ADJUSTABLE SUPPORT AND BRACING SYSTEMS

Abstract

A support system comprises a post comprising a first planar member defining first openings, a second planar member orthogonally attached to the first planar member defining second openings. The support system comprising a bracket removably attachable to the post and comprising first projections for engaging the first openings, second projections for engaging the second openings, wherein when the one or more first projections are engaged to the one or more first openings and the one or more second projections are engaged to the one or more second openings, movement of the bracket is restricted in the horizontal plane. The bracket and post comprising structure for attaching braces, for support walkways and shelves and handrail structures.

Claims

1. A support system comprising: a post having a first post end and a second post end, the post comprising: a first planar member extending from at least a portion of the first post end to the second post end, the first planar member defining one or more first openings, and a second planar member orthogonally attached to the first planar member extending from at least a portion of the first post end to the second post end, the second planar member defining one or more second openings; and a bracket removably attachable to the post, the bracket comprising: one or more first projections for engaging the one or more first openings, and one or more second projections for engaging the one or more second openings, wherein a first axis extends from the first post end to the second post end, a second axis extends along the first planar member perpendicular to the first axis, and a third axis extends along the second planar member perpendicular to the first axis, and wherein when the one or more first projections are engaged to the one or more first openings and the one or more second projections are engaged to the one or more second openings, movement of the bracket is restricted at least along the second and the third axes.

2. The system of claim 1, wherein the post is configured to attach to a vertical surface.

3. The system of claim 1, wherein the first planar member defines two or more first openings aligned relative to the first axis.

4. The system of claim 1, wherein the second planar member defines two or more second openings aligned relative to the first axis.

5. The system of claim 1, wherein each of the first projections comprise a first groove for engaging a first edge of one of the first openings proximate the second post end.

6. The system of claim 1, wherein each of the second projections comprise a second groove for engaging a second edge of one of the second openings proximate the second post end.

7. The system of claim 1, wherein each of the first openings are keyed with a first larger portion proximate the first post end and each of the first projections comprises a first pair of side grooves for engaging each of the first openings distal the first post end.

8. The system of claim 1, wherein each of the second openings are keyed with a second larger portion proximate the first post end and each of the second projections comprises a second pair of side grooves for engaging each of the second openings distal the first post end.

9. A bracing system for bracing a wall against a bracing surface comprising: a post having a first post end and a second post end, the post comprising: a first planar member extending from at least a portion of the first post end to the second post end, the first planar member defining one or more first openings, and a second planar member orthogonally attached to the first planar member extending from at least a portion of the first post end to the second post end, the second planar member defining one or more second openings; a bracket removably attachable to the post, the bracket comprising: one or more first projections for engaging the one or more first openings, and one or more second projections for engaging the one or more second openings; and a brace having a first brace end and a second brace end, the brace for attaching to the bracket proximate the first brace end and engaging the bracing surface at the second brace end, wherein a first axis extends from the first post end to the second post end, a second axis extends along the first surface perpendicular to the first axis, and a third axis extends along the second surface perpendicular to the first axis, and wherein when the one or more first projections are engaged to the one or more first openings and the one or more second projections are engaged to the one or more second openings, movement of the bracket is restricted at least along the second axis and the third axis.

10. The system of claim 9, wherein the wall is an insulated concrete form wall.

11. The system of claim 9, wherein the first planar member defines two or more first openings aligned relative to the first axis.

12. The system of claim 9, wherein the second planar member defines two or more second openings aligned relative to the first axis.

13. The system of claim 9, wherein each of the first projections comprises a first groove for engaging a first edge of one of the first openings proximate the second post end.

14. The system of claim 9, wherein each of the second projections comprises a second groove for engaging a second edge of one of the second openings proximate the second post end.

15. The system of claim 9, wherein each of the first openings are keyed with a first larger portion proximate the first post end and each of the first projections comprises a first pair of side grooves for engaging each of the first openings distal the first post end.

16. The system of claim 9, wherein each of the second openings are keyed with a second larger portion proximate the first post end and each of the second projections comprises a second pair of side grooves for engaging each of the second openings distal the first post end.

17. The system of claim 9 further comprising an alternate brace having a first alternate brace end and a second alternate brace end, the alternate brace for attaching to the post proximate the first alternate brace end and engaging the bracing surface at the second alternate brace end.

18. The system of claim 9, wherein the bracket defines two or more pocket openings for removably engaging a pocket member for a handrail post.

19. The system of claim 9, wherein the bracket comprises a bracket surface defining one or more walkway openings for attaching a walkway to the bracket.

20. The system of claim 9, wherein the bracket defines one or more bracket opening for attachment with the brace.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] For a more complete understanding of the disclosure, reference is made to the following description and accompanying drawings, in which:

[0030] FIG. 1 is a perspective view of an embodiment of the bracing and support system;

[0031] FIG. 2A is a detail of an embodiment of a post;

[0032] FIG. 2B is a detail of an alternative first opening of an embodiment of a post;

[0033] FIG. 2C is a detail of an alternative second opening of an embodiment of a post;

[0034] FIG. 3A is a perspective view of an embodiment of a bracket removably attached to an embodiment of a post;

[0035] FIG. 3B is a detail view of an embodiment of a pocket;

[0036] FIG. 4A is a perspective view of an embodiment of a bracket;

[0037] FIG. 4B is a detail view of an embodiment of a first protrusion of the bracket of FIG. 4A;

[0038] FIG. 4C is a detail view of an alternative first protrusion of an embodiment of a bracket;

[0039] FIG. 4D is a detail view of an embodiment of a second protrusion of the bracket of FIG. 4A;

[0040] FIG. 4E is a detail view of an alternative second protrusion of an embodiment of a bracket;

[0041] FIG. 5A and FIG. 5B are illustrations of an embodiment of a bracket being installed to an embodiment of a post;

[0042] FIG. 6 is a side view of an embodiment of the bracing and support system; and

[0043] FIG. 7 is a side view of an embodiment of the bracing and support system using an alternative brace.

DETAILED DESCRIPTION

[0044] Unless otherwise defined, all technical and scientific terms used herein generally have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. Exemplary terms are defined below for ease in understanding the subject matter of the present disclosure.

[0045] The term a or an refers to one or more of that entity; for example, a bracket refers to one or more brackets or at least one bracket. As such, the terms a (or an), one or more and at least one are used interchangeably herein. In addition, reference to an element or feature by the indefinite article a or an does not exclude the possibility that more than one of the elements or features are present, unless the context clearly requires that there is one and only one of the elements. Furthermore, reference to a feature in the plurality (e.g. systems), unless clearly intended, does not mean that the systems or methods disclosed herein must comprise a plurality.

[0046] About and approximately, when referring to a measurable value such as an angle, a dimension, and the like, is meant to encompass variations of ?10%, ?5%, ?1%, ?0.5% or ?0.1% of the specified amount. When the value is a whole number, the term about is meant to encompass decimal values, as well the degree of variation just described. It is to be understood that such a variation is always included in any given value provided herein, whether or not it is specifically referred to.

[0047] And/or refers to and encompasses any and all possible combinations of one or more of the associated listed items (e.g. one or the other, or both), as well as the lack of combinations when interrupted in the alternative (or).

[0048] Comprise as is used in this description and in the claims, and its conjugations, is used in its non-limiting sense to mean that items following the word are included, but items not specifically mentioned are not excluded.

[0049] Adjustable support and bracing systems generally comprise a fixed support member, providing a vertical plane with a plurality of attachment points. The fixed support member may be a post, a portion of a wall, a portion of a structure and/or the like. Attaching members comprising brackets, braces and/or the like are generally removably engaged to the fixed support member to removably attach the attaching members thereto. A plurality of attachment points permit the attaching member to be attached to the fixed support member at various user adjustable heights. Systems comprising two or more support members, each removably attached to a fixed support member allow installation of support sections, such as planks, dimensional lumber and/or the like between support members providing the ability to form structures such as shelves, walkways and/or the like.

[0050] In some embodiments disclosed herein, the attaching members and the fixed support members each comprise cooperating mechanical features for removable engagement and/or attachment. In some embodiments, the fixed support member define a plurality of openings and the attaching members comprise one or more projections for engaging the openings to removably attach the attaching member at varying heights relative to the fixed support member. In some embodiments, the fixed support members comprise a plurality of projections and the attaching members comprise one or more openings for engaging the projections to removably attach the attaching members at varying heights relative to the fixed support member.

[0051] In some embodiments disclosed herein, the fixed support member is a post comprising at least two surfaces, wherein the two surfaces are orthogonal to one another, and each of the two surfaces defines a plurality of openings. Attaching members such as brackets, braces and/or the like comprise at least two sets of projections for engaging the openings on each of the two surfaces. The attaching members and fixed support members, such as posts, are removably engaged and/or attached using cooperating openings and projections on two orthogonal planes providing significantly increased stability over support members and attaching members attached on a single plane. In some embodiments of fixed support members and attaching members disclosed herein, specific attributes of openings and projections and their combinations are considered to ensure that support and bracing systems are functional.

[0052] In some embodiments disclosed herein, brackets comprise features which permit attachment to braces and other components for facilitating attachment of shelves, handrails, walkways, and/or the like, in addition to connection to the fixed support members.

[0053] Referring to FIG. 1, in some embodiments disclosed herein, a support system 100 comprises a plurality of posts 104 and brackets 140, wherein each post 104 is attached to a wall 102 or other support structure. In some embodiments disclosed herein, each of the posts 104 is installed approximately vertical. The posts 104 have a first post end 106 and a second post end 108. Referring to FIG. 2A, in some embodiments disclosed herein, the post 104 comprises at least a first planar member 110 and a second planar member 120, wherein the first planar member 110 and the second planar members 120 are orthogonally attached to each other and both planar members 110, 120 extend from the first post end 106 and the second post end 108 or any portion thereof. Referring to FIG. 1 and FIG. 2A, a y-axis runs from the first post end 106 to the second post end 108 representing about a vertical orientation, a x-axis extends along the first planar member perpendicular to the y-axis and a z-axis extends along the second planar member perpendicular to the y-axis and the x-axis, wherein the x-axis and the z-axis are about horizontal.

[0054] Referring to FIG. 2A, in some embodiments disclosed herein, the first planar member 110 defines one or more first openings 112, which may be aligned parallel to the y-axis, at different vertical positions. In some embodiments disclosed herein, each of the first openings 112 are arranged equidistantly apart from one another. In some embodiments disclosed herein, each of the posts 104 have approximately identical distributions of first openings 112. Referring to FIG. 2A, in some embodiments disclosed herein, the second planar member 120 defines one or more second openings 122, which may be aligned parallel to the y-axis, at different vertical positions. In some embodiments disclosed herein, each of the second openings 122 are arranged equidistantly apart from one another. In some embodiments disclosed herein, each of the posts 104 have approximately identical distributions of second openings 122. In some embodiments disclosed herein, each of the posts 104 comprises a third planar member 130 attached to the second planar member 120, the third planar member 130 defining one or more openings 132 for attaching the post 104 to the wall 102 or other structure using fasteners such as screws, nails, bolts, rivets and/or the like. The third planar member 130 may run the entire length from the first post end 106 to the second post end 108 or any portion thereof and may have one or more gaps or breaks between the first post end 106 to the second post end 108. In some embodiments disclosed herein, the post 104 alternatively comprises one or more tabs, flaps, and/or the like to attach the post 104 to the wall 102. The post 104 may be assembled from discrete components, molded, cast or formed of sheet metal.

[0055] Referring to FIG. 3A, in some embodiments disclosed herein, the bracket 140 comprises a bracket body 142, one or more first projections 144 for engaging the one or more first openings 112 and one or more second projections 154 for engaging the one or more second openings 122. In some embodiments disclosed herein, the bracket 140 defines one or more openings 162 proximate the one or more second projections 154 to provide a user with increased visibility of the interaction in operation between bracket 140 and the post 104, including of the interaction in operation of the one or more second projections 154 and the one or more second openings 122. The brackets 140 may be assembled from discrete components, molded, cast or formed of sheet metal. In embodiments, the bracket 140 comprises a engagement member 164 for engaging the third planar member 130. In some embodiments disclosed herein, the engagement member 164 comprises a engagement member planar plate 166 for contacting the third planar member 130 and/or the wall 102. In some embodiments disclosed herein, the engagement member planar plate 166 comprises one or more openings 168, which align with the one or more openings 132 of the third planar member 130, which permit attachment of the bracket 140 to the wall 102 using fasteners, providing a more secure connection therebetween. In some embodiments disclosed herein, bracket 140 may also be attached to the wall 102 through the one or more openings 168 unobstructed by the third planar member 130.

[0056] In some embodiments disclosed herein, the bracket 140 comprises a support surface 170, which is generally at a right angle relative to the wall 102 when the bracket 140 is removably attached to the post 104, wherein a post 104 installed generally vertically results in a relatively level support surface 170. In some embodiments disclosed herein, the support surface 170 may be an edge of the bracket 140 and may contain an unleveled and/or uneven surface. Referring to FIG. 1, when two or more posts 104 are installed proximate to one another with brackets 140 removably attached thereto at approximately the same vertical positions, one or more planks, boards, beams and/or the like can be supported on the support surfaces 170 to support persons such as for scaffolding or materials such as for shelving. In some embodiments disclosed herein, the support surface 170 defines one or more openings 172 for planks, boards, beams and/or the like to be attached to the support surfaces 170 using fasteners.

[0057] In some embodiments disclosed herein, the design of the openings and protrusions of each of the post 102 and bracket 140 include shapes, relative sizes and fit to provide enhanced security, safety and/or support. Each of the first openings 112 may be any suitable shape including rectangular, oval and/or the like. Referring to FIG. 2A, in some embodiments disclosed herein, each of the first openings 112 are keyed, wherein the first openings 112 are generally rectangular, with a width a and a height b, with a wider portion 114 proximate the first post end 106 having a width a. In some embodiments disclosed herein, the first planar member 110 further defines one or more mirrored first openings 116, which are identical to the first openings 112 and mirrored about the x-axis wherein each of the mirrored first openings 116 comprise a wider portion 118 proximate the second post end 108. The combination of the first openings 112 and the mirrored first openings 116 permits installation of the posts 104 with the first post end 106 at the bottom of the wall 102 and the second post end 108 at the top of the wall 102, which may be desirable and/or required in particular applications to facilitate appropriate location and attachment of the third planar member 164 to the wall 102. Referring to FIG. 2B, in some embodiments disclosed herein, alternative first openings 112a and mirrored first openings 116a are not keyed.

[0058] Referring to FIG. 4A and FIG. 4B, in some embodiments disclosed herein, each of the first projections 144 comprise a pair of grooves 146. In some embodiments disclosed herein, the non-grooved portion of the first projections 144 have a width d and the grooves 146 have a depth c to accommodate the thickness of the first planar member 110 with a near interference fit and a width between grooves d which is about equal to a (and less than d) such that when the grooves 146 are positioned within the rectangular portion of the first openings having a width a, the first projections are obstructed from passing horizontally along the z-axis through the first openings 112. Further, when the first projections 144 are positioned horizontally within the first opening 112 distal the wider portion 114, the bracket 140 is restricted from movement along the x-axis and the z-axis. Movement of the bracket 140 is restricted relative the z-axis as a portion of the first planar member 110 is sandwiched within the grooves 146 of the first projection 144. Movement of the bracket 140 is restricted relative the x-axis as the sides of the grooves 146 are delimited by the sides of the first openings 112. It is understood that if the post 104 is installed with the first post end 106 at the bottom of the wall 102 and the second post end 108 at the top of the wall 102, the mirrored first openings 116 and the wider portions 118 would be used in place of the first openings 112 and the wider portions 114.

[0059] In some embodiments disclosed herein, each of the second openings 122 may be any suitable shape including rectangular, oval and/or the like. Referring to FIG. 2C, in some embodiments disclosed herein, each of alternative second openings 122a are keyed, wherein the alternative second openings 122a are generally rectangular, with a width u and a height v, with a wider portion 126 proximate the first post end 106 having a width u. In some embodiments disclosed herein, the second planar member 120 further defines one or more mirrored second openings, which are identical to the alternative second openings 122a and mirrored about the z-axis wherein each of the mirrored second openings comprise a wider portion proximate the second post end 108. The combination of the alternative second openings 122a and the mirrored second openings permits installation of the posts 104 with the first post end 106 at the bottom of the wall 102 and the second post end 108 at the top of the wall 102, which may be desirable and/or required in particular applications to facilitate appropriate location and attachment of the third planar member 164 to the wall 102.

[0060] Referring to FIG. 4E, in some embodiments disclosed herein, each of alternative second projections 154a comprise a pair of grooves 158. In some embodiments disclosed herein, the non-grooved portion of the alternative second projections 154a have a width x and the grooves 158 have a depth w to accommodate the thickness of the second planar member 120 with a near interference fit and a width between grooves x which is about equal to u (and less than x) such that when the grooves 158 are positioned within the rectangular portion of the second openings having a width u, the second projections are obstructed from passing horizontally along the x-axis through the second openings 112. Further, when the alternative second projections 154a are positioned horizontally within the second opening 122 distal the wider portion 126, the bracket 140 is restricted from movement along the x-axis and the z-axis. Movement of the bracket 140 is restricted relative the x-axis as a portion of the second planar member 120 is sandwiched within the grooves 158 of the alternative second projection 154a. Movement of the bracket 140 is restricted relative the z-axis as the sides of the grooves 158 are delimited by the sides of the second openings 122. It is understood that if the post 104 is installed with the first post end 106 at the bottom of the wall 102 and the second post end 108 at the top of the wall 102, the mirrored second openings and the wider portions would be used in place of the second openings 122 and the wider portions 126.

[0061] Referring to FIG. 4A and FIG. 4D, in some embodiments disclosed herein, each of the second projections 154 comprises a hook groove 156 distal the support surface 170. The depth of the hook groove 156 has a depth to accommodate the thickness of the second planar member 120 with a near interference fit. When the second projection 154 is positioned within the second opening 122 with the hook groove 156 engaging an edge of the second opening 122, the bracket 140 is further restricted from movement relative to the x-axis. The first projection 144 resting against a bottom side of the first opening 112 and the hook grooves 156 resting against a bottom side of the second openings 122 provides vertical support for the bracket 140. Further, where the engagement member 164 of the bracket 140 is in contact with the third planar member 130 and/or the wall 102, the brackets 140 are further vertically supported.

[0062] Referring to FIG. 4C, in some embodiments disclosed herein, each of alternative first projections 144a comprises a hook groove 148 distal the support surface 170. The depth of the hook groove 148 has a depth to accommodate the thickness of the first planar member 110 with a near interference fit. When the alternative first projection 144a is positioned within the first opening 122 with the hook groove 148 engaging an edge of the first opening 112, the bracket 140 is further restricted from movement relative to the z-axis. The alternative first projection 144a resting against a bottom side of the first opening 112 and the hook grooves 148 resting against a bottom side of the first openings 112 provides vertical support for the bracket 140. Further, where the engagement member 164 of the bracket 140 is in contact with the third planar member 130 or the wall 102, the brackets 140 are further vertically supported.

[0063] A method of use of some embodiments of the system disclosed herein comprises a post 104 defining a plurality first openings 112 and second openings 122, and the bracket comprises a single first protrusion 144 proximate the support surface 170 and two or more second protrusions 154, wherein the first openings 112 are keyed, the first protrusion 144 comprises a grooved portion 146 and the second protrusions comprise hook portions 156. Initially, the post 104 is installed on the wall 102 with the first planar member 110 parallel the wall 102 and the second planar member 120 perpendicular between the first planar member 110 and the wall 102. To removably attach a bracket 140 to the post 104, the first protrusion 144 is inserted into the first opening 112 at an angle relative to the x-axis as shown in FIG. 5A. The bracket 140 is then rotates back such that the second protrusions 154 are inserted in the second openings 122 as shown in FIG. 5B. The bracket 140 is then lowered such that the grooved portion 146 and the hook grooves 156 rest against the first planar member 110 and the second planar member 120 of the post 104 respectively. While the above description applies to embodiments wherein the first openings 112 are keyed, the first protrusions 144 comprise grooves 146 and the second protrusions 154 comprise hook grooves 156, the method of use would apply similarly to all embodiments above including where the first openings 112 are not keyed, the first protrusions 144 comprise hook grooves 148, the second openings 122 are keyed and the second protrusions comprise grooves 158.

[0064] Embodiments of the support system 100 disclosed above are suitable for applications such as scaffolding and shelving where the wall 102 is stable and capable of supporting demands of the system in addition to other structural elements. In some embodiments disclosed herein, the support system 100 is configured to provide support or bracing to the wall 102. In some embodiments disclosed herein, a brace 190 is attached to either the bracket 140 or the post 104 to provide support or bracing to the wall 102.

[0065] In some embodiments disclosed herein, the support system 100 is used in insulated concrete forms (ICF) systems. Concrete walls in building construction are commonly constructed using ICF systems. In conventional concrete wall-forming systems, a pair of panels is set up at a spacing corresponding to the desired thickness of the finished wall, thus creating a cavity between the panels. As necessary or desired, reinforcing bars are positioned within the formwork cavity. The form panels are secured in position using form ties extending between the form panels, and/or by means of external temporary bracing. Fluid concrete is then introduced into the formwork cavity. After the concrete has cured sufficiently, the formwork panels are removed from the concrete wall. ICF systems combine plastic foam insulation panels and spacing means (such as plastic tie members) to create assemblies in which the insulation panels take the place of conventional wall form panels (e.g., plywood forms), and remain in place as permanent insulation after the concrete wall has been cast and cured. ICF systems thus reduce or eliminate the need to strip forms from the finished wall, thereby reducing construction labour costs. As well, construction time and costs are further reduced because wall insulation does not have to be installed as a separate task subsequent to wall construction. When pouring fluid concrete into the formwork cavity, it is necessary to support the ICF system using bracing and other means. In some embodiments disclosed herein, an ICF wall 102 is placed on a footing or other structure. Improved stability provided by some of the embodiments of the support system 100 disclosed herein provide a more stable environment for ICF systems, wherein better support with less shifting requires less additional bracing structure to maintain a required safety level.

[0066] Referring to FIG. 3A and FIG. 6, in some embodiments disclosed herein, the bracket 140 defines one or more brace attachment openings 174 and one or more brace set point openings 178 to connect a brace 190 using fasteners. In some embodiments disclosed herein, the brace 190 comprises a foot member 192 distal the bracket 140 for engaging a surface such as the ground and one or more brace attaching openings, and may comprises a turnbuckle 194 for adjusting the length of the brace 190. In some embodiments disclosed herein, the foot member 192 comprises a pin. In some embodiments disclosed herein, the bracket 140 further comprises a set attachment slot 176. In operation, the brace 190 is attached to the bracket 140 using the brace set point opening 178 and the set attachment slot 176, wherein the brace 190 can rotate relative the bracket 140 relative the brace set point opening 178, allowing adjustment of the angle of the brace 190. Once the desired angle of the brace 190 is achieved, the fasteners in the brace set point opening 178 and the set attachment slot 176 are tightened and an additional fastener may be used to fix the brace 190 to the bracket 140 using one of the brace attachment openings 174. In some embodiments disclosed herein, the brace 190 comprises a section of dimensional lumber such as a 2?4 or a 2?6.

[0067] Referring to FIG. 2A, in some embodiments disclosed herein, the second planar member 120 defines one or more alternative brace attachments openings 127 for securing a brace 190 thereto. Referring to FIG. 7, in some embodiments disclosed herein, the brace attaching openings of the brace 190 is attached to the alternative brace attachment openings 127 using fasteners, which may be on the same side as the bracket 140 or where the post 104 extends past the wall 104, the brace 190 can be attached for the foot member 192 to engage a surface on the opposing side of the wall 102 as illustrated in FIG. 7.

[0068] Referring to FIG. 1, as described above, planks, dimensional lumber and/or the like may be placed on and/or affixed to support surfaces 170 of the brackets 140 providing the ability to form structures such as shelves, walkways and/or the like. Referring to FIG. 3A and FIG. 4A, in some embodiments disclosed herein, the bracket 140 further defines one or more member attachment openings 180 for attaching an accessory member to the bracket 140. In some embodiments disclosed herein, the accessory member is a pocket 184 sized to receive a portion of a portion of a railing structure, such as a 2?4 piece of dimensional lumber as shown in FIG. 1. Referring to FIG. 3B, the pocket 184 comprises one or more pocket hook protrusions 188 for securing the pocket to the bracket 140. In some embodiments disclosed herein, the bracket 140 may define one or more bracket attachment openings 186 for securing dimensional lumber in the pocket 184 using fasteners.

[0069] Although embodiments have been described above with reference to the accompanying drawings, those of skill in the art will appreciate that variations and modifications may be made without departing from the scope thereof as defined by the appended claims.