REMOVABLE PROFILE FASTENING AND INSULATION SYSTEM

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

See Application Data Sheet.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

Not applicable.

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC OR AS A TEXT FILE VIA THE OFFICE ELECTRONIC FILING SYSTEM (EFS-WEB)

Not applicable.

STATEMENT REGARDING PRIOR DISCLOSURES BY THE INVENTOR OR A JOINT INVENTOR

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a profile fastening and insulation system, of the type used for securing and acoustically insulating omega-type or double-T profiles, which are used for mounting plasterboard (drywall), floating elements or other cladding elements in board form (such as acoustically insulating panels) in cladding installations or in the renovation of both vertical (walls) and horizontal (ceilings) surfaces.

2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98

Currently, and as a reference to the state of the art, profile fastening for claddings is typically done by screwing the profile directly onto the surface to be renovated. The use of direct fastening of long profiles on surfaces with poor flatness, due to poor workmanship or deformation of the surfaces over time, presents difficulties in installation, as it is necessary to screw and unscrew the same point repeatedly to achieve the desired alignment of the profile. On the other hand, with the advancement of cladding materials in acoustic protection elements, this profile fastening system is acoustically inadequate due to the creation of an acoustic bridge between the profile and the surface, as a result of direct contact with the mounting elements, generating undesirable noise.

Fastening elements intended to also provide acoustic insulation between the surface to be renovated and the profile are known, but these systems are designed for a specific profile with particular dimensions, and the parts that compose them have fixed sizes for use with a specific profile. In the case of omega profiles, widely used in this sector, the dimensions of the profiles are not standardised, with different profile sizes being used depending on the country. Using such fastening and bracing elements requires manufacturing a specific element for each profile used, which becomes ineffective if an element designed for other dimensions is used by mistake, thus requiring a larger manufacturing and sales catalog and requiring installers to check and match each profile with its appropriate fastening element. These are non-versatile, hard-to-select, and economically costly solutions.

Additionally, some fastening elements are known that can adapt to different profile sizes, but their use is excessively complex, as they consist of an adjustable support with an elastomeric insulating element in direct contact with the mounting surface (wall or ceiling), or surface to be installed or renovated, and they also require additional elastomeric insulating elements to isolate the mounting elements. These insulating elements complicate the proper leveling of the profiles, as it is harder to shim a flexible or deformable insulating element, which is in direct contact with the mounting surface and typically has flatness problems. Moreover, this configuration results in a more complex assembly since fastening the profiles to the support requires attaching the support with two mounting elements and additionally adjusting the profile fastening with four mounting and/or fixing elements. Tightening numerous fasteners to the mounting surface (wall or ceiling) may lead to misalignment of the profile level, as it becomes necessary to tighten and loosen each mounting element multiple times to level the profile, which can result in defective installations. Additionally, the large volume of elastomer used increases manufacturing costs, as it is the most expensive material in the fastening and mounting systems.

BRIEF SUMMARY OF THE INVENTION

In view of the above, the present invention refers to a profile fastening and insulation system with at least two aligned profile flanges extending away from each other, such as omega or double-T profiles. The fastening and insulation system includes a rigid plate for fastening to the mounting surface, which may be a wall, ceiling or any other surface where the fastening and insulation system is to be installed. Attached to this rigid plate are at least two opposing sliding clamps facing the flanges of the central profile, such that the sliding clamps can move closer to or further from the profile flanges. The rigid plate includes a single centrally positioned hole through which a mounting means, such as a nail or screw, is introduced into the wall or ceiling. The rigid plate also houses at least two insulating blocks. Each insulating block, typically made of an elastomeric material, is placed at each end of the rigid plate—that is, at least one on each side of the profile—inserted inside at least two sliding clamps and always on the exterior face of the rigid plate, which is the same side where the profile is placed. Thus, once assembled, each insulating block will partially cover the profile flanges and the mounting elements used to secure the sliding clamps through the fixing holes.

“Mounting surface” refers to any horizontal or vertical surface where the removable profile fastening and insulation system is installed, such as walls, ceilings or any type of vertical or horizontal structure.

“Interior face of the rigid plate” refers to the surface of the rigid plate that is in contact with the mounting surface, and which is less visible once the profile fastening and insulation system is installed.

“Exterior face of the rigid plate” refers to the surface of the rigid plate opposite the interior face, and visible to the installer.

“Interior of the sliding clamp” refers to the space between the sliding clamp and the exterior face of the rigid plate, laterally defined by the sliding wings and the stop wing of the sliding clamp.

This configuration achieves great simplicity in assembling and leveling the system. With the use of a rigid, removable plate, it is possible to pre-align the profiles by aligning several rigid plates, which is easier than aligning a single longitudinal element such as a profile or a molded elastomer shaped to the profile. The inclusion of a single central positioning hole helps align the rigid plates, allowing their placement along a drawn line on the mounting surface or with the help of a laser level line. Additionally, the single central positioning hole also facilitates leveling the rigid plate using wedges or shims, which is common in this type of installation. This leveling is crucial in renovation work where mounting surfaces (walls or ceilings) typically exhibit flatness issues such as bulging or leaning in vertical surfaces.

In this way, the rigid plate can be placed and anchored to the mounting surface (wall or ceiling), and then the sliding clamps with their insulating blocks can be mounted, positioning the insulating blocks inside the sliding clamps on either side of the removable profile to hold and reposition it by sliding the clamps—without needing to disassemble the rigid plate—allowing convenient adjustment by simply sliding the clamps.

The use of at least two identical insulating blocks saves insulating material and simplifies manufacturing, as the material can be cut from sheets or rolls without molding. Furthermore, each insulating block insulates the profile from the exterior face of the rigid plate, the sliding clamps, and the mounting elements used to secure the clamps, eliminating the need to independently insulate the mounting elements with an additional elastomer element.

For better fastening of the profile flanges between the insulating blocks, each insulating block includes an insertion groove capable of partially housing a profile flange. During installation, it is only necessary to align each profile flange with the groove in the insulating block and slide the clamp containing the block toward the profile to insert the flange into the groove and continue sliding until the entire flange perimeter is inserted. Thus, the fastening area will have a length similar to the profile flange and the width of the insulating block, improving the grip between the insulating block and the profile. Dimensions of the insulating block may vary depending on installation needs. These insertion grooves may not be necessary if the profile flanges are short and, due to the elastomeric deformation of the insulating block, the profile flange becomes sufficiently embedded in the block.

Alternatively, the rigid plate includes at least two sliding grooves, one at each end of the plate, perpendicular to the axis of the profile once installed, into which the sliding clamp is slidably engaged via at least two sliding wings. These wings prevent longitudinal movements of the profile or movement along its axis. By restricting these longitudinal movements, cracks and deformations in the plasterboard or other board-type cladding elements installed on them are avoided. They also allow easy sliding of the clamp thanks to its clamp folds.

Each sliding groove may include an insertion hole that allows mounting (and dismounting) of the sliding clamp into the sliding groove. Thanks to this feature, the sliding clamps can be easily mounted or replaced when necessary. Pressing on opposite sliding grooves reduces the distance between them, making it possible to insert the sliding clamp into the insertion hole, typically in the central area. Then, by sliding the clamp to its farthest position, the insertion hole becomes available to insert the opposite sliding clamp. Since the sliding clamps of the fastening and insulation system are identical mirrored elements, there is no need for a large variety of parts or special attention to the relative position of the clamp in the system, and because they are removable, the insulating block they contain can be replaced with another offering different insulating properties, easily adapting to various acoustic needs.

Each sliding wing may end in a U-shaped clamp fold that acts against the sliding groove in the rigid plate, preventing accidental detachment or fall of the sliding clamp and its insulating block.

Each sliding clamp may also include a stop wing at its end to securely house the insulating block, preventing it from coming loose during sliding and allowing for a secure push against the profile by the sliding clamps.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

To better understand the nature of the invention, the attached drawings illustrate one industrial embodiment, which is purely exemplary and not limiting.

FIG. 1 shows an exploded view of the fastening and insulation system (1), in which the profile (3) with its two profile wings (3a) is located in front of the rigid plate (2), with the sliding groove (2b) and the outer face (2d) visible. On each side of the profile (3) there is an insulating block (5) with an insertion groove (5a) and a sliding interlock (4), showing the fastening hole (4a), the sliding wings (4b), the interlock bend (4c), and the stop wings (4d).

FIG. 2a shows a side view of the fastening and insulation system (1) in the open position, prior to securing the profile (3), where the profile (3) with its two profile wings (3a) is positioned such that each wing (3a) faces an insertion groove (5a) of an insulating block (5). The insulating block (5) is seen to be enclosed between the sliding interlock (4) by the sliding wings (4b) and the stop wings (4d), and the rigid plate (2), where the sliding groove (2b) with the insertion hole (2b.1) at its centre is visible, to which the sliding interlock (4) is slidably linked via its sliding wings (4b). FIG. 2b shows a front view of the fastening and insulation system (1) in the open position, prior to securing the profile (3), in which the profile (3) with its two profile wings (3a) is positioned such that each wing (3a) faces an insulating block (5). The insulating block (5) is seen enclosed within the sliding interlock (4), where the fastening hole (4a) is visible. FIG. 2c shows a cross-section of the fastening and insulation system (1) along axis A-A of FIG. 2b, in the open position, prior to securing the profile (3), in which the profile (3) with its two profile wings (3a) is positioned such that each wing (3a) faces an insertion groove (5a) of an insulating block (5). The insulating block (5) is seen enclosed between the sliding interlock (4), where the cross-section of the fastening hole (4a) and the stop wings (4d) are visible, and the outer face (2d) of the rigid plate (2), showing the sliding groove (2b) with the insertion hole (2b.1) at its centre, the inner face (2c) and the section of the positioning hole (2a).

FIG. 3a shows a side view of the fastening and insulation system (1) in the closed position, where the profile (3) with its two profile wings (3a) is inserted into an insertion groove (5a) of an insulating block (5). The insulating block (5) is seen enclosed between the sliding interlock (4) by the sliding wings (4b) and the stop wings (4d), and the rigid plate (2), with the sliding groove (2b) and the insertion hole (2b.1) at its centre visible, to which the sliding interlock (4) is slidably linked via its sliding wings (4b). FIG. 3b shows a front view of the fastening and insulation system (1) in the closed position, where the profile (3) with its two profile wings (3a) is inserted into an insulating block (5). The insulating block (5) is seen enclosed in the sliding interlock (4), where the fastening hole (4a) is visible. FIG. 3c shows a cross-section of the fastening and insulation system (1) along axis A-A of FIG. 3b, in the closed position, where the profile (3) with its two profile wings (3a) is inserted into an insertion groove (5a) of an insulating block (5). The insulating block (5) is seen enclosed between the sliding interlock (4), showing the cross-section of the fastening hole (4a) and the stop wings (4d), and on the outer face (2d) of the rigid plate (2), where the sliding groove (2b) with the insertion hole (2b.1) at its centre, the inner face (2c), and the cross-section of the positioning hole (2a) are visible.

FIG. 4a shows a perspective view of the rigid plate (2), in which the positioning hole (2a), the sliding grooves (2b) with the insertion hole (2b.1) at their centre, the visible outer face (2d), and the indicated inner face (2c) are observed. FIG. 4b shows a perspective view of a sliding interlock (4), in which the fastening hole (4a), its sliding wings (4b) ending in interlock bends (4c), and the stop wing (4d) are observed. FIG. 4c shows a perspective view of a sliding interlock (4) joined to the rigid plate (2), in which the connection between the elements is shown through the insertion of the interlock bends (4c) of the sliding wings (4b) of the sliding interlock (4) into the sliding grooves (2b) of the rigid plate (2), where the insertion hole (2b.1) at its centre is visible.

FIG. 5 shows a cross-section of the fastening and insulation system (1) in installation, in which the profile (3) with its two profile wings (3a) is inserted into an insertion groove (5a) of an insulating block (5). The insulating block (5) is seen enclosed between the outer face (2d) of the rigid plate (2), fixed to the mounting surface by the fixing means (6), with the sliding groove (2b) and the insertion hole (2b.1) at its centre visible, and the sliding interlock (4) secured by mounting means (7), where the stop wing (4d) is visible.

In these figures, the following references are indicated:

• • 1. Fastening and insulation system.
  • 2. Rigid plate.
    • 2a. Positioning hole
    • 2b. Sliding groove
      • 2b.1. Insertion hole
    • 2c. Inner face
    • 2d. Outer face
  • 3. Profile.
    • 3a. Profile wings
  • 4. Sliding interlock.
    • 4a. Fastening hole
    • 4b. Sliding wings
    • 4c. Interlock bend
    • 4d. Stop wing
  • 5. Insulating block.
    • 5a. Insertion groove
  • 6. Fixing means.
  • 7. Mounting means

DETAILED DESCRIPTION OF THE INVENTION

In view of the above, the present invention refers to a removable fastening and insulation system (1) for profiles (3) with at least two aligned profile wings (3a) extending apart from each other. It comprises a rigid plate (2) attached to a mounting surface, such as any surface on which the fastening and insulation system (1) is to be installed. To this rigid plate (2), at least two sliding interlocks (4) are connected, positioned opposite and facing the profile wings (3a) of the profile (3), which is situated between the sliding interlocks (4). The rigid plate (2) is removable and comprises a single positioning hole (2a) through which a fixing means (6)—such as a nail or screw—is inserted to fasten the rigid plate (2), connecting it to the mounting surface via its inner face (2c). The rigid plate (2) also houses at least two insulating blocks (5). Each insulating block (5) is placed at one end of the rigid plate (2), i.e., at least one on each side of the profile (3) and within a sliding interlock (4), on the outer face (2d) of the rigid plate (2), partially covering the profile (3) and the mounting means (7), such as nails or screws used to fasten or secure the sliding interlocks (4) (one mounting means (7) per sliding interlock (4)).

Thanks to this configuration, having a rigid plate (2) allows for pre-alignment of the profiles (3). First, several rigid plates (2) are aligned, which will later hold the profile (3) at multiple points along its length—this is easier than aligning a single longitudinal profile (3). The presence of a single, central positioning hole (2a) facilitates the alignment of the rigid plates (2), allowing accurate positioning using a line drawn on the mounting surface or a laser level line, and fixation using just one fixing means (6). Additionally, this single central positioning hole (2a) simplifies leveling of the rigid plate (2) using wedges or shims—for instance, by inserting the wedge until the proper level is reached without the need to tighten and loosen multiple fixing elements (6) repeatedly. Leveling is crucial in rehabilitation work where mounting surfaces (walls or ceilings) may have bulges or unevenness. These uneven surfaces can force the profile (3) to follow their contour, potentially causing cracks or deficiencies in the installation of lining boards. This configuration of rigid plates (2) thus provides great simplicity in installation and leveling.

Once the rigid plate (2) is positioned and fixed to the mounting surface (wall or ceiling) using fixing means (6), the sliding interlocks (4) with their insulating blocks (5) can be mounted. The removable profile (3) is placed between the insulating blocks (5) located inside the sliding interlocks (4). The insulating blocks (5) are placed on either side of the removable profile (3) to secure it. Once the profile (3) is held between the insulating blocks (5), it can be repositioned by sliding the sliding interlocks (4) that contain the insulating blocks (5) before securing the final position of the interlocks with conventional mounting means. The profile (3) can be repositioned as many times as necessary without disassembling the rigid plate (2) or the profile (3), allowing for easy adjustment by simply sliding the sliding interlocks (4). This enables a correct and quick installation by a single installer, without the need for another person to hold the profile (3). Once the proper position of the profile (3) is determined, each sliding interlock (4) is secured with a single fixing means (7), significantly simplifying the assembly process.

Using at least two identical insulating blocks (5) allows for material savings and easier manufacturing, as the blocks can be cut from sheets or rolls without molding. Furthermore, each insulating block (5) insulates the profile (3) from the outer face (2d) of the rigid plate (2)—which is connected to the mounting surface by its inner face (2c)—from the sliding interlocks (4), and from the mounting means (7) used to fix the interlocks. This eliminates the need to insulate the mounting means (7) separately with an additional elastomer element.

For improved retention of the profile wings (3a) between the insulating blocks (5), each insulating block (5) may have an insertion groove (5a) capable of partially housing a profile wing (3a). During installation, it's only necessary to align each profile wing (3a) with the insertion groove (5a) of the insulating block (5) and slide the sliding interlock (4) containing the insulating block (5) towards the profile (3) to insert the profile wing (3a) into the insulating block (5), and continue sliding to fully insert the wing, if desired. The fixing area will therefore normally have the length of the profile wing (3a) and the width of the insulating block (5), thus improving grip between the insulating block (5) and the profile (3). These insertion slots (5a) may not be necessary in cases where the profile wings (3a) are short enough to embed themselves into the elastomeric insulating block (5) by deformation.

Preferably, the rigid plate (2) has at least two sliding grooves (2b)—one at each end—perpendicular to the axis of the installed profile (3), into which the sliding interlock (4) is slidably connected via at least two sliding wings (4b). These sliding wings (4b) prevent longitudinal movement (along the axis) of the profile (3). By restricting longitudinal movement, cracks and deformations are avoided in plasterboards or other drywall systems installed on them. They also allow easy sliding of the sliding interlock (4) via its interlock bends (4c).

Each sliding groove (2b) may have an insertion hole (2b.1) to allow assembly (and disassembly) of the sliding interlock (4) into the sliding groove (2b). This feature allows for easy assembly and replacement of the sliding interlocks (4) by pressing opposing sliding grooves (2b). By pressing the sliding grooves (2b) toward the centre of the rigid plate (2), the distance between them decreases, making it possible to insert the sliding interlock (4) into the insertion hole (2b.1) (usually in the centre). Then, by sliding the interlock to its farthest position, the insertion hole (2b.1) becomes free again so the opposite interlock can be inserted. Since the sliding interlocks (4) of the fastening and insulation system (1) are identical mirrored elements, spare parts management is simplified: there's no need for many part references or to worry about the left-right position of the interlock relative to the system. Also, since the sliding interlocks (4) are removable, their insulating blocks (5) can be replaced with others of different insulating properties, allowing easy adaptation of the fastening and insulation system (1) for profiles (3) to the acoustic needs of the installation site.

Preferably, each sliding wing (4b) ends in a U-shaped interlock bend (4c) that acts against the sliding groove (2b) of the rigid plate (2) and prevents the sliding interlock (4) and hence the profile (3) housed between the insulating blocks (5) from coming loose.

In addition, each sliding interlock (4) is provided at one end with a stop wing (4d), which allows the insulating block (5) to be safely retained during the sliding assembly of the interlocks (4) and ensures a secure push of the insulating block (5) against the profile (3) during assembly.

Variations in material, shape, size and component arrangement that do not alter the essence of the invention are considered within the scope of the invention and can be reproduced by a person skilled in the art.