Finishing Material Standoff Member For A Structural Support and Installation Method Therefor

Abstract

A standoff members and a method of installation of fastenable standoff members for use in fastening finishing material to structural metal supports. The standoff member is configured with a structural support mating surface a transversely spaced finishing material mating surface. The structural support mating surface has a fastener penetration zone within which zone a fastener may be driven into the structural support. The structural support mating surface may also include an intermediary bonding adhesive or double sided adhesive tape designed for structural applications present between the structural support mating surface and the structural support. The present invention also encompasses, in a preferred form, a method of installation and/or utilization of fastenable standoff framing members wherein a structural support mating surface having a transversely spaced finishing material mating surface is fixed to a structural support. The fastenable standoff is fixed at a fastener penetration zone of the structural support mating surface. A fastener is driven through the fastener penetration zone into the structural support.

Description

FIELD OF THE INVENTION

The present invention relates to the finishing of structural supports. In particular, this invention relates to structural support finishing components and a method of installing the structural support finishing components so that finishing material such as wallboard may be affixed to the structural supports.

BACKGROUND OF THE INVENTION

The construction of commercial and residential structures often requires the use of structural supports such as metal load bearing supports. These structural supports are typically sturdy rectangular, square, and/or planar members having dimensions which are often several inches in width and which incorporate substantially surfaces meeting at right angles. The structural supports are commonly constructed of such materials as steel, aluminum, iron, and/or alloys of such metals. In one application, the structural supports are typically intended to receive a compressive load on one end and transmit the compressive load to a second end of the structural support with insignificant lateral deflection. In another application, these structural supports as designed to carry horizontal loads. Conventionally these structural supports exist in almost any commercial or residential setting and include columns, struts, posts, I-beams, and/or other common structures such as spandrel beams, joists, girders, trusses, and rafters.

It is well known that exposed structural supports introduce several potential problems. For instance, the exposed structural supports often do not mesh or blend into the aesthetic design flow of the building into which they are incorporated. In addition, unprotected structural supports, when composed mainly of metal, may be subject to corrosion from salts and moisture. Furthermore, the structural supports are often formed of extremely heavy, dense, and thick metals and/or concrete that prevent finishing material fasteners from embedding into the structural supports. For at least this reason, the sealing, coating, covering, and/or encasing of these structural supports is a labor intensive and expensive operation.

Conventionally, finishing material such as wallboard, paneling, fireproofing, insulation, and/or other materials are installed with the use of intermediate framing elements to cover the surfaces of structural supports. The framing elements are installed to provide a surface that finishing material fasteners can easily embed in. However, the framing element typically used to mount the finishing material to the structural supports is a full-length steel stud. A full-length steel stud is often several feet in length and is relatively expensive. The full-length steel studs, because of their sizable dimensions, require a number of man-hours to install in a typical building project. In addition, since the typical full-length steel stud is configured to be a load bearing structure, the use of steel studs for the purpose of merely attaching finishing material to the structural supports is wasteful and inefficient. Furthermore, the full-length steel studs, due to their large dimensions, often waste valuable interior room space due to the void they create between the finishing material and the structural supports.

SUMMARY OF THE INVENTION

Briefly stated, the present invention in a preferred form is generally directed toward fastenable standoff members and a method of installing fastenable standoff members for use in attaching finishing material to structural supports. The fastenable standoff member includes a structural support mating surface which is transversely spaced from a finishing material mating surface. The structural support mating surface has a fastening portion through which a fastener may be projected into the structural support for the purpose of securing the fastenable standoff member to the structural support. The structural support mating surface may also be associated with a bonding adhesive or double sided adhesive tape element configured to provide adhesion between the structural support mating surface and the structural support.

The present invention also encompasses, in a preferred form, a method of installation and/or utilization of a fastenable standoff member which includes a structural support mating surface and a transversely spaced finishing material mating surface wherein the fastenable standoff member is fixed to a structural support. The fastenable standoff member is fixed to the structural support by driving a fastener through a fastening portion of the fastenable standoff member. The structural support mating surface may also include a bonding adhesive or double sided adhesive tape between the structural support mating surface and the structural support.

The fastenable standoff member is configured to provide a finishing material mating surface which is transversely spaced from the structural support by a desired distance. Multiple finishing material mating surfaces can be employed for the efficient attachment of finishing material to the exterior surface of multiple structural supports. In addition, the exterior of a structural support may be converted from a channeled or fluted surface to a substantially square or rectangular shape.

Thus, among other things, the present invention provides a new and improved structural support finishing component to facilitate the covering and/or attaching of a structural support with a finishing material, particularly in a cost effective manner.

The present invention also provides a new and improved method of installing and utilizing a standoff member for attachment of finishing material to a structural support in an efficient, safe and cost effective manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention will be evident to one of ordinary skill in the art from the following detailed description with reference to the accompanying drawings, in which:

FIG. 1 is a side view of a fastenable standoff member with associated fasteners in accordance with the present invention.

FIG. 2 is a side view of a fastenable standoff member with associated fasteners attached to a structural support, shown in section, in accordance with the present invention.

FIG. 3 is a side view of an alternative embodiment of a fastenable standoff member with associated fasteners attached to a structural support, shown in section, support in accordance with the present invention.

FIG. 4 is top view, partly in phantom, of the fastenable standoff member of FIG. 3 in accordance with the present invention.

FIG. 5 is top view, partly in phantom, of the fastenable standoff member of FIG. 1 in accordance with the present invention.

FIG. 6 is a top view of another alternative embodiment of the fastenable standoff member in accordance with the present invention.

FIG. 7 is a side view, partly in phantom, of the fastenable standoff member of FIG. 6 in accordance with the present invention.

FIG. 8 is a side view, partly in phantom, of the fastenable standoff member of FIG. 6 associated with a structural support and finishing material in accordance with the present invention.

FIG. 9 is a side view, partly in phantom, of the fastenable standoff member of FIG. 2 associated with a structural support and finishing material, both shown in section, in accordance with the present invention.

FIG. 10 is a fragmentary elevated view, partly in phantom, showing a possible installation of fastenable standoff members associated with structural supports and finishing material in accordance with the present invention.

FIG. 11 is a cut away side view of the fastenable standoff member of FIG. 8 associated with a channeled structural support and finishing material, both shown in section, in accordance with the present invention.

FIGS. 12A-12B show, respectively, a side view, partly in phantom, and a top view, partly in phantom, of an embodiment of a fastenable standoff member utilizing double sided adhesive tape in accordance with the present invention.

FIGS. 12C-12D show, respectively, a side view and an end view of a channel insert present in the fastenable standoff member of FIG. 12A-12B.

FIGS. 13A-13C show, respectively, a side view, partly in phantom and a top view and bottom view, partly in phantom, of an embodiment of a fastenable standoff member utilizing a fastening portion in accordance with the present invention.

FIGS. 14A-14B show, respectively, a side view and an end view of a channel insert present in the fastenable standoff member of FIGS. 13A-13C.

FIGS. 15A-15C show, respectively, a bottom view, a top view, partly in phantom, and a side view, partly in phantom, of an embodiment of a fastenable standoff member utilizing a fastening portion accessible through an opening in the finishing material mating surface in accordance with the present invention.

FIGS. 15D-15E show, respectively, an end view and a side view of a channel insert present in the fastenable standoff member of FIGS. 15B-15C.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings wherein like numerals represent like parts throughout the several Figures, a fastenable standoff member or framing bracket in accordance with the present invention is generally designated by the numeral 10. The fastenable standoff member 10, as shown in FIGS. 1 and 5, includes a finishing material mating surface 12. The finishing material mating surface 12 is transversely spaced apart from a structural support mating surface 14. Between the finishing material mating surface 12 and the structural support mating surface 14 is a finishing material fastener intrusion zone 16. The fastenable standoff member 10 may be formed from sheet metal such as galvanized or stainless steel sheets, and/or from plastic such as glass filled fiber reinforced plastics. In one embodiment, the standoff member 10 is manufactured from 25 gauge galvanized steel. The fastenable standoff member 10 may also be cast, milled, or extruded using materials such as ferrous and non-ferrous metals, plastics, ceramics and/or polymeric materials. The fastenable standoff member 10 may have a substantially seamless construction.

In one embodiment of the invention, the finishing material mating surface 12 is transversely spaced apart from a structural support mating surface 14 by a side wall 13. The structural support mating surface 14 and side wall 13 preferably has a cutout 18 which allows portions (x, y) of the structural support mating surface 14 to be movably adjusted relative to each other. Portions (x, y) of the structural support mating surface may be adjusted manually to form a variety of angles relative to one another. For example, the portions (x, y) may be bent to form an angle between about 60° and about 270°. It should be understood that angles greater than about 180° can be employed in an inside corner formed by a structural support(s). The orientations (x, y) of the structural support mating surface may be adjusted through bending a hinge 20 of the fastenable standoff member 10. The hinge 20 is formed adjacent the cutout 18 on the finishing material mating surface 12. In one example, the standoff member or framing bracket is dimensioned so that portions x and y have a length of 3 inches (7.62 cm) and the spacing between surfaces 12 and 14 is 0.825 inches (2.10 cm). The height along hinge 20 is approximately 2.5 inches (6.35 cm).

The fastenable standoff member 10 includes a fastening tab 22 which functions as an easily accessible fastening plate. The fastening tab 22, in one embodiment of the invention, is approximately 0.75 inches (1.91 cm) may be formed from a portion of the structural support mating surface 14 that extends laterally beyond the side wall 13 and the finishing material mating surface 12. A fastener 24 is driven through the fastening tab 22. The fastener 24 includes a head 26 which prevents the fastener 24 from passing entirely through the fastening tab 22. The fastener head 26 provides a retentive bearing surface that holds the structural support mating surface 14 against a structural support 28, as shown in FIG. 2.

In one embodiment of the invention, as shown in FIG. 2, the fastenable standoff member 10 is fixed to a structural support 28 by the fastener 24. The fastener 24 extends through the fastening tab 22 and into the structural support 28. A variety of fasteners may be used for fixing the fastenable standoff member 10 to the structural support 28. For example, the fastener 24 may be a screw, a rivet, a bolt, or a pin. The fastener 24 may be driven by a powder actuated device. For example, a pin having a length between about 0.5 inches (1.27 cm) to about 3 inches (7.62 cm), with or without a washer, may be driven through the fastening portion 22 and into the structural support 28 by a .27 caliber (6.8 mm) cartridge load (not shown). Other sized powder loads such as .22 caliber (5.6 mm) and powder loads having different relative driving powers may also be used. Pneumatic and mechanical drivers can also be used to drive the fastener 24.

The cutout 18, in one embodiment of the invention may be configured to accommodate a nub 30 which is often present on the corner of a structural support 28. The nubs 30 more frequently occur in concrete columns. In some cases, the nub 30 is an artifact of the process of cold or hot forming the structural support 28. The cutout 18 receives the nub 30 such that the structural support mating surface 14 can make substantially flush and uninterrupted contact with the sides of the structural support 28. The hinge 20 allows the relative size of the cutout 18 to be adjusted such that a good fit is made between the structural support mating surface 14 and the structural support 28. In addition, the cutout 18 adjustment also assures that the hinge 20 is substantially adjacent a true corner 32 of the structural support 28. This alignability allows numerous fastenable standoff members 10 to be installed along a length of a structural support 28, as shown in FIG. 10, such that the hinge 20 of each fastenable standoff member 10 is in substantial alignment. This allows finishing material 38 to be installed without deflection of the finishing material 38 between two or more structural supports 28 and without misalignment of edges of the finishing material 38 at, for example, corners and butt joints.

In one embodiment of the invention, as shown in FIGS. 3 and 4, the fastenable standoff member 10A has a fastening portion 22a that is located within the perimeter of an access opening 34 in the finishing material mating surface.

In one embodiment of the invention, as shown in FIGS. 6 and 7, the fastenable standoff member 10B may have an opening 34a in the finishing material mating surface 12b that provides access to the fastening portion 22b. A secondary finishing material mating surface 12a may be present which is located adjacent to the structural support mating surface 14a. A ledge 36 may be present near the intersection of the auxiliary finishing material mating surface 12a and the structural support mating surface 14a. In use, as shown in FIG. 8, the finishing material mating surface 12b and/or the auxiliary finishing material mating surface 12a may be associated with a finishing material 38. For example, the finishing material 38 may be drywall, foam, wood, metal, and/or any composite material that provides the desired isolation, protection and/or aesthetic properties. The finishing material 38 may be fixed to the fastenable standoff member 10b by a fastener 40 which extends through the finishing material 38 and the auxiliary finishing material mating surface 12a and extends into the fastener intrusion zone 16.

With reference to FIG. 9, in one embodiment of the invention, the finishing material 38 may be fixed to the fastenable standoff member 10 with a fastener 40. For example, a wall board screw may be used to fasten a panel of wall board to the fastenable standoff member 10. The wall board is retained by the head 42 of the fastener.

With reference to FIG. 11, in one embodiment of the invention, the structural support may be an I-beam having channels 50. The fastenable standoff member 10B may be attached inside and/or outside the channel such that finishing material 38 can be fixed to the finishing material mating surface 12b and/or the auxiliary finishing material mating surface 12a. This allows the structural support channels 50 and/or the sides of the structural support 28 to be covered.

In one embodiment of the invention, as shown in FIGS. 12A-12D, the fastenable standoff member 10C may be constructed from a piece of sheet metal which has been bent into a channel shape. A cut is made either prior to bending or after bending the cutout 18 is formed. On either side of the cutout 18 a channel module 15, as shown in FIGS. 12B and 12C, is fixed. The channel module 15 may be fixed to the channel shape by spot welds 17, clinches, etc. The channel module includes the structural support mating surface 14 and a portion of side wall 13. The channel shape includes the finish material mating surface 12.

In one embodiment of the invention, as shown in FIGS. 12A and 12B, adhesive may be used to attach the fastenable standoff member 10C to the structural support 28. For example, double-sided adhesive tape 52 may be fixed to the structural support mating surface 14 such that an adhesive surface of the tape 52 may contact and bind to a structural support.

In one embodiment of the invention, as shown in FIGS. 13A-13C, the fastenable standoff member 10D may be constructed from a piece of sheet metal which has been bent into a channel shape. A cutout 18 is formed either prior to bending or after forming the channel shape. On either side of the cutout 18 a channel module 15a, as shown in FIGS. 14A and 14B is fixed. The channel module 15a may be fixed to the channel shape by spot welds 17. The channel module includes the structural support mating surface 14, a fastening portion 22, and a portion of side wall 13. The channel shape includes the finish material mating surface 12.

In one embodiment of the invention, as shown in FIGS. 15A-15C, the fastenable standoff member 10E is constructed from a piece of sheet metal which has been bent into a channel shape. A cut is made either prior to bending or after forming the channel shape. On either side of the cutout 18 a channel module 15b, as shown in FIGS. 15D and 15E is fixed. The channel module 15 may be fixed to the channel shape by spot welds 17. The channel module includes the structural support mating surface 14, and a portion of side wall 13. The channel shape includes the finish material mating surface 12, and an access opening 34.

In one embodiment of the invention, an adhesive 54, as shown in FIG. 3, is applied to the structural support mating surface 14 to replace or augment the fastener 24. The adhesive 54 may be, for example, a thermoset, a thermoplast, a latex or an alkyd adhesive, examples of which are epoxies, acrylics, urethanes and silicones. For instance, hot melt adhesives, spray adhesives, glues, or other construction adhesives well known in the art or combinations thereof may be used. Thus, the adhesive 54 may be a latex based construction adhesive having quick set properties and a high bonding strength. The adhesive 54 may render the fastenable standoff member 10A substantially immovable within 15 minutes and may be fully cured within 24 hours. An example of such an adhesive is the available commercially made Loctite® Power Grab™ construction adhesive distributed by Henkel Consumer Adhesives, Inc. A suitable hot melt adhesive may include the Henkel Corporation 7804 FRM HV hot melt adhesive which has flame retardant properties and has a high viscosity.

The invention also encompasses a construction method wherein the fastenable standoff member 10, 10A, 10B, 10C, 10D, 10E is employed for finishing a structural support 28. The fastenable standoff member 10, 10A, 10B, 10C, 10D, 10E is attached to the structural support by a fastener 24 and/or an adhesive 54 to the structural support at various pre-selected vertical or horizontal positions depending on, for example, the finishing material 38 to be utilized. This attachment is accomplished, for example, as shown in FIG. 9, by extending a fastener through the fastening portion 22, and/or by coating the structural support mating surface 14 and/or coating a portion of the structural support with the adhesive 54 (FIG. 3). The adhesive 54 may be subjected to activation through additional procedures, for example the application of heat, mixing the adhesive with a catalyst, or by allowing the coated adhesive time to become tacky or otherwise ready for use. A pre-applied double side tape 52 may also be utilized. The adhesive coated structural support mating surface 14 is then bonded to the structural support 28.

A hot melt adhesive can be utilized by placing it between the structural support mating surface 14, 14a and the structural support 28.

The fastenable standoff member 10, 10A, 10B, 10C, 10D, 10E may then be selectively heated with, for example, a torch such that the thermal set adhesive deforms or flows. The heat is then removed and the fastenable standoff member 10, 10A, 10B, 10C, 10D, 10E becomes bonded to the structural support member 28. If required, the standoff member 10, 10A, 10B, 10C, 10D, 10E can be repositioned by reheating the adhesive.

Depending on the application desired, the steps of mounting further fastenable standoff members 10, 10A, 10B, 10C, 10D, 10E to the structural support 28 at other locations is efficiently accomplished. The finishing material mating surface 12, 12a, 12b of each fastenable standoff member 10, 10A, 10B, 10C, 10D, 10E can be arranged to form co-planar framing members so that the finishing material 38 may be aligned and fastened in place. The finishing material 38 is preferably mounted to the fastenable standoff members 10, 10A, 10B, 10C, 10D, 10E by fastening with, for example, a screw 40 which extends through the finishing material 38 and the finishing material mating surface 12, 12a, 12b such that the distal shaft portion of the fastener enters and is fully received in the fastener intrusion cavity 16. The fastenable standoff members 10, 10A, 10B, 10C, 10D, 10E have sufficient structural rigidity so they are not crushed during the wallboard fastening.

In one preferred installation, standoff members or framing brackets 10 are spaced at a maximum of 48 inches (121.92 cm) on center and are located on all four corners of a tubular steel column. The brackets 10 were fastened to the corners with half-inch (1.27 cm) powder actuated fasteners driven through the center of the tabs 22. Chips and board was then attached to the brackets by one inch Phillips head self-drilling, self-tapping fine thread screws which are spaced 48 inches (121.92 cm) on center. It will be appreciated that for tube columns with a four-inch dimension (10.16 cm), the standoff members or framing brackets can be installed vertically offset by the weight of the bracket. For tube columns greater than the four-inch dimensions (10.16 cm), suitably dimensioned standoff members or framing brackets 10 can be located at the same horizontal level on all four corners.

While various preferred embodiments have been illustrated to describe the invention, various modifications, alternatives and adaptations may be made thereto without departing from the spirit and the scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.

Claims

1. A standoff member for attaching finishing material to a structural support comprising:

a structural support mating surface;

at least a first finishing material mating surface connected to the structural support mating surface and spaced therefrom; and

at least a first fastener intrusion cavity defined at least partially by a spacing between the structural support mating surface and the finishing material mating surface.

2. The standoff member of claim 1 wherein the member has a pair of channel portions.

3. The standoff member of claim 2 further comprising a hinge portion disposed between said channel portions.

4. The standoff member of claim 2 wherein said channel portions are oriented at an angle to each other.

5. The standoff member of claim 2 further comprising a tab integrally extending from said channel portions.

6. The standoff member of claim 1 wherein said member is manufactured from steel.

7. The standoff member of claim 4 further comprising a cut out which permits the angle between said channel portions to be changed.

8. A standoff member assembly for attaching material to a structural support comprising:

a structural support;

at least a first standoff member and a second standoff member, said first and second standoff members each having a structural support mating surface attached to said structural support;

said first and second standoff members each having at least a first finishing material mating surface connected to the structural support mating surface and spaced therefrom;

said first and second standoff members each having at least a first fastener intrusion area defined at least partially by a spacing between the structural support mating surface and the first finishing material mating surface; and

said first finishing material mating surface of the first standoff member and said first material mating surface of the second standoff member being substantially parallel.

9. The standoff member assembly of claim 8 wherein said first and second standoff members each having at least a fastening portion through which extends a fastener, said fastener is in retentive association with said first and second standoff fastening portions and with said structural support.

10. The standoff member assembly of claim 8 wherein the member has a pair of channel portions.

11. The standoff member assembly of claim 10 wherein said channel portions of each standoff member are oriented at an angle to each other.

12. The standoff member assembly of claim 11 further comprising a tab integrally extending from said channel portions.

13. The standoff member assembly of claim 8 wherein said standoff member is manufactured from steel.

14. The standoff member assembly of claim 11 further comprising a cut out portion between said channel portions of standoff member.

15. A method for attaching a finishing material to a structural support comprising:

providing at least one standoff member having a structural support mating surface and a parallel finishing material mating surface;

mounting said structural support mating surface to said structural support;

contacting a finishing material to be fastened to at least one finishing material mating surface; and

securing the finishing material with a fastener such that a portion of the fastener enters a fastener intrusion area defined at least partially by a spacing between the structural support mating surface and the finishing material mating surface.

16. The method of claim 15 wherein a fastening portion extends from said structural support mating surface and further comprising driving a fastener through the fastening portion into the structural support such that the standoff member is attached to the structural support.

17. The method of claim 15 wherein said mounting step further comprises applying adhesive to said structural support mating surface.

18. The method of claim 15 wherein said structural support is a column with four corners and further mounting a plurality of standoff members at vertically spaced locations at each of said corners.