“Frame Assembly with Concealed Connectors”

FIELD OF THE INVENTION

[0001] This invention generally relates to a frame assembly with elongate frame members and concealed connectors, wherein the elongate frame members self-align and the connectors are concealed from view.

[0002] One embodiment of the invention provides a pyramidal frame assembly with precise dimensions and wherein the means of connection between the sides of the pyramid is concealed (hidden from view).

[0003] Another embodiment of the invention provides a geodesic dome frame assembly with concealed connectors.

TERMINOLOGY

[0004] The following specific terminology is used in the context of the present invention:

• “align” in relation to the elongate frame members means to position adjacently

connected elongate frame members so as to bound a planar surface;

• “chamfered” in relation to the elongate frame members means a planar or compound cut oriented both radially and laterally across the end of the elongate frame member (which may be hollow). Typically, the chamfering of the ends of the elongate frame members having a circular cross-section results in a cut across the elongate frame member that has an elliptical shape or two or more elliptical shapes that may overlap or cut into each other (and may be an elliptical annulus). In relation to non-circular cross-section elongate frame members the term chamfered is also used in the context of the present invention - even though such a cut may not be strictly considered as a chamfer;

• “compound” in relation to the cuts applied to the ends of the elongate frame

members means two or more cuts that are at an angle to each other;

• “conceal” in relation to the interaction of the elongate frame members and the

connectors means to hide the connectors from view;

• “frame” in relation to the present invention means an assembly formed of elongate members joined together with one or more connectors, whereby the assembly of the elongate frame members and the one or more connectors forms a structure capable of supporting itself or something else;

• “at least partly hollow” in relation to the present invention means that the end portions of the elongate frame members are at least partly hollow for receiving a connector for joining the elongate frame members together. That is, the hollow portion of the elongate frame members do not have to extend the entire length of the elongate frame member, although the hollow portion could extend the entire length of the elongate frame member without altering the efficacy of the connection, provided the hollow portion is sufficiently long to receive the portion of the connector that extends into the elongate member, whilst maintaining concealment of the connector;

• “planar surface” in relation to the alignment of the elongate frame members means that elongate frame members, when joined with the connectors, align to form or bound surfaces which are two-dimensional;

• "self-align" in relation to the elongate frame members means that adjacent elongate frame members, when fitted together with the connectors, align into planar surfaces without the need for additional elements to achieve accurate alignment; and,

• “self-alignment” has the same meaning as self-align.

[0005] It is important to note that the elongate frame members could be hollow or at least partly hollow along their length.

[0006] It is also important to note that it is the frame assembly that has precision in its final fitment, and this could be achieved even where the connectors are somewhat less than precise, because it is the cooperation of adjoining faces of the elongate frame members that leads to the frame assembly being precise and concealing the connectors.

[0007] It is also important to note that the chamfered ends of the elongate frame members of the present invention are not the same as a“saddle cut”, since in the present invention the faces of the ends of adjacent elongate frame members are two-dimensional and are intended to mate, whereas in a saddle cut the face of one pipe is cut with a three- dimensional curve to match the outside curved surface of an adjoining pipe, so as to join the end of one pipe part way along the length of another pipe. That is, the saddle cut is not “planar” nor is it“compound”, a saddle cut is three-dimensional.

BACKGROUND TO THE INVENTION

[0008] Typically, prior art frames assemblies are formed of connectors and elongate frame members. The connectors are typically fixed to the ends of the elongate frame members or fitted into the end of the elongate frame members. The present invention deals with the latter.

[0009] A shortcoming of conventional frame assemblies is that the connectors are visible. Often such connectors are made a feature of the design of the frame assembly. See for example, US2,904,360 by Gamlen, US4,413,570 by Haigh and US5, 011 ,323 by Liuo.

[0010] Another shortcoming of many frame assemblies is that adjacent elongate frame members either do not align accurately or require further elements to achieve accurate alignment. See for example, US3,854,831 by Gutner and US5,516,225 by Kvois.

[0011] The present invention seeks to overcome these shortcomings by providing elongate frame members that are able to self-align (without needing additional alignment elements) and capable of concealing the connectors that join the elongate frame members together so that the connectors are not visible.

SUMMARY OF THE INVENTION

[0012] Therefore, it is an object of the present invention to provide a frame assembly with elongate frame members capable of self-alignment and with connectors that are concealed from view.

[0013] In accordance with one aspect of the present invention, there is provided a frame assembly comprising: a plurality of elongate frame members each with end portions that are at least partly hollow; and one or more connectors dimensioned to be inserted into the end portions of the elongate frame members to join the elongate frame members together into a structure; wherein the end portions of the elongate frame members cooperate to self-align; and wherein the end portions of the elongate frame members are shaped to conceal the connectors from view.

[0014] In accordance with another aspect of the present invention, there is provided an elongate frame member for a frame assembly, the elongate frame member comprising: an elongate body, one end portion located at one end of the elongate body; another end portion located at the other end of the elongate body; wherein the end portions are at least partly hollow; and wherein the end portions cooperate so that two adjacent elongate frame members can self- align when joined together with connectors to form the frame assembly.

[0015] In accordance with another aspect of the present invention, there is provided a method of aligning elongate frame members with connectors for forming a frame assembly, the method comprising the steps of: chamfering end portions of the elongate frame members to precise angles so that adjacent elongate frame members of predetermined lengths can abut each other to form a planar surface; and inserting the connectors into hollow end portions of the elongate frame members to join the elongate frame members together; wherein the adjacent elongate frame members cooperate to self-align upon the connectors; and wherein the connectors are concealed from view by the elongate frame members.

[0016] Typically, the ends of the elongate frame members have one or more chamfers oriented to mate with chamfers of adjacent elongate frame members to align the elongate frame members. The chamfers also have the effect of concealing the connectors.

[0017] Typically, the chamfering of the ends of the elongate frame members results in a cut across each elongate frame member that has an elliptical shape or two or more elliptical shapes that may overlap or cut into each other (and may be an elliptical annulus).

[0018] Typically, the ends of the elongate frame members are hollow.

[0019] Optionally, the entire length of the elongate frame members may be hollow.

[0020] The elongate frame members may be solid with their ends hollowed out or drilled out to accept the connectors.

[0021] Typically, the hollow end portions of the elongate frame members conceal the connectors.

[0022] Throughout the specification, unless the context requires otherwise, the word “comprise” or variations such as“comprises” or“comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers. Likewise, the word“preferably” or variations such as“preferred”, will be understood to imply that a stated integer or group of integers is desirable but not essential to the working of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The nature of the invention will be better understood from the following description of specific embodiments of the present invention, given by way of example only, with reference to the accompanying drawings in which:

[0024] Figure 1 is a perspective view, seen from the side, of an apex connector of a pyramidal frame assembly in accordance with one embodiment of the present invention;

[0025] Figure 2 is a perspective view seem from the side, of a corner connector of a pyramidal frame assembly in accordance with the embodiment of Figure 1 ;

[0026] Figure 3 is a perspective view, seen from the side, of an apex connector of a pyramidal frame assembly in accordance with another embodiment of the present invention;

[0027] Figure 4 is a perspective view seem from the side, of a corner connector of a pyramidal frame assembly in accordance with the embodiment of Figure 2;

[0028] Figure 5 is a square pyramidal frame assembly created with the connectors of Figures 1 and 2 or 3 and 4;

[0029] Figure 6 is a perspective view, seen from above, of a portion of the apex of the pyramidal frame assembly of Figure 5, shown with the elongate frame members only partly inserted onto the connector;

[0030] Figure 7 is a perspective view, seen from below, of the portion of the apex of the pyramidal frame assembly of Figure 6;

[0031] Figure 8 is a plan view of the apex of the pyramidal frame assembly of Figure 5, shown with the elongate frame members slightly separated on the connecter and with one of the elongate frame members removed, demonstrating how the elongate frame members self-align;

[0032] Figure 9 is a perspective view, seen from above, of a corner of a rectangular prism frame assembly;

[0033] Figure 10 is a perspective view, seen from above, of the corner portion of Figure 9, shown with the elongate frame members separated from the connector; and

[0034] Figure 1 1 is a perspective view from below of a rectangular prism frame assembly in accordance with the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0035] Shown in Figures 1 to 4 are two exemplary embodiments of sets of connectors in accordance with the present invention. These two sets of connectors are capable of making a frame assembly in the form of a pyramidal frame assembly 10, as shown in Figure 5, with a square base and triangular sides.

[0036] The present invention shall now be described with particular reference to the square pyramid of Figure 5, however, it is to be understood that the teachings are of general applicability and other shapes of frame assemblies are also possible, including, for example, rectangular prisms, hexagonal prisms and even more complex shapes, such as, for example, a tent or house shape or geodesic domes or any type of space frame including.

[0037] Referring specifically to Figures 1 ,2 and 5 the pyramidal frame assembly 10 comprises eight elongate frame members 12, an apex connector 14 and four corner connectors 16.

[0038] Typically, the elongate frame members 12 are tubular with a substantially constant cross-section along their length. The elongate frame members 12 each comprise an elongate body 17, one end portion 18 located at one end of the elongate body 17 and another end portion 19 located at the other end of the elongate body 17. The two end portions 18 and 19 are at least partly hollow for receiving the connectors 14 and/or 16.

Typically, the hollow end portions 18 and 19 are circular in cross-section. Typically, the hollow end portions 18 and 19 are substantially similar or the same, although they could be different depending upon the nature of the frame assembly 10 that they are forming.

Conveniently the elongate frame members 12 can be formed from pipe or hollow rod.

[0039] The hollow end portions 18 and 19 of the elongate frame members 12 do not have to extend the entire length of the elongate frame members 12, although the hollow end portions 18 and 19 could extend the entire length of the elongate frame members 12 without altering the efficacy of the connection, provided the hollow portions 18 and 19 are sufficiently long to receive the portion of the connectors 14 or 16 that extend into the elongate frame members 12, so as to maintaining concealment of the connectors 14 and/or 16. Where the hollow end portions 18 and 19 extend the entire length of the elongate frame members 12 the hollow end portions 18 and 19 combine into one hollow core.

[0040] The apex connector 14 is circular in cross-section and has four spigots 20 joined at a junction 22. Typically, the apex connector 14 is made of solid materials, although they could be made from hollow materials.

[0041] Each corner connector 16 is also circular in cross-section, but has three spigots 30 joined together at a junction 32.

[0042] Conveniently, the apex connectors 14 and 16 are made by 3D printing or moulded or are cast or formed by welding bars together (provided the welding does not alter the dimensions or orientation of the spigots 20 and does not interfere with the abutment of the chamfered edges 34).

[0043] Typically, the spigots 20 and 30 are longer than they are wide. More particularly, the spigots 20 and 30 are more than twice as long as their transverse dimension. Still more particularly, the spigots 20 and 30 are between two to three times as long as they are wide. The hollow end portions of the elongate frame members 12 must be at least as long as the length of the spigots 20 and 30 so as to conceal the connectors 14 and 16.

[0044] The apex connector 14 and the corner connector 16 could be made from plastics materials, wooden materials or metals materials or even a combination of these materials.

[0045] The angles of the spigots 20 and 30are set in accordance with the design

requirements of the frame assembly 10. For example, in relation to a pyramidal frame assembly, based upon the Giza pyramid, with a base made from elongate frame members 12 having a length of 1000 mm, and ascending elongate frame members 12 having lengths of 932.6 mm and producing a pyramidal frame assembly 10 having a height of 624 mm, requires corner spigots 30 with an ascending angle of 45.0°to the horizonal, and apex spigots 20 having a descending angle of 45.0° to the vertical.

[0046] The spigots 20 and 30 of the connectors 14 and 16, respectively, are dimensioned to have an interference fit with the elongate frame members 12.

[0047] Typically, the elongate frame members 12 and the connectors 14 and 16 are circular in cross-section, although they could have other cross-sectional shapes, such as, for example, triangular, square, hexagonal and the like.

[0048] The end portions of each of the elongate frame members 12 have chamfered edges 34, as shown in Figures 6 to 8. In the exemplary embodiment each elongate frame member 12 has two chamfered edges 34 that cut across the elongate frame member 12 and meet at an inner cusp 36 and an outer cusp 38. The chamfered edges 34 are planar, two- dimensional surfaces. Particularly as shown in Figure 8, the chamfered edges 34 enable adjacent elongate frame members 12 fitted onto the spigots 20 of the connector 14 (or the spigots 30 of the connector 16) to abut neatly along the planar surface. This abutment causes the elongate frame members 12 to self-align. In the case of circular cross-section elongate frame members 12 the planar face defines a segment of an elliptical annulus.

Since each elongate frame member 12 abuts two other elongate frame members there are two planar faces for each elongate frame member 12 and the planar faces are at acute angles to each other and typically intersect or cut into each other at the cusps 36 and 38. In this way the elongate frame members 12 can abut to self-align. The elongate frame members 12 also conceal the connectors 14 and 16 from view.

[0049] The visual appearance of the abutment of adjacent elongate frame members 12 is identical to the apex connector 14 and the edge connector 16 shown in Figures 1 and 2, as seen at the joins of their respective spigots 20 and 30.

[0050] Abutting the elongate frame members 12 causes them to align themselves and achieves some torsional rigidity. That is, the capability of the elongate frame members 12 to self-align is achieved by the abutment of the end portions of adjacent elongate frame members 12.

[0051] Referring specifically to Figures 3 and 4 the pyramidal frame assembly 10 may also or alternatively comprise eight elongate frame members 12, and an apex connector 44 and four corner connectors 46. The connectors 44 and 46 are similar to the connectors 14 and 16, respectively except that the connectors 44 and 46 have circumferential grooves 50 located proximate the free ends of their spigots 52 and 54, respectively, distal from their junctions 56 and 58, respectively.

[0052] The grooves 50 are dimensioned to received O-rings (not shown) for the purpose of forming an interference fit with the elongate frame members 12. By this means the spigots 52 and 54 may be shorter than in the previous embodiment, provided the material from which the connectors 44 and 46 are made are sufficiently strong. With the O-ring connectors the spigots 52 and 54 can be less than twice as long as their width, and almost as short as their width. Also, the spigots 52 and 54 do not themselves have an interference fit with the elongate frame members 12. That is the spigots 52 and 54 have a width dimension that is less than the internal dimensions of the elongate frame members 12.

[0053] Conveniently the O-rings are made from rubber or other resilient material. The O-rings are typically smaller than the external diameter of the spigots 52 and 54. The O-rings are expanded over the free ends of the spigots 52 and 54 and elastically contract into the grooves 50.

[0054] Alternatively, the O-rings could be made of resilient metals materials, in which case a transverse cut is provided through the metal O-ring to allow it to resiliently expand over free ends of the spigots 52 and 54 and resiliently contract into the grooves 50.

[0055] In an alternative arrangement the spigots 20, 30, 52 and 54 may have circumferential or longitudinal ridges to assist with providing mechanical interference between the spigots 20, 30, 52 and 54 and the end portions of the elongate frame members 12 for providing fixing between the connectors 14, 16, 44 and 46 and the elongate frame members 12.

[0056] In another arrangement the spigots 20, 30, 52 and/or 54 may be adhered to the elongate frame members 12, either temporarily or permanently with adhesive, such as, for example construction grade adhesive. Adhesive also has the benefit of providing torsional resistance to relative movement of the elongate frame members 12 where they have circular cross-sections.

[0057] In another arrangement the spigots 20, 30, 52 and/or 54 could be provided with a spring means for engaging with the hollow end portion 18, 19 of the elongate frame member 12

[0058] In yet another arrangement the connectors 14 and 16 could have different numbers of the spigots 20, 30, 52 and/or 54 so as to create a frame assembly which is other than pyramidal in shape. For example, connectors 14 and 16 with five and/or six of the spigots 20, 30, 52 and/or 54 may be used to create a geodesic dome structure.

[0059] In yet other arrangements the connectors 14 and 16 could have between 4 and 8 (or more) spigots 20, 30, 52 and 54 to form a space frame assembly for supporting a roof or the like.

[0060] In another embodiment there is provided a rectangular prism frame assembly 70, one corner of which is shown in Figures 9 and 10. The rectangular prism frame assembly 70 is similar to the frame assembly 10 and like numerals denote like parts. The main difference is that the rectangular prism frame assembly 70 has square cross-section elongate frame members 12 and square cross-section hollow end portions 18 and 19.

[0061] It is to be understood that the square cross-section elongate frame members 12 could have circular cross section hollow end portions 18 and 19.

[0062] It is also to be understood that the circular cross-section elongate frame members 12 could have square cross-section hollow end portions 18 and 19.

USE

[0063] In use, the angles of the spigots 20, 30, 52 and 54 are set in accordance with the design requirements of the frame assembly 10. To form the pyramid 10, one connector 14, 44 with four spigots 20, 52 and four connectors 16, 46 each with three spigots 30, 54 are required. For example, in relation to a pyramidal frame assembly, based upon the Giza pyramid, with a base made from elongate frame members 12 having a length of 1000 mm, and ascending elongate frame members 12 having lengths of 932.6 mm and producing a pyramidal frame assembly 10 having a height of 624 mm, requires corner spigots 30, 54 with an ascending angle of 45.0° to the horizonal, and apex spigots 20, 52 having a descending angle of 45.0° to the vertical.

[0064] Where the frame assembly is square or rectangular prism, connectors 14 and 16 with three of the spigots 20, 30, 52 and 54 set at 90 degrees to each other are used and the size of the frame assembly does not alter the angle of the spigots 20, 30, 52 and 54. The size of the rectangular prism frame is set by the length of the elongate frame members 12.

[0065] In the case of a geodesic dome, connectors 14 and 16 with five and/or six spigots 20, 30, 52 and 54 are required. Depending upon the size of the geodesic dome, connectors with five spigots 20, 30, 52 and 54 may not be needed.

[0066] The connectors 14 and 16 are forced into the elongate frame members 12 to form the frame assembly 10. The forceable fitment of the connectors 14 and 16 is against the resistance of the interference fit of the connectors 14 and 16 with the end portions 18 and 19 of the elongate frame members 12.

[0067] Similarly the connectors 44 and 46 are inserted into the elongate frame members 12 against the resistance of the O-rings interfering with the elongate frame members 12.

[0068] In each case the ends of the elongate frame members 12 slide over the spigots 20,

30, 52 and 54 until the chamfers of adjacent elongate frame members 12 abut. This forces the adjacent elongate frame members 12 to align into planar surfaces without the need for additional alignment means.

[0069] Also, once the adjacent elongate frame members 12 abut and align, the elongate frame members 12 conceal the spigots 20, 30, 52 and 54 and their connectors 14 and 16.

INDUSTRIAL APPLICABILITY

[0070] The frame assembly 10, 70 and connectors 14, 16, 44 and 46 of the present invention are suitable for making frames, such as for storage devices, pyramids, space frames and even geodesic domes. The frame assembly 10, 70 of the present invention is applicable to the creation of frames with precise dimensions and where aesthetics of concealment of connectors is desired or needed.

[0071] The frame assembly 10,70 and connectors 14, 16, 44 and 46 of the present invention resides and operates in the field of frames. More particularly the present invention resides and operates in the field of precision frames and aesthetic frames.

[0072] The consequence of the use of the frame assembly 10,70 and connectors 14, 16, 44 and 46 of the present invention is that a precise frame assembly 10,70 can be made with no visible signs of connection between the elongate frame members 12.

REFERENCE SIGNS

[0073] The specification uses the following reference signs:

10 frame assembly

12 elongate frame member

14 apex connector

16 corner connector

17 elongate body

18 end portion

19 end portion

20 spigots

22 junction

30 spigots

32 junction

34 chamfered edges

36 inner cusp

38 outer cusp

44 apex connector

46 corner connector

50 circumferential grooves

52 spigot

54 spigot

56 junction

58 junction

70 rectangular prism frame assembly

ADVANTAGES

[0074] The frame assembly 10, 70 and connectors 14, 16, 44 and 46 of the present invention have the advantage that it enables the fabrication of precise frame structures.

[0075] The frame assembly 10, 70 of the present invention also has the advantage that the elongate frame members 12 self-align to form planar surfaces. The self-alignment achieved with the chamfered end portions of the elongate frame members 12 avoids the need to use other means to achieve alignment and precision.

[0076] The frame assembly 10, 70 of the present invention also has the advantage that the connectors 14, 16, 44 and 46 used to join the elongate frame members 12 together are concealed.

[0077] The frame assembly 10, 70 of the present invention has the further advantage that the elongate frame members 12 can align even where the elongate frame members 12 have a circular cross-section.

[0078] The frame assembly 10, 70 of the present invention has the further advantage that it is precise in its dimensions.

[0079] The frame assembly 10, 70 of the present invention has the further advantage that it has the aesthetic appeal of having no visible means by which the elongate frame members (12) are joined together.

[0080] The frame assembly 10, 70 of the present invention has the further advantage that it allows for speedy construction of frames on site, as well as prefabrication of frames off-site, for assembly on-site, for example, using construction adhesive.

MODIFICATIONS AND VARIATIONS

[0081] It will be readily apparent to persons skilled in the relevant arts that various modifications and improvements may be made to the foregoing embodiments, in addition to those already described, without departing from the basic inventive concepts of the present invention. For example, other shapes of frame assemblies may also be created with the connectors and frame members of the present invention, by using varying the number of spigots 20, 30, 52, 54 per connector 14, 16, 44, 46 and the relative angles therebetween. These may include rectangular frames, multisided frames, even geodesic dome shaped frames or space frames whose outer frame vertices define a planar surface for supporting roofing panels or the like. Also, the elongate frame members 12 could be made of hollow bar with a relatively thick wall section. Further, the connectors 14, 16, 44, 46 could be made of other materials, such as, for example, ceramic, bamboo, rubber materials or the like. Still further the elongate frame members 12 could be curved or otherwise non-straight, and could be irregular in shape provided they are elongate.