1. Field of the Invention
The present invention relates generally to panel support brackets. More particularly, the present invention relates to support brackets for use in bracing support panels for tile installation.
2. Related Art
Installing tile in environments subject to wet conditions, such as shower and bath areas, has been popular for many years. Many such tile installations utilize cementitious mortar, which is used to bond tiles to an underlying attachment surface, after which a cementitious grout material is then applied between the tiles to fill gaps between adjacent tiles. Because grout is generally a porous material, water can and does seep through the grout, and so the eventual presence of water behind (or under) the tiles must be addressed in the tile installation. In general, the water that seeps through the grout should be both prevented from seeping into surrounding structure of the building, such as wall framing or sub flooring, and should be directed in some manner toward a drain of the shower or bath.
To aid in these goals, many conventional tiling installations utilize a vapor barrier of some type, such as plastic sheeting, which is installed against walls or floors over which the tile will be installed. In most applications, a lower vapor barrier, commonly known as the shower pan, is placed where the floor of the shower will be installed and generally extends a short distance up the walls of the shower. The pan is coupled to the drain of the shower in a manner that allows water to flow from the pan into “weep holes” formed in the drain. Sheets of vapor barrier are then attached to walls of the shower such that the wall vapor barriers overlap, and terminate within, the pan. In this manner, water flowing down the wall sheets of vapor barrier will flow into the pan and drain through the weep holes. Thus, water which seeps through the grout of the tile installation travels along the vapor barrier, either on the walls or the floor of the shower, until the water eventually flows into the weep holes of the drain of the shower.
The wall and floor components of the vapor barrier essentially form a “perimeter,” about which exists a dry environment, and within which exists a wet environment. Thus, wall framing and sub floor materials about the vapor barrier perimeter can be formed from a variety of materials, including wooden materials, as the framing and sub floor materials will not likely be exposed to moisture. However, any materials within the vapor barrier perimeter should be capable of withstanding a wet environment, due to the seepage of water through the grout of the tile installation.
When a ledge, such as a seat or shelf, is installed in shower areas, the ledge is generally framed within the perimeter of the vapor barrier, and thus must generally be framed from materials which can withstand a wet environment. For this reason, seats or shelves in shower areas are very rarely framed with wooden materials because wooden materials are susceptible to rot when exposed to moisture. Thus, only “non-wooden” materials are generally used to frame seats or shelves in shower or bath areas.
The most common conventional method of utilizing non-wooden materials for framing seats or shelves involves the placement of cement blocks or bricks within the vapor barrier perimeter. The cement blocks are generally placed in the location where the seat or shelf is to be tiled and are arranged to form the shape of the seat or shelf. Generally, the concrete blocks are placed or installed into position and an often large quantity of brick mortar is used to fill voids in and between the blocks or bricks, and to provide a smooth finish over the blocks or bricks. Multiple applications of brick mortar are often necessary to ensure that the seat frame is true and sufficiently smooth to receive tiles. This process results in a substantially solid seat or shelf being formed from bricks or blocks that are partially filled with and covered by mortar. Once this solid “frame” of the seat or shelf is completed, tile can be set or laid upon the frame in the finished tile installation.
While this method has proven at least partially effective in some applications, it suffers from a number of problems. For example, as cement blocks and brick mortar are relatively heavy materials, use of them as “framing” material adds considerably to the weight of the overall installation. In addition, due to the large quantity of brick mortar used, erection of the underlying “frame” for a conventional tiled seat typically takes at least a full day of work and cure time before tile can be set or laid over the block frame. Also, the use of square or rectangular bricks or blocks often limits the choice of geometry of the seat or shelf, as forming elaborate shapes becomes difficult when using square or rectangular frame components.
For at least these reasons, framing of tile seats or shelves for use in wet environments remains problematic to tile installers.
It has been recognized that it would be advantageous to develop a system for framing seats, shelves or ledges to receive tiles for use in wet environments that minimizes weight associated with the framing and provides greater flexibility for altering sizes and heights of the seats, shelves or ledges.
The present invention provides a corner brace configured to support a tile-bearing panel, including a pair of brackets, disposed at a transverse angle to one another and being configured to be disposed in a corner between the tile-bearing panel and another panel or a support surface. At least one of the brackets can have at least two ribs, each of which can extend from an inner base to an enlarged outer head. The at least two ribs can form at least one mortar receiving channel therebetween which can have an enlarged chamber and a narrower opening with respect to the enlarged chamber. The mortar receiving channel can be configured to at least partially interlock with mortar applied between the panel and the bracket to aid in securing the panel to the corner brace and thus to the other panel or support surface.
In accordance with another aspect of the invention, a method for bracing a tile-bearing panel is provided, including the steps of: applying mortar to at least one of: i) the panel; and ii) a bracket of a corner brace being configured to be coupled to the panel to support the panel; pressing the panel and bracket together to interlock the bracket within the mortar by forcing the mortar into a mortar receiving channel formed between at least two ribs associated with the bracket, the mortar receiving channel having an enlarged chamber and a narrower opening with respect to the enlarged chamber; affixing another bracket of the corner brace to another panel or a support surface; and retaining the bracket of the corner brace adjacent the panel until the mortar cures within the mortar receiving channel to couple the bracket to the panel.
In accordance with another aspect of the invention, a method for forming a tiled ledge for use in a wet environment is provided, including the steps of: attaching at least one corner brace to a wall; applying mortar to at least one of: i) a tile-bearing panel of the ledge; and ii) a bracket of the corner brace being configured to be coupled to the panel; pressing the panel and bracket together to interlock the bracket within the mortar by forcing the mortar into a mortar receiving channel formed between at least two ribs associated with the bracket, the mortar receiving channel having an enlarged chamber and a narrower opening with respect to the enlarged chamber; retaining the bracket of the corner brace adjacent the panel until the mortar cures within the mortar receiving channel and couples the bracket to the panel; and applying tiles to the tile-bearing panel.
Additional features and advantages of the invention will be apparent from the detailed description which follows, taken in conjunction with the accompanying drawings, which together illustrate, by way of example, features of the invention.
Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used herein to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the inventive features illustrated herein, and additional applications of the principles of the inventions as illustrated herein, which would occur to one skilled in the relevant art and having possession of this disclosure, are to be considered within the scope of the invention.
As illustrated in
At least one of the brackets, for example 12a in
By at least partially interlocking with mortar applied between the panel 13a and the bracket 12a, the mortar receiving channel 24a provides a mechanical coupling between the bracket and the panel; as the mortar becomes “locked” in the receiving channel after cure. This mechanical coupling is in addition to any chemical bonding that may occur between the mortar and the bracket of the brace. This feature of the invention is advantageous in the embodiments of the invention that include a brace formed of a polymeric material, as conventional mortar materials may not bond well chemically with the polymeric brace. By forming the mortar receiving channel between at least two ribs 14a and 14a′, the mortar applied to the brace is forced past the narrower opening 28a of the mortar receiving channel and “sets up,” or cures, within the enlarged chamber 26a, thereby forming a mechanical interlock between the brace and the mortar, and thus the support panel 13a. The present invention thus advantageously allows the brace to be formed from a lightweight, durable material even in the case where the lightweight material utilized may not bond well with conventional mortar products.
The corner brace of the present invention can thus be used to brace or support a tile-bearing panel to allow the tile bearing panel to be secured to another panel, or to some other supporting structure, such as a wall of a building. In a typical scenario, shown by example in top view in
The method can include the further step of affixing another bracket (12a in
The corner brace can be formed from a variety of materials, including cementitious materials, metals, plastics, etc., or a combination or composite of one or more materials. In one aspect of the invention, the corner brace is formed of a water resistant material. As used herein, the term “water resistant material” is to be understood to refer to a material that is substantially impervious to significant deterioration due to contact with water. Such materials can include, for example, cementitious materials, aluminum, polymers, stainless steel, etc. In one embodiment of the invention, the water resistant material includes high-impact polystyrene. Braces of the present invention formed of high-impact polystyrene can be manufactured through a variety of methods known to those skilled in the art, including protrusion, pultrusion, injection-molding, etc.
The tile-bearing panel can similarly be formed from a number of materials, including, in one aspect of the invention, material commonly referred to as “backer board,” which is a cementitious material formed in a sheet, similar in appearance to gypsum drywall. Backer board is commonly used on floors to provide a relatively stiff underlying surface on which tiles are laid. As the backer board is generally formed from cementitious materials, conventional cementitious mortar provides a good bond between the tiles and the backer board. Suitable types of backer board include, without limitation, cementitious backer boards having paper and/or fiberglass fillers, and gypsum backer boards having paper and/or fiberglass fillers. While it is contemplated that conventional cementitious mortar can be utilized with the present invention, in some embodiments of the invention, the mortar can include epoxy mortar, polymer modified cementitious mortar, epoxy adhesives and combinations or variations thereof.
While corner braces in accordance with the present invention can be used in a variety of applications, the brace can be particularly effective when used in framing a seat or other such ledge or projection that will be subject to a wet environment, such as in a bath or shower area. As shown for example in
For example, the corner braces 10 shown in
Similar to bulkhead 50b of
The corner braces of the present invention can offer a tile installer great flexibility in framing a ledge or seat in a tub or bath installation. As discussed, the braces can allow an installer to form angles of varying degree. In addition, the overall length of the braces can be varied to provide flexibility. For example, in one aspect of the invention, the overall length of the brace can be relatively short, on the order of being twice a width of either of the pair of brackets 12a, 12b. In this manner, a series of braces can be coupled along an edge of a tile-bearing panel or other support structure to brace one or more tile-bearing panels, similar to the arrangement illustrated in
Braces having relatively short lengths have proven advantageous in providing flexibility to the framing process, as the installer can easily attach one or more braces, as needed, along an edge of a panel, as dictated by the installation at hand. The installer thus need not cut the braces to length, as the case would be when the frame for a seat or ledge is formed from elongate lumber material. In addition, the relatively short length of the braces can allow a height of the ledge or shelf to be customized without requiring that the installer form the height of the ledge accordingly to a predetermined size of the bracing material, such as is the case when cement blocks are used as framing material.
Returning now to
Additional features of the invention are illustrated in
Returning again to
Returning to
It will be appreciated that seats or shelves formed in accordance with the present invention are framed by a series of panels which define a frame or enclosure having a variety of shapes. In addition to providing sufficient support to bear the weight of users or goods on the seat or shelf, the enclosure can be utilized to provide a variety of effects to the bath or shower area. For example, air vents or steam supply lines (not shown) can be routed through the enclosure to provide ventilation or steam to the shower area. In addition, lighting fixtures (not shown) can be disposed within the enclosure to provide utility and/or decorative lighting effects to the bath or shower area.
The present invention also provides methods for utilizing the corner braces discussed herein. The methods can be utilized to brace a tile-bearing panel and can include the steps of: applying mortar to at least one of: i) the panel; and ii) a bracket of a corner brace being configured to be coupled to the panel to support the panel; pressing the panel and bracket together to interlock the bracket within the mortar by forcing the mortar into a mortar receiving channel formed between at least two ribs associated with the bracket, the mortar receiving channel having an enlarged chamber and a narrower opening with respect to the enlarged chamber; affixing another bracket of the corner brace to another panel or a support surface; and retaining the bracket of the corner brace adjacent the panel until the mortar cures within the mortar receiving channel to couple the bracket to the panel.
The methods can also be utilized to form a tiled ledge for use in a wet environment, and in one embodiment can include the steps of: attaching at least one corner brace to a wall; applying mortar to at least one of: i) a tile-bearing panel of the ledge; and ii) a bracket of the corner brace being configured to be coupled to the panel; pressing the panel and bracket together to interlock the bracket within the mortar by forcing the mortar into a mortar receiving channel formed between at least two ribs associated with the bracket, the mortar receiving channel having an enlarged chamber and a narrower opening with respect to the enlarged chamber; retaining the bracket of the corner brace adjacent the panel until the mortar cures within the mortar receiving channel and couples the bracket to the panel; and applying tiles to the tile-bearing panel.
It is to be understood that the present invention can be utilized in erecting shelves or seats in both new bath or shower installations and in existing bath or shower areas. For example, brackets in accordance with the present invention can be attached within existing tile baths or showers by utilizing an epoxy capable of bonding the brackets to tiled surfaces. In this manner, a seat or shelf can be installed within a bath or shower area that has already been tiled. In addition, while the seat or shelf shown in
It is to be understood that the above-referenced arrangements are illustrative of the application for the principles of the present invention. It will be apparent to those of ordinary skill in the art that numerous modifications can be made without departing from the principles and concepts of the invention as set forth in the claims.
Number | Name | Date | Kind |
---|---|---|---|
2301672 | Akam | Nov 1942 | A |
3605137 | Stollenwerk | Sep 1971 | A |
D244942 | Bobrovniczky | Jul 1977 | S |
4508301 | Nicholson et al. | Apr 1985 | A |
4720069 | Bessinger | Jan 1988 | A |
D319509 | Ogilvie | Aug 1991 | S |
5064158 | Brazier et al. | Nov 1991 | A |
5243799 | Schluter | Sep 1993 | A |
5289663 | Schluter | Mar 1994 | A |
5542218 | Rompel | Aug 1996 | A |
D373738 | Nagai et al. | Sep 1996 | S |
5927033 | Kreckl | Jul 1999 | A |
6082062 | Alflen | Jul 2000 | A |
6094878 | Schluter | Aug 2000 | A |
6261394 | Raineri | Jul 2001 | B1 |
6434901 | Schluter | Aug 2002 | B1 |
20040093816 | Smythe | May 2004 | A1 |