DUAL-SIDED MOUNTING BRACKET

Abstract

A dual-sided mounting bracket for a facade support system includes an L-shaped member having a baseplate for securing to a wall structure and a leg extending from and transverse to the baseplate. The leg defines inside and outside surfaces and a plane. The leg has first and second clips formed therein on opposing sides of a height centerline and extending opposite directions from the leg plane. The clips each define an angled opening at free ends thereof and a capture region adjacent to the angled openings. The first and second clips are configured to receive the support member in either the first or second clip. A support system for supporting a facade on a wall structure includes at least two dual-sided mounting brackets and support member.

Claims

1. A dual-sided mounting bracket for a facade support system for supporting a facade on a wall structure, the support system including a support member, the mounting bracket comprising: a baseplate comprising an inside surface and an outside surface and configured to secure to the wall structure; and a leg extending from and transverse to the baseplate, the leg having a height centerline and defining a plane extending in a length dimension and a height dimension, wherein the leg comprises: a leg body connected to the baseplate at a junction, the leg body having an inside surface and an outside surface and having a free end opposite the baseplate; a first clip extending proud in a first direction from the plane and offset to a first side of the height centerline, the first clip comprising a first angled opening at the free end of the body, wherein the first clip is configured to receive and resiliently retain the support member between the first clip and the leg body; and a second clip extending proud in a second direction from the plane and offset to a second side of the height centerline, the second clip comprising a second angled opening at the free end of the body, wherein the second clip is configured to receive and resiliently retain the support member between the second clip and the leg body.

2. The dual-sided mounting bracket of claim 1, further comprising a gasket layer secured to the outside surface of the baseplate.

3. The dual-sided mounting bracket of claim 2, wherein the baseplate comprises at least one mounting hole through the baseplate and the gasket layer is secured to the outside surface and across the at least one mounting hole, the gasket layer comprising a polymer.

4. The dual-sided mounting bracket of claim 1, further comprising an intermediate finger within the plane and centered on the height centerline between the first clip and the second clip.

5. The dual-sided mounting bracket of claim 4, further comprising: a first mounting hole through the leg body at the free end of the leg body at a position above the first and second clips in the height dimension; a second mounting hole through the leg body at the free end of the leg body at a position below the first and second clips in the height dimension; and a third mounting hole through the intermediate finger at the free end of the leg body; wherein the mounting bracket is configured to be secured to the support member with fasteners through each of the first, second, and third mounting holes.

6. The dual-sided mounting bracket of claim 1, further comprising first and second ribs extending proud of the inside surface of the baseplate and the inside surface of the leg body.

7. The dual-sided mounting bracket of claim 6, wherein the first rib extends continuously across a first portion of the baseplate, the junction, and a first portion of the leg, and the second rib extends continuously across a second portion of the baseplate, the junction, and a second portion of the leg.

8. The dual-sided mounting bracket of claim 7, wherein first and second ribs terminate in the length dimension along the leg at or before a first bend of the first clip and the second clip.

9. The dual-sided mounting bracket of claim 6, wherein the first rib is located at a position above, in the height dimension, the height centerline, the first clip, and the second clip and the second rib is located at a position below, in the height dimension, the height centerline, the first clip, and the second clip.

10. The dual-sided mounting bracket of claim 1, wherein the first and second clips each include a first bend between the clip and the leg body, the first bend away from the plane, a second bend spaced from the first bend along the clip, the second bend toward the plane, and a third bend spaced from the second bend along the clip, the third bend away from the plane.

11. The dual-sided mounting bracket of claim 10, wherein the third bends respectively define the first and second angled openings.

12. The dual-sided mounting bracket of claim 11, wherein a first clip segment is defined between the first bend and the second bend, a second clip segment is defined between the second bend and the third bend, and a third clip segment is defined from the third bend to the free end.

13. The dual-sided mounting bracket of claim 12, wherein the first bend is an acute angle away from the plane, the second bend forms an obtuse angle between the first clip segment and the second clip segment and the second clip segment forms an acute angle towards the plane, and the third bend forms an obtuse angle between the second clip segment and the third clip segment and forms an acute angle away from the plane.

14. The dual-sided mounting bracket of claim 13, wherein the acute angle formed by the third clip segment away from the plane is greater than the acute angle of the second clip segment towards the plane and less than the acute angle of the first clip segment away from the plane.

15. A dual-sided mounting bracket for a facade support system for supporting a facade on a wall structure, the support system including a support member, the mounting bracket comprising: a baseplate comprising an inside surface and an outside surface and configured to secure to the wall structure, the baseplate extending in a width dimension from a free end to a connected end; a gasket layer secured to the outside surface of the baseplate; a leg extending from and transverse to the baseplate, and forming an L with the baseplate, the leg having a height centerline and defining a plane extending in a length dimension and a height dimension, wherein the leg comprises: a leg body connected to the connected end of the baseplate at a junction, the leg body having an inside surface and an outside surface and having a free end opposite the baseplate; a first clip extending proud in a first direction from the plane and offset to a first side of the height centerline, the first clip comprising a first angled opening at the free end of the body, wherein the first clip is configured to receive and resiliently retain the support member between the first clip and the leg body; a second clip extending proud in a second direction from the plane and offset to a second side of the height centerline, the second clip comprising a second angled opening at the free end of the body; and an intermediate finger within the plane and centered on the height centerline between the first clip and the second clip; and first and second ribs extending proud of the inside surface of the baseplate and the inside surface of the leg body.

16. The dual-sided mounting bracket of claim 15, wherein the baseplate comprises at least one mounting hole through the baseplate and the gasket layer is secured to at least the outside surface of the baseplate and across the at least one mounting hole, the gasket layer comprising a polymer.

17. The dual-sided mounting bracket of claim 15, further comprising: a first mounting hole through the leg body at the free end of the leg body at a position above the first and second clips in the height dimension; a second mounting hole through the leg body at the free end of the leg body at a position below the first and second clips in the height dimension; and a third mounting hole through the intermediate finger at the free end of the leg body; wherein the mounting bracket is configured to be secured to the member with fasteners through each of the first, second, and third mounting holes.

18. The dual-sided mounting bracket of claim 15, wherein the first rib extends continuously across a first portion of the baseplate, the junction, and a first portion of the leg, and the second rib extends continuously across a second portion of the baseplate, the junction, and a second portion of the leg; wherein first and second ribs terminate in the length dimension along the leg at or before a first bend of the first clip and the second clip; and wherein the first rib is located at a position above, in the height dimension, the height centerline, the first clip, and the second clip and the second rib is located at a position below, in the height dimension, the height centerline, the first clip, and the second clip.

19. A support system for a facade on a wall structure, the support system comprising: a dual-sided mounting bracket formed as an L-shaped member and comprising: a baseplate comprising an inside surface and an outside surface and configured to secure to the wall structure, the baseplate extending in a width dimension from a free end to a connected end; a gasket layer secured to the outside surface of the baseplate; a leg extending from and transverse to the baseplate, and forming an L with the baseplate, the leg having a height centerline and defining a plane extending in a length dimension and a height dimension, wherein the leg comprises: a leg body connected to the connected end of the baseplate at a junction, the leg body having an inside surface and an outside surface and having a free end opposite the baseplate; a first clip extending proud in a first direction from the plane and offset to a first side of the height centerline, the first clip comprising a first angled opening at the free end of the body; a second clip extending proud in a second direction from the plane and offset to a second side of the height centerline, the second clip comprising a second angled opening at the free end of the body; and an intermediate finger within the plane and centered on the height centerline between the first clip and the second clip; and first and second ribs extending proud of the inside surface of the baseplate and the inside surface of the leg body; and a support member having first and second legs in an L-shape; wherein the first leg of the support member first leg is positioned between the first or second clip and a planar portion of the transverse leg.

20. The dual-sided mounting bracket of claim 19, further comprising: a first mounting hole through the leg body at the free end of the leg body at a position above the first and second clips in the height dimension; a second mounting hole through the leg body at the free end of the leg body at a position below the first and second clips in the height dimension; and a third mounting hole through the intermediate finger at the free end of the leg body; wherein the mounting bracket is configured to be secured to the support member with fasteners through each of the first, second, and third mounting holes.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] FIG. 1 is a perspective view of a wall structure showing a backup wall, insulation, a facade, and a facade support system having a dual-sided mounting bracket according to embodiments of the present disclosure, portions of the rainscreen and insulation shown broken away for ease of illustration;

[0024] FIG. 2 is a perspective view of bracket and a support member, showing the support member engaged with the bracket;

[0025] FIG. 3A is a top view of the bracket illustrating the bracket and support member;

[0026] FIG. 3B is a top view of the bracket illustrating the bracket and clip angles;

[0027] FIG. 4 is a front view of the bracket; and

[0028] FIG. 5 is a side view of the bracket.

DETAILED DESCRIPTION

[0029] While the present disclosure is susceptible of embodiments in various forms, there is described presently preferred embodiments with the understanding that the present disclosure is to be considered an exemplification and is not intended to limit the disclosure to the specific embodiments illustrated.

[0030] Referring now to the figures and in particular to FIG. 1, there is shown a wall structure S that includes a backup wall B which, as illustrated is a block wall. Other backup wall structures S will be recognized by those skilled in the art. The wall structure S can further include insulation I, a facade 10, such as a rainscreen and a facade support system 12 in accordance with the present disclosure. Other elements may be present between the insulation I and the backup wall B and between the insulation I and the facade 10, such as condensation and waterproof barriers/films and the like. In addition, an air space A may be present between the insulation I and the facade 10. Other examples of facades, rain screens, and support systems are described in co-pending U.S. application Ser. Nos. 17/161,798 and 17/833,369 and U.S. Pat. Nos. 11,643,808 and 11,674,316, which are each incorporated by reference herein in their entireties and disclose features which may be combined with features disclosed herein to arrive at further combinations within the scope of the present disclosure.

[0031] As seen in FIG. 1, the facade support system 12 includes vertical support members 14 and/or horizontal support members 16. The vertical support members 14 are secured to the backup wall B or structure S by a series or plurality of dual-sided mounting brackets 18 according to embodiments disclosed herein. In an example, the horizontal support members 16 may be optionally secured to the vertical support members 14. In examples, the vertical support members 14 are typically 8-12 ft in length, although the presently disclosed mounting brackets may be used with shorter or longer lengths of vertical support members as well. The mounting brackets 18 are exemplarily arranged in a grid and the spacing between mounting brackets may depend upon the construction of the backup wall B or structure S or the facade 10. In one example, the mounting brackets 18 may be vertically spaced 24 inches and horizontally spaced 32 inches. In another example, the mounting brackets 18 may be vertically spaced 36 inches and horizontally spaced 16 inches. In still further examples, the mounting brackets 18 are oriented+/?90 degrees from the orientation shown and horizontal support member 16 are secured between the mounting brackets 18 as described herein.

[0032] The mounting bracket 18 is depicted in further detail in FIGS. 2, 4, and 5, and is an L-shaped member that includes a baseplate 20 that is mounted to the backup wall B or structure S as described herein. The mounting bracket 18 includes a leg 22 that extends outwardly from, and transverse to, the baseplate 20 to define a juncture 24 between the baseplate 20 and leg 22. The leg 22 is formed of a leg body with an inside surface 26 within the interior angle ? of the L-shape between the baseplate 20 and the leg 22 and an outside surface 28 opposite the inside surface and outside of the L-shape. The body of the leg 22 is connected to the baseplate 20 at the juncture 24. The mounting bracket 18 has a height H, a width W is defined primarily by the baseplate 20, and a length L is defined primarily by the leg 22. The body of the leg 22 further defines a plane P.

[0033] The mounting bracket 18 can include one or more strengthening ribs 52. The strengthening ribs may extend continuously from the baseplate 20 through the juncture 24 and along the leg 22. In another example, the strengthening ribs 52 may be provided as separate rib intervals on the baseplate 20, at the juncture 24, and on the leg 22. The strengthening ribs 52 extend proud into the interior of the L-shape formed between the baseplate 20 and the leg 22. As will be discussed in further detail herein, the strengthening ribs 52 may be constructed in a range of dimensions, however, in embodiments, the strengthening ribs 52 terminate in the length dimension along the leg 22 prior to the clips 30 as detailed herein. The strengthening ribs 52 are exemplarily constructed in a stamping process to form the ribs 52 from the material of the mounting bracket 18.

[0034] The mounting bracket 18 can also include one or more mounting holes 54 in the baseplate 20 to receive fasteners to secure the baseplate 20 to the backup wall B or wall structure S. A gasket layer 60 is provided on an outside surface 62 of baseplate 20 of the mounting bracket 18. The outside surface 62 is opposite an inside surface 64. The inside surface 64 of the baseplate 20 faces the L-shape between the baseplate 20 and the leg 22. The gasket layer 60 may be integrally constructed with the baseplate 20 or otherwise secured thereto. The gasket layer 60 is exemplarily of silicone or other polymer material. The gasket layer 60 may be applied as a liquid or flowable state and may be dried or cured to form an ambiently stable structure. If curing is used, such curing may exemplarily include, but is not limited to chemical, light, or heat curing. In other examples, the gasket layer 60 may be secured to the mounting bracket 18 with an adhesive. The gasket layer 60 may generally cover the width W and height H extent of the baseplate 20. While not depicted in FIG. 4, still further examples of the bracket have the gasket layer 60 extend across the inside surface 64 of the baseplate 20 as well. Further examples may additionally surround the edges of the baseplate with the gasket layer 60.

[0035] As shown in FIG. 4, the gasket layer 60 may further extend across the mounting holes 54. In use, the backup wall B or wall structure S may include components, features, or layers that provide thermal, air, and/or moisture barriers. In practice, fasteners used with mounting brackets, puncture such barriers when securing the mounting bracket 18 to the backup wall B or wall structure S. The gasket layer 60 as described herein, forms a seal about each of these punctures and has been found to mitigate the effect of these punctures, improving the resulting thermal, air, and/or moisture barrier in the final completed structure. Examples of the gasket layer 60 that extend across both the outside surface 62 and the inside surface 64 further provide the gasket layer across the mounting holes 54 and additional barrier between the baseplate 20, gasket layer 60, backup wall B or wall structure S.

[0036] The leg 22 includes a pair of clips 30A, 30B (collectively, 30) formed therein. The clips 30 are exemplarily formed by cuts 32 inwardly from a free end 34 into the body of the leg 22. In an example, the cuts 32 may be made with a die, although other machining and/or manufacturing processes will be recognized and are not limiting on the scope of the present disclosure. The clips 30 extend in opposite directions from the plane P of the leg 22. One clip (exemplarily 30A) extends proud of the outside surface 28 of the leg 22 and another clip (exemplarily 30B) extends proud of the inside surface 26 of the leg 22, as described in further detail herein. The clips 30 are vertically spaced apart in the height H dimension and thus define an intermediate finger 36 therebetween. The intermediate finger 36 is exemplarily centered on a height centerline C of the mounting bracket 18 and leg 22. The clips 30A, 30B are thus evenly spaced about the height centerline C. In an example, the intermediate finger 36 and the clips 30A, 30B are the same size in the height H and length L dimensions, although it will be recognized that the intermediate finger 36 may differ in dimension from the clips 30 in other examples.

[0037] Referring particularly to FIG. 3B, the clips 30 are exemplarily mirrored about the plane P. In an embodiment, each clip 30 include a first bend 38 away from the plane P and defining a first clip segment 66, a second bend 40 back towards the plane P and defining a second clip segment 68, and a third bend 42 away from the plane P and defining a third clip segment 70. The first bend 38 is formed at an obtuse supplemental angle ? exemplarily of 145 degrees. The second bend 40 is formed at an obtuse supplemental angle ? exemplarily of 140 degrees. The angle ? is exemplarily less than the angle ? of the first bend 38. The third bend 42 is formed at an obtuse supplemental angle ? exemplarily of 160 degrees. The angle ? is exemplarily greater than either of angles ? or ?. Each of these angles may exemplarily be +/?10 degrees, +/?5 degrees, +/?2 degrees, or other ranges from the values stated, while remaining within the scope of the present disclosure.

[0038] In reference to the plane P, the first bend 38 forms an acute supplemental angle ?, which is exemplarily 35 degrees, between the first clip segment 66 and the plane P. The second clip segment 68 forms angle ? relative to the plane P. The angle ? is exemplarily 5 degrees. The third clip segment 70 forms angle ? relative to the plane P. The angle ? is exemplarily 15 degrees. Each of these angles may exemplarily be +/?10 degrees, +/?5 degrees, +/?2 degrees, or other ranges from the values stated, while remaining within the scope of the present disclosure.

[0039] This configuration of bends 38, 40, 42 forms an angled opening 44 between an end 46 of the clip 30 and the plane P of the leg 22 at the angle co. The angled opening 44 necks down to a capture region 48 about the third bend 42, that then widens or opens, as seen at 50, to the second bend 40. Other angles and bend configurations will be recognized by those skilled in the art and are within the scope and spirit of the present disclosure.

[0040] The leg 22 includes one or more mounting holes 54 through which fasteners F are received to secure the support member 14, 16 to the leg 22. The mounting holes 54 in the leg 22 can be circular or elongated/notched or the leg 22 can include both circular and elongated/notched mounting holes 54. Elongated mounting holes, exemplarily provide a degree of movement between the support member 14, 16 and the mounting bracket 18 so as to accommodate variation due to thermal expansion. As previously described, the clips 30A, 30B define an intermediate finger 36 therebetween. The intermediate finger 36 includes a mounting hole 54 and is exemplarily centered on the height centerline C. The intermediate finger 36 thus provides a fastener mounting point to the support member 14, 16 at the height centerline C of the mounting bracket 18. This centered mounting point may provide an improved connection between the mounting bracket 18 and the support member 14, 16. In an example, three fasteners F may be used, one at the intermediate finger 36, one vertically above the clips 30 and one vertically below the clips 30.

[0041] A present mounting bracket 18 is formed from steel, such as stainless steel, such as type 304 stainless steel. Other suitable materials will be recognized by those skilled in the art. The mounting brackets 18 can be fabricated having a wide variety of sizes. The presently contemplated brackets 18 may have a non-limiting height H of about 4 inches and a non-limiting length L between 1-12 inches. The bracket 18 may have a non-limiting width of about 3-6 inches. Other mounting bracket 18 dimensions will be appreciated by those skilled in the art.

[0042] In use, a series of vertically aligned mounting brackets 18 will be secured to the backup wall B or structure S using fasteners F driven through the holes 54 in the baseplates 20 into the backup wall B or structure S. The gasket layer 60 provides a seal about the puncture caused by the fastener F driven into the backup wall B or structure S. An installer selects a side of the mounting bracket 18 in which the vertical member 14 is to be installed. It will be recognized that in applications, the vertical member 14 need not be secured to a same side of all of the mounting brackets 18. The mounting brackets 18 may be arranged rotated 180 degrees from one another, so long as the legs 22 and the respective clips 30 are in vertical alignment. This is a feature of the mounting bracket presently disclosed in that mounting brackets may be secured to the backup wall B or structure S in different orientations so as to accommodate positional obstructions (e.g. conduits, joints, mounting systems, etc.) while providing the mounting point to the vertical member, both for resilient connection to a clip 30 as well as fastening with one or more fasteners F.

[0043] The installer inserts a leg 56 of the vertical member 14 (the vertical members are typically angle or L-shaped members, for example as shown in FIGS. 1 and 2) into the angled opening 44 and to and into the capture region 48 to hold the vertical member 14 in the mounting brackets 18. The force of the leg 56 into the angled opening 44 spreads the clip 30, and particularly the clip 30 at the capture region 48 away from the plane P in the direction of arrow 72. The clip 30 is resilient against this deformation and places a corresponding spring force against the leg 56 and the leg 22. This resiliently, secures the vertical member 14 to the mounting bracket 18, while permitting sliding movement of the leg 56 relative to the mounting bracket 18. Once the vertical member 14 is plumb and in its final, proper position in the mounting brackets 18, fasteners F are driven through the legs' holes 54 and into the vertical member 14.

[0044] The present dual-sided mounting bracket 18 having clips 30A, 30B extending from the inside surface 26 and outside surface of the leg 22 provides extreme advantages over known mounting brackets. For example, because the mounting bracket 18 has clips on both sides of the leg 22, the vertical member 14 can be secured to either side of the leg 22. This makes installation considerably easier in that a right-handed individual can install the vertical member 14 on the left side of the mounting bracket 18 or a left-handed individual can install the vertical member 14 on the right side of the mounting bracket 18 and readily install a fastener F through the mounting bracket 18 and into the vertical member 14.

[0045] Further, the dual-sided mounting bracket 18 allows for installation in tight or difficult to reach and install locations, for example, corners and edges, in that a vertical member 14 can be installed to an inside surface 26 an outside surface 28 of the mounting bracket 18. As previously noted, while the description herein is made with reference to an example wherein the support members are arranged vertically (e.g. vertical support member 14). It is recognized and contemplated within the scope of the present disclosure that the dual-sided mounting brackets 18 described herein may be oriented +/?90 from the orientation shown in the figures to secure to a horizontally oriented support member (e.g. horizontal support member 16). In such an example, the mounting brackets 18 are secured to the backup wall B or the structure S with the leg 22 in a horizontal orientation. A leg of a horizontal support member 16 is resiliently received within a clip 30A, 30B to either side of the leg. The position of the horizontal support member 16 can be adjusted relative to the backup wall B or the structure S before fasteners F fixedly secure the horizontal support member 16 to the brackets 18.

[0046] In the present disclosure, the words a or an are to be taken to include both the singular and the plural. Conversely, any reference to plural items shall, where appropriate, include the singular. All percentages are percentages by weight, unless otherwise noted.

[0047] It will also be appreciated by those skilled in the art that the relative directional terms such as sides, upper, lower, top, bottom, rearward, forward and the like are for explanatory purposes only and are not intended to limit the scope of the disclosure.

[0048] Citations to a number of references are made herein. The cited references are incorporated by reference herein in their entireties. In the event that there is an inconsistency between a definition of a term in the specification as compared to a definition of the term in a cited reference, the term should be interpreted based on the definition in the specification.

[0049] In the above description, certain terms have been used for brevity, clarity, and understanding. No unnecessary limitations are to be inferred therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed. The different systems and method steps described herein may be used alone or in combination with other systems and methods. It is to be expected that various equivalents, alternatives, and modifications are possible within the scope of the appended claims.

[0050] This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to make and use the invention. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.