Abstract:
A hanger bracket for mounting a skewed beam at a junction of two adjacent beams includes a supporting section configured to support the skewed beam. Fixing flanges substantially perpendicular to the supporting section are configured for attaching the bracket to the adjacent beams along surfaces of the fixing flanges positioned to engage respective ones of the adjacent beams when attached thereto. The surfaces define planes that are non-parallel and non-coincident with each other. Reinforcing faces are located between the supporting section and each of the fixing flanges. The reinforcing faces are inclined relative to the supporting section and fixing flanges. Holes in at least one of the supporting section and the reinforcing faces are configured to receive fasteners to secure the skewed beam to the hanger bracket.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. application Ser. No. 14/265,006, filed Apr. 29, 2014, the entirety of which is incorporated herein by reference. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    This invention relates to a hanger bracket for mounting a beam at a junction of two adjacent beams, particularly for mounting a skewed beam between two adjacent beams. 
       BACKGROUND 
       [0003]    Trusses used in building constructions largely comprise roof trusses and floor trusses. To achieve a variety of building frame designs truss-to-truss connections can be perpendicular and also skewed. In roof trusses a skewed truss is used to form a ‘hip’ roof and the roof trusses are known as hip trusses. The trusses in a ‘hip’ roof are designed such that, at a junction of two trusses, there is a third truss which intersects the junction at an angle. Generally, the junction between adjacent beams in a hip roof is a perpendicular junction between the two adjacent beams. Such trusses are found not only in hip roof trusses, but could also apply to floor trusses supporting a skewed floor truss or any other trusses fixed at an angle to a junction, and are referred to herein as a ‘skewed truss’. Such connections are therefore made at a junction of two beams, where a third beam intersects the junction at an angle. 
         [0004]    There are standard techniques for mounting a skewed truss or beam in-between a perpendicular truss and a girder truss. One technique is to mount both the skewed truss and the perpendicular truss using a single bracket. When using a single bracket the weight of the skewed truss and the perpendicular truss are supported by the bracket, which is fixed to the girder truss. The skewed truss is secured in position on the bracket and between the girder truss and perpendicular truss by a tie that is nailed to the skewed truss. The disadvantage of this method is that the bracket is not necessarily optimised for the purpose of supporting a skewed truss, resulting in the securing method being unstable and the bracket being oversized. Furthermore, heavy loads from skewed trusses can lead to deflection of brackets. 
         [0005]    There also exist fixed angle brackets for mounting to a girder truss that allow both a perpendicular and a skewed truss to be mounted. However, each bracket is restricted to a single angle at which the skewed truss can be mounted, and have complex geometry to accommodate mounting multiple trusses. 
         [0006]    Another technique for mounting a skewed truss or beam is to first mount the perpendicular truss to the girder truss with a first bracket, and then use a supplementary bracket, known as a hanger bracket, to mount the skewed truss. The supplementary bracket relies on the perpendicular truss connection to already be made, at least in part, by the first bracket. The supplementary hanger bracket is then mounted to the already constructed perpendicular connection, and the skewed truss, supported on the hanger bracket, is secured thereto from underneath through one or more holes in the bottom of the hanger bracket. This technique is effective in securing the hip truss to the hanger bracket; however, the supplementary bracket has been known to deflect under loads, resulting in shifting of the skewed truss. Another disadvantage of the supplementary bracket method is that the head of the fixing screw can interfere with the plasterboard ceiling, which is mounted directly onto the underside of the truss or beam. 
         [0007]    The current methods and products for attaching a skewed beam, while effective, could be improved. 
       SUMMARY 
       [0008]    In one aspect, a hanger bracket for mounting a skewed beam at a junction of two adjacent beams generally comprises a supporting section configured to support the skewed beam. Fixing flanges substantially perpendicular to the supporting section are configured for attaching the bracket to the adjacent beams along surfaces of the fixing flanges positioned to engage respective ones of the adjacent beams when attached thereto. The surfaces define planes that are non-parallel and non-coincident with each other. Reinforcing faces are located between the supporting section and each of the fixing flanges. The reinforcing faces are inclined relative to the supporting section and fixing flanges. Holes in at least one of the supporting section and the reinforcing faces are configured to receive fasteners to secure the skewed beam to the hanger bracket. 
         [0009]    In another aspect, a hanger bracket for mounting a skewed beam at a junction of two adjacent beams generally comprises a supporting section having a first side edge and a second side edge opposite the first side edge. A first reinforcing face extends upward from a bend along the first side edge of the supporting section. The first reinforcing face has an angled edge opposite the bend along the first side edge of the supporting section. A second reinforcing face extends upward from a bend along the second side edge of the supporting section. The second reinforcing face has an angled edge opposite the bend along the second side edge of the supporting section. A first fixing flange extends upward from a bend along the angled edge of the first reinforcing face. A second fixing flange extends upward from a bend along the angled edge of the second reinforcing face. The first and second fixing flanges are non-parallel and non-coincident with each other. 
         [0010]    In yet another aspect, a hanger bracket for mounting a skewed beam at a junction of two adjacent beams generally comprises a supporting section configured to support the skewed beam. Fixing flanges substantially perpendicular to the supporting section are configured for attaching the bracket to the adjacent beams. The fixing flanges lye in different planes to each other. Reinforcing faces are located between the supporting section and each of the fixing flanges. The reinforcing faces are inclined relative to the supporting section and fixing flanges. The reinforcing faces have one or more holes configured to receive fasteners to secure the skewed beam to the hanger bracket. 
         [0011]    In an embodiment of the invention the reinforcing faces are structured to bear the load of the skewed beam. In some embodiments the reinforcing faces form a diagonal inclination between the support section and the fixing flanges. In further embodiments, the reinforcing faces are inclined at obtuse angles relative to the supporting section and fixing flanges. 
         [0012]    In a further embodiment the supporting section has one or more holes through which the skewed beam is secured to the hanger bracket. 
         [0013]    In another embodiment of the current invention the reinforcing faces have one or more holes through which the skewed beam is secured to the hanger bracket and, in some embodiments, the supporting section defines a lowermost plane of the bracket and holes in the securing faces are positioned above the lowermost plane. 
         [0014]    In yet a further embodiment of the invention the reinforcing faces are inclined relative to the supporting section at an inclination angle of between 5° and 85°, and preferably between 30° and 60°. 
         [0015]    In an embodiment each reinforcing face is substantially triangular, whereby the supporting section is connected along one side of the triangle and a fixing flange is connected along another side of the triangle. 
         [0016]    In order to use the bracket in combination with different girder brackets, the fixing flanges may, in one aspect, have groups of fixing holes where each group corresponds to overlap with the fixing holes of different girder brackets, over which the hanger bracket can be fixed. 
         [0017]    The hanger bracket is preferably formed by folding a blank of sheet metal that has been cut to shape, and that may have been first pre-punched, pre-lasered or pre-drilled with fixing holes. 
         [0018]    Other features will be in part apparent and in part pointed out hereinafter. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  is an isometric view of a hanger bracket in accordance with an embodiment of the invention; 
           [0020]      FIG. 2 a    is a front view of the hanger bracket without mounting or securing holes shown; 
           [0021]      FIG. 2 b    is a plan view of the blank with the fold lines denoted; 
           [0022]      FIG. 3  is a plan view of the bracket; 
           [0023]      FIG. 4  is a side view of the bracket; 
           [0024]      FIG. 5 a    is an isometric view of the bracket in use mounted to a small girder bracket, with the skewed beam secured from underneath; 
           [0025]      FIG. 5 b    is an isometric view of the bracket in use mounted to a large girder bracket, with the skewed beam secured from underneath; 
           [0026]      FIG. 5 c    is an isometric view of the bracket in use mounted to a small girder bracket, with the skewed beam secured from the sides; and 
           [0027]      FIG. 5 d    is an isometric view of the bracket in use mounted to a large girder bracket, with the skewed beam secured from the sides. 
       
    
    
       [0028]    Corresponding reference characters indicate corresponding parts throughout the drawings. 
       DETAILED DESCRIPTION 
       [0029]      FIGS. 1 to 5   d  illustrate a hanger bracket  100  for mounting a skewed beam  600  at a junction of two adjacent beams.  FIGS. 5 a  to 5 d    show the two beams which form the junction as perpendicular beams  400 ,  500 . 
         [0030]    The hanger bracket  100  comprises a horizontal supporting section  120  to support a skewed beam  600  and fixing flanges  140 ,  142 , that attach the hanger bracket  100  to the perpendicular beams  400 ,  500 . Fixing flanges  140 ,  142  attach to vertical faces of adjacent beams  400 ,  500  so that supporting section  120  lies horizontally to support the load of skewed beam  600 . The spatial planes in which the fixing flanges lie are different to each other as the fixing flanges are intended to fix to adjacent beams that lie in different planes, and namely that meet at an angled junction, such as the perpendicular junction illustrated. It is however understood that the junction could be formed at any angle greater than 0° and less than 180°, and hence the fixing flanges  140  also lie in planes that are angled at greater than 0° and less than 180°. 
         [0031]    Reinforcing faces  130 ,  132  located between the supporting section  120  and each of the fixing flanges  140 ,  142  are inclined relative thereto and connect the supporting section  120  to each of the perpendicular fixing flanges  140 ,  142 . The supporting section  120  and/or reinforcing faces  130 ,  132  also have one or more securing holes  122  through which the skewed beam  600  can be secured to the hanger bracket  100  using screws  700 . The screws  700  used for securing the skewed beam  600  may have a countersunk head, capable of being recessed into the supporting section  120 , in order to avoid protrusion of the head of the screw into the plasterboard ceiling. 
         [0032]    In this description it is understood that the term ‘skewed beam’ can also refer to a skewed truss, such as a ‘hip truss’, or any other structural component to be joined to another structural component at an angle other than 90° or a straight connection. 
         [0033]    Referring to  FIGS. 2 a    and  2   b,  the supporting section  120  may be substantially the same width as the skewed beam  600 , reducing the likelihood of deflection of the supporting section  120  due to the weight of the beam  600 . Furthermore, by connecting the fixing flanges  140 ,  142  to the supporting section  120  by the most direct path the reinforcing faces  130 ,  132  form rigid struts that bear the load of the skewed beam  600  and strengthen the hanger bracket  100 . This is achieved by having a diagonal inclination angle α between the supporting section  120  and the fixing flanges  140 ,  142 . The angles between the fixing flanges  140 ,  142  and the reinforcing faces  130 ,  132  are obtuse angles. Furthermore, the angles between the reinforcing faces  130 ,  132  and the supporting section are obtuse angles. 
         [0034]    Referring to  FIGS. 1, 2   a,    3  and  4 , when using the securing holes  122  of the reinforcing faces  130 ,  130  the screws  700 , or other fasteners such as bolts or nails, are used to secure the skewed beam  600  in a manner whereby the screws  700  do not protrude into the plasterboard ceiling that is mounted directly onto the underside of the beams. This is achieved by positioning the securing holes  122  in the reinforcing faces  130 ,  132  higher than the supporting section  120  which supports the skewed beam  600 , and namely higher than a lowermost plane in which the supporting section  120  lies, so that the screws  700  enter at an angle and the heads of the screws  700  do not protrude lower than the supporting section  120 , or the lowermost plane. 
         [0035]    It is understood that the invention will function using either the securing holes  122  of the supporting section  120  or the securing holes  122  of the reinforcing faces  130 ,  132 . As such, choosing to only include only one set of securing holes  122  would not deviate from the scope of the invention. 
         [0036]    The hanger bracket  100  is typically used as a secondary bracket, or supplementary bracket, in conjunction with a girder bracket. Illustrated in  FIGS. 5 a  to 5 d    is a hanger bracket  100  used in conjunction with a large girder bracket  200  or a small girder bracket  300 , in order to support and secure a skewed beam  600  (forming the lower chord of a ‘hip truss’) between perpendicular beams  400 ,  500 .  FIGS. 5 a  and 5 b    show securing the skewed beam  600  through securing holes  122  in the supporting section  120 .  FIGS. 5 c  and 5 d    show the skewed beam  600  secured through securing holes  122  in the reinforcing faces  130 ,  132 . 
         [0037]    The fixing flanges  140 ,  142  of the hanger bracket  100  each have a number of fixing holes  144 . As shown in  FIGS. 5 b  and 5 d    the fixing holes  144  of the hanger bracket  100  are positioned such that the fixing holes  144  align with mounting holes in larger girder bracket  200 .  FIGS. 5 a  and 5 c    illustrate the hanger bracket  100  mounted over a small girder bracket  300 , with fixing holes  144  of the hanger bracket  100  aligning with the mounting holes of the small girder bracket  300 . In this embodiment of the hanger bracket  100  the fixing holes  144  in the fixing flanges  140 ,  142  include a group of holes for alignment with the large girder bracket  200  and a group of holes for alignment with the small girder bracket  300 . It is understood that fixing holes  144  need not align with more than one girder bracket  200 ,  300  and could be arranged to only align with one size or one manufacturer&#39;s girder bracket. Additionally, it is also understood that the fixing holes  144  could be positioned to align with other brackets. 
         [0038]    As shown in  FIGS. 5 b  and 5 d    the hanger bracket  100  is fixed to the perpendicular beams  400 ,  500  by screws which extend through the fixing holes  144  in the fixing flanges  140 ,  142  and through the mounting holes of the large girder bracket  200 .  FIGS. 5 a  and 5 c    illustrate a similar situation, in which the hanger bracket  100  is mounted over the small girder bracket  300 , through mounting holes. It is understood that the screws for fixing the hanger bracket  100  to the perpendicular beams  400 ,  500  could be replaced with any fixing means that serve this function, for example bolts or nails. 
         [0039]    Once the hanger bracket  100  is mounted to the perpendicular beams  400 ,  500 , the skewed beam  600  can be placed on the supporting section  120  of the hanger bracket  100 , providing vertical support to the skewed beam  600 . The skewed beam  600  can be permanently secured to the hanger bracket  100  by screws  700  through securing holes  122  in the supporting section  120  or securing holes  122  in the reinforcing faces  130 ,  132 . Alternatively, the skewed beam  600  can be permanently secured to the hanger bracket  100  by screws  700  through securing holes  122  in the supporting section  120  and securing holes  122  in the reinforcing faces  130 ,  132 . 
         [0040]    As discussed, the reinforcing faces  130 ,  132  of the hanger bracket  100 , which are inclined from the supporting section  120  to the fixing flanges  140 ,  142 , may have securing holes  122  for securing the skewed beam  600  to the hanger bracket  100 . The skewed beam  600  can be permanently fixed to the hanger bracket  100  by screws  700  which extend through the securing holes  122  in the reinforcing faces  130 ,  132 . As the reinforcing faces  130 ,  132  are inclined, when the screws  700  are in their final position the heads of the screws  700  are also above the lowermost plane of the hanger bracket  100 , and as a result will also be above the ceiling line and will not protrude into the plasterboard ceiling. 
         [0041]      FIGS. 2 a  and 2 b    illustrate a blank  110  from which the hanger bracket  100  is formed. The blank  110  consists of five regions: the supporting section  120 ; two reinforcing faces  130 ,  132 ; and two fixing flanges  140 ,  142 . The regions are denoted by bend/fold lines  114 ,  115 ,  116 ,  117 . Bend line  114  and bend line  115  are on opposite sides of the supporting section  120 , bend line  114  and bend line  116  are on opposite sides of the first reinforcing face  130 , and bend line  115  and bend line  117  are on opposite sides of the second reinforcing face  132 . The holes  122 ,  144  can be either formed at the same time as the blank  110 , or can be punched, drilled or lasered, or the like, once the blank is formed. 
         [0042]    The blank  110  can be made out of sheet metal; however it could also be made of other materials. Preferably the blank  110 , and the holes  122 ,  144 , are stamped from sheet metal that is between 1 mm to 3 mm thick. It is, however, understood that other methods of manufacturing, such as laser cutting, and/or using another thicknesses of material would be capable of providing a similar outcome without moving away from the scope of the current invention. 
         [0043]    As will be clear, the positions at which the bend lines  114 ,  115 ,  116 ,  117  are placed, and the angle at which the reinforcing faces  130 ,  132  and fixing flanges  140 ,  142  are bent, will be directly related to the specific design. In this embodiment the reinforcing faces  130 ,  132  are substantially triangular with the supporting section  120  connected along one side of the triangle and a fixing flange  140 ,  142  connected along another side of the triangle. An inclination angle α of 45° is considered ‘ideal’, however, various constraints will affect the angle that is chosen for a specific hanger bracket  100 . However, it is understood that, depending on the shape of reinforcing faces  130 ,  132 , the inclination angle between the reinforcing faces  130 ,  132  and the supporting section  120  could range from anywhere between 5° and 85°, and more preferably between 30° and 60°. 
         [0044]    While the embodiment of the hanger bracket  100  shown in the figures is designed for a skewed beam  600  at an angle of 45°, it can accommodate a limited range of skewed angles either side of 45°. It is also understood that if a skewed beam  600  is required to be mounted at an angle other than substantially 45° the bend lines  114 ,  115 ,  116 ,  117 , and the angle at which the reinforcing faces  130 ,  132  and fixing flanges  140 ,  142  are bent, may be modified to accommodate a skewed beam at the desired angle. 
         [0045]    Referring to  FIG. 1 , the hanger bracket  100  is formed by folding the blank  110  at bend lines  114 ,  115 ,  116 ,  117 . The bend lines  114 ,  115 ,  116 ,  117  are positioned such that when folded the supporting section  120 , the first fixing flange  140 , and the second fixing flange  142 , are perpendicular to each other, that is, the face of each is perpendicular to the other two faces. 
         [0046]    From the foregoing, it is evident that the present invention provides a bracket, for mounting a skewed beam, including trusses, at a junction of two beams, which is less likely to deflect under the weight of the skewed beam. 
         [0047]    Furthermore, it is evident that the present invention may also provide the ability to mount a skewed beam, including trusses, at a junction of two beams, using a hanger bracket that allows the fasteners securing the skewed beam to be attached above the ceiling line. 
         [0048]    It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention. As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 
         [0049]    In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word “comprise” or variations such as “comprises” or “comprising” is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.