CROSS REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional application No. filed on Dec. 31, 2018 for “L” BRACKET CLOSED WALL CONNECTOR, which is incorporated by reference as if fully set forth.
FIELD OF INVENTION
The present invention relates generally to the art of exterior walls of buildings, and more specifically to an apparatus that secures a wall panel to the building and the method of installation thereof.
BACKGROUND
In a traditionally built exterior building wall, the structural frame of the wall is bolted to the foundation during construction. Anchor bolts fixed to the foundation secure the wall forms and other construction portions to the concrete slab foundation. Most commonly, anchor bolts are cast-in-place in preset positions, wherein the bolt head is cast into the concrete and the threaded end extends out of the foundation. The structural frame of the wall is constructed by securing the bottom plate to the foundation. The bottom plate is secured by predrilling holes into the bottom plate. The size and placement of the holes correspond with the position of the anchor bolts. The bottom plate is placed flat on the concrete foundation with the threaded ends of the anchor bolts extending up through the holes of the bottom plate. The nut of the anchor bolt is screwed onto the bolt threads to secure the bottom plate. The remaining exterior wall components are then installed.
However, some wall systems are constructed from prefabricate wall panels. A wall panel may be assembled with the structural frame attached to the wall's interior and exterior components. In this case, after the prefabricated wall panel is placed onto the threaded ends of the anchor bolts, the anchor bolts are no longer accessible to screw the nut onto the anchor bolt threads. Because the threads of the anchor bolts are no longer accessible, there is no way to secure the prefabricated wall panel to the anchor bolt or foundation.
Therefore, there is a need for a device and method to secure prefabricated wall panels to a foundation or base.
SUMMARY
A closed wall connector is provided comprising an “L” shaped bracket. The “L” shaped bracket includes a horizontal leg and a vertical leg. The horizontal leg includes a first plurality of apertures. The vertical leg includes a second plurality of apertures. The closed wall connector also includes a first plurality of fasteners to connect the horizontal leg to a base through the first plurality of apertures, and a second plurality of fasteners to connect the vertical leg to a wall panel through the second plurality of apertures. The base may be a floor, a ceiling, or a foundation.
A wall is also provided. The wall includes a closed wall connector and a wall panel including a bottom plate, a top plate, and sheathing. The closed wall connector includes the details and embodiments previously discussed. The bottom plate, top plate, and/or sheathing of the wall panel are connected to the vertical leg of the closed wall connector with the second plurality of fasteners.
A method of installing the wall is also provided. The method includes receiving the closed wall connector, connecting the horizontal leg of the closed wall connector to a base with a first plurality of fasteners, placing a wall panel onto the horizontal leg and adjacent to the vertical leg of the closed wall connector, and connecting the wall panel to the vertical leg with a second plurality of fasteners. The closed wall connector and the wall panel include the details and embodiments previously discussed.
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 closed wall connector, wall panel, and method shown.
FIG. 1A is an elevation view of a closed wall connector connected to a floor.
FIG. 1B is an elevation view of the closed wall connector connected to a foundation.
FIG. 1C is an elevation view of the closed wall connector connected to a ceiling.
FIG. 2 is a plan view of the horizontal leg of the closed wall connector shown in FIGS. 1A and 1C.
FIG. 3 is a plan view of the horizontal leg of the closed wall connector shown in FIG. 1B.
FIG. 4 is a plan view of the vertical leg of the closed wall connector shown in FIGS. 1A-1C.
FIG. 5 is an elevation view of a wall panel being placed in two closed wall connectors.
FIG. 6 is an elevation view of the wall panel connected to the closed wall connectors.
FIG. 7 is an elevation view of a bottom plate of the wall panel connected to the closed wall connector.
FIG. 8 is an elevation view of the wall panel connected to the closed wall connector with base boards installed.
FIG. 9 is a flow chart of a method of installing the closed wall connector and the wall panel.
DETAILED DESCRIPTION
A closed wall connector that quickly and easily connects a prefabricated or closed wall panel to the building is provided. The closed wall connector includes an “L” shaped bracket. The “L” shaped bracket includes a horizontal leg and a vertical leg. The horizontal leg includes a first plurality of apertures. The vertical leg includes a second plurality of apertures. A first plurality of fasteners connects the horizontal leg to a base through the first plurality of apertures. The base may be a foundation, floor, or ceiling of a building. A second plurality of fasteners connects the vertical leg to a wall panel through the second plurality of fasteners. The wall panel may be prefabricated. The connector provides a way to connect a prefabricated or closed wall panel to a foundation, floor, or ceiling of a building without accessing the inside of the wall panel.
A wall is also provided. The wall includes a closed wall connector and a wall panel including a bottom plate, a top plate, and sheathing. The closed wall connector includes the details and embodiments previously discussed. The bottom plate, top plate, and/or sheathing of the wall panel are connected to the vertical leg of the closed wall connector with the second plurality of fasteners.
A method of installing the wall panel is also provided. The method includes receiving the closed wall connector, connecting the horizontal leg of the closed wall connector to a base with a first plurality of fasteners, placing a wall panel onto the horizontal leg and adjacent to the vertical leg of the closed wall connector, and connecting the wall panel to the vertical leg with a second plurality of fasteners. The method provides a simple and efficient way to connect a prefabricated or closed wall panel to a foundation, floor, or ceiling, thereby decreasing the time to construct and install an exterior wall of a building and cutting construction costs.
As shown in FIGS. 1A-1C, a closed wall connector 100 is provided. The closed wall connector 100 connects a closed wall panel or prefabricated wall panel to a base 250a, 250b, 250c. The closed wall connector 100 includes an “L” shaped bracket 200. The “L” shaped bracket 200 includes a vertical leg 210 and a horizontal leg 220. The horizontal leg 220 connects the closed wall connector 100 to the base 250a, 250b, 250c. The horizontal leg 220 includes a first plurality of apertures 230. The first plurality of apertures 230 is configured to receive a first plurality of fasteners 240a, 240b. As shown in FIGS. 1A-1C, the horizontal leg 220 is connected to a base 250a, 250b, 250c by a first plurality of fasteners 240a, 240b. The fasteners 240a, 240b connect the horizontal leg 220 to the base 250a, 250b through the first plurality of apertures 230. The shank of the fastener 240a, 240b extends through the first plurality of apertures 230 into the base 250a, 250b, 250c. The head of the first plurality of fasteners 240a, 240b is tight against the horizontal leg 220 thereby securing the closed wall connector 100 to the base 250a, 250b, 250c. The horizontal leg 220 of the closed wall connector 100 may also include openings (not shown) for mechanical, electrical, and plumbing utilities. The openings allow the mechanical, electrical, and plumbing utilities to run from floor to floor without interference. The vertical leg 210 is configured to connect to the closed wall panel. The length of the vertical leg 210 and horizontal leg 220 depend on the size needed to transfer loads from the closed wall panel to the base 250a, 250b, 250c. The closed wall connector 100 may be made from galvanized steel, aluminum, or any material with sufficient strength to transfer loads from the closed wall panel to the base 250a, 250b, 250c.
FIG. 1A is an elevation view of a closed wall connector 100 connected to a floor 250a. A fastener 240a extends through an aperture 230 in the horizontal leg 220 to connect the closed wall connector 100 to a base 250a. In FIG. 1A, the base 250a is a floor of a building. The first plurality of fasteners 240a used to connect the horizontal leg 220 to the floor 250a may be any fasteners, such as screws or nails. The fastener 240a must have properties that allow the loads applied to the closed wall panel to transfer to the floor 250a.
FIG. 1B is an elevation view of the closed wall connector 100 connected to a foundation 250b. As shown in FIG. 1B, the base 250b may be a concrete foundation. The first floor closed wall panels are connected to a foundation 250b. In this embodiment, the first plurality of fasteners 240b that connect the horizontal leg 220 to the foundation 250b may be anchor bolts and nuts. The anchor bolt may be a post-installed concrete anchor or the anchor bolt may be a cast-in-place embedded concrete anchor, shown in phantom in FIG. 1B. The fastener 240b must have properties that allow the loads applied to the closed wall panel to transfer to the base 250b.
FIG. 1C is an elevation view of the closed wall connector 100 connected to a ceiling 250c. As shown in FIG. 1C, the base 250c may be a ceiling. In this embodiment, the fasteners 240a connect the horizontal leg 220 of the closed wall connector 100 to the ceiling 250c. Like the embodiment shown in 1A, the first plurality of fasteners 240a may be any fasteners, such as screws. The fastener 240a must have properties that allow the loads applied to the closed wall panel to transfer to the ceiling 250c.
FIG. 2 is a plan view of the horizontal leg 220 of the closed wall connector 100 shown in FIGS. 1A and 1C. The width W of the horizontal leg 220 may be approximately the same width as the closed wall panel. Alternatively, the width W of the horizontal leg 220 may be shorter than the closed wall panel and multiple closed wall connectors 100 may be used to connect the closed wall panel to the base 250a, 250b, 250c. The plurality of apertures 230a-n configured to receive fasteners 240a to connect the horizontal leg 220 to the base 250a, 250c are spaced along the horizontal leg 220. As shown in FIG. 2, there may be two rows of apertures 230a-n. Although FIG. 2 depicts two rows of apertures 230a-n, the horizontal leg 220 may include more or less rows of apertures 230a-n. The spacing and number of apertures 230a-n correspond with the number of fasteners 240a needed to secure the closed wall connector 100 to the floor 250a or ceiling 250c of a building. Moreover, the spacing and number of apertures 230a-n correspond with the number of fasteners 240a needed to transfer loads from the closed wall panel to the floor 250a or ceiling 250c. The diameter of the apertures 230a-n corresponds to the diameter of the fastener 240a.
FIG. 3 is a plan view of the horizontal leg 220 of the closed wall connector 100 shown in FIG. 1B. The plurality of apertures 230a-n configured to receive fasteners 240b to connect the horizontal leg 220 to the base or foundation 250b are spaced along the horizontal leg 220. As shown in FIG. 2, there may be a single row of apertures 230a-n. Although FIG. 2 shows a single row of apertures 230a-n, the horizontal leg 220 may include additional rows. The spacing and number of apertures 230a-n correspond with the number of fasteners or anchor bolts 240b needed to secure the closed wall connector 100 to the foundation 250b of a building. Moreover, the spacing and number of apertures 230a-n correspond with the number of fasteners 240b needed to transfer loads from the closed wall panel to the foundation 250b. The diameter of the apertures 230a-n corresponds to the diameter of the anchor bolt 240b.
FIG. 4 is a plan view of the vertical leg 210 of the closed wall connector shown 100 in FIGS. 1A-1C. The vertical leg 210 of the closed wall connector 100 includes a second plurality of apertures 260a-n. The second plurality of apertures 260a-n is configured to receive fasteners 242 (not shown in FIG. 4). The fasteners 242 connect the closed wall panel to the vertical leg 210. As shown in FIG. 4, there may be a single row of apertures 260a-n. Although FIG. 4 shows a single row of apertures 260a-n, the vertical leg 210 may include additional rows. The spacing and number of apertures 260a-n correspond with the number of fasteners 242 needed to secure the closed wall panel to the closed wall connector 100. Moreover, the spacing and number of apertures 260a-n correspond with the number of fasteners 242 needed to transfer loads from the closed wall panel to the closed wall connector 100. The diameter of the apertures 260a-n corresponds to the diameter of the fasteners 242.
FIG. 5 is an elevation view of a wall panel 300 being placed in two closed wall connectors 100. The wall panel 300 may be a prefabricated or pre-assembled, closed wall assembly. The wall panel 300 includes at least one bottom plate 310. Although one bottom plate 310 is shown in FIG. 5, the wall panel 300 may include two or three bottom plates 310. The wall panel 300 may also include at least one top plate 340. The bottom plate 310 and top plate 340 may be made from any structurally rigid material such as wood 2×4s or aluminum. The wall panel 300 also includes sheathing 320. Additionally, the wall panel 300 may include drywall 330. As shown in FIG. 5, the drywall 330 may be held up from the bottom of the wall panel 300 to facilitate the wall panel 300 and vertical leg 210 connection. The drywall 330 may also be held down from the top of the wall panel 300 to facilitate the wall panel 300 and vertical leg 210 connection. The drywall 330 may be extended to the bottom of the bottom plate 310 and to the top of the top plate 340 on the non-sheathed side of the wall panel 300. As shown in FIG. 5, the depth of the “L” shaped bracket 200 may correspond to the depth of the wall panel 300. The “L” shaped bracket 200 may be a continuous bracket the width of the wall panel 300.
FIG. 6 is an elevation view of the wall panel 300 connected to the closed wall connectors 100. As shown in FIG. 6, the sheathing 320 of the wall panel 300 butts up against the vertical leg 210 of the “L” shaped bracket 200. The vertical leg 210 includes the second plurality of apertures 260. A second plurality of fasteners 242 connects the closed wall connector 100 to the wall panel 300. The shank of the fastener 242 extends through the aperture 260 into the wall panel 300 and the head of the fastener 242 is tight against the vertical leg 210. The second plurality of fasteners 242 extends through the second plurality of apertures 260 and through the sheathing 320 and into the bottom plate 310 and/or top plate 340 of the wall panel 300. The plurality of fasteners 242 can be any shear fastener such that the shear load applied to the wall panel 300 is transferred to the closed wall connector 100 and base 250a, 250b, 250c.
FIG. 7 is an elevation view of a bottom plate 310 of the wall panel 300 connected to the closed wall connector 100. FIG. 7 depicts the bottom plate 310 and sheathing 320 connected to the vertical leg 210 of the closed wall connector 100, wherein the first plurality of fasteners 240b is anchor bolts and nuts and the base 250b is a concrete foundation. Because the end of the anchor bolt and nut may be bulky and protrude up from the horizontal leg 220 of the closed wall connector 100, the bottom of the bottom plate 310 may be routed out to create a space 350 to fit over the head and nut of the anchor bolts 240b. The bottom of the bottom plate 310 may have a space 350 to accommodate any type of fastener.
FIG. 8 is an elevation view of the wall panel 300 connected to the closed wall connector 100 with base boards 400 installed. As shown in FIG. 8, at least one base board 400 may be added to the bottom of the wall panel 300. The base board 400 on the sheathed side of the wall panel 300 covers up the connection to the closed wall connector 100 and encloses or seals up the wall assembly. Although not shown, crown molding or trim may be added to the top of the wall panel 300 to cover up the connection with the closed wall connector 100 at the ceiling and enclose or seal up the wall assembly. The baseboard or trim provide a finished look by concealing the closed wall connector 100.
FIG. 9 is a flow chart of a method of installing the closed wall connector and the wall panel 600. The method 700 includes the step 710 of receiving an “L” shaped bracket 200. The “L” shaped bracket 200 includes the details and embodiments previously described. In particular, the “L” shaped bracket includes a vertical leg 210 and a horizontal leg 220. The horizontal leg 220 includes a first plurality of apertures 230 and the vertical leg 210 includes a second plurality of apertures 260.
The method 600 includes the step 620 of connecting the horizontal leg 220 of the “L” shaped bracket 200 to a base 250a, 250b, 250c. The horizontal leg 220 may be connected to the base 250a, 250b, 250c with a first plurality of fasteners 240a, 240b through the first plurality of apertures 230. The base 250a, 250b, 250c may be the floor, the concrete foundation, and/or the ceiling. The shank of the fastener 240a, 240b extends through the aperture 230 and the head or nut of the fastener 240a, 240b is tight against the horizontal leg 220. The horizontal leg 220 may be connected by driving, drilling, screwing, or hammering the fastener 240a, 240b through the aperture 230 into the base 250a, 250b, 250c, or if the fastener 240b is a cast in place anchor bolt, the horizontal leg 220 may be connected by sliding the end of the anchor bolt through the aperture 230 and screwing a nut onto the end of the anchor bolt.
The method 600 includes the step 630 of placing a wall panel 300 against the horizontal leg 220 and adjacent to the vertical leg 210 of the “L” shaped bracket 200. The wall panel 300 is placed in the “L” shaped bracket 200 so that the bottom or top of the wall panel 300 abuts the horizontal leg 220 and the sheathing 320 abuts the vertical leg 210. The wall panel 300 includes the details and embodiments previously described.
The method 600 also includes the step 640 of connecting the vertical leg 210 of the “L” shaped bracket 200 to the wall panel 300. The wall panel 300 is connected to the vertical leg 210 with a second plurality of fasteners 242 through the second plurality of apertures 260. As previously described, the second plurality of fasteners 242 extends through the second plurality of apertures 260 and into the sheathing 320 and the bottom plate 310 or the top plate 340. The shank of the fastener 242 extends through the aperture 260 and the head or nut of the fastener 242 is tight against the vertical leg. The vertical leg 210 may be connected by driving, drilling, screwing, or hammering the fastener 242 through the aperture 260 into the sheathing 320 and the bottom plate 310 or the top plate 340. The method 600 may also include installing base boards 400 at the bottom of the wall panel 300.
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 closed wall connector, the wall, and the method 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.
Patent Application
20200208397
