Field of the Invention

The present invention relates to spacer brackets and/or support brackets of the type used in support grids for secondary sheeting on top of original roof structures. More specifically, the invention relates to spacer brackets used in the construction of roof insulation systems. The brackets of the invention may also be used on wall structures such as fagades.

Background

A common wall or roof structure, sometimes also called a ‘twin skin’ structure, comprises two layers, an outer skin structure and a structure underneath, providing space for insulation material between the two layers.

Such a wall or roof structure comprises as support in the space between the two layers a grid of metal bars supported on an array of metal brackets mounted on the structure underneath. The structure underneath may be roof purlins or an existing roof or wall. The brackets are typically L-shaped, comprising a shaft and a foot, the shaft for connecting with the outer structure and the foot for affixing to the structure underneath. An outer structure such as a roof membrane, metal cladding or rain screen, is then affixed to the grid. By way of the bracket, a cavity may be provided between the structure underneath and the outer structure, which can be filled with insulating material to improve the energy rating of the building beneath. Such grid and bracket structures are described in United Kingdom patent publications GB2240558B and GB2509301 B by the present applicant.

The present invention is concerned with providing improvements to existing roof arrangements.

Summary of the Invention

In accordance with a first aspect of the invention, there is provided a spacer bracket as defined in claim 1. The spacer bracket is for a support grid system of the type comprising elongate bars. The spacer bracket comprises a stem with a head portion at its proximal end and a foot at its distal end. The head portion comprises an engagement arrangement to connect the spacer bracket in a transverse orientation relative to an elongate bar to be provided. The bracket comprises in the transverse orientation laterally of the head portion one or more elongate passages.

Support grid systems provide support to an outer sheet or cladding structure on an inner structure beneath. Support grid systems are typically comprised of a grid of metal bars (also called grid bars) or beams. The grid is supported on spacer brackets. Spacer brackets may be made from sheet metal, typically formed with angles, ribs and/or corrugations for stability. The grid bars are of elongate dimension and the support brackets if positioned underneath are typically oriented transversely to the elongate dimension, i.e. such that the plane of the metal sheet extends perpendicularly to the extension of the metal bar.

The elongate passages are suitable to serve as channel or guide for fixing means such as screws. By positioning the elongate passages laterally of the head portion, i.e. laterally of the engagement arrangement to connect with the elongate bar, it can be achieved that the elongate passages are also located laterally of the elongate bar once the spacer bracket is connected to it. This makes the elongate passages more easily accessible from above, e.g. to insert or tighten fixtures, by minimising an overlap with the elongate bar.

The more lateral positioning of the elongate passages for the fixing means also allows a wider footprint to be designed of the fixing means received therein, with correspondingly improved load capacity.

In some embodiments, the head portion protrudes proximally of the stem beyond the elongate passages.

The elongate passages may extend along only part of the length of the spacer bracket. The head portion, and in some embodiments also a portion of the stem, may therefore extend further (i.e., higher up for a vertically installed bracket) than the elongate passages. This allows shorter fixing means such as screws to be used, compared to an arrangement in which the elongate passages extend over the full length of the spacer bracket.

In some embodiments, at least one of the elongate passages is provided with pre inserted fixing means, such as screws, bolts, or nails.

As the elongate passages are positioned laterally of the elongate bar these can be mounted before or after the spacer bracket is offered to the elongate bar. The screws may be preloaded in the elongate passages to further simplify the installation of the spacer brackets.

In some embodiments, the one or more elongate passages are formed by edge portions of the stem.

For instance, the elongate passages may be formed by turning or beading an edge of the stem sufficiently to provide a channel. Particularly for sheet metal brackets this allows an elongate passage to be formed integrally with the stem.

In some embodiments, one or more elongate passages are angled towards the foot.

The inclined angle achieves a better resilience against lateral loads. By positioning the elongate passages laterally of the stem along only part of the length of the stem, the angle of incline can be designed independently of the length of the stem. Further, the elongate passages facilitate maintaining a pre-determined angle of the fixing means.

In some embodiments, the proximal ends of the elongate passages protrude laterally beyond the head portion.

The proximal ends are understood to be the ends nearer the head portion (i.e., the upper ends for a vertically installed bracket), where a screw is to be inserted. In some variants, the distal ends of one or more elongate passages may have a small degree of overlap with the head portion. By ensuring that at least the proximal ends are laterally outside the footprint of the head portion, the elongate passages are easily accessible for fixing means. In some embodiments, two elongate passages are on opposite sides of the head portion.

Thereby the elongate passages are positioned on both sides of the elongate bar when the spacer bracket is attached to the elongate bar.

The spacer bracket may be of unitary construction. In some embodiments, the spacer bracket is manufactured from a sheet metal, such as galvanised steel. In some embodiments, the elongate passages are integral with the spacer bracket. In some embodiments, the head portion is integral with the spacer bracket. It will be understood that some of the elements may be provided by separate elements.

In some embodiments, the stem comprises a corrugation arrangement.

One or more corrugations may extend along part of the stem or along the entire length of the stem.

In some embodiments, the foot is provided by a distal edge of the stem.

In contrast to an L-shaped bracket with a rectangular footprint area, by positioning the elongate passages laterally of the stem, the footprint area of the present bracket may be defined by an area as small as the edge of a metal sheet, which provides considerably lower thermal transfer behaviour. The edge may further provided with cut-outs and/or undulations to provide fewer contact points than a line contact. This may further reduce thermal transfer properties. Nevertheless, embodiments of the spacer bracket may comprise an angled foot.

In some embodiments, one or more elongate passages extend to the distal edge of the stem, and the foot has a footprint constituted by the distal edge of the stem and by distal edges of the one or more elongate passages.

In some embodiments, the spacer bracket is comprised in a roof construction.

The invention may be provided in the form of a roof construction comprising a plurality of spacer brackets according to any one of the embodiments of the first aspect. In some embodiments, the spacer bracket is comprised in a wall construction.

The invention may be provided in the form of a wall construction comprising a plurality of spacer brackets according to any one of the embodiments of the first aspect.

Description of the Figures

Exemplary embodiments of the invention will now be described with reference to the Figures, in which:

Figure 1 is a perspective view of part of a roof construction to which embodiments of the present invention relate;

Figures 2a-2c show, respectively, a top edge, front view and underside edge of an embodiment;

Figures 3a-3c show, respectively, a top edge, front view and underside edge of another embodiment;

Figure 4 shows a top view image of an exemplary embodiment; and Figure 5 shows an end view image of the Figure 4 embodiment.

Description

Figure 1 shows a perspective view of a part of a support grid system 1 of a roof structure, comprising a roof purlin 2 constituting part of an underneath structure onto which there is mounted a metal bar 4 of elongate dimension. Figure 1 shows a single metal bar 4 and it is understood that a grid of multiple metal bars 4 provides a support structure for an outer roof or membrane (not shown). The metal bar 4 could be mounted onto another structure instead of the roof purlin 2 illustrated in Figure 1, such as onto an original roof to be insulated. The metal bar 4 is supported on the roof purlin 2 by an array of L-shaped brackets 6 of which two L-shaped brackets 6 are illustrated in Figure 1. The L-shaped bracket 6 may be of the type disclosed in United Kingdom patent GB2509301B by the present applicant, with a head formation configured for a so-called twist-and-lock engagement to a profiled metal bar 4. The engagement mechanism is arranged such that it locks when the plane of the stem of the L-shaped bracket is oriented transversely to the extension of the metal bar 4. It can be imagined that a sufficient number of L-shaped brackets 6 can be used to support any length or number of metal bars 4 to create a grid support of desired size. If required, additional load brackets 8 may be installed to further improve the overall stability. The metal bars 4 serve as immediate or intermediate support for an outer structure (not shown) to be mounted externally (e.g., as a roof structure or as a fagade structure). The cavity defined by the height of the L- shaped brackets between the inner structure underneath and the outer structure may be provided with insulation material.

The L-shaped brackets 6 comprise a foot portion formed by bending an end of the bracket’s metal sheet, and provide a generally rectangular footprint sufficient to accommodate two screws 5. The stability imparted by the L-shaped brackets avoids in many practical scenarios the need for a load bracket 8. However, the footprint area of the L-shaped bracket 6 may provide a thermal bridge to the structure underneath, particularly if the foot print area is designed to be sufficiently large to accommodate screws 5. Insulation material 7 may be provided underneath each L-shaped bracket 6.

Figures 2a to 2c show views of a spacer bracket 10 in accordance with an embodiment, whereas Figures 2a and 2c are end views, of the top edge and underside edge, respectively, each aligned with the corresponding front view 2b. Herein, numerals indicated in Figures 2a, 2b or 2c may be described with specific reference to only one of Figures 2a, 2b or 2c to avoid repetition.

The spacer bracket 10 as shown in Figure 2b is formed from a unitary piece of sheet metal from a suitable material such as galvanised steel (although other types of steel and metal or suitable materials may be used) and comprises a main shaft 30 constituting a stem defining an elongate extension (length). At one end of the main shaft 30 is provided an anchor portion 20 constituting a foot, to be positioned on a building structure, roof purlin or the like. At the end opposite the anchor portion 20, the main shaft 30 comprises a connector formation 40 constituting a head, to be engaged with a metal bar or similar structure that is supported more distally to the building structure than the foot. The connector formation 40 may be of the form described in United Kingdom patent publication GB2240558B, or may be another suitable connector formation.

Extending along its length the main shaft 30 comprises corrugations 32 (see also profile illustrated in Figure 2a) to improve its load-bearing properties. The corrugations 32 extend along the full length of the shaft 30 although it will be appreciated different corrugation patterns may be provided if appropriate.

The anchor portion 20 comprises two wings 22a, 22b that extend laterally of the main shaft 30 and extend along only part of the length of the main shaft 30 (in Figure 2b, the wings extend about one third of the length of the main shaft 30). The distal ends (i.e. lower ends) of the wings 22a, 22b are coterminous with the lower edge of the main shaft 30. The lateral edges of the wings 22a, 22b are rolled, or formed to provide a beaded edge, to each define a channel 24a, 24b (see profile illustrated in Figure 2c) with a circular, or generally circular, section. The channels 24a, 24b constitute elongate passages sufficient to hold a suitable fixing means such as a screw, bolt or nail to be provided. It will be understood that the diameter of the channels 24a, 24b can be modified during manufacture by adjusting beading parameters. If necessary, the wings 22a, 22b can be designed wider to allow larger channel diameters to be created, and/or to position the channels further away from the main shaft 30.

By positioning the channels 24a, 24b on opposite sides of the main shaft 30, a good level of stability can be provided, while still allowing the spacer bracket 10 to be manufactured from a unitary sheet. The wall thickness of each channel 24a, 24b is defined by the thickness of the metal sheet and so can be much thinner than the corresponding material that would otherwise be designed when locating screw holes in a foot of an L-shaped bracket. This allows the fixing means to be positioned relatively further away, laterally, from the stem 30.

As the distal ends of the wings 22a, 22b are coterminous with the lower edge of the main shaft 30, the distal edge 21 of the spacer bracket 10 is defined by the lower edge of the anchor portion 20 and the lower edges of the wings 22a, 22b only. The footprint area in contact with a structure underneath (see distal edge 21 illustrated in Figure 2c) is therefore considerably smaller than a corresponding rectangular footprint of an L- shaped bracket would be expected to be. Fixing means such as screws can be securely retained in the channels 24a, 24b.

The channels 24a, 24b are positioned laterally along the main shaft 30, sufficiently far from the main shaft 30 that the extension of the channel axis is clear of the connector formation 40, i.e. in the transverse orientation laterally of a metal bar 4 to be provided (see also Figures 4 and 5 below). This allows screws to be inserted separately of any engagement of a connector formation 40 with a metal bar. As such, screws or other suitable fixing means may be inserted before or after the connector formation 40 is offered to the metal bar. The spacer bracket 10 may be pre-loaded with fixing means such as screws located in the channels 24a, 24b.

By providing the channels 24a, 24b along only a portion of the spacer bracket 10, the channel length can be designed to be the same for different spacer distances, because the channel length is independent of the length of the main shaft 30. In other words, the proximal edge 41 of the connector formation 40 is not affected by the design (diameter, shape, lateral spread, and/or length) of the channels 24a, 24b.

Figures 3a to 3c show another embodiment of a spacer bracket 11. Figures 3a-3c correspond to Figures 2a to 2c and the same numerals are used for equivalent components without repeating the description thereof. The spacer bracket 11 as shown in Figure 3b comprises a main shaft 30 with a connector formation 40 of the same geometry as the spacer bracket 10, but a different anchor portion 20a and correspondingly different distal edge 21a. The anchor portion 20a comprises, located at the distal end of the main shaft 30, two wings 23a, 23b that extend laterally of the main shaft 30. Similar to the two wings 22a, 22b of the spacer bracket 10, the two wings 23a, 23b extend over only part of the length of the main shaft 30. The lateral edges of the wings 23a, 23b are tapered, converging towards the distal end. The lateral edges of the wings 23a, 23b are each rolled to provide a beaded edge defining a channel 25a, 25b with a circular section in the manner described in relation to the channels 24a, 24b of the spacer bracket 10. The channels 25a, 25b constitute elongate passages and are inclined towards the foot, whereby fixing means such as screws located in the channels are urged to engage the surface underneath at an angle, which improves the stability of the construction against lateral loads.

By providing the channels 25a, 25b along only a portion of the spacer bracket 11, the channel angle can be designed to be the same for different spacer distances, because the channel incline angle is independent of the length of the main shaft 30.

Figures 4 and 5 shows a photograph from above and an end view, respectively, of a sample construction 12 utilising a metal bar 4 supported on two spacer brackets 11 that are connected such that the plane of the spacer brackets 11 is oriented transversely relative to the extension of the metal bar 4. Figures 4 and 5 show screws 50 received in the channels 25a, 25b that protrude laterally from the general footprint of metal bar 4, ie the upper ends of the channels 25a, 25b remain accessible independently of the presence of a metal bar 4 on the connector formation 40 (not visible in Figure 4).

This allows the spacer brackets 10, 11 to be used with sliding “twist-and-lock” type connector formations that can be fixed in location at any position along the metal bar 4. Indeed, the spacer bracket 10 or 11 may be provided as a component with preloaded screws 50 before it is fixed to a structure underneath. Likewise, the metal bar 4 may be preloaded with a number of spacer brackets 10, 11, which may also be preloaded with screws 50. By providing the spacer brackets with elongate channels for the fixing means, these can be preloaded without the lower ends of the fixing means protruding beyond the distal edge 21 before installation of the bracket. This facilitates positioning a spacer bracket on an underneath structure with fixing means preloaded.

It may be appreciated that the profile of the metal bar 4 in Figures 4 and 5 corresponds to that of the Figure 1 scenario. As such the spacer brackets 10, 11 are believed to provide excellent inter-system compatibility with existing grid support systems that would otherwise have used L-shaped brackets.

It will be understood that the spacer bracket may be made from multiple component parts. Although described herein with a particular type of connector formation, the spacer brackets may comprise other types of head formation. As can be imagined, the length of the main shaft and therefore the length of the spacer bracket can be designed according to different requirements independently of the configuration of the elongate passages.

The elongate passages may be lined with an additional material, i.e. inner surfaces and/or upper seating surfaces of the channels may be provided with additional material or with a coating. The material may have plastic properties to better retain fixing means. The seating material may have thermal properties, e.g. to minimise a thermal bridge between the fixing means (e.g. a screw, nail or simlar) and the elongate passage when the screw is engaged in a structure underneath.

Although described in relation to roof structures, the spacer brackets may be used for wall structures and cladding.