Abstract:
A bracket or retrofitting panels to a structure is provided with first, second and top walls which define a channel. The channel is sized and shaped to enclose existing fasteners on the structure. A base flange may cantilever from the first or second walls and extend away from the first and second walls to enable a user to secure the bracket to the structure prior to placing new panels on the bracket. Another base flange may cantilever away from the second wall, toward the first wall, and be sized to place a leading edge portion of the base flange adjacent existing fasteners on the structure to locate the bracket before installation and prevent lateral movement of the bracket along existing panels.

Description:
BACKGROUND 
       [0001]    Lightweight steel-framed structures typically employ ribbed building panels to cover the roof and walls of the structure. Oftentimes, the building panels are constructed from metal, such as steel or aluminum. The building panels are formed to have a rib and valley profile to strengthen the building panels despite their thin construction. 
         [0002]    Over time, due to natural deterioration or damage from various causes, the building panels on structures need to be replaced. However, the removal and replacement of the building panels consumes a great deal of labor and financial resources. Oftentimes, the best solution to the repair of a structure having deteriorating or damaged building panels is to simply retrofit the structure with new roof or wall panels by directly securing the new building panels to the existing building panels. In this manner, the labor and expense of removing the existing building panels can be saved. 
         [0003]    One example of a system for retrofitting a structure with new building panels is taught by U.S. Pat. No. 5,367,848. The system is essentially provided with an elongated bracket having a Z-shaped cross-section. The bracket is designed to extend transversely across the existing building panels adjacent the location of a frame member. A series of notches are formed within the one generally vertical wall member of the Z-shaped bracket to allow the bracket to “nest” onto and over the ribbed profile of the existing building panel. A bottom wall portion extends outwardly from the bracket and is provided with apertures so that the user may secure the bracket to the existing building panel using a plurality of new fasteners. A top flange provides a mating surface for supporting the new building panel. A second series of new fasteners are used to secure the new building panel to the bracket. While the design of the bracket solved a number of problems existing in the art at the time it was introduced, it suffers from a number of deficiencies. First, the goal in retrofitting building panels is to reduce the overall labor and materials required to retrofit the new building panels onto the structure. The design of the Z-shaped bracket requires a full first course of fasteners to secure the bracket to the existing building panel. Then, a full second course of fasteners is required to secure the new building panel to the bracket. An additional deficiency with the bracket stems from its Z-shaped design. The bottom wall member is secured to the existing building panel alone. The new building panel is fastened only to the top wall member of the bracket. Accordingly, there is no direct structural connection between the new building panel and the frame member of the building. The strength of the connection between the new building panel and the building itself depends upon the strength of the bracket. Moreover, the Z shape provides only one vertically-oriented wall member, which provides a less than desirable level of stability when forces are exerted on the new building panels. 
         [0004]    Another example of a system and method of retrofitting building panels is disclosed by U.S. Pat. No. 7,174,686, which is owned by the assignee of the present invention. That system is provided with a bracket having forward and rearward walls that are coupled to one another by a top wall, forming an open channel between the forward and rearward walls. In use, the bracket is disposed along the exterior surface of existing building panels such that a course of existing fasteners is disposed within the open channel of the bracket. One or more new building panels are then placed closely adjacent the top wall of the bracket and a single course of new fasteners is disposed through the new building panels, the bracket, the existing building panels, and a sub-frame of the building. This bracket design provides numerous improvements over other prior art brackets. However, the bracket design does not necessarily provide for accurate placement of the bracket, prior to the installation of the new building panels. An undesirable degree of lateral movement is permitted between the bracket and the course of existing fasteners in certain applications. Moreover, preferred methods of using this design of bracket do not always provide for optimal placement of the bracket to receive the final course of new fasteners that secure the new panels with the structure. 
         [0005]    Accordingly, what is needed is a new system and method for retrofitting building panels to a structure that not only provides a convenient and accurate manner of retrofitting building panels but also decreases the labor and materials required to implement the system, while increasing the overall stability of the new building panels with respect to the structure. 
       SUMMARY 
       [0006]    This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key aspects or essential aspects of the claimed subject matter. Moreover, this Summary is not intended for use as an aid in determining the scope of the claimed subject matter. 
         [0007]    The bracket of the present invention is provided for use in retrofitting new building panels to a structure having existing building panels that are fastened to frame members. The bracket is generally provided with a first wall and a second wall that are coupled to one another at their upper end portions by a top wall. The interconnection between the first, second and top walls defines a channel that extends along the length of the bracket. The bottom end portions of the first and second walls are selectively shaped to mimic the rib and valley profile of the existing building panels, permitting the bracket to substantially engage its lower end portion with the upper surface of the existing building panel. 
         [0008]    One or more base flanges may be provided to cantilever from the lower end portions of the first and/or second walls. In one embodiment, the at least one base flange may cantilever away from the bracket so that it may be used with a small number of fasteners to pre-install the bracket prior to installation of the new building panels. Another embodiment of the base flange may cantilever inwardly, toward a center portion of the bracket. The channel is shaped and sized to substantially enclose the existing fasteners, which couple the existing building panel to the frame member. Accordingly, a single elongated bracket may be positioned to enclose a course of existing fasteners across the existing building panel. The inwardly cantilevered base flange may be positioned adjacent the course of existing fasteners, preventing the bracket from sliding forward or rearward with respect to the existing building panel and properly positioning the bracket. A single course of new fasteners is then used to secure the new building panel to the bracket and the existing building panel. In a preferred embodiment, the fasteners will also engage the frame member. 
         [0009]    It is therefore one of the principal objects of the present invention to provide a bracket for retrofitting new building panels to a structure with a minimal amount of materials and labor. 
         [0010]    A further object of the present invention is to provide a bracket for retrofitting building panels to a structure that can be adapted for use with existing building panels having nearly any profile. 
         [0011]    Yet another object of the present invention is to provide a bracket that reduces the typical number of steps required for retrofitting building panels to a structure. 
         [0012]    A further object of the present invention is to provide a bracket that provides at least one base flange that helps locate the bracket in position before new panels are secured to the bracket and a building structure. 
         [0013]    Still another object of the present invention is to provide a bracket for retrofitting new building panels to a structure that uses a base flange to temporarily secure the bracket to existing building panels, prior to placement of the new building panels. 
         [0014]    Yet another object of the present invention is to provide a bracket for retrofitting new building panels to a structure that uses a base flange to engage existing fasteners on the structure to locate the bracket before its installation. 
         [0015]    These and other objects of the present invention will be apparent after consideration of the Detailed Description and Figures herein. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various views unless otherwise specified. 
           [0017]      FIG. 1  is a perspective view of one embodiment of the bracket of the present invention as the same might be used to secure a new roof panel to an existing roof panel on a structure; 
           [0018]      FIG. 2  is an isometric view of the embodiment of the bracket of  FIG. 1 ; 
           [0019]      FIG. 3  is a top view of the bracket depicted in  FIG. 1 ; 
           [0020]      FIG. 4  is a side elevation view of the bracket depicted in  FIG. 1 ; 
           [0021]      FIG. 5  is a cross-sectional view of the bracket depicted in  FIG. 4 ; 
           [0022]      FIG. 6  is a partial end elevation view depicting one manner in which the bracket depicted in  FIGS. 1-5  could be used to secure a new roof panel to an existing roof panel on a structure; 
           [0023]      FIG. 7  is an isometric view of a second embodiment of the bracket of the present invention; 
           [0024]      FIG. 8  is a top view of the bracket depicted in  FIG. 7 ; 
           [0025]      FIG. 9  is a side elevation view of the bracket depicted in  FIG. 8 ; 
           [0026]      FIG. 10  is a cross-sectional view of the bracket depicted in  FIG. 9 ; 
           [0027]      FIG. 11  is a partial end elevation view depicting one manner in which the bracket depicted in  FIG. 7  could be used to secure a new roof panel to an existing roof panel on a structure; 
           [0028]      FIG. 12  is an isometric view of a third embodiment of the invention; 
           [0029]      FIG. 13  is a top view of the embodiment of  FIG. 12 ; 
           [0030]      FIG. 14  is a side view of the embodiment of  FIG. 12 ; 
           [0031]      FIG. 15  is an end view of the embodiment of  FIG. 12 ; and 
           [0032]      FIG. 16  is a partial end elevation view depicting one manner in which the bracket of  FIG. 12  may be used to secure a new roof panel to an existing panel on a structure. 
       
    
    
     DETAILED DESCRIPTION 
       [0033]    Embodiments of the invention are described more fully below with reference to the accompanying figures, which form a part hereof and show, by way of illustration, specific exemplary embodiments. These embodiments are disclosed in sufficient detail to enable those skilled in the art to practice the invention. However, embodiments may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. The following detailed description is, therefore, not to be taken in a limiting sense in that the scope of the present invention is defined only by the appended claims. 
         [0034]    The bracket  10  of the present invention is generally depicted in  FIGS. 1-16  in various embodiments. A first embodiment of the invention is shown in  FIGS. 1-6  while a second embodiment of the invention is shown in  FIGS. 7-11  and a third embodiment of the invention is shown in  FIGS. 12-16 . Generally, the bracket  10  is provided with a first wall  12 , second wall  14  and a top wall  16 . The first wall  12 , second wall  14  and top wall  16  are coupled to one another so that they define a channel  18  that extends along the length of the bracket  10 . In a preferred embodiment, the lower end portions of the first wall  12  and the second wall  14  are shaped to have a profile that mimics a profile of the rib portions  20  and valley portions  22  of the existing building panels  24 , as depicted in  FIG. 1 , so that the bracket  10  nests with the existing building panels  24 . 
         [0035]    At least one base flange  26  may be coupled with the lower end portion of either or both of the first wall  12  and the second wall  14 . In one aspect, a first base flange  26 ′ may be provided to cantilever away from the first wall  12  and the second wall  14 , such as depicted in  FIG. 2 . In another embodiment, the first base flange  26 ′ may be provided to cantilever away from the lower end portion of the first wall  12  toward the second wall  14 , as depicted in  FIG. 7 . Another aspect of the invention provides for a second base flange  26 ″, which may be provided to cantilever from the lower end portion of the second wall  14 . While it is contemplated that the second base flange  26 ″ could be provided to extend away from both the first wall  12  and the second wall  14 , a preferred embodiment disposes the second base flange  26 ″ in a manner that cantilevers it away from the second wall  14  toward the first wall  12 . One or more embodiments may make it desirable to use both a first base flange  26 ′ and a second base flange  26 ″. However, it is contemplated that only one of a first base flange  26 ′ or a second base flange  26 ″ may be used. In any embodiment, it will be preferred that any base flange  26  be provided to extend along a plane that is generally parallel with a plane along which the top wall  16  extends, as depicted in  FIGS. 5 and 10 . The term “generally parallel” is used as it is contemplated that minor angular positioning or bends in the top wall  16  or the base flange  26  or their orientation with respect to one another may cause a few degrees deviation from parallel, depending upon the circumstances and application at hand. 
         [0036]    The channel  18  should be sized and shaped to substantially enclose one or more of the existing fasteners  28 , which secure the existing building panels  24  to the frame member or purlin  30  of the structure. A new building panel  32  may then be placed into position against the top wall  16  of the bracket  10 . As can be seen in  FIGS. 1 and 7 , the height of the bracket  10  defines the spaced relationship between the existing building panel  24  and the new building panel  32 . Therefore, where a larger or smaller distance between the two building panels is desired, the height of the bracket  10  should be fabricated or adjusted accordingly. This may become particularly relevant where an insulative material is to be disposed between the existing building panel  24  and the new building panel  32 . The insulative material may be one of several known insulative materials used generally in the construction industry and should be selected based upon the particular insulating and environmental conditions present for the given job site. The distance between the existing building panel  24  and the new building panel  32  will also become a consideration where the lifting and flexing effects of wind on the building panels is a concern. 
         [0037]    In the embodiment of  FIGS. 12-16 , the base flange  26 ′″ cantilevers outwardly from the lower end portion of the first wall  12  and a base flange  26 ′″ cantilevers outwardly from the lower end portion of the second wall  14 . 
         [0038]    In use, the bracket  10  is simply positioned so that the profile of the lower end portion of the first wall  12  and the second wall  14  align with the profile of the existing building panel  24  and the channel  18  substantially encloses one or more of the existing fasteners  28 . In one embodiment, the new building panels  32  may be placed against the top wall  16  and secured in place with new fasteners  34 . However, in a preferred embodiment, the bracket  10  will be pre-located, using one or more base flanges  26 , to ensure proper alignment of the bracket  10 . In one aspect, the first base flange  26 ′ may be used to temporarily tack the bracket in position. With the first base flange  26 ′ extending away from both the first wall  12  and the second wall  14 , a mounting flange is provided to receive a small number of new fasteners  34  that will secure the first base flange  26 ′ with at least an existing building panel  24 , as depicted in  FIG. 6 . One or more openings  35  may be provided through the base flange  26 ′, where self-tapping fasteners are not used. Only a small number of fasteners  34  will be required, as permanent mounting will be afforded when the new building panels  32  are secured to the bracket  10  and the structure. Temporarily securing the bracket  10  prevents movement of the bracket  10  with respect to the structure while the new building panels  32  are being located onto the bracket  10 . 
         [0039]    In another preferred embodiment, however, a second base flange  26 ″ is provided, having a leading edge  36  and a depth that extends between the leading edge  36  and the lower end portion of the second wall  14 . The bracket  10  is positioned closely adjacent the outwardly facing surface of the existing building panel  24  so that the leading edge  36  of the second base flange  26 ″ rests closely adjacent at least one existing fastener  28 . The depth of the second base flange is preferably provided so that, when the leading edge  36  of the second base flange  26 ″ is positioned closely adjacent at least one existing fastener  28 , the at least one existing fastener will be positioned adjacent, but not on, an axis that extends perpendicularly through an approximate center of the width of the top wall  16  of the bracket  10 . The reasoning for this will become apparent on examination of  FIGS. 6 and 11 , as a new fastener  34  will later be passed through the center portion of the bracket  10 . Accordingly, the second base flange  26 ″ will locate the bracket  10  such that inserting new fasteners along an approximate centerline of the bracket  10  will ensure that the new fasteners  34  are passed through the relevant structures, near the existing fasteners  28  and into the frame member  30 . Positioning both the first base flange  26 ′ and second base flange  26 ″ to extend inwardly, as depicted in  FIG. 11 , permit both of the base flanges to serve as position locators. In such an instance, however, a sufficient space should be provided between the leading edges of both base flanges to not only permit the passage of head portions of the existing fasteners  28  but also take into account that existing courses of fasteners may deviate from a straight line. 
         [0040]    Once the bracket  10  has been located with respect to the existing building panels  24  and the existing fasteners  28 , new building panels  32  may be positioned atop the top wall  16  of the bracket  10 . New fasteners  34  can be disposed through the new building panel  32  and into the bracket  10 , existing building panel  24 , and preferably the frame member  30  as well. However, it is contemplated that in certain applications, the new building panel  32  may be secured by engaging the fastener  34  with only the bracket  10  and the existing building panel  24 . The fasteners  34  depicted in  FIG. 6  is shown to be a self-tapping screw. However, standard roofing fasteners and the like may all be used, depending on the particular circumstances. 
         [0041]    The first wall  12  and second wall  14  are depicted in  FIGS. 5 and 10  as being spaced from one another in an angular relationship, wherein the upper end portions of the first wall  12  and second wall  14  are spaced from one another a distance that is greater than the distance between the lower end portions of the first wall  12  and second wall  14 . However, variations to this shape are contemplated. For example, the first wall  12  and second wall  14  may be positioned to be generally parallel with one another. Moreover, the size and length of the top wall  16  may be varied to provide a larger or smaller surface upon which the new building panel  32  will rest. However, it is preferred that the first wall  12  and second wall  14  be of generally equal length and in a spaced-apart relationship so that a stable forward and rearward footing is provided, which resists forward or rearward tipping or flexing of the bracket  10  and the new building panel  32 . The stability of the new building panel  32  is amplified when used with the bracket  10  and coupled to the frame member  30 , as depicted in  FIGS. 6 and 11 . In this manner, the stability of the structure is enhanced by the shape of the bracket  10  but not solely dependent thereon. 
         [0042]    Although the invention has been described in language that is specific to certain structures and methodological steps, it is to be understood that the invention defined in the appended claims is not necessarily limited to the specific structures and/or steps described. Rather, the specific aspects and steps are described as forms of implementing the claimed invention. Since many embodiments of the invention can be practiced without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended.