OFFSET FASTENING BRACKET FOR INSULATED METAL PANELS

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 63/730,299 filed on December 10, 2024, which is incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to insulated metal panels. More particularly, the present disclosure relates to utilizing an offset fastening bracket for installing and replacing insulated metal panels.

BACKGROUND

Insulated metal panels (IMPs) are widely used in building construction due to their excellent thermal insulation properties, durability, and aesthetic appeal. These panels typically comprise an insulating foam core interposed between two metal sheets. One of the key features of IMPs is their concealed fastening system, which allows for a clean and uninterrupted exterior appearance. This system involves installing the panels in a specific direction so that each new panel laps over the fasteners of the previous panel, effectively hiding them from view.

While this concealed fastening system provides a sleek and visually appealing finish, it poses significant challenges when it comes to replacing damaged or defective panels. The primary issue arises from the difficulty in accessing and removing the fasteners, which are located on the back side of the panel and are generally only accessible from within the building. This often necessitates cutting the fasteners from the interior, which can be a labor-intensive and time-consuming process.

One common method of replacing damaged IMPs involves using back fasteners that engage only the interior surface or skin of the panel. While this method maintains the fastener-free aesthetic on the exterior, it compromises the structural integrity of the panel. The interior skin alone does not provide the same level of strength and support as the original installation method, leading to potential malformations or failures over time.

Another method employs through-fasteners that engage both the front and back surfaces of the IMP, ensuring a structurally sound installation. However, this approach results in visible fasteners on the exterior of the building, detracting from the clean and seamless appearance that is one of the key selling points of IMPs.

These challenges highlight the need for an improved apparatus and method for replacing IMPs. Such a solution should maintain the strength and integrity of the original installation while preserving the aesthetic appeal of the concealed fastening system. Addressing this need would provide significant benefits in terms of both functionality and appearance, enhancing the overall value and utility of IMPs in building construction.

The present disclosure seeks to solve this and other problems.

SUMMARY OF EXAMPLE EMBODIMENTS

In some embodiments, an offset bracket comprises a first portion and a second portion, wherein the first portion and second portion have intersecting planes. In some embodiments, the first portion and second portion may be perpendicular to one another. The first portion comprises at least one aperture, which may be in the shape of a slot extending laterally across the first portion. The second portion comprises at least one aperture. The first portion is configured to couple to an IMP and the second portion is configured to couple to a structural member, such as a hollow structural section (HSS) post.

In some embodiments, a method of removing and replacing an IMP comprises cutting the fasteners of the respective IMPs, pushing the panels outwardly from the building to remove them, coupling one or more offset brackets to the IMPs via a bolt or other fastener that passes through a front portion and a rear portion of the IMP, inserting the IMPs into the gap in the wall, ensuring the IMPs lap with the prior panels to thereby conceal the fasteners, holding the IMPs in place while the offset brackets are secured to the building structure using bolts, screws, or other fasteners, and then tightening the bolt from the IMP to the bracket to ensure a secure coupling.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a front perspective view of an offset bracket for use with IMPs;

FIG. 2 illustrates a side, detailed view of IMPs needing to be replaced on a structure;

FIG. 3 illustrates a side, detailed view of IMPs being removed from the structure;

FIG. 4 illustrates a side, detailed view of the IMPs removed from the structure;

FIG. 5 illustrates a side, detailed view of replacement IMPs being coupled to the structure;

FIG. 6 illustrates a side, detailed view of replacement IMPs coupled to the structure;

FIG. 7 illustrates a top, plan detailed view of IMPs fastened to a structure in the prior art;

FIG. 8 illustrates a top, plan detailed view of IMPs fastened to a structure using offset brackets;

FIG. 9 illustrates a top, plan detailed view of an assembly of an offset bracket to an IMP; and

FIG. 10 illustrates a top, plan detailed view of an IMP coupled to a structural member via an offset bracket.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

The following descriptions depict only example embodiments and are not to be considered limiting in scope. Any reference herein to “the invention” is not intended to restrict or limit the invention to exact features or steps of any one or more of the exemplary embodiments disclosed in the present specification. References to “one embodiment,” “an embodiment,” “various embodiments,” and the like, may indicate that the embodiment(s) so described may include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Further, repeated use of the phrase “in one embodiment,” or “in an embodiment,” do not necessarily refer to the same embodiment, although they may.

Reference to the drawings is done throughout the disclosure using various numbers. The numbers used are for the convenience of the drafter only and the absence of numbers in an apparent sequence should not be considered limiting and does not imply that additional parts of that particular embodiment exist. Numbering patterns from one embodiment to the other need not imply that each embodiment has similar parts, although it may.

Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of the invention, which is to be given the full breadth of the appended claims and any and all equivalents thereof. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Unless otherwise expressly defined herein, such terms are intended to be given their broad, ordinary, and customary meaning not inconsistent with that applicable in the relevant industry and without restriction to any specific embodiment hereinafter described. As used herein, the article “a” is intended to include one or more items. When used herein to join a list of items, the term “or” denotes at least one of the items, but does not exclude a plurality of items of the list. For exemplary methods or processes, the sequence and/or arrangement of steps described herein are illustrative and not restrictive. 

It should be understood that the steps of any such processes or methods are not limited to being carried out in any particular sequence, arrangement, or with any particular graphics or interface. Indeed, the steps of the disclosed processes or methods generally may be carried out in various sequences and arrangements while still falling within the scope of the present invention.

The term “coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.

The terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous, and are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including, but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes, but is not limited to,” etc.).

As previously discussed, there is a need for an improved apparatus and method for replacing IMPs. Such a solution should maintain the strength and integrity of the original installation while preserving the aesthetic appeal of the concealed fastening system. The offset bracket and installation method disclosed herein solve these needs and provide significant benefits in terms of both functionality and appearance, enhancing the overall value and utility of IMPs in building construction.

Referring to FIG. 1, in some embodiments, an offset bracket 100 comprises a first portion 102 and a second portion 104, wherein the first portion 102 and second portion 104 have intersecting planes. In some embodiments, as shown, the first portion 102 and second portion 104 may be perpendicular to one another. The offset bracket may be of single manufacture and bent to the desired angle in relation to one another. However, it will be appreciated that the first portion 102 and second portion 104 may be two independent articles that are welded or otherwise coupled to one another. The first portion 102 comprises at least one aperture 106, which, as shown, may be in the shape of a slot extending laterally across the first portion 102. However, it will be appreciated that a plurality of apertures may also be used in place of the slot. The second portion 104 comprises at least one aperture 108A-B. As will be discussed herein, the first portion 102 is configured to couple to an IMP and the second portion 104 is configured to couple to a structural member, such as a hollow structural section (HSS) post.

Referring now to FIGS. 2-6, in some embodiments, a method of removing and replacing IMPs is shown. In particular, FIG. 2 illustrates a plurality of damaged IMPs 110A-B and a plurality of non-damaged IMPs 112A-B, all fastened to a structural member 114 (e.g., HSS post) of a structure. In a first step, the method comprises cutting the fasteners 116A-B of the respective damaged IMPs 110A-B from inside the structure. With the fasteners 110A-B cut, the damaged IMPs 110A-B may be forced outwardly from the structural member 114, as shown in FIG. 3. Once the damaged IMPs 110A-B are removed, as shown in FIG. 4, the remaining portion of the fasteners 116A-B may be accessed from the outside via panel openings 118A-B, and ground down, if needed, to ensure they are flush with the structural member 114.

Referring to FIG. 5, replacement IMPs 120A-B are readied by coupling an offset bracket 100A-B at each joint. As shown, this is accomplished by inserting a bolt 122A-B through the front, lap portion 124A-B of each replacement IMP 120A-B so as to remain concealed behind the non-damaged IMPs 112A-B. The bolt 122A-B then passes through an aperture 106 of the first portion 102 of each offset bracket 100A-B. With the offset brackets 100A-B preferably loosely coupled to the replacement IMPs 120A-B, a user may then insert the replacement IMPs 120A-B into the panel openings 118A-B. As shown in FIG. 6, once the replacement IMPs 120A-B are seated flush with the structural member 114, the second portion 104 of each offset bracket 100A-B may be coupled to the structural member 114, such as by using screws 126A-D through the apertures 108A-B of each second portion 104. The bolts 122A-B may then also be tightened to ensure secure fastening in the proper position. As a result, the replacement IMPs 120A-B are properly secured through both the front and the back of the panel, while being securely fastened to the structural member 114, which enhances structural integrity without altering the exterior facing aesthetics, overcoming the limitations of the prior art.

The offset bracket 100 may also be used during the initial wall cladding phase as well, to provide easier access to make future repairs. For example, as shown in FIG. 7, the prior art fastens an IMP 128 directly to the structural members 114. Because the fasteners 116 are not accessible, they must be cut to be removed, which is a difficult and time-consuming process. Instead, and referring to FIG. 8, the IMP 128 may be fastened to the structural members 114 using the offset bracket 100 disclosed herein. It will be understood that FIG. 8 shows a fully-assembled IMP wall cladding assembly 130, which may the result of a replacing prior art installations or may be initially built using the offset bracket 100 and method disclosed herein.

Accordingly, in some embodiments, a wall cladding assembly 130 for a structure comprises a plurality of IMPs 128, wherein each IMP 128 comprises at least one offset bracket 100 coupled at the lap portion/joint (not visible in this top view, but illustrated in the side view of FIGS. 5-6) so that both the offset bracket 100 and any fasteners securing it are concealed from the exterior when fully assembled.

In this embodiment, when an IMP becomes damaged and in need of replacement, a user may simply unthread the screws and/or bolts from the relevant offset bracket(s) 100, remove the damaged IMP, replace the damaged IMP with a non-damaged IMP and then fasten the non-damaged IMP to the structural members 114 via respective offset brackets 100.

Referring now to FIGS. 9-10, a method of assembling an offset bracket 100 to an IMP 128 is shown. As shown, an offset bracket 100 is placed on an interior side 132 of the IMP 128. A plurality of bolt apertures 134A-B may be drilled through the lap portion 124 of the IMP 128 and to the interior side 132 of the IMP 128. In some embodiments, a span bracket 136 may be positioned on the lap portion 124 prior to inserting the bolts 122A-B therethrough. In other words, the span bracket 136 is interposed between the IMP 128 and the heads of the bolts 122A-B. The bolts 122A-B pass through the bolt apertures 134A-B and into the one or more apertures 106 of the first portion 102. The nuts 138A-B may then be coupled to the respective bolts 122A-B to thereby secure the offset bracket 100. It will be appreciated that while a span bracket 136 is shown, it is not required, and may be replaced with washers or with nothing.

Referring to FIG. 10, with the offset bracket 100 loosely coupled to the IMP 128 (e.g., nuts 138A-B not fully tightened), one or more screws 126A may be inserted through the second portion 104 and into the structural member 114, thereby securing the IMP 128 to the structure.

Accordingly, it will be appreciated from the foregoing that the offset bracket 100 and method of assembly disclosed herein solve the need for an improved apparatus and method for replacing IMPs. The offset bracket 100 and method maintain the strength and integrity of the original installation while preserving the aesthetic appeal of the concealed fastening system, overcoming limitations of the prior art.

It will be appreciated that systems and methods according to certain embodiments of the present disclosure may include, incorporate, or otherwise comprise properties or features (e.g., components, members, elements, parts, and/or portions) described in other embodiments. Accordingly, the various features of certain embodiments can be compatible with, combined with, included in, and/or incorporated into other embodiments of the present disclosure. Thus, disclosure of certain features relative to a specific embodiment of the present disclosure should not be construed as limiting application or inclusion of said features to the specific embodiment unless so stated. Rather, it will be appreciated that other embodiments can also include said features, members, elements, parts, and/or portions without necessarily departing from the scope of the present disclosure.

Moreover, unless a feature is described as requiring another feature in combination therewith, any feature herein may be combined with any other feature of a same or different embodiment disclosed herein. Furthermore, various well-known aspects of illustrative systems, methods, apparatus, and the like are not described herein in particular detail in order to avoid obscuring aspects of the example embodiments. Such aspects are, however, also contemplated herein.

Exemplary embodiments are described above. No element, act, or instruction used in this description should be construed as important, necessary, critical, or essential unless explicitly

described as such. Although only a few of the exemplary embodiments have been described in detail herein, those skilled in the art will readily appreciate that many modifications are possible in these exemplary embodiments without materially departing from the novel teachings and advantages herein. Accordingly, all such modifications are intended to be included within the scope of this invention.