Connector for Building Members

Description

BACKGROUND

This disclosure relates generally to the field of building construction connectors, more particularly to a connector for attaching a first building member to a second building member with fasteners. More particularly, the disclosure relates to a connector and an associated system wherein the connectors having a single form factor can be used to make a variety of first-to-second building member connections-including, for example, beam to joist, joist to ledger, post to beam, and stringer to rim connections.

In construction and building fields, connectors are common for assisting in the connection of one building member to another. Connectors commonly provide an intermediate “base” structure with one or more hole guides for fasteners for a user to drive fasteners through to attach the building members to each other, with the base structure having a specific form for a specific type of connection. Hangers are often formed of metal, such as steel, and include numerous sides and surfaces used for attaching to a support member and beam, and holding and supporting the beam. For example, a typical joist hanger for attaching a deck or floor joist includes two opposed upright side panels on each side of a joist connected by a lower web that supports the bottom of the joist, and optionally side flanges off the side panels that abut the ledger. A joist hanger is just one of countless examples of connectors for use in connecting building members to each other.

One common problem associated with known connectors is that each of them is specifically designed and dimensioned for a single use with a single dimension of lumber. This requires many different hangers to accommodate a variety of building member connections in any given construction setting. It would be useful to provide a connector with capabilities to improve upon these common issues. For example, it would be useful to have a hanger that allows a user to form numerous different building member connections.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of the disclosed connector;

FIG. 2 is a perspective view of the connector of FIG. 1 from a different position;

FIG. 3 is a rear elevation view of the connector of FIGS. 1-2;

FIG. 4 is a front elevation view of the connector of FIGS. 1-2;

FIG. 5 is a side cross sectional view of the connector of FIGS. 1-2;

FIG. 6 is a front perspective view of another embodiment of the disclosed connector referred to as a dual sided or saddle connector;

FIG. 7 is a front perspective view of the connector of FIG. 6 from another angle;

FIG. 8 is a front elevation view of the connector of FIGS. 6-7;

FIG. 9 is a rear elevation view of the connector of FIGS. 6-7;

FIG. 10 shows an exemplary beam-to-joist building assembly using the connector of FIGS. 1-2 with building members in skeletal view;

FIG. 11 is a side view of the building assembly of FIG. 10 with building members in skeletal view;

FIG. 12 is a top view of the building assembly of FIG. 10 with building members in skeletal view;

FIG. 13 shows an exemplary joist-to-ledger building assembly using the connectors of FIGS. 1-2 and FIGS. 6-7 with building members in skeletal view;

FIG. 14 is a front bottom perspective view of the building assembly of FIG. 13 with building members in skeletal view;

FIG. 15 is a top view of the building assembly of FIG. 13 with building members in skeletal view;

FIG. 16 shows an exemplary post-to-beam building assembly using connectors of FIGS. 1-2 from a perspective view with building members in skeletal view;

FIG. 17 is a front elevation view of the building assembly of FIG. 16 with building members in skeletal view;

FIG. 18 is a bottom elevation view of the of the building assembly of FIG. 16 with building members in skeletal view;

FIG. 19 shows an exemplary stringer-to-rail building assembly using the connector of FIGS. 1-2 from a front perspective view;

FIG. 20 is a side elevation view of the building assembly of FIG. 19;

FIG. 21 is a bottom elevation view of the building assembly of FIG. 19;

FIG. 22 is a perspective view of the connector of FIGS. 1-2 with fasteners installed and building members omitted for clarity;

FIG. 23 is a side elevation view of the connector of FIGS. 1-2 with fasteners installed;

FIG. 24 is a rear elevation view of the connector of FIGS. 1-2 with fasteners installed;

FIG. 25 is a front elevation view of the connector of FIGS. 1-2 with fasteners installed;

FIG. 26 shows a collated strip of connectors like those depicted in FIGS. 1-2;

FIGS. 27A-27D depict steps of an installation of a joist to a beam using the connector of FIGS. 1-2;

FIGS. 28A-28E show steps of an installation of a joist to a ledger using the connector of FIGS. 6-7 and connectors of FIGS. 1-2;

FIGS. 29A-29E show steps of an installation of a post to a beam using connectors of FIGS. 1-2;

FIGS. 30A-30C show another embodiment of a saddle connector in use for leveling and attaching a joist to a ledger;

FIGS. 31A-31C show a use of the connector of FIGS. 1-2 for leveling a joist to a ledger;

FIG. 32 is a front elevation view of another embodiment of a saddle connector with offset side connectors;

FIG. 33 is a front perspective view of the saddle connector of FIG. 32;

FIG. 34 is a front perspective view of another embodiment of a saddle connector;

FIG. 35 is a front elevation view of the saddle connector of FIG. 34;

FIGS. 36A and 36B show views of another embodiment of a dual-sided or saddle connector with breakaway scores;

FIG. 37 shows another embodiment of a dual-sided or saddle connector in accordance with the disclosure from a front perspective view;

FIG. 38 is a front elevation view of the connector of FIG. 37;

FIG. 39 is a rear elevation view of the connector of FIG. 37;

FIG. 40 is a side elevation view of the connector of FIG. 37;

FIG. 41 shows an alternate embodiment of a dual-sided or saddle connector with breakaway score lines from a front perspective view; and

FIG. 42 is a front elevation view of the connector of FIG. 41.

DETAILED DESCRIPTION

Among the benefits and improvements disclosed herein, other objects and advantages of the disclosed embodiments will become apparent from the following wherein like numerals represent like parts throughout the figures. Detailed embodiments of a connector for building members are disclosed; however, it is to be understood that the disclosed embodiments are merely illustrative of the invention that may be embodied in various forms. In addition, each of the examples given in connection with the various embodiments of the invention are intended to be illustrative, and not restrictive.

Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrase “in some embodiments” as used herein does not necessarily refer to the same embodiment(s), although it may. The phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although it may. Thus, as described below, various embodiments may be readily combined without departing from the scope or spirit of the invention.

As used herein, “based on” is not exclusive and permits being based on additional factors not expressly described unless the applicable context clearly dictates otherwise.

In addition, as used herein, the term “or” is equivalent to the term “and/or,” unless the context clearly dictates otherwise. The term “based on” is not exclusive and allows for being based on additional factors not described unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.”

Further, the terms “substantial,” “substantially,” “similar,” “similarly,” “analogous,” “analogously,” “approximate,” “approximately,” and any combination thereof mean that differences between compared features or characteristics is less than 25% of the respective values/magnitudes in which the compared features or characteristics are measured and/or defined.

Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.

The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the inventive subject matter and does not pose a limitation on the scope of the inventive subject matter otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the inventive subject matter.

Groupings of alternative elements or embodiments of the inventive subject matter disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.

Disclosed herein are embodiments of a single connector and a dual sided “saddle” connector for use in forming connections between two building members in a multitude of different configurations. Various uses of disclosed embodiments of single and double connectors are also disclosed, which are non-limiting to the inventive scope.

Within the disclosed system, one or more single connectors can also be used in tandem with a dual sided connector in various settings, depending on the desired connection to be made or assembled. Altogether, the disclosed embodiments provide a system with nearly endless versatility for making countless different attachments between a first building member and second building member, as will be described herein.

FIGS. 1-5 and 22-25 show an embodiment of a single connector 10 in isolation. FIGS. 22-25 include a set fastener 50 and a structural fastener 52 extending through a set screw guide 24 and toenail guide 26, respectively, for illustrative purposes.

FIGS. 6-9 show a first embodiment of a dual sided connector 100 in isolation. FIGS. 10-21 depict exemplary building assemblies installed with use of one or more of the connectors, 10 and 100, demonstrating the versatility of the disclosed embodiments. FIGS. 27A-29E show steps of forming various building assemblies using the disclosed embodiments of the connectors, 10 and 100.

The remaining Figures show additional embodiments of connectors and/or uses thereof, further illustrating the versatility of the disclosed embodiments.

The connector 10 generally comprises a base 11 with a front 20 and rear 22, and extends in a first direction between opposed first and second lateral edges, 12, 14, and in a second direction between opposed first and second longitudinal edges, 16, 18. Herein, the respective edges are intentionally not referred to as a “top”, “bottom”, “right” or “left” edge because the connector 10 is designed to be usable in any angular configuration in order to fit a variety of needs in the building construction industry. The rear 22 defines a rear placement surface which may be substantially flat or includes multiple portions that combine to define a rear placement surface. While not depicted, the rear may include a surface texture such as teeth, prongs, tabs, undulations, roughness or similar configured to puncture, to aid friction and/or dig into or grip the surface of wooden building member to aid in creating a strong rigid connection.

As shown, the front 20 of the base include an elevated structural body 28 for structurally supporting the fasteners, when installed. The structural body 28 includes a set screw guide hole 24 that extends substantially perpendicular through the base such that a fastener (i.e., set screw) 50 driven through the set screw guide 24 embeds substantially perpendicular to the outer face of a building member on which the rear 22 of the connector 10 is placed. The structural body 28 defines a leveraging surface 32 about the set screw guide 24 on which the head of the set screw 50 abuts when driven into a building member.

The structural body 28 also has a ramp 30 through which the toenail guide 26 extends obliquely through the body, and which forms a leveraging surface for the head of a structural fastener 52 when driven into the building member. In the depicted embodiment, the ramp 30 extends obliquely upward from a proximal position near or at the second lateral edge 14. With reference to FIG. 5, the toenail guide 26 may have a central axis A that is angled within an approximate range of 15-75° relative to the flat rear surface 23 or a planar surface on which the rear surface abuts during installation. More preferably, the central axis A of the toenail guide 26 is angled within an approximate range of 30-60°. In the depicted preferred embodiment, the axis A of the toenail guide 26 is approximately 45°.

As can be seen most clearly in FIG. 5 and FIGS. 22-25, the set screw hole 24 extends substantially perpendicular from the front side 20 to the rear side 22. These Figures also show the toenail guide 26 extending through from the front 20 to the rear 22 at an obliquely inclined angle.

When the connector 10 is positioned with the first lateral edge 12 in a top position, the toenail guide 26 extends obliquely upward toward the first lateral edge 12 from a proximal end positioned near the second lateral edge 14. As noted above, in the depicted preferred embodiment, the toenail guide 26 extends at an angle of approximately 45°. Additionally, each of the set screw guide 24 and toenail guide 26 is offset laterally between the respective lateral edges, 12 and 14, and offset longitudinally between the respective longitudinal edges, 16 and 18.

In the depicted embodiment, when the connector 10 is positioned with the first lateral edge 12 in a top position, the proximal (front) end of the toenail guide 26 is below the proximal (front) end of the set screw guide 24, and the respective distal ends of the toenail guide 26 and set screw guide 24 exit the rear 22 of the connector 10 at approximately the same height. This relative relationship, along with the other properties of the connector 10, has shown to provide robust attachment strength and particularly effective load transferring from the attached building members through the fasteners and into the connector when installed in a building structure or sub-structure. The combined relationships of the elements within the connector 10 have shown to provide a strong attachment between building members and yield high structural integrity of the resulting building assembly.

The laterally and longitudinally offset positioning of the toenail guide 26 and set screw guide 24 allows two connectors 10 to be used on opposite sides of a building member, for example a joist, and aligned with each other to form a connection, without risking opposite fasteners obstructing each other when driven into the joist, as well as reducing the likelihood of wooden building materials splitting. This will be described in greater detail below with reference to the assembly Figures.

As shown primarily in FIGS. 1-4, the toenail guide 26 may include a textured inner wall surface for assisting driving the fastener. In the case of the depicted embodiments, the inner wall surface includes a series of elongated ribs that the threads of the fastener grip while rotating, enhancing the installation efficiency. The set screw guide may similarly include a texture although the depicted embodiment does not include such texture.

In the connector 10 and other embodiments described below, the structural body 28 is a forward elevated portion of the front side 20 of the base 11 that is sized and shaped to effectively transfer load from the fasteners into the base 11 when installed in a building assembly. The structural body 28 may expand outwardly from the proximal portion toward the second lateral edge 14 to its distal portion toward the first lateral edge 12 such that it is wider at the distal end, however, this is a non-limiting characteristic.

FIGS. 31A-31C illustrate another use of this embodiment of the connector 10 for leveling a building member (here, leveling a joist J to a ledger L). As shown, the connector 10 can be installed on a top face of the first building member (joist J) with a portion 80 extending rearwardly over the rear edge of the building member to form a temporary alignment flange via driving a set screw 50 through the set screw guide 24. This provides a placement surface for aligning the top of the first building member (joist J) to the top of the second building member (ledger) and ensuring a flush alignment, essentially hanging on the top of the ledger. Once the joist is aligned in this manner, an installer can attach the joist to the ledger using additional connectors 10 (as will be described in detail below) or in another way, and then remove the set screw 50 from the alignment connector on top, thereby yielding a level joist/ledger connection without requiring meticulous leveling measurements.

In another embodiment, FIG. 26 shows a collated series 900 of connectors 10′. Here, each of the connectors 10′ is substantially similar to the connector of FIGS. 1-2 and attached to an adjacent connector 10′ via one or more intervening tabs 90′. The configuration of the collation provides a twofold benefit. First, the tabs 90′ may be scored and configured to be breakable to release a connector 10′ or multiple connectors 10′ from the remaining connectors in the strip for installation. Additionally, each connector 10′ may be spaced at a specific preferred location relative to adjacent connectors 10′ for forming building connections according to code or custom when not broken off individually. This configuration provides for an efficient installation without requiring the installer to measure between individual connectors while installing. Other embodiments may include multiple different scores or breakable portions between each adjacent connector 10′ to give installers additional variability.

FIGS. 6-9 show another embodiment of a connector 100, referred to as a dual-sided or “saddle” connector. This embodiment includes a first connector unit 101 spaced from a second connector unit 102 by a lower web 104, which defines a channel therebetween. Preferably, each of the connector units, 101, 102, shares many of the key features of the connector 10 of FIGS. 1-5 and described above. Indeed, the connector units, 101, 102, may have substantially identical elements to the connector 10, although this is not a requirement.

As shown, the first connector unit 101 of the connector 100 has a body 119 that extends between first and second lateral edges 111 and 113, and between first and second longitudinal edges 115 and 117. The body further defines a set screw guide 123 and a toenail guide 125 in a respective elevated structural body, 127, 128. Like the earlier embodiment of the connector 10, each of the connector unit bodies 119, 120 includes a substantially flat inner surface or may include surface texture for improving friction (akin to the rear surface of the connector 10). The second connector unit 102 similarly includes a body 120 extending between first and second lateral edges 112 and 114, and between first and second longitudinal edges 116 and 118. In the depicted embodiment, the relative positioning of the set screw guides 123/124 and toenail guides 125/126 is reversed between the first connector unit 101 and second connector unit 102 so that the toenail guides, 123 and 124, do not align with each other and the toenail guides 125 and 126, do not align with each other. This can be seen most clearly with reference to the front elevation view of FIG. 8, wherein the set screw guide 123 is positioned closer to the second lateral edge 113 than the toenail guide 125 is in the first connector unit 101, and the toenail guide 126 is positioned closer to the second lateral edge 114 than the set screw guide 124 is in the second connector unit 102. In the preferred embodiment, the set screw guide 123 of the first connector unit 101 may be substantially laterally aligned with the toenail guide 126 of the second connector unit, and the toenail guide 125 of the first connector unit 101 may be substantially laterally aligned with the set screw guide 124 of the second connector unit 102. This relative positioning of the respective guide holes avoids fasteners obstructing one another and reduces the likelihood of wood splitting when driven into a building member, like a joist J.

Each of the first connector unit 101 and second connector unit 102 also includes an elevated structural body 127 and 128 with substantially the same characteristics and properties of the structural body 28 of the connector 10. Like the earlier embodiment, the structural bodies, 127 and 128, are sized, shaped and positioned to help transfer load from the fasteners into the respective bases when installed in a building assembly.

The inner/rear sides, 119 and 120, define a placement surface that can be substantially flat surface or include multiple portions that combine to form an abutment surface for engaging with the outer surface of the building member to which the connector 100 is engaged. Also like the earlier embodiment of the connector 10, the inner/rear sides may be textured or may include undulations, teeth or other elements for enhancing friction and/or gripping the underlying building member.

FIGS. 30A-30C depict another embodiment of a saddle connector 700 with an extension flange 780 extending from the web 704, which may optionally have a hole for a fastener 755. As shown in these Figures, the connector 700 can be used for leveling a first building member to a second building member, such as the depicted joist and ledger. Here, the connector 700 is attached on the top edge of the joist J with the flange 780 extending from the joist rear edge. Set screws can be driven through set screw guides 724 in the side connector units, 713, 714, in addition to or in lieu of the web screw 755. The joist J is engaged with the ledger L with the flange 780 on the top surface of the ledger, ensuring that the joist J is level. The joist J can thereafter be attached to the ledger via structural screws through toenail guides 726 in the side connector units, 713, 714, and/or using additional connectors like those shown as reference numerals 10 and 100. For example, an installer can position a connector 10 beneath the connector 700 on each side of the joist J and attach the joist with structural screws driven through the toenail holes and joist and into the ledger. Once the joist and ledger are attached (detailed steps below), the connector 700 can optionally be removed.

FIGS. 32-33 depict another embodiment of a saddle connector 800. This embodiment is similar to the earlier embodiment of the saddle connector 100, but with connector units 801 and 802 that have an uneven length between the respective first edges, 811, 812, and respective second edges, 813, 814. This configuration is advantageous in that it vertically staggers the set screw guides, 823, 824, and toenail guides 824, 826, an even greater distance from each other than the earlier embodiment. Like the earlier embodiment of the saddle connector 100, in this embodiment of the saddle connector 800, a support web 804 extends between the first connector unit 801 and the second connector unit 802 proximate the respective first edges, 811, 812.

Specifically, FIGS. 13-15 depict a joist to beam connection employing a saddle connector 100 and two opposing connectors 100. In this connection, the saddle connector 100 is positioned with its web 104 abutting the lower edge of the joist J with the first connector unit 101 on one side of the joist and the second connector unit 102 on the other side of the joist. One single connector 10 is attached above the second edge of the first connector unit 101 of the saddle connector 100 and an opposite single connector 10 is attached above the second edge of the second connector unit 102. Additional connectors may be used as desired to accommodate larger building member or simply as preferred to create a stronger connection. As can be seen in the skeletal views, the offset position of the respective toenail guides and set screw guides allows the structural screws and set screws to be driven into the building materials without obstructing one another.

While non-limiting, FIGS. 13-22 are illustrative of the adaptable nature of the connector 10 and saddle hanger 100 for forming numerous different connections between building members.

FIGS. 10-12 depict an exemplary beam-to-joist installation 200 using the connector 10. As shown, the connection between the first building member (beam B) and second building member (joist J) can be made by placing the joist J on the beam B as usual and aligning a connector 10 with its rear surface 23 against a side surface of the beam B with its first lateral edge 12 upright against the bottom surface/edge of the joist J. Typically, the connector 10 is first secured in the preferred location via driving the set screw 50 substantially perpendicularly through the set screw guide hole 24 and into the beam B. The joist J is attached via driving a structural fastener 52 through the angled toenail guide 26 at an oblique angle, through a portion of the beam B, and into the joist J at the preferred angle. Here, the structural fastener 52 is driven into the bottom edge of the joist J at approximately 45° relative thereto. While not depicted, a second connector 10 can be installed on the opposite side of the joist J in the same configuration to form a stronger connection between the respective building members. The relative positions and configuration of the toenail guide hole 26 and set screw guide hole 24 ensure that the opposing set screws 50 and opposing structural fasteners 52 are offset from one another when driven into the building members.

Steps of Typical Installation of Deck Beam to Joist:

• • Position the connector 10 on the face of the carrying beam B with the first lateral edge 12 against the joist J lying directly above and the toenail guide 26 laterally centered on the joist J (FIG. 27A).
  • Drive the set screw 50 to fix the connector 10 to the beam B (FIG. 27A).
  • Drive the structural fastener 52 upward through the oblique toenail guide 26 (FIG. 27B), through the beam B and into the joist J at the preset angle until the head of the fastener 52 abuts the ramp 30 (FIG. 27C) to yield the beam-to-joist assembly 200 (FIG. 27D).

FIGS. 13-15 depict an exemplary joist-to-ledger installation 300 using connectors 10 and a saddle connector 100. To form this installation, a saddle connector 100 can first be attached to a joist J with the connector units, 101, 102, on opposite sides of the joist and the web 104 along the bottom edge of the joist. An installer can slide the saddle connector 100 into preferred position at the rear end of the joist J and then attach it to the joist via driving set screws 50 into each of the set screw guide holes 24 and into the respective sides of the joist J. Thereafter, the installer can position the joist with its rear end against the front side of the ledger L, optionally with use of a connector 10 hanging over the top edge of the joist, as shown in FIGS. 32A-32C. The joist is thereafter attached via driving structural fasteners 52 through the opposing toenail guide holes, 125, 126, in the connector units, 101, 102, through an end portion of the joist J and into the ledger L. As shown in FIGS. 13-15, additional fasteners can be installed with use of additional connectors 10, depending on code requirements and/or installation preferences. As shown here, a second connector 10 can be installed proximate the second lateral edge 114 of the second connector unit 102. In the depicted installation, the second connector 10 is positioned rotated 90° relative to its position in FIGS. 10-12, again demonstrating the adjustability and versatility of the disclosed embodiments. In this position, the second connector 10 is positioned with its second longitudinal edge 18 downward adjacent to the second lateral edge 114 of the second connector unit 102 of the saddle connector 100, and its first longitudinal edge 16 positioned on top. This positioning provides for the structural fasteners 52 to be driven obliquely through the rear end of the joist J substantially parallel to the structural fasteners 52 attaching the saddle connector 100 (and parallel to the upper and lower surfaces of the joist J). Also shown, a first connector 10 is installed on the opposite side of the joist J with its first longitudinal edge 16 adjacent the second lateral edge 113 of the first connector unit 101 of the saddle connector 100. In this position, the structural fastener 52 is driven obliquely through the rear end of the joist J and into the leger L, also parallel to the structural fastener 52 of the saddle connector 100 and the structural fastener 52 of the second connector 10. Additional connectors 10 can be used to attach more fasteners as may be desired for a given assembly or dimension of building materials.

Steps of Typical Installation of Joist to Ledger:

• • Attach saddle connector 100 on the bottom of the joist J flush with the end of the joist by driving a set screw 50 on each side (FIG. 28A).
  • Align the top of the joist J flush with the top of the ledger L (optionally using a removable connector 10, as described above) (FIG. 28A) and drive structural fasteners 52 through oblique toenail guides 125, 126, through the joist J and into the ledger L at the preset angle until the head of the fastener abuts the ramp 129, 130 (FIG. 28B).
  • Install connectors 10 above the saddle connector 100 on each side of the joist J with their respective first lateral edge 12 against the ledger L such that the toenail guides 26 are pointed towards the ledger (connectors 10 should be no less than 2 inches from the top of the deck joist according to code) (FIG. 28C) and secure connectors 10 in place by driving set screws 50 into joist J (FIG. 28C).

Drive structural screws 52 through the oblique toenail guides 26 at the preset angle until the head of the fastener 52 abuts the ramp 30 to yield the joist to ledger connection 300 (FIG. 28D-28E).

The installation 300 of FIGS. 13-15 further illustrate the variability of uses of the connector 10 provided by the laterally and longitudinally offset positioning of the set screw guide 24 and toenail guide 26. Identical connectors 10 can be used on opposite sides of building members (like joists) in this manner, aligned vertically and horizontally relative to each other, and attached without the respective set screws 50 and structural fasteners 52 obstructing one another as would occur if the set screw guide 24 and/or toenail guide 26 were positioned centrally aligned on the body 20 of the connector. This concept is illustrated clearly with reference to the top skeletal views of FIGS. 13-15, which show the structural fasteners 52 driven obliquely and passing over/under each other within the joist.

FIGS. 16-18 depict an exemplary post-to-beam installation 400 using a plurality of single connectors 10. As shown, a beam B is positioned on a post P extending transversely across the top end of the post. One or more connectors 10 are positioned on each of the front side and rear side of the post with their respective first lateral edges 12 facing upward, typically abutting the bottom surface of the beam B. In this arrangement, structural fasteners 52 can be driven obliquely upward through the top end of the post P and embedded into the beam B to attach them together.

Steps of Typical Installation of Post to Beam:

• • Set the beam B in place laying over the post P (beams can be centered over the post or flush to one side of the post) (FIG. 29A).
  • Position a first connector 10 with rear 20 against the post P under one of the outermost plies of the beam B and first lateral edge 12 against the post with toenail guide 26 centered on the middle of the beam B (FIG. 29B).
  • Drive a set screw 50 into the post P to fix the connector 10 in place (FIG. 29C).
  • Drive a structural fastener 52 through the toenail guide 26, through the post P and into the beam ply at the preset angle until the head of the structural fastener abuts the ramp 30 (FIG. 29D).
  • Install three more connectors 10 in the same orientation so that there are two connectors on each face of the post P, each aligned with a ply of the beam B, to form the post-to-beam connection 400 (FIG. 29E).

FIGS. 19-22 depict an exemplary stringer-to-rim installation 500 using connectors 10. Here, the rear edge of the stringer S is positioned against the front face of the rail R with connectors 10 positioned on each lateral side of the stringer S with their respective first lateral edge 12 against the rail R. The connectors 10 are attached to the stringer S in these positions via set screws 50 driven perpendicularly into the stringer. Then the stringer S is attached to the rail R via structural fasteners 52 driven obliquely through the rear end of the stringer and embedded into the rail R. As with the embodiment of the installation of FIGS. 13-15, the longitudinally and laterally offset positioning of the set screw guides 24 and toenail guides 26 in the body 20 of the connectors 10 permit the fasteners to be installed on opposite sides without obstructing one another and in a way that reduces the probability of the wood material splitting.

Steps of Typical Installation of Stair Stringer to Deck Rim:

• • Set the stringer S at the proper height against the rim R (code requires the stringer to be supported along its total height by a rim board or structural blocking).
  • Place the first connector 10 alongside the stringer so that the edge of the connector C is no less than 1 inch from the top or bottom edge of the stringer S with the first lateral edge 12 toward the rim R (i.e., the oblique toenail guide hole point towards the rim R).
  • Drive the set screw 50 through the set screw guide 24 to fix the connector to the stringer S.
  • Drive the structural fastener 52 through the toenail guide 26 at the preset angle, and through the rear end of the stringer S and into the rim R until the fastener head abuts the surface of the ramp 30.
  • Install three more connectors 10 with respective first lateral edge 12 facing the rim R via the same steps to yield an installation 500 with two connectors 10 on each side face of the stringer S at matching heights (offset lateral positioning of the guide holes creates a staggered pattern for the structural screws 52 when mounted at the same height on opposing sides).

The exact positions and angular arrangements of the connectors, 10 and 100, in the exemplary installations of FIGS. 10-22 are non-limiting. Part of the inventiveness of the connector 10 lies in its adjustability. Accordingly, the connector can be used to attach building members in a virtually endless number of installations.

While not shown in the Figures, embodiments of the connector 10 exist that include an indexing element, such as a molded notation, arrow, notch or other marking in one or both of the first lateral edge 12 and second lateral edge 14 to identify the lateral positioning of the toenail guide 26. Users can use the indexing element to align the connector relative to a building member with the toenail guide laterally positioned to guide the structural fastener 52 into a preferred location. This is particularly advantageous when installing a beam to a joist and post to beam, for example. In these installations, it is important to laterally align the toenail guide around the center of the joist or a particular ply of the beam during installation.

Additionally, various specific shapes and characteristics of the elements that form the connectors, 10 and 100, are possible without departing from the inventive spirit of the disclosed embodiments of the connector. The guides are angled at preferred angles to drive fasteners and install a robust “toenail” connection between a first building member and second building member which complies with code requirements.

FIGS. 35 and 36 depict another embodiment of a dual sided saddle connector 600. This embodiment is generally structurally similar to the earlier embodiment of FIG. 6 in that it includes a first connector unit 601 spaced from a second connector unit 602 with a web 604 extending between them to define a channel. In this embodiment, each of the connectors transitions to the web 604 via a bowed section 650 extending from the respective front edge, 615/616, to the respective rear edge 617/618. As depicted in FIGS. 35 and 36, the respective bowed sections 650 may have be tubular with a quasi-circular cross section with a portion extending laterally outward from each connector unit 601/602 and a portion extending longitudinally downward from the web 604. The specific shape of the bowed sections 650 is non-limiting provided that the shape provides a spring function, allowing outward flexation of the connector units 601/602 upon application of an outward force and inward return upon removal of the outward force. In this manner, the embodiment of the connector 600 can accommodate beams of varying thicknesses while also clamping to some beams. As also shown in FIGS. 35-36, the connector units 601/602 may each include more than one oblique toenail guide, like those shown as reference numerals 625, 625′, 626 and 626′. Each connector unit 601/602 additionally includes at least one set screw guide 623/624 extending substantially perpendicularly therethrough. As with the earlier embodiments, the opposite toenail guides and set screw guides are preferably vertically offset from one another to prevent opposing fasteners from obstructing one another. Additionally, the quantity, relative positioning and configurations of the toenail guides and set screw guides are applicable to embodiments of the connector without the bowed spring sections, including those shown in the earlier FIGS. 6-8 and 32-33, for example.

FIG. 36 shows another embodiment of a connector 900 with a series of scores 950/951/952 in sections of the body of the connector. In the depicted embodiment, the scores are formed as rearward elongate V-notches. As shown, the connector 900 includes a score line (V-notch) 950 in the corner that transitions between the connector unit 901 and the web 904, a score line 952 in the opposite corner that transitions between the connector unit 902 and web 904, and a score line 951 in an intermediate position within the web 904. The score lines are configured and positioned to allow a user to optionally break off a portion of the connector 900 depending on a specific installation. For example, the connector 900 can be broken at score line 951 to accommodate a double wide beam, with the connector unit 901 on one side of the beam with a first section 903 of the web 904 underneath the beam, and the connector unit 902 on the opposite side of the beam with a second section 905 underneath the beam spaced from and the first section 903. For other installations, an installer can break the connector 900 at one of the corner score lines, 950 or 951. Additional embodiments exist with score lines that take a different configuration, such as a series of indentations or spaced apart perforations in the surfaces of the connector, and embodiments with score lines in different positions in the connector.

FIGS. 37-40 show views of yet another embodiment of a saddle connector 1000. This embodiment shares many general elements and characteristics with earlier embodiments of saddle connectors, including a first connector unit 1001 spaced from a second connector unit 1002 with respective inner surfaces that are substantially parallel to one another. The first connector unit 1001 extends longitudinally between first and second longitudinal edges, 1011, 1013, and laterally between first and second lateral edges, 1015, 1017. Likewise, the second connector unit 1002 extends longitudinally between first and second longitudinal edges, 1012, 1014, and laterally between first and second lateral edges, 1016, 1018. The first and second connector units, 1001, 1002, are substantially commensurate in dimension, while differing in relative location of their respective toenail guides and set screw guides, as will be discussed in detail below. The first connector unit 1001 and second connector unit 1002 are separated by a lower support web 1004 extending between and connecting the respective first lateral edges, 1011, 1012. The support web 1004 has an inner surface that is substantially perpendicular to the inner surfaces of the first connector unit 1001 and second connector unit 1002. A beam receipt channel is defined between the inner surfaces and the web.

In the depicted preferred embodiment, each of the connector units, 1001, 1002, has a respective pair of toenail guides, 1025, 1025′ and 1026, 1026, with a respective set screw guide, 1023 and 1024, positioned laterally between the spaced apart pair of toenail guides in each connector unit. As with the earlier embodiments, each of the toenail guide holes, 1023, 1024, extends substantially perpendicularly through the inner surface of its respective connector unit. Each of the toenail guide hole openings extends from a support ledge, 1031, 1032, a raised body away from the outer surface of the respective connector unit, 1001, 1002.

Each of the toenail guide holes, 1025, 1025′, 1026, 1026′, extends obliquely through a force transfer unit 1039, 1039′, 1040, 1040′ formed as a raised body away from the rear of the respective connector unit and defining a front ramp, 1029, 1029′, 1030, 1030′. Each force transfer unit is formed as a solid molded member integral with its respective connector unit, 1001, 1002, and thus integral with the other force transfer units and support ledges. Each force transfer unit extends outward from the outer surface of the body of its connector unit and defines a front ramp angled at approximately 45° relative to the inner surface of the connector unit, and thus, approximately 45° relative to a building member positioned within the channel defined between the web 1004 and the connector units, 1001, 1002. The force transfer units include additional features such as a solid body that extends rearward from the front ramp and transitions into the body of the connector unit. Additionally, a rib extends laterally between each force transfer unit and the intermediate support ledge defining the set screw guide hole.

The force transfer units, 1039, 1039′, 1040, 1040′, with respective front ramps, 1029, 1029′, 1030, 1030′, and the support ledges, 1031, 1032, are sized and shaped to transfer the load of an elongated beam to the support structure within which it is attached, rather than the toenail fasteners and set screws bearing the load themselves. In this way, the connector 1000 provides substantially improved strength relative to many known connectors or hangers with similar features.

Additionally, with reference to the front and rear elevation views of FIGS. 38-39, the toenail guides, 1025, 1025′, of the first connector unit 1001 are offset in the lateral direction from the toenail guides, 1026, 1026′, of the second connector unit 1002 (vertical direction in the drawings). The set screw guide 1023 of the first connector unit 1001 is also offset in the lateral direction from the set screw guide 1024 of the second connector unit 1002. This relative positioning of the guides (and accordingly, the force transfer units, shelves and fasteners, when installed) aids in providing a robust connection between a beam and a structural building member, for example, a joist to a ledger. The relative positioning also avoids the fasteners obstructing each other when driven into the connector 1000 to attach a beam to a support member and reduces splitting of wooden building materials.

FIGS. 38-39 additionally help depict the relative thicknesses of the force transfer units that define the toenail guide holes, 1025, 1025′, 1026, 1026′, the laterally extending structural ribs, 1041, 1042, and the support ledges, 1031, 1032. As shown, in this embodiment, the ribs have an outward thickness that is similar to that of the ledges, and is less than that of the force transfer units. These relative thicknesses have shown to provide the connector 1000 and the building assemblies within which the connector is used with significantly improved structural integrity.

FIGS. 41 and 42 depict another embodiment of a saddle connector 1100. This embodiment includes substantially the same features as the previous embodiment of the saddle connector 1000, including a first connector unit 1101 spaced from a second connector unit 1102, each extending between opposite first and second lateral edges and between opposite first and second longitudinal edges with a support web connecting them at their first lateral edges. Each of the connector units, 1101, 1102, includes respective toenail guides, 1125, 1125′, 1126, 1126′, defined by a respective force transfer units 1139, 1139′, 1140, 1140′ and a set screw guide defined by a support ledge, 1131, 1132. Each of these elements has a similar configuration to the like element in the embodiment of the saddle connector 1000, including surfaces and relative sizes and thicknesses. Additionally, as shown in FIGS. 41-42, integral lateral ribs extend between the force transfer units and the support ledge.

The only distinguishing feature between the connector 1100 and the connector 1000 is that the connector 1100 includes front-to-rear extending score lines or notches 1150 in each corner between the web 1104 and first connector unit 1100, and between the web 1104 and the second connector unit 1102. An additional score line/notch 1151 extends through an intermediate section of the support web 1104. These notches are configured to allow a user to optionally break away portions of the connector 1100 for use in different settings, as explained above with reference to the connector of FIG. 36.

The depicted embodiments are preferably formed from molded plastic, allowing the product to be designed in many different specific shapes and contours while also providing resiliency. For example, the respective edges of the connectors shown in the Figures are substantially straight, which is common in the industry, however, this is a non-limiting feature. Embodiments exist with one or more edges that have a non-straight contour. Additionally, forming the connectors 600 and 700 from molded plastic allows outward flexation and spring-back action in connector 600 and facilitates breaking at the score lines in connector 700.

While preferred embodiments of the foregoing have been set forth for purposes of illustration, the foregoing description should not be deemed a limitation of the invention herein. Accordingly, various modifications, adaptations and alternatives may occur to one skilled in the art without departing from the spirit and the scope of the present invention.