Conduit support bracket system

A conduit support bracket is provided. The support bracket has an elongated base that can be secured to a pair of adjacent joists having a space between the joists. The support bracket has a vertical support arm secured to the base at one end of the arm. The length of the support arm is adjustable. A support platform is secured to the opposite end of the support arm. The support platform can be rotated both horizontally and vertically to adjust the orientation of the support platform. As many support brackets as needed may be used at intervals to support a length of conduit in an elevated position above joists.

FIELD OF THE INVENTION

The present invention relates generally to a system of support brackets for supporting conduit such as air ducts.

BACKGROUND

When constructing buildings such as residential homes or commercial properties, conduit such as air ducts are typically installed in an enclosed space above the ceiling of the building or home. Conduit installation typically occurs during construction of the frame of the structure before sheetrock or insulation have been installed. The conduit generally runs above a series of parallel joists that support the ceiling of the structure. Due to building codes that may require a specified amount of space above the ceiling for insulation, conduits such as air ducts are typically installed two to three feet above ceiling joists. In order to support air ducts in an elevated position above the joists, builders typically construct supporting wooden structures on an ad hoc basis for each construction job. This additional construction step is time consuming and inefficient and thus adds to the overall construction cost.

Accordingly, a need exists in the art for a conduit support bracket system that provides quick, simple installation of support structures for supporting conduit such as air ducts in an elevated position above ceiling joists.

SUMMARY

In accordance with the present invention, a conduit support bracket system is provided. The system comprises a plurality of individual support brackets that may be used in combination to support a length of conduit such as an air duct. Each support bracket comprises an elongated base, a vertical support arm secured to the base, and a support platform secured to the support arm. The base is configured to secure the base to a pair of adjacent and generally parallel joists having a space between the joists, which typically ranges from 16 inches to two feet. The base of the support bracket spans the space between the joists and may be bolted, screwed, or otherwise fastened to each of the joists in order to secure the base to the two adjacent joists. The support arm extends upwardly from the base in a direction generally perpendicular to the base. The length of the support arm is adjustable such that the height of the support platform may be adjusted.

The support platform preferably has an elongated shape and has an upper surface on which conduit may be supported. In a preferred embodiment, the support platform is configured to rotate in a horizontal direction. Thus, the elongated support platform may be set in a position generally parallel to the elongated base or may be rotated so that the platform and base are at any desired angle up to a 90-degree angle. In a preferred embodiment, the support platform is also configured to rotate in a vertical direction. Thus, the support platform may be rotated such that the upper surface of the support platform remains in the horizontal plane to ensure a level surface for supporting conduit even if the base is not level. The support bracket has locking mechanisms, which are preferably locking clamps, that lock the support platform in a fixed position after the height and the orientation of the support platform have been adjusted as necessary by the user.

The support brackets of the present bracket support system allow quick and easy installation of conduit during construction without the need for ad hoc construction of supporting structures for elevating conduit above ceiling joists. Because the orientation and general positioning of the support platform of each support bracket may be adjusted, the present system provides versatility in installing conduit in any desired configuration during the construction of any residential or commercial structure.

Accordingly, one object of the present invention is to provide a support bracket system suitable for supporting a length of conduit such as an air duct in an elevated position above ceiling joists.

DETAILED DESCRIPTION

The term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” components A, B, and C can contain only components A, B, and C, or can contain not only components A, B, and C, but also one or more other components.

In accordance with the present invention, a conduit support bracket system is provided. The system comprises a plurality of individual support brackets that may be used in combination to support a length of conduit, such as an air duct, piping, or similar type of conduit.FIGS. 1 and 2illustrate two support brackets20supporting an air duct100in an elevated position above a pair of adjacent, generally parallel wooden joists200.FIG. 3illustrates two support brackets20without the air duct for ease of illustrating the brackets.

Each support bracket20comprises an elongated base22, a support arm24, and a support platform26. The elongated base22is configured to secure the base22to joists200that have a space between the joists. Joists typically have a spacing of at least one foot. In many structures, joists have a standard spacing, which is typically 16 inches or two feet of spacing between adjacent joists. The elongated base22spans the space between the joists200and may be bolted, screwed, or otherwise fastened to each of the joists200in order to secure the base22to the joists200. The base22preferably has holes extending therethrough for fastening the base22to joists200using screws or bolts. In a preferred embodiment, the base22has a set of holes that are 16 inches apart and another set of holes that are two feet apart. As shown inFIGS. 1-3, the base22is fastened to adjacent joists200that are 16 inches apart by a pair of lag bolts screwed into an inner set of holes that are 16 inches apart. The outer set of holes of the base22shown inFIGS. 1-3are preferably two feet apart. To secure the base22to joists having different spacing, the inner hole on one side of the base may be utilized in combination with an outer hole on the opposite side of the base. Additional holes may also be drilled through the base22if existing holes are not spaced appropriately.

The support bracket20may further comprise at least one fastener adapted for use with the base22for securing the base22to joists200. In a preferred embodiment, the fastener may be a lag bolt, as shown inFIGS. 1-3, a screw, or any other fastener suitable for securing the base22to wooden joists200or to joists made of other materials, which may have pre-drilled holes. In other embodiments, the fastener may comprise at least one U-bolt sized to fit around a joist for securing the base to the joist.

As shown inFIG. 3, the support arm24has a first end secured to the base22, and the support platform26is secured to a second end of the support arm24. The support arm24extends upwardly from the base22in a direction generally perpendicular to the base. The support arm24is in a generally vertical position when the support bracket20is in an upright position, as shown inFIG. 3.

The length of the support arm24is adjustable such that the height of the support platform26may be adjusted. In one embodiment, as shown inFIGS. 1-5, the support arm24comprises an extension rod38slidably disposed within a tube40such that the support arm24is extendable by sliding the extension rod38out of the tube40and collapsible by sliding the extension rod38into the tube40. In this embodiment, the tube40is secured to the base22and extends upwardly from the base22in a direction generally perpendicular to the base, and the support platform26is secured to one end of the extension rod38that is disposed outside of the tube40.

As best seen inFIGS. 4 and 5, the support bracket20further comprises an arm clamp34configured to lock the extension rod38in a fixed axial position within the tube40such that the extension rod cannot slide into or out of the tube40. Thus, when the arm clamp34is in an open configuration, as shown inFIG. 4, the extension rod38can be moved freely into or out of the tube40in order to adjust the length of the support arm24, which accordingly adjusts the height of the support platform26. When the height of the support platform26is adjusted as desired, the arm clamp34may be moved to a closed configuration, as shown inFIG. 5. When in a closed configuration, the extension rod38is locked in place and cannot move into or out of the tube40.

The support platform26preferably has an elongated shape and has an upper surface on which conduit100may be supported, as best seen inFIG. 3. In a preferred embodiment, the support platform26is configured to rotate horizontally. Thus, the elongated support platform26may be set in a position generally parallel to the elongated base22or may be rotated so that the support platform26and base22are at any desired angle.FIG. 10illustrates two support brackets20with each respective support platform26horizontally rotated in a counterclockwise direction (from a top view perspective), as indicated by the arrows inFIG. 10. The support platform26may be rotated horizontally by rotating the extension rod38within the tube40. When the arm clamp34is in a closed configuration, the arm clamp34locks the extension rod38in a fixed rotational position such that the extension rod38cannot be rotated within the tube40, as well as locking the extension rod38in a fixed axial position within the tube40. The horizontal rotation of the support platform26allows the brackets20to be used to support an air duct100running parallel to ceiling joists200, as shown inFIG. 1, or running at any angle to the joists, such as a 45-degree or a 90-degree angle.

In an alternative embodiment, as shown inFIG. 6, the support arm24is a telescoping arm comprising segments of varying diameter. In this embodiment, the telescoping support arm24may have one or more rotating locks42configured to lock a segment of the support arm24in a fixed axial position relative to an adjacent segment by turning a rotating lock42in a defined direction. Turning the rotating lock42in the opposite direction releases the corresponding segment such that the length of the support rod24may be adjusted to a desired length. A telescoping support arm with multiple segments may be advantageous in application in which an air duct needs to be supported at a height of four feet or higher.

In a preferred embodiment, the support platform26is further configured to rotate vertically. Thus, the support platform26may be rotated such that an upper surface of the support platform26remains in the horizontal plane, as shown inFIG. 3, to ensure a level surface for supporting conduit100. In some applications, such as shown inFIG. 11, adjacent joists200may not be at exactly the same level or height, as indicated by the dashed lines inFIG. 11. In such cases, the upper surface of the support platform26may be leveled by rotating the support platform26in a vertical direction.FIG. 11illustrates two support brackets20with each respective support platform26vertically rotated in a clockwise direction (looking left to right), as indicated by the arrows inFIG. 11. In this embodiment, the connection between the extension rod38and the support platform26is hinged to allow vertical rotation of the support platform26. In this embodiment, the support bracket20further comprises a platform clamp36configured to lock the support platform26in a fixed vertical rotational position such that the support platform26cannot rotate about its hinged connection to the extension rod38. The platform clamp36functions similarly to the arm clamp34described previously. When the platform clamp36is in an open configuration, the support platform26may be rotated freely in a vertical direction. When the platform clamp36is in a closed configuration, the support platform26is locked in a fixed position with respect to vertical rotation, though the support platform26may still be rotated horizontally and the length of the support arm24may still be adjusted utilizing the arm clamp34.

In a preferred embodiment, the support platform26is elongated and has two ends each having an upwardly extending edge46, as shown inFIG. 9. The edges46at each end of the support platform26prevent a conduit such as an air duct100from potentially sliding off of the support platform26. As shown inFIGS. 1 and 2, when installing a length of conduit100, the conduit is positioned such that it lays on the support platform26in a direction generally perpendicular to the elongated support platform26.

In a preferred embodiment, as best seen inFIGS. 3 and 8, the elongated base22has a longitudinally configured slot28therethrough. In this embodiment, the lateral position of the support arm24is adjustable by laterally sliding the end of the support arm24secured to the base22along the length of the slot28in a desired direction. In a preferred embodiment, as best seen inFIGS. 3 and 7, the tube40is secured to the base22via a base plate30having fasteners extending through the slot28. Thus, the tube40, along with the base plate30, may slide laterally within the length of the slot28. The fasteners prevent the tube40from detaching from the base22but are not tightened in a manner that would prevent the tube40from sliding laterally within the slot28. In this embodiment, the support bracket20comprises at least one, and preferably two, base clamps32configured to lock the support arm24in a fixed lateral position on the base22, as best seen inFIG. 8, such that the support arm24cannot slide laterally. When the base clamps32are in an open configuration, the support arm24may slide freely along the length of the slot28in order to adjust the lateral position of the support arm. When the base clamps32are in a closed configuration, the lateral position of the support arm24on the base22is fixed. Lateral adjustment of the support arm24, and thus the support platform26, provides added flexibility in the positioning of an air duct100to be supported by the support brackets20.

The base clamps32, arm clamp34, and platform clamp36, are each preferably a manually operated toggle clamp having a clamping surface (not shown) that applies inward pressure on the base22, on the extension rod38, and on a plate attached to the support platform26, respectively, when in a closed configuration. However, it should be understood that any type of locking clamp suitable for locking each respective component of the support bracket in a fixed position may be utilized.

As shown inFIG. 7, the base22may optionally have side braces44to provide additional support for the base plate30as the base plate slides along the length of the slot28.

To use the present conduit support bracket system, a plurality of support brackets20are secured to joists200in a spaced manner to provide a series of support platforms26that provide support for a continuous length of conduit in an elevated position above the joists. For ease of illustration,FIGS. 1 and 2show only a short length of an air duct100supported by two brackets20secured to adjacent joists200. The support brackets may be secured to the joists in any suitable manner, but are preferably screwed or bolted to the joists. One each of the support brackets20are secured to the joists in a desire location, the orientation and positioning of each support platform26may be adjusted by rotating the support platform26vertically and/or horizontally, by adjusting the height of the support platform26, and/or by adjusting the lateral positioning of the support platform26relative to the base22. The length of the support arm24of each of the support brackets20may be adjusted such that each of the support platforms26is at approximately the same level in order to provide a level horizontal plane of support for the conduit. Once the positioning and the orientation of each support platform26is set as desired, the conduit may be positioned on the upper surface of the support platform26of each of the support brackets20such that the length of the conduit is supported by the plurality of support brackets20. After adjustments are made to each of the brackets20, the conduit preferably rests on the upper surface of each support platform26in a position generally perpendicular to each support platform26. Each of the support platforms26preferably has an upwardly extending edge46, as shown inFIG. 9. In this case, the conduit100is positioned between the edges46to prevent the conduit from sliding off of any of the support platforms26.

In an alternative embodiment, the length of the support platform26may be adjustable to support air ducts100of varying widths. For instance, in the embodiment shown inFIG. 9, the length of the support platform26may be adjusted so that each of the upwardly extending edges46fits flush against the sides of a generally rectangular air duct100.

As previously stated, both the support platform26and the base22are preferably elongated in shape. As used herein, elongated indicates a length to width ratio of at least 3 to 1. Utilizing an elongated base22and support platform26reduces the weight and bulkiness of each of the support brackets20, thereby making it easier to use and install brackets in small, enclosed working spaces. In addition, utilizing a single base22structure that spans between joists200with a single support arm24connecting the base22to the support platform26also reduces bulkiness and generally simplifies the design. The support bracket20may be constructed of any suitable material, such as metal or a hard plastic material, which may reduce weight. Different components of the bracket may be constructed of different materials.

The support brackets of the present bracket support system allow quick and easy installation of conduit during construction without the need for ad hoc construction of supporting structures for elevating conduit above ceiling joists. Because the height, the orientation, and the lateral positioning of the support platform of each support bracket may be adjusted, the present system provides versatility in installing conduit in any desired configuration during the construction of any residential or commercial structure.

The methods shown and described above are exemplary. Though certain characteristics of the present inventions are described above, the description is illustrative only. It is understood that versions of the invention may come in different forms and embodiments. Additionally, it is understood that one of skill in the art would appreciate these various forms and embodiments as falling within the scope of the invention as disclosed herein.