Abstract:
A device and method for mounting an exterior cantilevered beam to a building holds the exterior cantilevered beam away from the building and provides superior waterproofing. In some embodiments, a strap member is used to spread loading forces onto interior building support members that are arranged perpendicular to an exterior wall of the building. In other embodiments of the invention, mounting members that include necks extending through exterior walls and away from the walls are used to mount an exterior cantilevered beam to the building, and to keep the exterior beam supported away from the exterior wall.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention is directed to methods and apparatus for attaching an exterior cantilevered beam to a building. 
     2. Background of the Related Art 
     FIG. 1 shows a deck  50  attached to an exterior wall  40  of a building. The deck  50  includes cantilevered supporting beams  54 , and a handrailing  56 . The most common way to attach the deck  50  to the exterior wall  40  of the building, is to first attach a support plate  52  to the exterior wall  40  of the building. The support plate  52  can be attached to the exterior wall  40  using lag bolts, nails, or other suitable methods. Typically, the support plate  52  is simply attached to an interior support beam  58 , such a rim-joist or floor-joist. 
     The weight of the deck itself, and the weight of any articles or people that are placed on the deck  50  create a force F 1  which pushes the deck downward. Because the left end of the deck is attached to the building, the force F 1  also creates a rotational moment M. The moment M results in the support beams  54  applying separate and opposed forces to the support plate  52 . A first force F 2  pushes in at the bottom of the support plate  52 , and a second force F 3  pulls the support plate  52  away from the wall of the building  40 . 
     Because the support plate  52  on the exterior of the building is attached to the support member  58  inside the building, the two forces F 2  and F 3  tend to rotate the exterior support plate  52  and the interior support member  58 . This can cause warping, and stresses that adversely affect the exterior wall  40  and any interior floor that rests on the interior support member  58 . 
     In addition, because the support plate  52  is directly attached to the exterior wall  40  of the building, small gaps between the exterior wall  40  and the support plate  52  can hold water or moisture for long periods of time. Any fasteners used to attach the exterior support plate  52  to the exterior wall  40  of the building can provide a pathway that allows water and moisture to pass into the building  40 . The moisture that collects between the support plate  52  and the exterior wall  40 , and any moisture that passes into the building, can cause rotting, and other negative consequences which adversely affect the structural integrity of the building. 
     SUMMARY OF THE INVENTION 
     Devices and methods embodying the present invention are intended to overcome one or more of the disadvantages of prior art methods for attaching a deck or balcony to an exterior of building. 
     Devices and methods embodying the invention spread the loading forces applied to interior support members of a building by an exterior deck or balcony to those interior support members that are best able to withstand the forces. 
     Methods and devices embodying the invention can also improve the waterproof integrity of the exterior wall of the building at the point where a deck or balcony is attached to the exterior wall. 
     In addition, devices and methods embodying the invention result in an exterior deck or balcony being held a small distance away from an exterior wall of the building such that water and moisture will not collect in apertures formed between the deck or balcony and the exterior wall of the building. 
     A mount embodying the invention, for attaching an exterior cantilevered beam to a building, may include upper and lower bolts that pass through an exterior wall of the building, and through a first interior support member having a length axis that is arranged substantially parallel to the exterior wall of the building. Ends of the upper and lower bolts that penetrate the exterior wall and extend beyond the wall are configured to be attached an exterior cantilevered beam. The mount also includes a strap that is attached to the upper bolt and to a second interior support member having a length axis that runs substantially perpendicular to the exterior wall of the building. 
     A second embodiment of the present invention may include a mounting member having a flat base, a neck that extends from the flat base, and a substantially straight bore that passes through the neck and the flat base. The flat base of the mounting member is configured to be attached to an interior support member of a building such that the neck of the mounting member extends through a hole in an exterior wall of the building. A screw can then be used to attach an exterior cantilevered beam to the mounting member. The screw would pass through the bore of the mounting member and into the interior support member. The screw may include threads that cooperate with threads formed on an interior bore of the mounting member. 
     A method, embodying the invention, for creating a mount for an exterior cantilevered beam, may include the steps of creating upper and lower holes that extend through an exterior wall of a building, and through a first interior support member having a length axis that is substantially parallel to the exterior wall. The method would also include a step of attaching a strap to a second interior support member having a length axis that is arranged substantially perpendicular to the exterior wall. Next, an upper bolt would be inserted through the upper hole, and through a hole in the strap. A lower bolt would be inserted through the lower hole. A plurality of nuts would then be threaded onto the upper and lower bolts. An exterior cantilevered beam could then be attached to ends of the upper and lower bolts that extend through the exterior wall. 
     A second method, embodying the invention, for forming a mount includes the steps of: forming a hole through an exterior wall of a building, attaching a mounting member to an interior support member, and providing a screw that is configured to be attached to the mounting member. In this method, the mounting member would include a flat base, a neck that extends from the flat base, and a substantially straight bore that passes through the neck and through the flat base. In some embodiments, the screw may have threads that are intended to connect with threads formed on an interior of the bore. In other embodiments, the screw may pass completely through the bore, and the threads may attach to an interior support member behind the mounting member. In still other embodiments, the threads may connect with both threads on the bore and with the interior support member. 
     Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objects and advantages of the invention may be realized and attained as particularly pointed out in the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Preferred embodiments of the invention will be described in conjunction with the following drawing figures, wherein like elements are referred to with like reference numbers, and wherein: 
     FIG. 1 is an elevation view showing a deck attached to an exterior of a building; 
     FIG. 2 is an elevation view showing mounting details for a first embodiment of the invention; 
     FIG. 3 is a plan view of the first embodiment of the invention; 
     FIG. 4 is a plan view showing how support members for an exterior balcony may be connected to a building using embodiments of the invention; 
     FIGS. 5A and 5B are top and front views of a mounting member embodying the invention; 
     FIG. 6 is a side view of a mounting member embodying the invention attached to a beam; and 
     FIG. 7 is an elevation view showing an additional embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     For purposes of the following description, and in the claims, the term “bolt” is used to refer to an item that is used to hold two items together. This term should be interpreted to cover any type of fixation device that performs the function of a typical bolt. 
     The first mounting system embodying the invention is shown in FIGS. 2 and 3. The mounting system is used to attach an exterior cantilevered beam to an exterior side of a building. The exterior cantilevered beam could be used as a structural member of a outdoor deck or balcony, or for other structural purposes. 
     In the elevation view shown in FIG. 2, an exterior cantilevered beam  90  is attached to an exterior of a building. The mounting system passes through a first interior support member  62   a - 62   b , as well as exterior wall  60  of the building. The first interior support member  62   a - 62   b  is used with a second interior support member  66  to support an interior floor  110  of the building. A threshold  112  is located in a doorway which opens onto an outdoor deck  92  formed on the exterior cantilevered beam  90 . 
     The exterior cantilevered beam  90  is attached to an upper bolt  74  and a lower bolt  76 . The ends of the upper and lower bolts  74 ,  76  protrude from the exterior wall  60  of the building. The upper and lower bolts  74 ,  76  are attached to the first interior support member  62   a - 62   b . In addition, the upper bolt  74  is also attached to the second interior support member  66 . 
     The first interior support member includes a first board  62   a  and a second board  62   b . These boards can be interior rim-joists, or normal floor-joists. Although the embodiment shown in FIG. 2 includes two boards, in other embodiments, only a single interior rim-joist  62   b  might be present. In embodiments like the one shown in FIG. 2, the second board  62   a  could be a part of the structural support system for the floor  110 , or the second board  62   a  could be added at the time the mounting bolts are installed. The use of the second mounting board  62   a  would provide increased rigidity and structural integrity to the mounting system. In still other embodiments, a third support beam that runs parallel to the two boards  62   a - 62   b , could be added for even more increased structural rigidity. In any event, in the embodiment shown in FIGS. 2 and 3, the two boards together form a first interior support member  62   a - 62   b . The first interior support member  62   a - 62   b  has a longitudinal axis that is arranged parallel to the exterior wall  60  of the building. 
     The second interior support member  66  has a longitudinal axis that runs perpendicular to the exterior wall  60  of the building. The second interior support member  66  could be a normal floor joist used to support the interior floor  110  of the building. In other embodiments, like the one shown in FIG. 3, the second interior support member  66  could be a board bridging two interior floor joists. In the embodiment shown in FIG. 3, the second interior support member  66  is simply a board which is attached between a first floor joist  62   b , which is actually a rim joist, and a second floor joist  68 . 
     An L-shaped strap member  100  is attached to the second interior support member  66 . The L-shaped strap member  100  includes a first, long leg which is arranged along the second interior support member  66 . A plurality of nails  102  are used to attach the L-shaped strap member  100  to the second interior support member  66 . A short leg of the L-shaped strap member  100  lies along the first interior support member  62   a - 62   b . A hole is formed through the short leg of the L-shaped strap member  100 . The upper bolt  74  passes through the hole in the short leg in the L-shaped strap member  100 , then through a hole in the first interior support member  62   a - 62   b , and then through a hole in the exterior wall  60 . The end of the bolt  74  protrudes from the exterior wall  60 . Similarly, the lower bolt  76  passes through a hole in the first interior support member  62   a - 62   b , and through a hole in the exterior wall  60 . The end of the lower bolt  76  also protrudes from the exterior wall  60 . 
     In the embodiment shown in FIGS. 2 and 3, a first flange  72   a  is positioned between the heads of the bolts  74 ,  76  and an interior side of the first interior support member  62   a - 62   b . A second flange  72   b  is positioned on the outer side of the first interior support member  62   a - 62   b . The upper bolt  74  and the lower bolt  76  pass through holes in the first and second flanges  72   a ,  72   b . Nuts  80  are threaded onto the upper and lower bolts  74 ,  76  and the nuts adjacent the second flange  72   b  served to sandwich the first interior support member  62   a - 62   b  between the first flange  72   a  and the second flange  72   b.    
     Additional nuts may be threaded onto the upper and lower bolts  74 ,  76  such that the additional nuts extend from the second flange  72   b  through the exterior wall  60 . In the embodiment shown in FIG. 2, the third nut  80  on each of the upper and lower bolts  74 ,  76  forms a bearing surface which will hold the exterior cantilevered beam  90  away from the exterior wall  60 . 
     A third flange  72   c  and a fourth flange  72   d  are then sandwiched on either side of the end plate of the exterior cantilevered beam  90 . Additional nuts  80  are threaded onto the ends of the upper and lower bolts  74 ,  76  to trap the cantilevered beam  90  between the third and fourth flanges  72   c ,  72   d . As a result, the exterior cantilevered beam  90  is held away from the exterior wall  60 . 
     As mentioned above, weight placed on the exterior cantilevered beam  90  tends to cause a first force which would press the bottom of the exterior cantilevered beam against the exterior wall  60 . Thus, the cantilevered beam  90  tends to push the lower bolt  76  into the building. In addition, a second force tends to pull the top of the exterior cantilevered beam  90  away from the exterior wall  60 . Thus, the cantilevered beam tends to pull the upper bolt  74  away from the building. 
     Because the upper bolt  74  is attached to the L-shaped strap member  100 , the force applied to the upper bolt  74  by the exterior cantilevered beam  90  will be spread to the second interior support member  66 , which has a longitudinal axis that is arranged perpendicular to the exterior wall. This helps to better spread the forces applied by the exterior cantilevered beam  90  among the interior support members so that the first interior support member  62   a - 62   b  is less likely to be twisted or warped out of position. 
     In addition, because the exterior cantilevered beam  90  is held away from the exterior wall  60 , an air gap will exist between the exterior wall  60  and any deck or balcony that is formed on top of the exterior cantilevered beam  90 . This helps to prevent the collection of moisture against the exterior wall  60 , which prevents rot or mildew from occurring in the exterior wall  60 . Further, a waterproofing material, such as a caulk  67 , may be placed in the holes passing through the exterior wall  60  and around the upper and lower bolts  74 ,  76 . The caulking material  67  helps to prevent water or moisture from entering the building through the holes penetrating the exterior wall  60 . 
     A plan view of several different exterior cantilevered beams  90  attached to an exterior wall  60  of the building is shown in FIG.  4 . In the arrangement shown in FIG. 4, a plurality of floor joists  66  are located in the interior of the building, and a longitudinal axis of each of the floor joists  66  is arranged perpendicular to the exterior wall  60 . A rim joist  62   b  runs along the interior of the wall  60 . The wall of the building can include a sheath or insulation layer  61 , as well as an exterior finish layer  60 , such as stucco or siding. 
     In the arrangement shown in FIG. 4, four exterior cantilevered beams  90  are connected to additional beams  94  to form the basis of an exterior deck. In addition, upright support posts  96  can be attached to the exterior cantilevered beams  90 , or the additional support members  94 . The upright support posts  96  can be used to create a hand railing. Planking or other types of decking material can be attached to the cantilevered beams  90  and the additional beams  94  to create the floor of the deck or balcony. 
     An L-shaped strap member  100  is attached to the upper bolts holding each of the exterior cantilevered beams  90  to the building. The long-legs of the L-shaped strap members  100  are then attached to an interior support member having a length axis arranged perpendicular to the exterior wall. However, as shown in FIG. 4, the exterior cantilevered beams  90  do not always align with floor joists that have a length axis that is perpendicular to the exterior wall. For this reason, it may necessary to add additional interior support members to the existing floor joists so that the L-shaped strap members  100  can be properly connected. 
     In the arrangement shown in FIG. 4, the rightmost exterior cantilevered beam  90  is aligned with a floor joist  66  having a length axis that is perpendicular to the exterior wall  60 . An L-shaped strap member  100  is nailed to the interior floor joist  66  with a plurality of nails  102 . A bolt then passes through the short leg of the L-shaped strap member  100  and the end of the bolt is connected to the exterior cantilevered beam  90 . 
     In the case of the exterior cantilevered beam  90  second from the right, the exterior cantilevered beam  90  is not properly aligned with an interior floor joist  66 . For this reason, it is necessary to add an additional board  69   a  on one side of the interior floor joist  66  so that the L-shaped strap member  100  can be properly aligned with the end of the exterior cantilevered beam  90 . The long leg of the L-shaped strap member  100  is then nailed to both the interior floor joist  66  and the first board  69   a . A bolt passes through the short leg of the L-shaped strap member  100  and the end of the bolt is attached to the exterior cantilevered beam  90 . 
     In the case of the exterior cantilevered beam  90  second from the left, two additional boards  69   a ,  69   b  must be attached to an interior floor joist  66  so that the L-shaped strap member  100  can be properly aligned with an end of the exterior cantilevered beam  90 . 
     In the case of the left-most exterior cantilevered beam  90 , the exterior cantilevered beam  90  is even further offset from any of the existing interior floor joists  66 . In this instance, a bridge member  120  is first attached between adjacent interior floor joists  66 . A support member  114  is then attached between the bridge member  120  and the rim joist  62   b . The long leg of the L-shaped strap member  100  is then nailed to the support member  114  with a plurality of nails  102 . This allows the exterior cantilevered beam  90  to be mounted to the L-shaped strap member  100  with an upper bolt  74 , even though the exterior cantilevered beam  90  is located between two interior floor joists  66 . 
     A second device and method for attaching an exterior cantilevered beam to a building is done with the support member shown in FIGS. 5A and 5B. As shown in these figures, the support member  130  includes a flat base  138 . In the embodiment shown in FIGS. 5A and 5B, the flat base  138  is square. However, the flat base  138  could also be round, or have other shapes. 
     A plurality of apertures  132  pass through the flat base  138 . The apertures  132  are configured to allow fasteners to pass therethrough so that the support member can be attached to a support member of a building. A neck  136  is formed on the support member  130 , the neck extending away from the flat base  138 . A bore  134  passes down through the center of the neck  136 , and through the flat base  138 . The interior of the bore  134  may be threaded. 
     FIG. 6 shows an end flange of an exterior cantilevered beam  90  attached to the top of the neck  136  of a mounting member  130 . The end of exterior cantilevered beam  90  is sandwiched between two washers or flanges  78 . A bolt  140  passes through the washers or flanges  78 , the exterior cantilevered beam  90  and into the bore  134  of the mounting member  130 . Threads on the bolt  140  cooperate with the threads on the inside of the bore  134  to firmly hold the exterior cantilevered beam  90  against the end of the neck  136 . 
     A mounting arrangement using two mounting members  130  to attach an exterior cantilevered beam  90  to an exterior of a building is shown in FIG.  7 . As shown therein, upper and lower mounting members  130  are attached to an interior support member  62   a - 62   b  with a plurality of fasteners  64  which pass through apertures in the flat bases of the mounting members  130 . The fasteners  64  could be nails, screws, or any other type of fastener capable of firmly attaching the flat base  138  of the mounting member  130  to the interior support member  62   a - 62   b . The neck  136  of the mounting member  130  then protrudes through holes formed in an exterior wall  60  of the building. The ends of the necks  136  extend out away from the exterior wall  60 . 
     An exterior cantilevered beam  90  is then attached to the mounting members  130 , and to the interior support member  62   a - 62   b , with lag bolts  140  or any other suitably shaped screw. The lag bolts  140  may include threads that cooperate with threads on interior bores of the mounting members  130 . In addition, the threads on the lag bolts  140  may also screw into the interior support member  62   a - 62   b  to better attach the exterior cantilevered beam  90  to the building. A waterproofing material  67 , such as caulk, is then placed in the holes in the exterior wall  60  around the necks  136  of the mounting members  130 . The caulking  67  prevents water or moisture from passing into the building though the holes in the exterior wall  60 . 
     Because the necks  136  of the mounting members  130  protrude out away from the exterior wall  60 , the end of the cantilevered beam  90  is held away from the exterior wall  60 . As mentioned above, this helps to prevent the collection of water or moisture against the exterior wall  60 . In addition, the mounting members  130  allow an exterior deck or balcony to be attached to the exterior wall of the building long after construction of the building has been finished. The mounting members  130  can be attached to the interior support member  62   a - 62   b  before the exterior wall  60  of the building is finished. After the mounting members  130  have been attached, the exterior wall  60  of the building can be formed around the necks  136  of the mounting members  130 . The waterproofing material  66  can be inserted or applied around the necks of the mounting members to insure that a waterproof seal is maintained. Then, after the building has been finished, an exterior deck or balcony can be mounted by attaching the exterior cantilevered beam  90  to the mounting members using the lag bolts  140 . 
     In the arrangement shown in FIGS. 2 and 3, the upper and lower bolts  74 ,  76  can be mounted to the first interior support member  62   a - 62   b  and the second interior support member  66  before the building is completed. Then, an exterior wall  60  can be formed around the upper and lower bolts  74 ,  76 . Waterproofing caulk or other materials  66  can be placed in the holes of the exterior wall  60  to ensure that a waterproof seal is maintained. The protruding ends of the upper and lower bolts  74 ,  76  can then be left in place until such time as an exterior deck or balcony is to be mounted to the building. 
     In the embodiments described above, two bolts have been used to attach an exterior cantilevered beam to a building. However, in particular embodiments of the invention, only a single bolt can be used at the top of an exterior cantilevered beam, or more than two bolts can be used. Also, the number of nuts that are used with the bolts in an embodiment as shown in FIGS. 2 and 3 could be different. 
     Further, although the embodiment shown in FIG. 7 utilizes lag bolts  140  that penetrate both a mounting member  130  and portions of an interior support member, in other embodiments of the invention, the lag bolt may only extend into the mounting member  30 . Further, in still other embodiments like the ones shown in FIG. 7, a bolt could pass completely through a mounting member  130  without interacting with interior threads on the mounting member, and then attach to an interior support member. 
     The foregoing embodiments are merely exemplary and are not to be construed as limiting the present invention. The present teaching can be readily applied to other types of apparatuses. The description of the present invention is intended to be illustrative, and not to limit the scope of the claims. Many alternatives, modifications, and variations will be apparent to those skilled in the art. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. For example, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure parts together, whereas a screw employs a helical surface, in the environment of fastening parts, a nail and a screw may be equivalent structures.