Connector assembly

FIELD OF THE INVENTION

p-0002The present invention relates to connectors, and more particularly to connectors for use in connecting two frame members.

BACKGROUND OF THE INVENTION

p-0003It is known to connect frame members with connectors. Many connectors exist in the prior art that can be used to quickly and efficiently assemble and disassemble frame members. In particular, many connectors exist specifically for joining profiled bars or frame members with peripheral channels formed therein. The connectors of the prior art couple two frame members together by inserting the connector pieces in the channels of the profiles and using screws or other fasteners to hold the connector pieces together. Generally, each connector in the prior art allows the user to connect two frame members in one particular configuration. For example, one connector may provide an end-to-end connection while another connector may provide a perpendicular connection. The location of the connectors is generally fixed once the connectors are installed into the frame members.

p-0004Many connectors also include external features (e.g., plates) that fit on the outside of the profiles. These connectors may offer additional flexibility such as allowing two frame members to be joined at different angles using the same connector. However, the external features do not allow two frame members to be located flush against one another. The external features introduce additional spaces between frame members and make alignment with other frame members difficult if other connectors are used which do not contain external features.

SUMMARY OF THE INVENTION

p-0005The present invention relates to connectors and provides a connector that is internal to the frame members while still allowing the user to have maximum flexibility in positioning the two frame members. The present invention also provides a tight connection between two frame members, substantially locking the two frame members against any relative movement, including translational movement as well as rotational movement.

p-0006One embodiment of the present invention is directed to a connector configured to interconnect two frame members. The connector includes a connector member including a body and a fulcrum. The body has a first end and a second end spaced from the first end and is configured to be received within a channel in a first one of the two frame members. The fulcrum is coupled to the body between the first end and the second end and provides a pivot point about which the body can pivot within the channel of the first frame member to selectively lock the two frame members against relative movement.

p-0007Another embodiment of the present invention is an assembly having a first frame member including a channel, a second frame member, and a connector member interconnecting the first frame member and the second frame member. The connector member includes a body and a fulcrum. The body has a first end and a second end spaced from the first end and is received within the channel in the first frame member. The fulcrum is coupled to the body between the first end and the second end and provides a pivot point about which the body pivots within the channel of the first frame member to selectively lock the first and second frame members against relative movement.

p-0008Yet another embodiment of the present invention includes a method of connecting two frame members. The method includes inserting a connector member into a channel in a first frame member and coupling the connector member to a second frame member. The method further includes pivoting the connector member from a first pivot position within the channel, in which the frame members are free to move with respect to each other, to a second pivot position within the channel, in which the frame members are substantially locked against relative movement.

p-0009Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

p-0010<figref idrefs="DRAWINGS">FIG. 1</figref> is a perspective view of an assembly including a connector in accordance with the present invention, the assembly including two frame members, a connector member, and a tee nut.

p-0011<figref idrefs="DRAWINGS">FIG. 2</figref> is a perspective view of the connector member of <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0012<figref idrefs="DRAWINGS">FIG. 3</figref> is a perspective view of the tee nut of <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0013<figref idrefs="DRAWINGS">FIG. 4</figref> is a perspective view of a frame member of <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0014<figref idrefs="DRAWINGS">FIG. 5</figref> is a section view along line <b>5</b>-<b>5</b> of <figref idrefs="DRAWINGS">FIG. 1</figref>, illustrating a first pivot position of the connector member of <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0015<figref idrefs="DRAWINGS">FIG. 6</figref> is a section view similar to <figref idrefs="DRAWINGS">FIG. 5</figref>, illustrating a second pivot position of the connector member of <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0016<figref idrefs="DRAWINGS">FIG. 7</figref> illustrates a second embodiment of the present invention utilizing two connector members.

p-0017<figref idrefs="DRAWINGS">FIG. 8</figref> is a perspective view of an assembly including a connector in accordance with the present invention, the assembly including two frame members, two connector members, and a cabinet.

p-0018<figref idrefs="DRAWINGS">FIG. 9</figref> is an enlarged partial view of a portion of one frame member, one connector member, and the cabinet of <figref idrefs="DRAWINGS">FIG. 8</figref>, shown with a portion of the cabinet removed for clarity.

DETAILED DESCRIPTION

p-0019Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

p-0020<figref idrefs="DRAWINGS">FIG. 1</figref> illustrates one embodiment of the present invention in which two substantially identical structural members or frame members <b>10</b>, <b>14</b> are connected using a connector embodying the present invention. Although the present embodiments are described with respect to frame members, it is not necessary that the present invention be used to build frames. A connector in accordance with the present invention may be used to connect any two members, as long as they are rigid enough to sustain the locking action produced from pivoting of the connector member, as described below. Thus, the use of the term “frame members” herein and in the appended claims is intended to include any structural members (e.g., profiled bars, cabinets, boxes, etc.) although not necessarily used to construct a frame. The individual components of the assembly shown in <figref idrefs="DRAWINGS">FIG. 1</figref> include a connector member <b>18</b>, a tee nut <b>22</b>, and the frame members <b>10</b>, <b>14</b>, which are shown in greater detail in <figref idrefs="DRAWINGS">FIGS. 2-4</figref>.

p-0021With reference to <figref idrefs="DRAWINGS">FIG. 2</figref>, the connector member <b>18</b> has a body with a first end <b>26</b> spaced apart from a second end <b>30</b>, and a fulcrum <b>34</b> located between the first end <b>26</b> and the second end <b>30</b>. In the illustrated embodiment, the fulcrum <b>34</b> is formed by a dowel pin <b>36</b> inserted in an aperture in the body. One skilled in the art will understand that there are many ways to form a fulcrum <b>34</b> on the connector member <b>18</b>. In some embodiments, the fulcrum <b>34</b> may be formed using two dowel pins, inserted in an aperture on each side of the body. The apertures may be formed in the body of the connector member <b>18</b> when it is initially formed, or a portion of material may be removed from the body by any suitable process to form the apertures in the connector member <b>18</b> after it is initially formed. In other embodiments, the fulcrum <b>34</b> may be formed integrally with the connector member <b>18</b>, or the fulcrum <b>34</b> may be formed of a suitable piece of material that is welded or otherwise attached to a flange <b>50</b> on the connector member <b>18</b> such that it functions as the fulcrum <b>34</b>.

p-0022The connector member <b>18</b> further includes a first bore <b>38</b> adjacent the first end <b>26</b> and a second bore <b>42</b> adjacent the second end <b>30</b>. In the illustrated embodiment, the bores <b>38</b>, <b>42</b> are threaded to receive threaded fasteners, described in further detail below. The body of the connector member <b>18</b> has a cross-sectional shape that is substantially the same as a channel <b>46</b> in the first frame member <b>10</b> (see <figref idrefs="DRAWINGS">FIG. 1</figref>) such that the connector member <b>18</b> can be inserted into the channel <b>46</b> in the first frame member <b>10</b>. The connector member has flanges <b>50</b> that define an exterior surface <b>54</b> of the connector member <b>18</b>. The connector member <b>18</b> is inserted into the channel <b>46</b> of the first frame member <b>10</b>. The exterior surface <b>54</b> communicates with an interior surface of the channel <b>46</b>, which will be described below with reference to <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref>. In the present embodiment, the connector member <b>18</b> has a substantially constant cross-sectional shape and as illustrated, a T-shape cross-section. Of course, it is not necessary that the connector member <b>18</b> be formed in a T-shape. The cross-sectional shape of the connector member <b>18</b> should generally correspond to the shape of the channel <b>46</b> in which it is slidably received.

p-0023The connector member <b>18</b> has a maximum height HI that is smaller than a height H<b>4</b> (see <figref idrefs="DRAWINGS">FIG. 4</figref>) of the channel <b>46</b> in the first frame member <b>10</b>. Therefore, no portion of the connector member <b>18</b> will extend outside the channel <b>46</b> in a direction perpendicular to a longitudinal axis <b>58</b> of the frame member <b>10</b> when the connector member <b>18</b> is inserted therein. The flange <b>50</b> of the connector member <b>18</b> has a height H<b>2</b>, which will be described below.

p-0024The connector member <b>18</b> may be formed by any suitable manufacturing process and may be formed of any suitable material such that it can withstand the forces generated when the two frame members <b>10</b>, <b>14</b> are locked against relative movement, as described below. In the illustrated embodiment, an optional groove <b>62</b> extends longitudinally in the connector member <b>18</b> and is provided as an alignment aid for machining the connector member <b>18</b>. Of course, the groove <b>62</b> may not be necessary if the connector member <b>18</b> is formed using a molding or casting process rather than a cutting or machining process.

p-0025Referring now to <figref idrefs="DRAWINGS">FIG. 3</figref>, the tee nut <b>22</b> may also be referred to as a second connector member. However, in order to easily distinguish between the first connector member and the second connector member of the present embodiment, the second connector member will be referred to as a tee nut <b>22</b>. It is important to note that the present invention does not require the use of a tee nut <b>22</b>. In fact, the present invention does not require the use of a second connector member. The connector member <b>18</b> of the present invention may be coupled to the second frame member <b>14</b> in any suitable manner such that pivoting of the connector member <b>18</b> produces a locking action, described in detail with respect to <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref> below, to selectively lock the two frame members <b>10</b>, <b>14</b> against relative movement. It is also important to note that the second frame member <b>14</b> may be any reasonable structure or enclosure member, such as a cabinet, electrical box, watertight box, explosion proof box, etc., that the connector member may be coupled with.

p-0026Referring to <figref idrefs="DRAWINGS">FIGS. 1 and 3</figref>, the tee nut <b>22</b> contains a threaded bore <b>66</b> in the body to receive a fastener <b>70</b> for coupling the connector member <b>18</b> to the tee nut <b>22</b>. The tee nut <b>22</b> has a cross-sectional shape that is substantially the same as a channel <b>74</b> in the second frame member <b>14</b> such that the tee nut <b>22</b> can be inserted therein. The tee nut <b>22</b> has flanges <b>78</b> that define an exterior surface <b>82</b> of the tee nut <b>22</b>.

p-0027When the tee nut <b>22</b> is inserted into the channel <b>74</b> of the second frame member <b>14</b>, the exterior surface <b>82</b> communicates with an interior surface of the channel <b>74</b>, which will be described below with reference to <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref>. In the present embodiment, the cross-sectional shape of the tee nut <b>22</b> is substantially a T-shape. Of course, it is not necessary that the tee nut <b>22</b> be formed in a T-shape. The shape of the tee nut <b>22</b> should generally correspond to the shape of the channel <b>74</b> in which it is slidably received.

p-0028The tee nut <b>22</b> has a maximum height H<b>3</b> that is smaller than a height H<b>6</b> (see <figref idrefs="DRAWINGS">FIG. 1</figref>) of the channel <b>74</b> in the second frame member <b>14</b>. Therefore, no portion of the tee nut <b>22</b> will extend outside the channel <b>74</b> in a direction perpendicular to a longitudinal axis <b>86</b> of the frame member <b>14</b> when the tee nut <b>22</b> is inserted therein.

p-0029Like the connector member <b>18</b>, the tee nut <b>22</b> may be formed by any suitable manufacturing process or combination of processes. The tee nut <b>22</b> may also be formed of any suitable material such that it can withstand the forces generated when the two frame members <b>10</b>, <b>14</b> are locked against relative movement, as described below.

p-0030In the illustrated embodiment shown in <figref idrefs="DRAWINGS">FIG. 1</figref>, the frame members <b>10</b>, <b>14</b> are substantially the same. Therefore, only the first frame member <b>10</b> will be explained in detail with reference to <figref idrefs="DRAWINGS">FIG. 4</figref>. The first frame member <b>10</b> has a substantially rectangular cross-section with channels <b>46</b> formed along the entire length of each face. The channels <b>46</b> have a cross-sectional shape that is generally T-shaped in the present embodiment to receive the connector member <b>18</b>. Because the channels <b>46</b> are T-shaped, flanges <b>90</b> are defined in the first frame member <b>10</b>. The flanges <b>90</b> define interior surfaces <b>94</b> of the channels <b>46</b>.

p-0031The first frame member <b>10</b> may be formed from any suitable material, depending on the desired application, such that it can withstand the forces generated when the two frame members <b>10</b>, <b>14</b> are locked against relative movement, as described below. Also, the cross-sectional shape of the channels <b>46</b> may vary as long as the connector member <b>18</b> is of similar cross-sectional shape and may be slidably inserted in the channels <b>46</b>. The frame members <b>10</b>, <b>14</b> may be formed by any suitable manufacturing process or combination of processes. It is well known, for example, to form frame members <b>10</b>, <b>14</b> by extrusion of aluminum. The aluminum profiles commonly used in industry provide light-weight, strong frame members that can be readily used with connectors embodying the present invention.

p-0032Other variations of frame members <b>10</b>, <b>14</b> may also be used in connection with the present invention. For example, the channels <b>46</b>, <b>74</b> of the frame members <b>10</b>, <b>14</b> do not need to extend the entire length of the frame members <b>10</b>, <b>14</b>. The channels <b>46</b>, <b>74</b> simply need to accommodate the connector members <b>18</b>, <b>22</b>. However, shortening of the channels <b>46</b>, <b>74</b> limits the range of possible configurations of the two frame members <b>10</b>, <b>14</b>. In fact, the second frame member <b>14</b> does not need to contain channels <b>74</b>. The second frame member <b>14</b> simply needs to be coupled to the first connector member <b>18</b> such that pivoting of the connector member <b>18</b> produces a locking action, substantially inhibiting relative movement between the two frame members <b>10</b>, <b>14</b>, as described below.

p-0033Before explaining the operation of the first embodiment of the present invention in detail, it is important to note the relationship between the connector member <b>18</b> and the channel <b>46</b> of the first frame member <b>10</b>. With reference to <figref idrefs="DRAWINGS">FIG. 2</figref>, the connector member <b>18</b> has a generally T-shaped cross-section with an overall height H<b>1</b> of the body and a height H<b>2</b> of the flange <b>50</b>. With reference to <figref idrefs="DRAWINGS">FIG. 4</figref>, the channel <b>46</b> in the first frame member <b>10</b> has an overall height H<b>4</b> and a height H<b>5</b> of the receiving portion defined between the interior surface <b>94</b> and the bottom of the channel <b>46</b>. The proportions of the connector member <b>18</b> are formed such that the connector member <b>18</b> may be inserted into the channel <b>46</b> of the first frame member <b>10</b>. The height H<b>1</b> of the connector member <b>18</b> is less than the height H<b>4</b> of the channel <b>46</b> such that no portion of the connector member <b>18</b> will extend outside the channel <b>46</b> of the first frame member <b>10</b> in a direction perpendicular to the longitudinal axis <b>58</b> of the first frame member <b>10</b> when the connector member <b>18</b> is inserted therein. Furthermore, the height H<b>2</b> of the flange <b>50</b> on the connector member <b>18</b> is less than the height H<b>5</b> of the receiving portion of the T-shaped channel <b>46</b> such that the fulcrum <b>34</b> can be accommodated within the channel <b>46</b> and coupled to both the exterior surface <b>54</b> defined by the flange <b>50</b> of the connector member <b>18</b> and the interior surface <b>94</b> defined by the flange <b>90</b> of the first frame member <b>10</b>.

p-0034The operation of the first embodiment of the present invention will be described in detail with reference to <figref idrefs="DRAWINGS">FIGS. 1-6</figref>. The connector member <b>18</b> is coupled to the tee nut <b>22</b> by a fastener <b>70</b> (see <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref>) that extends through the second bore <b>42</b> in the connector member <b>18</b> and engages the bore <b>66</b> in the tee nut <b>22</b>. The fastener <b>70</b> connects the connector member <b>18</b> to the tee nut <b>22</b> while still allowing the connector member <b>18</b> and tee nut <b>22</b> to rotate about an axis <b>98</b> (see <figref idrefs="DRAWINGS">FIG. 1</figref>) through the center of the fastener <b>70</b>.

p-0035The connector member <b>18</b> is slidably engageable with the channel <b>46</b> in the first frame member <b>10</b>, and the tee nut <b>22</b> is slidably engageable with the channel <b>74</b> in the second frame member <b>14</b>, as shown in <figref idrefs="DRAWINGS">FIG. 1</figref>. Therefore, the first frame member <b>10</b> can be moved (e.g. translated) relative to the connector member <b>18</b> in either direction along an axis <b>58</b> defined longitudinally through the center of the first frame member <b>10</b>. Similarly, the second frame member <b>14</b> can be moved relative to the tee nut <b>22</b> in either direction along an axis <b>86</b> defined longitudinally through the center of the second frame member <b>14</b>.

p-0036Neither the connector member <b>18</b> nor the tee nut <b>22</b> extends outside the channels <b>46</b>, <b>74</b> of the frame members <b>10</b>, <b>14</b> in a direction perpendicular to the longitudinal axes <b>58</b>, <b>86</b> of the frame members <b>10</b>, <b>14</b>. The connector is fully contained within the channels <b>46</b>, <b>74</b> of the frame members <b>10</b>, <b>14</b>, allowing it to connect the frame members <b>10</b>, <b>14</b> internally. Therefore, no modification to the frame members <b>10</b>, <b>14</b> or channels <b>46</b>, <b>74</b> is necessary in order to use the present invention, giving the present invention more flexibility over the prior art requiring drilling or modification of the frame members in order to use the prior art connectors.

p-0037When connected, the frame members <b>10</b>, <b>14</b> may each be rotated 0 to 360 degrees about the axis of rotation <b>98</b>. This degree of flexibility allows the user to connect two frame members <b>10</b>, <b>14</b> lying in substantially parallel planes (e.g., arranged such that the longitudinal axes <b>58</b>, <b>86</b> of the frame members <b>10</b>, <b>14</b> lie in substantially parallel planes) in any angular orientation with respect to the longitudinal axes <b>58</b>, <b>86</b>. The user should position the frame members <b>10</b>, <b>14</b> such that the first bore <b>38</b> in the connector member <b>18</b> is accessible, as shown in <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0038Once the first and second frame members <b>10</b>, <b>14</b> are positioned in the desired orientation (both translational and rotational), the user tightens the fastener <b>102</b> (e.g., a set screw), located in the first bore <b>38</b> of the connector member <b>18</b>. The set screw <b>102</b> may be inserted in the first bore <b>38</b> of the connector member <b>18</b> when the user is ready to lock the frame members <b>10</b>, <b>14</b> together. Alternatively, the set screw <b>102</b> may be coupled to the connector member <b>18</b> before the connector member <b>18</b> is slidably engaged within the channel <b>46</b> of the first frame member <b>10</b> such that the set screw <b>102</b> does not significantly restrict movement of the connector member <b>18</b> within the channel <b>46</b>. Tightening of the fastener <b>102</b> will cause the connector member <b>18</b> to move from a first pivot position, in which the two frame members <b>10</b>, <b>14</b> are free to move relative to one another, to a second pivot position, in which the two frame members <b>10</b>, <b>14</b> are substantially locked against relative movement, both translational and rotational. The first pivot position and second pivot position will be described in detail with reference to <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref> below.

p-0039As shown in <figref idrefs="DRAWINGS">FIG. 5</figref>, the set screw <b>102</b> has been inserted in the threaded bore <b>38</b> of the connector member <b>18</b> and tightened to the point at which it is extending out of the bore <b>38</b> and is in engagement with the bottom of the channel <b>46</b>. The connector member <b>18</b> is shown to be substantially parallel within the channel <b>46</b>, indicated by the exterior surface <b>54</b> of the connector member <b>18</b> being substantially parallel to interior surface <b>94</b> of the channel <b>46</b>. In this position, the connector member <b>18</b> is free to translate within the channel <b>46</b>, and the frictional forces caused by the set screw <b>102</b> abutting the bottom of the channel <b>46</b> will not significantly inhibit translational movement of the first frame member <b>10</b> relative to the connector member <b>18</b>.

p-0040If the user continues to tighten the set screw <b>102</b>, as shown in <figref idrefs="DRAWINGS">FIG. 6</figref>, the rotation of the set screw <b>102</b> will cause the first end <b>26</b> of the connector member <b>18</b> to move upward along the threaded portion of the set screw <b>102</b>. The movement of the first end <b>26</b> of the connector member causes the connector member <b>18</b> to pivot about the fulcrum <b>34</b> within the channel <b>46</b>. The pivoting of the connector member <b>18</b> is illustrated by showing that the exterior surface <b>54</b> of the connector member <b>18</b> and the interior surface <b>94</b> of the channel <b>46</b> are closer together at the first end <b>26</b> and further apart at the second end <b>30</b> of the connector member <b>18</b>. The pivoting of the connector member <b>18</b> allows it to substantially inhibit translational movement of the first frame member <b>10</b> relative to the connector member <b>18</b> due to the wedging action at the first end <b>26</b>.

p-0041The user can take advantage of the pivoting action of the connector member <b>18</b> during assembly of the two frame members <b>10</b>, <b>14</b> by not tightening the set screw <b>102</b> as much as possible. The set screw <b>102</b> may be tightened to differing degrees according to user preference to cause the connector member <b>18</b> to pivot slightly, wedging the connector member <b>18</b> in the channel <b>46</b> of the first frame member <b>10</b>. Depending on how much the connector member <b>18</b> is pivoted, the wedging action of the connector member <b>18</b> can be adjusted to slightly or moderately inhibit movement of the frame member <b>10</b> relative to the connector member <b>18</b>. This may make it easier for the user to make adjustments to the position of the frame member <b>10</b>. For example, the frame member <b>10</b> may generally remain where positioned even though the set screw <b>102</b> is not fully tightened if the forces acting on the frame member <b>10</b> do not fully overcome the wedging force of the connector member <b>18</b> in the channel <b>46</b>.

p-0042Furthermore, the pivoting action of the connector member <b>18</b> forces the second end <b>30</b> of the connector member <b>18</b> in a downward direction (as shown in <figref idrefs="DRAWINGS">FIGS. 5 and 6</figref>), applying a tensile force to the fastener <b>70</b> in the downward direction. Because the fastener <b>70</b> is threaded and coupled to the tee nut <b>22</b> through a threaded bore <b>66</b>, the fastener <b>70</b> cannot move axially unless it is rotated with respect to the tee nut <b>22</b>. Therefore, there is not only a force being applied to the fastener <b>70</b> in the downward direction (due to the pivoting of the connector member <b>18</b>) but there is also a reactionary force being applied to the fastener <b>70</b> in the upward direction (due to the threaded engagement with the tee nut <b>22</b>), thus placing the fastener <b>70</b> in tension. Although the fastener <b>70</b> has been described as a threaded fastener <b>70</b>, the fastener <b>70</b> can be any suitable fastener <b>70</b> (e.g., a rivet) that can be used to couple the connector member <b>18</b> to the tee nut <b>22</b>. The threaded portions are not required but clearly allow less axial movement of the fastener <b>70</b> prior to being placed in tension.

p-0043The tension on the fastener <b>70</b> causes the exterior surface <b>82</b> defined by the flange <b>78</b> of tee nut <b>22</b> to be pulled tight against the interior surface <b>110</b> defined by the flange <b>106</b> of the second frame member <b>14</b>. This is illustrated by showing a small clearance in <figref idrefs="DRAWINGS">FIG. 5</figref> between the exterior surface <b>82</b> and the interior surface <b>110</b> and by eliminating this clearance in <figref idrefs="DRAWINGS">FIG. 6</figref>. Without the clearance, the tee nut <b>22</b> can no longer slide in the channel <b>74</b> of the second frame member <b>14</b>, substantially inhibiting translational movement of the second frame member <b>14</b> relative to the tee nut <b>22</b>.

p-0044The tension applied to the fastener <b>70</b> substantially inhibits rotational movement of the frame members <b>10</b>, <b>14</b> by increasing the amount of torsion required to overcome the tension and rotate the connector members <b>18</b>, <b>22</b>, and therefore the frame members <b>10</b>, <b>14</b>, with respect to each other.

p-0045In summary, tightening of the set screw <b>102</b> causes the connector member <b>18</b> to pivot within the channel <b>46</b> in the first frame member <b>10</b>. The pivoting action causes the connector member <b>18</b> to act similar to a wedge and substantially inhibit translational movement of the first frame member <b>10</b> relative to the connector member <b>18</b>. The pivoting of the connector member <b>18</b> also places the fastener <b>70</b> in tension. This tension causes the tee nut <b>22</b> to be pulled tight against the second frame member <b>14</b>, as described above, eliminating the clearance between the exterior and interior surfaces <b>82</b>, <b>110</b> and substantially inhibiting translational movement of the second frame member <b>14</b> relative to the tee nut <b>22</b>. The tension applied to the fastener <b>70</b> substantially increases the amount of torsion required to rotate the connector members <b>18</b>, <b>22</b> with respect to each other, which substantially inhibits rotational movement of the frame members <b>10</b>, <b>14</b>, relative to one another. Thus, tightening of the set screw <b>102</b> causes the body of the connector member <b>18</b> to pivot about the fulcrum <b>34</b> within the channel <b>46</b> of the first frame member <b>10</b> to selectively lock the first and second frame members <b>10</b>, <b>14</b> against relative movement. Readjustment of the frame members <b>10</b>, <b>14</b> is achieved simply by loosening and retightening of the set screw <b>102</b> located near the first end <b>26</b> of the connector member <b>18</b>.

p-0046The connector and frame members <b>10</b>, <b>14</b> may be assembled in many different sequences, providing the user with additional flexibility. The user may choose to first place the tee nut <b>22</b> into the channel <b>74</b> of the second frame member <b>14</b>. Then, the user may couple the connector member <b>18</b> to the tee nut <b>22</b> using the fastener <b>70</b>. Finally, the user may slide the first frame member <b>10</b> onto the connector member <b>18</b> by inserting the connector member <b>18</b> into the channel <b>46</b> in the first frame member <b>10</b>. The user may adjust the position of the frame members <b>10</b>, <b>14</b> and tighten the set screw <b>102</b> as described above to substantially restrict relative movement (e.g., translational and rotational) between the two frame members <b>10</b>, <b>14</b>.

p-0047The user may also decide to use a different sequence of events in using the connector. For example, the user may first couple the connector member <b>18</b> to the tee nut <b>22</b> by inserting the fastener <b>70</b> into the second bore <b>42</b> of the connector member <b>18</b> and the bore <b>66</b> of the tee nut <b>22</b>. Then, the user may slide the connector member <b>18</b> into the channel <b>46</b> of the first frame member <b>10</b> and the tee nut <b>22</b> into the channel <b>74</b> of the second frame member <b>14</b>. The user may adjust the frame members <b>10</b>, <b>14</b> with respect to each other and then tighten the set screw <b>102</b> until it abuts the first frame member <b>10</b>. The user may adjust the set screw <b>102</b> slightly such that it partially restricts relative movement of the two frame members <b>10</b>, <b>14</b>, make slight adjustments, and then fully tighten the set screw <b>102</b> until the frame members <b>10</b>, <b>14</b> are substantially locked against relative movement, both translational and rotational. One skilled in the art will realize that there are many ways in which two frame members <b>10</b>, <b>14</b> may be joined using a connector embodying the present invention.

p-0048<figref idrefs="DRAWINGS">FIG. 7</figref> illustrates a second embodiment of the present invention in which two frame members <b>10</b>, <b>14</b> are secured using substantially identical connector members <b>18</b><i>a, </i><b>18</b><i>b. </i>The connector members <b>18</b><i>a, </i><b>18</b><i>b </i>of the second embodiment are substantially the same as the connector member <b>18</b> of the first embodiment described above with respect to <figref idrefs="DRAWINGS">FIGS. 1-6</figref>. Therefore, the connector members <b>18</b><i>a, </i><b>18</b><i>b </i>will not be described again in detail.

p-0049The user operates the connector in the same manner as in the first embodiment. The connector members <b>18</b><i>a, </i><b>18</b><i>b </i>are coupled together by a fastener <b>70</b> and are slidably engageable within the channels <b>46</b>, <b>74</b> of the frame members <b>10</b>, <b>14</b>. The frame members <b>10</b>, <b>14</b> may be positioned in any desired orientation such that access to at least one fastener, again referred to as a set screw <b>102</b><i>a, </i><b>102</b><i>b, </i>is preserved.

p-0050Once the frame members <b>10</b>, <b>14</b> are positioned as desired, the user tightens either of the exposed set screws <b>102</b><i>a, </i><b>102</b><i>b </i>located adjacent the first ends <b>26</b> of the connector members <b>18</b><i>a, </i><b>18</b><i>b. </i>For example, tightening of the set screw <b>102</b><i>a </i>coupled to the first connector member <b>18</b><i>a, </i>will result in movement of the first connector member <b>18</b><i>a </i>from a first pivot position, in which the frame members <b>10</b>, <b>14</b> are free to move with respect to each other, to a second pivot position, in which the frame members <b>10</b>, <b>14</b> are substantially locked against relative movement, both translational and rotational. Similarly, tightening of the set screw <b>102</b><i>b </i>coupled to the second connector member <b>18</b><i>b, </i>will result in movement of the second connector member <b>18</b><i>b </i>from a first pivot position, in which the frame members <b>10</b>, <b>14</b> are free to move with respect to each other, to a second pivot position, in which the frame members <b>10</b>, <b>14</b> are substantially locked against relative movement, both translational and rotational. Therefore, when access to both set screws <b>102</b><i>a, </i><b>102</b><i>b </i>is preserved, it does not matter which set screw <b>102</b><i>a, </i><b>102</b><i>b </i>the user chooses to tighten. In some instances, as further described below, both set screws <b>102</b><i>a, </i><b>102</b><i>b </i>can be tightened. Of course, the user may also choose to arrange the frame members <b>10</b>, <b>14</b> such that access to only one set screw (e.g., <b>102</b><i>a</i>) is preserved. In such a case, the exposed set screw (e.g., <b>102</b><i>a</i>) would be tightened to lock the frame members <b>10</b>, <b>14</b> against relative movement.

p-0051Readjustment of the frame members <b>10</b>, <b>14</b> in the second embodiment may be achieved by loosening and retightening of at least one of the set screws <b>102</b><i>a, </i><b>102</b><i>b. </i>As previously stated, the user is not required to maintain access to both of the set screws <b>102</b><i>a, </i><b>102</b><i>b. </i>One or the other may remain inaccessible in a desired configuration, and the integrity of the connection is not compromised. The strength of the forces produced to substantially lock the frame members <b>10</b>, <b>14</b> against relative movement does not depend upon which set screw <b>102</b><i>a, </i><b>102</b><i>b </i>is tightened.

p-0052The second embodiment of the present invention provides one example of how a connector embodying the present invention may provide additional flexibility over the first embodiment, shown in <figref idrefs="DRAWINGS">FIG. 1</figref>. For example, the user may choose to tighten one set screw <b>102</b><i>a </i>until it abuts the first frame member <b>10</b>. Then, the user may make final adjustments to the orientation of the two frame members <b>10</b>, <b>14</b> before tightening the other set screw <b>102</b><i>b </i>to substantially lock the frame members <b>10</b>, <b>14</b> against relative movement. One skilled in the art will understand the numerous ways in which a connector embodying the second embodiment of the present invention provides added flexibility to the user.

p-0053<figref idrefs="DRAWINGS">FIG. 8</figref> illustrates an enclosure member (i.e., another type of frame member) in the form of a cabinet <b>114</b> secured to two frame members <b>10</b> using a connector embodying the present invention. The cabinet <b>114</b> contains a hinged door <b>118</b> to provide access to the contents of the cabinet <b>114</b>. However, in other embodiments, the cabinet <b>114</b> may not contain a hinged door <b>118</b>. For example, it may contain a sliding door, cover, etc. Some cabinets <b>114</b> may not contain a door <b>118</b> and may be designed to remain either open or closed at all times.

p-0054The cabinet <b>114</b> contains two threaded bores <b>126</b> (see FIG. <b>9</b>—only one is shown) for the purpose of mounting, as will be described in detail below. In the illustrated embodiment, the threaded bores <b>126</b> are formed by fixing a threaded nut <b>130</b> to a back wall <b>122</b> of the cabinet <b>114</b> in alignment with the bore in the back wall <b>122</b>. The nut <b>130</b> may be fixed to the back wall <b>122</b> by any reasonable means such as welding, adhesive, etc. In other embodiments, the back wall <b>122</b> of the cabinet <b>114</b> may be thicker such that a threaded bore may be formed directly in the back wall <b>122</b> or the bore in the back wall <b>122</b> may be non-threaded, yet engageable with the fastener <b>70</b> to secure the fastener <b>70</b> in the bore. In yet other embodiments, the threaded bore <b>126</b> may be a nut <b>130</b> that is not fixed to the back wall <b>122</b>. Of course, other components may also be used to provide threaded or non-threaded bores <b>126</b> for use with the present invention. The cabinet <b>114</b> may be provided with standard mounting kits, tabs, brackets, or other mounting devices that may contain threaded or non-threaded bores for use with the invention.

p-0055Of course, the threaded bores <b>126</b> may also be formed in other walls of the cabinet <b>114</b>, depending on the desired mounting position of the cabinet <b>114</b> with respect to the frame members <b>10</b>. In some situations, it may be beneficial to mount a cabinet <b>114</b> in a corner such that a side wall of the cabinet is mounted to one frame member <b>10</b> and the back wall <b>122</b> of the cabinet is mounted to a different frame member <b>10</b>. In other situations, the cabinet <b>114</b> may be mounted underneath a frame member <b>10</b> such that the top of the cabinet <b>114</b> contains the threaded apertures <b>126</b> for mounting the cabinet <b>114</b> to the frame member <b>10</b>. Furthermore, washers or other components may be included on either or both sides of the back wall <b>122</b>.

p-0056With reference to <figref idrefs="DRAWINGS">FIG. 8</figref>, the frame members <b>10</b> are shown oriented in a vertically upright position. One connector member <b>18</b> is used to couple each side of the cabinet <b>114</b> to the corresponding frame member <b>10</b>, which will be described in detail with reference to <figref idrefs="DRAWINGS">FIG. 9</figref>. Alternatively, the frame members <b>10</b> may be oriented in a horizontal direction or in a different angular configuration, depending on the desired application.

p-0057With reference to <figref idrefs="DRAWINGS">FIG. 9</figref>, the first frame member <b>10</b> is coupled to the cabinet <b>114</b> using only one connector member <b>18</b>. The operation of the connector member <b>18</b> is the same as described above and will not be described again in detail. The fastener <b>70</b> extends through the second bore <b>42</b> in the connector member <b>18</b> and threadably engages the threaded aperture <b>126</b> formed by the back wall <b>122</b> of the cabinet <b>114</b> and the fixed nut <b>130</b>, as described above. The connector member <b>18</b> pivots within the channel <b>46</b> in the first frame member <b>10</b> in the same manner as described with respect to <figref idrefs="DRAWINGS">FIGS. 1-6</figref> by tightening the set screw <b>102</b>. The pivoting action of the connector member <b>18</b> causes the cabinet <b>114</b> to be substantially locked against movement (e.g., translational and rotational) relative to the connector member <b>18</b> and the frame member <b>10</b>.

p-0058Thus, the connector member <b>18</b> may be used to connect two frame members <b>10</b>, <b>114</b> without modification to either of the frame members <b>10</b>, <b>114</b>. Furthermore, readjustment of the position of the cabinet <b>114</b> does not require opening of the cabinet <b>114</b> or removal of the contents inside the cabinet <b>114</b>. The user simply needs to loosen and tighten the set screw <b>102</b>, as discussed above, to adjust the location or position of the cabinet <b>114</b>.

p-0059Connectors in accordance with the present invention may be used to connect aluminum profiles (e.g., Bosch Rexroth aluminum profiles) internally, offering better access to add panels and better clearance for other parts. As described above, the frame members <b>10</b>, <b>14</b> do not need to be identical. Two frame members <b>10</b>, <b>14</b> with different sizes of profile may be joined with appropriate fittings. In this way, connector members embodying the present invention may be used as transition connectors between different sized frame members <b>10</b>, <b>14</b>. Similarly, connector members in accordance with the present invention may be used to connect frame members <b>10</b>, <b>14</b> of different manufacturers.

p-0060Connectors such as those described in the first embodiment offer greater access to the channels <b>46</b>, <b>74</b> in the frame members <b>10</b>, <b>14</b> because the tee nut <b>22</b> generally takes up less space than the connector member <b>18</b> with a fulcrum <b>34</b>. Connectors such as those described in the second embodiment, in which both connector members <b>18</b><i>a, </i><b>18</b><i>b </i>contain a fulcrum <b>34</b><i>a, </i><b>34</b><i>b, </i>can provide maximum flexibility because a joint or connection point between two frame members <b>10</b>, <b>14</b> may be adjusted at either side of the joint if access to both fasteners (e.g., set screws <b>102</b><i>a, </i><b>102</b><i>b</i>) is preserved.

p-0061As described above, the present invention could also be used with only one connector member <b>18</b> by securing the fastener <b>70</b> directly into the second frame member <b>14</b>, <b>114</b> without the use of a tee nut <b>22</b> or second connector member <b>18</b><i>b. </i>In particular, the second frame member <b>14</b> may be any reasonable structure or enclosure member, such as a cabinet <b>114</b>, electrical box, watertight box, explosion proof box, etc. In applications where the second frame member <b>14</b> contains a threaded aperture <b>126</b> in which the fastener <b>70</b> may be threadably engaged, no modification to the second frame member <b>14</b> would be necessary. Although some embodiments may require machining of the second frame member <b>14</b> to include a threaded bore or other receiving mechanism, this method provides additional flexibility to the invention by allowing any two frame members <b>10</b>, <b>14</b>, <b>114</b> to be connected together.

p-0062Various features and advantages of the invention are set forth in the following claims.