[0001] The present invention relates to construction of

buildings using C-channel members, typically light gauge and made of folded steel, typically in domestic or small-scale commercial construction.

BACKGROUND

[0002] There are a large number of junctional devices used in both metallic construction methods in industry, although in relation to light gauge steel construction there is a limited range. Most junctional devices for light gauge construction are single use, being adapted to a permanent structure which is not intended to be disassembled and reassembled. With the increasing demand for temporary structures, junctional methods are needed which allow modular reusable components to be created.

[0003] There is a need to provide an improved reusable connector system to with enhanced strength, convenience, simplicity and/or durability.

SUMMARY OF THE INVENTION

[0004] According to a broad aspect of the invention there is provided a system of connectors for connecting to metal C- channel members in building construction, the C-channel members having a channel formed by web and opposed flange surfaces , the system comprising a plurality of connectors of one or more connector types , the connectors being of a rigid block

composition, at least a first connector type being sized and shaped to join together the C-channel members in more than one relative orientation, the first connector type comprising one or more holes on one or more faces for fastening the connector to the C-channel members and to other connectors.

[0005] In one embodiment, the one or more holes on one or more faces comprise one or more holes for fastening the connector to the C-channel members through the flanges of the C-channel members .

[0006] In one embodiment, the holes of the first connector type include straight-through bolt holes allowing a bolt to be passed through from one side of the connector to the other.

[0007] In one embodiment, the more than one relative orientation includes two C-channel members joined in parallel with the respective channels facing one another to form a box beam or column.

[0008] In one embodiment, the more than one relative orientation includes two C-channel members joined in parallel with the respective channels facing away from one another to form an I- beam or I-column.

[0009] In one embodiment, the more than one relative orientation includes two C-channel members joined at right angles.

[0010] In one embodiment, the more than one relative orientation includes another C-channel member joined at right angles to the box beam or column. [0011] In one embodimen , the more than one relative orientation includes at least two of the box beams or columns joined at right angles .

[0012] In one embodiment, wherein the two C-channel members are a first C-channel member and a 2nd C-channel member and the connector of the first type is adapted to form the box beam or column so that:

a first part of the connector engages an inside surface of the first C-channel member;

a second part of the connector engages an inside surface of the second C-channel member; and

one or more screws fastens the C-channel members in position to the connector through one or more screw holes in the first and second parts of the connector and through corresponding holes in the C-channel members .

[0013] In one embodiment, the two C-channel members are a first C-channel member and a 2nd C-channel member and the connector of the first type is adapted to form the box beam or column so that:

a first part of the connector engages an inside surface of the first C-channel member;

a second part of the connector engages an inside surface of the second C-channel member; and

one or more bolts fastens the C-channel members in position to the connector through one or more of the holes disposed in the first and second parts of the connector and through

corresponding holes in the C-channel members .

[0014] In one embodiment,

the first and second parts comprise regions disposed on opposite first and second side faces of the connector

respectively which engage at least an inside surface of the web of the corresponding C-channel members .

[0015] In one embodiment:

the one or more holes comprise a first straight- through bolt hole providing a straight line access path all the way through the connector from the first side face to the second side face; and

the corresponding holes in the C-channel members comprise holes disposed in the corresponding webs;

whereby a single bolt may be passed through the first straight- through bolt hole and the corresponding holes in the C-channel members .

[0016] In one embodiment:

the one or more holes comprise a first bolt hole in a first side face extending through to a first nut receiving face or first embedded thread disposed between the first side face and a midpoint of the connector midway between the first and second side faces, and a second bolt hole in the second side face extending through to a second nut receiving face or 2nd embedded thread disposed between the second side face and the midpoint; and

the corresponding holes in the C-channel members are disposed in the corresponding webs ;

whereby

a first bolt may be passed through the first bolt hole and the corresponding hole in the first C-channel member and secured with a first nut bearing on the first nut receiving face or with the first embedded thread, and

a second bolt may be passed through the second bolt hole and the corresponding hole in the second C-channel member and secured with a second nut bearing on the second nut receiving face or with the 2nd embedded thread. [0017] In one embodimen , :

the first part of the connector comprises a first end of opposite third and fourth sides of the connector each engaging the respective opposed flange of the first C-channel member; and the second part of the connector comprises a second end of the opposite third and fourth sides of the connector each engaging the respective opposed flanges of the second C-channel member.

[0018] In one embodiment, the one or more screw holes are disposed on the first and second ends and the corresponding holes in the C-channel members are disposed on the flanges thereof .

[0019] In one embodiment, the connector of the first type has first and 2nd opposite side faces and:

the one or more holes comprise a first bolt hole in the first side face extending through to a first nut receiving face disposed between the first side face and a midpoint of the connector midway between the first and second side faces, and a second bolt hole in the second side face extending through to a second nut receiving face disposed between the second side face and the midpoint; and

the corresponding holes in the C-channel members are disposed in the corresponding webs ;

whereby

a first bolt may be passed through the first bolt hole and the corresponding hole in the first C-channel member and secured with a first nut bearing on the first nut receiving face, and a second bolt may be passed through the second bolt hole and the corresponding hole in the second C-channel member and secured with a second nut bearing on the second nut receiving face;

and the first bolt hole and the 2nd bolt hole meet to also form a first straight-through bolt hole allowing a bolt to be passed all the way through the connector from the first side face to the 2nd side face.

[0020] In one embodiment, the system of connectors further comprises screw holes disposed in the first and 2nd side faces on either side of the first and 2nd bolt holes.

[0021] In one embodiment, a width of the connector between the first and 2nd side faces matches a width of the C-channel member between the opposed flanges so that the connector may be

connected to the C-channel member with screws passing through the flanges into the screw holes .

[0022] In one embodiment, the system of connectors further comprises 3rd and 4th opposite side faces at right angles to the first and 2nd opposite side faces, and corresponding 3rd and 4th bolt holes, 3rd and 4th corresponding nut receiving faces and a 2nd straight-through bolt hole allowing a bolt to be passed all the way through the connector from the 3rd side face to the 4th side face.

[0023] In one embodiment, the midpoint between the first and 2nd side faces and the midpoint between the 3rd and 4th side faces coincide .

[0024] In one embodiment, the first connector type further comprises a third straight- through bolt hole is oriented at right angles to the first and 2nd straight-through bolt holes.

[0025] In one embodiment, the first connector type is sized and shaped so it can also be installed inside a third C-channel member and fastened thereto through the flanges of the C-channel member so that the first or second straight-through bolt hole is oriented along the third C-channel member, whereby connectors of the first connector type may be used with a bolt passing through the first or second straight-through bolt holes to attach a single C-channel member at right angles to another connector of the system forming part of a box-section beam or column.

[0026] In one embodiment, the first connector type is sized and shaped so it can also be installed inside a C-channel member and fastened thereto through the flanges of the C-channel member so that the third straight-through bolt hole is oriented across the C-channel member and perpendicular to its web, whereby

connectors of the first connector type may be used in each of two C-channel members with a bolt passing through both third straight-through bolt holes and corresponding apertures in the webs of the C-channel members to attach the two C-channel members together in parallel with the channels facing away from one another to form an I-beam or I-column.

[0027] In one embodiment, the system further comprises a joining piece for stacking two of the connectors of first type together in the direction of the third straight-through bolt hole to form a cube shaped connector which can be used to form and join up to 6 box-section beams or columns along x,y and z axes at a single intersection .

[0028] In one embodiment, the system may further comprise a second connector type being sized and shaped to function in two applications: in a first application to join together a first and second C-channel member at right angles ; and in a second application to provide a secure attachment point for a bolt through one flange of a C-channel member; the second connector type having: opposite first and second sides each with a screw hole and being sized to fit inside the C-channel with the first side engaging one flange of the C-channel member and the second side engaging an opposite flange of the C-channel member; and a third and fourth side oriented at right angles to the first and second sides with a straight-through bolt hole passing through the connector from the third side to the fourth side, the third side also having screw holes on either side of the straight- through bolt hole; whereby in the first application, the first and second C-channel members can be joined at right angles by: a connector of the second type being fastened inside the first C- channel member with screws passed through holes in the flanges of the second C-channel member into the screw holes of its first and second sides, with the third side and opposite fourth side being oriented facing with the bolt hole directed perpendicular to a web of the first C-channel member; and the first and second C-channel members being able to be joined with a bolt passed through the straight-through bolt hole of the connector of the second type installed in the first C-channel member and also through a bolt hole in a connector of the first or second type installed in the second C-channel member; and whereby in the second application, a connector of the second type is placed inside the C-channel member with the third side engaging the flange and fastened using screws into the screw holes in the third side passed through corresponding holes in the flange, providing a secure attachment point for a bolt through the straight-through bolt hole in the third side and a corresponding hole in the flange .

BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1A and Figure IB are perspective views showing front and back faces of a connector of the first type according to an embodiment of the invention; [0030] Figure 1C is a plan view of the visible face of the connector shown in Figure IB;

[0031] Figure ID is a side view of another face of the connector shown in Figure IB;

[0032] Figure IE is a cross-section through the plane extending perpendicularly out of the page and defined by line B-B shown in Figure IB, with diagonal line shading representing intersection with the solid;

[0033] Figure IF is a cross-section through the plane extending perpendicularly out of the page and defined by the line D-D shown in Figure IB, with diagonal line shading representing intersection with the solid;

[0034] Figure 1G is a side view of another face of the connector shown in Figure IB;

[0035] Figure 1H is a plan view of the visible face of the connector shown in Figure 1A;

[0036] Figure 1J is a cross-section through the plane extending perpendicularly out of the page and defined by the line A-A in Figure 1H ;

[0037] Figure IK is a cross-section through the plane extending perpendicularly out of the page and defined by the line C-C in Figure 1G;

[0038] Figure 2 is a perspective view of the connector of the first type in the embodiment shown in Figure 1A in use to create a box section out of two C-channels , and to connect another C- channel at right angles thereto;

[0039] Figure 3A is a perspective view of a cube shaped

connector formed from two of the connectors of the first type shown in Figure 1A and a connector sleeve;

[0040] Figure 3B is a perspective view of the sleeve partly shown in Figure 3A;

[0041] Figure 4 is a perspective view of the cube shaped connector of Figure 3A in use to join up to 6 box sections together;

[0042] Figure 5A is a perspective view of a connector of the second type according to an embodiment of the invention in use to provide a bolt connection through a web of a C-channel;

[0043] Figure 5B is a perspective view of the connector of the second type of Figure 5A in use to provide a bolt connection through a flange of a C-channel.

DETAILED DESCRIPTION OF EMBODIMENTS

[0044] An embodiment of the current invention will now be described.

[0045] Referring first to Figures 1A to IK, where a connector of the first type according to an embodiment of the invention is shown from various views and cross-section as described above, the connector of the first type 100 comprises four identical sides, although in different embodiments the sides need not be identical due to their different function in use, and for the purposes of defining the invention the upper and lower sides shown in Figure 1A will be referred to as first and second sides respectively, and the left and right sides in Figure 1A

(corresponding to the right and left sides in Figure IB) will be referred to as the third and fourth sides respectively.

[0046] The numerical dimensions shown in Figure 1C, Figure ID, Figure 1G and Figure IK are expressed in millimetres.

[0047] Connector 100 is 88 mm on each side in width and 38 mm in depth, external dimensions chosen to essentially wholly fit inside a standard light gauge C-channel member commonly used in the construction industry. Connector 100 is in the shape of a block constructed from a reinforced polymer, such as glass fibre reinforced nylon or similar, and is manufactured typically by injection or other moulding, the or a combination of moulding and drilling, but could also be manufactured using other methods such as pressing or for small volumes 3-D printing. The physical properties of connector 100 are selected to provide a strong, rigid connector which is able to provide a secure connection point for light gauge C-channel members and attached nuts and bolts, and preferably also to allow the use of self-tapping screws repeatedly in appropriately sized screw holes, allowing reconfiguration and reuse of structural modules constructed using the invention.

[0048] The first side face of connector 100 comprises screw holes 103 and 104 on opposite ends thereof and a first bolt hole 111 disposed in the middle. Screw holes 103 and 104 have an internal diameter of 3.9 mm suitable for receiving self-tapping "tech screws" and the openings thereof are located within a recessed bevelled region designed to conform to "dimpled" screw holes commonly provided in the flanges of C-channels. First bolt hole 111 has an internal diameter of 8.42 millimetres, suitable to slidingly receive 8mm bolts . [0049] Identical second side face of connector 100 comprises corresponding screw holes 107 and 108 and second bolt hole 113. Similarly, identical third side face of connector 100 comprises screw holes 109 and 110 and third bolt hole 114. Similarly, identical fourth side face of connector 100 comprises screw holes 105 and 106 and fourth Bolt hole 112.

[0050] First bolt hole 111 and second bolt hole 113 are coaxial and meet at a midpoint 140 and together provide a first

straight-through bolt hole having a straight line access path all the way through the connector from the first side face to the second side face, enabling a long bolt to be passed all the way through the connector if desired. The long bolt may be used when passed through holes in the C-channel member associated with connector 100 to connect with other connectors of the first type associated with the same or other C-channel members, or alternatively may connect to other accessories such as brackets to be disposed on an outside face of the C-channel member.

[0051] First bolt hole 111 also comprises first nut receiving face 131 disposed between the first side face and a midpoint 140 of connector 100. Similarly, second bolt hole 113 also comprises a second nut receiving face 133 disposed between the second side face and the midpoint 140 of connector 100. Thereby, a short first bolt may be passed through first bolt hole 111 and secured with a first nut inserted sideways into first nut receiving slot 138, the first nut bearing on the first nut receiving face 131; and similarly a short second bolt may be passed through second Bolt hole 113 and secured with a second nut inserted sideways into corresponding second nut receiving slot 139, the second nut bearing on the second nut receiving face 133. The short bolts may be used when passed through holes in the C-channel member associated with connector 100 to connect with other connectors of the first type associated with the same or other C-channel members, or alternatively may connect to other accessories such as brackets to be disposed on an outside face of the C-channel member. This may be achieved at the same time as leaving free the axial straight-through bolt hole 150 to be described below.

[0052] The identical third, and fourth side faces have

corresponding identical features. In this embodiment, the third bolt hole 114 and fourth bolt hole 112 meet at right angles at the midpoint 140 and similarly form a second straight-through bolt hole, which intersects with the first straight-through bolt hole described above.

[0053] Connector 100 further comprises an axial third straight- through bolt hole 150 also of 8.42 mm internal diameter which allows a bolt to be passed straight through connector 100 in an axial direction parallel to the first, second, third and fourth sides which may also in use be parallel to an axis of a beam or column constructed as described below. An hexagonal nut- receiving slot 152 is provided on the front face shown in Figure 1A in the case that it is desired to secure a threaded bolt at that location.

[0054] Referring now in addition to Figure 2, connector 100 of the first type is shown joining together a first C-channel member 200 and a second C-channel member 250 to form a box- section beam or column. As described below, an I-section beam or column is also achievable with this embodiment.

[0055] Dimple 211 with hole 210 in the centre thereof in the flange 201 of first C-channel member 200 fits into the dimpled recess around screw hole 110 in the third side of connector 100, and a self-tapping screw (not shown) may be screwed through hole 210 in flange 201 to be secured into a screw hole 110. Similarly, opposed flange 202 comprises a similar dimple and hole which fits into the dimpled recess around screw hole 105 in the fourth side of connector 100. When screwed into place, a first part of connector 100 which engages with the flanges of first C-channel member 200 comprises at least region 122 on a first end of the third side face surrounding screw hole 110 and region 123 on a first end of the fourth side face surrounding screw hole 105. Engagement with web 203 of first C-channel member 200 also may occur through the first side face of connector 100 at regions 126 and 127. In an alternative mode of attachment, connector 100 may be bolted through web 203 to first C-channel member 200 using bolt hole 111 in which case

engagement necessarily occurs through regions 126 and 127, and may occur through regions 122 and 123.

[0056] Similarly, second C-channel member 250 with flanges 251 and 252 and web 253 is attached in this embodiment through flange 251 with a self-tapping screw through hole 260 at the centre of dimple 261 into screw holes 109 in engagement contact region 124 disposed in a second part of the third side face, and similarly through flange 252 into screw hole 106 in engagement contact region 125 in a second part of the fourth side face. Again in an alternative mode of attachment, connector 100 may be bolted through web 255 to second C-channel member 250 using bolt hole 113.

[0057] The beam or column may be joined by multiple connectors of first type disposed at intervals of typically about 450 mm along a length thereof, or as required to offer connection opportunities for other constructional elements.

[0058] It will be appreciated that the axial straight-through bolt hole 150 , of which hexagonal nut receiving slot 152 is visible in Figure 2, may be used to pass a long threaded bolt along a central axis of the beam or column which may connect to or pass through further connectors in the beam or column, provided the straight-through path is clear of another bolt. This enables strengthening of the beam or column as desired.

[0059] Figure 2 also shows how in this embodiment of the connector of the first type is sized and shaped to also be installed inside a single C-channel member 300 and fastened thereto through flanges 301 and 302 so that the second straight- through bolt hole comprising hole 133 is oriented along a length of C-channel member 300. This enables a bolt passing through the second straight-through bolt hole to attached through a hole 270 in web 253 of second C-channel member 250 through bolt hole 113 and attached by a nut in nut receiving slot 139, or 138, or alternatively extended entirely through the beam or column and connected elsewhere. This allows a single C-channel member 300 to be attached at right angles to the box-section beam or column.

[0060] The same configuration of the connector inside C-channel member 300 can be used to form an I-beam whereby connectors of the first connector type may be used in each of two C-channel members with a bolt passing through both third straight-through bolt holes and corresponding apertures in the webs of the C- channel members to attach the two C-channel members together in parallel with the channels facing away from one another to form the I-beam or I-column.

[0061] Figure 3A shows a cube shaped connector which can be formed from 2 connectors of first type 160 and 170 and a joiner 180. Joiner 180 is shown in Figure 3B and preferably has a profile suited to match the internal landscape of the connectors of first type to provide multiple points of engagement. [0062] Figure 4 shows the use of the composite cube shaped connector to join up to 6 of the box section beams or columns in 3 dimensions. Central cube-shaped connector 400 is shown oriented along a defined labelled Z axis, in an expanded view of a 6-way attachment. Beams or columns 500, 501, 502, and 503 are aligned along defined X and Y axes , each of which has a

duplicate cube-shaped connector or 410, 420, 430, 440 at a connection end thereof (some partly obscured) , each duplicate cube-shaped connector being also oriented along the Z axis. This allows 2 bolts to be used to connect each of the beams or columns 500, 501, 502, 503 through bolt holes such as 401, 402, 403, 404 in the connectors of the first type, while leaving the axial (Z axis) third straight-through bolt hole of the central cube shaped connector 400 unimpeded by using bolts which terminate at the nut-receiving slots in the central cube shaped connector 400. Along the Z axis, single connectors of the first type 450, 460 at connection ends of beams or columns 511 and 510 respectively also oriented along the Z axis can be connected to the central cube 400 by means of a bolt through the aligned axial third straight-through bolt holes of the connectors 450, 460 and the central cube 400. As described above, the bolts may extend some distance along either or both of any of the beams or columns to provide a desired amount of strengthening, and in particular a single strengthening bolt may extend straight through the Z axis in both directions if desired.

[0063] Referring now to Figure 5A and 5B, this embodiment further comprises a second connector type 600 which is sized and shaped essentially as approximately one half of the connector of the first type and is adapted to function in two applications. While the connector of the first type in this embodiment can be used for these 2 applications , it can be useful to have a one- half connector of the 2nd type as described herein. First side 620 and opposite second side 630 each comprise a screw hole such as 603 and are spaced apart by 88 mm to snugly fit across and inside the first C-channel member 300 with the first side 620 engaging the flange 301 and the second side 630 engaging an opposite flange 302 of C-channel member 300. A third side 650 is disposed between the first and second sides and is oriented at right angles thereto and comprises a straight-through bolt hole 610 passing through the middle of the third side 640 and emerging on opposite fourth side 640. Third side 650 also comprises screw holes 601 and 602. The distance between the opposite third and fourth sides is sufficiently small to enable the connector 600 to fit inside the C-channel member 300 under lips 304, 305. The connector 600 is also sufficiently small to be alternatively oriented with the straight-through bolt hole 610 facing along the length of the C-channel member as described below. As described above in relation to the connector of the first type, the connector of the 2nd type can also be used to form I-section beams or columns.

[0064] In the first application, the connector of the second type is used to join first C-channel member 300 to a second C- channel member (not shown) at right angles by fastening

connector 600 through the screw holes in the first and second sides 620 and 632 the flanges 301 and 302 of the first C-channel member 300, with the fourth side 640 being oriented facing outwards perpendicular to web 303 with the bolt hole 610 directed through an aperture in the web 303. The second C- channel member (not shown) may be connected at right angles to first C-channel member 300 using a bolt through bolt hole 610 extending through a bolt hole of a connector of the first type installed in the second C-channel member as shown in Figure 2, or alternatively a bolt hole of another connector of the second type installed in the second C-channel member rotated by 90° similar to Figure 5A but the third and fourth sides rotated by 90° compared with Figure 5A. [0065] In the second application shown in Figure 5B, , connector of the second type 600 is placed inside C-channel member 300 with the third side 650 engaging one of the flanges 302 and fastened to the flange 302 using screws into the screw holes 601, 602, providing a secure attachment point for a Bolt passed through the straight-through bolt hole 610 in the third and fourth sides and a corresponding hole (not shown) in the flange. This application enables a secure foundation for a bolt anywhere along a flange of a C-channel member, which may be used for example to securely attach a bracket which may enable cladding to be attached to a C-channel member used as a wall joist.

[0066] It can be seen from the above description that

embodiments of the invention allow connectors of only 1 or 2 types to provide wide number of relative orientations for a connecting C-channel members, including providing a means of constructing box section or I -section beams or columns and reversibly joining them with bolts to each other or to C-channel members. The invention offers an opportunity also to construct modular, typically rectangular, frame elements from C-channels which can be bolted together through adjacent connectors to form building structures and easily unbolted for dismantling and later re-use in other building structures.

[0067] Persons skilled in the art will also appreciate that many variations may be made to the invention without departing from the broadest scope of the invention, which is determined from the consistory clauses and claims.

[0068] For example, the particular dimensions shown are

exemplary only and different sizes of C- channel members and corresponding connector dimensions are contemplated, including C-channel members with 180 mm width webs, used for structural floors, and 70 mm webs used for lightweight office partitions. Similar variations apply to flanges . The example provided above is typical for wall, floor and roof construction. While the embodiment connector of the first type is composed of a fibre reinforced plastic, any rigid block composition of sufficient strength is within the broadest scope.

[0069] Further, it is not intended that the holes in the connector in the broadest aspect are limited to holes in which bolts are slidingly passed therethrough or threaded holes able to accept screws or unthreaded holes able to accept screws - in its broadest aspect the invention extends to connectors with any holes suitable for receiving a fastening element of any type. Further, the term "bolt" refers in its broadest sense, unless the context requires otherwise, to a fastening element being adapted to engage with a constant diameter threaded nut, free or embedded, or an embedded threaded sleeve. Accordingly, while it is preferred to use nut receiving slots for removable nuts in the embodiment shown above, alternative embodiments with restricted functionality can use embedded threads which cannot be removed. Also, the term "screw" refers to a tapered fastening element adapted to screw into the hole of the connector, typically able to tap its own thread in the hole.

[0070] Further still, the terms "side" and "side faces" in the claims are intended to be interpreted in terms of the different functions of the described sides or side faces rather than visually and extend to surfaces which may not be recognisably distinct or uniformly flat and which may continuously curve into adjacent sides or faces.

[0071] Further still, the invention in its broadest aspect extends to systems where the one or more holes on one or more faces include one set of holes for performing the function of fastening the connector to the C-channel members and another set of holes for performing the function of fastening the connector to other connectors, as well systems where some or all of the holes can form both functions .

[0072] In the claims which follow and in the preceding

description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or

"comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention .

[0073] It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.