Bracket For A-Frame Structure

Abstract

A bracket and bracket system for constructing an A-frame structure consisting of leg frame members supporting an upper cross beam, such as that used for a children's play set. The bracket includes an elongated top with two side walls, each side wall continuous with the greater part of the top's elongated edges, with each side wall having a second side wall, hereby forming a flange on each side of the bracket for nesting of the leg frame members. The flange is situated in one side of the side wall such that there exists full integral diagonal bracing between the flange and the elongated top of the bracket, with the diagonal bracing being of the same continuous piece of bracket material as at least one of the flanges and as the elongated top of the bracket.

Claims

1. A bracket for securing a cross beam to frame members, for constructing an A-frame structure, comprising: (a) an elongated top wall for receiving and securing the cross beam, the top wall having two elongated sides, with each elongated side having a first side wall, continuous with the greater part of said elongated side, and extending downward from the top wall; and (b) an L-shaped flange in each said first side wall for receiving and securing a frame member into the flange's inside corner, said flange formed of the first side wall itself and of a second side wall extending generally perpendicular from the first said side wall, the second side wall generally even with the end of the top wall.

2. The bracket of claim 1, wherein each first side wall has one edge continuous with the greater part of the top wall's elongated side, and another edge continuous with the greater part of the length of the flange.

3. The bracket of claim 1, wherein the shape of the first side walls is generally any shape in which a triangle can be inscribed such that the triangle's hypotenuse is oriented to run between the bracket top and bracket flange.

4. The bracket of claim 1, wherein the flanges are generally large enough to encompass two sides of a 4.times.4 wood frame member.

5. The bracket of claim 1, wherein each flange has fastener holes in each side of the flange for drawing the frame member into the flange's inside corner.

6. The bracket of claim 5, wherein the flange's fastener holes are elongated.

7. The bracket of claim 1, wherein the bracket is formed from a one-piece construction containing no weldments.

8. The bracket of claim 1, wherein the bracket is formed of heavy gauge metal.

9. A method for constructing an A-frame structure using a bracket comprising the following steps: (a) providing a bracket including: (i) an elongated top with two first side walls, each side wall extending from one of the top's two elongated edges, each side wall angling downward and outward off of the top, with each first side wall having a second side wall, hereby forming a flange on each side of the bracket for nesting of the leg frame members; and (ii) integral diagonal bracing between said flanges and said elongated top of the bracket, in the form of said first side wall which is of the same one piece of material as the bracket top and at least one of the flanges, and which said first side wall is continuous with both the greater part of the length of the bracket top, and of the length of each flange; (b) securing the cross beam to the top of the bracket; and (c) securing each of two frame members to one of the bracket's flanges.

10. The method of claim 9, wherein the shape of the first side walls is generally any shape in which a triangle can be inscribed such that the triangle's hypotenuse is oriented to run between the bracket top and bracket flange.

11. The method of claim 9, wherein the flanges are generally large enough to encompass two sides of a 4.times.4 wood frame member.

12. The method of claim 9, wherein each flange has fastener holes in each side of the flange for drawing the frame member into the flange's inside corner.

13. The method of claim 12, wherein the flange's fastener holes are elongated.

14. The method of claim 9, wherein the frame member is secured to the bracket flange using bolts.

15. The method of claim 14, wherein the bolts are bolts with nuts, which are tightened alternatively between the two flange sides, to draw the frame member flush into the flange's inside corner.

16. The method of claim 9, wherein the cross piece is secured to the bracket top using bolts.

17. The method of claim 9, wherein the bracket will mate with a cross beam of many size widths other than just 4.times.6 beams, and will mate with frame members of many size widths other than just 4.times.4 members.

18. The method of claim 9, wherein the bracket is of one-piece construction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1—is a perspective view of an A-frame structure constructed with the bracket.

[0022] FIG. 2—is a perspective view of the bracket system, comprised of the bracket, a top cross beam member, and 2 leg timber frame members.

[0023] FIG. 3—is a perspective view of the bracket.

[0024] FIG. 4—is of the front, side, and top views of the bracket, and of two other perspective views of the bracket.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0025] Referring to the drawings in detail, particularly to FIG. 1, there is a play structure A-frame comprised of a bracket system 21 at each end of the horizontal beam.

[0026] Referring to FIG. 2, there is a play structure assembly bracket system 21 shown, having a horizontal beam 18 and a plurality of leg timbers 19 and 20 secured to said beam by the bracket 17. Beam 18 is preferred to be constructed of 4.times.6 timber, and leg timbers 19 and 20 are preferred to be constructed of 4.times.4 timbers. Bracket 17 is configured to hold and secure two leg timbers 19 and 20 in an A-frame position, and to support and secure beam 18 to said leg timbers. The beam and leg timbers are preferred to be constructed of ordinary store bought timber, chosen from common pre-cut lengths, with no additional special cuts needed.

[0027] Referring to FIG. 3, the bracket 17 of my invention is preferably made from a single piece of sheet metal plate, cut by known means such as with a laser cutting machine, and bent into form by known means such as with a press brake machine. The bracket 17 has an elongated top surface 1, with two triangular walls 2 and 3, each shaped as an isosceles right triangle, and positioned as mirror images of each other. Said walls 2 and 3 each share the edge, 8 and 9 respectively, of a “leg” of these right triangles with the elongated side of the top surface, at which edges 8 and 9 the bracket 17 is bent downward 60 degrees from the horizontal top, creating walls 2 and 3 that slope outwardly and downwardly at 30 degrees from vertical. Each of said walls 2 and 3 share the edge, 10 and 11 respectively, of the other “leg” of these right triangles with an elongated wall, 4 and 5 respectively. These elongated walls 4 and 5 are turned up, away from each other, at 90 degrees to the walls 2 and 3, along said edges, forming an L-channel flange on each side of this end of the bracket 17.

[0028] Top surface 1 has a plurality of holes 16, cut by known means such as with a laser cutting machine, for securing of the beam 18 to the bracket 17. In the preferred configuration, there are two holes each 16 towards each elongated end of said top surface 1. Each flange portion, formed of wall 2 and 3, with wall 4 and 5 respectively, has a plurality of horizontally slotted holes 14 and 15 in both walls of each flange, for drawing in and securing the leg timbers 19 and 20 to inside of said flange. In the preferred configuration, each of these walls has two of these slotted holes in the flange portion, one of these two slotted holes being located in proximity to the upper end, and the other slotted hole located in proximity to the lower end, of each of walls 2, 3, 4 and 5. As a benefit, with holes for bolts in the walls 2 and 3, along with holes for opposing bolts in walls 4 and 5, these opposing bolts negate any possibility of the timber leg completely splitting and failing where attached to the bracket.

Operation of the Invention

[0029] This bracket design greatly facilitates achieving a very solid, wobble-free connection between the bracket 17, the beam 18, and the leg timbers 19 and 20. And the assembly operation with this bracket is greatly simplified so that even a lesser skilled person can achieve the same solid connection every time, with much less opportunity for messing up.

[0030] In the preferred configuration a 4.times.6 beam timber, and two 4.times.4 leg timbers can be selected from common pre-cut lengths available from a local retailer. The timbers can be used as-is, with no additional cuts required. With this bracket it is also of no importance the exact width of the timbers, which is greatly simplifying, for the reason that wood timbers, being a natural product, all vary in width.

[0031] First, with the beam 18 laying on the ground, the bracket 17 can be placed upside down on the beam, and used as a template to mark the location for the drilling of the four fastener holes 16 in the beam. The bracket is removed and the holes drilled completely through the beam. Then, again laying on the ground, each leg timber can be held flush inside, and to the top of one of each of the bracket's two flanges, with the four bracket holes 14 and 15 of each flange used as a template to mark the location for the drilling of four holes through the timber. The bracket is then removed and these four holes are drilled through the leg timber. Each leg timber is then held inside a flange while four fasteners, preferably hex bolts 25, are inserted, and then washers 26 and lock nuts 27 are attached to each bolt. These four bolts are then alternately tightened, between both sides of the leg, to draw the leg timber completely flush, snug, and tight into the inside corner of the brackets's flange. After two leg timbers are secured in this way to the bracket, a horizontal timber 29 is secured across the two legs. The resulting “A” shaped structure, with bracket affixed, is then held in a raised-up position, with the length of one of the two leg timbers completely resting on the ground. This structure is then held against the beam 17, with the beam resting on its side on the ground, while four hex bolts 22, along with washers 23 and lock nuts 24, are then easily inserted and tightened.

[0032] In all of the above described connections there are no complicated positioning of the pieces, nor any way to improperly secure fasteners. This bracket system utilizes bolts, so there is also no opportunity to poorly fasten fasteners such as in the case of over tightening screws and stripping out the screw holes. The bolts are always easily insertable while just holding the pieces somewhat close to each other, and the bolt fasteners are easily and verifiably tightened without any way to secure them wrong.

Conclusion, Ramifications, and Scope of the Invention

[0033] Yet, as simple as it is, the bracket will form a tight and wobble-free connection every time. This is principally due to the effective combination of two critical design elements. First, the element of an L-channel flange with slotted holes in both of flange walls allows the leg timbers to be drawn in and held immobile by the strength and rigidity of the integral flange itself, which completely restricts any movement along the horizontal axes. Just as important, as wood timber shrinks in width over time, as it invariably does, the bolts can be easily tightened to always maintain the legs flush and tight against the solid flange. This one bracket makes an immobile connection to both the beam timber and the leg timbers, effectively restricting any movement in all three axes, resulting in a structure that moves as one. No other bracket or bracket system known relies upon this method of pulling the timber tight into a flange corner. Which means that all other brackets allow the timber to float inside of a semi-restraint that is larger than the timber itself. Because of the leveraged forces at work on a play structure, this will always result in unpleasant wobble of the structure. Myriads of bracket designs exist, but almost none are capable of controlling this wobble over the life of the play structure, let alone controlling it as of day one of the finished structure. Many other brackets utilize either a bracket's face, flange or tube to roughly hold the timbers in place, but no known bracket element pulls the leg timber tightly to just one inside corner of the flange of the bracket. Other brackets that utilize a four-sided tube to receive the leg timber can never be expected to be the exact width of the timber, either when new or after shrinkage, so that design type relies upon bolts or screws to try to minimize lateral wobble, but the great forces of leverage on the set are way too much for the screws and or bolts to have any effect. Some other brackets pull the leg timber to one face of the bracket, effectively controlling wobble along one axis. But along the other axis the bolts and or screws pass through bracket holes that are by necessity sized larger than the exact thickness of the bolts or screws, and even ⅛ inch of excess movement in the bracket at the top of the play structure will translate into inches of unsettling wobble movement at the bottom of the play structure. And there are some other brackets that feature an L-shaped flag or U-shaped channel, but none of these feature slotted fastener holes that will permit the leg timber to be drawn tightly against a flange corner. Instead, these same brackets feature plain round fastener holes. There is no way to maintain the leg timbers tight against one inside bracket corner with ordinary fastener holes. First, even if the builder perfectly marks the fastener hole centers' locations, the wood grain will invariably carry the drill bit off of its intended line. If an attempt is then made to pull the timber tight into a flange corner, it will not be possible because the opposing, perpendicular fastener design of the bracket will prevent the leg timber from being drawn tight towards any flange corner. It should be mentioned that this now becomes an unpleasant task for the builder to try to achieve a collection of four perfectly drilled holes. Even in the case where the builder has somehow achieved this feat, so as to start with timber flush against a corner, as soon as the wood timber shrinks as it will always do, the flushness is lost, with no available method to pull it tight against a corner again, because of these opposing, perpendicular fasteners.

[0034] The second critical element of this bracket is the integral diagonal bracing of the bracket. The flange that securely holds the leg timbers extends up diagonally to and along the full length of the elongated top surface. This diagonal constraint between the beam 18 and the leg timbers 19 and 20 effectively restricts the independent lateral movement of the timbers. Additionally, the top surface is adequately elongated to provide an extended line to which to hold the beam as immobile as do the flanges with the leg timbers. In summary, both the leg supports and the beam supports hold the timbers immobile, with the integral diagonal bracing locking the two together.

[0035] Thus, this combination of flanges with slotted holes, together with the integral diagonal bracing element of the bracket, results in a bracket that holds the timbers immobile, with no wobble. Of added value, the bracket is very simple and straight-forward to use, with no cutting of timbers required, and little possibility of incorrect installation.

[0036] While my above description contains many specifics, these should not be construed as limitations on the scope of the invention, but rather as an exemplification of one preferred embodiment thereof. Many other variations of the bracket, with the same critical elements, are possible. For example, the bracket might be comprised of two pieces—two sides—that join along the elongated top portion to form the bracket, rather than the bracket being fabricated from one single piece of sheet metal plate. Also, the bracket might be constructed of a strong composite material or plastic, rather than the metal plate of the preferred embodiment. The timbers used might be constructed of a man-made composite material. The timbers used might be of a different size than stated in the preferred embodiment, as this bracket fits equally well many sizes of timbers. The bracket might have fillets on the bends between the top surface and the side walls as a means of strengthening the bends. Additionally, the angle of these bends might be some other angle other than 30 degrees from vertical. The bracket walls 2 and 3 need not be triangular in shape, as any shape that functions to diagonally brace the flange portion to the elongated top surface will equally suffice. For instance, the shape of these walls 2 and 3 could be square or rectangular. In place of washers for the bolts that secure the timbers to the bracket, larger metal or composite plates, on the opposing side of each flange wall, could be used to spread out the force of the fastener over the surface area of the timber. Alternatively, instead of the washers or these plates, a second, separate L-channel piece could be used opposing to the bracket's flange, to hold one end of the bolt to form a clamping mechanism over the leg timbers. There could be any number/plurality of holes attaching the timbers to the bracket. Alternatively, the bolts through the L-channel flange could be placed diagonally through the flange corner, diagonally through the leg timber, and into an opposing L-channel piece, with which to clamp the leg member to the bracket. As an alternative connection for the bracket to beam, instead of washers or larger plates, an inverted U-channel plate over the top of the beam timber could receive the bracket bolts. Or, the top portion of the bracket could have a square tube enclosure for receiving the beam.

[0037] Accordingly, the scope of the invention should be determined not by just the embodiments illustrated, neither by the described preferred embodiment.

[0038] In summary, my invention is of simply elegant design and fabrication, that delivers a foolproof installation for an unwavering wobble-free result—unlike any a-frame structure bracket heretofore seen.