FLOOR TO WALL CONNECTOR

Abstract

A floor to wall connector is provided. The floor to wall connector comprises a wall bracket and a floor bracket. The wall bracket includes a floor receiver. The wall bracket is configured to connect to a wall panel. The floor bracket includes an opening. The floor bracket is configured to connect to a floor panel. The floor receiver of the wall bracket is configured to insert into the opening of the floor bracket thereby connecting the wall panel to the floor panel. A floor and wall system including the floor to wall connector and a method of connecting a wall panel to a floor panel via the floor to wall connector is also provided.

Description

FIELD OF INVENTION

The present invention relates generally to the art of wall installation, and more specifically to a floor to wall connector and method of installation.

BACKGROUND

Exterior wall panels of buildings are installed by connecting the wall panels to the exterior facing end of floor panels. Brackets to connect the wall panel to the floor panel are installed on-site while the wall panel is lifted and held in position. The installation is time and labor intensive because the connection requires numerous fasteners. A crane must hold the wall panel in place while the numerous fasteners are installed, taking a great deal of time. The connectors and method of installing the wall panels to the floor panels are costly and time consuming.

SUMMARY

A floor to wall connector is provided that can be installed to a floor panel and wall panel prior to lifting the wall panel into place. The connector provides a lifting point of the wall panel and provides an easy and simple mechanism to connect a floor panel and wall panel thereby reducing labor and equipment time and costs. The floor to wall connector comprises a wall bracket and a floor bracket. The wall bracket includes a floor receiver. The wall bracket is configured to connect to a wall panel. The floor bracket includes an opening. The floor bracket is configured to connect to a floor panel. The floor receiver of the wall bracket is configured to insert into the opening of the floor bracket thereby connecting the wall panel to the floor panel.

A floor and wall system is also provided. The floor and wall system includes a wall panel, a wall bracket, a floor panel, and a floor bracket. The wall bracket is attached to the wall panel. The wall bracket includes a floor receiver. The floor bracket is attached to the floor panel. The floor bracket includes an opening. The floor receiver of the wall bracket is configured to insert into the opening of the floor bracket to connect the wall panel to the floor panel. A method of connecting the wall panel to the floor panel via the floor to wall connector is also provided.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description will be better understood when read in conjunction with the appended drawings. For the purpose of illustration, there is shown in the drawings different embodiments. It should be understood, however, that the teachings are not limited to the precise floor to wall connector, floor and wall system, and method of connecting a wall panel to a floor panel shown.

FIG. 1 is an exploded view of a floor to wall connector.

FIG. 2 is an isometric view of a floor to wall connector.

FIG. 3 is a top view of the floor to wall connector in FIG. 2.

FIG. 4 is a front view of the floor to wall connector in FIG. 2.

FIG. 5 is a back view of the floor to wall connector in FIG. 2.

FIG. 6 is a right side view of the floor to wall connector in FIG. 2.

FIG. 7 is a left side view of the floor to wall connector in FIG. 2.

FIG. 8 is an isometric view of a plurality of floor brackets connected to a floor panel and a plurality of wall brackets connected to a wall panel.

FIG. 9 is an isometric view of a wall panel connected to a floor panel.

FIG. 10 is a flow chart of a method of connecting a wall panel to a floor panel.

DETAILED DESCRIPTION

A floor to wall connector is provided that simplifies the mechanism to connect a wall panel to a floor panel and simplifies the method of connecting a wall panel to a floor panel. The connector can be installed off-site or on-site prior to lifting the wall panel thereby saving time and costs.

FIG. 1 is an exploded view of a floor to wall connector 100. The floor to wall connector 100 is configured to connect a wall panel to a floor panel. The floor to wall connector may be made of metal. More specifically, the floor to wall connector may be made of forged or welded steel. The floor to wall connector 100 includes a wall bracket 200 and a floor bracket 300.

The wall bracket 200 is configured to attach to a wall panel. The wall bracket 200 may be comprised of an L bracket with a first leg 210 and a second leg 220 attached at an approximately 90 degree angle. The first leg 210 is configured to abut the interior side of a wall panel. The first leg 210 may include a plurality of openings 212. The openings 212 receive fasteners, such as screws, to attach the wall bracket 200 to a wall panel. The second leg 220 is configured to extend into the wall panel. The second leg 220 transfers load from the wall bracket 200 and fasteners to the wall panel. The wall bracket 200 includes a floor receiver 230. The floor receiver 230 may be comprised of an L bracket attached to the first leg 210. The wall bracket 200 may also include a bracket stiffener 232. The bracket stiffener 232 is positioned to support the floor receiver 230 and strengthen the joint between the floor receiver 230 and the first leg 210. The floor receiver 230 and the bracket stiffener 232 may be welded to the first leg 210. The floor receiver 230 may include a threaded hole 234 to receive a lifting hook 240. The lifting hook 240 may be an eye bolt. The lifting hook 240 is configured to receive a hoist which allows a crane to lift, place, and hold the wall bracket 200 attached to a wall panel. The lifting hook 240 may screw into the threaded hole 234. The threads allow the lifting hook 240 to be removed after the wall panel attached to the wall bracket 200 is installed and connected to a floor panel. The floor receiver 230 may also include threaded holes 236 to receive height adjustment screws 242. The height adjustment screws 242 may be screwed into and unscrewed in the threaded holes 236 to adjust the wall bracket 200 vertically. The adjustment screws 242 may include lock nuts 244 to lock the adjustment screws 242.

The floor to wall connector 100 also includes a floor bracket 300 configured to connect to a floor panel. The floor bracket 300 may be comprised of an L bracket with a first leg 310 and a second leg 320 attached at an approximately 90 degree angle. The first leg 310 is configured to abut the end of the floor panel that abuts the wall panel. The second leg 320 is configured to abut the top side of a floor panel. The second leg 320 may include a plurality of openings 322. The openings 322 receive fasteners, such as screws, to attach the floor bracket 300 to a floor panel. The second leg 320 may also include slotted holes 324 that receive fasteners, such as screws, to attach the floor bracket 300 to a floor panel. The slotted holes 324 allow the floor bracket 300 to be loosely attached to the floor panel while being adjusted along the length of the slotted holes 324. The second leg also includes an opening 326 configured to receive the floor receiver 230. The opening 326 has a corresponding size and shape to the floor receiver 230, but the opening 326 may be slightly larger than the floor receiver 230 to allow the wall bracket 200 to be adjusted while the floor receiver 230 is inserted in the opening 326 in the floor bracket 300. After the floor receiver 230 is inserted into the opening 326 and the wall panel is set in place, the wall bracket 200 may be locked in place via locking screws 334. The locking screws 334 screw into threaded sleeves 330 attached to the second leg 320 of the floor bracket 300. The threaded sleeves 330 may be attached to the second leg 320 via a spacer 332. The spacer 332 may be welded to the second leg 320 and the threaded sleeve 330. The spacer 332 puts distance between the second leg 320 and the threaded sleeves 330 so that the locking screws 334 can be screwed into the threaded sleeves 330. After the locking screws 334 are screwed into the threaded sleeves 330, set screws 336 may be screwed into threaded holes 338 in the top of the threaded sleeves 330.

FIGS. 2-7 show a floor to wall connector 100 wherein the wall bracket 200 and the floor bracket 300 are connected. The floor receiver 230 of the wall bracket 200 inserts through the opening 326 in the second leg 320 of the floor bracket 300 to connect the wall bracket 200 to the floor bracket 300. Once inserted through the opening 326, the floor receiver 230 may be adjusted horizontally or left and right within the slightly oversized opening 326. The height adjustment screws 242 are screwed through threaded holes 236 in the floor receiver 230 until the end of the height adjustment screws 242 rest on the top of the second leg 320 of the floor bracket 300. The wall bracket 200 may be adjusted vertically by screwing the height adjustment screws 242 in and out of the threaded holes 236 to change the distance between the second leg 320 of the floor bracket 300 and the floor receiver 230 of the wall bracket 200. Once the floor receiver 230 is positioned in the opening 326 so that the wall panel attached to the wall bracket 200 is properly placed, the locking screws 334 lock the wall bracket 200 in its position by screwing through the threaded sleeves 330 until the ends of the locking screws 334 are tight against the floor receiver 230. The locking screws 334 lock the wall bracket 200 in place by clamping the floor receiver 230 against the side of the opening 326 in the second leg 320 of the floor bracket 300. The set screws 336 are then threaded in the holes 338 in the threaded sleeves 330 to further lock the locking screws 334 in place.

The floor to wall connector 100 can be attached to wall panels and floor panels prior to lifting and placing the wall panel. The floor to wall connector 100 also provides a holding point for lifting the wall panel with a crane thereby eliminating the need for an additional lifting mechanism. The connector 100 also includes features which provide options for adjusting the floor bracket 300 in and out and adjusting the wall bracket 200 left and right and up and down relative to the building. These options for adjustment account for site tolerances. The connector 100 also has a slim profile which reduces the effort required to cover the connector 100. The connector also provides fire protection, withstands seismic events, and uses a minimum number of mechanical fasteners.

FIG. 8 shows a plurality of floor brackets 300 connected to a floor panel 400 and a plurality of wall brackets 200 connected to a wall panel 500. FIG. 8 shows a floor panel 400. The floor panel 400 may be comprised of cross-laminated timber, cold formed steel, or a light wood frame. The floor panel 400 includes at least one floor bracket 300 mounted to the floor panel 400 with fasteners 410, such as screws, that extend through the openings 322 and slotted holes 324 in the second leg 320 of the floor bracket 300 shown in FIGS. 1-3. As shown in FIG. 8, the second leg 320 of the floor bracket 300 abuts the top of the floor panel 400. The first leg 310 of the floor bracket 300, not visible in FIG. 8, abuts the edge of the floor panel 400 that abuts the wall panel 500. The floor panel 400 includes a notch or opening at the location of the opening 236 in the floor bracket 200 so that when a floor receiver 230 is inserted into the opening 236 of the floor bracket 200, the floor receiver 230 extends into the notch or opening of the floor panel 400.

The wall panel 500 includes at least one wall bracket 200 to connect the wall panel 500 to the floor panel 400. The wall panel 500 may be an exterior wall panel of a building. The wall panel 500 may be comprised of cross-laminated timber, cold formed steel, or a light wood frame. The wall brackets 200 are attached to the wall panel 500 with fasteners 510, such as screws, that extend through the openings 212 in the first leg 210 of the wall bracket 200 shown in FIGS. 1, 2, 4, and 5. As shown in FIG. 8, the wall bracket 200 is mounted towards the top, interior end of the wall panel 500 so that the lifting hook 240 extends up past the top of the wall panel 500. The first leg 210 of the wall bracket 200 abuts the interior side of the wall panel 500. The second leg 220 of the wall bracket 200, not visible in FIG. 8, extends into the wall panel 500. The wall panel 500 may include a notch at the location of the second leg 220 of the wall bracket 200 to allow the second leg 220 to extend into the wall panel 500. The second leg 220 inserted in the wall panel 500 aligns the wall bracket 200 and also transfers or spreads the load applied to the wall bracket 200 when the wall bracket 200 is lifted and when connected to the floor panel 400. The second leg 220 provides a mechanism to transfer load through bearing of the wall panel 500 on the second leg 220 rather than the fasteners 510.

The floor brackets 300 and the wall brackets 200 are mounted at corresponding locations so that the wall panel 500 is at its engineered or designed location when the wall bracket 200 is connected to the floor bracket 300. The wall panels 500, including the wall bracket 200, may be prefabricated. The floor panels 400, including the floor bracket 300, may be prefabricated. Installation of the wall panel 500 and its connection to the floor panel 400 is simple, quick, and easy because the wall bracket 200 and the floor bracket 300 can be installed prior to lifting, holding, and positioning the wall panel 500. The wall panel 500 connects to the floor panel 400 by inserting the floor receivers 230 of the wall brackets 200 into the corresponding openings 326 of the floor brackets 300.

FIG. 9 is an isometric view of a wall panel 500 connected to a floor panel 400. FIG. 9 shows a section of a wall panel 500 connected to a section of a floor panel 400 via a wall bracket 200 and a floor bracket 300. As shown in FIG. 9, the top of the floor panel 400 may include a notch 420 to accommodate the floor bracket 300. The notch 420 allows the floor bracket 300 to sit flush or below the top of the floor panel 400 when the floor bracket 300 is attached. The wall panel 500 is connected to the floor panel 400 by inserting the floor receiver 230, not visible in FIG. 9, into the opening 326, not visible in FIG. 9, of the floor bracket 300 and into the floor panel 400. A hoist 600 connected to the lifting hook 240 allows a crane to lift and position the wall panel 500. Once in position, the height adjustment screws 242 are set and the locking screws 334 are tightened. After the wall panel 500 is connect to the floor panel 400 via the wall bracket 200 and the floor bracket 300, the lifting hook 240 can be removed by unscrewing the lifting hook 240.

FIG. 10 is a flow chart of a method of connecting a wall panel to a floor panel 1000. The method 1000 includes the step 1010 of receiving a wall panel including a wall bracket and a floor panel including a floor bracket. The wall panel, wall bracket, floor panel, and floor bracket include the same details and embodiments previously described.

The method 1000 may also include the step 1020 of lifting the wall panel to its engineered or designed location on a building. The wall panel is lifted and held where the wall panel should be connected to the floor panel. The wall panel may be lifted with a crane and a hoist connected to the lifting hook of the wall bracket attached to the wall panel.

The method 1000 includes the step 1030 of connecting the wall panel to the floor panel by connecting each wall bracket attached to the wall panel with a corresponding floor bracket attached to the floor panel. The wall panel is connected to the floor panel by inserting the floor receiver of the wall bracket into the floor receiver opening in the floor bracket.

The method 1000 may include the step 1040 of vertically setting the height of the wall panel via the wall bracket by screwing or unscrewing the height adjustment screws.

The method 1000 may include the step 1050 of locking the wall panel in place via the wall bracket by screwing in the locking screws until the locking screws are tight against the wall bracket.

The method 1000 may include the step 1060 of removing the lifting hook from the wall bracket. The lifting hook may be removed from the wall bracket after the wall panel is connected to the floor panel. The lifting hook may be removed by unscrewing it from the threaded opening in the floor receiver.

Having thus described in detail a preferred selection of embodiments of the present invention, it is to be appreciated and will be apparent to those skilled in the art that many physical changes could be made to the floor to wall connector, wall and floor system, and method of connecting a wall panel to a floor panel without altering the inventive concepts and principles embodied therein. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore to be embraced therein.

Claims

1. A floor to wall connector comprising: a wall bracket including a floor receiver, the wall bracket configured to connect to a wall panel; anda floor bracket including an opening, the floor bracket configured to connect to a floor panel;wherein the floor receiver is configured to insert into the opening.

2. The floor to wall connector of claim 1, wherein the wall bracket is a first L bracket.

3. The floor to wall connector of claim 1, wherein the floor receiver is a second L bracket.

4. The floor to wall connector of claim 1, wherein the wall bracket includes a bracket stiffener.

5. The floor to wall connector of claim 1, wherein the floor bracket is a third L bracket.

6. The floor to wall connector claim 1, wherein the floor bracket includes at least one slotted opening configured to receive at least one fastener configured to connect the floor bracket Lo the floor panel.

7. The floor to wall connector of claim 1, wherein the wall bracket includes a removable lifting hook.

8. The floor to will connector of claim 1, wherein the floor to wall connector is made of metal.

9. A floor and wall system comprising; a wall panel;a wall bracket attached to the wall panel, the wall bracket including a floor receiver;a floor panel; anda floor bracket attached to the floor panel, the floor bracket including, an opening;wherein the floor receiver is configured to insert into the opening.

10. The floor and wall system of claim 9, wherein the wall bracket is a first L bracket.

11. The floor and wall system of claim 9, wherein the floor receiver is a second L bracket.

12. The floor and wall system of claim 9, wherein the wall bracket includes a bracket stiffener.

13. The floor and all system of claim 9, wherein the floor bracket is a third L bracket.

14. The floor and wall system of claim 9, wherein the wall bracket includes a removable lifting hook.

15. The floor and wall system of claim 9, wherein the floor to wall connector is made of metal.

16. The floor to wall system of claim 9, wherein the floor panel is a cross-laminated timber panel.

17. The floor and wall system of claim 9, wherein the wall panel is a cross-laminated timber panel.

18. The floor and wall system of claim 9, further comprising a second wall bracket attached to the wall panel, the second wall bracket including a second floor receiver.

19. The floor and wall system of claim 18, further comprising a second floor bracket attached to the floor panel, the second floor bracket including a second opening, wherein the second floor receiver is configured to insert into the second opening.

20. A method of connecting a wall panel to a floor panel, the method comprising receiving the wall panel, the wall panel including a wall bracket, the wall bracket including a floor receiver;receiving the floor panel, the floor panel including a floor bracket, the floor bracket including and opening; andconnecting the wall bracket to the floor bracket by inserting the floor receiver into the opening.