Patent Publication Number: US-2010115871-A1

Title: Mounting bracket and method for mounting cladding panels to a structure

Description:
The present invention is directed to mounting bracket and method for mounting cladding panels, particularly to walls and ceilings. The system is especially suited to, although not limited to, use in the mounting of plasterboard panels in buildings. 
     At present, when interior cladding panels such as plasterboard are to be mounted to the walls and ceilings of a building, the process requires a great deal of manual effort from joiners or fitters. Usually, the mounting of such panels is a job carried out by two person teams. During the mounting process, the two individuals must balance the panels while at the same time attaching the panels to structural elements such as joists or stud partitions. The attachment is normally achieved by fixtures such as nails or screws being pushed through the panel into the structural element by a nail gun or the like. In order to balance the panel whilst applying the fixtures, the fitters are often using their head or shoulder to support the panel, particularly when fitting ceiling panels. Such practices can greatly increase fatigue in the fitters and also cause injury. 
     Once the panels are mounted, conventional practice requires that the join between the panels is covered before a plaster coating is applied over the panels and the join. The join is normally covered using a suitable tape. Having to tape over the join in this way increases the time taken to prepare the panelled area for plastering. 
     It is an aim of the present invention to obviate or mitigate one or both of the aforementioned disadvantages. 
     According to a first aspect of the present invention, there is provided a mounting bracket for mounting a cladding panel to a structure, the mounting bracket comprising:
         a body having first and second walls spaced from one another and a third wall extending between the first and second walls;   a first aperture located in the first wall, and a second aperture located in the second wall, wherein the apertures are substantially co-axial and adapted to receive a fixture therein; and   at least one pair of resilient flanges projecting from the third wall, the pair of flanges adapted to clamp a portion of a cladding panel between them.       

     Preferably, the pair of flanges are adapted such that the channel has a greater width at the third wall than at the end of the flanges remote from the body. 
     Preferably, the body has a fourth wall spaced from the third wall and extending between the first and second walls, and the mounting bracket further comprises a second pair of resilient flanges projecting from the fourth wall in a direction substantially opposite to a direction of the first pair of flanges, the second pair of flanges adapted to clamp a portion of a further cladding panel between them. 
     Preferably, the first and second pairs of flanges are adapted such that the first and second channels have a greater width at the third and fourth walls, respectively, than at the end of the flanges remote from the body. 
     Preferably, the third and fourth walls of the body are substantially parallel to one another. Most preferably, the body is cuboidal and the first, second, third and fourth walls define the walls of the cuboid. 
     Preferably, the diameter of the second aperture is greater at the outer surface of the second wall than at any point internal thereof. 
     In an alternative embodiment, the body has a substantially L-shaped profile and the third and fourth walls are substantially at right angles to one another. The second wall comprises first and second portions, wherein the first portion is substantially at right angles to the second portion. 
     Preferably, the second aperture is located at the vertex of the angle between the first and second portions of the second wall. 
     Preferably, the body and flanges are elongate and the mounting bracket comprises a plurality of pairs of first and second apertures spaced along the length of the body. 
     Another alternative embodiment further comprises fifth and sixth walls which are substantially at right angles to the first and second walls, respectively, and a third aperture located in the fifth wall of the body, and a fourth aperture located in the sixth wall of the body, wherein the third and fourth apertures are substantially co-axial and adapted to receive a second fixture therein. 
     Preferably, the diameter of the second and fourth apertures is greater at the outer surface of their respective walls than at any point internal thereof. 
     Preferably, the body and flanges are elongate and the mounting bracket comprises a plurality of pairs of first and second, and third and fourth, apertures spaced along the length of the body. 
     Preferably, one or more of the flanges is provided with a plurality of openings located in the surface thereof. Most preferably, the openings extend across the entire depth of the one or more flanges. 
     According to a second aspect of the invention, there is provided a method of mounting a cladding panel to a structure comprising a plurality of structural elements, the method comprising the steps of:
         fixing one or more first mounting brackets according to the first aspect of the invention to a structural element;   clamping a first end of a cladding panel between two resilient flanges of the first mounting bracket whilst supporting a second end of the cladding panel;   clamping the second end of the cladding panel between two resilient flanges of one or more second mounting brackets according to the first aspect of the invention; and   fixing the second mounting bracket to an adjacent structural element.       

     According to a third aspect of the invention, there is provided a fixture comprising:
         a threaded elongate body, the body having a driving head formed at a first end thereof and a point formed at a second end thereof; and   a collar having an internal recess adapted to receive the driving head therein;   wherein the collar has an abutment extending radially outwards from the body and facing the second end thereof.       

     Preferably, the abutment is at a first end of the collar and a second end of the collar is located adjacent the driving head, wherein the second end of the collar includes a lip portion having a greater diameter than the remainder of the collar and the external circumference of the lip portion has a rounded profile. 
     Preferably, the collar has a concave profile where its diameter increases from the first end towards the lip portion, and an axial length greater than the largest diameter of the lip portion. 
     Preferably, the body and head are formed separately from the collar. Most preferably, the collar is formed from aluminum and the body and head are formed from steel. 
    
    
     
       Preferred embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: 
         FIG. 1  is a perspective view of a mounting bracket for mounting at least two cladding panels to a structure; 
         FIG. 2  is a perspective view of a mounting bracket for mounting at least one cladding panel to a structure; 
         FIG. 3  is a perspective view of a mounting bracket for mounting at least two cladding panels to an external corner of a structure; 
         FIG. 4  is a perspective view of a mounting bracket for mounting at least two cladding panels to an internal corner of a structure; 
         FIG. 5  is a perspective view of a member for concealing the join between adjacent cladding panels; 
         FIG. 6  is a side view of a fixture for securing cladding panels to a structure; and 
         FIG. 7  is a perspective view of the fixture shown in  FIG. 6 . 
     
    
    
       FIG. 1  shows a mounting bracket, generally designated  1 , for mounting cladding panels to a structure. The mounting bracket  1  comprises a body  2  which is preferably cuboidal and hollow. The shape of the body  2  is defined by an upper wall  4 , a lower wall  6  and a pair of side walls  8 , 10 . Extending outwardly from the respective side walls  8 , 10  are a pair of resilient flanges  12 , 14 . Along with their respective side walls  8 , 10 , the pairs of flanges  12 , 14  define a pair of channels  16 , 18  extending along opposite sides of the body  2 , where the respective pairs of flanges  12 , 14  project in directions which are substantially opposite to one another. Each flange  12 , 14  of a pair is formed such that they taper to an edge  20 , 22  remote from the body  2 . In addition, each flange of a pair is also formed such that it curves inwardly towards the other flange of the pair. As a result, the width W 1  of the channels  16 , 18  adjacent the side walls  8 , 10  of the body  2  is greater than the width W 2  of the channels  16 , 18  at the edges  20 , 22  of the flanges  12 , 14  remote from the body  2 . 
     The first and second walls  4 , 6  of the body contain a first aperture  24  and a second aperture  26 , respectively. The apertures  24 , 26  are co-axial in order to receive a fixture as will be explained below. The second aperture  26  has an internal opening  28  and is countersunk, wherein the diameter of its external opening  27  at the outer surface of the second wall  6  is greater than that of any other portion of the aperture  26 . This allows the head of a fixture put through the body  2  to lie within the second aperture  26  instead of protruding therefrom. 
     The body  2  and the pairs of flanges  12 , 14  are preferably integrally formed from a resilient plastics material. The plastics material is preferably extruded into the required form and can be extruded in short sections, as shown here in  FIG. 1 , or else in extended lengths of around 5-6 m. In the case of the extended lengths, these can be cut to a preferred length after extrusion. In one preferred embodiment, the lengths are cut into 2.4 m long sections. In order for the brackets  1  to be fixed to regularly spaced structural elements such as floor joists or the studs of a stud partition wall, the co-axial apertures  24 , 26  are longitudinally spaced along the extended lengths such that their centres are 60 cm apart. This spacing is dictated by the requirements of building regulations, which require the structural elements of floors, ceilings and the like to be themselves 60 cm apart. 
       FIG. 2  shows an alternative embodiment of the mounting bracket shown in  FIG. 1 . In  FIG. 2 , the mounting bracket  101  is identical to the mounting bracket of  FIG. 1 , save for the fact that only one pair of flanges  112  is provided on the side wall  108  of the body  102 . With the side wall  108 , the pair of flanges  112  define a channel  116  extending along one side of the body  102 . The upper and lower walls  104 , 106  of the body  102  contain a first aperture  124  and a second aperture  126 , respectively. The apertures  124 , 126  are co-axial in order to receive a fixture as will be explained below. As with the embodiment of  FIG. 1 , the second aperture  126  has an internal opening  128  and is countersunk. 
     The way in which the mounting brackets are used will now be described. Initially, individual mounting brackets or lengths thereof are fixed to the structural elements (e.g. joists, beams or studs) of the structure being clad. These mounting brackets are intended to clamp a first end of a cladding panel. The mounting brackets are held against the structural elements so that the upper wall  4 , 104  of the body  2 , 102  lies along the structural element, with the lower wall  6 , 106  facing away from the structural element. Fixtures are then applied through the apertures  24 , 26 , 124 , 126  into the structural elements to fix the brackets  1 , 101  to the structural elements. 
     As will become apparent, the embodiments of the mounting brackets shown in  FIGS. 1 and 2  are for different applications. The first embodiment of  FIG. 1  is intended for use away from the edges of a ceiling or wall, for example, when cladding panels are to be mounted on either side of the structural element to which the mounting bracket is fixed. In contrast, the second embodiment of the mounting bracket, as shown in  FIG. 2 , is intended for use where a cladding panel is only required on one side of a structural element. An example of such an instance would be where the structural element is the first or last joist in a ceiling where the ceiling meets a structural wall. 
     Once the first mounting brackets have been fixed to a structural element, a first end of a cladding panel, such as a plasterboard panel for example, is located in the channel  16 , 116  of the fixed mounting bracket. The inward taper of the flanges  12 , 112  defining the channel ensure a frictional, clamping engagement with the first end of the panel, as the panel thickness is greater than the width W 2  of the channel, but less than the width W 1  of the channel. Once the first end of the panel is clamped by the first mounting bracket(s), a fitter supports the second end of the panel while they engage the second end of the panel with the channel  18  of at least one second mounting bracket. Again, the taper of the flanges  14  forming the channel ensures a frictional, clamping engagement with the second end of the panel. Once the second mounting bracket has engaged the second end of the panel, the fitter lifts the second end of the panel and mounting bracket(s) until the upper wall  4  contacts an adjacent structural element. More fixtures are then applied through the apertures  24 , 26  of the second mounting bracket into the adjacent structural element to fix the second mounting bracket thereto. The cladding panel is then held against the structural elements by the first and second mounting brackets. If a number of panels are required to clad a wall or ceiling, for example, the process can be repeated using additional mounting brackets of the type shown in  FIG. 1 . For the final structural element, a mounting bracket of the type shown in  FIG. 2  will be used to complete the process. 
     The embodiments of the mounting bracket shown in  FIGS. 1 and 2  are for use in situations where a continuous, substantially flat surface is to be clad. However, there are instances where the surface being clad will include both external and internal corners. The embodiments of  FIGS. 3 and 4  are for use in this instance. 
       FIG. 3  shows a mounting bracket, generally designated  301 , for mounting cladding panels around an external corner. The mounting bracket  301  comprises a body  302  which itself comprises first and second body portions  303 , 305 . The first and second body portions  303 , 305  lie substantially at right angles to one another. The first body portion  303  has a first side wall  308  remote from the second body portion  305 , whilst the second body portion  305  has a second side wall  310  remote from the first body portion  303 . The body  301  has a substantially L-shaped profile such that the first and second side walls  308 , 310  are substantially at right angles to one another. Extending outwardly from the respective side walls  308 , 310  are a pair of flanges  312 , 314 . Along with their respective side walls  308 , 310 , the pairs of flanges  312 , 314  define a pair of channels  316 , 318  extending substantially at right angles to one another along opposite sides of the body  302 . Each flange  312 , 314  of a pair is formed in the same manner as those in the embodiments of  FIGS. 1 and 2 , with the same taper and consequent difference in the widths W 1  and W 2  of the channel. The first body portion  303  has a first aperture  324  and a second aperture  326 , whilst the second body portion  305  has a third aperture  325  and a fourth aperture  327 . The apertures are identical to those of the embodiments of  FIGS. 1 and 2 . 
     As with the previously described embodiments, the body  302  and the pairs of flanges  312 , 314  are preferably integrally formed from a resilient plastics material. The plastics material is preferably extruded into the required form and can be extruded in short sections, as shown here in  FIG. 3 , or else in extended lengths of around 5-6 m. In the case of the extended lengths, these can be cut to a preferred length after extrusion. In one preferred embodiment, the lengths are cut into 2.4 m long sections. In order for the brackets  301  to be fixed to regularly spaced structural elements, such as floor joists or the studs of stud portions, the co-axial apertures  324 , 326  are spaced along the extended lengths such that their centres are 60 cm apart. This spacing is dictated by the requirements of building regulations, which require the structural elements of floors, ceilings and the like to be themselves 60 cm apart. 
       FIG. 4  shows a further embodiment of a mounting bracket, generally designated  401 , for mounting cladding panels in an internal corner. The mounting bracket  401  is similar to the embodiment shown in  FIG. 3 . In the interests of brevity, the features of the embodiment of  FIG. 4  which are identical to those of the embodiment of  FIG. 3  will not be described again here. Instead, each feature which is identical has simply been assigned a replacement reference number in  FIG. 4  which is prefixed with “ 4 ______” instead of “ 3 ______”. Where the fourth embodiment differs from the third embodiment is in the location of the apertures for receiving a fixture. The first aperture (not shown) and second aperture  426  are arranged co-axially in the body  402  such that their shared axis passes through the vertex of the substantially 90° angle between the first and second body portions  403 , 405 . As a result, a fixture inserted through the first and second apertures will enter directly into the internal corner of the structural element. 
     The third and fourth embodiments of the mounting bracket can be utilised in substantially the same manner as the first and second embodiments. In other words, the channels  312 , 314 , 412 , 414  are adapted to receive an end of a cladding panel, either before or after the mounting brackets  301 , 401  have been fixed to a structural element. 
     The first to fourth embodiments of the mounting brackets are adapted such that the body portions of the brackets will cover the gaps between the ends of adjoining cladding panels which are held in the channels of the mounting brackets. However, gaps between the ends of the panels which are transverse to the mounting brackets, and hence not held by the mounting brackets, will still be visible. These gaps are covered by the concealing member illustrated in  FIG. 5 . 
     The concealing member, generally designated  501 , comprises a body  502  which is preferably cuboidal and hollow. The shape of the body  502  is defined by an upper wall  504 , a lower wall  506  and a pair of side walls  508 , 510 . Extending outwardly from the respective side walls  508 , 510  are a pair of flanges  512 . The body  502  and the pair of flanges  512  give the concealing member  501  a shape in the form of an inverted “T”. Each flange  512  is formed such that it tapers to an edge  520  remote from the body  502 . In addition, each flange  512  is also formed such that it curves upwardly (when viewed in  FIG. 5 ) towards the body  502 . 
     The upper and lower walls  504 , 506  of the body  502  contain a first aperture  524  and a second aperture  526 , respectively. The apertures  524 , 526  are co-axial in order to receive a fixture as will be explained below. The second aperture  526  is countersunk, allowing the head of a fixture put through the body  502  to lie within the second aperture  526  instead of protruding therefrom. 
     The body  502  and flanges  512  are preferably integrally formed from a resilient plastics material. The plastics material is preferably extruded into the required form and can be extruded in short sections, as shown here in  FIG. 5 , or else in extended lengths of around 5-6 m. In the case of the extended lengths, these can be cut to a preferred length after extrusion. In one preferred embodiment, the lengths are cut into 2.4 m long sections. In order for the members  501  to be fixed to regularly spaced structural elements, such as floor joists or the studs of stud portions, the co-axial apertures  524 , 526  are spaced along the extended lengths such that their centres are 60 cm apart. 
     In use, the concealing member  501  is applied in much the same way as the mounting brackets. The lengths of the concealing member  501  are positioned so that the body  502  locates in the transverse gap between adjoining cladding panels with the upper side (when viewed in  FIG. 5 ) of the flanges  512  contacting the cladding panels. The concealing member  501  is then fixed to an appropriate structural element by a fixture applied through the apertures  524 ,  526 . If desired, further fixtures can be applied directly through the flanges  512  and cladding panels into the structural element. With the concealing members in place, a smooth surface is presented for plastering or similar surface treatment. 
     A fixture suitable for fixing the mounting brackets and concealing members to structural elements in shown in  FIGS. 6 and 7 . The fixture, generally designated  601 , comprises an elongate body  602  having a head  603  located at a first end  605  of the body  602 . The body  602  has a second end  608  remote from the head  603  which tapers to a point  610 . The body also includes a helical thread  606  running the length thereof, the thread ending adjacent the point  610 . The fixture  601  also comprises a collar  604  which is threaded onto the body  602  until the head  603  abuts an internal recess (not shown) in the collar  604 . The body  602  and head  603  are preferably separate from the collar  604  so that the body and head can rotate relative to the collar  604  when being driven. The internal diameter of the collar  604  is such that the collar  604  is held against the head  603  in a friction fit and cannot move away from the head  603  without a predetermined force being applied to overcome the friction. In this way, the collar  604  remains at the end of the fixture  601  remote from the tip  610  but still allows the body  602  to rotate independently when being driven. 
     When in position on the body  602 , the collar  604  has a first end  612  remote from the head  603  and a second end  614  adjacent the head  603 . The first end  612  of the collar  604  has a larger diameter than that of the body  602  and the thread  606  combined. As a result, a step or abutment  616  is formed at the first end  612  of the collar  604 . The surface of the step  616  faces towards the second end  608  of the body  602 . The collar  604  also has an intermediate portion  613  between its first and second ends  612 , 614 . The external diameter of the collar  604  increases from the first end  612  through the intermediate portion  613  and a transition portion  620  to a lip portion  618  at the second end  614 . Consequently, the collar  604  has a concave profile when the fixture is viewed from the side in the manner seen in  FIG. 6 . The lip  618  has a diameter that is greater than any diameter of the remainder of the collar  604 . The lip  618  has an outer circumference which has a rounded profile, where the upper and lower edges of the lip  618  have diameters which are smaller than the diameter of a portion of the lip lying between those edges. The collar  604  preferably has an axial length L greater than the largest diameter D of the lip portion  618 . 
     In use, the fixture  601  will be driven into a structural element (usually made of wood) directly or else through a cladding panel first. The head  603  includes one or more grooves  605  for receiving the head of an appropriate driving tool. As the head  603  is driven, the body  602  will rotate and the thread  606  will grip into the receiving material. During this process, loose material will pass back along the thread  606  in the direction of the collar  604 . The step  616  provided on the collar  604  ensures that none of the loose material can pass by the fixture  601  during the driving process. Instead, the loose material is compacted by the step  616  as the fixture  601  is driven further into the substrate. This is particularly beneficial if the fixture is being initially driven through a relatively friable material such as plasterboard, as the compacted material improves the hold between the fixture and the plasterboard. 
     Once the fixture  601  is driven into the structural element, the step  616  plays a further role in ensuring that the fixture is not driven in too far. Thus, the collar  604  ensures that the fixture  601  cannot be driven further into a surface once the entire thread is in the surface, as the step  616  prevents any further movement in the direction of driving. Additionally, by ensuring that the transition area  620  between the intermediate portion  613  and the lip  618  of the collar  604  has a radius of curvature and is non-planar, no flat surfaces are presented which could damage the surface as the fixture  601  is being driven. Instead, the curved transition area  620  and rounded profile of the lip  618  compress the surrounding material in the surface in a number of directions, thereby avoiding any large shear forces on adjacent material in the surface. 
     The mounting brackets of the present invention ensure that cladding panels can be mounted to structural elements without the panels being fixed directly to the elements by fixtures. As a result, the risk of breaking cladding panels, especially where they are made from plasterboard, is greatly reduced. A fitter does not have to be concerned with how far from an edge of the panel they can use a fixture without cracking or breaking the panel. 
     Additionally, the mounting brackets make it easier for pairs of fitters or joiners to clad a structure. By being able to engage one end of the panel in mounting brackets already fitted to a structural element, a fitter does not need to support the panel or apply fixtures directly to the panel itself. Consequently, fitters can avoid the injuries and discomfort that can occur when having to support and fit a panel at the same time. 
     Both the mounting brackets and concealing members offer a further benefit in that they conceal the gaps between adjacent cladding panels. This removes the need for any additional concealing steps such as the application of a concealing tape over the gaps. A plaster coating can therefore be applied over the brackets, members and cladding panels immediately. By ensuring that the outer, and thus exposed, apertures of each bracket and member are countersunk, the heads of the fixtures used are concealed below the exposed surface. 
     The fixture of the present invention, as shown in  FIGS. 6 and 7 , offers additional benefits for the fitter. As described above, the step provided by the collar of the fixture ensures that material loosened during the driving process is compacted. Consequently, the fixture has an improved grip in the surrounding material. The step also ensures that the fixture cannot be driven too far into the surface. By ensuring that the transition area between the intermediate portion of the fixture head and the lip of the collar has a radius of curvature and the lip has a rounded profile, the risk of breaking relatively friable materials such as plasterboard is reduced. Most conventional fixtures comprise a planar surface between the body of the fixture and the head, where the surface either faces directly towards the material surface or is at an angle thereto. In either case, the flat surface means that large shear forces are applied to the surface material as the fixture is driven in. This often causes fracturing of the surface material. In ensuring that all surfaces of the head of the fixture are covered by the collar, such fracturing is avoiding with the fixture of the present invention. 
     The bodies of the brackets and members are preferably hollow and guide blocks can be provided to ensure that abutting lengths of the components are correctly aligned. Opposite ends of a guide block are fixed into the abutting open ends of the bodies when they are fixed to the structural elements. 
     The flanges extending from the bodies of the mounting brackets and concealing members can be provided with a number of openings therein. When the cladding panels and mounting brackets are being plastered over, plaster will fill the apertures. This can improve the bond between the plaster coat and the mounting brackets and/or concealing members. In a preferred embodiment, the apertures are diamond- or kite-shaped and extend across the entire depth of the flanges. This has been found to set the plaster into the most rigid shape, and thus improve the hold of the plaster on the mounting/concealing components. 
     The head and body of the fixture may be formed separately from the collar. The preferred material for the collar of the fixture is aluminum. The body and head of the fixture are preferably formed from steel. 
     These and other modifications and improvements can be incorporated without departing from the scope of the invention.