Integral connectors in tubular beams for building structures

Abstract

Tubular beams for building frames include laser-cut ends to form highly-accurate integrally-formed tab connectors for connecting the beams together and to other building beams. The tab connectors are integrally formed of continuous and contiguous material of the metal beam and are spaced apart to closely engage a second beam for secure and reliable and stress-distributed connection. The tab connectors can be formed and/or bent to define a pocket oriented at a desired angle for receiving a mating beam, such as for supporting a roof truss at a desired pitch. Fasteners extend through holes in the tabs and into or through the second beam for securing the beams together. The tab connectors can be cut to many different shapes, formed to any orientation, and made to accurately mate with corresponding structure of the mating second beam, regardless of the angle and size of the two beams.

1 . A building frame suitable to meet building code requirements for human occupancy, comprising:
 a structural tubular metal beam including a plurality of walls, with two or more of the walls opposing each other and each including a tab connector extending therefrom, each tab connector being formed from continuous and contiguous material of the respective wall from which the tab connector extends and each tab connector being bent to extend parallel a common direction and to define a pocket therebetween that extends at an acute angle to a longitudinal axis of the tubular metal beam;   a mating beam having opposing side surfaces, the tab connectors being configured to closely engage the opposing side surfaces of the mating beam, each tab connector including a pattern of holes for fasteners, and the material of the structural beam and the tab connectors being sufficiently thick and strong to form a structural joint as part of the building frame meeting building code requirements for human occupancy.   
   
   
       2 . The building frame defined in  claim 1 , including at least one second tab connector extending from a remaining one of the walls, the second tab connector including a pattern of holes for fasteners. 
   
   
       3 . The building frame defined in  claim 1 , wherein the tab connectors each comprise a flange with parallel linear edges. 
   
   
       4 . The building frame defined in  claim 1 , wherein the tab connectors each include a plurality of flanges having a first width and supported by a necked area of reduced width. 
   
   
       5 . The building frame defined in  claim 1 , wherein the remaining walls include support flanges extending therefrom and being configured to engage and support the mating beam in the pocket. 
   
   
       6 . A structural juncture for use in a constructed building frame, comprising:
 a first tubular metal beam defining a first longitudinal direction and having an end, opposing first and second walls, and opposing third and fourth walls forming a tube with the first and second walls;   a second beam defining a second longitudinal direction having opposing first and second surfaces forming a first dimension and having opposing third and fourth surfaces forming a second dimension;   a pair of tab connectors formed inboard of the end of at least one of the first and second walls and being integrally formed of continuous and contiguous material of the metal beam; the pair of tab connectors being bent outward from the associated one wall and being spaced apart the first dimension, the second beam being positioned between the pair of tab connectors; and   a plurality of fasteners extending through holes in the pair of tab connectors and into the second beam for securing the second beam to the first beam.   
   
   
       7 . The structural juncture defined in  claim 6 , including a second pair of tab connectors formed in a second of the first and second walls and being integrally formed of continuous and contiguous material of the metal beam; the second pair of tab connectors being bent outward from the associated second wall and being spaced apart the first dimension, the second beam being positioned between the second pair of tab connectors and secured thereto by the fasteners. 
   
   
       8 . The structural juncture defined in  claim 7 , wherein the first-mentioned pair of tab connectors and the second pair of tab connectors align to hold the second beam so that the second longitudinal direction extends perpendicular to the first longitudinal direction. 
   
   
       9 . The structural juncture defined in  claim 7 , wherein the first-mentioned pair of tab connectors and the second pair of tab connectors align to hold the second beam so that the second longitudinal direction extends at an acute angle to the first longitudinal direction. 
   
   
       10 . The structural juncture defined in  claim 7 , including a third pair of tab connectors formed in at least one of the third and fourth walls for holding an end of a third beam abuttingly against sides of the first beam. 
   
   
       11 . The structural juncture defined in  claim 6 , wherein the third and fourth walls each include an integral plate-attachment flange formed by a C-shaped cut made into the third and fourth walls, the flange including holes for receiving fasteners that extend through the flange into the second beam. 
   
   
       12 . A structural juncture for use in a constructed building frame, comprising:
 a first tubular metal beam defining a first longitudinal direction and having an end, opposing first and second walls, and opposing third and fourth walls forming a tube with the first and second walls;   a second beam defining a second longitudinal direction having opposing first and second surfaces forming a first dimension and having opposing third and fourth surfaces forming a second dimension;   a tab connector extending from the first wall and formed integrally of continuous and contiguous material of the first wall by first and second oppositely-facing non-linear cuts made into an end of the first wall but without similar cuts made into the second wall opposing the first wall, the tab connector including holes suitable for securing the second beam to the first beam to form the junction suitable for use in constructing a building frame.