Adjustable Joist Hanger
An easily-stackable joist support structure is provided having prefabricated tabs embedded within the main plane of the support structure to allow the tabs to be bent during construction. The tabs typically have both slot screw holes and fixed screw holes. Once the tabs are bent (typically to a 90 degree angle), a screw partially engaged through the slot and the joist can hold the joist in place while the joist is adjusted before the screw is fully engaged. Then screws can be engaged through the fixed screw holes to fully hold the joist in place. The support structure can be Z-shaped so that one ledge lays on top of the ceiling track before the support structure is attached to the track, and the other ledge is used to support the joist before the joist is attached to the support structure.
This application claims priority to U.S. Provisional Application Ser. No. 62/093,320, filed Dec. 17, 2014. This and all other extrinsic materials identified herein are incorporated by reference in their entirety.
FIELD OF THE INVENTIONThe field of the invention is joist support structures.
BACKGROUNDThe background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided in this application is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
All publications identified in this application are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided in this application, the definition of that term provided in this application applies and the definition of that term in the reference does not apply.
Construction of a building begins with a solid foundation and a solid frame upon which holds the building infrastructure together. Proper attachment mechanisms and placement of wall studs relative to one another is imperative. While studs can be directly attached to tracks and ceiling joists, intermediary support structures are preferred to improve the connection and placement of the framing elements.
CA 2,525,416 to Hall teaches a C-shaped track apparatus that helps guide joist placement in between the top and bottom rims of the C-shape during construction. Hall's attachment apparatus, however, requires a joist to be inserted in between the top and bottom of the C-shape, which requires precise control over the heavy joist during placement. In addition, Hall's track apparatus requires a separate connector bracket to be used to connect the joist and the track to one another, which can be easily lost, misplaced, or misaligned during construction.
U.S. Pat. No. 7,240,459 to Daudet also teaches a C-shaped joist rim apparatus with an integrated attachment tab that helps to attach the joist to the ceiling. Since the attachment tab is integrated into the ceiling track, the separate connector bracket is not needed, and the construction process is simplified. But Daudet's ceiling track is difficult to stack, since the integrated attachment tabs are perpendicular the C-shaped rims. In addition, Daudet's joist rim still uses C-shaped tracks, which requires precise control over the heavy joist. Such precise control is very difficult, even when using large construction machinery to help support the joist.
U.S. Pat. No. 8,091,316 to Beck teaches a Z-shaped ceiling track apparatus with integrated tabs that allow a construction worker to lay the joist on top of the ceiling track apparatus without needing such precise control to wedge a joist between top and bottom lips of a C-shaped apparatus. Beck's ceiling track apparatus, however, are even more difficult to stack since the Z-shape encourages stacked multiple apparatus to lean to the side and fall over. In addition, Beck's ceiling track apparatus fails to account for joists that are placed slightly out of alignment and need to be repositioned using mechanical means to make last-minute adjustments.
Thus, there is still a need for improved joist support structures that are easier to stack and provide additional adjustment mechanisms.
SUMMARY OF THE INVENTIONThe inventive subject matter provides apparatuses, systems and methods in which a joist support structure has bending tabs with adjustment slots and fixed holes to enable adjustable joist placement prior to more permanent fixation of a joist to the joist support structure. A user can partially engage a screw through the slot to hold a joist in place along one axis while the user slides the joist along the main axis to make final adjustments. Once the slot screw is fully engaged, substantially holding the joist in place, fastening screws can be engaged through the fixed screw holes. The tabs lie in the plane of the main body of the support structure during shipping to allow for easy stacking, and are preferably perforated along the edge where the tabs bend to improve the ability to bend the tabs. The joist support structure is preferably Z-shaped to allow a prefabricated deck to be easily set on top of the lower ledge of the support structure before screws are set in place.
In one aspect of the inventive subject matter, the inventors contemplate a joist support structure that includes a support body and a tab disposed on the side of the support body. The tab couples the support body to a joist. The tab has an adjustment slot and a number of holes on it that are used to fasten the support body to the joist. Preferably, the tab has two key configurations: a flat configuration where the tab is coplanar with the side of the support body and a bent configuration where the tab is bent to an angle greater than zero (e.g., a 90 or 45 degree angle) relative to the side of the support body.
In some embodiments, the support body has a Z-shaped cross-section with an upper flange that is designed to abut a top surface of a track or other surface and a lower flange that is designed to abut a bottom surface of a joist (e.g., the support body rests on a track while simultaneously supporting a joist). Generally, the support body is configured to couple the upper flange to a top surface of the track and couple the lower flange to the bottom surface of the joist, for example using screw holes or other fastener support mechanisms. In other embodiments, the support body has a C-shaped cross-section having an upper flange that is designed to abut a top surface of a joist and a lower flange that is designed to abut a bottom surface of the same joist.
In preferred embodiments, the tab is formed with the support body (e.g., by machining, casting, forging, cutting, or the like). To facilitate bending, the tab can be formed in the side of the support body such that there are structural weaknesses along a line where the bend is intended to occur compared to other portions of the support body. For example, perforation holes could be formed along the line, or a groove could be worn away along the line.
The inventors additionally contemplate that more than one tab per joist can be preferable to increase the strength of the coupling between the joist and the support body. In embodiments having two tabs, for example, the tabs can bend outward from the side of the support body in different directions (e.g., opposite directions). Outside of bending direction, multiple tabs on a particular support body are generally the same in terms of size, shape, and hole/slot configuration.
In some embodiments, the joist support structure also includes a fastener (e.g., a screw or a nut and bolt) to couple the support body to a joist via the adjustment slot, and a plurality of fasteners (e.g., screws or nuts and bolts) to further couple the support beam to the joist via the first plurality of holes. In these embodiments, it can be preferable for the screw passing through the adjustment slot to have a larger cross section than any of the other screws.
In another aspect of the inventive subject matter, the inventors contemplate a method of fastening a joist to a joist support structure using a tab as described above (e.g., a tab having an adjustment slot and a plurality of holes). To fasten a joist to the joist support structure, the first step is to place the joist support structure in a desired location (e.g., put it into place in a construction site). The second step is to bend the tab such that a portion of the tab is at an angle relative to the side of the joist support structure (e.g., substantially perpendicular to the joist). The third step is to position the joist such that a side of the joist is substantially parallel to the tab and an end of the joist is near the tab. The fourth step is to loosely fasten the joist to the tab using a fastener (e.g., a screw or nut and bolt) that passes through the adjustment slot of the tab and into the side of the joist. The fifth step is to repositioning the joist to be level, and the last step is to firmly fasten the joist to the tab using a number of fasteners (e.g., screws or nuts and bolts) and the holes on the tab. Although described in a particular order, these steps do not all necessarily have to occur in the order described above.
In some embodiments, the steps of bending the tab, positioning the joist, loosely fastening the joist to the tab, repositioning the joist, and firmly fastening the joist can all be completed with a second, separate tab in conjunction with the first tab. The inventors contemplate that any number of tabs can be used without departing from the inventive concepts described in this application.
Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided in this application is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.
In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention may contain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
Unless the context dictates the contrary, all ranges set forth in this application should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
As used in the description in this application and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description in this application, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
The recitation of ranges of values in this application is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated in this application, each individual value is incorporated into the specification as if it were individually recited in this application. All methods described in this application can be performed in any suitable order unless otherwise indicated in this application or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments in this application is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
Groupings of alternative elements or embodiments of the invention disclosed in this application are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found in this application. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is in this application deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
One should appreciate that the disclosed techniques provide many advantageous technical effects including the ability to stack tabbed joist support structures for shipping where the tabs are unified with the main body of the joist support structure, the ability to slide the joist along a slot of the tab before fixing the joist in place, and the ability to easily stack prefabricated ceilings on top of a joist support structure.
The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
As used in this application, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.
As shown, both the first tab 102 and the second tab 104 are flat and lay substantially flat within the main body 106 of the joist support structure 100 prior to bending the tabs 102 and 104. “Substantially flat within the main body” for purposes of this application means that the tab is coplanar with the main body of the joist support structure and it does not deviate more than 5 degrees in any direction from the plane of the main body 106.
In the embodiment shown in
In other embodiments, a bending tool can be provided that helps to bend the tab into a desired position. Typically such tab unbending tools increase a force applied to the tab to assist in bending the tab. An exemplary bending tool 800 can be seen in more detail in
As shown in
In
Once the joist support structure 300 is properly attached to the C-shaped floor track 304 and C-shaped ceiling track 308 (and preferably the C-shaped vertical studs 302 & 310), the joist 306 can be laid on top of the lower flange 314 of the joist support structure 300. Preferably there is also another joist support structure opposite the one shown that is holding the other side of the joist 306 during installation. A user of this system can then use a fastener (e.g., a screw, a nut and bolt, or any other appropriate fastener) to partially fasten the joist 306 to the joist support structure 300. This can be accomplished, for example, by hand-tightening a nut and bolt to hold the joist 306 to the joist support structure 300. Once the fastener is partially engaged in the adjustment slot, the joist 306 is held in contact with the joist support structure 300. When held in contact with the joist support structure 300, the joist 306 can move slightly in a direction parallel to the angle of the tabs 316 the joist 306 is connected to. Such limited movement allows for adjustments without the danger of the joist moving drastically (e.g., falling). Once the joist 306 has been positioned correctly, the fastener can be fully engaged (e.g., tightened) in the adjustment slot, and additional fasteners (e.g., screws, nuts and bolts, and the like) can be engaged into the four holes surrounding the slot (these slots and holes are best seen in
In
Joist hangars of the inventive subject matter are stackable for easy transport (due in large part to their level profiles and lack of protruding components since the tabs begin in an unbent configuration), and are reversible to ensure that a single Z-shaped joist hangar can be used on either the left or right side of a track. Joist hangars can be made from a variety of materials including, steel, aluminum, iron, and metal alloys. In embodiments using steel, the steel is preferably 18 or 20 gage to facilitate tab bending, but smaller gages like 16 and 14 gage steel can also be used to form the joist hangars.
In preferred applications, the Z-shaped hangar is placed over a bearing wall track and is screwed into the track (and possibly other structural elements, such as studs) using pilot holes. Once the Z-shaped joist hangar is in place and the tabs are unfolded to a desired angle from the web of the joist hangar (e.g., 90, 45, or 60 degrees), joists can be laid on top of the lower flange of the joist hangar. A fastener (such as a screw or nut and bolt) can be partially engaged in the slot to ensure the joist remains moveably in place while the joist is positioned properly, and once the joist is positioned properly, the joist can be firmly held in place by using fasteners with the remaining holes.
This is particularly useful where an entire prefabricated floor panel is used. Lift bolts with eye nuts (as seen in
It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts in this application. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.
Claims
1. A joist support structure, comprising:
- a support body;
- a first tab disposed on a side of the support body that couples the support body to a joist, the first tab comprising (a) a first adjustment slot and (b) a first plurality of holes; and
- wherein the first tab has (1) a first flat configuration wherein the first tab is coplanar with the side of the support body and (2) a first bent configuration wherein the first tab is bent to a first angle greater than zero relative to the side of the support body.
2. The joist support structure of claim 1, wherein the support body has a Z-shaped cross-section providing an upper flange configured to abut and a top surface of a track and a lower flange configured to abut and a bottom surface of the joist.
3. The joist support structure of claim 2, wherein upper flange is further configured to couple to the top surface of the track and the lower flange is further configured to couple to the bottom surface of the joist.
4. The joist support structure of claim 1, wherein the support body has a C-shaped cross-section providing an upper flange configured to abut a top surface of the joist and a lower flange configured to abut a bottom surface of the joist.
5. The joist support structure of claim 1, wherein the first tab is formed with the support body by at least one of machining or casting.
6. The joist support structure of claim 1, wherein the first tab in the first bent configuration is oriented at substantially a 90 degree angle to the side of the support body.
7. The joist support structure of claim 1, further comprising a set of perforated holes along a folding line of the first tab to facilitate bending of the first tab to the first bent configuration.
8. The joist support structure of claim 1, comprising a second tab configured to attach to the side of the support body.
9. The joist support structure of claim 8, wherein the second tab has (1) a second flat configuration wherein the second tab is coplanar with the side of the support body and (2) a second bent configuration wherein the second tab is bent to a second angle greater than zero relative to the side of the support body.
10. The joist support structure of claim 9, wherein the first tab is configured to bend in a first direction to fasten to the joist and the second tab is configured to bend in a second direction to fasten to the joist, wherein the first direction is different from the second direction.
11. The joist support structure of claim 8, wherein the second tab couples the support body to the joist via (a) a second adjustment slot and (b) a second plurality of holes.
12. The joist support structure of claim 1, further comprising a slot screw to couple the joist support structure via the first adjustment slot and a set of screws configured to further couple the joist support structure to the joist via the first plurality of holes.
13. The joist support structure of claim 12, wherein a cross-sectional area of the slot screw is larger than a cross-sectional area of any of the set of screws.
14. A method of fastening a joist to a joist support structure, where the joist support structure has a first tab having an adjustment slot and a plurality of holes, the method comprising the steps of:
- placing the joist support structure in a desired location relative to the joist;
- bending the first tab such that a portion of the first tab is at a first angle greater than zero relative to the side of the joist support structure on which the first tab is disposed;
- positioning the joist such that a side of the joist is substantially parallel to the first tab and an end of the joist is near the first tab;
- loosely fastening the joist to the first tab using a fastener that passes through the adjustment slot of the first tab and into the side of the joist;
- upon loosely fastening the joist to the first tab, repositioning the joist relative to the joist support structure; and
- upon repositioning the joist, firmly fastening the joist to the first tab using a plurality of fasteners and the plurality of holes on the first tab.
15. The method of claim 14, wherein the fastener comprises a screw.
16. The method of claim 14, wherein the plurality of fasteners comprise screws.
17. The method of claim 14, wherein the first tab is substantially perpendicular to the joist after the step of bending.
18. The method of claim 14, further comprising the steps of:
- bending a second tab having a second adjustment slot and a second plurality of holes, where the second tab is also disposed on the joist support structure, such that a portion of the second tab is at a second angle greater than zero relative to the side of the joist support structure on which the second tab is disposed;
- positioning the joist such that a side of the joist is substantially parallel to the second tab and the end of the joist is near the second tab;
- loosely fastening the joist to the second tab using a second fastener that passes through the second adjustment slot of the first tab and into the side of the joist;
- upon loosely fastening the joist to the second tab, repositioning the joist relative to the joist support; and
- upon repositioning the joist, firmly fastening the joist to the first tab using a second plurality of fasteners and the plurality of holes on the second tab.
19. The method of claim 14, wherein the step of bending the first tab is performed using a bending tool provided with the joist support structure.
20. The method of claim 14, wherein the step of bending the first tab is performed by bending the first tab along a first row of perforation holes along a side of the first tab.
Type: Application
Filed: Dec 17, 2015
Publication Date: Jun 30, 2016
Inventor: Darrell Meyer (Anaheim, CA)
Application Number: 14/973,613