Structural support apparatus, system, and method

Abstract

Structural support apparatus, system, and installation method, comprising a base member adapted for being mounted to an existing building structure, an attachment bracket mounted to the base member at a pivot point adapted to be set securely to an angle selected during installation, the attachment bracket also adapted for mounting to a wood riser having openings therein to match the attachment bracket.

Claims

1. A structural support apparatus for use in interconnecting an additional structure to an existing building structure, comprising: a base member including: a mounting plate configured to be mounted to the existing building structure, and a receiver member having a through hole that defines a pivot point; and an attachment member configured to be pivotably attached to the base member, wherein a first plurality of pivot pin holes are arranged radially around the pivot point of the receiver member, a through hole in a first end of the attachment member defines the pivot point in the attachment member, and a second plurality of pivot pin holes are arranged radially around the pivot point of the attachment member, wherein the first end of the attachment member is pivotably attached to the receiver member via at least one locking pin inserted through one of the first plurality of pivot pin holes formed in the receiver member and one of the second plurality of pivot pin holes formed in the attachment member, and a second end of the attachment member is coupled directly or indirectly to the additional structure, wherein the second end of the attachment member is coupled indirectly to the additional structure at least in part by: the attachment member being secured to a structural member via at least one fastener; and the structural member being attached to the additional structure to anchor the additional structure to the existing building structure, and wherein the second end of the attachment member is inserted into one of a slot, hole, opening, and groove formed in the structural member, and the structural member includes left and right lower straddling portions on either side of the one of a slot, hole, opening, and groove, and a plurality of transverse holes pre-drilled through the left and right lower straddling portions.

2. The structural support apparatus of claim 1, wherein the attachment member is pivotable to a plurality of possible angles relative to the base member.

3. The structural support apparatus of claim 1, wherein the structural member is a roof riser.

4. The structural support apparatus of claim 1, wherein the attachment member includes a plurality of holes configured to align with the plurality of transverse holes pre-drilled through the left and right lower straddling portions of the structural member.

5. The structural support apparatus of claim 1, wherein in an assembled state in which the second end of the attachment member is inserted into the structural member, the first and second opposing surfaces of the attachment member are hidden from view.

6. The structural support apparatus of claim 1, wherein the attachment member has a first opposing surface and second opposing surface, a width of which is wider than a thickness of the attachment member.

7. The structural support apparatus of claim 1, wherein the receiver member is a first receiver member, the base member further includes a second receiver member having a through hole defining the pivot point and a third plurality of pivot pin holes arranged radially around the pivot point, the third plurality of pivot pin holes in the second receiver member being in alignment with the first plurality of pivot pin holes in the first receiver member, and the at least one locking pin is inserted through one of the first plurality of pivot pin holes in the first receiver member, one of the second plurality of pivot pin holes in the attachment member, and one of the third plurality of pivot pin holes in the second receiver member.

8. The structural support apparatus of claim 1, wherein a number of the first plurality of pivot pin holes in the receiver member is different from a number of the second plurality of pivot pin holes in the attachment member.

9. The structural support apparatus of claim 1, wherein the first plurality of pivot pin holes in the attachment member are arranged at 30 degree increments around the pivot point, and the second plurality of pivot pin holes in the receiver member are arranged 36 degree increments around the pivot point.

10. The structural support apparatus of claim 1, wherein the base member is attached to a roof of the existing building structure via screws installed over existing shingles, and the structural support apparatus further comprises a waterproofing layer between the base member and the existing shingles.

11. The structural support apparatus of claim 1, wherein the base member is attached to a vertical wall of the existing building structure via screws, and the structural support apparatus further comprises a waterproofing layer between said base member and the existing vertical wall.

12. The structural support apparatus of claim 1, further comprising: a pivot connecting member configured to attach the attachment member to the receiver member via the pivot point, the pivot connecting member being configured to cover and secure the at least one locking pin.

13. The structural support apparatus of claim 1, wherein the base member includes a plurality of holes configured for mounting the base member to the existing structure via fasteners.

14. The structural support apparatus of claim 1, wherein the additional structure is a patio roof, an eyebrow-type support structure, or an angled handrailing.

15. A structural support apparatus for use in interconnecting an additional structure to an existing building structure, comprising: a base member including: a mounting plate configured to be mounted to the existing building structure, and a receiver member having a through hole that defines a pivot point; and an attachment member configured to be pivotably attached to the base member, wherein a first plurality of pivot pin holes are arranged radially around the pivot point of the receiver member, a through hole in a first end of the attachment member defines the pivot point in the attachment member, and a second plurality of pivot pin holes are arranged radially around the pivot point of the attachment member, wherein the first end of the attachment member is pivotably attached to the receiver member via at least one locking pin inserted through one of the first plurality of pivot pin holes formed in the receiver member and one of the second plurality of pivot pin holes formed in the attachment member, a second end of the attachment member is coupled directly or indirectly to the additional structure, and a pivot connecting member configured to attach the attachment member to the receiver member via the pivot point, the pivot connecting member being configured to cover and secure the at least one locking pin.

16. The structural support apparatus of claim 15, wherein the attachment member is pivotable to a plurality of possible angles relative to the base member.

17. The structural support apparatus of claim 15, wherein the attachment member is secured to a structural member via at least one fastener, and the structural member is a roof riser.

18. The structural support apparatus of claim 15, wherein the additional structure is a patio roof, an eyebrow-type support structure, or an angled handrailing.

19. The structural support apparatus of claim 15, wherein a number of the first plurality of pivot pin holes in the receiver member is different from a number of the second plurality of pivot pin holes in the attachment member.

20. The structural support apparatus of claim 15, wherein the second end of the attachment member is coupled indirectly to the additional structure at least in part by: the attachment member being secured to a structural member via at least one fastener; and the structural member being attached to the additional structure to anchor the additional structure to the existing building structure, and wherein the second end of the attachment member is inserted into one of a slot, hole, opening, and groove formed in the structural member; and the structural member includes left and right lower straddling portions on either side of the one of a slot, hole, opening, and groove, and a plurality of transverse holes pre-drilled through the left and right lower straddling portions.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a partially-exploded side perspective view of components of a structural support apparatus according to an aspect and embodiment of the disclosure;

(2) FIG. 2A is a side view of a plurality of structural support apparatus according to an aspect and embodiment of the disclosure and showing a portion of a variety of angles at which each structural support apparatus may be locked;

(3) FIG. 2B is a side view of another plurality of structural support apparatus according to an aspect and embodiment of the disclosure and showing another portion of a variety of angles at which each structural support apparatus may be locked;

(4) FIG. 3 is a partially-exploded side perspective view of a structural support apparatus in combination with, illustrating how the structural support apparatus may be attached to, for example, a riser-type structural member;

(5) FIG. 4 is a perspective view of two alternative embodiments for structural members showing a slot in each riser-type structural member where the attachment member will be inserted and secured;

(6) FIG. 5 is a perspective view of a completed installation of a patio roof showing the elevated patio roof supported on one side by a plurality of combined support structure apparatus and riser structural members on an existing sloped roof;

(7) FIG. 6 is a right side view of a partial existing building roof structure showing a structural support apparatus and structural member combination attached to the partial building roof structure and supporting a partial patio cover roof structure in accordance with an aspect and embodiment of the disclosure; and

(8) FIG. 7 is a table showing possible attachment member angle positions relative to a base member and associated pivot pin alignment identification information for each such angular position.

DESCRIPTION OF EMBODIMENTS

(9) Referring to FIGS. 1-6, in accordance with one or more aspects of the invention, there is provided a structural support apparatus 100 comprising: a base member 101 comprising a mounting plate 102 that can be secured to an existing roof 150, 153, or the side of a building, by means of lag screws 108, and one or more preferably concentrically-aligned receiver members 106, preferably integral with the mounting plate 102 and adapted to be attached to a pivotable attachment member 110.

(10) The attachment member 110 defines a plurality of holes 112 allowing the attachment member to be attached to a structural member 126 with a plurality of fasteners 134, such as nut and bolt combinations 134, 138, such as (2) ½″×71/2″ galvanized bolts, and (4) ½″×21/2″ bridge/timber washers 136, required for side to side shear, wherein each bolt is adapted for installation of the apparatus 100 on the roof-riser structural member 126 together with fastening of a corresponding nut 138 thereon.

(11) Such installation is accomplished preferably such that an enlarged head 135 of each bolt 134 is adapted to be positioned closely adjacent a right lower straddling portion 129 (FIG. 3) of the roof-riser structural member 126, and the corresponding nut 138 is adapted to be positioned closely adjacent a left lower straddling portion 127 of the roof-riser structural member, the left lower straddling portion 127 and the right lower straddling portion 129 of the roof-riser structural member 126 being thus positioned between each the head 135 of the bolt 134 and the nut 138 (including any washers 136), the right lower straddling portion of the roof-riser structural member being adapted to be positioned between the head 135 of the bolt 134 (including any washer 136) and the attachment member 110, and the left lower straddling portion 127 of the roof-riser structural member 126 being adapted to being positioned between the nut 138 (including any washer 136) and the attachment member 110 when the apparatus 100 is attached to the roof-riser structural member.

(12) The structural apparatus 100 may also be used to install an eyebrow-type structural member, an angled handrail, or other structural member, as will be appreciated by those skilled in the art. Preferably, a waterproofing layer 104, such as a butyl rubber layer 104, is interposed between a bottom portion of the mounting plate 102 and the existing roof structure 150.

(13) Referring specifically to FIGS. 1, 5 and 6, the mounting plate 102 is adapted to be installed on an existing roof 150 on top of existing shingles or other roof coverings 153 by means of lag screws 108. The ability to install the base member 100 over existing roof materials, along with the waterproofing layer 104 between the mounting plate 102 and the existing roof 150, 153, allows the waterproof nature of the existing roof to be preserved.

(14) To further ensure waterproofing in such an installation on a roof structure 150, 153, and as can be seen in FIG. 6, the structural support member 100 is preferably installed outside of the occupancy envelope 172 of the existing structure, to avoid any leakage into the existing structure. That is, when installed on a surface 153 of an existing roof 150, the structural support member 100 is preferably installed at a location just outside of an outer bearing wall 160 as shown in FIG. 6, and adjacent, e.g., just beyond an angled extension 176 extending up from the bearing wall 160. In other words, and for maximum headroom of a patio roof structure 140, the mounting plate 102 of the structural support apparatus 100 is preferably installed away from an outer fascia member 170, but between the outer fascia member and the extension member 176 from bearing wall 160, so as to be outside of the building occupancy envelope 172. Further, preferably for such an installation for a patio roof riser combination 100, 126, the plate member 102 is preferably screwed with lag bolts 108 through the roof covering portion 153 and into tail portions 174 of rafter members extending beyond bearing wall 160 as shown in FIG. 6.

(15) The receiver members 106 of base member 101 are preferably partially cylindrical at upper locations thereof and extend vertically from the mounting plate 102. The receiver members define a hole 103 acting as a pivot point 114, and a plurality of pivot pin holes 122. The attachment member 110 is attached to the receiver members 106 by means of a pivot connecting member 116 that is inserted in the hole 103 to establish the pivot point 114 of both the receiver members and the attachment member. The attachment member 110 may pivot to a plurality of angles as shown in FIGS. 2A and 2B relative to the base member and is locked into the desired angle by means of preferably titanium locking pins 124 inserted into aligned pivot pin holes 122.

(16) In another aspect and embodiment of the invention, the pivot pin holes 122 are placed radially in the receiver members 106 at a consistent distance from the center of the pivot point 114, and corresponding pivot pin holes 123 are placed radially in the attachment member 110 at the same distance from the center of the pivot point. As the attachment member 110 is pivoted, one or more of the pivot pin holes 122 in the receiver member 106 and the corresponding pivot pin holes 123 in the attachment member align. Where the pivot pin holes 122 and 123 align, one or more locking pins 124 may be inserted to secure the desired angle.

(17) In accordance with a preferred embodiment, the pivot connecting member 116 comprises a flanged head pivot connecting bolt 118 and a flanged pivot connecting nut 120. By inserting the pivot connecting bolt 118 in the holes 103 and through pivot points 114 of both the receiver members 106 and the attachment member 110, the attachment member may thus be pivoted to a desired angle. Once the locking pins 124 have been inserted into aligned holes 122, 123, the flanged pivot connecting nut 120 may be fastened on the pivot connecting bolt 118, to the effect that the pivot connecting member bolt flange 133 and the pivot connecting nut flange 131 covers and secures the locking pins 124 in place. The partial cylindrical structure at the upper locations of the receiver members make them both appealing to the eye and also make them well-adapted for supporting forces to be exerted at the central openings through them, at the angular pivot pin through holes in them, and from the flange bolt and flange nut surfaces thereon.

(18) Referring specifically to FIGS. 2A and 2B, it is noted that the installation of the base member 100 may be done on existing roofs and building sides of a variety of pitches. Once the base member 101 is attached to an existing roof, the installation of a vertical structural member 126 (such as a vertically-oriented structural member for a roof riser) is facilitated by pivoting the attachment member 110 to a vertical position and securing it in place by means of the locking pins 124 inserted in aligned pivot pin holes 122, 123.

(19) In another aspect and embodiment of the invention, the number of pivot pin holes 122 in the attachment member 110 may be different than the number of pivot pin holes in the receiver member 106. This arrangement allows for alignment of one or more of the pivot pin holes 122, 123 at a larger number of possible desired angles. In a preferred embodiment, the attachment member 110 has twelve (12) pivot pin holes spaced at 30 degrees around the center of the hole 103, around pivot point 114, and the receiver member has ten (100 pivot pin holes spaced at 36 degrees around the center of the hole 103, around center of the pivot point 114. In this configuration, alignment of one or more pivot pin holes 122, 123 is realized at increments of 6 degrees (as shown in FIGS. 2A and 2B), resulting in 16 different angles ranging from 0 degrees to 180 degrees.

(20) Referring to FIGS. 2A, 2B, and 7, together these FIGS. illustrate a preferred embodiment wherein the attachment member preferably has twelve (12) equally-spaced, and radially-spaced, transversely-oriented, pivot pin holes 123 around a central pivot point 114 opening 103 in the lower end of the attachment member (as can also be seen in FIG. 1). In this preferred embodiment, the slotted receiving member sidewalls 106 each preferably has ten (10) equally-spaced, and radially-spaced, transversely-oriented, pivot pin holes 122 around central pivot point 114 openings 103 in each lateral sidewall 106 thereof. Note that each of the numbers of pivot pin holes 122, 123 is evenly divisible into 360 degrees, which makes this combination preferred since it yields, as further described in connection with FIGS. 2A, 2B, and 7, a large and sufficient number of positions for most structural member applications, but it also allows for sufficient material to sufficiently handle forces associated with such applications. Nevertheless, it will be appreciated that other combinations of pivot pin numbers in attachment members and receiver members may be used for the applications referred to herein, namely for added roof structural member applications, for eye-brow structure applications, and for hand-rail support applications, without departing from the scope of the system and apparatus as claimed.

(21) In FIG. 7, there are provided along an upper left-hand column, a plurality of rotated angle combinations made in 6-degree increments and numbered 1-31 for a 12-pivot-pin-hole attachment member as indicated by the upper row of numbers in the table of 0, 30, 60, . . . 330, corresponding to the radially-oriented pivot pin holes 123 in a first vertical position of such as illustrated by row number 1. Thus, as the attachment member is rotated in 6-degree increments, each pivot pin hole is likewise advanced 6 degrees from its previous position.

(22) The table further correlates these varying angle positions with corresponding pivot pins 122 at a lower portion of the table with rows labeled 1-10 corresponding with 10 such pivot pin holes 122. Thus, as the attachment member is rotated in 6-degree increments, the table illustrates by calling out which row number 1-31 associated with the pivot pin holes 123 is being considered (i.e., for an 18-degree rotation of the attachment member, row number 4 would be considered) and shows the corresponding radial locations of the successive pivot pin holes 123. Then, below in the table, it can be seen that row 4, for example, associated with an 18-degree rotation of the attachment member, correlates that alignment of the pivot pin holes 122 will occur with pivot pin holes 123 at 108 degrees and 288 degrees. In this way, it will be appreciated that there are 31 different possible combinations of degree rotation ranging between zero and 180 degrees as further shown in FIGS. 2A and 2B.

(23) This aspect and disclosure of the embodiment makes the apparatus a fixable-hinged, pivotable-upon-installation apparatus in that it makes it possible to easily adjust and thereafter fix the structural attachment member 100 to any desired pitch angle for a roof installation, an eyebrow-type installation, or a handrail support installation. Further adjustments to pitch may also be achieved by making the diameter of the holes 112 of the attachment member slightly smaller than the diameter of through holes in structural members 126, 126′ before final tightening, as further described herein. Thus, together, these advancements in this field make for much easier and effective installation of support structures.

(24) Thus, as an example of the alignment of the pivot pin holes 123 in the attachment member 110 as it is pivoted, it is noted that with 12 pivot pin holes 123 evenly spaced on the attachment member 110 the pivot pin holes 123 are located at 0, 30, 60, 90, 120, 150, 180, 210,240,270, 300, and 330 degrees around the center of the pivot point 114. With 10 pivot pin holes 122 in the receiver members 106, the pivot pin holes are located at 0, 36, 72, 108, 144, 180, 216, 252, 288, and 324 degrees around the center of the pivot point 114. When the attachment member 110 is oriented perpendicular to the mounting plate 101 of the base member 100, pivot point holes 123 in the attachment member 110 and pivot point holes 122 the receiver members 106 are aligned at zero degrees and 180 degrees, and titanium locking pins 124 may be inserted to lock the attachment member 110 in those pivot pin holes and at that angle, as can be seen in the table in FIG. 7. (Please note that the 360-degree position illustrated in the table is the same as 0-degree position).

(25) As another example, if the attachment member 110 is pivoted to 24 degrees, the pivot pin holes 123 on the attachment member will be at 24, 54, 84, 114, 144, 174, 204, 234, 264, 294, 324 and 354 degrees. Thus, the pivot pin holes at 144 and 324 degrees will then be aligned as can be verified in FIG. 7.

(26) Referring specifically to FIGS. 3 and 4, there are provided a structural support member 100 and riser-type structural member 126 combination (FIG. 3) and pre-cut alternate riser-type structural members 126, 126′ (FIG. 4). As shown in FIG. 4, structural member 126 has cut therein a slot 130 that is constrained, or closed, both at an end and on either side, whereas structural member 126′ has cut therein an open slot 130′ constrained, or closed, only at an end thereof, and such that each side of the slot is open. The riser mounting holes 128 are located to correspond with the mounting holes 112 in the attachment member 110.

(27) Of course, slot 130 in structural member 126 allows the attachment member 110 to be more completely hidden within the structural member 126 upon installation, whereas slot 130′ in structural member 126′ allows edges of the attachment member 110 to be seen within the structural member upon installation. Each structural member 126, 126′ has pre-drilled transversely-oriented mounting holes 128 passing through left 127 and right 129 straddling portions of the structural members.

(28) Once the plate member 102 of the base member 101 has been mounted to a building structure, such as a roof 150, 153 (FIG. 6), and the attachment member 110 has been secured at a desired angle, a riser structural member 126, 126′ may be installed on the attachment member 110 by inserting the attachment member into a riser mounting slot 130, 130′, respectively. The riser structural member 126, 126′ is secured to the attachment member 110 by means of riser connecting, or fastening, members 134 inserted through riser mounting holes 128 and the attachment mounting holes 112. The insertion of such fastening members 134 is accomplished as installation of the structural support apparatus 100 onto an existing structure followed by installation of the structural member 126, 126′ onto the structural support apparatus, comprising the following steps: fixing the mounting plate 102 of the base member 101 and attachment member 110 in combination to the existing structure, inserting the attachment member 110 into one of a slot, hole, and notch 130, 130′ in the structural member 126, 126′, and fastening the structural member 126, 126′ to the attachment member 110 by passing a fastener 134, such as a heavy-duty bolt, first through a first portion 129 of the structural member, then through a hole 112 defined in the attachment member 110, and then through another portion 127 of the structural member before securing the fastener 134 to the attachment member 110 and structural member 126, 126′ with a nut 138. Of course, it will also be appreciated that there may be provided intermediate washers 136, such as bridge/timber washers, interposed between a head portion 135 of each bolt 134 and the right straddling portion 129 of the structural member 126, 126′, with another washer interposed between each nut 138 and the left straddling portion 127 of the structural member 126, 126′.

(29) In a preferred aspect and embodiment of the disclosure, the riser connecting member 134 thus comprises: a riser connecting bolt 134, two riser connecting washers 136, and a riser connecting nut 138, as shown in FIG. 3. In alternative embodiments, the riser connecting members may be comprised of decorative elements that are consistent with other mounting hardware used in the construction of a structural support member, for example for a roof-riser-type patio roof 140, thus adding to the visual attractiveness of the finished structure.

(30) In a preferred embodiment, the riser-type structural members 126, 126′ may comprise a 4 inch by 4 inch wood post which may be customized, for example, squared off at an upper end for interfacing with patio roof 140 members, such as a cross member, and angle cut at a lower end for corresponding with, for example, the pitch of an existing roof 150, 153. Such riser-type structural members 126, 126′ may also be cut for desired height at the work site, and the riser mounting slots 130, 130′, together with riser mounting holes 128, may be realized using common construction tools and techniques available at the work site.

(31) In another aspect and embodiment of the invention, the structural attachment member 110 may have smaller-diameter holes 112 than the diameter of the structural member 126, 126′ mounting holes 128. This will allow the installer to complete fine adjustments of the riser-type structural member 126 to achieve true vertical during installation, even if the attachment member 110 is not quite exactly at vertical after aligned holes 122, 123 are pinned with pivot pins 124. In this way, installers are enabled in more easily achieving true plumb level for the riser-type structural members 126, 126′ for more accurate construction.

(32) Thus, by way of example, it will be appreciated that this invention provides the installer with the ability to install the apparatus 100 without cutting into an existing roof, and the ability to adjust the mounting angle of a riser structural member 126, 126′ to accommodate various roof pitches. Further, it will be appreciated that the present invention allows a more visually-appealing, and easy-to-accomplish installation, where solid structural support may be achieved without undue effort and in a way that enhances the use of natural building materials (such as wooden structural members) otherwise employed in surrounding existing building structures.

(33) While a preferred embodiment of the present invention has been shown and described, it will be apparent to those skilled in the art that many changes and modifications may be made without departing from the invention in its broader aspects. For example, it will be appreciated that one of ordinary skill in the art may mix and match the various components of the various embodiments of the invention without departing from the true spirit of the apparatus and method as claimed. The appended claims are therefore intended to cover any changes and modifications as fall within the true spirit and scope of the invention.