Traditionally shower pans used in shower stalls are installed on top of a bathroom subfloor. As is typical, shower pans of all types, whether prefabricated or custom configured for a particular space, comprise a surface that is gently sloped towards a drain outlet. The need for a slope and the thickness of the materials comprising the shower pan have a distinct thickness that rises above flooring placed on a subfloor. Further, especially in the instance of a custom shower pan, finish flooring material is installed on top of the shower pan surface adding additional thickness.
Because of the added thickness of the shower pan over the surrounding bathroom floor, there usually must be a lip at the intersection of the pan with the surrounding floor to both provide for a visual transition for a shower user and to contain water from the shower in the stall. These lips can detract from the aesthetics of a shower stall, and even more significantly hinder access to and from the shower by the disabled and elderly.
While processes for recessing the subfloor of a bathroom in the region over which a shower pan is to be installed are known, they are usually very labor intensive, and accordingly expensive. Furthermore, if the recessed subfloor is not properly installed, which typically comprises wood bracing and blocking, the load carrying capacity of the recessed floor might not be adequate to handle the loads incident on it.
Embodiments of the present invention include a joist bracket that can be implemented with a set of differently configured brackets, that when secured to one or more of floor joists, walls, and existing normal height subfloor, can lower a subfloor a predetermined amount. The predetermined amount can typically be sufficient to permit the installation of a shower pan of appropriate slope towards a drain and permit a curb-less transition between the surrounding floor and the shower stall floor. In some variations, part of the floor may be lowered more than some other part to accommodate different types of shower pans and drains.
In one embodiment, a combination of brackets for recessing a portion of a subfloor in a room a predetermined amount relative to subflooring attached to a top surface of floor joists spanning across the room, the combination of brackets can include, but is not limited to, a first set of joist brackets and a second set of joist brackets. The first set of joist brackets can be substantially Z-shaped and include a substantially vertical planar joist bracket leg extending (i) upwardly from an intersection along a bottom edge with a substantially horizontal planar joist bracket bottom flange, and (ii) downwardly from an intersection along a top edge with a substantially horizontal planar joist bracket upper flange. The joist bracket upper flange can be defined by a plurality of evenly spaced outwardly extending tabs further defining a plurality of cutouts between the tabs. Each of the plurality of tabs can include a borehole for receiving a fastener. One or more of the plurality of tabs can include punched protrusions extending downwards substantially perpendicular to the tab. The punched protrusions can include a pointed end for penetrating a floor joist to initially secure the joist bracket to a floor joist before fasteners are passed through the boreholes. The upper flange of the first set of brackets can be defined by a first end including a partial tab and a second end including a portion of a cutout. The second set of joist brackets can be substantially similar to the first set of joist brackets. The upper flange of the second set of brackets can be defined by a first end including a partial cutout and a second end including a portion of a tab. Of significant note, when one of the first set of joist brackets are placed proximate one of the second set of joist brackets proximate one another on a floor joist, a cutout our a tab can be formed from ends of the two joist brackets.
The tabs of a first joist bracket are configured to nest in cutouts of a second joist bracket from the first set of brackets and the tabs of the second joist bracket are configured to nest in the cutouts of the first joist bracket when installed on opposing sides of a floor joist. Of significant note, when a pair of joist brackets from the first set of joist brackets are installed on a floor joist opposite one another, an overhang on either side of both brackets can be limited to approximately 1/32″. More specifically, an overall length of two joist brackets mated opposite one another can be limited to approximately 1/16″ longer than a length of one of the joist brackets. Similar to the first set of joist brackets, brackets from the second set of joist brackets installed on opposing sides of a floor joist, the tabs and cutouts are configured to mate with one another.
In one embodiment, a substantially Z-shaped joist bracket can include, but is not limited to, an upper flange, a lower, a vertical planar leg, a first end, and a second end. The upper flange can be defined by (i) a plurality of evenly spaced outwardly extending tabs, (ii) a plurality of cutouts each located between the tabs, (iii) one or more boreholes for receiving a fastener therethrough, and (iv) one or more protrusions extending downwardly and substantially perpendicular to the plurality of tabs. The vertical planar leg can extend (i) upwardly from an intersection along a bottom edge with the bottom flange, and (ii) downwardly from an intersection along a top edge with the upper flange. The first end can be defined by the upper flange having a partial cutout. The second end can be defined by the upper flange having a partial tab.
In another embodiment, a joist bracket system can include, but is not limited to, a first joist bracket and a second joist bracket. The first joist bracket can be defined by an upper flange, a lower flange, a vertical planar leg, a first end, and a second end. The upper flange defined by (i) a plurality of evenly spaced outwardly extending tabs, (ii) a plurality of cutouts each located between the tabs, (iii) one or more boreholes for receiving a fastener therethrough, and (iv) one or more protrusions extending downwardly and substantially perpendicular to the plurality of tabs. The vertical planar leg can extend (i) upwardly from an intersection along a bottom edge with the bottom flange, and (ii) downwardly from an intersection along a top edge with the upper flange. The first end can be defined by the upper flange having a partial cutout. The second end can be defined by the upper flange having a partial tab. The second joist bracket can be substantially similar to the first joist bracket but can have a first end defined by an upper flange having a partial tab and a second end defined by the upper flange having a partial cutout.
In yet another embodiment, a combination of brackets for recessing a portion of a subfloor in a room a predetermined amount relative to subflooring attached to a top surface of floor joists spanning across the room can include a combination of brackets. The combination of brackets can include, but is not limited to, a first set of Z-shaped brackets adapted to be installed on opposing sides of a floor joist and a second set of Z-shaped brackets adapted to be installed on opposing sides of the floor joist and proximate one of the first set of Z-shaped brackets. Each of the at least two substantially Z-shaped brackets can be defined by an upper flange, a lower flange, and a vertical planar leg. The upper flange can have (i) a plurality of evenly spaced outwardly extending tabs, (ii) a plurality of cutouts each located between the tabs, (iii) one or more boreholes for receiving a fastener therethrough, and (iv) one or more protrusions extending downwardly and substantially perpendicular to the plurality of tabs. The vertical planar leg can extend (i) upwardly from an intersection along a bottom edge with the bottom flange, and (ii) downwardly from an intersection along a top edge with the upper flange. A first end of the first set of Z-shaped brackets can each be defined by the upper flange having a partial cutout and a second end defined by the upper flange having a partial tab. A first end of the second set of Z-shaped brackets can each be defined by the upper flange having a partial tab and a second end defined by the upper flange having a partial cutout.
The brackets are typically comprised of steel but can be made of aluminum or a fiber reinforced plastic in variations. When two joist brackets are installed on opposing sides of a floor joist, an overhang from a first joist bracket when opposing a second joist bracket can be minimal (e.g., 1/32″). As can be appreciated, this can allow for more precise placement of the joist brackets in proximity to one another.
The terms and phrases as indicated in quotation marks (“ ”) in this section are intended to have the meaning ascribed to them in this Terminology section applied to them throughout this document, including in the claims, unless clearly indicated otherwise in context. Further, as applicable, the stated definitions are to apply, regardless of the word or phrase's case, to the singular and plural variations of the defined word or phrase.
The term “or” as used in this specification and the appended claims is not meant to be exclusive; rather the term is inclusive, meaning either or both.
References in the specification to “one embodiment”, “an embodiment”, “another embodiment, “a preferred embodiment”, “an alternative embodiment”, “one variation”, “a variation” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment or variation, is included in at least an embodiment or variation of the invention. The phrase “in one embodiment”, “in one variation” or similar phrases, as used in various places in the specification, are not necessarily meant to refer to the same embodiment or the same variation.
The term “couple” or “coupled” as used in this specification and appended claims refers to an indirect or direct physical connection between the identified elements, components, or objects. Often the manner of the coupling will be related specifically to the manner in which the two coupled elements interact.
The term “directly coupled” or “coupled directly,” as used in this specification and appended claims, refers to a physical connection between identified elements, components, or objects, in which no other element, component, or object resides between those identified as being directly coupled.
The term “approximately,” as used in this specification and appended claims, refers to plus or minus 10% of the value given.
The term “about,” as used in this specification and appended claims, refers to plus or minus 20% of the value given.
The terms “generally” and “substantially,” as used in this specification and appended claims, mean mostly, or for the most part.
Directional and/or relationary terms such as, but not limited to, left, right, nadir, apex, top, bottom, vertical, horizontal, back, front and lateral are relative to each other and are dependent on the specific orientation of a applicable element or article, and are used accordingly to aid in the description of the various embodiments and are not necessarily intended to be construed as limiting.
Referring generally to
As generally shown in
As shown in
The joist brackets 100, 100′ can have a generally “Z” shape and can have varying lengths. The joist brackets 100, 100′ can each include means for temporarily securing to a joist beam and a means for more permanently securing to the joist beam. As can be appreciated, by temporarily securing the joist brackets 100, 100′ to a joist beam, one or more additional joist brackets can be temporarily secured to ensure proper spacing and placement. In an instance where a joist bracket may be wrongly placed, the joist bracket can be removed and placed in a correct location with minimal effort prior to the joist bracket being more securely coupled to the joist beam.
As generally shown, the upper flange 106 can be defined by a plurality of cut-outs 110, a plurality of tabs 112, a plurality of tab boreholes 114, and a plurality of tab nails 116. The plurality of cut-outs 110 can be implemented to allow for opposing joist brackets to be placed on either side of a joist opposite each other and nestle. The cut-outs 110 can generally be sized slightly larger than each of the tabs 112 such that a tab can fit within an area defining the cutout. Typically, each of the plurality of tabs 112 can include one of the plurality of tab boreholes 114 for receiving fasteners therethrough. It is to be appreciated that at least two or more of the tabs may include boreholes for receiving fasteners. The plurality of tab boreholes 114 can be provided in a center of each upper flange tab for purposes of securing the bracket to a top surface of a floor joist beam. In another variation, additional boreholes can be provided through each upper flange tab giving an installer more options when attaching the upper flange to a joist permitting him/her to avoid any fasteners that may already have been driven into the joist.
As shown in
Of significant note, and as shown in Figures IC-1D, one of the vertices of the triangular protrusion (tab nail 116) can extend into and include a portion of the vertical leg 104. The tab nails 116 can be implemented to serve as a “third hand” when screwing the joist bracket down such that the bracket would may not move out of place. The tab nails 116 can be hammered into the floor joist beam and keep the bracket in place prior to more permanent securement to a floor joist beam. Of note, the tab nails 116 are not intended to replace screws or nails but provide stability when securing the bracket to a joist beam.
Referring to
Referring to
Of significant note, as shown in
In one example, the joist brackets 100, 100′ can be substantially Z-shaped and include a substantially vertical planar joist bracket leg extending (i) upwardly from an intersection along a bottom edge with a substantially horizontal planar joist bracket bottom flange, and (ii) downwardly from an intersection along a top edge with a substantially horizontal planar joist bracket upper flange. The joist bracket upper flange can be defined by a plurality of evenly spaced outwardly extending tabs further defining a plurality of cutouts between the tabs. The tabs can have a generally trapezoidal shape and the cutouts may be defined by a void area having a generally trapezoidal shape. Each of the plurality of tabs can include a borehole for receiving a fastener. One or more of the plurality of tabs can include punched protrusions (or tab nails) extending downwards substantially perpendicular to the tab. The punched protrusions can include a pointed end for penetrating a floor joist to initially secure the joist bracket to a floor joist before fasteners are passed through the boreholes. The upper flange can be defined by a first end including a partial tab and a second end including a portion of a cutout. The tabs of a first joist bracket are configured to nest in cutouts of a second joist bracket and the tabs of the second joist bracket are configured to nest in the cutouts of the first joist bracket when installed on opposing sides of a floor joist.
The joist brackets 100, 100′ can be comprised of any suitable material although brackets comprised of thinner sheet or plate are preferred. Accordingly, the brackets are typically made with a material having relatively high strength and high stiffness permitting thinner planar sections are preferred. Most commonly, the brackets are made of 14-18 gauge steel or stainless-steel plate. The dimensions of the brackets can vary, but embodiments of the set are configured so that when each is installed according to the described process the amount of subfloor drop offered by each relative to the top surface of a floor joist (or any other reasonable reference height) is the same for each bracket. For the specific embodiment(s) described herein, the dimensions given make the brackets suitable for use with standards for residential construction in the United States. As can be appreciated, the various dimensions can be easily adjusted for different construction materials and the standard dimensions of those materials in other embodiments. Pertinent standard dimensions of building materials that affect the dimensions of the illustrated embodiments include the 1½″ thickness of a standard 2×4 framing stud and the 23/32″ thickness of a standard sheet of OSB subfloor sheathing.
The various embodiments and variations thereof, illustrated in the accompanying Figures and/or described above, are merely exemplary and are not meant to limit the scope of the invention. It is to be appreciated that numerous other variations of the invention have been contemplated, as would be obvious to one of ordinary skill in the art, given the benefit of this disclosure. All variations of the invention that read upon appended claims are intended and contemplated to be within the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 63/592,994, filed Oct. 25, 2023.
Number | Date | Country | |
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63592994 | Oct 2023 | US |