Structural connector and related assembly method using same

Abstract

A structural connector for a manufacturing assembly includes a body portion sized to be substantially fitted into an open end of a first hollow structural component of a manufacturing assembly. The structural connector includes at least one flexible cantilevered ear portion which is sized to engage with a corresponding lateral opening provided in the first hollow structural component. Once seated, the connector accepts at least one fastener extending laterally through a second structural component which is fitted orthogonally, relative to the open end of the first structural component, permitting interconnection between the second structural component and the first structural component.

1 . A structural connector for a manufacturing assembly involving at least two hollow components, said structural connector comprising: 
 a body portion adapted to be fitted substantially within an open end of a hollow first component;    at least one flexible cantilevered ear portion extending from said body portion, said at least one ear portion including a protrusion sized to extend into a lateral opening in said first component for fixing said connector therewith; and    means for receiving at least one fastener for permitting interconnection between said first component and a second hollow component that is disposed orthogonally relative to said open end of said first component.    
   
   
       2 . A structural connector as recited in  claim 1 , wherein said fastener receiving means includes at least one fastener hole disposed in a base portion of said connector.  
   
   
       3 . A structural connector as recited in  claim 1 , wherein at least a portion of said structural connector is made from a highly flexible material.  
   
   
       4 . A structural connector as recited in  claim 1 , wherein said connector is made from a molded plastic.  
   
   
       5 . A structural connector as recited in  claim 1 , wherein said connector body portion is sized to seat substantially entirely within the open end of said first structural component.  
   
   
       6 . A structural connector as recited in  claim 1 , including a pair of flexible cantilevered ear portions disposed on opposing lateral sides of said body portion.  
   
   
       7 . A structural connector as recited in  claim 6 , including a pair of internal walls defining an inner cavity, said flexible cantilevered ear portions being disposed parallel to said internal walls and outboard therefrom.  
   
   
       8 . A structural connector as recited in  claim 7 , including a recess between said internal walls and said ear portions into which said ear portions can inwardly flex.  
   
   
       9 . A method for interconnecting at least two components of a manufacturing assembly, said method comprising the steps of: 
 inserting a connector into one open end of a first hollow structural component, said connector comprising a body portion sized to substantially engage the open end of said first structural component and including at least one flexible cantilevered ear portions;    inserting said connector into said open end until a protrusion formed at the end of said at least one flexible cantilevered ear portion is caused to extend into lateral openings formed in said first structural component, thereby fixing said connector;    aligning a second hollow structural component relative to the open end of said first structural member such that fastener holes of said connector are axially aligned with corresponding fastener holes of said second structural component; and    mounting fasteners through the aligned fastener holes to fix the first and second structural components together.    
   
   
       10 . A method as recited in  claim 9 , wherein said second hollow structural component is disposed orthogonally relative to the open end of said first structural component.  
   
   
       11 . A method as recited in  claim 10 , including the step of additional steps of mounting at least a third structural component to said assembly using a said connector.  
   
   
       12 . A manufacturing assembly comprising: 
 at least two structural components, each of said components being hollow and including at least one open end; and    at least one connector for interconnecting at least two of said components, said connector including a body portion sized to be substantially fitted into the open end of a first structural component and further including at least one flexible cantilevered ear portion, said at least one ear portion including a protrusion sized for engaging a lateral opening formed in the open end of said first structural component when said connector is seated therein.    
   
   
       13 . An assembly as recited in  claim 12 , wherein said at least one flexible cantilevered ear portion is made from a molded plastic material.  
   
   
       14 . An assembly as recited in  claim 12 , wherein said connector is entirely made from a molded plastic.  
   
   
       15 . An assembly as recited in  claim 12 , wherein each of said structural components are made of metal.  
   
   
       16 . An assembly as recited in  claim 12 , wherein each of said structural components is made from extruded aluminum.  
   
   
       17 . An assembly as recited in  claim 12 , wherein the body portion of said connector includes means for retaining at least one fastener, said second structural component being arranged orthogonally relative to the open end of said first structural component and having aligned openings permitting the passage of said at least one fastener through said openings of said second component, thereby permitting said first and second structural components to be attached to one another.  
   
   
       18 . An assembly as recited in  claim 17 , wherein said connector includes a pair of interior walls defining an inner cavity and said ear portions are provided parallel to said interior walls and outboard relative thereto.  
   
   
       19 . An assembly as recited in  claim 18 , including a gap between at least one interior wall and said at least one ear portion, providing spacing to permit said ear portion to be flexed inwardly when said connector is initially inserted into the open end of said first structural component.  
   
   
       20 . An assembly as recited in  claim 19 , wherein said gap is sized to permit the passage of said at least one fastener when said second structural component is attached thereto.  
   
   
       21 . An assembly as recited in  claim 20 , wherein the passage of a said fastener into said gap prevents flexion of said at least one cantilevered ear portion.  
   
   
       22 . An assembly as recited in  claim 12 , wherein said connector includes at least one pair of flexible cantilevered ear portions, each of said pair of ear portions being disposed on opposing lateral sides of said body portion.