US20090151289A1

US20090151289A1 - Joint

Info

Publication number: US20090151289A1
Application number: US11/954,976
Authority: US
Inventors: George S. Liu
Original assignee: LNL Building Products Inc
Current assignee: LNL Building Products Inc
Priority date: 2007-12-12
Filing date: 2007-12-12
Publication date: 2009-06-18
Also published as: CN101398023B; CN101398023A

Abstract

A joint for connecting at least two members; wherein the joint includes a first scalloped face having peaks and troughs located at an end of a first member and a second scalloped face having peaks and troughs located at the end of the second member. The resulting seam designed to minimize the visual impact of the joint.

Description

FIELD OF THE INVENTION

The present invention relates to a joint for connecting members. More particularly, the present invention relates to a joint for connecting members wherein the joint seam is curvilinear, obscuring the presence of the joint.

BACKGROUND AND SUMMARY OF THE INVENTION

The joining of members utilizing an end joint dates back millennia and joint types are voluminous in the art. When joining members using an end joint it is desirable to produce a joint that exhibits both strength and aesthetic value. While many joints provide strength to the finished product, their designs lack aesthetic value. Most conventional end joints have seams creating unnatural lines detracting from the look of the joint.
The present invention recognizes the need to provide a joint of sufficient strength for a variety of applications while also providing an aesthetic quality desired by consumers.
The present invention is a joint for connecting members having a grain pattern. The end of the first member may have a first scalloped surface. The first scalloped surface has a series of peaks and troughs. A second scalloped surface is located at the end of a second member. The second scalloped surface also includes a series of peaks and troughs; however, the pattern of the peaks and troughs on the second scalloped surface has a complimentary relationship to the peaks and troughs of the first scalloped surface. The angles of the scalloped surfaces also have a complimentary relationship to each other. The peaks and troughs may be formed by a plurality of router bits of varying dimension or other similar technique. The members may be cut manually or by machine. The members may be any material having a grain pattern; including but not limited to, various species of wood or wood composites having a grain pattern.
The scalloped surfaces are then brought into fitted relation with each other. The peaks of one scalloped surface nestle into the troughs of the other scalloped surface and vice versa. The scalloped surfaces may then be affixed to one another using a number of methods; including but not limited to, adhesives or nailing. The resulting joint provides greater surface area over traditional mitered joints and the nestling of the peaks and corresponding troughs provides additional strength to the joint.
The joining of the scalloped surfaces produces a scalloped joint seam. The scalloped joint seam is the result of fitting the two scalloped surfaces together. The scalloped joint seam visually minimizes the joint by removing the angled edges and distinct harsh transitions normally found in conventional joints. Because of the removal of the angled edges and distinct transitions in the joint seam, the grain patterns of each member seemingly blend together, thereby obscuring the presence of the joint. The joint may be utilized in a variety of applications; including but not limited to, rails, furniture, windows, doors, cabinets, and other applications requiring the joining of members to achieve a desired length member.
Other systems, methods, features and advantages of the invention are, or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.

FIG. 1 is a perspective view of an embodiment of a first member having a scalloped surface.

FIG. 2 is a perspective view of an embodiment of a second member having a scalloped surface.

FIG. 3 is a cross section view of an embodiment of a first and second scalloped surface.

FIG. 4 is a perspective view of an embodiment of a first member having a scalloped surface.

FIG. 5 is a perspective view of an embodiment of a second member having a scalloped surface.

FIG. 6 is a perspective view of an exemplary embodiment of the joint of the present invention.

FIG. 7 is a perspective view of an exemplary embodiment of the joint of the present invention.

FIG. 8 is a photographical illustration of an exemplary embodiment of the joint of the present invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENT(S)

FIG. 1 illustrates an exemplary embodiment of a first member 100 of the present invention. The first member 100 has a top surface 102, a bottom surface 104, a first side surface 106, a second side surface 108, and an end surface 110. A scalloped surface 112 is located at an end of the first member 100. The scalloped surface 112 is cut to produce a top scalloped edge 114 and a bottom scalloped edge 116. The scalloped edges 114 and 116 are designed to provide a smooth edge eliminating harsh angled intersections. The scalloped surface 112 is cut so that the bottom surface 104 of the first member 100 extends beyond the top surface 102 of the first member 100. The scalloped surface 112 is further comprised of a number of peaks 118 and a number of troughs 120. The number of peaks and troughs 118 and 120 lie on the scalloped surface 112 and correspond to the curve of the scalloped edges 114 and 116. The peaks and troughs 118 and 120 run between the top and bottom surfaces 102 and 104. In the embodiment shown in FIG. 1, the scalloped edges 114 and 116 are matching and located on both the top and bottom surface 102 and 104 of the first member 100.
FIG. 2 illustrates an exemplary embodiment of a second member 200 of the present invention. FIG. 2 illustrates the second member 200 as viewed from below to better illustrate the features of the present invention. The second member has a top surface 202, a bottom surface 204, a first side surface 206, a second side surface 208 and an end surface 210. A scalloped surface 212 is located at an end of the second member 200. The scalloped surface 212 is cut to produce a top scalloped edge 214 and a bottom scalloped edge 216. The scalloped edges 214 and 216 are designed to provide a smooth edge eliminating angled lines. The scalloped surface 212 is cut so that the top surface 202 of the second member 200 extends beyond the bottom surface 204 of the second member 200. The scalloped surface 216 is further comprised of a number of peaks 218 and a number of troughs 220. The peaks and troughs 218 and 220 lie on the scalloped surface 212 and correspond to the curve of the scalloped edges 214 and 216. The peaks and troughs 218 and 220 run between the top and bottom surfaces 202 and 204. The scalloped edges 214 and 216 are matching and located on both the top and bottom surfaces 202 and 204 of the second member 200.
The pattern of the scalloped edges 216 and 218 and the corresponding number of peaks and troughs 218 and 220 of the second member 200 are complimentary to the pattern of the scalloped edges 116 and 118 and the corresponding number of peaks and troughs 218 and 220 of the first member 100. The complimentary pattern allows the number of peaks 118 of the first member 100 to nestle into the number of troughs 220 of the second member 200 and vice versa as the scalloped surface 112 of the first member 100 and scalloped surface 212 of the second member 200 are brought into engagement.
The members 100 and 200 have an exposed grain pattern specific to the type or species of wood used in the construction of the members 100 and 200. To maintain the aesthetic quality of the joint, members 100 and 200 may be the same type of wood. The grain pattern of members 100 and 200 may include a series of lines and swirls. A router bit (or blade) is one appropriate tool for forming the scalloped surfaces 112 and 212 producing the scalloped edges 114, 116, 214, and 216. The shape of the scalloped edges 114, 116, 214, and 216 is determined by the exposed grain pattern of members 100 and 200. For example, multiple router bits each having a different height, width and blade design may be used to cut different scalloped edges 114, 116, 214, and 216 based on the exposed grain pattern of the members 100 and 200. Furthermore, scalloped edges 114 and 214 may be offset from the associated scalloped edges 116 and 216 such that the peaks and troughs traverse the scalloped surface at an angle across, rather than down, the scalloped surface.
In other exemplary embodiments of the present invention, the first and second members 100 and 200 may be replaced with a wood composite having an exposed grain pattern.
This complimentary design is further illustrated in FIG. 3. FIG. 3 illustrates a cross sectional view of the joint formed by placing scalloped surface 112 of the first member 100 in fitted relation to the scalloped surface 212 of the second member 200. As the scalloped surfaces 112 and 212 are brought into engagement, the peaks 118 of the first member 100 nestle into the corresponding troughs 220 of the second member 200. Likewise, the peaks 218 of the second members 200 nestle into the troughs 120 of the first member 200.
In other exemplary embodiments, the scalloped edges 114, 116, 214, and 216 are adjusted to aid in disguising the joint. The scalloped edges 114, 116, 214, and 216 may be adjusted by increasing/decreasing the amplitude of the curves and/or increasing/decreasing the frequency of the curves (see FIGS. 6 and 7). The amplitude and frequency of the scalloped edges 114, 116, 214, and 216 are selected based on the exposed grain pattern of the members 100 and 200. As the scalloped edges 114, 116, 214, and 216 are adjusted the corresponding peaks and troughs 118, 120, 218, and 220 are also adjusted. As the amplitude of the scalloped edges 114, 116, 214, and 216 increases/decreases the height of the corresponding peaks 118 and 218 and depth of the troughs 120 and 220 increase/decrease accordingly. Likewise as the frequency of the scalloped edges 114, 116, 214, and 216 increases/decreases the number of corresponding peaks and troughs 118, 120, 218, and 220 also increase/decrease. The scalloped edges 114, 116, 214, and 216 may also have either a symmetrical or asymmetrical curve shape depending on the grain of the exposed wood.
FIG. 4 illustrates a side view of an exemplary embodiment of a first member 100 of the present invention. The first member 100 has a top surface 102, bottom surface 104, first side surface 106 (not shown in FIG. 4), second side surface 108, and an end surface 110. A scalloped surface 112 is located at an end of the first member 100. The scalloped surface 112 is cut so that the bottom surface 104 of the first member 100 extends beyond the top surface 102 of the first member 100. The scalloped surface 112 is comprised of a number of peaks 118 and a number of troughs 120. This first member 100 is brought into complimentary engagement with the second member 200 to form a joint of the present invention.
The scalloped surface 112 intersects the top surface 102 at an angle β₁with the intersection labeled as 114; and intersects the bottom surface 104 at an angle α₁. The sum of angles α₁and β₁is approximately 180°, wherein the angle α₁is not equal to the angle β₁. The angle of the scalloped surface 112 provides increased surface area over conventional butt joints, with or without a scalloped feature. The angle also allows the scalloped surface 112 of the first member 100 to complimentary engage the scalloped surface 212 of the second member 200.
FIG. 5 illustrates a side view of an exemplary embodiment of a second member 200 of the present invention. The second member 20 has a top surface 202, bottom surface 204, first side surface 206, second side surface 208 (not shown in FIG. 5), and an end surface 210. A scalloped surface 212 is located at an end of the second member 200. The scalloped surface 212 is cut so that the top side 202 of the second member 200 extends beyond the bottom surface 204 of the second member 200. The scalloped surface 212 is comprised of a number of peaks 218 and a number of troughs 220 (not shown in FIG. 5). This second member 200 is brought into complimentary engagement with the first member 100 to form a joint of the present invention.
The scalloped surface 212 intersects the top surface 202 at an angle β₂, with the intersection labeled as 214; and intersects the bottom surface 204 at an angle α₂. The sum of angles α₂and β₂is approximately 180°, wherein the angle α₂is not equal to the angle β₂. The angle of the scalloped surface 212 provides increased surface area over conventional butt joints. The angle also allows the scalloped surface 212 of the second member 200 to complimentary engage the scalloped surface 112 of the first member 100. Further, the sum of angles α₁and β₂is approximately 180°. Likewise, the sum of angles α₂and β₁is approximately 180°. The relationship between the angles allows for a complimentary fit between the scalloped surfaces 112 and 212 of the first and second members 100 and 200.
FIG. 6 illustrates an exemplary embodiment of the joint of the present invention. The scalloped surface 112 of the first member 100 and scalloped surface 212 of the second member 200 are brought complimentary engagement thereby defining a curvilinear seam 600 a. The curvilinear seam 600 a may run across the top surfaces 102 and 202 between the first and second members 100 and 200. The curvilinear seam 600 a may also run across the bottom surfaces 104 and 204 between the first and second members 100 and 200. The curvilinear seam 600 a removes the angled edges and distinct transitions in the joint seam. The curvilinear seam 600 a further blends the grain patterns of the first member 100 and second member 200, thereby obscuring the presence of the joint.
FIG. 7 illustrates another exemplary embodiment of the joint of the present invention. The scalloped surface 112 of the first member 100 and scalloped surface 212 of the second member 200 are brought complimentary engagement thereby defining a curvilinear seam 600 b. The curvilinear seam 600 b may run across the top surfaces 102 and 202 between the first and second members 100 and 200. The curvilinear seam 600 b may also run across the bottom surfaces 104 and 204 between the first and second members 100 and 200. The curvilinear seam 600 b removes the angled edges and distinct transitions in the joint seam. The curvilinear seam 600 b further blends the grain patterns of the first member 100 and second member 200, thereby obscuring the presence of the joint.
Both curvilinear seams 600 a and 600 b are examples of the shape the joint may take. FIG. 6 illustrates a curvilinear seam 600 a having a symmetrical design. FIG. 7 illustrates a curvilinear seam 600 b having an asymmetrical design. The curve of the scalloped edges 114, 116, 214, and 216 defining the curvilinear seam 600 a and 600 b is selected to visually minimize the appearance of the joint and based upon the exposed grain pattern of the wood species used. In other exemplary embodiments the curvilinear seam 600 a and 600 b may take any curved form thus minimizing the appearance of the joint.
The scalloped surfaces 112 and 212 may then be secured to one another. In an exemplary embodiment, an adhesive may be applied to the interfacing scalloped surfaces 112 and 212. The increased surface area of the scalloped surfaces 112 and 212 allows a greater amount of adhesive to be used resulting in a stronger joint as compared to a traditional butt joint. In other exemplary embodiments, a mechanical fastener may be employed. The mechanical fastener would traverse the scalloped surfaces 112 and 212, securing the first and second members 100 and 200 to one another.
FIG. 8 is photograph of an exemplary embodiment of the present invention. FIG. 8 illustrates the exposed grain pattern 800 a and 800 b on the first and second members 100 and 200. The exposed grain patterns 800 a and 800 b have visually different patterns in that the lines and swirls of the exposed grain pattern 800 a on the first member 100 do not match the lines and swirls of the exposed grain pattern 800 b on the second member 200. It is this mismatching of exposed grain patterns 800 a and 800 b across a joint seam that contributes to the visual impact of a joint. The present invention may minimize this impact through the use of scalloped edges 114 and 214.
The scalloped edges 114 and 116 are brought into complimentary communication with one another forming a curvilinear seam 600 a. The curvilinear seam 600 a may have either a sinusoidal shape or an irregular shape, based upon the exposed grain patterns 800 a and 800 b found on the first and second members 100 and 200. The curvilinear seam 600 a removes the angled edges and distinct transitions in the joint seam. The curvilinear seam 600 a further blends the grain patterns 800 a and 800 b of the first member 100 and second member 200, thereby obscuring the presence of the joint. The curvature of the curvilinear seam 600 a may help to minimize the visual impact of the different exposed grain patterns 800 a and 800 b.
While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents.

Claims

1. An apparatus comprising:

a first member having a top surface, a bottom surface, a first side surface, a second side surface, an end surface and a scalloped surface, said scalloped surface comprising at least one peak and at least one trough;

a second member having a top surface, a bottom surface, a first side surface, a second side surface, an end surface and a scalloped surface, said scalloped surface of said second member comprising a number of troughs corresponding to the number of peaks of said scalloped surface of said first member and a number of peaks corresponding to the number of troughs of said first member, wherein said scalloped surface of said second member and said scalloped surface of said first member provide a complimentary engagement with one another thereby defining a curvilinear seam across at least one surface selected from the group consisting of: top surface and bottom surface between said first member and said second member, said scalloped surface of said first member and said scalloped surface of said second member secured to one another.

2. The apparatus of claim 1 wherein each said peak and each said trough of said first member extend from said top surface to said bottom surface.

3. The apparatus of claim 1 wherein said scalloped surface of said first member and said scalloped surface of said second member are secured to one another by a mechanical fastener.

4. The apparatus of claim 1 wherein said scalloped surface of said first member and said scalloped surface of said second member are secured to one another by an adhesive deposited therebetween.

5. The apparatus of claim 1 wherein said first member and said second member each comprise wood.

6. The apparatus of claim 1 wherein at least one surface selected from the group consisting of: top surface and bottom surface of said first member displays a grain pattern and at least one surface selected from the group consisting of: top surface and bottom surface of said second member displays a grain pattern, said curvilinear seam minimizing noticeable differences between said grain pattern of said first member and said grain pattern of said second member.

7. The apparatus of claim 6 wherein each said peak and each said trough of said first member extend from said top surface to said bottom surface.

8. The apparatus of claim 6 wherein said scalloped surface of said first member and said scalloped surface of said second member are affixed to one another by a mechanical fastener.

9. The apparatus of claim 6 wherein said scalloped surface of said first member and said scalloped surface of said second member are affixed to one another by an adhesive deposited therebetween.

10. The apparatus of claim 6 wherein said first member and said second member each comprise wood.

11. An apparatus comprising:

a first member having a scalloped surface, said scalloped surface comprising at least one peak and at least one trough;

a second member having a scalloped surface, said scalloped surface of said second member comprising a number of troughs corresponding to the number of peaks of said scalloped surface of said first member and a number of peaks corresponding to the number of troughs of said first member, wherein said scalloped surface of said second member and said scalloped surface of said first member provide a complimentary engagement with one another thereby defining a curvilinear seam between said first member and said second member, said scalloped surface of said first member and said scalloped surface of said second member secured to one another.

12. The apparatus of claim 11 wherein said scalloped surface of said first member and said scalloped surface of said second member are secured to one another by a mechanical fastener.

13. The apparatus of claim 11 wherein said scalloped surface of said first member and said scalloped surface of said second member are secured to one another by an adhesive deposited therebetween.

14. The apparatus of claim 11 wherein said first member and said second member each comprise wood.

15. The apparatus of claim 11 wherein said first member displays a grain pattern and said second member displays a grain pattern, said curvilinear seam minimizing noticeable differences between said grain pattern of said first member and said grain pattern of said second member.

16. The apparatus of claim 15 wherein said scalloped surface of said first member and said scalloped surface of said second member are secured to one another by a mechanical fastener.

17. The apparatus of claim 15 wherein said scalloped surface of said first member and said scalloped surface of said second member are secured to one another by an adhesive deposited therebetween.

18. The apparatus of claim 15 wherein said first member and said second member each comprise wood.

19. A method of joining two members, said method comprising the steps of:

providing a first member, said first member having a top surface, a bottom surface, a first side surface, a second side surface, an end surface and a scalloped surface, said scalloped surface comprising at least one peak and at least one trough;

providing a second member, said second member having a top surface, a bottom surface, a first side surface, a second side surface, an end surface and a scalloped surface, said scalloped surface of said second member comprising a number of troughs corresponding to the number of peaks of said scalloped surface of said first member and a number of peaks corresponding to the number of troughs of said first member, wherein said scalloped surface of said second member and said scalloped surface of said first member provide a complimentary engagement with one another thereby defining a curvilinear seam across at least one surface selected from the group consisting of: top surface and bottom surface between said first member and said second member;

placing said scalloped surface of said first member in complimentary engagement with said scalloped surface of said second member; and

securing said scalloped surface of said first member to said scalloped surface of said second member.

20. The method according to claim 19 additionally comprising the step, prior to the placing step, of:

applying an adhesive to at least one surface selected from the group consisting of: said scalloped surface of said first member and said scalloped surface of said second member.

21. The method according to claim 19 wherein said scalloped surface of said first member is secured to said scalloped surface of said second member by an adhesive.

22. The method according to claim 19 wherein said scalloped surface of said first member is secured to said scalloped surface of said second member by a mechanical fastener.

23. A method of joining two members, said method comprising the steps of:

providing a first member having a scalloped surface comprising at least one peak and at least one trough;

providing a second member having a scalloped surface, said scalloped surface of said second member comprising a number of troughs corresponding to the number of peaks of said scalloped surface of said first member and a number of peaks corresponding to the number of troughs of said first member, wherein said scalloped surface of said second member and said scalloped surface of said first member provide a complimentary engagement with one another thereby defining a curvilinear seam between said first member and said second member;

24. The method according to claim 23 wherein said scalloped surface of said first member is secured to said scalloped surface of said second member by an adhesive.

25. The method according to claim 23 wherein said scalloped surface of said first member is secured to said scalloped surface of said second member by a mechanical fastener.

26. The method according to claim 23 additionally comprising the step, prior to the placing step, of: