Abstract
Reinforcing bracket system, for use with gypsum sheathing and other construction materials. The brackets are made from a resilient material, such as metal or metal alloy, and consist of a generally flat, planar main body, possibly with a central portion, which may be solid or hollow, and/or a raised lip, and fastener bores for attaching the bracket to sheeting, and legs for anchoring the bracket in a panel. Mending plates may also be used in a system, along with special-purpose tools for applying adhesive and affixing the brackets and plates.
Claims
1. A reinforcing bracket comprising: a load plate in the configuration of a polygonal prism, said load plate comprising a top side and an opposing bottom side; a plurality of fastener bores extending through said load plate from said top side to said opposing bottom side; and a plurality of legs extending downward from an outside surface of said load plate.
2. The reinforcing bracket of claim 1, wherein said load plate is generally in the configuration of a triangular prism having truncated tips.
3. The reinforcing bracket of claim 2, wherein said load plate is generally in the configuration of a right triangular prism having truncated tips.
4. The reinforcing bracket of claim 3, wherein said load plate further comprises a central portion generally in the configuration of a right triangular prism.
5. The reinforcing bracket of claim 4, wherein said central portion comprises a hollow opening.
6. The reinforcing bracket of claim 4, wherein said load plate further comprises a raised lip adjacent to and surrounding said central portion.
7. The reinforcing bracket of claim 6, wherein said each leg in said plurality of legs is generally in the configuration of a triangular prism attached to said load plate at a base of said triangular prism and having an opposing tip projecting away from said load plate.
8. The reinforcing bracket of claim 7, wherein said plurality of fastener bores comprises at least three fastener bores, a first fastener bore of said at least three fastener bores being disposed at a first corner of said load plate, a second fastener bore of said at least three fastener bores being disposed at a second corner of said load plate, and a third fastener bore of said at least three fastener bores being disposed at a third corner of said load plate.
9. A system for installing drywall panels comprising a plurality of the reinforcing bracket of claim 8 and a plurality of mending plates, each of said mending plates comprising: a mending plate load plate in the configuration of a rectangular prism, said mending load plate comprising a top side and an opposing bottom side; a plurality of mending plate fastener bores extending through said mending plate load plate from said top side to said opposing bottom side; and a plurality of mending plate legs extending downward from an outside surface of said mending plate load plate.
10. A method for installing drywall panels on a stud frame using the system of claim 9, comprising: providing a stud frame comprising a plurality of studs connected to form a grid; providing a first drywall panel; applying an adhesive to a front side of said stud frame; positioning said first drywall panel on said stud frame such that said an outer periphery of said first drywall panel adheres to said stud frame via said adhesive; disposing a first reinforcing brackets of said plurality of reinforcing brackets in a first corner of said first drywall panel such that said legs and said fastener bores of said first reinforcing bracket are vertically aligned with said stud frame; hammering said first reinforcing bracket into said first drywall panel such that said legs are driven into said stud frame; fastening said first reinforcing bracket to said first drywall panel and said stud frame by driving a fastener through each of said fastener bores and through said first drywall panel into said stud frame; and repeating said disposing, hammering, and fastening steps for each corner of said drywall panel.
11. The method of claim 10, further comprising: providing a second drywall panel; applying an adhesive to a front side of said stud frame; positioning said second drywall panel on said stud frame adjacent said first drywall panel such that said an outer periphery of said second drywall panel adheres to said stud frame via said adhesive; disposing a second reinforcing bracket of said plurality of reinforcing brackets in a first corner of said second drywall panel such that said legs and said fastener bores of said first reinforcing bracket are vertically aligned with said stud frame; hammering said first reinforcing bracket into said second drywall panel such that said legs are driven into said stud frame; fastening said first reinforcing bracket to said second drywall panel and said stud frame by driving a fastener through each of said fastener bores and through said second drywall panel into said stud frame; and repeating said disposing, hammering, and fastening steps for each corner of said second drywall panel.
12. The method of claim 11, further comprising: providing a second drywall panel; applying an adhesive to a front side of said stud frame; positioning a first mending plate on said stud frame at a seam between said first drywall panel and said second drywall panel such that at least some of said legs of said first mending plate are vertically positioned over said first drywall panel and stud and at least some of said legs of said mending plate are vertically positioned over said second drywall panel and said stud frame; hammering said first mending plate into said second drywall panel such that said legs are driven into said first drywall panel, said second drywall panel, and said stud frame; and fastening said first mending plate into said stud frame by driving a fastener through each of said mending plate fastener bores into said stud frame.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 depicts an isometric elevation view of a reinforcing bracket according to the present disclosure.
[0022] FIG. 2 depicts an alternative isometric elevation view of a reinforcing bracket according to the present disclosure.
[0023] FIGS. 3A and 3B depict an embodiment of a reinforcing bracket according to the present disclosure being installed on a construction panel.
[0024] FIG. 4 depicts a side elevation view of a reinforcing bracket according to the present disclosure.
[0025] FIG. 5 depicts a top elevation view of a reinforcing bracket according to the present disclosure.
[0026] FIG. 6 depicts a back elevation view of a reinforcing bracket according to the present disclosure.
[0027] FIG. 7 depicts an isometric exploded view of a reinforcing bracket according to the present disclosure with an uninstalled fastener.
[0028] FIG. 8 depicts an assembled view of a reinforcing bracket according to the present disclosure with an installed fastener.
[0029] FIG. 9 depicts a top elevation view of a construction panel having a plurality of reinforcing brackets disposed thereon according to the present disclosure.
[0030] FIG. 10 depicts a detailed view of a construction panel having a reinforcing bracket disposed thereon according to the present disclosure.
[0031] FIG. 11 depicts a schematic view of a pair of construction panels in an installed position with the locations for placing a plurality of reinforcing brackets denoted.
[0032] FIGS. 12A, 12B, and 12C depict alternative embodiments of a reinforcing bracket according to the present disclosure.
[0033] FIGS. 12A, 12B, and 12C depict alternative embodiments of a reinforcing bracket according to the present disclosure.
[0034] FIGS. 13A, 13B, 13C, and 13D depict an alternative embodiment of a reinforcing bracket according to the present disclosure.
[0035] FIGS. 14A, 14B, 14C, and 14D depict a method for using the alternative embodiment of a reinforcing bracket according to FIG. 13.
[0036] FIGS. 15A, 15B, 15C, 15D, 15E, and 15F depict an embodiment of a mending plate for use with a reinforcing bracket according to the present disclosure.
[0037] FIGS. 16A, 16B, 16C, and 16D depict a method for using a reinforcing bracket and mending plate according to the present disclosure.
[0038] FIGS. 17A, 17B, and 17C depict an installation tool for use with a reinforcing bracket and/or mending plate according to the present disclosure.
[0039] FIGS. 18A, 18B, 18C, 18D, 18E and 18F depict an adhesive applicator tool for use with a reinforcing bracket and/or mending plate according to the present disclosure.
DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0040] The following detailed description and disclosure illustrates by way of example and not by way of limitation. This description will clearly enable one skilled in the art to make and use the disclosed systems and methods, and describes several embodiments, adaptations, variations, alternatives and uses of the disclosed systems and methods. As various changes could be made in the above constructions without departing from the scope of the disclosures, it is intended that all matter contained in the description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0041] FIGS. 1 and 2 depict an embodiment of a reinforcing bracket (101) according to the present disclosure. FIGS. 4, 5, and 6 provide alternative elevation views of the reinforcing bracket. In the depicted embodiments, the reinforcing bracket (101) comprises a main body, referred to herein as a load plate (103), a receiving bore (105) for accepting a fastener, and a plurality of anchors (107), referred to herein as legs. The primary function of the load plate (103) is to receive and distribute shear load that the structure may receive, such as during high winds, seismic activity, or other stresses that apply shear load. The size and shape of the load plate (103) may vary from embodiment to embodiment. The size and thickness may depend on, and/or be proportional to, the dimensions of the gypsum sheathing with which the device will be used, with larger sheathing using a reinforcing bracket (101) with larger load plates capable of receiving and distributing larger loads over a larger area.
[0042] As can be seen in FIGS. 1 and 2, the depicted load plate (103) is a generally flat, planar structure having a generally triangular configuration with truncated tips (109). Said differently, the depicted load plate (103) is an irregular hexagon, which has two side dimensions applied to alternating sides. This shape has several advantages, including that triangular geometries have superior structural integrity characteristics, and the truncated tips (109) provide a flat or linear edge that allows the reinforcing bracket (101) to be placed adjacent to the edge of a panel, as shown in FIGS. 3A, 3B, 9, 10 and 12. Additionally, this configuration simplifies construction, as the anchors/legs (107) can be formed from a single piece of sheet metal or other material and bent into position.
[0043] Other dimensions and configurations of the load plate are also possible, including fully triangular (without truncated tips), as shown in FIG. 12A, triangular with truncated tips but having alternate side dimensions, such as shown in FIG. 12B, and rectangular, such as shown in FIG. 12C.
[0044] The depicted load plate has as receiving bore (105) disposed therethrough from a top to a bottom side. The depicted receiving bore (105) is a round element whose main axis is generally perpendicular to the main plane of the load plate (103). This improves the ease of installing a fastener and assists with ensuring the fastener enters the underlying construction material perpendicularly, which ordinarily provides a strong connection. The depicted receiving bore (105) is disposed near a first corner (110), which, as described below, has a different configuration of anchors (107) from the other corners (112). The size, shape, and position of the receiving bore (105) may vary from embodiment to embodiment based upon, among other things, the type of fastener to be used, which may in turn vary depending on the type of material from which the underlying panel is constructed. In an embodiment, the fastener bore (105) may be threaded or have other features for facilitating a connection with the fastener.
[0045] In the depicted embodiment, the reinforcing bracket (101) comprises a plurality of anchors, or legs (107). In the depicted embodiment, the legs (107) have a generally triangular configuration, with the base of the triangle attached or connected to the load plate (103), and an opposing point or tip projecting away from the load plate (103). The depicted legs (107) are disposed approximately perpendicularly from the main plane of the load plate (103), which facilitates installation and minimizes disruption of the internal structure of the sheathing panel, but other angles may be used. By way of example and not limitation, the angle may be slightly acute (i.e., leaning inwardly towards the middle of the bracket (101)) or may be slightly obtuse (i.e., leaning outwardly away from the middle of the bracket (101)). In the depicted embodiment, all of the legs (107) have about the same angle, but in an alternative embodiment, one or more legs may have angles that differ from the rest.
[0046] The depicted embodiment comprises four legs (107), with two disposed on adjacent lateral sides of the truncated tip (107) of a first corner (110), and two more each disposed on the truncated tips (107) of the other corners (112). In the depicted embodiment, the first corner (110) also comprises the fastener bore (105), and the multiple leg (107) configuration provided for the first corner (110) provides additional anchoring support for the legs (107) at the area of the load plate (103) where fastening will occur. This provides additional structural strength for receiving and distributing loads, and reduces fastener movement, which could result in disengagement of the fastener and reinforcing bracket (101). The legs (107) may be constructed from a single piece of material, such as sheet metal, which is cut to size with a CNC or metal stamping machine and then bent into final position, or manufacturing techniques known in the art.
[0047] As shown in FIGS. 12A, 12B, and 12C, other structures may also be used with similar principles. For example and not limitation, the embodiment of FIG. 12B has a roughly pear-shaped configuration, with two legs at the first corner (110), and the other two legs disposed at the other corners (112), and a shorter triangular side disposed between the other corners (112) to lend the load plate (103) the pear shape shown.
[0048] Although three or four legs are shown in the depicted embodiments, in an alternative embodiment, more or fewer may be used. By way of example and not limitation, the embodiment of FIG. 12C has a roughly rectangular configuration, with two legs at a first end (110), and a single additional leg (107) disposed at an opposing end (112), resulting in a configuration having 3 legs. The number of legs used in a given embodiment may vary depending on various characteristics, such as the size and composition of the panel and of the load plate (103), and will generally be selected to strike a balance between having a sufficient number of legs (107) to achieve a secure attachment that assists with distributing shear load, while also not perforating the sheathing or disrupting the internal structure any more than is needed to achieve such an attachment. By way of example and not limitation, in an alternative embodiment, one or more of the other corners (112) may also have a similar leg configuration to that of the first corner (110).
[0049] FIGS. 3A and 3B depict an embodiment of a reinforcing washing according to the present disclosure being installed on gypsum sheathing. FIG. 3A depicts the reinforcing bracket (101) disposed on a panel (113) with a fastener (111) prepared to be inserted through the fastener bore (105) and through the panel (113) to affix the panel (113) to an underlying stud (123). FIG. 3B depicts the reinforcing bracket (101) with the fastener (111) inserted through the fastener bore (105). The legs (107) are anchored in the body of the panel (113) and the fastener (111) passes through the body of the panel (113) to connect to the stud (123). FIG. 8 and FIG. 9 depict the reinforcing bracket (101) without a panel (113), but with the fastener prepared for installation (FIG. 8) and installed (FIG. 9).
[0050] The fastener (111) may be any type of fastener suitable for use in construction, based on the type, size, and composition of the panel and bracket (101), and will generally have a retaining means (113) to anchor the fastener to the reinforcing bracket (101). In the depicted embodiment, the retaining means (113) is a fastener head (113) having a radius larger than that of the fastener bore (105).
[0051] FIG. 9 depicts a top elevation view of a panel (113) having a plurality of reinforcing brackets (101) disposed thereon and FIG. 10 depicts a detailed view of a panel (113) having a reinforcing bracket (101) disposed thereon according to the present disclosure. As shown in FIGS. 9 and 10, the shape of the load plate (103) facilitates placement of the reinforcing brackets (101) on the panels (113) in advantageous positions. The truncated tips (109) of the load plate (103) allow the load plate (103) to be spaced adjacent to the lateral edges of the panels (113) without extending beyond the edge. This is important for avoiding interference when installing adjacent panels (113) (as shown in FIG. 11). Additionally, when the reinforcing bracket (101) is used in a panel (113) corner, as seen in FIG. 9, the triangular load plate (103) shape allows the reinforcing bracket (101) to be placed very near to the corner without material extending beyond the edge of the panel (113). FIG. 11 depicts a schematic view of a pair of panels (113) in an adjacently installed position, with a plurality of locations (121) for placing a plurality of reinforcing brackets denoted. The schematic of FIG. 11 is exemplary and non-limiting, and alternative spacing configurations can and will be used in an embodiment.
[0052] FIGS. 13A, 13B, 13C, and 13D depict an alternative embodiment. In the depicted embodiments of these FIGs., the bracket (101) comprises a load plate (103) generally in the configuration of a right triangle. In the depicted embodiment, a central portion (116) of the load plate (103) is solid, but, in an alternative embodiment, this central portion (116) may be a hollow opening (116). Although a right triangle is depicted, other shapes are also possible, and may include, without limitation, other polygonal configurations. In the depicted embodiment, the central portion (116) is also generally in the configuration of a right triangle having side lengths proportional to those of the load plate (103). In the depicted embodiment of these FIGS., fastener bores (105) are disposed at the corners, near where the sides converge. The depicted embodiment has one bore in each of the three corners, but this is not limiting and, in alternative embodiments, there may be more or fewer bores, and they may be disposed in other locations, such as along the sides. The depicted embodiment further includes a raised surface (114) surrounding the central portion (116). This surface is generally in the configuration of raised lip formed of a top flat surface adjacent the central portion (116) connected to the load plate (103) by an inclined section. This raised surface imparts increased strength. This configuration distributes shear loading at the fastener locations that walls experience during events such as windstorms and other sources of similar stress vectors on the panels.
[0053] The depicted embodiment is generally triangular, with the tips of the triangular shape truncated (109) as shown in the FIGs. As noted, this truncated shape (109) improves ease of installation and spacing, and also eliminates the acute angles that would otherwise appear in the corner, resulting in sharp triangular corners that are more likely to damage the drywall when installed. As shown in the FIGs., the truncated shape also provides a surface for attaching legs (107). The depicted embodiment has a plurality of legs (107) extending downward from the outside perimeter of the load plate (103), generally in locations near the non-right corners and along the non-hypotenuse sides. In the depicted embodiment, the legs (107) and fastener bores (105) are disposed in locations on the load plate (103) corresponding to where the drywall will be attached to underlying framing material. Thus, in alternative embodiments using other shapes, corresponding elements would naturally be disposed in similar locations on the shape.
[0054] To install this embodiment, adhesive is optionally applied between a panel (113) and a stud (123) as shown in FIG. 14A. Next, the bracket (101) is oriented so that the right angle is disposed in one of the perpendicular corners of the panel (113), and the bracket (101) is positioned such that the fastener bores (105) are vertically aligned over a stud (123), as shown in FIG. 14B. A tool, described elsewhere herein, is then used to drive the legs (107) into the body of the panel (113), and fasteners (111) are inserted through the fastener bores (105) to affix the bracket (101) to the stud (123) on the opposing side of the panel (113), as shown in FIG. 14C. This places the fasteners (111) as far away from the edge of the panel (113) as is reasonable possible for increased strength and less risk of tear-out near the edges, but still close enough to secure the panel (113) to the stud (123). Additionally, as shown in FIGS. 14A, 14B, and 14C, the corner of the frame is made of two studs (123), and the bracket (101) provides additional structural support to the frame by the fasteners (111) being inserted into both. This reduces unwanted stud (123) movement, which can damage and weaken the panels (13). The depicted embodiment uses double-legs (109) for further strengthening. Additionally, often two adjacent panels (113) will be affixed to a single shared stud (123), and the bracket (101) assists with spacing and connection. Generally, one bracket (101) is used in each corner of a panel (113), as shown in FIGS. 16C and 16D.
[0055] In some embodiments, a mending plate (201) may be used to further secure the seams between adjacent panels (113). A non-limiting, exemplary embodiment of one such mending plate (201) is shown in FIGS. 15A, 15B, 15C, 15D, 15E, 15F, and in FIGS. 16A, 16B, 16C, and 16D. The depicted mending plate (201) is conceptually similar to the bracket (101), in that is comprises a main body in the form of a load plate (203) with at least one fastener bore (205) extending therethrough, and at least one leg (207) extending therefrom on one side. In the depicted embodiment, the load plate (203) is in a generally quadrilateral configuration, specifically, rectangular, with two fastener bores (205) disposed at opposite sides. Two pairs of legs (207) extend from opposing corners. The depicted mending plate (201) has truncated corners, for similar reasons described elsewhere herein. The purpose of the mending plate is to connect adjacent panels (113) at a seam and inhibit movement, and the size, quantity, and placement of both the elements of the mending plate (201) may necessarily vary from embodiment to embodiment depending on the specific configuration of panels (113) to which it will be attached. In the depicted embodiment, the panels (113) are two vertically adjacent panels (113) sharing a stud (123). The legs (207) are disposed at an obtuse angle relative to the installation direction/orientation. As seen in FIGS. 16C and 16D, the mending plate (201) is installed by straddling the seam between panels (113) with two legs (207) entering each panel (113), and fasteners (111) disposed through the bores (205) holding the mending plate (201) in place. The legs (207) engage in the underlying stud (123), inhibiting unwanted panel (113) movement and reducing panel (113) shifting during shear loading. In the depicted embodiment, three mending plates (201) are used for a full size 48 panel, but in alternative embodiments, a different number may be used depending on site-specific factors, such as, but not necessarily limited to, panel composition, dimensions, stud material, and seam length.
[0056] In an embodiment, the bracket (101) and/or mending plate (201) may be installed using an impact or punch-down tool. An embodiment of such a tool is depicted in FIGS. 17A and 17B, and an embodiment of the installation process is shown in FIGS. 17C and 17D. The tool (301) generally comprises a main body (303) sized and shaped to fit over some of all of the load plate (103) or (203) of a bracket (101) or mending plate (201). The depicted tool (301) has a roughly triangular main body (303) in the configuration of a right triangle for installing a bracket (101). The main body (303) is connected to a punch-down handle (305) by a shaft (305) extending from a topside and may include one or more magnets on the bottom side to assist in tool (301) placement and to hold the bracket (101) in place. The punch-down handle (305) may be a static handle, or may comprise an impact, or down-punch, mechanism, of a type that is well-known in the art. The tool (301) is used by placing it on the component to be installed, placing the component in the proper location, and pressing downward, as shown in FIGS. 17C and 17D. The depicted handle (305) is removable and thus can be used with multiple differently-shaped main bodies (303) for punching down different elements (e.g., a bracket (101) and/or a mending plate (201)).
[0057] In an embodiment, adhesive may be applied using a specialized tool, an embodiment of which is depicted in FIGS. 18A-18D, and a method of use of which is shown in FIGS. 18E-18F. The depicted applicator is conceptually similar to a caulk gun, except that the adhesive is deposited using a specialized nozzle. The depicted nozzle has a generally cylindrical main body carrying extruded adhesive away from the supply tube, and directed it through a deposit head. The deposit head is a flatter, wide element having a plurality of openings for depositing adhesive, the central axis of the openings being generally parallel with the central axis of the cylindrical main body. A pair of guides are disposed on opposing sides of the deposit head. The distance between the guides is about the width of dimensioned lumber, such that they hold the deposit head in place laterally on the stud when in use. The applicator is then used in a manner similar to a caulk gun, and the plurality of holes in the deposit head evenly distribute roughly parallel rows of adhesive on the stud. In an embodiment, the deposit head may further comprise one or more inner guides, which are shown as fins disposed between adhesive openings, which stabilize a vertical distance between the deposit head and the stud to ensure the minimum flow of adhesive is adequate.
[0058] Throughout this disclosure, geometric terms may be used to characterize, among other things, sizes, shapes, dimensions, angles, distances, and relationships. These terms may be used with qualifiers such as generally, about, and approximately. One of ordinary skill in the art will understand that, in the context of this disclosure, these terms are used to describe a recognizable attempt to conform a device or component to the qualified term. By way of example and not limitation, components described as being generally coplanar will be recognized by one of ordinary skill in the art to not be actually coplanar in a strict geometric sense because a plane is a purely geometric construct that does not actually exist and no component is truly planer, nor are two components ever truly coplanar. Variations from geometric descriptions are unavoidable due to, among other things, manufacturing tolerances resulting in shape variations, defects, imperfections, non-uniform thermal expansion, natural wear, minor variations that are nevertheless recognizable as the qualified term, and other deformations. One of ordinary skill in the art will understand how to apply geometric terms, whether or not qualified by relative terms such as generally, about, and approximately, to describe a reasonable range of variations from the literal geometric term in view of these and other considerations appropriate to the context. Additionally, the use of the conjunctive and disjunctive should not necessarily be construed as limiting, and the conjunctive may include the disjunctive, and vice versa.
[0059] While the invention has been disclosed in conjunction with a description of certain embodiments, including those that are currently believed to be the preferred embodiments, the detailed description is intended to be illustrative and should not be understood to limit the scope of the present disclosure. As would be understood by one of ordinary skill in the art, embodiments other than those described in detail herein are encompassed by the present invention. Modifications and variations of the described embodiments may be made without departing from the spirit and scope of the invention.
