GB2423097A

GB2423097A - Support bracket

Info

Publication number: GB2423097A
Application number: GB0518895A
Authority: GB
Inventors: John Toy
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-02-11
Filing date: 2005-09-16
Publication date: 2006-08-16
Anticipated expiration: 2025-09-16
Also published as: GB2423097B; GB0518895D0; GB0502882D0

Abstract

A support bracket 20 comprises a body portion 22 having first and second ends 24, 26 and a longitudinal axis A extending between said ends. A planar mounting portion 28 extends laterally from the longitudinal axis A, which is adapted in use to be connected to a first structural element. The second end 26 is of substantially tubular section having a longitudinal axis extending generally parallel to the longitudinal axis A of the body portion, the second end being adapted in use to be connected to a second structural element (16 figure 5). The support bracket may be made from flat sheet metal and used to secure a roofing bar relative to a rafter. A later embodiment relates to a method of making said support bracket.

Description

Support Bracket The present invention relates to a support bracket, in

particular, but not exclusively to a roof support bracket for supporting roofing bars on a superstructure.

In twin skin metal roof assemblies such as the Ashgrid system, it is known to mount a roofing bar on a rafter using a support bracket. Such a prior art support bracket, indicated generally at 1 0 in Figure 1, is formed from a single piece of bent galvanised steel sheet and comprises a generally flat body portion 12, and a mounting portion 14 which extends from a first end 1 2a of the body portion 12 generally perpendicular thereto. The mounting portion 14 is provided with a plurality of apertures through which fasteners such as screws or bolts may pass in order to fasten the mounting portion 14 onto a rafter. A second end 1 2b of the body portion 1 2 is provided with cut-outs which permit it to engage with a corresponding roofing bar 1 6. As can be seen in Figure 1, this support bracket 1 0 engages with the roofing bar 1 6 such that the join between the body portion 1 2 and the mounting portion 1 4 extends generally perpendicular to a longitudinal axis of the roofing bar 1 6.

If significant vertical load is placed on a such a roof assembly, the prior art support bracket 1 0 fails by the bending of the second end 1 26 of the body portion 1 2 and bending at the interface between the mounting portion 1 4 and body portion 1 2. Moreover, it has been found that if significant sideways force is applied to the roofing bar 1 6 along the longitudinal axis of the bar 1 6, the roofing bar 1 6 tends to exhibit significant sideways movement (or sway) relative to the rafter on which it is supported. To combat this mechanical, it is known to provide "sway brackets" in addition to the main support brackets 1 0. These sway brackets 1 8 are illustrated in Figure 2 and are also made from galvanised steel sheet, but are screwed to both the roofing bar 1 6 and the rafter. The sway brackets 1 8 are arranged with the plane of the sheet extending generally parallel to the longitudinal axis of the roofing bar 1 6, SO as to significantly reduce such sideways movement of the roofing bar 1 6.

It will be appreciated that the need to provide two sorts of brackets in order to obtain a stable roofing system significantly complicates the manufacture and assembly of a roofing system. Moreover, with recent and imminent legislation setting increasingly stringent standards for thermal insulation of building structures, it will shortly be necessary to increase the separation of the roofing bars from the rafters in twin skin metal roof assemblies, and to achieve this in the existing system, it will be necessary to significantly increase the length of the body portion 1 2 of the roofing bracket described above. This will further increase the mechanical instability of a roof assembly made using prior art support brackets 1 2 and sway brackets 1 8 as described above.

According to a first aspect of the invention, a support bracket comprises a body portion having a first end and a second end and a longitudinal axis extending between its first end and second end, and a substantially planar mounting portion extending from the first end of the body portion laterally of the longitudinal axis thereof and being adapted in use to be connected to a first structural element, the second end being of substantially tubular section having a longitudinal axis which extends generally parallel to the longitudinal axis of the body portion, the second end being adapted in use to be connected to a second structural element.

By virtue of having a second end of substantially tubular section, the mechanical stability of the support bracket when subjected to loading along its longitudinal axis is increased. Moreover, the second end may readily be connected to a second structural element such as a roofing bar in a variety of orientations with respect to the roofing bar, and thus, when such a support bracket is used in a roof assembly, the need to provide two different types of support bracket to minimise the risk of sway of the roofing bar relative to a superstructure beneath is eliminated.

Preferably the support bracket is formed from a single sheet of material which is shaped so that the second end of the body portion is a generally cylindrical tube. In this case, preferably the support bracket is made from sheet metal.

Preferably the second end of the body portion is provided with a plurality of apertures or recesses which are adapted in use to engage with corresponding engagement formations on the second structural element to retain the support bracket relative to the second structural element.

Preferably the mounting portion extends generally perpendicular to the first end of the body portion. The mounting portion may be provided with a plurality of apertures which are adapted to receive fasteners by means of which the mounting portion may be fastened to the first structural element.

The first end of the body portion may be provided with one or more ribs which extend generally parallel to the longitudinal axis of the body portion.

The provision of such ribs may further enhance the mechanical stability of the support bracket. Apertures may be provided in the body portion, particularly adjacent the first end thereof, in order to save weight and to reduce the heat transfer path through the bracket.

The support bracket may be a roof support bracket which is adapted to secure a roofing bar relative to a rafter.

According to a second aspect of the present invention a method of making a support bracket comprises the steps of taking a piece of substantially flat sheet material having a first end portion and a second end portion and a longitudinal axis extending between the first end portion and the second end portion, forming at the first end portion a substantially planar mounting portion which extends laterally of the longitudinal axis, which is adapted in use to engage with a first structural element, and bending and shaping the second end portion to form a substantially tubular section with a longitudinal axis which extends generally parallel to the longitudinal axis of the support bracket.

Preferably the method further includes the steps of bending the first end portion to form the mounting portion so that the mounting portion extends substantially perpendicular to the remainder of the first end portion.

Preferably the method further includes the steps of cutting at least one recess or aperture in the second end portion prior to bending and shaping the second end portion to at least substantially enclose the elongate space.

The invention is now described, by way of example only, with reference to the accompanying drawings, in which, FIGURE 1 is an illustration of a prior art roof support bracket and roofing bar assembly; FIGURE 2 is an illustration of a prior art sway bracket and roofing bar assembly; FIGURE 3 is a perspective view of a support bracket according to the present invention; FIGURE 4 is an illustration of the support bracket of Figure 3 from above; FIGURE 5 is an illustration of the support bracket of Figure 3 in engagement with a roofing bar; FIGURE 6 is an illustration of the cross section through the support bracket and roofing bar assembly of Figure 4; FIGURE 7 is a perspective view of a modified embodiment of the invention; FIGURE 8 is a perspective view of of the embodiment illustrated in figure 7, from the other side; and FIGURE 9 is a plan view of the bracket illustrated in figure 7.

Referring to the figures 3 to 6, a support bracket 20 includs a body portion 22 having a first end 24 and a second end 26 and a longitudinal axis A extending between the first end 24 and second end 26. The support bracket is formed from a single, rectangular sheet of material which is, in this example, approximately 375mm long and 11 5mm wide. In this case, the support bracket is made from 2mm thick mild steel sheet. The body portion 22 of the support bracket in this example is around 345mm in length.

The first end 24 is substantially flat, whereas the material at the second end 26 is bent to form a generally cylindrical tube with a cylinder axis which coincides with the longitudinal axis A of the support bracket 22. The second end 26 is bent such that the longitudinal edges of the second end 26 of the body portion come together to form a seam which extends along the length of the cylindrical tube generally parallel to the longitudinal axis A of the support bracket 20 generally centrally relative to the width of the support bracket 20. Whilst the longitudinal edges of the second end 26 of the body portion 22 may be joined together, by welding or soldering for example, in this embodiment, the seam is left open with the longitudinal edges of the order of 1 mm apart.

By virtue of the bending of the second end 24 of the body portion 20 whilst keeping the first end 24 flat, the body portion 22 also includes an intermediate portion 34 in which the body portion 22 curves in accordance with the transition from the flat first end 24 to the tubular second end 26.

Thus, the width of the intermediate portion 34 decreases, approximately linearly, from the width at the first end 24 of the body portion 22, i.e. around 11 5mm, to the diameter of the cylindrical second end 26, i.e. around 40mm.

The support bracket 22 is also provided with a mounting portion 28, which extends from the first end 24 of the body portion 22 substantially at right angles thereto. The mounting portion 28 is integral with the remainder of the support bracket 20 and is formed by bending a portion of material at the first end 24 of the body portion 22, in this embodiment, in the same direction to the direction in which the second end 24 is bent into its tubular configuration, until the first end 24 is generally Lshaped in longitudinal cross-section. The mounting portion 28 extends for around 30mm from the first end 24 of the body portion 22.

It should be appreciated that the mounting portion 28 may extend in the opposite direction to the direction in which the second end 24 is bent into its tubular configuration.

As mentioned above, the first end 24 of the body portion 22 is substantially flat, in particular when compared to the second end 26. The first end 24 is not completely flat, however, as, in this example, it is provided with two strengthening ribs 30 which extend generally parallel to the longitudinal axis A of the body portion 22. The ribs 30 are generally semi-circular when viewed in transverse cross-section, and extend continuously from the body portion 22 along the mounting portion 28. The strengthening ribs 30 are spaced along the width of the support bracket 20 so that the distance between the ribs 30 is approximately twice the distance between each rib and the adjacent longitudinal edge of the support bracket 20.

The mounting portion 28 is provided with four apertures 32 which are adapted to receive fasteners such as screws or bolts, by means of which the mounting portion 28 may be fastened to a first structural element. Two of these apertures 32 are spaced between the two strengthening ribs 30, and each of the other two apertures 32 are located between one of the ribs 30 and the longitudinal edge of the support bracket 20.

The second end 26 of the body portion 22 is provided with a plurality of apertures 36 which are adapted in use to engage with corresponding engagement formations on a second structural element 1 6 to retain the support bracket relative to the second structural element. In this example, the second end 24 includes two apertures 36a, 36b which extend through the wall of the generally cylindrical tube. The first aperture 36a is formed from two generally rectangular recesses which are cut out from the longitudinal edges of the second end 26 of the body portion 22 and which meet at the seam of the cylindrical tube to form a rectangular aperture 36a in the tube wall. The second aperture 366 is formed from a generally U- shaped aperture, having a base and two upwardly extending sides, which is provided in the second end 26 of the body portion 22 generally centrally between the two longitudinal edges. Thus, the apertures 36a, 36b are diametrically opposite one another, and in this example, the second aperture 36 is located on the same side of the body portion 22 as the side from which the mounting portion 28 extends. The first aperture 36a is closer to the free end of the body portion 22 than the second aperture 36b.

It should be appreciated that, by virtue of having a generally cylindrical second end 26, the mechanical stability of the support bracket 20 when subjected to loading along its longitudinal axis A is increased. Moreover, the provision of strengthening ribs 30 may further enhance the mechanical stability of the support bracket 20.

The support bracket 20 may be made using conventional metal forming techniques. A rectangular piece of sheet metal of appropriate dimensions is cut from a roll of sheet metal, the strengthening ribs 30 are pressed into one end of the piece, the apertures 32 drilled between the strengthening ribs 30, and the apertures 36a, 36b are cut from the other end. The end including the apertures 32 is folded to form the mounting portion 28, and then second end 26 folded into its generally cylindrical tube configuration.

The second end 26 of the body portion 22 is adapted to engage with an elongate roofing bar 1 6 with a longitudinal axis B as illustrated in Figures 5 and 6. The roofing bar 16, which is adapted to be used in the Ashgrid roofing system, includes an elongate top face 1 6a from either longitudinal edge of which extends a side wall 1 6b, 1 6c generally perpendicular to the top face 1 6a. At the free edge of the first side wall 1 6b there is provided a first flange 1 6d which extends towards the second side wall 1 6c generally perpendicular to the side walls 1 6b. 1 6c. At the free edge of the second side wall 1 6c there is provided a second flange 1 6e which extends towards the first side wall 1 6b generally perpendicular to the side walls 1 6b, 1 6c. The second flange 1 6e also includes a lip formation 1 6f which extends from a free edge of the second flange 1 6e towards the top face 1 6a.

The apertures 36a, 36b are configured such that the support bracket 20 may be engaged with the roofing bar 1 6 by inserting the first flange 1 6d into the first aperture 36a of the support bracket 20 so that the flange 1 6d engages with the uppermost edge of the aperture 36a, and the second flange 1 6d and lip formation 1 6e into the second aperture 36b of the support bracket so that the flange 1 6d engages with the upper edge of the base of the U- shaped aperture 36b and the lip formation 1 6e extends into the upwardly extending sides of the U-shaped aperture 36b. The support bracket 20 may be slid along the roofing bar 1 6 to a desired position relative to the bar 1 6, the flanges 1 6c, 1 6d and lip formation 1 6e retaining the support bracket 20 in engagement with the roofing bar 1 6. The mounting portion 28 may then be engaged with a structural element such as a rafter by passing fasteners such as bolts or screws through the apertures 32 provided in the mounting portion 28 and into the rafter. The support bracket may thus be used to support a roofing bar 1 6 on a superstructure such as a rafter.

The apertures 36a, 26b are positioned and configured such that the free end of the second end 26 of the body portion 22 engages with the top face 1 6a of the roofing bar 1 6, the longitudinal axis of the support bracket A extends generally perpendicular to the longitudinal axis B of the roofing bar 1 6, and in this example, the longitudinal axis of the roofing bar 1 6 extends generally perpendicular to the plane of the first end 24 of the body portion 22.

It should be appreciated that by varying the position of the apertures 36a, 36b around the circumference of the cylindrical second end 24, whilst still maintaining the apertures 36a, 36b diametrically opposite one another, it is possible to vary the angle between the longitudinal axis B of the roofing bar 1 6 and the plane of the first end 24 of the support bracket 20. Since it is relatively easy to alter the position of the apertures 36a, 36b without making substantial modifications to the tools used to manufacture the support bracket 20, it is correspondingly simple to manufacture a range of support brackets 20 which may be connected to a roofing bar 1 6 in a variety of orientations. By using such a range of support brackets 20 in a single roofing system, the need to provide separate sway brackets to minimise the possibility of sway of the roofing bars 1 6 under the action of forces parallel to the plane of the roof is eliminated.

Moreover, in the prior art Ashgrid system, as the body portion 1 2 of the support bracket 1 2 is substantially flat, in order to ensure that the support bracket 20 is retained with its longitudinal axis B generally perpendicular to the longitudinal axis B of the roofing bar 1 6, the support bracket 1 2 is designed to be slid along the roofing bar 1 6 at an angle of less than 90" and then rotated into the desired perpendicular orientation, rotation causing mechanical locking of the support bracket 10 in the desired perpendicular orientation.

Such rotation is rendered unnecessary using the support bracket 20 of the present invention, as the engagement of the tubular second end 26 of the support bracket 20 with the top face 1 6a of the roofing bar 1 6 ensures that the support bracket 20 is retained in the correct perpendicular orientation.

It should be appreciated that, whilst it is preferable for the second end 26 of the support bracket 20 to be cylindrical as described above, so that the position of the apertures 36a, 36b may be varied without restriction and the support bracket 20 connected to a roofing bar 1 6 in a wide variety of orientations, the second end 26 need not have a generally circular transverse cross-section. Instead, the second end 26 may at least substantially enclose a space with a cross-section which is square, rectangular, triangular, or any other shape.Whilst the support bracket 20 described above is adapted to be slid along a roofing bar 1 6, the portion of the second end 26 of the support bracket 20 between the free edge and the second aperture 36b may be shaped to allow the support bracket 20 to be attached to the roofing bar 1 6 by "snap fitting" it on the roofing bar 1 6 without the need to slide it along the roofing bar 1 6. For example, the portion of the second end 26 between the free edge and the second aperture 36b may be shaped such that the cylinder radius is minimum at the free edge and the edge of the second aperture, and increases between these edges.

In the bracket 40 illustrated in figures 7 to 9, the body portion 42 adjacent the first end 44 is of channel section, having a pair of flange formations 46 extending to one side of the body portion 42, a flange formation 64 defining each of the longitudinal edges of the body portion 42. The end of the central part of the body portion 42 which forms the base of the channel section, is bent perpendicular to the body portion 42, to the opposite side of the body portion 42 as the flange formations 46, to provide a mounting portion 48, while the ends of the flange formations 46 are bent perpendicularly, outwardly to provide mounting portions 50, the mounting portions 50 being coplanar with the mounting portion 48. In this manner, mounting portions 48,50 are provided to both sides of the longitudinal axis A of the body portion 42 of the bracket 40. Lip formations 52 may be provided along one edge of the mounting portions 48 or 50, to assist in alignment of the bracket 40 with a support surface and apertures 54 are provide on the mounting portions 48,50 through which fastening means may be located to secure the bracket to a support structure. In an alternative embodiment, the ends of the flange formations 46 may be bent inwardly towards one another, to provide mounting portions 50.

As with the previous embodiment, reinforcing ribs may be provided on the body portion 42 and mounting portions 48,50 of the bracket 40. Moreover one of more apertures may be provided in the body portion 42, in order to reduce the weight of the bracket 40 and reduce the heat flow path through the bracket 40.

Any such apertures may be lipped, in order to reinforce the body portion 42.

When used in this specification and claims, the terms "comprises" and "comprising" and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components but need not include such other features.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof.

Claims

1. A support bracket comprising a body portion having a first end and a second end and a longitudinal axis extending between its first end and second end, and a substantially planar mounting portion extending from the first end of the body portion laterally of the longitudinal axis thereof and being adapted in use to be connected to a first structural element, the second end being of substantially tubular section having a longitudinal axis which extends generally parallel to the longitudinal axis of the body portion, the second end being adapted in use to be connected to a second structural element.

2. A support bracket according to claim 1 wherein the support bracket is formed from a single sheet of material which is shaped so that the second end of the body portion is a generally cylindrical tube.

3. A support bracket according to claim 2 wherein the support bracket is made from sheet metal.

4. A support bracket according to any preceding claim wherein the second end of the body portion is provided with a plurality of apertures or recesses which are adapted in use to engage with corresponding engagement formations on the second structural element to retain the support bracket relative to the second structural element.

5. A support bracket according to any preceding claim wherein the mounting portion extends generally perpendicular to the first end of the body portion.

6. A support bracket according to any preceding claim wherein the mounting portion is provided with a plurality of apertures which are adapted to receive fasteners by means of which the mounting portion may be fastened to the first structural element.

7. A support bracket according to any preceding claim wherein the first end of the body portion is provided with one or more ribs which extend generally parallel to the longitudinal axis of the body portion.

8. A support bracket according to any preceding claim wherein the support bracket is a roof support bracket which is adapted to secure a roofing bar relative to a rafter.

9. A method of making a support bracket comprising the steps of taking a piece of substantially flat sheet material having a first end portion and a second end portion and a longitudinal axis extending between the first end portion and the second end portion, forming at the first end portion a substantially planar mounting portion which extends laterally of the longitudinal axis which is adapted in use to engage with a first structural element, and bending and shaping the second end portion to form a substantially tubular section with a longitudinal axis which extends generally parallel to the longitudinal axis of the support bracket.

10. A method according to claim 9 wherein the method further includes the steps of bending the first end portion to form the mounting portion so that the mounting portion extends substantially perpendicular to the remainder of the first end portion.

11. A method according to claim 9 or 1 0 wherein the method further includes the steps of cutting at least one recess or aperture in the second end portion prior to bending and shaping the second end portion to enclose the elongate space.

1 2. A support bracket substantially as hereinbefore described with reference to and as shown in the accompanying drawings.

13. A method of making a support bracket substantially as hereinbefore described with reference to the accompanying drawings.

14. Any novel feature or novel combination of features described herein and/or in the accompanying drawings.