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Description  |
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BACKGROUND
1. Field of the Invention
The present invention relates to bracket supports of the type that are
commonly employed in certain wall structures, such as partitions that
include a plurality of spaced vertical studs defining the wall frame. More
particularly, the invention herein pertains to a substantially integral
support that offers significant economic advantages over conventional
structures.
2. Description of the Prior Art
An often-utilized wall construction that is particularly favored by retail
business establishments and offices includes a frame formed by a plurality
of spaced, vertically arranged wall studs. Often such studs are metallic
and generally U-shaped in cross section, opposed flanges providing
strength and anchor points for the wallboard panel surfaces of the
partition-type wall units. Construction of this type is almost universally
employed at the present time in the division of office space into tenants'
preferred anrrangements as it is both economical and semipermanent,
allowing easy rearrangement for new occupants.
Commonly, shelf space adjacent the partition is desired. Thus, a series of
wall shelves will be provided, each shelf positioned at a right angle to
the wallboard surface. These shelves are usually supported by brackets
that protrude from and are anchored in some manner within the partition.
A number of arrangements have been provided in the past for properly
mounting such brackets securely. The bracket support must provide adequate
resistance to the weight and bending moments that are transferred to it in
consequence of the loading of the cantilevered wall shelves. Further, the
geometry of such support must be fully compatible with the wall unit and
studs.
A common bracket supporting mechanism generally includes an elongated,
often slotted, core member of bar steel or the like. The slots in this
member are intended to engage a mating tongue that projects inwardly at
the inner end of the conventional wall bracket. A critical feature of the
overall bracket support pertains to the mode of securing the slotted
support bar to the wall. Such apparatus, often an elongated housing, must
not only accommodate the slotted core member in a secure manner but also
be compatible with the wall unit and the bracket. Means must be provided
to stabilize the core member both laterally and vertically as it is not
inherently stable. Further, ready access to the slots of the core member
and the enhancement of bracket stability are quite desirable.
The multiple requirements of a bracket support design have resulted in a
number of solutions. Generally, such designs have included a vertical
channel for retaining the bracket support core or bar. Numerous
configurations have been employed for cooperatively engaging such channel
to the remainder of the wall unit. Examples of designs that include an
upright channel for receiving a slotted support bar and that are adapted
to be secured to a wall are disclosed in the following U.S. patents: U.S.
Pat. NO. 3,714,748 of Costruba for "Support Structure for Shelving" issued
Feb. 6, 1973; U.S. Pat. No. 3,730,477 of J. R. Wavrunek for "Bracket
Support Unit for Integral Wall Construction" issued May 1, 1973; U.S. Pat.
No. 3,492,766 of W. R. Andrews for "Adjustable Stud" issued Feb. 3, 1970;
U.S. Pat. No. 3,509,669 of G. J. Plemeng for "Support Structure for
Shelving" issued May 5, 1970; U.S. Pat. NO. 3,407,547 of J. Doke et al.
for "Metallic Wall Stud Structure for Supporting Shelf Brackets" issued
Oct. 29, 1968; and U.S. Pat. No. 3,394,507 of J. Doke for "Metallic
Structure for Interior Walls to Carry Shelf Brackets and Wallboard" issued
July 30, 1968.
A critical feature of a practical support design is cost, both of
manufacture and of upkeep as wall units are designed for economy. Related
to economy of upkeep is the inherent reliability of a design. The bracket
supports disclosed in the Costruba, Andrews and Plemeng patents employ
angle bars, spot welded to the core support bar, to define a stabilizing
outwardly-protruding passageway for the bracket. The angle bars form, with
the support bar, a slidable arrangement within the upright channel formed
inside the bracket support housing. While such a passageway is
advantageous both in terms of bracket stability and protection of the
surrounding drywall from chipping and fraying, this type of construction
requires numerous fabrication steps and results in a structure that
includes numerous welds subject to fracture.
The Wavrunek patent discloses a bracket support in which the passageway is
formed of a molded piece integral with an upright housing including an
interior channel. However, the increased reliability of this design is
achieved only at the cost of the substantial added fabrication costs that
result from the extrusion process as opposed to more economical processes
such as cold rolling and the like.
SUMMARY OF THE INVENTION
The disadvantages of the prior art set forth above and others are addressed
and overcome by the present invention which provides an elongated housing
for receiving an elongated support bar having a plurality of slots to
engage the inner end of at least one wall bracket. Such housing, which is
adapted to be secured to a closely-spaced pair of wall studs, includes a
horizontal section that is substantially T-shaped and includes a laterally
disposed channel for receiving the support bar, an inwardly projecting
closed recess for accommodating the inner end of such wall bracket(s) and
an open, outwardly projecting passageway for laterally stabilizing the
wall bracket.
The laterally disposed channel provided by the invention comprises opposed
flanges, each of which includes opposed, spaced apart lateral members
integral with an inwardly disposed member forming a general U-shape. The
passageway comprises opposed, spaced apart outwardly-projecting blades,
each of which is integral with a lateral member forming one of the
flanges. Finally, the closed recess provided by the invention comprises
spaced apart, inwardly projecting members integral with a transverse
lateral member to form a generally U-shaped configuration. Each of the
inwardly-projecting members is integral with one of the lateral members
forming the flanges so that the elongated housing comprises a unitary
configuration.
In a further aspect, the invention provides an improved bracket support
structure. This structure includes an elongated roll formed housing
comprising a single integral structure. Such structure includes a
laterally disposed channel for receiving a bracket support bar, an
inwardly-projecting closed recess for accommodating the inner end of at
least one wall bracket and an open, outwardly-projecting passageway for
lateraly stabilizing the bracket. In addition, means are provided for
applying an inwardly-directed force upon such passageway.
The foregoing and additional features and advantages of the invention will
become further apparent from the detailed description that follows. This
description is accompanied by a set of drawing figures. Common numerals of
the written description and the figures are associated with common
features of the invention, like features of the invention being associated
with like numerals throughout both the written description and the drawing
figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall partially broken perspective view of a wall unit, such
as a partition, incorporating a bracket support in accordance with the
invention.
FIG. 2 is an enlarged side elevation view taken along the section line 2--2
of FIG. 1 illustrating the manner of retention of a wall bracket by the
invention;
FIG. 3 is an enlarged top view of the housing of the invention taken along
section 3--3 of FIG. 1;
FIG. 4 is an exploded perspective of an end portion of the elongated
housing illustrating the end cap thereof for assisting the lateral
stability of a shelf bracket; and
FIG. 5 is an enlarged, partially broken perspective view which details the
manner in which the vertical position of the support bar is secured within
the laterally-directed channel of the bracket support.
DETAILED DESCRIPTION
Turning now to the drawings, FIG. 1 illustrates a wall unit of the type to
which the present invention may be readily adapted. Such construction is
prevalent and commonly found in retail establishments and office suites,
walls of the nature described below providing semi-permanent partitions of
otherwise barren office space.
The wall unit includes a metallic frame formed of regularly spaced pairs of
elongated vertical wall studs 10, 12 fixed, at their upper and lower
extremities, respectively, to a cap 14 and a track 16. Any of a number of
conventional means may be employed, including screws, brads, spot welds or
the like, for affixing the studs to the cap 14 and to the track 16.
As shown in FIG. 1, the wall studs 10 and 12 are generally U-shaped,
comprising, in the "back-to-back" arrangement disclosed, a web 18
intermediate outwardly-directed flanges 20 and 22. Likewise, both the cap
14 and the track 16 shown are generally U-shaped, the cap 14 including
downwardly-directed flanges 24 and 26 integral with a web 28 defining the
top of the wall unit and the track 16 including upstanding flanges 30 and
32 formed with a web 34 defining the bottom of the wall.
The various flanged members provide locations for attachment of wallboard
sections 36, 38 and 39. Once again, a number of conventional fastening
means such as nails, staples, screws and the like may be employed to
secure the drywall sections to the frame formed of the cooperative
arrangement of studs, cap and track.
The wall construction of FIG. 1 is generally similar to and of like
configuration with that disclosed in the Costruba patent and others. The
present invention will be shown to be compatible therewith and to numerous
variations thereof. The prime utility of the invention arises from common
need to support at least one pair of cantilevered, load-bearing wall
brackets such as 40, 40' or 42, 42' from the wall. Such brackets support
the shelving commonly required for product display (retail business),
bookshelves (office), general storage and numerous other uses.
The bracket support of the invention is shown generally at 44. As can be
seen, the support 44 includes laterally-directed mounting flanges 46 and
48 that are fixed to the outwardly-directed flanges of the closely-spaced
elongated wall studs 10 and 12. The brackets enter the inwardly-directed
portion of the support 44 (shown clearly infra) through a longitudinal
passageway 50 that is formed between a pair of exteriorly-directed,
spaced-apart blade members 52 and 54. Upper and lower caps 56 and 58
respectively, cooperate with the support 44 to stabilize the support
mechanism, provide fire stops and secure an elongated slotted support bar
(not shown in FIG. 1).
FIG. 2 is an enlarged elevation view taken along the section line 2--2 of
FIG. 1. As mentioned above, an elongated bar 60 is positioned within the
support member that includes a plurality of lengthwise-spaced slots 62,
64, 65 adapted to engage the inner end of a shelf bracket 40. As shown,
the inner end of the shelf bracket 40 includes upper and lower tongues 66
and 68 and a stabilizer 69 that assure the stability of a load-bearing
shelf in the vertical plane.
An inwardly-directed recess 70 is formed at the rear of the bracket support
between the support bar 60 and the back wall 71 of the support. The recess
allows sufficient room behind the inner end of the shelf bracket 40 for
the bracket to be easily inserted and/or removed from the supporting slots
of the bar 60. As should be evident, removal and/or insertion requires the
tilting of the bracket to accommodate passage of the upper and lower
tongues 66 and 68 through the slot 64.
The upper cap 56 includes downwardly-directed wings 72 and 74 that allow
the cap 56 to be securely clipped to the top of the support. The rear wing
72 (one of a pair) is fitted within the support at the recess 70 while, at
the same time, the front wing 74 (also one of a pair) exerts
inwardly-directed pressure on the blade member 54 that forms one side of
the exteriorly-directed passageway 50 shown in FIGS. 3 and 4. The clips
enhance the lateral stability of an inserted shelf bracket by exerting
inwardly-directed pressure on spaced-apart blade members that form the
passageway and outwardly-directed pressure at the rear of the support.
This combination of pressures exerts an inward torque on the paired
blades.
FIG. 3 is a sectional view of the bracket support taken at line 3--3 of
FIG. 1. The cross sectional geometry of the bracket support is shown
clearly in this view. The entire support unit, with the exception of the
upper and lower clips, is formed of a single piece of cold rolled sheet
steel or sheet metal, providing significant and obvious advantages over
conventional support units that require, for example, spot welding of
component parts to form a composite unit, extrusion, extensive machining
and the like.
In addition to the inwardly-directed recess 70 and the exteriorly-directed
passageway 50 already disclosed, the support includes a laterally-directed
channel 76 for receiving the support bar 60. The channel is defined by
opposed lateral flanges 78 and 80, each formed of spaced-apart lateral
members 82 and 84 integral with an inwardly-disposed member 86 in a
generally U-shape. Lateral member 82 is, in turn, roll formed integral
with an inwardly-projecting member 88 that forms one of the sidewalls of
the recess 70. Each of the opposed lateral members is, in turn, roll
formed integral with the back wall 71.
The passageway 50 admits the bracket within the wall so that its inner end
may engage the slots of the support bar. The substantial length of the
relatively narrow passageway 50 provides lateral stability for the bracket
while protecting the exposed edges of the wallboard partition sections 36
and 38 from the frictional forces that occur when the bracket is inserted
and/or removed from the wall.
Passageway 50 is defined by spaced-apart bladelike members 52, 54. Each of
the members 52, 54 includes an inner portion 92 and reversely-folded outer
portion 94. The inner portion is integral with the lateral member 84 of
flange 78. The outer portion 94 is roll formed integral with the inner
portion 92 and with a laterally-directed longitudinal attachment flange
46. An identical construction obtains with respect to the reversely folded
blade member 54. The opposed lateral attachment flanges 46 and 48 are
secured to the outer flanges of the wall studs by conventional fastening
means including but not limited to rivets, bolts, screws, nails, welds or
the like.
FIG. 4 is an exploded perspective view of the invention including the
unitary, roll formed support, upper clip 56 and support bar 60. As will be
appreciated from this view and from the preceding discussion, the
invention comprises a comprehensive unit for securing and stabilizing
load-bearing cantilevered shelves adjacent a partition-like wall unit. The
auxiliary clips further enhance the lateral stability afforded by the unit
by applying additional inwardly-directed force upon the passageway 50.
Unlike prior art bracket support housings and their equivalents, the
present invention, while comprehensively addressing the significant
parameters required of apparatus for securing a bracket to a wall
construction of the type disclosed, achieves significant economies that
are not realized by a non-unitary extruded or machined structure.
A further economy, that of rapid, accurate and facile installation of the
support 44 with respect to the wall studs forming the frame of the
partition is achieved by the present invention. Vertical slots 96, 98 are
formed within the laterally-directed mounting flanges 46 and 48
respectively. Associated with each of the slots is a hole 100 or 102 for
accepting a self tapping sheet metal screw of cross section substantially
coextensive with the area of such hole.
The slots 96 and 98 (and corresponding slots--and holes--located adjacent
the bottom of each bracket support) are provided for accepting screws to
form a slidable relationship, upon application of a moderate amount of
pressure, between the bracket support and adjacent wall studs. Such a
relationship is highly desirable during installation. Generally, a "water
line" is marked near the bottom of each wall stud, each water line
denoting a true level and optimum installation requires that the bottom of
each bracket support coincide with the water line of the studs to which
the support is attached.
Even an experienced installer will find it difficult and awkward to attend
to matching the bottom of a bracket support to the water line markings at
the same time he is affixing or securing the support to the studs. The
present invention greatly alleviates this dilemma. By inserting screws
initially only into the slots of the flanges 46 and 48, the installer need
not attain great accuracy in matching the water line. Rather, by applying
some pressure to either the top or the bottom of the support (by means of
a hammer, for example) it can be positioned with great accuracy after
initial placement. When such accuracy has been attained, screws may then
be inserted into the holes that are associated with the slots, permitting
the exact position of the support to be secured or anchored against
movement. In addition, the screws within the slots may be further
tightened down after final adjustment, enhancing the permanence of the
setting.
While the laterally-directed channel 76 of the support 44 is closely
roll-formed about the support bar 60 so that a substantial frictional
force exists therebetween, the vertical position of the bar 60 is
absolutely secured by the arrangement shown most clearly in FIG. 5. This
figure provides an enlarged, partially broken perspective view of the
manner in which the vertical position of the support bar 60 is effectively
"locked" within the channel 76.
As is shown in FIG. 5, the unitary form of the bracket support is roll
formed about the slotted bar 60 to form the upright lateral channel
defined, in part, by a laterally-directed flange including the lateral
members 82 and 84 and the connecting inwardly-projecting member 104. As
discussed above, the lateral member is integral with the inner and outer
portions 106 and 108 respectively that form the blade member 54 that is,
in turn, integral with the laterally-directed mounting flange 48.
SIde notches 110 and 111 are formed in pairs along the length of the
support bar by a stamping or like process. The notches act on reduced
sections for roll forming a corresponding plurality of paired
indentations, such as the indentation 112, onto the inwardly-projecting
member 112 (and corresponding member 86). The indentations act as flanges
that, in combination with the side notches of the slotted bar 60, form a
secure interlocking functional unit. Thus, the user may place large loads
on the bracket pairs 40, 40' and 42, 42' without worry regarding slippage
of the unwelded support bar 60 within the bracket support 44.
Thus it is seen that there has been brought to the art new and improved
apparatus for securing a load bearing shelf bracket to a wall of the type
comprising a frame of spaced vertical studs. While the invention has been
described in its presently preferred embodiment, it is not intended that
it be limited to such embodiment. Rather, it is only limited as defined by
the following set of claims and equivalents thereof.
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Description |
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