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 requiring locking washers to secure the insulation to the mounting bracket. 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 leg, a second leg, and at least one reinforcing member, wherein the middle portion extends between and connects the first leg and the second leg, wherein the first leg extends from the middle portion in a first direction, wherein the second leg extends from the middle portion in the first direction, and wherein the at least one reinforcing member extends from the middle portion in a second direction, the first direction and the second direction being opposite of one another.

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

3.-4. (canceled)

5. The mounting bracket of claim 1, wherein the first leg is perpendicular to the middle portion, and wherein the second leg is perpendicular to the middle portion.

6. (canceled)

7. The mounting bracket of claim 1, wherein the first leg includes a mounting flange that extends from and perpendicular to an end of the first leg.

8.-9. (canceled)

10. The mounting bracket of claim 1, wherein a depth of the second leg is greater than a depth of the first leg.

11.-12. (canceled)

13. The mounting bracket of claim 1, wherein the second leg includes a body having one or more barbs and a tapered end.

14. The mounting bracket of claim 13, wherein the body 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 differs from a number of the barbs on the opposite side of the body.

17. The mounting bracket of claim 13, wherein the second leg is symmetrical about a central axis of the body.

18. The mounting bracket of claim 1, wherein the at least one reinforcing member is perpendicular to the middle portion.

19. The mounting bracket of claim 1, wherein the at least one reinforcing member extends from the middle portion at an angle in the range of 45° to 90°.

20. The mounting bracket of claim 1, wherein the bracket body includes two reinforcing members spaced from one another by a distance that is less than or equal to a width of the middle portion.

21. The mounting bracket of claim 1, wherein a height of the at least one reinforcing member is less than a height of the middle portion, a depth of the first leg, and a depth of the second leg.

22. The mounting bracket of claim 1, wherein a height of the at least one reinforcing member is equal to a height of the middle portion.

23. The mounting bracket of claim 1, wherein a height of the at least one reinforcing member is less than or equal to a height of the middle portion and is more than half of the height of the middle portion.

24.-25. (canceled)

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

27. The mounting bracket of claim 1, wherein the bracket body is made of galvanized steel.

28. A curtain wall insulation system comprising: a plurality of mounting brackets; and a curtain wall insulation, wherein each mounting bracket comprises a bracket body having a middle portion, a first leg, a second leg, and at least one reinforcing member, wherein the middle portion extends between and connects the first leg and the second leg, wherein the first leg extends from the middle portion in a first direction, wherein the second leg extends from the middle portion in the first direction, and wherein the at least one reinforcing member extends from the middle portion in a second direction, the first direction and the second direction being opposite of one another.

29. The curtain wall insulation system of claim 28, wherein the curtain wall insulation system is free of a reinforcing member at a safing line of the curtain wall insulation system.

30. The curtain wall insulation system of claim 28, wherein a depth of the second leg is less than a depth of the curtain wall insulation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0050] 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:

[0051] FIG. 1 is a side sectional diagram of a representational portion of a conventional curtain wall insulation system.

[0052] 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.

[0053] FIGS. 3A and 3B illustrate the locking washer of FIG. 2C interfacing with the horizontal hanger of FIG. 2B.

[0054] FIGS. 4A and 4B illustrate the conventional insulation mounting system of FIGS. 2A-2C being used to mount curtain wall insulation.

[0055] 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 second leg of the mounting bracket. FIG. 5D is a front elevational view of the mounting bracket. FIG. 5E is a side elevational view of the mounting bracket.

[0056] FIG. 6 illustrates a portion of a test setup used to conduct a test in accordance with ASTM E2307-19 as described in the example of the present disclosure.

DETAILED DESCRIPTION

[0057] 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.

[0058] 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, the design of the unitary mounting brackets allow for installation of curtain wall insulation without the use or installation of a separate reinforcing member (e.g., T-shaped backer bar) as used in conventional insulation mounting systems. Accordingly, insulation can be mounted more quickly using the insulation mounting system of the present invention, as opposed to conventional insulation mounting systems.

[0059] 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.

[0060] The mounting bracket 500 includes a bracket body 502 that includes a middle portion 510, a first leg 520, a second leg 530, and at least one reinforcing member 540. The bracket 500 can be made of any suitable 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.

[0061] As seen in FIG. 5A, the middle portion 510 extends between and connects the first leg 520 and the second leg 530 to one another. In some exemplary embodiments, a height mp.sub.h of the middle portion 510 is greater than a depth fl.sub.d of the first leg 520 and a depth sl.sub.d of the second leg 530. In some exemplary embodiments, a depth mp.sub.d of the middle portion 510 is equal to a height fl.sub.h of the first leg 520 and a height sl.sub.h of the second leg 530. In some exemplary embodiments, a depth mp.sub.d of the middle portion 510 is equal to a height sl.sub.h of the second leg 530 and is less than a height fl.sub.h of the first leg 520.

[0062] The first leg 520 extends from the middle portion 510 in a direction forward of the middle portion 510, as seen in FIGS. 5A and 5E. In some exemplary embodiments, the first leg 520 is perpendicular to the middle portion 510. In some exemplary embodiments, the first leg 520 includes at least one aperture 522 therethrough to form a mounting hole. The at least one aperture 522 may be used to mount the bracket 500 to a support structure (e.g., mullion, transom) via a fastener (e.g., screw). In some exemplary embodiments, the first leg 520 includes a mounting flange 524 that extends from and perpendicular to an end of the first leg 520. In some exemplary embodiments, the mounting flange 524 includes an aperture 522 therethrough to form a mounting hole. In some exemplary embodiments, the aperture 522 extends through a depth fl.sub.d of the first leg. In some exemplary embodiments, the aperture 522 extends through a height fl.sub.h of the first leg. In some exemplary embodiments, the first leg 520 includes an aperture 522 that extends through a height fl.sub.h of the first leg and a mounting flange 524 having an aperture 522 that extends through a depth fl.sub.d of the first leg 520.

[0063] As seen in FIGS. 5A and 5E, the second leg 530 extends from the middle portion 510 in a direction forward of the middle portion 510. In some exemplary embodiments, (a central axis ca of) the second leg 530 is perpendicular to the middle portion 510. In some exemplary embodiments, a depth sl.sub.d of the second leg 530 is greater than a depth fl.sub.d of the first leg 520. In some exemplary embodiments, a height sl.sub.h of the second leg 530 is equal to a height fl.sub.h of the first leg 520 before the mounting flange 524. In some exemplary embodiments, a height sl.sub.h of the second leg 530 is less than a height fl.sub.h of the first leg 520. The second leg 530 includes a body 532 having one or more barbs 534. The body 532 includes a tapered end 536 beyond the barbs 534. The tapered end 536 facilitates passage of the second leg 530 into a piece of insulation, while the barbs 534 are operable to hold/secure the insulation on the second leg 530. The body 532 of the second leg 530 may function as a shelf-like ledge operable to support the weight of the insulation. In some exemplary embodiments, a depth sl.sub.d of the second leg 530 is less than a depth of a piece of insulation with which the mounting bracket 500 is used. Accordingly, in some exemplary embodiments, the second leg 530 does not extend completely through the insulation, which maintains the integrity of a facing of the insulation, if present. While the illustrated embodiment shows the same number of barbs 534 on each side of the body 532, the general inventive concepts are not so limited. In some exemplary embodiments, one or more barbs 534 are only on one side of the body 532. In some exemplary embodiments, the number of barbs 534 on one side of the body 532 differs from the number of barbs 534 on the other side of the body 532. While the illustrated embodiment shows the second leg 530 to be symmetrical about the central axis ca, the general inventive concepts are not so limited. In some exemplary embodiments, the size, shape, and/or positions of the barbs 534 differ on opposite sides of the central axis ca of the body 532.

[0064] As shown in FIG. 5C, in one specific exemplary embodiment, the body 532 of the second leg 530 includes four distinct barbs, i.e., a first barb 534-1, a second barb 534-2, a third barb 534-3, and a fourth barb 534-4. A size, shape, and angle of the first barb 534-1 and the second barb 534-2 are the same. A size, shape, and angle of the third barb 534-3 and the fourth barb 534-4 are the same. In this exemplary embodiment, at least one of the size, shape, and angle of the first and second barbs 534-1, 534-2 is different from that of the third and fourth barbs 534-3, 534-4. In this exemplary embodiment, the angle of at least the first and second barbs 534-1, 534-2 is 42 degrees. The general inventive concepts contemplate that the barbs 534 can have any angle suitable to hold the insulation once it is impaled on the second leg 530.

[0065] As mentioned above, the bracket body 502 includes at least one reinforcing member 540. The at least one reinforcing member 540 extends from the middle portion 510 in a direction rearward of the middle portion 510 (i.e., opposite the aforementioned forward direction). In some exemplary embodiments, the at least one reinforcing member 540 is a flange. In some exemplary embodiments, the at least one reinforcing member 540 extends from the middle portion 510 in a direction (or from a side) different and/or opposite than a direction (or side) that the first leg 520 and the second leg 530 extend from the middle portion 510. As seen in FIG. 5A, each of the reinforcing members 540 extend along a height dimension of the middle portion 510 and project outward along a depth dimension behind the middle portion 510, whereas the first leg 520 and the second leg 530 are extend across a width dimension of the middle portion 510 and project outward along a depth dimension in front of the middle portion 510. In other words, the at least reinforcing member 540 extends behind the middle portion 510 and the first leg 520 and the second leg 530 extend in front of the middle portion 510. In some exemplary embodiments, the at least one reinforcing member 540 is perpendicular (i.e., 90°) to the middle portion 510, as seen in FIG. 5B. In some exemplary embodiments, the at least one reinforcing member 540 extends from the middle portion 510 at an angle of less than or equal to 90°, such as at an angle in the range of 45° to 90°.

[0066] As shown in FIG. 5B, in one specific exemplary embodiment, the bracket body 502 includes two reinforcing members 540 extending from and perpendicular to the middle portion 510. In this exemplary embodiment, the two reinforcing members 540 are spaced from one another by a distance that is less than or equal to a width mp.sub.w, of the middle portion 510. In this exemplary embodiment, the reinforcing members 540 have a rectangular shape. The general inventive concepts contemplate that the bracket body 502 can have additional reinforcing members 540 extending from the middle portion 510 or a single reinforcing member 540 extending from the middle portion 510, preferably along a central axis of the middle portion. Furthermore, the general inventive concepts contemplate that the reinforcing member 540 can have any suitable shape, such as triangular, that allows the reinforcing member 540 to function as described herein.

[0067] In some exemplary embodiments, a height rm.sub.h of the reinforcing member 540 is less than a height mp.sub.h of the middle portion 510, a depth fl.sub.d of the first leg 520, and a depth sl.sub.d of the second leg 530. In some exemplary embodiments, a height rm.sub.h of the reinforcing member 540 is equal to a height mp.sub.h of the middle portion 510. In some exemplary embodiments, a height rm.sub.h of the reinforcing member 540 is less than or equal to a height mp.sub.h of the middle portion 510 but more than half of the height mp.sub.h of the middle portion 510 (i.e., 0.5mp.sub.h<rm.sub.h<mp.sub.h). In some exemplary embodiments, a height rm.sub.h of the reinforcing member 540 is less than a depth fl.sub.d of the first leg 520 but more than half of the depth fl.sub.d of the first leg 520 (i.e., 0.5fl.sub.d<rm.sub.h<fl.sub.d). In some exemplary embodiments, a height rm.sub.h of the reinforcing member 540 is less than a depth sl.sub.d of the second leg 530 but more than half of the depth sl.sub.d of the second leg 530 (i.e., 0.5sl.sub.d<rm.sub.h<sl.sub.d).

[0068] In some exemplary embodiments, a depth rm.sub.d of the reinforcing member 540 is less than a height mp.sub.h of the middle portion 510, a depth fl.sub.d of the first leg 520, and a depth sl.sub.d of the second leg 530. In some exemplary embodiments, a depth rm.sub.d of the reinforcing member 540 is less than a height rm.sub.h of the reinforcing member 540. In some exemplary embodiments, a depth rm.sub.d of the reinforcing member 540 is equal to a height rm.sub.h of the reinforcing member 540. In some exemplary embodiments, a depth rm.sub.d of the reinforcing member 540 is less than or equal to half of a height mp.sub.h of the middle portion 510 (i.e., rm.sub.d<0.5mp.sub.h). In some exemplary embodiments, a depth rm.sub.d of the reinforcing member 540 is less than or equal to three-quarters of a depth fl.sub.d of the first leg 520 (i.e., rm.sub.d<0.75fl.sub.d). In some exemplary embodiments, a depth rm.sub.d of the reinforcing member 540 is less than or equal to half of a depth sl.sub.d of the second leg 530 (i.e., rm.sub.d<0.5sl.sub.d).

[0069] The at least one reinforcing member 540 provides the bracket body 502 with greater structural integrity to resist deformation when acted on by external forces. In particular, when the mounting bracket 500 is used to install insulation (e.g., curtain wall insulation 102), the at least one reinforcing member 540 increases a depth of the mounting bracket 500 and provides at least one additional surface that is operable to bear against a support structure (e.g., mullion, transom) and thereby increase resistance to deformation by external forces, such as external forces exerted on a curtain wall insulation 102 due to the compression fit of a safing insulation 104. Accordingly, the mounting brackets 500 disclosed herein having at least one reinforcing member 540 can be used in a curtain wall insulation system 100 to prevent bowing or deformation of curtain wall insulation 102 due to the compression fit of the safing insulation 104 without the need for a separate reinforcement member (e.g., T-shaped backer bar 130) at or near the safing line.

[0070] In operation, one or more mounting brackets 500 are interfaced with a support structure (e.g., the mullion 152, the transoms 154, 156) in proximity to a location where insulation (e.g., the curtain wall insulation 102) is to be installed. More specifically, one or more mounting brackets 500 are secured to mullion 152 and transoms 154, 156 via fasteners, such as screws. After attaching the mounting brackets 500 to the mullion 152 and transoms 154, 156, curtain wall insulation 102 can be pressed onto the second leg 530 of each mounting bracket 500 such that the second leg 530 of each mounting bracket 500 penetrates the curtain wall insulation 102 such that a rear face of the curtain wall insulation abuts the middle portion 510 of each mounting bracket 500 and the barbs 534 on each second leg 530 effectively hold the curtain wall insulation 102 in place. The barbs 534 are suitable to secure the curtain wall insulation 102 to the mounting bracket 500 without the need for any additional structure (e.g., locking washers).

[0071] Alternatively, an insulation system incorporating the mounting brackets 500 of the present disclosure may be installed in a manner similar to an insulation system that utilizes the vertical hangers 210 and horizontal hangers 230 shown in FIGS. 2A and 2B. In particular, multiple mounting brackets 500 are interfaced with a portion of curtain wall insulation sized to fit within a curtain wall region (i.e., at least a portion of a region framed by a pair of parallel mullions and a pair of parallel transoms). More specifically, each mounting bracket 500 is pressed into the insulation so that a rear face of the insulation abuts the middle portion 510 of the mounting bracket 500, a side of the insulation abuts the first leg 520 of the mounting bracket 500, and the second leg 530 extends into, but not through, the insulation and the barbs 534 on the second leg 530 effectively secure the insulation to the mounting brackets 500. In this manner, the curtain wall insulation is interfaced with the mounting brackets 500.

[0072] Thereafter, the curtain wall insulation can be positioned and mounted in the curtain wall region. More specifically, a fastener (now shown), such as a screw, passes through the aperture 522 of each mounting bracket 500 to secure the mounting bracket 500 to a mullion or a transom. In this manner, the curtain wall insulation (e.g., curtain wall insulation 102) is mechanically secured within the curtain wall region. Typically, a piece of insulation (i.e., mullion cover) is then positioned over the mullion to protect it in the event of a fire. The mullion cover can be secured to the curtain wall insulation via fasteners, such as spiral screws or other separate mounting hangers/brackets.

[0073] It will be obvious to one of ordinary skill into the art, that any suitable number of the mounting brackets 500 can be used to secure the insulation (e.g., the curtain wall insulation 102) in the desired spaces.

[0074] Because the mounting bracket 500 operates to effectively install and affix the insulation without the need for locking washers and the like, the mounting bracket 500 allows for a simpler and quicker installation of fire perimeter insulation. Furthermore, because the mounting bracket 500 includes an integrated reinforcing member 540, there is no need to install a separate reinforcing member (e.g., T-shaped backer bar) required in conventional fire perimeter insulation systems and, thus, the mounting bracket 500 allows for a simpler and quicker installation of fire perimeter insulation.

Example

[0075] The following example illustrates the performance of mounting brackets according to the present disclosure as compared to conventional horizontal Impasse® insulation hangers (“conventional horizontal hangers”) available from Thermafiber, Inc. of Wabash, Ind., which are shown in FIG. 2B. This example is for purposes of illustration only and is not intended to limit the scope of the present disclosure.

[0076] In this example, a test was conducted in accordance with ASTM E2307-19 “Standard Test Method for Determining Fire Resistance of Perimeter Fire Barriers Using Intermediate-Scale, Multi-story Test Apparatus.” This test standard is intended to test for a system's ability to impede vertical spread of fire from a floor of origin to that above through a perimeter void, the void between an exterior wall assembly and a floor assembly.

[0077] As shown in FIG. 6, the test setup includes two identical pieces of mineral wool insulation 102, 102a (i.e., curtain wall insulation) attached to aluminum framing including mullions 152 and transoms 154. One piece of mineral wool insulation 102 was attached to the transom 154 using five mounting brackets 500 according to the present disclosure and two conventional vertical hangers 210 to attach the mineral wool insulation 102 to the mullions 152. The other piece of mineral wool insulation 102a was attached to the transom 154 using five conventional horizontal hangers 230 and two conventional vertical hangers 210 to attach the mineral wool insulation 102a to the mullions. The spacing of the five mounting brackets 500 attached to transom 154 and the spacing of the five conventional horizontal hangers 230 attached to transom 154 was identical. In addition, the mounting brackets 500 and the conventional horizontal hangers 230 were made of the same material and had the same thickness.

[0078] After conducting the test in accordance with ASTM E2307-19, it was observed that the mounting brackets 500 held its insulation 102 in place better than the conventional horizontal hangers 230 held its insulation 102a in place. This was observed by how much each piece of insulation 102, 102a sagged or drooped after being exposed to the fire test conditions at three points. When the insulation 102, 102a sags, gaps can be created in void material (i.e., safing insulation) that, if large enough, may allow flames to pass through causing the fire to spread. The first point corresponded to the edges of the mineral wool insulation 102, 102a adjacent the center mullion 152, the second point corresponded to the first mounting bracket 500 and the first conventional horizontal hanger 230 spaced from the center mullion 152, and the third point corresponded to the second mounting bracket 500 and the second conventional hanger 230 spaced from the center mullion. The sag at the first point for the mineral wool insulation 102 attached with the mounting brackets 500 was about 0.4 inches, whereas the sag at the first point for the mineral wool insulation 102a attached with the conventional horizontal hangers 230 was about 1 inch. The sag at the second point for the mineral wool insulation 102 attached with the mounting brackets 500 was about 0.4 inches, whereas the sag at the second point for the mineral wool insulation 102a attached with the conventional horizontal hangers 230 was about 0.8 inches. The sag at the third point for the mineral wool insulation 102 attached with the mounting brackets 500 was about 0.3 inches, whereas the sag at the third point for the mineral wool insulation 102a attached with the conventional horizontal hangers 230 was about 0.7 inches.

[0079] These results indicate that the mounting brackets 500 of the present disclosure maintain their shape and strength under fire exposure conditions better than the conventional horizontal hangers 230. In addition, these results indicate that the mounting brackets 500 of the present disclosure can provide a safer curtain wall insulation system than the conventional horizontal hangers 230 because the insulation is less likely to sag or droop, which reduces the ability of a fire to spread.

[0080] 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.