Patent Application
20220259877
This disclosure relates generally to a wall reinforcement system, and more particularly to a locking track with locking tabs that are configured to be attachable to posts.
Wall reinforcement systems are used to reinforce and restore foundations and walls of residential and commercial dwellings, such as those that are in disrepair and/or failing. Conventional wall reinforcement systems include various structural components that are attachable to and support at least a portion of the load from the existing structure being reinforced. Typically, the structural components are attached using fasteners. However, fasteners can be cumbersome to handle, structurally inefficient and costly. In some cases, the fasteners can break and/or become lost or stripped. Additionally, the fasteners introduce multiple additional pieces that require extra effort to store, handle, and install. Moreover, because the structural components are positioned in close proximity to the existing structure, inserting and securing the fasteners into the structural components can be difficult.
The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems of and needs from conventional wall reinforcement systems that have not yet been fully solved by currently available systems. Generally, the subject matter of the present application has been developed to provide a locking track and associated wall reinforcement systems and methods that overcome at least some of the above-discussed shortcomings of prior art systems.
Disclosed herein is a locking track for a wall reinforcement system. The locking track comprising a top panel, two opposing side panels and a channel defined between the top panel and the two opposing side panels. The locking track further comprises locking tabs formed in the two opposing side panels and extending into the channel. The preceding subject matter of this paragraph characterizes example 1 of the present disclosure.
The two opposing side panels extend perpendicularly relative to the top panel. The preceding subject matter of this paragraph characterizes example 2 of the present disclosure, wherein example 2 also includes the subject matter according to example 1, above.
At least one side panel of the two opposing side panels is angled inwardly toward the other one of the two opposing side panels, such that the angle between the at least one side panel and the top panel is less than ninety degrees. The preceding subject matter of this paragraph characterizes example 3 of the present disclosure, wherein example 3 also includes the subject matter according to any of examples 1-2, above.
At least one side panel of the two opposing side panels further comprises a flared end portion that flares outwardly away from the other one of the two opposing side panels. The preceding subject matter of this paragraph characterizes example 4 of the present disclosure, wherein example 4 also includes the subject matter according to example 3, above.
The locking tabs extend into the channel and upwardly, toward the top panel, at an oblique angle from the corresponding one of the two opposing side panels. The preceding subject matter of this paragraph characterizes example 5 of the present disclosure, wherein example 5 also includes the subject matter according to any of examples 1-4, above.
Each locking tab comprises a U-shaped portion cut into the corresponding one of the two opposing side panels and bent into the channel to form the locking tab. The preceding subject matter of this paragraph characterizes example 6 of the present disclosure, wherein example 6 also includes the subject matter according to any of examples 1-5, above.
A longitudinal position of each one of the locking tabs in one of the two opposing side panels corresponds with the longitudinal position of another one of the locking tabs in the other one of the two opposing side panels. The preceding subject matter of this paragraph characterizes example 7 of the present disclosure, wherein example 7 also includes the subject matter according to any of examples 1-6, above.
A longitudinal spacing between each one of the locking tabs in each of the two opposing side panels is uniform along the length of the locking track. The preceding subject matter of this paragraph characterizes example 8 of the present disclosure, wherein example 8 also includes the subject matter according to of any examples 1-7, above.
A longitudinal spacing between each one of the locking tabs in each of the two opposing side panels is non-uniform along the length of the locking track. The preceding subject matter of this paragraph characterizes example 9 of the present disclosure, wherein example 9 also includes the subject matter according to of any examples 1-8, above.
The locking tabs are arranged into multiple sets of locking tabs. The longitudinal spacing between locking tabs of a given set of the multiple sets is different than the spacing between adjacent ones of the multiple sets. The preceding subject matter of this paragraph characterizes example 10 of the present disclosure, wherein example 10 also includes the subject matter according to example 9, above.
The two opposing side panels are spaced apart from each other by a width of the top panel, such that the locking track has a C-shaped cross-section. The preceding subject matter of this paragraph characterizes example 11 of the present disclosure, wherein example 11 also includes the subject matter according to any of examples 1-10, above.
The locking track further comprises an upper ledge formed along the top panel at an intersection between the top panel and each of the two opposing side panels, such that the locking track has a T-shaped cross section. The preceding subject matter of this paragraph characterizes example 12 of the present disclosure, wherein example 12 also includes the subject matter according to any of examples 1-11, above.
Alternatively, the locking track further comprises a corrugation formed in each one of the two opposing side panels, the corrugation in each one of the two opposing side panels formed inwardly relative to the other one of the two opposing side panels, such that the locking track has a sigma-shaped cross section. The preceding subject matter of this paragraph characterizes example 13 of the present disclosure, wherein example 13 also includes the subject matter according to any of examples 1-12, above.
Further disclosed herein is a wall reinforcement system. The wall reinforcement system comprises a locking track, comprising a top panel, two opposing side panels, a channel defined between the top panel and the two opposing side panels, and locking tabs formed in the two opposing side panels and extending into the channel. The wall reinforcement system further comprises a post, comprising a web, two flanges extending transversely from the web, and at least one slot formed in each one of the two flanges. The at least one slot formed in each one of the two flanges receives a corresponding one of the locking tabs to lock the post to the locking track. The preceding subject matter of this paragraph characterizes example 14 of the present disclosure.
The wall reinforcement system further comprises a corrugated panel attachable to the locking track and configured to extend vertically from the locking track and parallel to the two flanges of the post, when the post is locked to the locking track. The preceding subject matter of this paragraph characterizes example 15 of the present disclosure, wherein example 15 also includes the subject matter according to example 14, above.
The locking track further comprises a panel support feature in a distal edge of one of the two opposing side panels. The corrugated panel further comprises a hook-like feature in a top edge of the corrugated panel. The panel support feature and the hook-like feature are configured to interlock in a clasping arrangement when the corrugated panel is attached to the locking track. The preceding subject matter of this paragraph characterizes example 16 of the present disclosure, wherein example 16 also includes the subject matter according to example 15, above.
The post is formed from a first material. The locking track is formed from a second material. The first material is stronger than the second material. The preceding subject matter of this paragraph characterizes example 17 of the present disclosure, wherein example 17 also includes the subject matter according to any of examples 14-16, above.
The locking tabs are arranged into multiple sets of locking tabs. A longitudinal spacing between locking tabs of a given set of the multiple sets is different than a longitudinal spacing between adjacent sets of the multiple sets. The post has a corresponding number of slots to the locking tabs of the given set. The longitudinal spacing between the locking tabs of the given set corresponds with a longitudinal spacing between the slots of the post. The preceding subject matter of this paragraph characterizes example 18 of the present disclosure, wherein example 18 also includes the subject matter according to any of examples 14-17, above.
The post comprises a plurality of posts. The plurality of posts, when locked to the locking track, are spaced apart from each other at uniform intervals along the locking track. The preceding subject matter of this paragraph characterizes example 19 of the present disclosure, wherein example 19 also includes the subject matter according to any of examples 14-18, above.
Additionally, disclosed herein a method of attaching parts of a wall reinforcement system. The method comprises orienting a post, comprising a web, two flanges extending transversely from the web, and at least one slot formed in each one of the two flanges, such that the flanges are parallel with two opposing side panels of a locking track. The locking track further comprising a top panel, a channel defined between the top panel and the two opposing side panels, and locking tabs formed in the two opposing side panels and extending into the channel. The method also comprises positioning the post along the locking track at a location where the at least one slot in each one of the two flanges is aligned with a corresponding one of the locking tabs. The method further comprises inserting the post into the channel of the locking track until the locking tabs engage with and are received into the corresponding slot. The preceding subject matter of this paragraph characterizes example 20 of the present disclosure.
The described features, structures, advantages, and/or characteristics of the subject matter of the present disclosure may be combined in any suitable manner in one or more examples, including embodiments and/or implementations. In the following description, numerous specific details are provided to impart a thorough understanding of examples of the subject matter of the present disclosure. One skilled in the relevant art will recognize that the subject matter of the present disclosure may be practiced without one or more of the specific features, details, components, materials, and/or methods of a particular example, embodiment, or implementation. In other instances, additional features and advantages may be recognized in certain examples, embodiments, and/or implementations that may not be present in all examples, embodiments, or implementations. Further, in some instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the subject matter of the present disclosure. The features and advantages of the subject matter of the present disclosure will become more fully apparent from the following description and appended claims, or may be learned by the practice of the subject matter as set forth hereinafter.
In order that the advantages of the subject matter may be more readily understood, a more particular description of the subject matter briefly described above will be rendered by reference to specific examples that are illustrated in the appended drawings. Understanding that these drawings depict only typical examples of the subject matter, they are not therefore to be considered to be limiting of its scope. The subject matter will be described and explained with additional specificity and detail through the use of the drawings, in which:
Reference throughout this specification to “one example,” “an example,” or similar language means that a particular feature, structure, or characteristic described in connection with the example is included in at least one example of the subject matter of the present disclosure. Appearances of the phrases “in one example,” “in an example,” and similar language throughout this specification may, but do not necessarily, all refer to the same example. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more examples of the subject matter of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more examples.
Referring to
The wall reinforcement system 100 additionally includes a plurality of posts 120 that run parallel with the wall 104 and perpendicular to the existing overhang structure 106 and the floor 102. Upper end portions 122 of the posts 120 are attached to the locking track 110 and lower end portions 124 of the posts 120 are attached to the floor 102. The lower end portions 124 are attached to the floor 102 by positioning the lower end portions 124 in holes excavated in the floor 102 and filling the holes with concrete, thus securing the lower end portions 124 in the holes. Accordingly, the posts 120 run from the existing overhang structure 106, along the corrugated panel 130, to the floor 102 such that the corrugated panel 130 is interposed (e.g., sandwiched) between the posts 120 and the wall 104. The posts 120 are spaced apart from each other, at uniform or non-uniform intervals, along the locking track 110 and the floor 102. The locking track 110 is made of a light-gauge steel in some examples and the posts 120 are made of a high-strength steel or a steel stronger than that of the locking track 110.
Loads experienced by the wall 104 are transferred from the wall 104 to the corrugated panel 130, to the posts 120, and from the posts 120 to the locking track 110 and the overhang structure 106 and/or to the floor 102. Similar loads from the existing overhang structure 106 are transferred from the existing overhang structure 106 to the floor 102 via the locking track 110 and posts 120.
Although fasteners can be used to attach the posts 120 to tracks, similar to the locking track 110, such a process can be cumbersome, inefficient, and costly. The fasteners can break, get lost, get stripped, and the like. Additionally, such a process introduces multiple additional pieces, which require added effort to store, handle, and install. Moreover, because one of the side panels 116 of the locking track 110 is positioned in close proximity to the wall 104, inserting fasteners into and fastening the fasteners to that side panel 116, which is on a back side of the locking track 110, can be difficult. The locking track 110 of the present disclosure eliminates these shortcomings associated with attachment of the posts 120 via fasteners by providing an attachment mechanism that secures the posts 120 to the locking track 110 without fasteners. Referring to
Referring to
The locking tabs 112 protrude from the side panels 116 inwardly into the channel 140 and extend upwardly, in a bottom-to-top direction (i.e., in a direction toward the top panel 114), at an oblique angle. Each one of the locking tabs 112 can be formed by cutting a U-shaped cut into a corresponding one of the side panels 116 and then bending the portion defined by the cut into the channel 140. Accordingly, as shown in
In some examples, each one of the locking tabs 112 in one of the side panels 116 corresponds with another one of the locking tabs 112 in the other one of the side panels 116. More specifically, the longitudinal position of each one of the locking tabs 112 in one of the side panels 116 is the same as that of another one of the locking tabs 112 in the other one of the side panels 116. The locking tabs 112 are paired in this manner at spaced apart intervals lengthwise along the locking track 110. The intervals between pairs of locking tabs 112 can be uniform or non-uniform. In some examples, as shown in
The spacing between adjacent locking tabs 112 corresponds with the spacing between the slots 129 of the upper end portion 122 of the posts 120. In other words, the spacing between the locking tabs 112 and the spacing between the slots 129 are such that each one of the slots 129 of a post 120 is alignable with corresponding one of the locking tabs 112 of the locking track 110.
As shown in
Referring to
To promote the attachment of the posts 120 to the locking track 110, in some examples, one or both of the side panels 116 of the locking track 110 is angled inwardly toward the other such that an angle θ between the side panel 116, that is angled, and the top panel 114 is less than 90 degrees (see, e.g.,
Depending on the particular application and constraints of the wall 104 being reinforced, the cross-sectional shape of the locking track 110 can be varied. For example, the C-shaped cross-section of the locking track 110 of
In some examples, the locking track 110 also includes features that helps hang and secure the corrugated panel 130. Referring to
In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “over,” “under” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.”
Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element.
As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination.
Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.
As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.
The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described examples are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the examples herein are to be embraced within their scope.
This application claims the benefit of U.S. Provisional Patent Application No. 63/151,042, filed Feb. 18, 2021, which is incorporated herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63151042 | Feb 2021 | US |
