Abstract:
An attic flooring and storage system for laying out a support floor in an attic or other framed structure, the system comprising a number of support brackets with a mounting saddle including at least one mounting guide for removably suspending the brackets over a joist type member while disposing the upper surface of at least one laterally projecting support wing to support and align a flooring panel with at least one angular brace constructed to transfer bending forces about a joint between the support wing and the adjacent mounting guide to the joist.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to a flooring system for use in attics and the like, which have ceiling joists and attic trusses. More specifically, it relates to a storage system that may be quickly, effectively installed using the floor joists. 
     2. Background Art 
     Additional storage place in homes is in great demand worldwide. This is particularly evident with the substantial increase in home based businesses. The most used storage location in a home is the garage. Many, if not most, homes are built with a garage with unfinished attic space. This attic space typically is constructed of joists spaced 16″ or 24″ apart, measured on center. The angular truss system above the joists creates a rather substantial open space that goes unused, or that may be converted into a storage space. 
     Home owners who wish to use this unfinished attic space for storage typically use boards or sheets of plywood, cut or whole, which have been pushed up between the joists and then placed atop the ceiling joists in a more or less haphazard manner. Larger sheets of plywood are frequently difficult to push up inside the attic space due to interference with the network of trusses. Thus, smaller sheets, narrower sheets, and boards are used to create a floor space above the spaced joists. 
     Using the various pieces of assorted wood for a floor usually results in a hodge-podge of floors, some narrow, some wide, and almost always leaves large gaps and unused spaces. In such a configuration placing boxes upon the temporary flooring becomes a challenge whereas some cartons may rest atop two or more spaced boards or may be precariously balanced atop one. At times when a full sheet of plywood is used, boxes are liberally stored atop it, one behind the other, with no access to the rearward boxes. In addition, these makeshift floors are unattractive and unsafe. The removal of cartons, or accidental striking, can result from a fall from the attic. 
     Another approach to creating storage space in a garage attic is to employ a skilled carpenter to build a secure flooring network atop the joists. This option is therefore permanent and requires a well thought out scheme ahead of time in order to ensure adequate use of flooring space, and for desired accessibility to users. Once in place this flooring may not be adjusted to accommodate various box and article sizes. 
     Having a permanent storage flooring installed professionally would typical cost between $1,800-3,500.00 for an average 2 car size garage of 360 sq. ft. This cost includes the materials and labor to (some garage attics having already been enclosed with a sheet rocked ceiling are very difficult to install a permanent flooring system), measure and make cuts to the Plywood sheets to be used as flooring in order to fit around trusses, electrical wiring or any other protruding obstacles. It also includes the labor to secure the flooring to the joists using screws or nails. To properly cut around trusses requires substantial planning and skill and use of power tools. Once the flooring is cut and secured to the joists by nails or screws it is permanent and may not be modified or adjusted without substantial effort and additional cost. 
     One potential solution is the Attic Dek attic flooring plastic panel system available from Home Depot. According to the Home Depot website, the Attic Dek attic flooring panel system provides the user with additional attic storage space. The Attic Dek system is sold in 10 packs of 16 in.×16 in. plastic flooring panels that purport to support up to 250 lb. and are vented so insulation can breathe easily. The panels are installed by laying them on top of ceiling joists and securing them with the included screws. However, the user must verify their joist spacing to avoid ordering wrong size and the 10 pack covers only 26⅔ sq. ft. In addition, this system is relatively expensive, requires some basic carpentry skills, does not work around trusses since the panels are pre-formed and pre-sized and lay directly atop the joists, and is not eco-friendly. 
     Another solution is the Infinite Attic saddle storage system, also available from Home Depot. The saddle storage system is provided in 30-78 Pack assortments that provide approximately 32 sq. ft.-192 sq ft. of brackets for supporting sheets of plywood for storage space in the attic. The saddles are designed to be used with one or more sheets of plywood and must use additional 2×2×8 lumber. The metal bracket has an elongated rectangular central section with a raised flat topped peak that rests atop a joist between two laterally opposed upwardly facing channels with outermost perpendicularly projecting upwardly narrow supports and is roughly similar to a square waveform with an enlarged inverted middle section and two spaced apart shorter channels to support 2×2×8 lumber which a sheet of plywood would lay over. These saddles utilize the available space between the attic trusses for a continuous, platform between trusses. While there are some advantages to such a system, the Infinite Attic saddle storage system requires multiple purchases, is difficult to work around electrical wires and fixtures as well as roof trusses. It requires extra measuring and cutting of the 2×2×8 lumber, some basic carpentry skills, and does not work with most insulation because the system including the 2×2×8 lumber impedes or hangs well over half the joist height, creating an obstacle for the insulation and existing wiring or plumbing. In addition this solution still requires screwing of the 2×2 lumber base and makes the additional cost and purpose of the Infinite Bracket counter intuitive. 
     Reviewing the foregoing solutions, such a seemingly simple task of creating flooring for storage in its unused attic space is expensive, requires extensive carpentry skills or a contractor, is inefficient with respect to installation and space utilization, creates accessibility issues and creates additional problems when encountering existing trusses, insulation, wiring or plumbing. An attic flooring and storage system that overcomes the numerous problems associated with these prior art systems and methods would be valuable to the home trade and many others. 
     SUMMARY OF THE INVENTION 
     The attic flooring and storage system of the present invention overcomes the problems associated with prior art. The present invention is a low cost alternative that may be installed by unskilled home owners and laborers. Likewise it provides a sturdy, flat surface with the potential to maximize the use of the attic space. It may also be changed, modified, or adjusted as desired. 
     The present invention uses our unique brackets to simply be positioned and fit over the attic joists, or rafters, whereby 4×8 sheets of OSB (oriented strand board) or plywood (cut perpendicular to the direction the joist is hung) can be used as flooring. Joists are generally hung 16″ or 24″ on center and therefore 4×8 sheets are to be measured and cut to fit between the joists accordingly. The floor panel then may be inserted into the attic space and thus rest atop the brackets to create a seamless floor. There is no need for cutting and manipulating around the trusses because the floor board lies flush with the top of the joist in between the joists. 
     The present invention consists of one component: a moveable structural bracket that supports substantial weight and holds a flooring panel in place to securely rest atop the structural brackets. Included in the invention is a template which allows the user to easily mark and drill 4 holes on the ends of each 2×4 plank (OSB or Plywood). These holes are used align the tab on the invention into the hole which “snaps” the board in place and holds securely on top of the Fast Floor Brackets. This is done by the user in a matter of minutes. While basic instructions for installation may be provided, the installation and use of the flooring system of the present invention is intuitive to most users. 
     The attic flooring and storage system of the present invention is properly installed without tools and without error. Once installed, users may quickly adjust the flooring space by sliding or moving the brackets along the joist and readjusting the OSB or Plywood panels to again rest securely, with its holes aligned atop the tab on the brackets. An unskilled user may create a longer storage flooring space in a matter of minutes. Likewise a user may disassemble the entire flooring system—brackets and panels—in just a few minutes, and reinstall it in a new location, for example a new home or rented residence. 
     At least one embodiment of the present invention is typically accounting for joists spaced at 16″ and 24″ centers to accommodate the large majority of standardized garage construction. However, any spacing may be fabricated to accommodate standards in countries incorporating the metric system. The unique structural support bracket is designed to mount atop standard non-dimensional wood, either 2×4&#39;s or 2×6&#39;s, in other words it mounts atop a rafter or joist that is approximately 1.5″ wide. Once in place the bracket is movable along the length of the rafter, either by sliding or pick up and replacement at a new location, or may be removed for use at a later time. 
     The present invention may be used in any number of applications in addition to a garage, as, for example, any unfinished attic system in a warehouse, barn, or other buildings. It may also be used in the attic space in the home (as opposed to the garage) in order to quickly create a suitable storage substrate atop the ceiling joists and atop the otherwise vulnerable, weak ceiling material, such as sheetrock or certain types of hanging ceilings. 
     The objectives of the present invention are to provide: 
     1) An attic storage system; 
     2) Creating a storage floor utilizing existing joists and rafters; 
     3) A storage substrate for attics; 
     4) An adjustable storage system; 
     5) An adjustable planar substrate; 
     6) A portable storage system for attics; 
     7) An adjustable support bracket for floor panels; 
     8) A movable support bracket for floor panels; 
     9) Flooring panels for attics; 
     10) Flooring panels for mounting atop support brackets; 
     11) Instructions and template to drill holes on each floor panel to align atop support brackets; 
     12) Flooring panels mounted atop support brackets used for storage; 
     13) A means of installing a storage system atop joists; 
     14) A means of using and storing items above joists; 
     15) A means of adjusting and moving a storage system, and; 
     16) A method of utilizing and securing the flooring panels to the brackets. 
     Furthermore it is an object of this application to illustrate the preferred embodiments and methods, and broadly state the scope of the present invention and its methods of uses. 
     All of the embodiments summarized above are intended to be within the scope of the invention herein disclosed. However, despite the discussion of certain embodiments herein, only the appended claims (and not the present summary) are intended to define the invention. The summarized embodiments, and other embodiments and aspects of the present invention, will become readily apparent to those skilled in the art from the following detailed description of the preferred embodiments having reference to the attached figures, the invention not being limited to any particular embodiment(s) disclosed. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1 a    is a perspective view of a support bracket in accordance with the principles of the present invention. 
         FIG. 1 b    is a perspective view of the support bracket of  FIG. 1 a    of the present invention mounted atop a joist. 
         FIG. 2  is a front view of a variation of the support bracket of the present invention. 
         FIG. 3  is a perspective view of the bottom side of an exemplary floor panel for use with one or more support brackets in accordance with principles of the present invention. 
         FIG. 4 a    is a perspective view of an exemplary floor panel of the present invention positioned above joists having support brackets in place. 
         FIG. 4 b    is a perspective view of the floor panel in  FIG. 4 a    placed atop the support brackets in  FIG. 4   a.    
         FIG. 4 c    is an end view of the floor panel of the present invention placed securely atop two brackets of the present invention. 
         FIG. 5  is a bottom view of a floor panel of the present invention with six notches. 
         FIG. 6  is a perspective view of an alternative embodiment of a support bracket in accordance with the principles of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     A. Description of the Present Invention 
     In  FIG. 1 a    support bracket  10  may be made from one continuous piece of metal in a series of bends with a centrally located upside down “U” member  20 , a left side support member  30 , and a right side support member  40 . Upside down “U” member  20  consists of a top plate  22  and two perpendicular right members or guides  24   a  and  24   b , which are connected to the top plate  22  at bends  26   a  and  26   b . Left and right side support members  30  and  40  consist of top members or wings  32  and  42  respectively, and angular support members or braces  34  and  44  respectively. The two top members  32  and  42  are connected to angular support members  34  and  44  at bends  36  and  46  respectively. As illustrated the braces  34 ,  44  of the respective angular support members  30  and  40  are connected to uprights  24   a ,  24   b  respectively, at bends  28   a  and  28   b  and the wings  32 ,  42  are connected to the uprights  24   a ,  24   b  at welds  38  and  48 , respectively. This forms a hollow space  45 ,  47  between each respective guide, wing, and brace set ( 24   a ,  32 ,  34  and  24   b ,  42 ,  44 ). In this exemplary embodiment, the upper surface of each wing  32 ,  42 , projects outwardly from its respective guide  24   a ,  24   b  at an intermediate point along a length of each guide and includes welds  38  and  48  to create a joint therebetween. By locating the upper surface of each wing below the upper surface of the top plate  22 , the broad wing upper surfaces may accept and support the floor panels from the joists they are suspended therefrom and provide a flat continuous surface over the top surface of each panel and the intermediate top surface of the top plate  22  as illustrated in  FIGS. 4 a , 4 b , and 4 c   . This continuous surface features assists in removing a tripping hazard due to uneven surfaces. 
     In  FIG. 1 b    the support bracket  10  of  FIG. 1 a    is mounted atop joist J with the upside down “U” member  20  serving as a saddle with a top plate  22  resting flush atop joist J and side support members  30  and  40  snugly secured against the two sides of the joist J. The guides may be spaced apart to ease a sliding adjustment along the top surface of the joist or more closely spaced to abut and squeeze the sides of the joist to more securely fix the brackets in place along a length of the joist, although they remain removable. The typical dimensions of the support bracket  10  would be that which fits snug upon attic or ceiling joists. For example, the distance between upright members  24   a  and  24   b  would be about 1.5″ in order to fit snug around a standard 2×4 joist which measures 1.5″ think by 3.5″ high. The length of upright supports  24   a  and  24   b  would typically be about 3.5″ to match the height of a 2×4. The outward length of top members  32  and  42  would typically be equal to the height of uprights  24   a  and  24   b , in other words about 3.5″. This configuration creates equal 45 degree angles at bends  36 ,  46 ,  28   a , and  38   b  (not shown). 
     These angles may be less or more but ideally an angle of about 45 degrees or less on bends  28   a  and  28   b  provide maximum structural capacity for loads to be placed upon the flooring, while providing sufficient surface for the flooring panels to rest upon. The braces  34 ,  44  generally project at an acute angle to their adjacent wings  32 ,  42  toward their adjacent guides  24   a ,  24   b  to intersect the guides at bends  28   a ,  28   b . In addition, the angled supports  34 ,  44  transfer forces placed upon the top wing members  32 ,  42  about the corresponding welded joints  38 ,  48  respectively back into the side of the joist J. This provides additional structural support to the bracket  10  versus a square waveform bracket such as the Infinite Attic support brackets which only have a single stress point at the lower edge leading to a higher likelihood of breakage and injury from a collapsing panel and especially from a weight bearing collapsing panel. The typical width of support bracket  10  is about 1.25″ but this may be increased or decreased as the case may be. Based on the revealed invention and the dimensions illustrated, floor panels mounted atop the support brackets can withstand a load of about 250 lbs per sq. ft. 
     The dimensions of the present invention may vary widely depending upon needs, countries, and the material used. For example, a support bracket may be 5.5″ tall to accommodate 2×6 joists, or a user may use one standard version at 3.5″ tall for all floor joists of 2×4, 2×6, 2×8, 2×10, and so on. Widths may vary and might be substantially wider for industrial applications. The support bracket material may be any number of types of steel, typically of a width of 0.003125 or thicker, but may also be thinner. The present invention may also be constructed of other metals, wood, or a heavy duty plastic. Other suitable materials will occur to one or ordinary skill in the art. The support brackets of the present invention may also include a series of holes such that a user may permanently affix a bracket to a joist or to a panel. 
     In  FIG. 2  support bracket  50  is similar in construction to that of bracket  10  with an upside down “U” shaped member  60 , and two side support members,  70  and  80 . While both are manufactured from a single piece of bent steel, support bracket  50  has bends  68  and  78  instead of welds such as  38  and  48  of  FIG. 1 a   . In this configuration, uprights  64   a  and  64   b  extend upward towards top plate  62  to complete the side support members  70  and  80 . In either bracket  10  or  50 , the structural capacity to withstand loads is about the same. The only difference of import is the lower cost of replacing two welds ( 38  and  48  of  FIG. 1 a   ) with bends  68  and  78 . 
     In  FIG. 3  floor panel  100  of the present invention is illustrated in an inverted disposition for clarity and consists of a bottom surface  110 , a top surface  120 , two ends  130   a  and  130   b , and  2  sides  140   a  and  140   b . Panel  100  is typically constructed of wood, particle board, MDF, laminate, composites, or rigid plastics about ¾″ thick, but other suitable materials and thicknesses may be used. Bottom surface  110  consists of four notches  112   a ,  112   b ,  112   c , and  112   d . These notches correspond in size to the top members  32  and  42  of bracket  10  in  FIG. 1 a   . The forward edge  51 ,  55  and rearward or trailing edge  53 ,  57  of each wing  32 ,  34 , respectively ( FIG. 1 a   ) provide an alignment feature for assisting the user in inserted the wings into the notches or recesses of the panels. It will be appreciated that a suitable alignment alternatives include at least a panel with a downwardly projecting peg for insertion into a recess, notch, or aperture in a corresponding bracket wing, a bracket wing with a boss, tab, or fin for engaging a complementary recess in the lower surface of the panel, and a track extending out of the guides for receiving a panel edge. 
     Installation of panel  100  atop bracket  10  is illustrated in  FIGS. 4 a  and 4 b    and is more efficacious when notches  112   a ,  112   b ,  112   c , and  112   d  are slightly larger than top members  32  and  42 . The depth of notches  112   a ,  112   b ,  112   c , and  112   d  accommodates the lateral wing recess from the top of the central bracket section  22 . However, deeper notches may be used on thicker panels and shallower notches on thinner panels. To provide a continuous upper storage surface, it is preferred to use notches matching the height of the central bracket section  22  relative to the opposing top members  32 ,  42 , respectively. With such arrangement, the upper surface of adjacent panels will be flush with the upper surface of the central bracket section  22  and thus remove likely tripping hazards. 
     Panel  100  may be in a number of sizes based on standard dimensions of spaced joists in a given country or region in that country. The wider the distance between joists typically dictates a thicker panel. An exemplary panel length is typically obtained from cutting a 4′×8′ sheet in half to produce two 4′×4′ panels but that too is not a fixed dimension. Standard lengths, widths, and thicknesses would be established for the various countries and applications. For example, in the U.S. a standard size panel to use above a standard 2×4 joist placed 16″ OC would be 14′/2″ wide and ½ inch to ¾ inch thick. 
     B. Method of Use of the Present Invention 
     In  FIG. 4 a    joists J 1  and J 2  have four support brackets  10   a ,  10   b ,  10   c , and  10   d  such as those in  FIG. 1 , spaced apart at approximately the same distance as notches  112   a ,  112   b ,  112   c , and  112   d  of panel  100 , such as that in  FIG. 3 . Panel  100  is then lowered atop the four support brackets and brackets  10   a ,  10   b ,  10   c , and  10   d  are then moved back and forth along joists J 1  and J 2  until they rest securely in notches  112   a ,  112   b ,  112   c , and  112   d  as illustrated in  FIG. 4 b   . Placement of storage goods may now be placed atop panel  100  up to a 250 lb per sq. ft. load or other storage capacity depending on the materials chosen for and size of the bracket and thickness of the panels. 
     In  FIG. 4 c    panel  100  is securely in place as notches  112   a  and  112   b  rest atop side member  46  of bracket  10   a  and side member  36  of bracket  10   b  respectively. Along either side of the panel/bracket installation as illustrated, additional panels may be placed in the corresponding span between those outward joists (not shown). 
     C. Variations 
     In addition to the many variations previously described, one obvious variation is a longer panel  200  as illustrated in  FIG. 5 . Panel  200  is essentially the same construction as panel  100  except that its longer length contains six notches:  212   a ,  212   b ,  212   c ,  212   d ,  212   e , and  212   f , instead of four. These six notches are specifically engineered to be placed at intervals that maximize structural integrity to meet the desired load requirements. It goes without saying that panels may contain any number of notches depending on length. 
     Another variation of the support bracket may be found in  FIG. 6  wherein like components are like numbered. In this exemplary embodiment, the support bracket, generally designated  310 , generally includes all of the same features as with the support brackets  10 ,  50  with the following variations. Each wing  332 ,  342  includes an upwardly turned tab  333 ,  335 , respectively, which is stamped or pressed out of the wing and bent upwardly to form an opening  337 ,  339 , respectively. The tabs are generally rectangular in vertical profile with rounded upper corners and constructed to engage an opening, recess, or slot in a panel placed thereon. The tabs facilitate alignment of the panels with the underlying support brackets. In this exemplary embodiment, the uppermost extent of each tab does not protrude above the height of the center section  320 . However, the uppermost extent of the tab may be flush with the upper surface of the center section or project beyond the upper surface of the center section. 
     Still referring to  FIG. 6 , the support bracket  330  also includes a set of fastener holes for a more secure assembly. In this exemplary embodiment, there are two fastener holes  351   a ,  351   b  projecting through the on the left brace  334 , two fastener holes  353   a ,  353   b  projecting through the right brace  344 , two fastener holes  357   a ,  357   b  on the left upright  324   a , and two fastener holes  359   a ,  359   b  on the right upright  324   b . The fasteners are generally vertically aligned on each section. They may also be offset from one another is desired to accommodate different fastener patterns. 
     In using the support bracket  330  of  FIG. 6 , a series of holes or slots may be introduced into a support panel. This may be facilitated for alignment purposes using a template. The support brackets  330  are then positioned atop opposing joists as with prior brackets  10 ,  50 . The panel is then placed onto the exposed support brackets to align the upright tabs  333 ,  335  with a corresponding hole, slot, or recess in the panel and then lowered or snapped into placed with the bottom surface of the panel resting atop the underlying wing  332 ,  334 . It will be appreciated that the tabs interlock with the corresponding holes to prevent significant slippage of the panel relative to the support bracket. A plurality of panels and support brackets may be used to provide a continuous or discrete support surface atop the joists. If desired, fasteners such as nails, screws, bolts, ties, straps, may be inserted through one or more fastener holes to secure a support bracket to an adjacent joist. The fasteners may be selected to provide a fixed or releasable connection. 
     The spirit of the present invention provides a breadth of scope that includes all methods of making and using. Any variation on the theme and methodology of accomplishing the same that are not described herein would be considered under the scope of the present invention. For example, the numbers for widths, thicknesses, lengths, recess depths, and other dimensional characteristics used herein are meant to be illustrative and not limiting. 
     Certain objects and advantages of the invention are described herein. Of course, it is to be understood that not necessarily all such objects or advantages may be achieved in accordance with any particular embodiment of the invention. Thus, for example, those skilled in the art will recognize that the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objects or advantages as may be taught or suggested herein. 
     Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. 
     It is also contemplated that various combinations or sub-combinations of the specific features and aspects of the embodiments may be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments may be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above.