Keder rail attachment for a fabric/panel building

Abstract

An keder rail and clamping anchor secure keder fabric to a building support beam. In one embodiment, the clamping anchor clamps about the support beam. In a second embodiment, the anchor passes through the support beam and compresses a pair of laterally extending keder rail feet against the support beam. A temporary keder rail anchor has a transitional member, support beam engagement, and keder rail engagement that displace and hold the second embodiment keder rail to an offset position relative to support beam prior to and during installation of keder fabric within the keder rail. A method of tensioning keder fabric uses this holder to secure the keder rail adjacent an edge of the structural beam while keder fabric is inserted. The holder is released and the keder rail is centered on the beam to tension the keder fabric, and the keder rail is secured to the structural beam.

Claims

1. A keder rail anchor operative with a generally planar top surface of a support I-beam and a keder rail and configured to support said keder rail in a position to receive flaccid keder fabric, said keder rail anchor comprising: a generally planar support beam engagement configured to engage on a major surface with said support I-beam generally planar top surface; a keder rail engagement distal and perpendicular to said support beam engagement; a first fastener configured to retain said support beam engagement to said support I-beam; a second fastener configured to retain said keder rail engagement to said keder rail; and a transitional member between and coupled with said support beam engagement and said keder rail engagement rising out of a plane defined by said generally planar support beam engagement and configured to terminate adjacent to and above a keder rail anchor foot, said transitional member, said support beam engagement, and said keder rail engagement configured to anchor said keder rail on and adjacent to an edge of said support I-beam generally planar top surface.

2. The keder rail anchor of claim 1, wherein said keder rail engagement comprises a generally planar member perpendicular to said support beam engagement.

3. The keder rail anchor of claim 2, wherein said keder rail anchor comprises a formed metal strap.

4. The keder rail anchor of claim 2, wherein said keder rail anchor further comprises an L-shaped geometry.

5. A keder rail anchor operative with a support I-beam and a keder rail and configured to support said keder rail in a position to receive flaccid keder fabric, said keder rail anchor comprising: a support beam engagement configured to engage with a first lateral half of a support I-beam generally planar top surface; a keder rail engagement adjacent to a lateral edge of said support I-beam generally planar top surface distal to said first lateral half, said keder rail engagement generally perpendicular to said support I-beam generally planar top surface; a first fastener configured to retain said support beam engagement to said support I-beam; a second fastener configured to retain said keder rail engagement to said keder rail; and a transitional member between and coupled with said support beam engagement and said keder rail engagement in contact with said support I-beam generally planar top surface adjacent to said support beam engagement and rising away from said support I-beam generally planar top surface adjacent to said keder rail engagement; said transitional member, said support beam engagement, and said keder rail engagement configured to anchor said keder rail on a second half of said support I-beam generally planar top surface in a position offset from and distal to a longitudinal center line that divides said support I-beam generally planar top surface into said first and second lateral halves.

6. The keder rail anchor of claim 5, wherein said support beam engagement comprises a generally planar member, and said keder rail engagement comprises a generally planar member perpendicular to said support beam engagement.

7. The keder rail anchor of claim 6, wherein said keder rail anchor comprises an L-shaped geometry.

8. The keder rail anchor of claim 7, wherein said keder rail anchor comprises a formed metal strap.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The foregoing and other objects, advantages, and novel features of the present invention can be understood and appreciated by reference to the following detailed description of the invention, taken in conjunction with the accompanying drawings, in which:

(2) FIG. 1 illustrates a preferred embodiment keder rail attachment designed in accord with the teachings of the present invention from a front elevational and partial section view.

(3) FIGS. 2 and 3 illustrate the preferred embodiment rail attachment of FIG. 1 as it may be attached to a support beam from a front elevational and partial section view to illustrate different attachment positions in greater detail.

(4) FIG. 4 illustrates an alternative embodiment barrier construction using the preferred embodiment keder rail attachment of FIG. 1, as used in an exemplary construction of an insulated building from a front elevational and partial section view.

(5) FIG. 5 illustrates a preferred embodiment keder rail clamp in combination with the preferred embodiment rail attachment of FIG. 1 from a front elevational and partial section view.

(6) FIG. 6 illustrates a preferred embodiment tensioning device in combination with the preferred embodiment rail attachment of FIG. 1 from a front elevational and partial section view.

(7) FIG. 7 illustrates the preferred embodiment tensioning device in combination with the preferred embodiment rail attachment of FIG. 1 from a top view.

(8) FIG. 8 illustrates a second alternative embodiment keder rail attachment designed in accord with the teachings of the present invention from a front elevational and partial section view, and with the keder rail secured by a holder in an offset position relative to the support beam ready for insertion of keder fabric.

(9) FIG. 9 illustrates the second alternative embodiment keder rail attachment of FIG. 8 from a front elevational and partial section view, and with the keder fabric and rail fully installed.

DESCRIPTION OF THE PREFERRED EMBODIMENT

(10) A preferred embodiment keder rail attachment 1 for a fabric or panel building designed in accord with the teachings of the present invention is illustrated in FIG. 1. Preferred embodiment keder rail attachment 1 has several primary components, including a keder rail 10, a support beam 30, a keder rail anchor 50, and a membrane 70.

(11) A preferred embodiment keder rail 10 is comprised of a longitudinally extensive box or rectangular extrusion, referred to here as the base 12. Base 12 is preferably hollow in order to save material cost and reduce weight, but may be solid. Base 12 preferably has two protrusions 14, 15 on the top of base 12 that form longitudinal cylinders with a circular opening on each of the front and back ends, and each cylinder having one open slit 18 extending in the longitudinal direction. These cylindrical protrusions 14, 15 are collectively referred to herein below as the keder track. A membrane 70 is formed from a fabric 72 with a keder bead 74 forming the edge. Keder bead 74 is preferably inserted in the front or back circular openings of the keder track and slid in longitudinally with fabric 72 protruding through open slit 18, as can be seen in FIG. 1. When lateral pressure is applied to fabric 72, open slit 18 in the longitudinal surface of the keder track is too small to allow keder bead 74 to pull out. End caps may be placed on the front and back ends of the keder track after the keder bead 74 is inserted, if desired.

(12) As described herein below, a keder rail clamp 90 may be used to attach keder rail 10 to a building's support beams 30 prior to keder bead 74 insertion. A tensioning tool 110, also described herein below, may be used to pull fabric 72 tight between keder rails 10 after keder bead 74 on each end of fabric 72 has been inserted. Tensioning tool 110 can then be used to pull one or both of keder rails 10 into position to be secured to support beam 30. In the preferred embodiment, the support beam is a known I-beam such as may be fabricated by welding or extrusion techniques, though as will become more apparent herein below and in accord with the teachings of the present invention, the support beam may assume other geometries or shapes.

(13) In alternative embodiments contemplated herein, the keder track may be formed as intrusions rather than cylindrical protrusions 14, 15, or may be positioned on base 12 differently, such as but not limited to being positioned on a lateral surface rather than the top surface. The number of tracks may also vary, as may be best suited for different uses.

(14) As seen in FIGS. 1-3, keder rail flap hooks 20 protrude from cylindrical protrusions 14, 15. After the keder membrane 70 and keder rails 10 are installed, adjacent keder flaps 76 illustrated in FIG. 4 are preferably affixed to keder rail flap hooks 20 by inserting their ends in an overlapping fashion into keder rail longitudinal slot 22 and sealably retained therein by insertion of elastomeric bead 78 therein. This provides a dual seal to better isolate the building interior from the elements. Keder flaps 76 may be adhered or secured to fabric 72 using any suitable technique, may be loosely placed adjacent thereto, or may alternatively be formed from a single relatively more rigid formed or molded part such as taught by the Reynolds published applications or the Green patent incorporated by reference herein above.

(15) One or more anchor bolts 52 preferably penetrate the lateral surfaces of the rectangular base 12, entering on one lateral surface and exiting through the other such as illustrated in FIG. 1. These anchor bolts 52 are preferably used to secure keder rail 10 to an underlying structure such as a support beam 30. While a bolt is preferred, other suitable fasteners may be incorporated as may be known in the fastener arts.

(16) As can be seen in FIGS. 2 and 3, anchor bolt 52 will also preferably penetrate two securing angles 58, 60 that run perpendicular to anchor bolt 52 and from anchor bolt 52 down to below the top surface of support beam 30. These securing angles 58, 60 then form 90 degree angles to run along the underside of support beam 30. Securing angles 58, 60 are preferably on opposite lateral sides of support beam 30 so that they can grip support beam 30 when forces are applied from any direction. As a result, keder fabric 72 may be attached to a top surface, side surface, or even an angled surface of support beam 30 in any orientation, such as but not limited to the longitudinal side running parallel or perpendicular to the ground. Securing angles 58, 60 will hold keder rail 10 to beam 30 prior to anchor bolt 52 being tightened, which again means keder rail 10 will stay coupled to support beam 30, regardless of beam 30 orientation with respect to gravity. This means that there is an opportunity for adjustment of keder rail 10 relative to support beam 30, until keder rail 10 is firmly anchored by fully tightening anchor bolt 52. Such adjustment was not heretofore possible with TEK screws.

(17) As can be seen in FIGS. 2 and 3, if keder rail 10 is not the same width as support beam 30, spacer blocks 54, 56 with holes for anchor bolt 52 may be placed on either side of keder rail 10, to fill the gap between keder rail 10 and securing angles 58, 60. When keder rail 10 is positioned at the edge of a support beam 30, as illustrated in FIG. 2, fabric 72 from cylindrical protrusion 14 may travel vertically down or at some direction offset between vertical and horizontal while fabric 72 from the opposite cylindrical protrusion 15 may travel outwards in a horizontal plane. This allows keder fabric 72 to form a corner on a structure without requiring any special equipment. Preferably, the anchor bolt heads would be located on the side with fabric 72 traveling in a vertical plane in order to minimize tears in the fabric 72. A rounded anchor bolt head as illustrated will further reduce fabric strain. Even though a 90-degree angle is shown here between the two fabrics 72, the fabric 72 may travel in any direction as is supported by the structure's design and the location of open slits 18 in keder rail 10.

(18) In the position illustrated in FIG. 3, spacer blocks 54, 56 may be placed on each side of keder rail 10, centering keder rail 10 on support beam 30. The keder fabric 72 would preferably travel in lateral directions, but could also travel in an upward or downward angle, as is allowed by the width of support beam 30 and anchor bolts 52.

(19) While spacer blocks 54, 56 are described here, the invention is not limited to such an implement. Alternatively, other devices may be used. For exemplary purposes, but not solely limiting the invention thereto, a U-shaped device may be used that connects to the bolt, projects laterally to the edge of the support beam 30, curves around and under the support beam 30, and then continues a short way before terminating. Other suitable apparatus known in the hardware arts may also be used.

(20) FIG. 4 illustrates an alternative keder rail attachment 2 in accord with the present invention with two opposed keder rails 10, 11. Keder rail 11 will be understood to include features and adjunct components similar to or identical to those of keder rail 10 already discussed herein above. The keder rails 10, 11 are secured to the interior and exterior surfaces of a building support beam 30 and fabric 72 is installed on both the interior and exterior surfaces using keder rails 10, 11 on opposed surfaces of support beams 30. Additional insulation 80 may optionally be installed between the spaced layers of keder fabric 72. In this embodiment, the interior and exterior layers of keder fabric 72 isolate insulation 80 from both the building interior and exterior. Keder flaps 76 and elastomeric beads 78 help ensure this isolation.

(21) As illustrated in FIG. 5, a preferred embodiment keder rail clamp 90 consists of a body 92 defining a horizontal region with a hole 94 for anchor bolt 52 insertion, a 90 degree angle to form a vertical surface adjacent to the edge of support beam 30, and another 90 degree angle in the opposite direction to wrap underneath the support beam 30 edge. The latter edge preferably contains a clamp bolt 98 to secure keder rail clamp 90 to support beam 30. Instead of the prior art method of attaching keder rail 10 to the building's frame while on the ground, in accord with the teachings of the present invention keder rail 10 is preferably affixed to a building's already constructed support frame using keder rail clamps 90 of FIG. 5. This is easily accomplished by screwing anchor bolts 52 into threaded openings or nuts 96. Keder rail 10 is positioned on the edge of support beam 30, rather in the center, to shorten the distance between the illustrated keder rail 10 and the previous adjacent keder rail 10. This allows keder beads 74 to be inserted into cylindrical protrusions 14, 15 of keder rail 10 without any tension in fabric 72. Next, the keder fabric 72 will need to be tensioned.

(22) FIG. 6 illustrates a preferred embodiment tensioning tool 110 that may be used to pull fabric 72 tight between keder rails 10 after the keder bead 74 on each end of fabric 72 has been inserted. Tensioning tool 110 will preferably be used to pull keder rail 10 into position to be secured to support beam 30, and will in this same process tension fabric 72. Preferred embodiment tensioning tool 110 consists of a winch 120 secured through a bolt 121 to a right angle brace bar 130 having an optional strengthening spanner bar 132 that forms a 45 degree angle across right angle brace bar 130, and an anchor tongue 134. Tensioning tool 110 may be made of any suitably strong material to withstand the forces necessary while remaining narrow in design. Steel is an exemplary material.

(23) As seen in FIGS. 5 and 6, support beams 30 preferably have small slots 34 pre-cut in beam vertical 32, for exemplary purposes at two foot intervals, to allow anchor tongue 134 of tensioning tool 110 to be inserted through. Only one slot 34 is needed per tensioning tool 110. The tensioning tool dimensions are preferably designed to fit the distance from slot 34 to the edge of support beam 30 without extra space so that when tension is applied, both the horizontal and the vertical surfaces of support beam 30 reinforce tensioning tool 110 in order to prevent undue stress on tensioning tool 110. While a slot 34 is preferred owing to the simplicity of machining in standard beams, it will be understood herein that other methods of coupling tensioning tool 110 to support beams 30 are contemplated herein, and may, for exemplary purposes, include the provision of a pocket on vertical 32 into which anchor tongue 134 may be received. Other suitable methods of removable coupling as are known in the fastener arts are contemplated herein.

(24) As seen in FIG. 6, a hook 129 and strap 128 are preferably secured to keder rail 10 in keder rail longitudinal slot 22 between cylindrical protrusions 14, 15. Strap 128 is fed around winch 120. A person will rotate winch handle 126 which turns ratchet 122, causing anti-reversing pawl 124 to click over ratchet 122 teeth. This wraps strap 128 about ratchet 122, shortening the distance between winch 120 and keder rail 10. As the winch turns and shortens strap 128, tensioning tool 110 is lifted, pivoting around the anchor in the support beam slot. Once brace bar 130 is flush with the support beam 30, further tightening of winch 120 applies lateral tension to keder rail 10 to displace keder rail 10. Hook 129 is preferably made of metal, such as aluminum or steel, but can be made of any suitable material that is strong enough to handle strong forces without bending or breaking. The strap 128 may for exemplary purposes be fabricated from a strong fabric, such as the kind used for seat belts and commercially available ratchet straps.

(25) Preferably, two tensioning tools 110 are used in two consecutive slots 34 simultaneously, and tensioning begins on one lateral end of keder rail 10. FIG. 7 illustrates this process. When the keder rail 10 is in position, it is secured as illustrated in FIGS. 2, 3 and 7 by affixing keder rail anchor bolt 52 and securing angles 58, 60. Slots 34 and anchor bolt holes may not line up because the distance between anchor bolt holes depends on structural design specifications such as wind load.

(26) Once keder rail anchor bolt 52 and securing angles 58, 60 are installed and tightened, the most lateral tensioning tool 110 is preferably released and moved to the slot that is medially concurrent to the other tensioning tool 110. The tensioning tools 110 are again adjusted until keder rail 10 is in the desired position. Again, an anchor bolt 52 is installed in the anchor bolt hole between the two tensioning tools 110, and the most lateral tensioning tool 110 is released and is inserted into the slot that is medially concurrent to the more medial tensioning tool 110. This process is repeated until the entire keder rail 10 has been tensioned and clamped. The clamps 90 of FIG. 5 may be replaced with the securing angles 58, 60 and spacer blocks 54, 56 illustrated in FIGS. 2 and 3, or with any other securing methods obvious to one familiar with the field.

(27) FIG. 8 illustrates a second alternative embodiment keder rail attachment, with keder rail secured by a holder in an offset position relative to the support beam ready for insertion of keder fabric. This second embodiment is distinguished from the preferred embodiment by the hundreds digit, as a two hundred rather than lacking a hundreds digit. Various components within each embodiment are designated by the ones and tens digits. However, many of the components are alike or similar between these two embodiments, so numbering of the ones and tens digits have been maintained wherever possible, such that identical, like or similar functions may more readily be identified between the embodiments. If not otherwise expressed, those skilled in the art will readily recognize the similarities and understand that in many cases like numbered ones and tens digit components may be substituted from one embodiment to another in accord with the present teachings, except where such substitution would otherwise destroy operation of the embodiment. Consequently, those skilled in the art will readily determine the function and operation of many of the components illustrated herein without unnecessary additional description.

(28) Second alternative embodiment keder rail attachment 200 incorporates a region for coupling to the keder fabric 70 which is similar or identical to that of preferred embodiment keder rail attachment 1, incorporating keder rail 210 having cylindrical protrusions 214, 215; an open slit 218; keder rail flap hooks 220; and a keder rail longitudinal slot 222; all of like geometry and function to those found in keder rail attachment 1. However, base 212 differs slightly from base 12, including a pair of keder rail anchor feet 224, which will be discussed in greater detail herein below.

(29) In the preferred embodiment keder rail attachment 1, the keder rail 10 is clamped in place prior to fastening with keder rail anchor 50. However, arranging and securing the clamp while not damaging the keder rail can be undesirably difficult. In order to facilitate installation of keder rail 10, in second alternative embodiment keder rail attachment 200, a holder 261 secures keder rail 210 to support beam 230 prior to and during installation of membrane 70.

(30) An anchor bolt 252 may for exemplary purpose fasten support beam engagement 262 to support beam 230, though any suitable fastener known from the myriad of fasteners available in the hardware arts will be considered to be incorporated herein. Support beam engagement 262 is a generally planar member, similar to a strap, that may for exemplary purposes fabricated from relatively thick and strong sheet steel. Nevertheless, the particular material or geometry of support beam engagement 262 is not critical to the present invention.

(31) Keder rail engagement 264 is distal to anchor bolt 252, and defines the foot of generally L shaped holder 261. Keder rail engagement 264 will preferably fit within the space between open slit 218 and anchor foot 224, and is in this embodiment fastened to keder rail 210 using one or more TEK screws 265. Rising from the plane of support beam engagement 262 to a level on base 212 above keder rail anchor foot 224 is transitional member 263, securely coupling support beam engagement 262 to keder rail engagement 264. The particular order of installation of holder 261 to support beam 230 and keder rail 210 is not critical, and so either TEK screws 265 or anchor bolts 252 may be installed first, or these may even be alternately installed.

(32) As may be apparent from FIG. 8, Keder rail 210 is in an offset position relative to the support beam 230. This allows ready insertion of keder fabric 272 by insertion of keder bead 274 into cylindrical protrusion 214. Once membrane 270 is installed, then keder rail 210 may be pulled into alignment with the center of beam 230, such as illustrated for exemplary purposes in FIG. 9.

(33) The particular technique and equipment used to pull keder rail 210 into place is not critical, but may for exemplary purposes comprise a suitable tool such as the ones illustrated in FIGS. 5-7. This would, of course, require that at least one holder 261 be removed from keder rail 210 and support beam 230. For example, where only two holders 261 are employed near distal longitudinal ends of keder rail 210, a first one of these two holders 261 may be removed after securing a puller between support beam 230 and keder rail 210. This would simply involve the removal of anchor bolt 252 and TEK screw 265. When keder rail 210 has then been pulled into alignment with the center of support beam 230, in the position generally illustrated in FIG. 9, a pair of anchor bolts 252 may be placed as shown in FIG. 9. Noteworthy here is that, if so desired, the anchor bolt 252 used in FIG. 8 may be removed and then replaced in the same hole through support beam 230, thus not requiring a second hole.

(34) While not essential, the pair of anchor bolts 252 illustrated in FIG. 9 will most preferably be provided with bevel or hillside washers 258 that are sloped to firmly engage with the gently sloped anchor feet 224. Without a matched slope between the bevel washers 258 and anchor feet 224, there will be a much smaller point of contact, which can lead to more extreme force distribution and thereby the increased likelihood of damage either during installation or use. Nevertheless, and as also visible in FIG. 9, the placement of anchor bolts 252 is adjacent to and optionally abutting with the most lateral extension points of anchor feet 224, and on laterally opposite sides thereof, thereby further ensuring no lateral shifting of keder rail 210 relative to support beam 230.

(35) While the leftmost anchor bolt 252 is illustrated with the bolt head down and the rightmost anchor bolt 252 is illustrated with the bolt head up, meaning the two are inverted relative to each other, the orientation of anchor bolts 252 is not critical to the present invention, and so the bolts may both be oriented in either direction as desired at the time of installation. Furthermore, the length of anchor bolts 252 is not critical, and may for exemplary purposes be shorter than that illustrated.

(36) If additional strength within keder rail 210 is desired or required, then an additional tube, bar, extrusion or the like 213 may be inserted within base 212. Extrusion 213 is inserted preferably after removal of all TEK screws 265, thereby ensuring that any weakening from holes made by TEK screws 265 are offset by the reinforcement provided by extrusion 213. By providing optional ledges 211, extrusion 213 may be of standard rectangular geometry and dimension, thereby avoiding the need for additional tooling while creating the option for two different strengths of keder rail 210 within the same exterior profile. Furthermore, these ledges 211 in combination with gently sloped anchor feet 224 provide extra material resulting in increased strength at a high stress point adjacent to bevel washer 258, without adding unnecessary and undesirable bulk. Nevertheless, and in an alternative embodiment contemplated herein, base 212 may omit ledges 211 and instead have a simple rectangular interior opening resembling that of preferred embodiment base 12.

(37) In an alternative embodiment contemplated herein, anchor feet 224 are laterally extended farther from the generally rectangular portion of base 12, and holes are provided through anchor feet 224 through which anchor bolts 252 will pass. However, the addition of this extra machining to drill holes through the anchor feet 224, and the extra material and extra bulk of the extended anchor feet 224 undesirably adds expense without consequentially improving performance. Further, as anchor feet 224 thin, there is a point where the material must still terminate or be too fragile for regular handling.

(38) While a keder rail 10, 210 is fabricated from a metal extrusion and the fasteners will typically comprise corrosion-resistant, plated, or coated metals, the components illustrated herein and alternatives or equivalents thereto may be manufactured from a variety of materials, including metals, resins and plastics, ceramics or cementitious materials, or even combinations or composites of the above. The specific material used may vary, though special benefits are attainable if several important factors are taken into consideration. First, a preferred material will offer corrosion resistance to avoid adverse weathering and aging due to condensation and other vagaries of weather. Furthermore, it is preferable that all materials are sufficiently tough and durable to not fracture, even when great forces are applied thereto.

(39) While the foregoing details what is felt to be the preferred embodiment of the invention, no material limitations to the scope of the claimed invention are intended. Further, features and design alternatives that would be obvious to one of ordinary skill in the art are considered to be incorporated herein. For exemplary purposes only, and not solely limiting thereto, the cylindrical protrusions 14, 15 may comprise any suitable geometry, and so will be understood broadly to comprise longitudinally open bodies each having a longitudinally extending open slit. As may be apparent then, the scope of the invention is set forth and particularly described in the claims hereinbelow.