Connector assembly for connecting building members

The present application is a continuation-in-part of U.S. Pat. No. 8,181,419, issued May 22, 2012, entitled “Connector for Connecting Building Members”. The contents of this patent U.S. Pat. No. 8,181,419 are expressly incorporated herein by reference.

The present invention relates to lightweight metal building components and more particularly to connecting assemblies for connecting metal building components together.

Movable or slideable construction member connections can be utilized in building design to prevent or limit damage due to varying or dynamic loads. Varying loads can arise from movement of equipment and personnel in the building as well as from environmental factors such as high winds and seismic activity. Flexing of construction members under varying load is expected and acceptable within code-specified limits. However, such flexing often means that some connections between members can cause damage if some relative movement between the connected members is not allowed. The building industry has recognized this problem. Movement between connected members has been accommodated by having sliding connections between the members to permit limited relative movement between the members while keeping the members otherwise securely connected together.

An approach commonly used is that of a slotted connection. In a typical configuration, a connector in the form of a plate or bracket is rigidly secured to or part of one of the members and slideably connected to the other member by means of one or more slots and fasteners. Typically the plate has slots, and shouldered or bushed screws, are projected through slots and into the other member. The screws are tightened to secure the members together but yet permit the members some range of relative sliding movement. The head of the fastener is prevented by the shoulder or bushing from clamping against the connector plate so that the plate can move along the length of the slot. For a more complete and detailed description of such connection devices, reference is made to U.S. Pat. Nos. 5,906,080; 6,612,087; 5,467,566; 7,503,150; and, 8,181,419; the disclosures of these patents are expressly included herein by reference.

The degree to which such devices function as intended is dependent upon proper installation. For example, should a shouldered screw be inserted and tightened off center in the slot, the shoulder would overlap and clamp the plate to the member. This clamping would render the connection more or less rigid and not slideable. Avoiding this kind of improper installation requires time and installer dexterity to properly align the screw in the slot.

A need exists for a connection assembly that will provide for easy and accurate screw placement to prevent inadvertent clamping together of the building members being connected and to thus facilitate slideable connection between the members

The present invention relates to a metal building component that includes an elongated slot having a breakaway washer integrally formed therein. The breakaway washer in one embodiment includes a series of raised dimples that extend outwardly from the face of the washer. A fastener having a flange is inserted through a centering opening in the washer. The fastener extends through the breakaway washer and connects to another building structure or component. The raised dimples provide an interface between the breakaway washer and a flange that forms a part of the fastener. More particularly, the raised maintain a clearance between the fastener head and the building component so that slideability may be achieved.

In another embodiment, the breakaway washer design is similar but in this case instead of employing the raised dimples, the breakaway washer is provided with a raised burr. The raised burr serves as an interface between the breakaway washer and the flange of the fastener, maintaining a clearance between the fastener head and the building component so that slideability may be achieved.

In another embodiment of the present invention, there is provided a track that includes one or more breakaway washers in both the flanges and the web of the track. This enables the track to move vertically and horizontally once the breakaway washers break away from the slots.

Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of the invention.

FIG. 1 is a perspective view of a metal building track having the breakaway washer incorporated therein.

FIG. 2 is an enlarged view showing the face of the breakaway washer.

FIG. 2A is a sectional view taken through the line 2 A- 2 A of FIG. 2 .

FIG. 2B is a sectional view taken through the line 2 B- 2 B of FIG. 2 .

FIG. 3 is an enlarged plan view showing the backside of the breakaway washer connected in a slot.

FIG. 4 is a fragmentary perspective view of a portion of a building structure showing the use of the breakaway washer to connect a series of studs to a track.

FIG. 5 is a perspective view of the fastener employed with the breakaway washer.

FIG. 6 is a fragmentary side elevational view showing the fastener extending through the breakaway washer.

FIG. 7 is a sectional view taken through the line 7 - 7 of FIG. 6 .

FIG. 8 is a fragmentary side view showing an alternate design for the breakaway washer.

FIG. 9 is a sectional view taken through the line 9 - 9 of FIG. 8 .

FIG. 10 is a sectional view showing the fastener extending through the breakaway washer shown in FIG. 8 and into an engagement with an adjacent said.

FIG. 11 shows one embodiment of the breakaway washer incorporated into a plate or clip structure.

FIG. 11A is a perspective view showing the plate or clip structure of FIG. 11 interconnecting a stud with a track.

FIG. 12 is another alternate embodiment showing a track having the breakaway washer design of the present invention incorporated into both the flanges and web of the track.

With further reference to the drawings, a building structure or connector assembly is shown therein. With reference to FIG. 1 there is shown a metal track indicated generally by the numeral 2 . Metal track 2 includes a pair of flanges 2 B and a web 2 A. Each flange includes a series of spaced apart slots 14 . As seen in FIG. 1 , each slot 14 is elongated and extends generally vertically. As will be appreciated by those skilled in the art, the track 2 is configured to connect to one or more studs via the flanges 2 B. In addition, the web 2 A of the track is typically connected to another building component or structure such as a floor or ceiling structure.

Incorporated into the slots 14 of the building member 2 is a breakaway metal washer 20 . The breakaway washer 20 shown in FIGS. 1-3 is designed to break away from its respective slot in response to a certain force or load being applied to the breakaway washer. The term “breakaway washer” means a member having a fastener opening and disposed in an elongated slot and initially fixed relative to the slot but designed to break away from the slot in response to a certain force being applied to it and to allow relative motion between the slot and the breakaway washer after it has broken away from the slot. The term “breakaway washer” does not imply a meaning normally associated with a conventional washer.

Viewing the breakaway washer 20 shown in FIGS. 1-3 , the same includes a main body. Projecting from the main body is a pair of offset tabs 20 B. As seen in the drawings, the offset tabs 20 B join opposed edges of one slot 14 . One advantage of the present design for the breakaway washer 20 is that the width of the tabs 20 B can be more closely controlled. This provides the ability to adjust the actual force required to break the washer 20 loose. The main body of the breakaway washer 20 includes a fastener-centering opening 22 for receiving the shaft of a fastener 16 to be described subsequently herein. The main body further includes a face 20 A. The face 20 A of the main body faces outwardly and the face is generally flat and includes a surface area.

Formed in the main body of the breakaway washer 20 is a series of dimples 20 C. The dimples 20 C project outwardly from the face 20 A of the breakaway washer 20 . More particularly, the series of dimples 20 C project slightly out of the planar face of the main body of the breakaway washer 20 . The height of the dimples can vary but in one embodiment, the dimple height is approximately 0.005 inches above the planar surface of the face 20 A. As will be discussed later, the purpose of the dimples 20 C is to provide clearance between the screw head and the main body of the flange 2 B. In one embodiment, the slot 14 should be able to move relative to the breakaway washer 20 when the washer actually breaks away. If the fastener binds the breakaway washer to the flange 2 B, then it is possible that the breakaway washer will not freely move within the slot 14 . Thus the dimples 20 C effectively provide clearance between the face 16 C of the fastener 16 and the main body of the flange 2 B, and that makes it more likely that when the breakaway washer actually breaks away in the slot 14 that the slot can freely move relative to the breakaway washer.

FIG. 3 shows the backside of the breakaway washer. Opposite the dimples 20 C is a series of slight depressions 20 D. When the depressions 20 D are formed, this tends to disperse metal in the breakaway washer 20 and causes the formation of the arcuate bulges 20 G. See FIGS. 2 and 3 . The arcuate bulges 20 G occupy space and tend to partially close the gap between the main body of the washer 20 and the edges of the slot 14 . This has the advantage of limiting the side-to-side movement of the main body once the washer has broken away from the slot 14 . The arcuate bulges 20 G are optional. In other embodiments, there would be no arcuate bulges 20 G. Instead the opposed sides of the breakaway washer 20 would be straight. In addition the main body includes upper and lower edges 20 E and side edges 20 F.

Forming a part of the connector assembly or the building assembly of the present invention is a fastener indicated generally by the numeral 16 . Fastener 16 includes an enlarged head or flange 16 B. Flange 16 B includes a face 16 C and the fastener 16 further includes a shaft 16 D. The design of the assembly disclosed herein is aimed at making the fastener 16 a conventional fastener. Typically fastener 16 is a so called “modified truss-head” screw also known as a “lath” screw. See FIG. 5 . Note the enlarged flange 16 B of the fastener 16 . The flange 16 B is wider than the width of the slot 14 . In the embodiments illustrated herein, there is no shoulder provided between the flange 16 B and the shaft 16 D. Again the fastener 16 is a conventional fastener. This has the advantage of making it easier for contractors to obtain rather than having to order special screws, especially screws having a certain size shoulder.

A typical application of the track 2 is shown in FIG. 4 . Here track 2 is connected to a series of studs 3 and to a floor or ceiling structure 1 . As will be appreciated by those skilled in the art, the connection that exists between the studs 3 and the track 2 enable relative movement between the track and the studs.

At each connection point between the track 2 and the stud 3 , the fastener 16 projects through the fastener center opening 22 and the breakaway washer 20 and into the flange 3 B of the stud 3 . Note that the dimples 20 C face the face 16 C of the fastener 16 . As the fastener 16 is screwed into the flange 3 B of the stud 3 , the face 16 C of the fastener will only contact the raised dimples 20 C. That is the dimples 20 C serve as a separator between the main body of the flange 2 B and the face 16 C of the fastener. In other words, the dimples 20 C tightly clamp the breakaway washer 20 against the flange 3 B of the stud but allow movement of the slot relative to the breakaway washer. As discussed above, this assures that once the breakaway washer is broken loose from the slot the slot can move freely about the washer and enable relative movement between the track 2 and the studs 3 .

Note FIGS. 2A and 2B which show the dimples 20 C raised above the planar surface of the main body of the breakaway washer 20 . Also in FIGS. 2A and 2B it can be seen that by forming the dimples 20 C that the underlying depressions of 20 D cause portions of the metal to bulge out to one side to form the arcuate bulges 20 G that tend to limit the side-to-side movement of the breakaway washer 20 when it breaks loose from the slot 14 . Note that FIG. 6 shows the fastener flange 16 B is sufficiently wide that it bridges the slot 14 . Note in FIG. 7 where the dimples 20 C are only slightly elevated over the face 20 A of the breakaway washer 20 but that the dimples prevent the flange 16 B from directly engaging the track flange 2 B. More particularly, the washer 20 is only engaged to the stud flange 3 B by the flange 16 B via the dimples 20 C.

Turning to FIGS. 8-10 , another embodiment for the breakaway washer 20 is shown. This embodiment is similar to the embodiment shown in FIGS. 1-7 . The main distinction is that the dimples 20 C have been replaced with a burr 40 . Note in FIG. 8 where the burr 40 is formed around the fastener centering opening 22 adjacent the face 20 A of the breakaway washer 20 . This is particularly shown in FIG. 9 . Note that in this example that the burr 40 extends approximately 0.010 inches above the face 20 A of the breakaway washer 20 . Thus when the fastener 16 is extended through the centering opening 22 the flange 16 B will engage the burr 40 and not the face 20 A of the breakaway washer 20 . Thus the burr 40 serves the same function as the raised dimples 20 C discussed above. Note in FIG. 10 where the slightly upwardly extending burr 40 engages the face 16 C of the flange 16 B and basically causes the flange 16 B to be spaced from both the face 20 A of the washer 20 and the flange 2 B of the track 2 . Again the fastener 16 clamps the washer 20 tightly against the flange 3 B of the stud 3 but allows movement of the slot relative to the breakaway washer.

The breakaway washer 20 can be employed in various building components such as components that interconnect building members. For example, the breakaway washer 20 can be employed in a connecting plate or bracket such as that shown in FIG. 11 and indicated generally by the numeral 12 . That is, the breakaway washer 20 having the raised dimples 20 C or the burr 40 can be incorporated into the slots 14 of the plate 12 . Plate 12 is bent in the form of a clip having a clip web 12 A and a clip flange 12 B disposed at approximately a right angle to the clip web. A bend in 12 C is formed between the flange 12 B and web 12 A. The breakaway washer 20 having the raised dimples 20 C is disposed within each slot 14 and the tabs thereof, tabs 20 B, are connected to the edges of the slot. As noted above, the plate 12 can be utilized as part of a connecting assembly for connecting two building members together. For example the plate can be utilized to connect a stud to a track structure. In such an example, the web 12 A is placed against the web 3 A of the stud and fastener 16 is inserted through the breakaway washers 20 into the web of the stud. The flange 12 B is in turn secured to the web of the track 2 . Thus when the washers 20 break away from the slots 14 it follows that there can be relative movement between the studs 3 and the track 2 . This example is illustrated in FIG. 11A .

Turning to FIG. 12 , an alternative design for the track 2 is shown. In this case, there is provided breakaway washers 20 in the web 2 A. Further there is provided a series of slots 14 in the web 2 A. These slots 14 are longitudinally aligned with the web 2 A. That is, the slots 14 in the web 2 A extend generally normal with respect to the slots 14 in the flanges 2 B. The breakaway washers 20 formed in the slots 14 in the web 2 A are generally planar and do not include the raised dimples 20 C or the burr 40 in this particular embodiment. It is appreciated that the breakaway washer 20 provided in the web 2 A could include a design utilizing the raised dimples 20 C or the burr 40 . It is conversely appreciated that the design using the planar breakaway washers in the web 2 A could be substituted for the dimpled or burred breakaway washer design in the flange 2 B, where a shouldered screw would be used instead of a shouldered, powder actuated fastener.

To attach the track 2 to an adjacent structure, the fastener provided is what is commonly referred to as a powder actuated fastener. In the FIG. 12 embodiment the powder actuated fastener is indicated generally by the numeral 50 . It includes a head 50 A, a shoulder 50 B and a shaft 50 C. The shoulder 50 B is designed to engage the breakaway washer 20 . This is to prevent the fastener head 50 A from directly engaging the web 2 A and clamping it tightly against the adjacent building structure. The diameter of the shoulder 50 B is smaller than the width of the slot 14 .

In the case of the FIG. 12 embodiment, the breakaway washers 20 incorporated into the side flanges 2 B are similar to those shown in FIGS. 1-3 with the raised dimples 20 C. The advantage of the track 2 shown in FIG. 12 is that because of the breakaway washers 20 exist in both the flanges 2 B and the web 2 A, the track can move both horizontally and vertically. The breakaway washers 20 provided in the web 2 A enable horizontal movement or drift while the breakaway washers 20 provided in the flanges 2 B enable the track 2 to move vertically.

The terms “underside”, “downward”, “upward”, “top”, “bottom”, “upper side”, “upper”, “horizontal”, “vertical” and similar terms or variation of the terms may be used throughout this disclosure. The terms are used merely to illustrate various embodiments and are not intended to limit the scope of the invention in any way.

The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the scope and the essential characteristics of the invention. The present embodiments are therefore to be construed in all aspects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.