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  Beam for screened enclosureThe Patent Description & Claims data below is from USPTO Patent Application 20070266671. Brief Patent Description - Full Patent Description - Patent Application Claims
[0001]This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/801,684, filed May 19, 2006. BACKGROUND OF THE INVENTION [0002]This invention relates generally to the field of beams, typically composed of aluminum, used in the construction of screened enclosures or the like. More particularly, the invention relates to such beams that are rectangular in cross-section, often referred to as a box beam, and even more particularly, to such beams that formed by the joining or mating of two separately extruded members. [0003]In the construction of screened enclosures and similar structures, it is desirable to provide structural support elements, and especially horizontally disposed support elements such as beams, that are relatively lightweight but meet minimum rigidity and strength requirements when used to span relatively long distances. Such beams are often composed of extruded aluminum, since this metal is lightweight, strong, and inexpensive in relation to other suitable materials in terms of manufacture and transport. The beams are generally rectangular in cross-section and are formed primarily hollow to conserve weight. The beams are typically manufactured using metal extrusion processes, and it is known to construct the beams by joining two generally C-shaped in cross-section members, where the short legs or flanges of each member are provided with coupling structures which are received by or mate with the corresponding coupling structure when the two members are brought together to form the rectangular beam. [0004]It is an object of this invention to provide an improved structure for a beam composed of a pair of mated members. SUMMARY OF THE INVENTION [0005]The invention is an improved hollow beam suitable for construction of screened enclosures and the like, the beam being composed of a mated pair of generally C-shaped extruded members, preferably of identical configuration. Each extruded member comprises a side wall, a male flange member forming one of the short arms of the C-shape, and a female flange member forming the other of the short arms of the C-shape. The combination of the male and female flanges define a coupling assembly and form the end walls of the beam, such that the two extruded members when aligned to create the generally rectangular beam are disposed in a mated condition whereby the end walls are comprised of the overlapping male and female flanges. Mechanical fasteners are provided to secure the male and female flange members to each other, thereby creating a box beam of high strength. [0006]The beam presents end walls having a planar exterior matting surface formed by the abutting outer surfaces of the male and female flange members. The exterior mating surface comprises the majority of the exterior of the end walls, the remainder portion comprising a pair of spline receiving channels that are used to secure screen panels to the beams in known manner. In an alternative embodiment, the female flange comprises a clip member having a resilient internal flange and a guide lip, such that proper alignment of the two extruded members is easily accomplished. Retention means comprising for example a series of ridges and channels are provided to mechanically interlock the two extruded members in the mated condition prior to insertion of eh mechanical fasteners. BRIEF DESCRIPTION OF THE DRAWINGS [0007]FIG. 1 is an end view of one embodiment of the beam. [0008]FIG. 2 is an end view of a C-shaped extruded member of the embodiment shown in FIG. 1. [0009]FIG. 3 is a partial end view of the tongue member of the male flange member of the embodiment shown in FIG. 1. [0010]FIG. 4 is a partial end view of the clip member of the female flange member of the embodiment shown in FIG. 1. [0011]FIG. 5 is an end view of another embodiment of the beam. [0012]FIG. 6 is an end view of the male flange member of the embodiment shown in FIG. 5. [0013]FIG. 7 is an end view of the female flange member of the embodiment shown in FIG. 5. [0014]FIG. 8 is a cross-sectional view of the upper portion of an alternative embodiment of the beam. DETAILED DESCRIPTION OF THE INVENTION [0015]With reference to the drawings, the invention will now be defined with regard for the best mode and the preferred embodiment. In general, the invention is a hollow, generally rectangular structural beam formed by the mating of two generally C-shaped extruded members. The extruded members forming the box beam are identical and are designed such that one extruded member will mate with another extruded member in a structurally supportive and generally secure manner by inverting one of the two extruded members and mating them together. The majority of the uppermost surface of the box beam is planar. [0016]One embodiment of the invention is shown best in FIGS. 1 and 2, wherein the beam 10 comprises a pair of generally C-shaped extruded members 20, each extruded member 20 being longitudinally extended. The extruded members 20 each comprise a generally planar side wall 21 and a pair of flange members extending perpendicularly from the side wall 21 to define the short arms of the C-shaped configuration, one being a male flange member 22 and the other being a female flange member 23. The flange members 22 and 23 extend the length of the beam 10. The combination of the extruded members 20, wherein one extruded member 20 is inverted or reversed and pressed against the other extruded member 20, defines a hollow interior 12 and an end wall 13 with a mated exterior surface 11, the mated exterior surface 11 being generally planar and extending across the majority of the end wall 13. A coupling assembly 30 defined by combined structure in the male flange member 22 and the female flange member 23 retains the two extruded members 20 in the mated position. Mechanical fastening elements 37, such as sheet metal screws, are utilized to further secure the two extruded members 20 in the mated position. Preferably, the extruded members 20 are configured identically, but it is possible that the may differ in certain respects without deviating from the invention as defined and claimed herein. [0017]As best shown in FIG. 4, the female flange member 23 of this embodiment comprises a clip member 31 that receives the tongue member 41 of the male flange member 22. The clip member 31 comprises an external flange 11 that is relatively rigid in comparison to a resilient internal flange 33. Internal flange 33 is preferably provided with a longitudinally extensive flex ridge or spring member 35 such that the internal flange 33 can be easily biased outwardly when the tongue member 41 is inserted into the clip member 31, but which imparts a compressive force against the tongue member 41 after it is properly positioned and aligned within the clip member 31. Most preferably a longitudinally extensive guide lip 34 is disposed on the free end of the internal flange 3, such that initial alignment of the two extruded members 20 is more easily accomplished. The female flange member 23 is also provided with a longitudinally extensive recessed shoulder 36, which corresponds to a longitudinally extensive lip 43 and channel 44 disposed on the male flange member 23, such that when the two extruded members 20 are mated, a generally planar mated exterior surface 11 is presented. [0018]The male flange member 22 of this embodiment comprises a longitudinally extensive tongue member 41 of relatively thin cross-section, the tongue member 41 being sized and configured to be received by the clip member 31 in a snug and secure fashion. A longitudinal spur member 42 is disposed on the exterior of male flange member 22 at the base of the tongue member 41, the spur member 42 comprising a lip 43 and a channel 44 configured to mate with the recessed shoulder 36 of the female flange member 23. [0019]While the biasing force of the internal flange 33 of the clip member 31 pressing the tongue member 41 against the external flange 32 serves to retain the two extruded members 20 in the mated condition, it is preferable to provide additional retention means 50 in support of this. For example as shown, the retention means 50 to impede separation may comprise a series of ridges 51 and channels 52 disposed on the contiguous surfaces of the tongue member 41 and external flange 32. [0020]The extruded members 20 preferably further comprise spline receiving channels 25 and internal reinforcing members 24. An external fastener alignment channel 26 may also be provided on the exterior of the external flange 32 to assist in the placement of mechanical fasteners 37. With this construction, the beam 10 presents end walls 13 having a planar, mated exterior surface 11 formed by the combination of the exterior surfaces of the male flange member 22 and the female flange member 23 that extends across and along the majority of the end wall 13. The mated exterior surface 11 extends farther outward than the edges 27 of the side walls 21, such that the distance between opposing mated exterior surfaces 11 is greater than the distance between opposing edges 27 on each side wall 21. This feature provides for a better aesthetic presentation and securer footing for installers during the assembly process, since a planar surface is present and any screen material attached to the beam 10 sits flush with the mated exterior surface 11 due to the reduced height of the edges 27. Continue reading... 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