FLOOR TO WALL CONNECTOR

A floor to wall connector is provided. The floor to wall connector comprises a wall bracket and a floor bracket. The wall bracket includes a floor receiver. The wall bracket is configured to connect to a wall panel. The floor bracket includes an opening. The floor bracket is configured to connect to a floor panel. The floor receiver of the wall bracket is configured to insert into the opening of the floor bracket thereby connecting the wall panel to the floor panel. A floor and wall system including the floor to wall connector and a method of connecting a wall panel to a floor panel via the floor to wall connector is also provided.

FIELD OF INVENTION

The present invention relates generally to the art of wall installation, and more specifically to a floor to wall connector and method of installation.

BACKGROUND

Exterior wall panels of buildings are installed by connecting the wall panels to the exterior facing end of floor panels. Brackets to connect the wall panel to the floor panel are installed on-site while the wall panel is lifted and held in position. The installation is time and labor intensive because the connection requires numerous fasteners. A crane must hold the wall panel in place while the numerous fasteners are installed, taking a great deal of time. The connectors and method of installing the wall panels to the floor panels are costly and time consuming.

SUMMARY

A floor to wall connector is provided that can be installed to a floor panel and wall panel prior to lifting the wall panel into place. The connector provides a lifting point of the wall panel and provides an easy and simple mechanism to connect a floor panel and wall panel thereby reducing labor and equipment time and costs. The floor to wall connector comprises a wall bracket and a floor bracket. The wall bracket includes a floor receiver. The wall bracket is configured to connect to a wall panel. The floor bracket includes an opening. The floor bracket is configured to connect to a floor panel. The floor receiver of the wall bracket is configured to insert into the opening of the floor bracket thereby connecting the wall panel to the floor panel.

A floor and wall system is also provided. The floor and wall system includes a wall panel, a wall bracket, a floor panel, and a floor bracket. The wall bracket is attached to the wall panel. The wall bracket includes a floor receiver. The floor bracket is attached to the floor panel. The floor bracket includes an opening. The floor receiver of the wall bracket is configured to insert into the opening of the floor bracket to connect the wall panel to the floor panel. A method of connecting the wall panel to the floor panel via the floor to wall connector is also provided.

DETAILED DESCRIPTION

A floor to wall connector is provided that simplifies the mechanism to connect a wall panel to a floor panel and simplifies the method of connecting a wall panel to a floor panel. The connector can be installed off-site or on-site prior to lifting the wall panel thereby saving time and costs.

FIG. 1is an exploded view of a floor to wall connector100. The floor to wall connector100is configured to connect a wall panel to a floor panel. The floor to wall connector may be made of metal. More specifically, the floor to wall connector may be made of forged or welded steel. The floor to wall connector100includes a wall bracket200and a floor bracket300.

The wall bracket200is configured to attach to a wall panel. The wall bracket200may be comprised of an L bracket with a first leg210and a second leg220attached at an approximately 90 degree angle. The first leg210is configured to abut the interior side of a wall panel. The first leg210may include a plurality of openings212. The openings212receive fasteners, such as screws, to attach the wall bracket200to a wall panel. The second leg220is configured to extend into the wall panel. The second leg220transfers load from the wall bracket200and fasteners to the wall panel. The wall bracket200includes a floor receiver230. The floor receiver230may be comprised of an L bracket attached to the first leg210. The wall bracket200may also include a bracket stiffener232. The bracket stiffener232is positioned to support the floor receiver230and strengthen the joint between the floor receiver230and the first leg210. The floor receiver230and the bracket stiffener232may be welded to the first leg210. The floor receiver230may include a threaded hole234to receive a lifting hook240. The lifting hook240may be an eye bolt. The lifting hook240is configured to receive a hoist which allows a crane to lift, place, and hold the wall bracket200attached to a wall panel. The lifting hook240may screw into the threaded hole234. The threads allow the lifting hook240to be removed after the wall panel attached to the wall bracket200is installed and connected to a floor panel. The floor receiver230may also include threaded holes236to receive height adjustment screws242. The height adjustment screws242may be screwed into and unscrewed in the threaded holes236to adjust the wall bracket200vertically. The adjustment screws242may include lock nuts244to lock the adjustment screws242.

The floor to wall connector100also includes a floor bracket300configured to connect to a floor panel. The floor bracket300may be comprised of an L bracket with a first leg310and a second leg320attached at an approximately 90 degree angle. The first leg310is configured to abut the end of the floor panel that abuts the wall panel. The second leg320is configured to abut the top side of a floor panel. The second leg320may include a plurality of openings322. The openings322receive fasteners, such as screws, to attach the floor bracket300to a floor panel. The second leg320may also include slotted holes324that receive fasteners, such as screws, to attach the floor bracket300to a floor panel. The slotted holes324allow the floor bracket300to be loosely attached to the floor panel while being adjusted along the length of the slotted holes324. The second leg also includes an opening326configured to receive the floor receiver230. The opening326has a corresponding size and shape to the floor receiver230, but the opening326may be slightly larger than the floor receiver230to allow the wall bracket200to be adjusted while the floor receiver230is inserted in the opening326in the floor bracket300. After the floor receiver230is inserted into the opening326and the wall panel is set in place, the wall bracket200may be locked in place via locking screws334. The locking screws334screw into threaded sleeves330attached to the second leg320of the floor bracket300. The threaded sleeves330may be attached to the second leg320via a spacer332. The spacer332may be welded to the second leg320and the threaded sleeve330. The spacer332puts distance between the second leg320and the threaded sleeves330so that the locking screws334can be screwed into the threaded sleeves330. After the locking screws334are screwed into the threaded sleeves330, set screws336may be screwed into threaded holes338in the top of the threaded sleeves330.

FIGS. 2-7show a floor to wall connector100wherein the wall bracket200and the floor bracket300are connected. The floor receiver230of the wall bracket200inserts through the opening326in the second leg320of the floor bracket300to connect the wall bracket200to the floor bracket300. Once inserted through the opening326, the floor receiver230may be adjusted horizontally or left and right within the slightly oversized opening326. The height adjustment screws242are screwed through threaded holes236in the floor receiver230until the end of the height adjustment screws242rest on the top of the second leg320of the floor bracket300. The wall bracket200may be adjusted vertically by screwing the height adjustment screws242in and out of the threaded holes236to change the distance between the second leg320of the floor bracket300and the floor receiver230of the wall bracket200. Once the floor receiver230is positioned in the opening326so that the wall panel attached to the wall bracket200is properly placed, the locking screws334lock the wall bracket200in its position by screwing through the threaded sleeves330until the ends of the locking screws334are tight against the floor receiver230. The locking screws334lock the wall bracket200in place by clamping the floor receiver230against the side of the opening326in the second leg320of the floor bracket300. The set screws336are then threaded in the holes338in the threaded sleeves330to further lock the locking screws334in place.

The floor to wall connector100can be attached to wall panels and floor panels prior to lifting and placing the wall panel. The floor to wall connector100also provides a holding point for lifting the wall panel with a crane thereby eliminating the need for an additional lifting mechanism. The connector100also includes features which provide options for adjusting the floor bracket300in and out and adjusting the wall bracket200left and right and up and down relative to the building. These options for adjustment account for site tolerances. The connector100also has a slim profile which reduces the effort required to cover the connector100. The connector also provides fire protection, withstands seismic events, and uses a minimum number of mechanical fasteners.

FIG. 8shows a plurality of floor brackets300connected to a floor panel400and a plurality of wall brackets200connected to a wall panel500.FIG. 8shows a floor panel400. The floor panel400may be comprised of cross-laminated timber, cold formed steel, or a light wood frame. The floor panel400includes at least one floor bracket300mounted to the floor panel400with fasteners410, such as screws, that extend through the openings322and slotted holes324in the second leg320of the floor bracket300shown inFIGS. 1-3. As shown inFIG. 8, the second leg320of the floor bracket300abuts the top of the floor panel400. The first leg310of the floor bracket300, not visible inFIG. 8, abuts the edge of the floor panel400that abuts the wall panel500. The floor panel400includes a notch or opening at the location of the opening236in the floor bracket200so that when a floor receiver230is inserted into the opening236of the floor bracket200, the floor receiver230extends into the notch or opening of the floor panel400.

The wall panel500includes at least one wall bracket200to connect the wall panel500to the floor panel400. The wall panel500may be an exterior wall panel of a building. The wall panel500may be comprised of cross-laminated timber, cold formed steel, or a light wood frame. The wall brackets200are attached to the wall panel500with fasteners510, such as screws, that extend through the openings212in the first leg210of the wall bracket200shown inFIGS. 1, 2, 4, and 5. As shown inFIG. 8, the wall bracket200is mounted towards the top, interior end of the wall panel500so that the lifting hook240extends up past the top of the wall panel500. The first leg210of the wall bracket200abuts the interior side of the wall panel500. The second leg220of the wall bracket200, not visible inFIG. 8, extends into the wall panel500. The wall panel500may include a notch at the location of the second leg220of the wall bracket200to allow the second leg220to extend into the wall panel500. The second leg220inserted in the wall panel500aligns the wall bracket200and also transfers or spreads the load applied to the wall bracket200when the wall bracket200is lifted and when connected to the floor panel400. The second leg220provides a mechanism to transfer load through bearing of the wall panel500on the second leg220rather than the fasteners510.

The floor brackets300and the wall brackets200are mounted at corresponding locations so that the wall panel500is at its engineered or designed location when the wall bracket200is connected to the floor bracket300. The wall panels500, including the wall bracket200, may be prefabricated. The floor panels400, including the floor bracket300, may be prefabricated. Installation of the wall panel500and its connection to the floor panel400is simple, quick, and easy because the wall bracket200and the floor bracket300can be installed prior to lifting, holding, and positioning the wall panel500. The wall panel500connects to the floor panel400by inserting the floor receivers230of the wall brackets200into the corresponding openings326of the floor brackets300.

FIG. 9is an isometric view of a wall panel500connected to a floor panel400.FIG. 9shows a section of a wall panel500connected to a section of a floor panel400via a wall bracket200and a floor bracket300. As shown inFIG. 9, the top of the floor panel400may include a notch420to accommodate the floor bracket300. The notch420allows the floor bracket300to sit flush or below the top of the floor panel400when the floor bracket300is attached. The wall panel500is connected to the floor panel400by inserting the floor receiver230, not visible inFIG. 9, into the opening326, not visible inFIG. 9, of the floor bracket300and into the floor panel400. A hoist600connected to the lifting hook240allows a crane to lift and position the wall panel500. Once in position, the height adjustment screws242are set and the locking screws334are tightened. After the wall panel500is connect to the floor panel400via the wall bracket200and the floor bracket300, the lifting hook240can be removed by unscrewing the lifting hook240.

FIG. 10is a flow chart of a method of connecting a wall panel to a floor panel1000. The method1000includes the step1010of receiving a wall panel including a wall bracket and a floor panel including a floor bracket. The wall panel, wall bracket, floor panel, and floor bracket include the same details and embodiments previously described.

The method1000may also include the step1020of lifting the wall panel to its engineered or designed location on a building. The wall panel is lifted and held where the wall panel should be connected to the floor panel. The wall panel may be lifted with a crane and a hoist connected to the lifting hook of the wall bracket attached to the wall panel.

The method1000includes the step1030of connecting the wall panel to the floor panel by connecting each wall bracket attached to the wall panel with a corresponding floor bracket attached to the floor panel. The wall panel is connected to the floor panel by inserting the floor receiver of the wall bracket into the floor receiver opening in the floor bracket.

The method1000may include the step1040of vertically setting the height of the wall panel via the wall bracket by screwing or unscrewing the height adjustment screws.

The method1000may include the step1050of locking the wall panel in place via the wall bracket by screwing in the locking screws until the locking screws are tight against the wall bracket.

The method1000may include the step1060of removing the lifting hook from the wall bracket. The lifting hook may be removed from the wall bracket after the wall panel is connected to the floor panel. The lifting hook may be removed by unscrewing it from the threaded opening in the floor receiver.

Having thus described in detail a preferred selection of embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made to the floor to wall connector, wall and floor system, and method of connecting a wall panel to a floor panel without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.