupling to that of Figure 1; Figures 6A to 6D show similar views to Figures 5A to 5D but for a modified coupling to that of Figure 5; 15 Figure 7 shows a perspective view of framework for a building in which couplings according to the present invention are employed; and Figures 8, 9 and 10 show respective detailed perspective views of in-situ couplings in the building 2 0 framework of Figure 7.

Modes for Carrying Out the Invention Reference will firstly be made to Figure 1, and then like reference numerals will be used to denote similar or like parts for the remaining drawings. Also, the 25 couplings of Figures 1 to 6 are typically used for joining purlins to rafters or girts to uprights (such as vertical posts or vertical wall members etc) . However, it should be appreciated that the couplings may be used for joining together other members when constructing building 30 framework (eg. batons to rafters or uprights).

Referring now to Figure 1, a coupling according to the present invention is shown in the form of a first connector 20. The connector 20 comprises a saddle member 22 and two fixtures 24,26 located on opposing sides and formed integrally with the saddle member 22. The saddle member 22 is typically shaped complementary to the external profile of a rafter R or upright U (Figures 7 to 5 10) and is adapted for temporary sliding along and then fixing at the rafter or upright. Each of the fixtures 24,26 is formed into the shape of a shoe that is complementary to an end of a purlin P or girt G (Figures 7 to 10) . Thus, a purlin or girt can be snugly received or 10 seated in each fixture for fastening therein.

Each fixture 24,26 is typically shaped, sized and disposed relative to the saddle member 22 such that in use an outer surface of the purlin P and rafter R, or girt G and upright U, are substantially flush with one another 15 (Figures 8 to 10). Generally the connector 20 is fabricated from a single steel sheet and press formed (bent/folded) without welding (as described below).

In accordance with the present invention, each fixture 24,26 is provided with flange means in the form of 20 laterally projecting lugs or plate portions 28,30. Each plate portion has a hole defined therethrough to enable it to be fixed to a rafter or upright at a location spaced from the saddle member (eg. via a screw, bolt, nail or other fastener). s 2 5 The present inventors have surprisingly discovered that when the flange means (eg. plate portions 28,30) is spaced from the rafter or upright engaging member (eg. saddle member 22) and is fastened to the rafter or upright, differential movement between the purlin and 3 0 rafter or girt and upright can be more readily accommodated. This results in a connector that is strong, more flexible, and longer lasting then, for example, the connector of AU59520/00. Such properties are also imparted to the building frame in which the connectors are employed.

In the connector of Figure 1, the saddle member 22 has sidewalls 32,34. Each sidewall has spaced-apart holes therethrough for enabling fastening of the saddle member to the rafter R or upright U (as shown below in Figures 9 and 10).

The larger holes 36 in saddle member 22 typically allow for the holding of the connector in a cutting and bending apparatus during formation of the connector (described below) but may optionally be used for fastening the saddle member to the rafter or upright.

It will be seen that each fixture 24,26 includes a backing wall 38 against which an end of a purlin or girt typically abuts. Three parallel cuts are made in either side of the backing wall 38 to enable formation of the remainder of the fixture. Each cut has a rounded end 40 so that, during folding of the connector, tearing at that end is prevented (ie. the rounded end prevents promulgation of the cut during folding/bending).

A lowermost of the cuts enables a fixture base 42 to be defined by folding up a portion of wall 38 about a fold line 43. Base sidewalls 44,45 are defined by inwardly folding lateral side portions adjacent to the base 42. As will be seen, each sidewall 44,45 has a hole therethrough such that a fastener (as described above, or for example a Tec screw) can be introduced therethrough to fasten the end of the purlin or girt when located in the fixture.

Similarly, fixture sidewalls 46,47 are defined by inwardly folding lateral side portions of wall 38. In the connector of Figure 1, two holes are provided in each fixture sidewall for the introduction of a fastener therethrough to fasten therein the end of the purlin or girt when located in the fixture.

The upward folding of base 42 and inward folding of walls 44, 45, 46 and 47 leaves the unfolded plate portions 5 28,30. Together with the saddle sidewalls 32,34 the plate portions 28,30 project laterally from backing wall 38 as shown. In front view (Figure 1C) the fixture/saddle sidewall combination on either side of the saddle member has, essentially, an I-shape, with fixing holes located 10 proximate to the extremities of this I-shaped configuration. Thus, when fasteners are introduced through these holes to fasten the connector to a rafter or upright, this side of the connector in its entirety is effectively fixed against movement, thus making for an 15 extremely strong fastening of the connector to the rafter or upright.

Furthermore, the provision of base 42 and two sets of sidewalls 44, 45 and 46, 47 surrounding the purlin or girt when located in the fixture, are such that when fasteners 20 are introduced through holes of each of these sidewalls, a very strong form of connection to the purlin or girt is made, and thus of the purlin or girt to the rafter or upright respectively. Hence, if there is any differential movement between the purlin or girt and rafter or upright, 25 the connectors by their configuration are sufficiently strong and sufficiently fastened to accommodate such movement.

Figures 2 through to 6 show variations on the first connector 20 of Figure 1. Like reference numerals are 3 0 used to denote similar or like parts. The connectors of Figures 2, 4 and 6 are used at the end of a frame (eg. at the end rafter (Figure 8) or corner upright CU of Figure 7) .

In Figure 2 a second connector 50 is shown having only a single fixture 24 (ie. fixture 2 6 is omitted) . Such a connector can be used, for example, to connect a purlin P to an end rafter R (as shown in Figure 8) or a 5 girt G to a corner upright CU. The second connector 50 of Figure 2 is otherwise as described for Figure 1.

Figure 3 shows a third connector 52 which is similar to Figure 1, but having shorter length fixtures 24,26, and thus shorter length fixture sidewalls 46,47. The third 10 connector is used to accommodate purlins or girts of lesser width than the first connector 20. In addition, it will be seen that each fixture sidewall 46,47 has only a single fixing hole therethrough, because the shorter width purlin or girt does not require additional fasteners. The 15 third connector is otherwise as defined for Figure 1.

Figure 4 shows a fourth connector 54 which is the same as the connector in Figure 3 except that the fixture 26 has been removed. Thus, the fourth connector 54 can be used on an end rafter (as shown in Figure 8) or on a 2 0 corner upright CU (as shown in Figure 7) . The components of the connector of Figure 4 are otherwise as described for Figure 1.

Figure 5 shows a fifth connector 56 wherein the saddle member is replaced with a plate member 58. In this 25 embodiment, the sidewalls 32,34 are omitted, and the backing wall 38 is connected directly to plate member 58 at fold line 60. This connector embodiment can be employed for a lesser width purlin or girt than that of Figure 1 and 2 or Figures 3 and 4. Alternatively, the 30 fixtures 24,26 can accommodate the end of a batten or other member therein.

In addition, the plate member 58 may be mounted on a rafter or upright etc. without fastening thereto, with the fastening being provided by the plate portions 28,30. However, as described above, the holes 3 6 may also be employed for fastening purposes.

Figures 6A to 6D show a sixth connector 62 wherein 5 the fixture 26 has been removed and replaced with a projecting hooking plate 64. The hooking plate 64 may or may not have holes therethrough for fastening it to a reverse side of a rafter or upright.

Figure 6E shows a seventh connector, being a 10 variation on the connector of Figures 6A to 6D, wherein the hooking plate 64 is omitted altogether, and the connector is either attached to the rafter or upright solely by plate portions 28,30 or, in addition, via holes 36 in plate member 58. The sixth and seventh connectors 15 can be employed on an end rafter or a corner upright etc. (as shown in Figures 7 and 8) .

Figure 7 shows a schematic perspective view of framework for a building (eg. a portal frame shed) employing connectors in accordance with the present 2 0 invention. In this regard, connectors according to the present invention can be used where a purlin P joins to a rafter R or where a girt G joins to an upright U (or CU).

Figures 8, 9 and 10 show detailed perspective views of the framework of Figure 7, with the longitudinal 25 capping plate CP of Figure 7 removed from Figures 8 and 10 for clarity.

Figure 8 shows the joining of purlins P to one side of an end rafter R using, for example, a preferred connector 50 of Figure 2. Figure 9 shows girts G on 3 0 either side of an upright U using either the preferred connector 2 0 of Figure 1 or the preferred connector 52 of Figure 3. In each case it will be seen how the plate portions 28,30 are spaced from the saddle member 22 to fasten the connector to as maximal a width of the rafter or upright as possible. It will also be seen that a connector is selected for a respective purlin or girt width such that an outer face of the purlin or girt in the 5 frame is typically flush with an outer face of the rafter or upright respectively. This enables cladding to be mounted flush against the framework without the need for spacing elements to be employed.

Typically the connectors according to the present 10 invention are advantageously formed from a single flat metal sheet, typically a steel sheet. In this regard, typically the rounded ends 40 of each cut are defined (eg. drilled) in the flat metal sheet. The various fastening holes are also defined (eg. drilled) in the sheet, as are 15 the positioning holes 36. Then, a cutting blade cuts a series of typically parallel cuts reaching to the rounded end 40 holes. The plate is then positioned in a jig of a bending machine (eg. with locating pins extending into the holes 3 6 to prevent the plate from moving during bending). 2 0 The plate is then clamped in positioned and bending/folding commences.

For the connector of Figure 1 (with modified steps being employed for each other connector) the backing walls 38 on either side of the connector are formed by folding 25 the sheet downwardly, to define the upper face of saddle member 22. Before or after this, the sidewalls 44,45,46 and 4 7 are formed by folding those portions upwardly (or inwardly) on either side of plate portions 28,30 as facilitated by the cuts. Rounded ends 40 prevent tearing 3 0 in the backing wall 38 during such folding.

The fixture base 42 is formed by folding wall 38 up around fold line 43, bringing the sidewalls 44,46 and 45,47 respectively into close proximity (as best shown in Figures IB and D).

Thus, connectors according to the invention can be formed from a single metal sheet without the need for 5 welding, casting etc., making them both rapid and economically feasible to fabricate. However, they can be formed by welding or casting if necessary.

Typically the connectors according to the present invention are used in metal frame buildings (eg. where the 10 rafters, uprights, purlins and girts are defined by RHS, typically of galvanised steel). However, the connectors according to the invention can also be employed with timber framed buildings. When used with steel RHS (rectangular hollow section, typically the connectors are 15 attached to the frame members using self-tapping screws such as Tec-screws.

Whilst the invention has been described with reference to a number of preferred embodiments it should be appreciated that the invention can be embodied in many 20 other forms.

Claims (19)

WHAT WE CLAIM IS:

1. A coupling for a purlin to rafter or girt to upright, the coupling comprising: - a rafter/upright member adapted for selective location 5 along the rafter or upright; - a purlin/girt fixture connected to the rafter/upright member, the purlin/girt fixture being adapted for securing to or locating an end of the purlin or girt; and flange means projecting from or near an end of the 10 purlin/girt fixture, remote from the fixture connection to the rafter/upright member, the flange means enabling fastening of the purlin/girt fixture remote end to the rafter or upright.

2. A coupling as claimed in claim 1 wherein the flange 15 means is one or two plate-like lugs respectively projecting laterally from one or opposing sides of the purlin/girt fixture remote end.

3. A coupling as claimed in claim 2 wherein the or each plate-like lug has a fixing hole defined therethrough, and 2 0 through which a fastener can be introduced to fasten the purlin/girt fixture remote end to the rafter/upright member.

4. A coupling as claimed in any one of the preceding claims wherein a purlin/girt fixture is connected to the 25 rafter/upright member on either side thereof such that the coupling straddles the rafter/upright member.

5. A coupling as claimed in any one of the preceding claims wherein the rafter/upright member is either a saddle or a plate. 30

6. A coupling as claimed in claim 5 wherein both the saddle and plate have a portion which abuts an outer face of the rafter or upright, with one or more fixing holes defined through the portion so. that a fastener can be - 14 - introduced to fasten the saddle or plate to the rafter or upright outer face.

7. A coupling as claimed in claim 5 or 6 wherein the saddle has one or two sidewalls which in use sit adjacent to respective sides of the rafter/upright member.

8. A coupling as claimed in claim 7 wherein the or each sidewall has one or more fixing holes defined therethrough, and through each of which a fastener can be introduced to fasten the rafter/upright member to a respective side of the rafter or upright.

9. A coupling as claimed in claim 7 or 8 when dependant on claims 2 or 3 wherein each saddle sidewall is spaced from the one or two plate-like lugs.

10. A coupling as claimed in any one of the preceding claims that is adapted such that, when the end of the purlin or girt is secured to or located in the purlin/girt fixture, respective outer surfaces of the rafter or upright and the purlin or girt are substantially flush.

11. A coupling as claimed in any one of the preceding claims wherein the purlin/girt fixture is formed integrally with the rafter/upright member.

12. A coupling as claimed in any one of the preceding claims that is fabricated from a steel sheet.

13. A coupling as claimed in any one of the preceding claims wherein the purlin/girt fixture is formed as a shoe being shaped internally substantially complementary to the end of the purlin or girt so that the end can be seated in the shoe for connection via the coupling to the rafter or upright.

14. A coupling substantially as herein described with reference to the accompanying drawings. 15

15. A method for forming from a metal sheet a coupling as defined in any one of the preceding claims, the method comprising the steps of: - defining a plurality of cuts in the sheet; and - bending portions of the sheet adjacent to the cuts so that the rafter/upright member, purlin/girt fixture and flange means are defined.

16. A method as claimed in claim 15 wherein the end of each cut is rounded to prevent sheet tearing during bending.

17. A method as claimed in claim 15 or 16 wherein fixing holes are defined in each of the rafter/upright member, purlin/girt fixture and flange means prior to bending.

18. A method as claimed in any one of claims 15 to 17 wherein the sheet is a single steel sheet.

19. A method for forming a coupling from a metal sheet substantially as herein described with reference to the accompanying drawings. ONESTEEL TRADING PTY LIMITED By its Attorneys rneys i£~ JAMES & 2 4 DEC 2003 RECEIVED 1