Flange connector for concrete structural component

Abstract

A flange connector is embedded in precast concrete structural member for use in joining adjacent concrete members together, wherein the flange connector is characterized by a center plate and legs extending back from each side of the center plate. Each of the legs is provided with projections extending from the top edge and bottom edge of the leg, in the same plane defined by the height and length of the leg. The projections extending from the top edge and the bottom edge of the leg may be mirror images of each other, so that the cross-sectional area of the leg is substantially the same over the portion of the leg with the projections. The legs of the flange connector may incorporate additional enhancements to increase the resistance to pull out, including a neck formed by notches in the top and bottom of each leg, adjacent the transition region extending from the center plate and one or more embossments creating a convex area on one side of each leg and a concave area on the opposite side of each leg.

Claims

1. A flange connector, comprising: (a) a center plate having a front, back, top, bottom, first side and second side; (b) a first transition region extending from the first side of the center plate and backward away from the front of the center plate, wherein the first transition region extends from the first side of the center plate to the proximal end of the first leg without deviation; (c) a second transition region extending from the second side of the center plate and backward away from the front of the center plate, wherein the second transition region extends from the second side of the center plate to the proximal end of the second leg without deviation; (d) a first leg having a top edge, a bottom edge, a proximal end extending from the first transition region, and a distal end opposite the proximal end, a spine extending a length of the first leg between the proximal end and the distal end, the first leg having a rectangular cross section characterized by a height, extending from the top edge to the bottom edge of the first leg, and a width, a plurality of projections extending from the top edge of the first leg, and a plurality of projections extending from the bottom edge of the first leg, wherein the first leg extends backward relative to the center plate at an angle of from 30° to 60°, and wherein the first leg further comprises a neck positioned between the proximal end and the distal end, and a shoulder positioned between the neck and the distal end, wherein the first leg has a height H.sub.1 at the position of the neck and a height H.sub.2 at the position of the shoulder, wherein H.sub.2 is greater than H.sub.1; (e) a second leg having a top edge, a bottom edge, a proximal end extending from the second transition region, and a distal end opposite the proximal end, a spine extending a length of the second leg between the proximal end and the distal end, the second leg having a rectangular cross section characterized by a height, extending from the top edge to the bottom edge of the second leg, and a width, a plurality of projections extending from the top edge of the second leg, and a plurality of projections extending from the bottom edge of the second leg, wherein the second leg extends backward relative to the center plate at an angle of from 30° to 60°, and wherein the second leg further comprises a neck positioned between the proximal end and the distal end, and a shoulder positioned between the neck and the distal end, wherein the second leg has a height H.sub.3 at the position of the neck and a height H.sub.4, at the position of the shoulder, wherein H.sub.4 is greater than H.sub.3; (f) wherein (i) the projections extending from the top edge of the first leg and the projections extending from the bottom edge of the first leg are in phase; and (ii) the projections extending from the top edge of the second leg and the projections extending from the bottom edge of the second leg are in phase; and (g) the flange connector is formed from a single piece of metal.

2. The flange connector of claim 1, wherein (i) the projections extending from the top edge and the bottom edge of the first leg are sinusoidal, and (ii) the projections extending from the top edge and the bottom edge of the second leg are sinusoidal.

3. The flange connector of claim 2, wherein (i) the spine of the first leg comprises between 70% and 90% of the height of the first leg, and (ii) the spine of the second leg comprises between 70% and 90% of the height of the second leg.

4. The flange connector of claim 2, wherein (i) the plurality of projections extending from the top edge of the first leg comprise a first projection, characterized by a first apogee, and a second projection, characterized by a second apogee, and wherein a distance between the first apogee and the second apogee of the first leg is from 1″ to 3″; and (ii) the plurality of projections extending from the top edge of the second leg comprise a first projection, characterized by a first apogee, and a second projection, characterized by second apogee, and wherein a distance between the first apogee and the second apogee of the second leg is from 1″ to 3″.

5. The flange connector of claim 4, wherein (i) the spine of the first leg comprises between 50% and 95% of the height of the first leg, and (ii) the spine of the second leg comprises between 50% and 95% of the height of the second leg.

6. The flange connector of claim 2, wherein (i) the first leg is oriented in a horizontal plane, based on the height and the length of the first leg; (ii) the second leg is oriented in a horizontal plane, based on the height and the length of the second leg; and (iii) the center plate tilts backward from the bottom to the top, at an angle of from 1° to 15°, in relation to a vertical.

7. The flange connector of claim 6, wherein the first transition region is embossed to provide a concave section on one side of the first transition region and a convex section on an opposite side of the first transition region, and wherein the second transition region is embossed to provide a concave section on one side of the second transition region and a convex section on an opposite side of the second transition region.

8. The flange connector of claim 1, wherein (i) the plurality of projections extending from the top edge of the first leg comprise a first projection, characterized by a first apogee, and a second projection, characterized by a second apogee, and wherein a distance between the first apogee and the second apogee of the first leg is from 1″ to 3″; and (ii) the plurality of projections extending from the top edge of the second leg comprise a first projection, characterized by a first apogee, and a second projection, characterized by second apogee, and wherein a distance between the first apogee and the second apogee of the second leg is from 1″ to 3″.

9. The flange connector of claim 8, wherein (i) the spine of the first leg comprises between 50% and 95% of the height of the first leg, and (ii) the spine of the second leg comprises between 50% and 95% of the height of the second leg.

10. An article comprising: (a) a concrete structural component having an outer surface; and (b) a flange connector embedded in the concrete structural component, the flange connector, having (i) a center plate having a front, back, top, bottom, first side and second side, wherein the front of the center plate is exposed in the outer surface of the concrete structural component; (ii) a first transition region extending from the first side of the center plate and backward away from the front of the center plate, wherein the first transition region extends from the first side of the center plate to the proximal end of the first leg without deviation; (iii) a second transition region extending from the second side of the center plate and backward away from the front of the center plate, wherein the second transition region extends from the second side of the center plate to the proximal end of the second leg without deviation; (iv) a first leg having a top edge, a bottom edge, a proximal end extending from the first transition region, and a distal end opposite the proximal end, a spine extending a length of the first leg between the proximal end and the distal end, the first leg having a rectangular cross section characterized by a height, extending from the top edge to the bottom edge of the first leg, and a width, a plurality of projections extending from the top edge of the first leg, and a plurality of projections extending from the bottom edge of the first leg, wherein the first leg extends backward relative to the center plate at an angle of from 30° to 60°, and wherein the first leg further comprises a neck positioned between the proximal end and the distal end, and a shoulder positioned between the neck and the distal end, wherein the first leg has a height H.sub.1 at the position of the neck and a height H.sub.2 at the position of the shoulder, wherein H.sub.2 is greater than H.sub.1; (v) a second leg having a top edge, a bottom edge, a proximal end extending from the second transition region, and a distal end opposite the proximal end, a spine extending a length of the second leg between the proximal end and the distal end, the second leg having a rectangular cross section characterized by a height, extending from the top edge to the bottom edge of the second leg, and a width, a plurality of projections extending from the top edge of the second leg, and a plurality of projections extending from the bottom edge of the second leg; wherein the projections extending from the top edge of the first leg and the projections extending from the bottom edge of the first leg are in phase; and the projections extending from the top edge of the second leg and the projections extending from the bottom edge of the second leg are in phase, wherein the second leg extends backward relative to the center plate at an angle of from 30° to 60°, and wherein the second leg further comprises a neck positioned between the proximal end and the distal end, and a shoulder positioned between the neck and the distal end, wherein the second leg has a height H.sub.3 at the position of the neck and a height H.sub.4, at the position of the shoulder, wherein H.sub.4 is greater than H.sub.3; and (vi) the flange connector is formed from a single piece of metal.

11. The article of claim 10, wherein (i) the projections extending from the top edge and the bottom edge of the first leg are sinusoidal, and (ii) the projections extending from the top edge and the bottom edge of the second leg are sinusoidal.

12. The article of claim 11, wherein the concrete structural component is a double tee having a stem and a horizontal flange, and wherein the flange connector is embedded in the flange.

13. The flange connector of claim 11, wherein (i) the plurality of projections extending from the top edge of the first leg comprise a first projection, characterized by a first apogee, and a second projection, characterized by a second apogee, and wherein a distance between the first apogee and the second apogee of the first leg is from 1″ to 3″; and (ii) the plurality of projections extending from the top edge of the second leg comprise a first projection, characterized by a first apogee, and a second projection, characterized by second apogee, and wherein a distance between the first apogee and the second apogee of the second leg is from 1″ to 3″.

14. The flange connector of claim 13, wherein (i) the first leg is oriented in a horizontal plane, based on the height and the length of the first leg; (ii) the second leg is oriented in a horizontal plane, based on the height and the length of the second leg; and (iii) the center plate tilts backward from the bottom to the top, at an angle of from 1° to 15°, in relation to a vertical.

15. The article of claim 14, wherein the first transition region is embossed to provide a concave section on one side of the first transition region and a convex section on an opposite side of the first transition region, and wherein the second transition region is embossed to provide a concave section on one side of the second transition region and a convex section on an opposite side of the second transition region.

16. The article of claim 13, wherein (i) the spine of the first leg comprises between 50% and 95% of the height of the first leg, and (ii) the spine of the second leg comprises between 50% and 95% of the height of the second leg.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is top perspective view of the flange connector, with a h twist transition to orient the legs horizontally.

(2) FIG. 2 is a top view of the flange connector of FIG. 1.

(3) FIG. 3 is an enlarged view of one of the legs of the flange connector of FIG. 2.

(4) FIG. 4 is a cross-section view of one of the legs of the flange connector of FIG. 2.

(5) FIG. 5 is a front view of the flange connector of FIG. 1.

(6) FIG. 6 is a side view of the flange connector of FIG. 1.

(7) FIG. 7 is a sectional view of the connector of FIG. 1 is a concrete member, namely a precast double tee.

DETAILED DESCRIPTION OF THE INVENTION

(8) Without intending to limit the scope of the invention, the preferred embodiments and features are hereinafter set forth. All of the United States patents and published applications cited in the specification are incorporated herein by reference.

Flange Connector

(9) FIGS. 1-6 disclose a flange connector within the scope of the present invention. Flange connector 1 has center plate 2, with top 3 and bottom 4. Center plate 2 has front 5, back 6, first side 7 and second side 8. Holes 9a, 9b and 9c are placed in the center plate 2 to align a blockout, which is used to orient the flange connector in a precast form and protect front 5 from being coated with concrete, when the precast member is manufactured.

(10) Transition region 10 extends from side 7, backward from front 5 of center plate 2, and is provided with a ½ twist to align leg 11 horizontally. Similarly, transition region 12 extends from side 8, backward from front 5 of center plate 2, and is provided with a ½ twist to align leg 13 horizontally. Referring to FIG. 2, legs 11 and 13 are shown extending backward relative to center plate 2 at an angle θ, which is approximately 45°. By way of example, angle θ may range from 30 to 60° relative to center plate 2. As illustrated in FIGS. 5 and 6, legs 11 and 13 may line in the same plane.

(11) Also within the scope of the invention is the option of the transition regions on either side of the center plate to align the legs in a vertical plane or anywhere in between a vertical and horizontal plane. For example, the transition region may have no twist, in which case the plane of the legs is aligned vertically, or the transition region may have ¼ twist, in which case the plane of the legs is aligned at a 45° angle between vertical and horizontal.

(12) Leg 11 has proximate end 14 extending from transition region 10 and distal end 15, opposite proximal end 14. Leg 11 has top edge 16 and bottom edge 17. Referring to FIGS. 2 and 3, leg 11 is provided with a series of projections 18, extending outward from top edge 16, and projections 19 extending outward from bottom edge 17. Projections 18 and 19 are in the same plane as leg 11. Top edge 16 and bottom edge 17 of leg 11 define a central band or spine 20, which extends from proximal end 14 to distal end 15.

(13) In the embodiment of the flange connector disclosed in FIGS. 1-5, projections 18 and 19 are sinusoidal. Furthermore, projections 18 and 19 are “in phase”, that is, when viewed perpendicular to the side of leg 11, projections 18 and 19 move together so that the cross-sectional height of leg 11 remains substantially constant, as shown by height “H” in FIG. 4. It can be understood that projections 18 and 19 of leg 11 may take other shapes than a sinusoidal wave. For example, the projections may be in the shape of a square wave or saw tooth.

(14) Regardless of the exact shape of the projections, it is believed to be advantageous to provide sufficient spacing between the apogee and nadir of the projections, to increase pull out strength. The distance between the apogees of the projections is shown by pitch “P” in FIG. 4. By way of example the pitch may range from 1″ to 3″.

(15) The features of leg 11 can be duplicated in leg 13 of flange connector 1. Accordingly, leg 13 is provided with proximal end 21 extending from transition region 12, and distal end 22, opposite proximal end 21. Leg 13 has top edge 23 and bottom edge 24. Projections 25 extend from top edge 23, and projections 26 extend from bottom edge 24. Top edge 23 and bottom edge 24 of leg 13 define a central band or spine 27, which extends from proximal end 21 to distal end 22. The orientation, alignment, spacing, height and pitch of the projections 25 and 26 of leg 13 may be substantially the same as disclosed herein with regard to projections 18 and 19 of leg 11.

(16) Referring to FIG. 4, the spine of each of the legs, that is, spines 20 and 27, may represent from 50% to 95% of height H, more particularly from 70% to 90% of height “H”, measured as the maximum distance from the edge of a leg to the projection directly on the opposite side, perpendicular to the longitudinal extent of the leg.

(17) Legs 11 and 13 may be provided with one or more additional enhancements to increase the pull out resistance of flange connector 1, when it is embedded in a concrete member. In the embodiment of the invention shown in FIGS. 1-6, two different enhancements are employed. First, legs 11 and 13 are provided with a neck and shoulder arrangement. Referring to FIGS. 1-3, leg 11 has neck 28, positioned between the proximal end 14 and the distal end 15. Neck 28 has a height H.sub.1. Leg 11 has shoulder 29 positioned between neck 28 and distal end 15, wherein the height of shoulder 29 is H.sub.2, and wherein the height of H.sub.2 is greater than the height H.sub.1. In the embodiment of the invention illustrated, the difference in height between neck 28 and shoulder 29 creates a notch at both top edge 16 and bottom edge 17 of leg 11. By way of example, the height H.sub.1 of neck 28 may be from 70% to 85% of the height H.sub.2 of shoulder 29.

(18) Leg 13 may be provided with a neck and shoulder feature, which is a mirror image of leg 11. Leg 13 has neck 30, positioned between the proximal end 21 and the distal end 22. Neck 30 has a height H.sub.3. Leg 13 has shoulder 31 positioned between neck 30 and distal end 22, wherein the height of shoulder 31 is H.sub.4, and wherein the height of H.sub.4, is greater than the height H.sub.3. The difference in height between neck 30 and shoulder 31 may be used to create notches at both top edge 23 and bottom edge 24 of leg 13.

(19) While notches created at both the top edges and bottom edges of the legs are illustrated, it is believed that an increase in the pull out resistance of the flange connector can nevertheless be realized with a single notch, for example, when the relative height difference between the neck and shoulder creates a notch at either the top edge or bottom edge of each of the legs, and at the opposite edge the transition between neck and shoulder is smooth.

(20) A second enhancement provided with flange connector 1 is one or more embossments incorporated in each leg, whereby the leg has been shaped to create a convex section on one side of the leg and a concave section on the opposite side of the leg. Leg 11 is provided with embossments 32a, 32b, 32c, and 32d, forming a raised, convex section on one side of leg 11 and a concave section on the opposite side of leg 11, for example by forging or stamping. Likewise, leg 13 is provided with embossment 33a, 33b, 33c, and 33d, forming a raised, convex section on one side of leg 13 and a concave section on the opposite side of leg 13. The embossments may also be provided in the transition regions. Transition region 10 has embossment 34, and transition region 12 has embossment 35. The concave and convex sections increase bond strength in concrete to improve resistance to shear and tensile loads. Additionally, the embossments in the transition region of the connector are believed to be particularly useful in increasing concrete capacity resistance to out-of-plane shear loadings.

(21) By way of example, the embossments may extend from the surface of flange connector 1 a distance of from 1.5 to 3.5 mm, in particular from 2 to 3 mm. In the embodiment of the invention illustrated, the embossments are surrounded by a flat area, corresponding to the surface of the leg. Multiple embossments may be incorporated in each of the legs, spaced out along the length.

(22) Legs 11 and 13 are provided with holes 36 and 37, respectively. The holes can be used to couple the flange connector to mesh, reinforcing rods, tensioning cables and the like, which are aligned in the concrete member, as is known in the art.

Structural Component Incorporating the Flange Connector

(23) The flange connector is incorporated in a concrete member, when the concrete member is cast. Typically, the concrete member is “precast”, that is the concrete is cast in a reusable mold or form, allowed to cure, and transported to the construction site, where it is incorporated into a structure. Examples of concrete structural components that may incorporate the flange connector include double tees, wall panels, and the like.

(24) Referring to FIG. 7, flange connector 1 is shown embedded in concrete member 40. In the embodiment illustrated, concrete member 40 is a double T, having a planar flange 41 and stem 42 extending downward. Flange connector 1 is supported on metal mesh 43, which may be placed approximately in the middle of flange 41. Bottom 4 of center plate 2 extends down below mesh 43 and below the plane defined by the bottoms of legs 11 and 13. As shown in FIG. 7, blockout 44 is used to support flange connector 1 in the mold and to keep concrete from covering center plate 2. After concrete member 40 has cured, the mold (not shown) and blockout 44 are removed, thereby exposing center plate 2 for welding.

(25) While flange connector 1 is illustrated in FIG. 7 as positioned above metal mesh 43, it is also within the scope of the invention to provide a precast concrete structure having the flange connector positioned below the metal mesh.

(26) There are, of course, many alternatives and modifications of the invention, which are intended to be included in the following claims.