INSULATION MOUNTING BRACKET

FIELD

The general inventive concepts relate to insulation systems and, more specifically, to a mounting bracket for use in insulation systems.

BACKGROUND

High rise buildings are typically constructed with concrete slab floors that “float” within an outer skin (i.e., windows and cladding materials interfaced with an aluminum framework). In other words, the outer skin does not carry the load of the floors. The intersection of the exterior (curtain) walls and these floor slabs provide a gap through which a fire on one floor may spread/climb vertically to floors above. Consequently, it is well known to insulate these gaps with fire-resistant materials to retard the spread of a fire from one floor to the next. This insulation takes the form of curtain wall insulation, safing insulation, and the like that fit in and around the framework (e.g., mullions and transoms). For example, U.S. Pat. No. 10,309,100, the entirety of which is incorporated herein by reference, describes a conventional curtain wall insulation system.

A conventional curtain wall insulation system 100 is shown in FIG. 1. The curtain wall insulation system 100 is useful for insulating a curtain wall structure 150 connected to a building structure (not shown). As one of skill in the art will appreciate, a curtain wall structure 150 is a type of exterior wall system commonly used on buildings, such as high-rise buildings, wherein the curtain wall structure 150 does not bear the load of the building structure. As see in FIG. 1, the curtain wall structure 150 is spaced from a floor slab 160 of the building structure to define a perimeter void 170. The curtain wall structure 150 includes framing defined by at least first and second vertically disposed and parallel mullions 152, at least one upper horizontally disposed transom 154, and at least one lower horizontally disposed transom 156. The curtain wall insulation system 100 provides thermal insulation and also provides a barrier to inhibit the spread of fire from one floor of a building to an upper adjacent floor through the perimeter void 170.

With continued reference to FIG. 1, the curtain wall insulation system 100 includes a curtain wall insulation 102. The curtain wall insulation 102 may be formed of various materials based on a desired failure temperature of the material such as mineral wool, which can maintain its integrity for more than five hours at temperatures of nearly 2,100° F. Such curtain wall insulation 102 is commercially available from Thermafiber, Inc. of Wabash, Ind. The curtain wall insulation 102 may have a thickness of 1 inch to 8 inches, and a density of 4 pounds per cubic foot to 8 pounds per cubic foot. The curtain wall insulation 102 is disposed within the framing and mechanically attached to the framing. Accordingly, the size and shape of the curtain wall insulation 102 will typically depend on the size and shape of the framing into which the curtain wall insulation 102 is being installed. The curtain wall insulation 102 may be mechanically attached to the framing with insulation hangers (not shown), such as Impasse® insulation hangers available from Thermafiber, Inc. of Wabash, Ind., or by other conventional means used to mechanically attach curtain wall insulation 102 to the framing, such as impaling pins or screws.

As shown in FIG. 1, the curtain wall insulation system 100 also includes a safing insulation 104 having a bottom surface 105 and a top surface 106. The safing insulation 104 is disposed within the perimeter void 170 and compression fit between the curtain wall insulation 102 and the floor slab 160. The safing insulation 104 inhibits flames and hot gases from moving from a first floor to an adjacent upper floor through the perimeter void 170. As with the curtain wall insulation 102, the safing insulation 104 may be formed of various materials based on a desired failure temperature of the material. In certain embodiments, the safing insulation 104 comprises mineral wool. The safing insulation 104 may have a thickness of 1 inch to 8 inches, and a density of 4 pounds per cubic foot to 8 pounds per cubic foot. Such safing insulation 104 is commercially available from Thermafiber, Inc. of Wabash, Ind. When installed, the safing insulation 104 is commonly compressed to varying degrees, but normally it is compressed to approximately 25%. After installation, the safing insulation 104 provides fireproof sealing of the perimeter void 170. Because the safing insulation 104 is compressed when installed, it provides some capability to expand which can seal openings or cracks that might otherwise develop in the perimeter void 170. Slight variations in the size of the perimeter void 170 due to expansion or other environmental changes are accommodated by the safing insulation 104 since it is compressed when placed in the perimeter void 170, and thus can provide an effective seal under various conditions.

In certain embodiments, the curtain wall insulation system 100 includes a reinforcement member 130 attached to and disposed between the mullions 152 and behind the curtain wall insulation 102. The reinforcement member 130 is positioned at a level corresponding to a level of the safing insulation 104, which level is commonly referred to as the safing line. The reinforcement member 130 prevents bowing or deformation of the curtain wall insulation 102 due to the compression fit of the safing insulation 104. The reinforcement member 130 may have various shapes or configurations. For example, the reinforcement member may have a T-shape, as shown in FIG. 1, an L-shape, or may be formed as a channel (e.g., C-shaped channel, U-shaped channel). Brackets (not shown) may be used to attach the reinforcement member 130 to the mullions 152. The reinforcement member 130 may be formed of various materials including, but not limited to, steel, galvanized steel, ceramics, and other heat resistant materials.

As shown in FIG. 1, the curtain wall insulation system 100 includes a mullion cover hanger 110 that is attached to the mullions 152 and a mullion cover 120 that is attached to the mullion cover hanger 110. The mullion cover 120 protects the mullions 152 from hot flames and gases during a fire. The mullion cover 120 may be formed of various materials based on a desired failure temperature of the material. In certain embodiments, the mullion cover 120 comprises mineral wool. The mullion cover 120 may have a thickness of 1 inch to 8 inches, and a density of 4 pounds per cubic foot to 8 pounds per cubic foot. Such mullion covers 120 are commercially available from Thermafiber, Inc. of Wabash, Ind.

In certain embodiments, and as shown in FIG. 1, the curtain insulation system 100 includes a lower mullion cover 121 attached to the mullion cover hanger 110, and an upper mullion cover 123 attached to the mullion cover hanger 110. The lower mullion cover 121 is installed so that a top surface 122 of the lower mullion cover 121 will abut a bottom surface 105 of the installed safing insulation 104. Similarly, the upper mullion cover 123 is installed so that a bottom surface 124 of the upper mullion cover 123 will abut a top surface 106 of the installed safing insulation 104. This configuration provides an effective seal of insulation that inhibits hot flames and gases from reaching the mullions 152.

As discussed above, the mullion cover hanger 110 can be attached to a mullion 152 (with fasteners, such as screws, or by welding) at a point above a floor slab 160 and at a point below the floor slab 160, where an installer has relatively open access for using electric tools, such as a power drill, electric screwdriver, or welder. After the mullion cover hanger 110 is installed on the mullion 152, an installer can easily attach the mullion cover 120 to the mullion cover hanger 110 without using electric tools, such as a power drill or electric screwdriver, or additional fasteners.

During a fire, there is a lot of turbulence, movement, and gravitational pull, all of which can cause the insulation to become dislodged, thereby allowing the fire to propagate to the next floor. Accordingly, mechanical fasteners are typically used to secure the insulation (e.g., the curtain wall insulation 102) to the building structure (e.g., the mullions 152 and the transoms 154, 156).

A conventional approach to mounting curtain wall insulation relies on mounting brackets. As shown in FIGS. 2A, 2B, and 2C, a conventional mounting system 200 includes a vertical hanger 210, a horizontal hanger 230, and a locking washer 250.

The vertical hanger 210 includes a body 212, a first leg 214, a second leg 216, and a flange 218. The first leg 214 extends from and perpendicular to the body 212. The second leg 216 extends from and perpendicular to the body 212. The flange 218 extends from and perpendicular to an end of the first leg 214. The flange 218 includes an aperture therethrough that forms a mounting hole 220. The mounting hole 220 is used to mount the vertical hanger 210 to a mullion via a fastener (e.g., screw). An end of the second leg 216 includes a pair of prongs 222, which are separated from one another by a gap. Each of the prongs 222 tapers into a pointed end.

The horizontal hanger 230 includes a body 232, a first leg 234, a second leg 236, and a flange 238. The first leg 234 extends from and perpendicular to the body 232. The second leg 236 extends from and perpendicular to the body 232. The flange 238 extends from and perpendicular to an end of the first leg 234. The flange 238 includes an aperture therethrough that forms a mounting hole 240. The mounting hole 240 is used to mount the vertical hanger 230 to a transom via a fastener (e.g., screw). An end of the second leg 236 includes a pair of prongs 242, which are separated from one another by a gap. Each of the prongs 242 tapers into a pointed end.

The locking washer 250 includes a body 252 with an aperture therethrough that forms a slot 254. The slot 254 has a thickness and width sufficient for the prongs 222 of the vertical hanger 210 and the prongs 242 of the horizontal hanger 230 to pass therethrough.

The conventional mounting system 200 functions as follows. Multiple vertical hangers 210 and multiple horizontal hangers 230 are interfaced with a portion of curtain wall insulation sized to fit within a curtain wall region (i.e., at least a portion of a region framed by a pair of parallel mullions and a pair of parallel transoms). More specifically, each vertical hanger 210 is pressed through the insulation so that a rear face of the insulation abuts the body 212 of the hanger 210, a side of the insulation abuts the first leg 214 of the hanger 210, and the prongs 222 extend through the insulation and beyond a front face of the insulation. Likewise, each horizontal hanger 230 is pressed through the insulation so that a rear face of the insulation abuts the body 232 of the hanger 230, a side of the insulation abuts the first leg 234 of the hanger 230, and the prongs 242 extend through the insulation and beyond a front face of the insulation. The second leg 216 of each vertical hanger 210 and the second leg 236 of each horizontal hanger 230 functions as a shelf-like ledge that supports the weight of the insulation.

For each pair of prongs 222, 242 extending through the insulation, a locking washer 250 is manually pressed onto the prongs so that the prongs pass through the slot 254 of the locking washer 250, as shown in FIG. 3A. Then, the prongs are manually bent in opposite directions, as shown in FIG. 3B, to effectively lock the insulation on the respective hangers 210, 230. In this manner, the curtain wall insulation is interfaced with the hangers 210, 230.

Thereafter, the curtain wall insulation can be positioned and mounted in the curtain wall region. More specifically, a fastener (now shown), such as a screw, passes through the mounting hole 220 of each vertical hanger 210 to secure the hanger 210 to a mullion. Likewise, a fastener (now shown), such as a screw, passes through the mounting hole 240 of each horizontal hanger 230 to secure the hanger 230 to a transom. In this manner, the curtain wall insulation (e.g., curtain wall insulation 102) is mechanically secured within the curtain wall region, as shown in the insulation installation 400 of FIG. 4A. Typically, a piece of insulation (i.e., the mullion cover 123) is then positioned over the mullion 152 to protect it in the event of a fire, as shown in the insulation installation 400 of FIG. 4B. The mullion cover 123 can be secured to the curtain wall insulation 102 via fasteners, such as spiral screws 402 or other separate mounting hangers/brackets.

While effective in mounting insulation within a curtain wall, the conventional insulation mounting system 200 requires transport and manual installation of many pieces (e.g., x brackets and x locking washers for a total of 2x pieces), which results in a relatively lengthy installation time. Accordingly, there is an unmet need for an improved insulation mounting system that requires transport and manual installation of significantly fewer pieces (e.g., ≤x total pieces) and, thus, can result in a significantly reduced installation time.

SUMMARY

The general inventive concepts relate to an insulation mounting system, including an innovative mounting bracket for use therein. The mounting bracket can support the insulation without the use of locking washers. Furthermore, the design of the mounting bracket allows for the installation of curtain wall insulation without the use or installation of a separate reinforcing member (e.g., T-shaped backer bar). Accordingly, insulation can be mounted more quickly using the insulation mounting system, as opposed to conventional insulation mounting systems.

In one exemplary embodiment, a mounting bracket is disclosed that comprises a bracket body having a middle portion, a first leg, a second leg, and at least one reinforcing member, wherein the middle portion extends between and connects the first leg and the second leg, wherein the first leg extends from the middle portion in a first direction, wherein the second leg extends from the middle portion in the first direction, and wherein the at least one reinforcing member extends from the middle portion in a second direction, the first direction and the second direction being opposite of one another.

In some exemplary embodiments, a height of the middle portion is greater than a depth of the first leg and a depth of the second leg.

In some exemplary embodiments, a depth of the middle portion is equal to a height of the first leg and a height of the second leg.

In some exemplary embodiments, a depth of the middle portion is equal to a height of the second leg and is less than a height of the first leg.

In some exemplary embodiments, the first leg is perpendicular to the middle portion.

In some exemplary embodiments, the first leg includes at least one aperture.

In some exemplary embodiments, the first leg includes a mounting flange that extends from and perpendicular to an end of the first leg. In some exemplary embodiments, the mounting flange includes an aperture.

In some exemplary embodiments, the second leg is perpendicular to the middle portion.

In some exemplary embodiments, a depth of the second leg is greater than a depth of the first leg.

In some exemplary embodiments, a height of the second leg is equal to a height of the first leg.

In some exemplary embodiments, a height of the second leg is less than a height of the first leg.

In some exemplary embodiments, the second leg includes a body having one or more barbs and a tapered end. In some exemplary embodiments, the body includes a plurality of the barbs. In some exemplary embodiments, the body includes four of the barbs. In some exemplary embodiments, a number of the barbs on one side of the body differs from a number of the barbs on the opposite side of the body.

In some exemplary embodiments, the second leg is symmetrical about a central axis of the body.

In some exemplary embodiments, the first leg and the second leg are parallel to one another.

In some exemplary embodiments, the at least one reinforcing member is perpendicular to the middle portion.

In some exemplary embodiments, the at least one reinforcing member extends from the middle portion at an angle in the range of 45° to 90°.

In some exemplary embodiments, the bracket body includes two reinforcing members space from one another by a distance that is less than or equal to a width of the middle portion.

In some exemplary embodiments, a height of the at least one reinforcing member is less than a height of the middle portion, a depth of the first leg, and a depth of the second leg.

In some exemplary embodiments, a height of the at least one reinforcing member is equal to a height of the middle portion.

In some exemplary embodiments, a height of the at least one reinforcing member is less than or equal to a height of the middle portion and is more than half of the height of the middle portion.

In some exemplary embodiments, a height of the at least one reinforcing member is less than a depth of the first leg and is more than half of the depth of the first leg.

In some exemplary embodiments, a height of the at least one reinforcing member is less than a depth of the second leg and is more than half of the depth of the second leg.

In some exemplary embodiments, the at least one reinforcing member is a flange.

In some exemplary embodiments, the bracket body is a unitary structure.

In some exemplary embodiments, the bracket body is made of galvanized steel.

In one exemplary embodiment, a curtain wall insulation system is disclosed that comprises a plurality of mounting brackets and a curtain wall insulation, each of the mounting brackets comprising a bracket body having a middle portion, a first leg, a second leg, and at least one reinforcing member, wherein the middle portion extends between and connects the first leg and the second leg, wherein the first leg extends from the middle portion in a first direction, wherein the second leg extends from the middle portion in the first direction, and wherein the at least one reinforcing member extends from the middle portion in a second direction, the first direction and the second direction being opposite of one another. Each of the mounting brackets may also have any of the other features shown, described, or otherwise suggested herein.

In some exemplary embodiments, the curtain wall insulation system is free of a reinforcing member disposed at or in proximity to a safing line of the curtain wall insulation system.

In some exemplary embodiments, a depth of the second leg is less than a depth of the curtain wall insulation.

Other aspects and features of the general inventive concepts will become more readily apparent to those of ordinary skill in the art upon review of the following description of various exemplary embodiments in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The general inventive concepts, as well as embodiments and advantages thereof, are described below in greater detail, by way of example, with reference to the drawings in which:

FIG. 1 is a side sectional diagram of a representational portion of a conventional curtain wall insulation system.

FIGS. 2A, 2B, and 2C illustrate various components of a conventional insulation mounting system. FIG. 2A shows various views of a vertical hanger. FIG. 2B shows various views of a horizontal hanger. FIG. 2C shows a locking washer for interfacing with the vertical hanger of FIG. 2A and the horizontal hanger of FIG. 2B.

FIGS. 3A and 3B illustrate the locking washer of FIG. 2C interfacing with the horizontal hanger of FIG. 2B.

FIGS. 4A and 4B illustrate the conventional insulation mounting system of FIGS. 2A-2C being used to mount curtain wall insulation.

FIGS. 5A-5E illustrate an insulation mounting bracket, according to one exemplary embodiment. FIG. 5A is a perspective view of the mounting bracket. FIG. 5B is a plan view of the mounting bracket. FIG. 5C is a detailed view of a second leg of the mounting bracket. FIG. 5D is a front elevational view of the mounting bracket. FIG. 5E is a side elevational view of the mounting bracket.

FIG. 6 illustrates a portion of a test setup used to conduct a test in accordance with ASTM E2307-19 as described in the example of the present disclosure.

DETAILED DESCRIPTION

Several illustrative embodiments will be described in detail with the understanding that the present disclosure merely exemplifies the general inventive concepts. Embodiments encompassing the general inventive concepts may take various forms and the general inventive concepts are not intended to be limited to the specific embodiments described herein.

The general inventive concepts relate to an insulation mounting system, including innovative mounting brackets for use therein. The mounting brackets are one-part structures that replace conventional multi-part structures for mounting insulation, such as in a curtain wall space. For example, these unitary mounting brackets can support the insulation without the use of locking washers. Furthermore, the design of the unitary mounting brackets allow for installation of curtain wall insulation without the use or installation of a separate reinforcing member (e.g., T-shaped backer bar) as used in conventional insulation mounting systems. Accordingly, insulation can be mounted more quickly using the insulation mounting system of the present invention, as opposed to conventional insulation mounting systems.

A single-piece mounting bracket 500, according to one exemplary embodiment, is shown in FIGS. 5A-5E. Although specific dimensions are illustrated in some of the drawings, the general inventive concepts are not limited to the disclosed dimensions.

The mounting bracket 500 includes a bracket body 502 that includes a middle portion 510, a first leg 520, a second leg 530, and at least one reinforcing member 540. The bracket 500 can be made of any suitable material. In some exemplary embodiments, the bracket 500 is made of a metal including, but not limited to, steel, galvanized steel, brass, and aluminum. Ceramic materials may also be used to form the bracket 500. In certain embodiments, the bracket 500 is formed of galvanized steel, and preferably 20 gauge galvanized steel.

As seen in FIG. 5A, the middle portion 510 extends between and connects the first leg 520 and the second leg 530 to one another. In some exemplary embodiments, a height mp_hof the middle portion 510 is greater than a depth fl_dof the first leg 520 and a depth sl_dof the second leg 530. In some exemplary embodiments, a depth mp_dof the middle portion 510 is equal to a height fl_hof the first leg 520 and a height sl_hof the second leg 530. In some exemplary embodiments, a depth mp_dof the middle portion 510 is equal to a height sl_hof the second leg 530 and is less than a height fl_hof the first leg 520.

The first leg 520 extends from the middle portion 510 in a direction forward of the middle portion 510, as seen in FIGS. 5A and 5E. In some exemplary embodiments, the first leg 520 is perpendicular to the middle portion 510. In some exemplary embodiments, the first leg 520 includes at least one aperture 522 therethrough to form a mounting hole. The at least one aperture 522 may be used to mount the bracket 500 to a support structure (e.g., mullion, transom) via a fastener (e.g., screw). In some exemplary embodiments, the first leg 520 includes a mounting flange 524 that extends from and perpendicular to an end of the first leg 520. In some exemplary embodiments, the mounting flange 524 includes an aperture 522 therethrough to form a mounting hole. In some exemplary embodiments, the aperture 522 extends through a depth fl_dof the first leg. In some exemplary embodiments, the aperture 522 extends through a height fl_hof the first leg. In some exemplary embodiments, the first leg 520 includes an aperture 522 that extends through a height fl_hof the first leg and a mounting flange 524 having an aperture 522 that extends through a depth fl_dof the first leg 520.

As seen in FIGS. 5A and 5E, the second leg 530 extends from the middle portion 510 in a direction forward of the middle portion 510. In some exemplary embodiments, (a central axis ca of) the second leg 530 is perpendicular to the middle portion 510. In some exemplary embodiments, a depth sl_dof the second leg 530 is greater than a depth fl_dof the first leg 520. In some exemplary embodiments, a height sl_hof the second leg 530 is equal to a height fl_hof the first leg 520 before the mounting flange 524. In some exemplary embodiments, a height sl_hof the second leg 530 is less than a height fl_hof the first leg 520. The second leg 530 includes a body 532 having one or more barbs 534. The body 532 includes a tapered end 536 beyond the barbs 534. The tapered end 536 facilitates passage of the second leg 530 into a piece of insulation, while the barbs 534 are operable to hold/secure the insulation on the second leg 530. The body 532 of the second leg 530 may function as a shelf-like ledge operable to support the weight of the insulation. In some exemplary embodiments, a depth sl_dof the second leg 530 is less than a depth of a piece of insulation with which the mounting bracket 500 is used. Accordingly, in some exemplary embodiments, the second leg 530 does not extend completely through the insulation, which maintains the integrity of a facing of the insulation, if present. While the illustrated embodiment shows the same number of barbs 534 on each side of the body 532, the general inventive concepts are not so limited. In some exemplary embodiments, one or more barbs 534 are only on one side of the body 532. In some exemplary embodiments, the number of barbs 534 on one side of the body 532 differs from the number of barbs 534 on the other side of the body 532. While the illustrated embodiment shows the second leg 530 to be symmetrical about the central axis ca, the general inventive concepts are not so limited. In some exemplary embodiments, the size, shape, and/or positions of the barbs 534 differ on opposite sides of the central axis ca of the body 532.

As shown in FIG. 5C, in one specific exemplary embodiment, the body 532 of the second leg 530 includes four distinct barbs, i.e., a first barb 534-1, a second barb 534-2, a third barb 534-3, and a fourth barb 534-4. A size, shape, and angle of the first barb 534-1 and the second barb 534-2 are the same. A size, shape, and angle of the third barb 534-3 and the fourth barb 534-4 are the same. In this exemplary embodiment, at least one of the size, shape, and angle of the first and second barbs 534-1, 534-2 is different from that of the third and fourth barbs 534-3, 534-4. In this exemplary embodiment, the angle of at least the first and second barbs 534-1, 534-2 is 42 degrees. The general inventive concepts contemplate that the barbs 534 can have any angle suitable to hold the insulation once it is impaled on the second leg 530.

As mentioned above, the bracket body 502 includes at least one reinforcing member 540. The at least one reinforcing member 540 extends from the middle portion 510 in a direction rearward of the middle portion 510 (i.e., opposite the aforementioned forward direction). In some exemplary embodiments, the at least one reinforcing member 540 is a flange. In some exemplary embodiments, the at least one reinforcing member 540 extends from the middle portion 510 in a direction (or from a side) different and/or opposite than a direction (or side) that the first leg 520 and the second leg 530 extend from the middle portion 510. As seen in FIG. 5A, each of the reinforcing members 540 extend along a height dimension of the middle portion 510 and project outward along a depth dimension behind the middle portion 510, whereas the first leg 520 and the second leg 530 are extend across a width dimension of the middle portion 510 and project outward along a depth dimension in front of the middle portion 510. In other words, the at least reinforcing member 540 extends behind the middle portion 510 and the first leg 520 and the second leg 530 extend in front of the middle portion 510. In some exemplary embodiments, the at least one reinforcing member 540 is perpendicular (i.e., 90°) to the middle portion 510, as seen in FIG. 5B. In some exemplary embodiments, the at least one reinforcing member 540 extends from the middle portion 510 at an angle of less than or equal to 90°, such as at an angle in the range of 45° to 90°.

As shown in FIG. 5B, in one specific exemplary embodiment, the bracket body 502 includes two reinforcing members 540 extending from and perpendicular to the middle portion 510. In this exemplary embodiment, the two reinforcing members 540 are spaced from one another by a distance that is less than or equal to a width mp_w, of the middle portion 510. In this exemplary embodiment, the reinforcing members 540 have a rectangular shape. The general inventive concepts contemplate that the bracket body 502 can have additional reinforcing members 540 extending from the middle portion 510 or a single reinforcing member 540 extending from the middle portion 510, preferably along a central axis of the middle portion. Furthermore, the general inventive concepts contemplate that the reinforcing member 540 can have any suitable shape, such as triangular, that allows the reinforcing member 540 to function as described herein.

In some exemplary embodiments, a height rm_hof the reinforcing member 540 is less than a height mp_hof the middle portion 510, a depth fl_dof the first leg 520, and a depth sl_dof the second leg 530. In some exemplary embodiments, a height rm_hof the reinforcing member 540 is equal to a height mp_hof the middle portion 510. In some exemplary embodiments, a height rm_hof the reinforcing member 540 is less than or equal to a height mp_hof the middle portion 510 but more than half of the height mp_hof the middle portion 510 (i.e., 0.5mp_h<rm_h<mp_h). In some exemplary embodiments, a height rm_hof the reinforcing member 540 is less than a depth fl_dof the first leg 520 but more than half of the depth fl_dof the first leg 520 (i.e., 0.5fl_d<rm_h<fl_d). In some exemplary embodiments, a height rm_hof the reinforcing member 540 is less than a depth sl_dof the second leg 530 but more than half of the depth sl_dof the second leg 530 (i.e., 0.5sl_d<rm_h<sl_d).

In some exemplary embodiments, a depth rm_dof the reinforcing member 540 is less than a height mp_hof the middle portion 510, a depth fl_dof the first leg 520, and a depth sl_dof the second leg 530. In some exemplary embodiments, a depth rm_dof the reinforcing member 540 is less than a height rm_hof the reinforcing member 540. In some exemplary embodiments, a depth rm_dof the reinforcing member 540 is equal to a height rm_hof the reinforcing member 540. In some exemplary embodiments, a depth rm_dof the reinforcing member 540 is less than or equal to half of a height mp_hof the middle portion 510 (i.e., rm_d<0.5mp_h). In some exemplary embodiments, a depth rm_dof the reinforcing member 540 is less than or equal to three-quarters of a depth fl_dof the first leg 520 (i.e., rm_d<0.75fl_d). In some exemplary embodiments, a depth rm_dof the reinforcing member 540 is less than or equal to half of a depth sl_dof the second leg 530 (i.e., rm_d<0.5sl_d).

The at least one reinforcing member 540 provides the bracket body 502 with greater structural integrity to resist deformation when acted on by external forces. In particular, when the mounting bracket 500 is used to install insulation (e.g., curtain wall insulation 102), the at least one reinforcing member 540 increases a depth of the mounting bracket 500 and provides at least one additional surface that is operable to bear against a support structure (e.g., mullion, transom) and thereby increase resistance to deformation by external forces, such as external forces exerted on a curtain wall insulation 102 due to the compression fit of a safing insulation 104. Accordingly, the mounting brackets 500 disclosed herein having at least one reinforcing member 540 can be used in a curtain wall insulation system 100 to prevent bowing or deformation of curtain wall insulation 102 due to the compression fit of the safing insulation 104 without the need for a separate reinforcement member (e.g., T-shaped backer bar 130) at or near the safing line.

In operation, one or more mounting brackets 500 are interfaced with a support structure (e.g., the mullion 152, the transoms 154, 156) in proximity to a location where insulation (e.g., the curtain wall insulation 102) is to be installed. More specifically, one or more mounting brackets 500 are secured to mullion 152 and transoms 154, 156 via fasteners, such as screws. After attaching the mounting brackets 500 to the mullion 152 and transoms 154, 156, curtain wall insulation 102 can be pressed onto the second leg 530 of each mounting bracket 500 such that the second leg 530 of each mounting bracket 500 penetrates the curtain wall insulation 102 such that a rear face of the curtain wall insulation abuts the middle portion 510 of each mounting bracket 500 and the barbs 534 on each second leg 530 effectively hold the curtain wall insulation 102 in place. The barbs 534 are suitable to secure the curtain wall insulation 102 to the mounting bracket 500 without the need for any additional structure (e.g., locking washers).

Alternatively, an insulation system incorporating the mounting brackets 500 of the present disclosure may be installed in a manner similar to an insulation system that utilizes the vertical hangers 210 and horizontal hangers 230 shown in FIGS. 2A and 2B. In particular, multiple mounting brackets 500 are interfaced with a portion of curtain wall insulation sized to fit within a curtain wall region (i.e., at least a portion of a region framed by a pair of parallel mullions and a pair of parallel transoms). More specifically, each mounting bracket 500 is pressed into the insulation so that a rear face of the insulation abuts the middle portion 510 of the mounting bracket 500, a side of the insulation abuts the first leg 520 of the mounting bracket 500, and the second leg 530 extends into, but not through, the insulation and the barbs 534 on the second leg 530 effectively secure the insulation to the mounting brackets 500. In this manner, the curtain wall insulation is interfaced with the mounting brackets 500.

Thereafter, the curtain wall insulation can be positioned and mounted in the curtain wall region. More specifically, a fastener (now shown), such as a screw, passes through the aperture 522 of each mounting bracket 500 to secure the mounting bracket 500 to a mullion or a transom. In this manner, the curtain wall insulation (e.g., curtain wall insulation 102) is mechanically secured within the curtain wall region. Typically, a piece of insulation (i.e., mullion cover) is then positioned over the mullion to protect it in the event of a fire. The mullion cover can be secured to the curtain wall insulation via fasteners, such as spiral screws or other separate mounting hangers/brackets.

It will be obvious to one of ordinary skill into the art, that any suitable number of the mounting brackets 500 can be used to secure the insulation (e.g., the curtain wall insulation 102) in the desired spaces.

Because the mounting bracket 500 operates to effectively install and affix the insulation without the need for locking washers and the like, the mounting bracket 500 allows for a simpler and quicker installation of fire perimeter insulation. Furthermore, because the mounting bracket 500 includes an integrated reinforcing member 540, there is no need to install a separate reinforcing member (e.g., T-shaped backer bar) required in conventional fire perimeter insulation systems and, thus, the mounting bracket 500 allows for a simpler and quicker installation of fire perimeter insulation.

Example

The following example illustrates the performance of mounting brackets according to the present disclosure as compared to conventional horizontal Impasse® insulation hangers (“conventional horizontal hangers”) available from Thermafiber, Inc. of Wabash, Ind., which are shown in FIG. 2B. This example is for purposes of illustration only and is not intended to limit the scope of the present disclosure.

In this example, a test was conducted in accordance with ASTM E2307-19 “Standard Test Method for Determining Fire Resistance of Perimeter Fire Barriers Using Intermediate-Scale, Multi-story Test Apparatus.” This test standard is intended to test for a system's ability to impede vertical spread of fire from a floor of origin to that above through a perimeter void, the void between an exterior wall assembly and a floor assembly.

As shown in FIG. 6, the test setup includes two identical pieces of mineral wool insulation 102, 102a (i.e., curtain wall insulation) attached to aluminum framing including mullions 152 and transoms 154. One piece of mineral wool insulation 102 was attached to the transom 154 using five mounting brackets 500 according to the present disclosure and two conventional vertical hangers 210 to attach the mineral wool insulation 102 to the mullions 152. The other piece of mineral wool insulation 102a was attached to the transom 154 using five conventional horizontal hangers 230 and two conventional vertical hangers 210 to attach the mineral wool insulation 102a to the mullions. The spacing of the five mounting brackets 500 attached to transom 154 and the spacing of the five conventional horizontal hangers 230 attached to transom 154 was identical. In addition, the mounting brackets 500 and the conventional horizontal hangers 230 were made of the same material and had the same thickness.

After conducting the test in accordance with ASTM E2307-19, it was observed that the mounting brackets 500 held its insulation 102 in place better than the conventional horizontal hangers 230 held its insulation 102a in place. This was observed by how much each piece of insulation 102, 102a sagged or drooped after being exposed to the fire test conditions at three points. When the insulation 102, 102a sags, gaps can be created in void material (i.e., safing insulation) that, if large enough, may allow flames to pass through causing the fire to spread. The first point corresponded to the edges of the mineral wool insulation 102, 102a adjacent the center mullion 152, the second point corresponded to the first mounting bracket 500 and the first conventional horizontal hanger 230 spaced from the center mullion 152, and the third point corresponded to the second mounting bracket 500 and the second conventional hanger 230 spaced from the center mullion. The sag at the first point for the mineral wool insulation 102 attached with the mounting brackets 500 was about 0.4 inches, whereas the sag at the first point for the mineral wool insulation 102a attached with the conventional horizontal hangers 230 was about 1 inch. The sag at the second point for the mineral wool insulation 102 attached with the mounting brackets 500 was about 0.4 inches, whereas the sag at the second point for the mineral wool insulation 102a attached with the conventional horizontal hangers 230 was about 0.8 inches. The sag at the third point for the mineral wool insulation 102 attached with the mounting brackets 500 was about 0.3 inches, whereas the sag at the third point for the mineral wool insulation 102a attached with the conventional horizontal hangers 230 was about 0.7 inches.

These results indicate that the mounting brackets 500 of the present disclosure maintain their shape and strength under fire exposure conditions better than the conventional horizontal hangers 230. In addition, these results indicate that the mounting brackets 500 of the present disclosure can provide a safer curtain wall insulation system than the conventional horizontal hangers 230 because the insulation is less likely to sag or droop, which reduces the ability of a fire to spread.

The scope of the general inventive concepts presented herein are not intended to be limited to the particular exemplary embodiments shown and described herein. From the disclosure given, those skilled in the art will not only understand the general inventive concepts and their attendant advantages, but will also find apparent various changes and modifications to the devices and systems disclosed. For example, while the exemplary embodiments described and shown herein relate to fire perimeter insulation, the inventive mounting brackets could be used to install other forms of insulation in building cavities. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the general inventive concepts, as described and/or claimed herein, and any equivalents thereof.

INSULATION MOUNTING BRACKET

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