Abstract:
An apparatus for securing members to a surface. The apparatus includes a mounting clamp, a mounting adaptor, a panel support member and a fastener. The panel support member and the mounting adaptor are slidably interconnected to one another. The mounting adaptor is fixedly interconnected to the mounting clamps using the fastener. The mounting adaptor may also include an area of reduced strength to permit the controlled failure of the apparatus in response to excess loading. The panel support member may be adapted to receive a panel. When installed on a surface, the apparatus obscures the view of mounting devices or equipment that may also be secured to the surface.

Description:
FIELD OF THE INVENTION 
     The present invention relates to adaptors used to secure members to two or more mounting locations on a surface. In particular, the invention relates to adaptors used for mounting panel support members to two or more mounts secured to a building surface. 
     BACKGROUND OF THE INVENTION 
     With the increased use of sheet metal panels in building construction, there has been an increased need to address ways in which various building attachments can be interconnected with a metal panel surface. For instance, there is often a need to attach heating and ventilation equipment, or other equipment to the roofs of buildings. Often, occupants and owners of buildings prefer that the brackets and support members used to secure such equipment to the building surface, as well as the equipment itself, remain hidden from view. However, providing a panel for obscuring the view of the mounting equipment has proven to be expensive and time consuming. Furthermore, the existing systems may cause damage to the surfaces to which they are attached should they be subjected to heavy stresses, such as when ice accumulates behind the panel or structure. 
     Existing systems for providing panels or structures to obscure mounting devices or equipment can be inflexible, and may require a relatively large amount of hand fitting to accommodate non-conventional installations. Examples of such non-conventional installations include those where the mounts to which the structure or panel is to be attached are themselves attached to ridges on metal roofs that are at nonstandard distances from each other. Other non-conventional installations include those where the structure or panel is to be attached to a metal roof having raised portions and the structure or panel is not perfectly perpendicular to the raised portions. 
     Systems for positioning panels so that they obscure the view of brackets or equipment mounted to building surfaces generally consist of members having a flat panel portion for obscuring the view of the brackets or equipment, and a mounting portion extending from the back of the panel portion at an angle that is substantially perpendicular to the panel portion. On such systems, the mounting portion is typically provided with holes for receiving fastening means. Generally, fastening means are positioned in the provided holes, and received by mounting devices secured at intervals along the roof. If the intervals at which the mounting devices are provided do not correspond to the distance between the holes in the mounting surface of the panel, new holes need to be drilled before the panel can be installed. Such custom fitting leads to increased costs and assembly time, because the installer must measure the required distance between holes, and then create holes in the mounting surface of the panel before the panel can be installed. 
     It would be advantageous to provide a mounting adaptor that can be attached to mounting brackets that are spaced at any interval along a surface. It would be advantageous to provide a mounting adaptor that is capable of being reliably and easily installed, to insure that its benefits are more readily attained. It would be advantageous to provide a mounting adaptor that is inexpensive to manufacture. 
     SUMMARY OF THE INVENTION 
     The present invention is generally directed towards a mounting adaptor and a mounting system that may be used to secure panels or structures to two or more mounting devices. Typically, these mounting devices are located on the exterior surface of a building. However, the present invention may be used in any application where a structure or member is to be attached to two or more mounting devices. In addition, the adaptor may be used to interconnect a member to a mounting surface through a mounting device at any point along the member. Although the present invention will generally be described in regard to attachment to a building surface, it will be appreciated that the invention may be used in connection with any situation in which it is desirable to attach a member to a mounting surface. 
     In one aspect of the present invention, a mounting adaptor is provided having a first portion adapted to be affixed to a mounting device. The mounting adaptor further includes a second portion adapted to slidably receive a panel support member. The mounting adaptor further features an area of reduced strength, to insure that excessive loading of the mounting adaptor results in a clean and predictable separation from the mounting device. In a preferred embodiment, the portion adapted to slidably receive a panel support member comprises a bead. In a more preferred embodiment, the mounting adaptor is manufactured from aluminum. In a most preferred embodiment, the mounting adaptor further comprises an alignment portion for holding the panel support member at an angle to the mounting adaptor. 
     In another aspect of the present invention, a mounting assembly is provided comprising at least two separate mounting devices interconnectable with a surface at two locations. The mounting assembly further includes at least two clip members interconnected to the mounting devices, wherein the clip members are provided with a beaded portion. A panel support member having a channel adapted to slidably receive the beaded portion of the clip members and a second channel adapted to receive a panel member is also provided. A panel member may then be positioned in the second channel portion of the panel support member. Thus, the mounting assembly positions the panel member apart from and at an angle to the mounting surface. In a preferred embodiment, the mounting assembly comprises clip members that have an area of reduced strength. In a further preferred embodiment of the mounting assembly, the area of reduced material comprises a line formed in the surface of the clip member. In another preferred embodiment, the mounting assembly positions the panel member at an angle to the mounting surface of about 90°. 
     In yet another aspect of the present invention, a roof assembly is provided. The roofing surface to which the assembly is to be attached includes a plurality of spaced longitudinal raised portions that are each laterally separated by a base portion, for example, a raised metal seam roof. At least two separate clamp or mounting members are interconnected to the raised portions of the building surface. A clip member or mounting adaptor having an attachment portion, a bead portion, and an alignment portion is secured to each of the clamp members using fasteners extending through holes in the attachment portion of the clip members. The clip members are further provided with an area of reduced strength. A panel support member having first and second channel portions and an alignment portion is interconnected to the clip members using the first channel portion. Panel members are then slidably received by the second channel portion of the panel support member. The alignment portion of the panel support member holds the panel member at an angle to the roofing surface, such that a view of objects behind the panel are obscured from observers. In a preferred embodiment, the area of reduced strength of the clip member comprises a formed line. In another preferred embodiment, the fastener comprises a bolt. 
     In a further embodiment, the invention provides a mounting adaptor for attaching a panel support member to a roof to obstruct a view of objects behind the member. The mounting adaptor has an attachment portion having a hole therethrough for receiving a fastener so that the mounting adaptor may be affixed to a mounting device. The attachment portion of the mounting adaptor is substantially a first thickness, but has a portion that is reduced to a second thickness along a line extending across at least a portion of the hole. The mounting adaptor further includes a bead portion for slidably receiving a panel support member. An alignment portion on the mounting adaptor holds the panel support member at an angle to the mounting adaptor. In another preferred embodiment, the mounting adaptor is affixed to the mounting device using a threaded fastener. In a further preferred embodiment, the mounting adaptor is constructed from aluminum. In another preferred embodiment, the alignment portion of the mounting adaptor is an alignment surface. 
     In an additional embodiment, the present invention provides a method for obscuring the view of certain objects. The method includes affixing at least two mounting members to a surface. At least two adaptor members having an attachment portion, a bead portion, and an alignment portion are provided. A panel support member having a first channel portion adapted to slidably receive the beaded portion of the adaptor members is engaged with the adaptor members. A first adaptor member is then positioned along the panel support member to a first position. The first adaptor member is then affixed to a first of the mounting members. The second adaptor member, also engaged with the first portion of the panel support member, is then positioned along the panel support member so that it is aligned with the second mounting member. The second adaptor member is then affixed to the second mounting member, whereby the panel support member is spaced apart from and at an angle to the surface. In a preferred embodiment, the panel support member is provided with a second channel for slidably receiving a panel member. In another preferred embodiment, the attachment portion of the adaptor member is provided with a hole therethrough to allow the adaptor member to be affixed to the mounting member using a threaded fastener. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side elevation of the components of a system for attaching panel members to a surface according to one embodiment of the invention; 
     FIG. 2 is a cross-section of a panel support member constructed in accordance with one embodiment of the present invention; 
     FIG. 3 is a cross-section of a mounting adaptor constructed in accordance with one embodiment of the present invention; and 
     FIG. 4 is a plan view of a mounting adaptor constructed in accordance with one embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION 
     In accordance with the present invention, an apparatus and method are provided to permit the easy and economical installation of panel members and structures to a surface. In particular, the present invention is directed to securing panel members to building surfaces. 
     With reference to FIG. 1, an apparatus constructed in accordance with one embodiment of the present invention is generally identified as mounting system  104 . The mounting system  104  generally comprises a panel support member (or cross member)  108 , a mounting adaptor (or clip member)  112 , a fastener  116 , and a mounting clamp  120 . The panel support member  108  spans the distance between at least two adjacent mounting clamps  120  while the mounting adaptor  112  provides an interface between the panel support member  108  and the mounting clamp  120 . Specifically, the mounting adaptor  112  engages the panel support member  108  in such a way that movement of the panel support member  108  with respect to the mounting adaptor  112  can only occur along a line perpendicular to the view illustrated in FIG.  1 . The fastener  116  secures the mounting adaptor  112  to the mounting clamp  120 , and additionally serves to clamp the panel support member  108 . 
     The components of the mounting system  104  may be formed from various materials, such as metal and alloys of metal, ceramics, plastics, or composites. In the embodiment illustrated in FIG. 1, the panel support member  108 , the mounting adaptor  112  and the mounting clamp  120  are formed from aluminum, which provides sufficient load-bearing capacity, while being corrosion resistant. Anodized aluminum and stainless steel are also materials that are particularly well-suited for constructing the components of the mounting system  104 . The fastener  116  can be formed from galvanized steel, stainless steel, steel, aluminum, brass, or any other material having sufficient tensile strength. Preferably, the fastener  116  is formed from a material that is resistant to corrosion. Corrosion resistance is a desirable attribute for the materials from which all the components of the mounting system  104  are constructed, as it provides for enhanced durability and appearance, particularly where the system is used on the exterior surface of a building, or in other applications where it is out-of-doors and is exposed to the elements. The panel support member  108  and the mounting adaptor  112  may be formed by a variety of methods, one of which is extrusion. The mounting clamp  120  and the fastener  116  may be formed by conventional machining or forming techniques. 
     The mounting clamp  120  typically has a slot formed in it for receiving the raised portion of the surface to which the clamp is to be affixed. Fastening members  124  may be provided in the mounting clamp to engage the raised portion of the mounting surface. Suitable fasteners  124  include screws or bolts threadably attached to the mounting body  120  through holes that communicate with the slot formed in the mounting body  120 . Suitable mounting clamps are disclosed in U.S. Pat. No. 5,228,248 issued Jul 20, 1993, U.S. Pat. No. 5,483,772 issued Jan. 16, 1996, U.S. Pat. No. 5,715,640 issued Feb. 10, 1998, and U.S. patent application Ser. No. 08/987,368, filed on Dec. 9, 1997, the disclosures of which are incorporated by reference herein. 
     A cross-section of the panel support member  108  is illustrated in FIG.  2 . The panel support member  108  generally includes a first channel portion  204  adapted to slidably receive the mounting adaptor  112 . Although in the illustrated embodiment the first channel portion  204  is illustrated as having a generally C-shaped cross section, other configurations are also contemplated by this invention. For example, rather than having a smooth, arcuate shape, the first channel portion  204  may be constructed from a series of straight segments. All that is required of the first channel portion  204  is that it be capable of slidably receiving the mounting adaptor  112  in a direction parallel to the longitudinal axis of the panel support member  108 , while resisting movement of the panel support member  108  relative to the mounting adaptor  112  in all other directions. 
     The longitudinal axis of the panel support member  108  is along a line perpendicular to the cross section of the panel support member  108  illustrated in FIG.  2 . The panel support member  108  is typically supplied in lengths ranging from about 16 inches to about 24 feet. More preferably, the panel support member  108  is available in lengths of up to about 20 feet. Most preferably, the panel support member  108  is provided in lengths of about 8 feet. The cross section of the panel support member  108  is generally constant across its entire length. Opposite the first channel portion  204  is the upright  208 . Located generally between the upright  208  and the channel portion  204  is the alignment portion  212 . The alignment portion  212  generally includes a planar upper alignment surface  216  and an alignment leg  220 . The alignment leg  220  protrudes from upright  208  and is positioned such that the distal portion  224  of the alignment leg  220  is opposite the upper alignment surface  216 . An alignment channel  228  is formed at the intersection of the alignment leg  220  and the upright  208 . Certain embodiments of the panel support member  108  also include holes at regular intervals along and through the alignment portion  212  for direct attachment of the panel support member  108  to mounting clamps  120 , without the use of mounting adaptors  112 . When the panel support member  108  is to be attached directly to mounting clamps  120 , the mounting clamps  120  are typically turned 180° to bring the hole (not shown) to receive the fastener  116  closer to the support member  108 , thereby allowing the upright  208  of the panel support member  108  to clear the mounting clamp  120 . Preferably, when the mounting clamp  120  is in a first position, the hole in the mounting clamp  120  for receiving the fastening the device  116  will align with the hole  328  in the mounting adapter  112 , and when the mounting clamp  120  is turned 180° the hole in the mounting clamp  120  will align with hole in the panel support member  108 . Such a configuration enhances the versatility of the system. 
     In the illustrated embodiment, the upright  208  is substantially perpendicular to the upper alignment surface  216 . However, this angle may be varied to suit the particular installation. An upper U-shaped channel  232  and a lower U-shaped channel  236  may be formed at both the top and bottom of the upright portion  208 . Together, upper U-shaped channel  232  and lower U-shaped channel  236  form the second channel portion  240  of the panel support member  108 . The second channel portion  240  is adapted to receive strips (e.g., planar strips) of material (not illustrated), such as metal roofing material. The width of the second channel portion  240  (i.e. the distance between the upper U-shaped channel  232  and lower U-shaped channel  236 ) may vary, but is preferably less than about 12″, more preferably less than about 6″, and most preferably about 2″. 
     A mounting adaptor in accordance with the present invention is illustrated in cross-section in FIG.  3 . The mounting adaptor, identified generally as mounting adaptor  112  includes an attachment portion  308 , a beaded portion  312 , and an alignment portion  316 . The attachment portion  308  generally includes a planar lower portion  320  and a planar upper portion  324 . The attachment portion  308  is further provided with hole  328  (not visible in FIG. 3, see FIG.  4 ), adapted to receive fastener  116  (see FIG.  1 ). Attachment portion  308  is additionally provided with reduced section  332 . Reduced section  332  is, in the embodiment illustrated in FIG. 3, located so that it intersects the hole  328  in the attachment portion  308 . 
     Adjacent to the attachment portion  308  is the beaded portion  312 . The beaded portion  312  generally includes bead  336 , upper channel portion  340  and lower channel portion  344 . The channels  340  and  344  are formed between the bead  336  and the upper radius  352  of the mounting adaptor  112 . The bead  336  of the beaded portion  312  is spaced apart from the upper radius  352  of the mounting adaptor  308  by leg  348 , such that bead  336  is generally centered within the circle described by the upper radius  352 . 
     Extending from the upper radius  352  of the mounting adaptor  112  is the alignment portion  316 . The alignment portion  316  generally includes upper planar surface  356  and lower planar surface  360 . Upper planar surface  356  and lower planar surface  360  are substantially parallel to each other, and they are in turn substantially parallel to the upper planar surface  324  and lower planar surface  320  of the attachment portion  308 . Extending from the upper planar surface  356  of the alignment portion  316  is alignment lip  364 . The alignment lip  364  is adapted to slidably engage the alignment channel  228  of the panel support member  108 . 
     The exact dimensions and configuration of the bead  336 , the upper channel portion  340 , the lower channel portion  344 , and the leg  348  are selected so that the surfaces of the first channel portion  204  of the panel support member  108  closely mate with the surfaces of the beaded portion  312  of the mounting adaptor  112 . Preferably, when the panel support member  108  and the mounting adaptor  112  are interconnected, the space generally defined beneath the upper radius  352  of the mounting adaptor  112  by the bead  336 , upper and lower channel portions  340  and  344 , and the leg  348  is substantially filled at least down to a plane or slightly below a plane extending from the lower planar surface  320 , by the first channel portion  204  of the panel support member  108 . Indeed, the only requirements for the beaded portion  312  and the first channel portion  204  is that they, alone or in cooperation with the alignment portion  212  of the panel support member  108  and the alignment portion  316  of the mounting adaptor  112 , prevent movement of the panel support member  108  relative to the mounting adaptor  112  in all directions except along a line perpendicular to the side elevation of FIG. 1, or the cross-sections of FIGS. 2 and 3 (i.e. along the longitudinal axis of the panel support member  108 ). Therefore, the configurations of the “beaded” portion  312  and the first channel portion  204  can be any suitable complementary configurations which prevent such movement. 
     In the illustrated embodiment, the mounting adaptor  112  has a width of approximately 3.5″, a length of approximately 2.75″, and a height of approximately 0.5″. Moreover, the attachment portion  308  of the mounting adaptor  112  of the illustrated embodiment has a nominal thickness of about 0.125″, while at the reduced section  332  the minimum thickness of the attachment portion  308  is about 0.03″. The outer radius of the upper radius  352  is approximately 0.3″, the outside radius of upper and lower channels  340  and  344  is approximately 0.2″, the diameter of the bead  336  is approximately 0.15″, and the length of the leg  348  is about 0.25″. With respect to the alignment portion  316  of the mounting adaptor  112 , the nominal thickness is about 0.125″, while the maximum thickness of about 0.17″ occurs at the alignment lip  364 . However, the dimensions can be varied to suit any desired application. 
     With reference now to FIG. 4, illustrating a top or plan view of the mounting adaptor  112  illustrated in cross-section in FIG. 3, it is possible to see the proportions of the length and width of the illustrated embodiment. Furthermore, it can readily be seen that the hole  328  is generally centered in the attachment portion  308 . In addition, it can be seen that the reduced section  332  is bisected by the hole  328 . 
     With reference again to FIG. 1, the interconnection of the panel support member  108 , the mounting adaptor  112 , the fastener  116 , and the mounting clamp  120  can readily be seen. Generally, the first channel section  204  of the panel support member  108  is received by the beaded portion  312  of the mounting adaptor  112 . As illustrated in FIG. 1, the first channel portion  204  of the panel support member  108  and the beaded portion  312  of the mounting adaptor  112  are closely mated, so that the mounting adaptor  112  may be engaged with the panel support member  108  by aligning it and then sliding it onto the panel support member  108  in a direction perpendicular to the view of the illustration (i.e. in a direction parallel to the longitudinal axis of the panel support member  108 ). Thus interconnected, the mounting adaptor  112  is free to move along a line perpendicular to the view of FIG. 1, but is prevented from moving in all other directions. 
     To provide further support against unwanted relative movement of the panel support member  108  and the mounting adaptor  112 , the lower surface  360  of the alignment portion  316  of the mounting adaptor  112  is adapted to interface with the alignment surface  216  of the alignment portion  212  of the panel support member  108 . Furthermore, the distal portion  224  of the alignment leg  220  engages the upper surface  356  of the alignment portion  316  of the mounting adaptor  112 . As an additional means to maintain the desired relationship between the panel support member  108  and the mounting adaptor  112 , the lip  364  of the alignment portion  316  of the mounting adaptor  112  is received by the channel  228  of the panel support member  108  in a closely fitting relationship. 
     With the panel support member  108  and the mounting adaptor  112  interconnected as above-described, the mounting adaptor  112  may be positioned along the length of the panel support member  108  by sliding it to the desired position. Typically, the mounting adaptor  112  is positioned such that the hole  328  is concentrically aligned with a hole (not illustrated) provided in the upper surface of the mounting clamp  120 . Thus aligned, a fastener  116  may be extended through the hole  328  of the mounting adaptor  112  and into the hole (not illustrated) of the mounting clamp  120 . In a preferred embodiment, the space between the lower planar surface  360  of the mounting adaptor  112  and the adjacent surface of the mounting clamp  120  is slightly less than the thickness of the alignment portion  212  of the panel support member  108  as measured from the upper alignment surface  216  to the bottom of the panel support member  108 . With such a configuration, tightening the fastening device  116  against the mounting adaptor  112  clamps the panel support member  108  between the mounting adaptor  112  and the top surface of the mounting clamp  120 . In this way, the panel support member  108  is prevented from moving relative to the mounting adaptor  112  along the longitudinal axis of the first channel  204  (i.e. perpendicular to the view of FIG.  1  and the cross-sections of FIGS.  2  and  3 ). 
     Although the present invention has been discussed in terms of a particular illustrated embodiment, it should be noted that other configurations may be employed. For example, the channel portion  204  of the panel support member  108  need not be in a generally circular shape, as in the illustrated embodiment. All that is required is that it be shaped to allow movement along the line perpendicular to a cross section of the panel support member  108  when mated with a corresponding section of the mounting adaptor  112 . Similarly, the alignment portion  212  of the panel support member  108  may be of any configuration capable of maintaining the desired relationship between the panel support member  108  and the mounting adaptor  112 . Also, it should be noted that the second channel portion of panel support member  108  need not be supplied with an additional panel member where the appearance of the panel support member  108  need not be changed. 
     The foregoing description of the present invention has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the invention to the form disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and the skill or knowledge of the relevant art, are within the scope of the present invention. The embodiments described hereinabove are further intended to explain best modes known for practicing the invention and to enable others skilled in the art to utilize the invention in such, or other, embodiments and with various modifications required by the particular applications or uses of the present invention. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.