Abstract:
A rail mount having a mounting plate and bracket for supporting a flexible conduit, such as plastic or metal tubing. The mounting plate includes upturned, laterally spaced ear portions, each including an aperture for receiving a supporting rail or rails, the rail or rails being suspended between parallel rigid beams, such as floor joists or wall studs.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention relates generally to mounting brackets for flexible conduits, and, more particularly, to such brackets configured for use in mounting flexible conduits to fixed panels, between wall studs, under flooring for supplying radiant heat to homes or other living or office structures. Specifically, the invention relates to an improved mounting plate for support of such brackets. 
         [0002]    For the past several years there has been an increased use of flexible tubing, commonly known as PEX (cross-linked polyethylene) tubing, which is to be used by plumbers in running water lines, versus a long-used copper tubing product. 
         [0003]    Prior to the advent of a clamping structure disclosed in Collins U.S. Pat. No. 6,352,224 (the &#39;224 patent) which is owned by the same Assignee as the present invention, the prior commercial clamping structures suffered from the disadvantage of the flexibility of the conduit itself and the manufacturing tolerances between the conduit position and the position and dimensional spacing of supporting structures. 
         [0004]    Installation of the tubing required significant manipulation of the conduit with respect to the bracket, and in particular, wherein the tubular conduit required a close bend, such as a 90° bend or a U-bend. This was often the case during sinuous installation of tubing used in radiant heating as the tubing was mounted and stretched end-to-end, or floor-to-ceiling of a room or other area. 
         [0005]    The prior &#39;224 patent is directed to a stationary support member providing a protruding bracket configured with an arcuate surface having a relatively close bend for supporting flexible tubular conduit, and to rigidly mount the conduit on a support structure, such as a flat sheet metal mounting plate arranged for direct attachment to a supporting surface. 
       SUMMARY OF THE INVENTION 
       [0006]    An object of the present invention is to provide a new, simple and efficient mounting plate and bracket for a stationary support member and for securing and adjustably mounting flexible tubular members to supporting structures. 
         [0007]    A further, important object of the invention is to provide brackets for supporting the aforementioned tubular members directly to a flat sheet metal mounting plate having means for adjustable attachment to at least one rail member extending across the vertical bracing existing between laterally spaced supporting members, such as vertical studs or horizontally positioned floor joists (parallel beams). A still further object of this invention is to provide brackets of such character that tubular conduit members can be facilely secured thereto with relative ease, but which may be maintained in place following installation thereof. 
         [0008]    In accordance with the initial presentation disclosed in the previous-mentioned &#39;224 patent, and in the concept disclosed herein, the present invention, in its preferred embodiment, may be applied to brackets made of a suitable stamped metallic material and, of a construction which defines a substantially elongated, arcuate, continuous channel for supporting the flexible conduit. The channel remains open for substantially its entire length and includes an intermediate portion, a proximal end portion and a distal end portion, each portion being defined by first and second continuous sidewall members for sidewise support of the conduit. The sidewalls each define a conforming margin configured to follow the arcuate contour of the channel. The undulating, open-ended, marginal contour permits curvilinear, sidewise insertion into the open-sided bracket and retention by the arcuate contour thereof. 
         [0009]    The improved adjustable mounting plate of the present invention includes an inwardly extending, semi-circular, flanged portion providing peripheral support for the inwardly extending proximal end portion of the arcuate bracket and for securing the bracket in direct connection with the mounting plate. When called for, the inwardly extending flanged portion may be of dimension permitting spot welding or brazing securement of the proximal end of the bracket. 
         [0010]    The mounting plate of this invention has been improved to provide facile installation procedure to allow a plumber or other installer, ease in insertion of the bracket unit at any position along the tubing line and securement in several mounting positions relative to a supporting rail or pair of rails adapted to extend across the open area of the space defined by parallel stationary support members, such as partioning wall studs or horizontal, closely positioned, floor joists. 
         [0011]    In particular, and as disclosed and claimed in the aforementioned &#39;224 patent, the arcuate channel of the bracket member preferably includes oppositely positioned sidewalls for sidewise support of the flexible conduit. The sidewalls and channel define a proximal end portion, an intermediate portion and a distal end portion for adjustable and removable support of the conduit. The first-mentioned sidewall is preferably tapered at its proximate end towards the mounting bracket to provide a semi-circular formation mating with an inwardly extending, semi-circular, flange, and which may be fastened thereto by means of spot welding or other securement means. 
         [0012]    These and other objects and features will become apparent to those skilled in the plumbing installation and other conduit installation arts upon reading the following description, and with reference to the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a perspective view of a clamping device including the improved, but unmounted version of the mounting plate of this invention, and having means for supporting a flexible conduit to be adjustably secured to a longitudinally extending rail member. 
           [0014]      FIG. 2A  is a perspective view of another embodiment of this invention illustrating the mounting plate/bracket assembly in further detail and comprising the improved clamping device of  FIG. 1 . 
           [0015]      FIG. 2B  is a right-side view, partially in section, of the second embodiment of the present invention taken along a plane  2 B- 2 B of the embodiment shown in the view of  FIG. 2A . 
           [0016]      FIG. 2C  is a right-side elevational view, similar to the view of  FIG. 2B , but further illustrating the embodiment of  FIG. 1 . 
           [0017]      FIG. 3  is a right-side elevational view of the clamping device of  FIG. 2B , and including a fragmentary distal portion of a flexible conduit (shown in phantom) supported by the clamping device of FIG.  2 B. 
           [0018]      FIG. 4  is a left-side elevational view, partially in section, of the integrally stamped and formed embodiment disclosed in the views of  FIGS. 2A and 2B . 
           [0019]      FIG. 5  is a front elevational view of the embodiment disclosed in  FIGS. 2A and 2B . 
           [0020]      FIG. 6  is a rear elevational view of the embodiment disclosed in  FIGS. 2A ,  2 B, and  5 . 
           [0021]      FIG. 7  is a top plan view of the embodiment of  FIGS. 2A and 2B . 
           [0022]      FIG. 8  is a bottom plan view of the embodiment disclosed in  FIGS. 2A and 2B . 
           [0023]      FIG. 9  is a perspective view of an installation of the improved clamping devices of this invention, and further illustrating the improved mounting plates being supported by a single rail member having a latching finger embodiment of  FIGS. 2A and 2B , and extending between two stationary support members, such as upright parallel studs customarily supplied for support and definition of defining wallboards. 
           [0024]      FIGS. 10A and 10B  are each illustrative of typical installations of the stationary mounting plate of the embodiments shown, in particular, in the view of  FIG. 4 . 
       
    
    
       [0025]    The view of  FIGS. 9 and 10A , for instance, show the improved mounting plate mounted on a single rail member, which rail member extends across the space defined by parallel, oppositely disposed, supporting wall stud members, and whereas the views of  FIGS. 10B and 11  illustrate the plate being further secured by means of a pair of parallel, spaced-apart, rail members  25 ,  26  where an installation so requires. 
         [0026]      FIG. 11  additionally illustrates the front side of a double rail support version of the mounting support plate of the present invention utilizing the addition of a conventional fastener, such as screw or bolt extending through the exposed mounting plate surface and through the additional surface of the added supporting rail where added strength is desired or required. 
       DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0027]    Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiments have been described, the details may be changed without departing from the invention, which is defined by the claims. 
         [0028]      FIGS. 1 through 11 , inclusive, illustrate preferred embodiments of the present invention as applied to a flexible tubular conduit of PEX cross-linked polyethylene material (shown in phantom in  FIG. 3 ). 
         [0029]    In the various drawing figures, it will be noted that the clamping device, denoted generally by the reference numeral  11 , includes the mounting plate  12  which may be stamped from a sheet-like metallic material, or vacuum-formed from a plastic molding material, or otherwise fabricated to include a circular opening  14  defined by an inwardly extending annular flange  16  surrounding the circular opening  14 , as shown. The flange  16  may be formed by conventional fabrication techniques, including use of punching, drawing or spinning tools and fixtures. 
         [0030]    The circular flange  16  is arranged to secure the supporting bracket  17  to the mounting plate  12  by means of spot welding, brazing or simple clamping, where feasible. It is also within the province of this invention to supply a mounting plate  12  made of a vacuum-formed, or other plastic forming techniques used in fabricating flat, sheet-like objects. In such case, plate  12  and the supporting bracket  17  may be joined together by means of conventional adhesive bonding or similar securing means for attaching adjoining plastic or resinous members. 
         [0031]    Although it is preferred to use metallic stampings to provide the clamping device  11 , it is within the province of this invention to utilize molded members of resinous plastic materials. 
         [0032]    The mounting plate  12  further includes a plurality of openings or apertures  20  for mounting the plate  12  and supporting bracket  17  to a stationary support structure, such as the laterally spaced, vertical wall studs  24  (see  FIG. 9 ). 
         [0033]    As shown in detail in the views of  FIGS. 1 ,  2 A,  2 B,  3 ,  4 ,  6 - 9 ,  10 A,  10 B, and  11 , the improved mounting plate  12  may be further stamped and bent to provide laterally spaced, upstanding ear portions  22 . The ear portions  22  are each preferably provided with elongated apertures or slots  23  for slidably receiving a rail member  25  (see  FIGS. 9-11 , inclusive) and in particular, where further support is required, a pair of rail members  25  and  26  (see  FIGS. 10B and 11 ). The rail members  25  and/or  26  are preferably stamped from flat stock and thereafter being seated within the respective slots  23  of the ears  22  of the respective versions of the mounting plate  12 . The rail members  25  and/or  26  are commercially known as HICO bars and come in predetermined lengths such as 18, 26 and 28 inches. Each rail member  25  and  26  typically has a series of uniform openings or apertures  27  formed along it length. Preferably, respective plate apertures  20  and rail apertures  27  may be aligned for positioning the mounting plate  12  longitudinally relative to both rails  25  and  26  for additional stability. 
         [0034]    As stated previously, the supporting bracket  17  is preferably formed from a sheet metal stamping to provide a continuous arcuate channel  19  having a proximal end  18  seated in the opening  14  of the plate  12  supported by and secured therein by means of the inwardly extending flange  16 . The surrounding flange  16  may be crimped around the bracket  17 , and if necessary, it may be spot welded or brazed to the proximal end  18  of the bracket  17 . The channel  19  includes oppositely disposed sidewalls  35  and  36 . As will be apparent from  FIGS. 1 and 2A , the sidewall  35  includes a crested intermediate portion  37  which extends above the margin  38  defining the sidewall  35  and tapers downwardly at both proximal end portion  18  and its distal end portion  40 . 
         [0035]    With particular regard to the views of  FIGS. 1 and 2A , it will be observed that an operating embodiment of the improved mounting plate  12  includes the feature or features of a simplified locking or latching means, in the form of the latching finger  45 / 50  for retaining the desired relative lateral position between the adjoining supporting rail  25  and/or rail  26  and the mounting plate  12 . The resilient latching finger  50  may be pierced or lanced and integrally formed or bumped to be laterally extending from the underside of the plate  12 , as shown in the embodiments of  FIGS. 2A ,  2 B and  5 . Thus, the leaf-like remaining free end portion of the biasing latching finger  45  may be stamped and formed to have its proximal end  46  being an integrally formed portion of the mounting plate  12  (see  FIG. 5 ). As illustrated in the embodiment of  FIGS. 1 and 2C , the latching finger  45  may be formed as a separate and independent member riveted (see rivets  52 ) or otherwise secured at its proximate end  53  by spot welding or other known securing technique. The distal end portion  46  is formed by known forming techniques and fixturing and tooling to be free from the surface of the mounting plate  12 . The distal end portion  47  the latching finger  45  is further bent, or otherwise formed, to be initially spaced from the inner surface of the plate  12  for freedom of movement during installation and positioning of the plate  12  with respect to the selected aperture  20  of the plate  12  and mating with the registering coaxial aperture  27 , in either or both of the selected rail members  25  or  26 . Thus, the distal end portion  47  of the latching finger  45 , as shown in  FIG. 2B , may be upended to further define a tapered tine portion  48  adapted to be biased towards insertion within the selected aperture  30  of the rail  25  or  26  when used. The tine portion  48  preferably extends through the aperture  30  of the respective rail members  25 ,  26  to the corresponding coaxial aperture  20  of the mounting plate  12 , thereby latching or locking the plate  12  to the respective rail  25 . 
         [0036]    Another embodiment of the present invention may be provided where relatively sophisticated fabrication techniques are available. The latching embodiment of  FIGS. 2A ,  2 B,  4 - 11 , inclusive, provide for an integrally formed leaf-like latching finger  50 . The embodiment of  FIGS. 1 and 2B  include an independently formed latching finger  45  stamped and formed from a flat sheet similar material thickness to that of the plate  20 . The latching finger  45  is mounted at its proximate end  53  to the plate  12  by means of conventional rivets  52 . 
         [0037]    It will also be apparent from the view of  FIG. 11 , that separate latching means may be provided by a self-tapping threaded screw  60  extending through the selected coaxial openings  20  and  30  respectively located in plate  12  and rail  25 ,  26 . A combined nut and bolt fastener  60  (not shown) may also be substituted for the screw  60 . 
         [0038]    Multiple plates  12  can be mounted on a single rail  25 . For example and as shown in  FIG. 9 , two plates could be used in an application calling for both hot and cold water supplies. In addition, it is contemplated that more than two plates  12  could be mounted on a single rail  25  as well. 
         [0039]    The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.