INSULATION MOUNTING BRACKET

Abstract

A one-piece insulation mounting bracket is disclosed. The mounting bracket readily supports the insulation (e.g., curtain wall insulation) without the need for separate fasteners, locking washers, etc. As a result, the insulation can be mounted more quickly than with conventional mounting systems.

Claims

1. A mounting bracket comprising a bracket body having a middle portion, a first sidewall, a first leg, a first shaped portion, a second sidewall, a second leg, and a second shaped portion, wherein the middle portion extends between and connects the first sidewall and the second sidewall; wherein the first leg extends from the first sidewall; wherein the first shaped portion extends from the first leg; wherein the second leg extends from the second sidewall; and wherein the second shaped portion extends from the second leg.

2.-3. (canceled)

4. The mounting bracket of claim 1, wherein the middle portion forms an angle θ with each of the first sidewall and the second sidewall; and wherein the angle θ is less than 90 degrees.

5. The mounting bracket of claim 4, wherein the angle θ is greater than 70 degrees.

6. (canceled)

7. The mounting bracket of claim 1, wherein the first leg is perpendicular to the first sidewall, and wherein the second leg is perpendicular to the second sidewall.

8. The mounting bracket of claim 1, wherein a height of the first leg is equal to a height of the first sidewall, and wherein a height of the second leg is equal to a height of the second sidewall.

9. The mounting bracket of claim 1, wherein a depth of the first leg is equal to a width of the first sidewall, and wherein a depth of the second leg is equal to a width of the second sidewall.

10.-12. (canceled)

13. The mounting bracket of claim 1, wherein the first shaped portion and the second shaped portion each include a body having one or more barbs and a tapered end.

14. The mounting bracket of claim 13, wherein the body of the first shaped portion includes a plurality of the barbs, and wherein the body of the second shaped portion includes a plurality of the barbs.

15. (canceled)

16. The mounting bracket of claim 14, wherein a number of the barbs on one side of the body of the first shaped portion differs from a number of the barbs on the opposite side of the body of the first shaped portion, and wherein a number of the barbs on one side of the body of the second shaped portion differs from a number of the barbs on the opposite side of the body of the second shaped portion.

17. The mounting bracket of claim 13, wherein the first shaped portion is symmetrical about a central axis of the body of the first shaped portion, and wherein the second shaped portion is symmetrical about a central axis of the body of the second shaped portion.

18. The mounting bracket of claim 17, wherein the central axis of the body of the first shaped portion is perpendicular to the first leg, and wherein the central axis of the body of the second shaped portion is perpendicular to the second leg.

19. The mounting bracket of claim 1, wherein the first shaped portion extends from an end of the first leg furthest from the first sidewall, and wherein the second shaped portion extends from an end of the second leg furthest from the second sidewall.

20.-21. (canceled)

22. The mounting bracket of claim 1, wherein a depth of the first shaped portion is greater than a depth of the first leg, and wherein a depth of the second shaped portion is greater than a depth of the second leg.

23. The mounting bracket of claim 1, wherein a depth of the first shaped portion is less than a depth of the first sidewall, and a depth of the second shaped portion is less than a depth of the second sidewall.

24. The mounting bracket of claim 1, wherein a depth of the first shaped portion is greater than a depth of the first sidewall, and wherein a depth of the second shaped portion is greater than a depth of the second sidewall.

25.-36. (canceled)

37. The mounting bracket of claim 1, wherein the bracket body is a unitary structure.

38. The mounting bracket of claim 1, wherein the bracket body is made of a metal or a metal alloy.

39. (canceled)

40. The mounting bracket of claim 1, wherein the bracket body includes a mounting cavity defined by the middle portion, the first sidewall, and the second sidewall; and wherein the mounting cavity is sized to be friction fit onto a mounting structure.

41. (canceled)

42. The mounting bracket of claim 1, wherein the bracket body further includes a mullion cover mount having a pair of spaced barbs.

43. A curtain wall insulation installation system comprising a plurality of mounting brackets according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0056] The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

[0057] FIG. 1 is a side sectional diagram of a representational portion of a conventional curtain wall insulation system.

[0058] FIGS. 2A, 2B, and 2C illustrate various components of a conventional insulation mounting system. FIG. 2A shows various views of a vertical hanger. FIG. 2B shows various views of a horizontal hanger. FIG. 2C shows a locking washer for interfacing with the vertical hanger of FIG. 2A and the horizontal hanger of FIG. 2B.

[0059] FIGS. 3A and 3B illustrate the locking washer of FIG. 2C interfacing with the horizontal hanger of FIG. 2B.

[0060] FIGS. 4A and 4B illustrate the conventional insulation mounting system of FIGS. 2A-2C being used to mount curtain wall insulation.

[0061] FIGS. 5A-5E illustrate an insulation mounting bracket, according to one exemplary embodiment. FIG. 5A is a perspective view of the mounting bracket. FIG. 5B is a plan view of the mounting bracket. FIG. 5C is a detailed view of a portion of the mounting bracket indicated in FIG. 5B. FIG. 5D is a front elevational view of the mounting bracket. FIG. 5E is a side elevational view of the mounting bracket.

[0062] FIG. 6 is a perspective view of an insulation mounting bracket, according to another exemplary embodiment.

DETAILED DESCRIPTION

[0063] Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described herein.

[0064] The general inventive concepts relate to an insulation mounting system, including innovative mounting brackets for use therein. The mounting brackets are one-part structures that replace conventional multi-part structures for mounting insulation, such as in a curtain wall space. For example, these unitary mounting brackets can support the insulation without the use of locking washers. Furthermore, in some exemplary embodiments, the unitary mounting brackets can interface with a support structure (e.g., mullion, transom) without the use of separate fasteners. Further still, in some exemplary embodiments, the unitary mounting brackets include means for supporting a mullion cover. Accordingly, insulation can be mounted more quickly using the insulation mounting system of the present invention, as opposed to conventional insulation mounting systems.

[0065] A single-piece mounting bracket 500, according to one exemplary embodiment, is shown in FIGS. 5A-5E. Although specific dimensions are illustrated in some of the drawings, the general inventive concepts are not limited to the disclosed dimensions.

[0066] The mounting bracket 500 includes a bracket body 502 that includes a middle portion 510, a first sidewall 520, a first leg 530, a second sidewall 540, and a second leg 550. The bracket 500 can be made of any suitable (i.e., heat-resistant) material. In some exemplary embodiments, the bracket 500 is made of a metal including, but not limited to, steel, galvanized steel, brass, and aluminum. Ceramic materials may also be used to form the bracket 500. In certain embodiments, the bracket 500 is formed of galvanized steel, and preferably 20 gauge galvanized steel.

[0067] The middle portion 510 extends between and connects the first sidewall 520 and the second sidewall 540 to one another. In some exemplary embodiments, a height mp.sub.h of the middle portion 510 is equal to a height fs.sub.h of the first sidewall 520 and a height ss.sub.h of the second sidewall 540. In some exemplary embodiments, a depth mp.sub.d of the middle portion 510 is equal to a width fs.sub.w of the first sidewall 520 and a width ss.sub.w of the second sidewall 540. The middle portion 510 forms an angle θ with each of the first sidewall 520 and the second sidewall 540, wherein 0 is less than 90 degrees. In some exemplary embodiments, θ is greater than 70 degrees and less than 90 degrees. In some exemplary embodiments, θ is approximately 85 degrees (see FIG. 5B). Due to this angle θ, the first sidewall 520 and the second sidewall 540 are not parallel to one another when the bracket 500 is in an uninstalled state.

[0068] The first leg 530 extends from the first sidewall 520. In some exemplary embodiments, the first leg 530 is perpendicular to the first sidewall 520. In some exemplary embodiments, a height fl.sub.h of the first leg 530 is equal to the height fs.sub.h of the first sidewall 520. In some exemplary embodiments, a depth fl.sub.d of the first leg 530 is equal to the width fs.sub.w of the first sidewall 520. The second leg 550 extends from the second sidewall 540. In some exemplary embodiments, the second leg 550 is perpendicular to the second sidewall 540. In some exemplary embodiments, a height sl.sub.h of the second leg 550 is equal to the height ss.sub.h of the second sidewall 540. In some exemplary embodiments, a depth sl.sub.d of the second leg 550 is equal to the width ss.sub.w of the second sidewall 540.

[0069] The bracket body 502 further includes a first shaped portion 560 and a second shaped portion 570. The first shaped portion 560 extends from the first leg 530. In some exemplary embodiments, the first shaped portion 560 extends from an end of the first leg 530 furthest from the first sidewall 520. In some exemplary embodiments, (a central axis ca.sub.1 of) the first shaped portion 560 is perpendicular to the first leg 530. The second shaped portion 570 extends from the second leg 550. In some exemplary embodiments, the second shaped portion 570 extends from an end of the second leg 550 furthest from the second sidewall 540. In some exemplary embodiments, (a central axis cat of) the second shaped portion 570 is perpendicular to the second leg 550.

[0070] In some exemplary embodiments, a height fsp.sub.h of the first shaped portion 560 is less than the height fl.sub.h of the first leg 530. In some exemplary embodiments, a width fsp.sub.w of the first shaped portion 560 is less than a width fl.sub.w of the first leg 530. In some exemplary embodiments, a depth fsp.sub.d of the first shaped portion 560 is greater than the depth fl.sub.d of the first leg 530. In some exemplary embodiments, the depth fsp.sub.d of the first shaped portion 560 is less than a depth fs.sub.d of the first sidewall 520. In some exemplary embodiments, the depth fsp.sub.d of the first shaped portion 560 is equal to the depth fs.sub.d of the first sidewall 520. In some exemplary embodiments, the depth fsp.sub.d of the first shaped portion 560 is greater than the depth fs.sub.d of the first sidewall 520 (see FIG. 5E). In some exemplary embodiments, a height ssp.sub.h of the second shaped portion 570 is less than the height sl.sub.h of the second leg 550. In some exemplary embodiments, a width ssp.sub.w of the second shaped portion 570 is less than a width sl.sub.w of the second leg 550. In some exemplary embodiments, a depth ssp.sub.d of the second shaped portion 570 is greater than the depth sl.sub.d of the second leg 530. In some exemplary embodiments, the depth ssp.sub.d of the second shaped portion 570 is less than a depth ss.sub.d of the second sidewall 540. In some exemplary embodiments, the depth ssp.sub.d of the second shaped portion 570 is equal to the depth ss.sub.d of the second sidewall 540. In some exemplary embodiments, the depth ssp.sub.d of the second shaped portion 570 is greater than the depth ss.sub.d of the second sidewall 540.

[0071] The first shaped portion 560 includes a body 562 having one or more barbs 564. The body 562 includes a tapered end 566 beyond the barbs 564. The tapered end 566 facilitates passage of the first shaped portion 560 through the insulation, while the barbs 564 are operable to hold/secure the insulation on the first shaped portion 560. The body 562 of the first shaped portion 560 acts as a shelf-like ledge operable to support the weight of the insulation. While the illustrated embodiment shows the same number of barbs 564 on each side of the body 562, the general inventive concepts are not so limited. In some exemplary embodiments, one or more barbs 564 are only on one side of the body 562. In some exemplary embodiments, the number of barbs 564 on one side of the body 562 differs from the number of barbs 564 on the other side of the body 562. While the illustrated embodiment shows the first shaped portion 560 to be symmetrical about the central axis ca.sub.1, the general inventive concepts are not so limited. In some exemplary embodiments, the size, shape, and/or positions of the barbs 564 differ on opposite sides of the central axis ca.sub.1 of the body 562.

[0072] The second shaped portion 570 includes a body 572 having one or more barbs 574. The body 572 includes a tapered end 576 beyond the barbs 574. The tapered end 576 facilitates passage of the second shaped portion 570 through the insulation, while the barbs 574 are operable to hold/secure the insulation on the second shaped portion 570. The body 572 of the second shaped portion 570 acts as a shelf-like ledge operable to support the weight of the insulation. While the illustrated embodiment shows the same number of barbs 574 on each side of the body 572 (see FIG. 5C), the general inventive concepts are not so limited. In some exemplary embodiments, one or more barbs 574 are only on one side of the body 572. In some exemplary embodiments, the number of barbs 574 on one side of the body 572 differs from the number of barbs 574 on the other side of the body 572. While the illustrated embodiment shows the second shaped portion 570 to be symmetrical about the central axis ca.sub.2, the general inventive concepts are not so limited. In some exemplary embodiments, the size, shape, and/or positions of the barbs 574 differ on opposite sides of the central axis ca.sub.2 of the body 572.

[0073] As shown in FIG. 5C, in one specific exemplary embodiment, the body 572 of the second shaped portion 570 includes four distinct barbs, i.e., a first barb 574-1, a second barb 574-2, a third barb 574-3, and a fourth barb 574-4. A size, shape, and angle of the first barb 574-1 and the second barb 574-2 are the same. A size, shape, and angle of the third barb 574-3 and the fourth barb 574-4 are the same. In this exemplary embodiment, at least one of the size, shape, and angle of the first and second barbs 574-1, 574-2 is different from that of the third and fourth barbs 574-3, 574-4. In this exemplary embodiment, the angle of at least the first and second barbs 574-1, 574-2 is 42 degrees. The general inventive concepts contemplate that the barbs can have any angle suitable to hold the insulation once it is impaled on the shaped portion.

[0074] A single-piece mounting bracket 600, according to another exemplary embodiment, is shown in FIG. 6. The mounting bracket 600 is similar to the mounting bracket 500 and like reference numbers have been used to show equivalent structure. The mounting bracket 600 includes a bracket body 602 with an integrated mullion cover mount 604 situated on the middle portion 510 of the bracket body 602. The mullion cover mount 604 includes a pair of spaced barbs 606. In some exemplary embodiments, the mullion cover mount 604 is permanently affixed to the middle portion 510 of the bracket body 602. In some exemplary embodiments, the barbs 606 are formed as part of the middle portion 510 of the bracket body 602, with the barbs 606 constituting the mullion cover mount 604.

[0075] The barbs 606 are operable to pierce and hold insulation (e.g., the mullion cover 121 or the mullion cover 123) for protecting the mullion 152. Consequently, the mounting bracket 600 does not require separate fasteners (e.g., the spiral screws 402) or a separate mullion cover mount (e.g., the mullion cover hanger 110) to support the mullion cover insulation.

[0076] The bracket 600 can be made of any suitable (i.e., heat-resistant) material. In some exemplary embodiments, the bracket 600 is made of a metal including, but not limited to, steel, galvanized steel, brass, and aluminum. Ceramic materials may also be used to form the bracket 600. In certain embodiments, the bracket 600 is formed of galvanized steel, and preferably 20 gauge galvanized steel.

[0077] In operation, the mounting bracket 500 or 600 is interfaced with a support structure (e.g., the mullion 152) in proximity to a location where insulation (e.g., the curtain wall insulation 102) is to be installed. More specifically, the mounting bracket 500/600 is friction fit onto the mullion 152, whereby the mullion 152 is received in a cavity 515 defined by the middle portion 510, the first sidewall 520, and the second sidewall 540 of the bracket body 502. The first sidewall 520 and the second sidewall 540 are able to flex outward relative to the middle portion 510, such that the angle θ increases. Typically, given the rectangular/square nature of the mullion 152, the angle θ will be approximately 90 degrees, such that the first sidewall 520 and the second sidewall 540 become substantially parallel to one another when the bracket 500 is in the installed state. The friction fit is suitable to secure the mounting bracket 500/600 to the mullion 152 without the need for any additional fasteners. Furthermore, use of the mounting bracket 500/600 to install the insulation increases the friction fit of the mounting bracket 500/600 on the mullion 152. In other words, the design of the mounting bracket 500/600 causes the weight of the insulation being supported by the mounting bracket 500/600 to exert a complementary force that acts to better “hold” the mounting bracket 500/600 in place relative to the mullion 152, such that the mounting bracket 500/600 resists sliding down or coming off of the mullion 152.

[0078] With the mounting bracket 500/600 affixed to the mullion 152, the first shaped portion 560 is situated on one side of the mullion 152 and the second shaped portion 570 is situated on the other side of the mullion 152. Given this configuration, the first shaped portion 560 and the second shaped portion 570 can each penetrate through curtain wall insulation 102 with the barbs 564, 574 on these shaped portions 560, 570 effectively holding the curtain wall insulation 102 in place. The barbs 564, 574 are suitable to secure the curtain wall insulation 102 to the mounting bracket 500/600 without the need for any additional structure (e.g., locking washers). Additionally, in the case of the mounting bracket 600, the mullion cover mount 604 is aligned with and facing away from a front of the mullion 152 when the bracket 600 is installed on the mullion 152. Accordingly, the mullion cover 121, 123 can be pressed onto the mullion cover mount 604 of the bracket 600 and held in place by the parallel barbed members 606.

[0079] It will be obvious to one of ordinary skill in the art, that any suitable number of the mounting brackets 500/600 can be used to secure the insulation (e.g., the curtain wall insulation 102, the mullion cover 121, 123) in the desired spaces.

[0080] Because the mounting brackets 500, 600 operate to effectively install and affix the insulation without the need for separate fasteners, locking washers, and the like, the mounting brackets 500, 600 allow for a simpler and quicker installation of fire perimeter insulation. Furthermore, because fewer of the mounting brackets 500, 600 will typically be needed to effectively install and affix the insulation, the mounting brackets 500, 600 allow for a simpler and quicker installation of fire perimeter insulation.

[0081] The scope of the general inventive concepts presented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices and systems disclosed. For example, while the exemplary embodiments described and shown herein relate to fire perimeter insulation, the inventive mounting brackets could be used to install other forms of insulation in building cavities. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and/or claimed herein, and any equivalents thereof.