Wall mounting bracket for mounting rails and method of manufacturing the same

Abstract

A wall-mounted bracket (1) is used to mount a long mounting rail as a cantilever to a wall or other supporting surface. The bracket comprises: a wall plate (2) having mounting holes (7, 8) for mounting the bracket to the wall by means of male fasteners; a socket (3) for inserting an end portion of the mounting rail, the socket comprising at least two flange profiles (9, 10), the at least two flange profiles (9, 10) having surrounding portions at their distal ends for interlocking with the end portion of the mounting rail, thereby inhibiting movement of the inserted end portion parallel to the wall plate. At least one of the surrounding portions has a fixing hole (20, 21) for passing the male fastener to fix the end portion of the mounting rail, thereby inhibiting the end portion from retracting from the socket; and a supporting edge (22) within the socket, the supporting edge being configured to interlock with the outer side or inner side of the end portion of the mounting rail, thereby inhibiting movement of the inserted end portion parallel to the mounting plate.

Description

Technical Field

[0001] The present invention relates to a metal wall mount for mounting an elongated mounting rail as a cantilever to a wall or other supporting surface. Background Art

[0002] Metal wall mounts for mounting rails are well known in the art. A typical mount consists of a wall plate for mounting the mount to the wall and a steel rail support welded to the wall plate. The rail support then receives a (profiled) mounting rail, which is typically attached to the support using clamps and / or sliding nuts and screws. The assembly of the metal wall mount and mounting rail is known as a cantilever. These cantilevers are often used to support or suspend mounting components, such as mounting systems for pipes and / or machinery.

[0003] A disadvantage of these known brackets is that the rail supports are welded to the wall panels. First, welding is not only an expensive process but also carries risks in terms of weld quality, as the welded portion in these known brackets represents the load-bearing connection between the wall panels and the rails. Second, welding precludes the use of pre-galvanized materials, as welding pre-galvanized materials can compromise weld quality and generate toxic fumes. Consequently, untreated materials are often used for brackets requiring welding, which are then galvanized afterward. This complicates the manufacturing process.

[0004] DE 196 13 795 discloses a cantilever in which the rail is joined to the wall plate by means of a mechanical connection, thereby eliminating the need for welding. However, a disadvantage of this known cantilever is that the wall plate in DE 196 13 795 does not provide sufficient reinforcement for the load-bearing mechanical connection between the wall plate and the rail to which the load on the rail is transferred. Summary of the Invention

[0005] It is an object of the present invention to provide an improved metal wall mount for a cantilever which alleviates the problems caused by welding while providing improved reinforcement.

[0006] This object is achieved by a metal wall mount bracket for mounting an elongated mounting rail (e.g., a generally C-shaped profile cross-section element) as a cantilever to a wall or other supporting surface, wherein the bracket is adapted to locate and retain an end portion of the mounting rail in the bracket and to secure said end portion to the bracket by means of at least one mechanical fastener, wherein the bracket comprises:

[0007] - a wall plate having a wall engaging side to be positioned against a wall or other supporting surface and a front side opposite the wall engaging side, wherein mounting holes extend from the front side to the wall engaging side for mounting the bracket to the wall by means of male fasteners,

[0008] The bracket also includes:

[0009] - a socket located on the front side of the wall plate for inserting the end portion of the mounting rail, the socket comprising at least two flange profiles formed integrally with the wall plate and having a proximal end connected to the wall plate and a distal end remote from the wall plate, wherein the flange profiles have surrounding portions at the distal ends, the surrounding portions being configured to together surround the end portion of the mounting rail so as to interlock with the outer side of the end portion of the mounting rail, thereby inhibiting movement of the inserted end portion parallel to the mounting plate, and wherein at least one of the surrounding portions has a fixing hole for passing a male fastener to fix the end portion of the mounting rail, thereby inhibiting the end portion of the rail from retracting from the socket,

[0010] - a support rim integrally formed on the front side of the wall plate in the socket, said support rim being configured to interlock with the outer or inner side of the end portion of the mounting rail, thereby inhibiting movement of the inserted end portion parallel to the mounting plate.

[0011] The bracket according to the present invention comprises a socket and a supporting edge formed on the wall plate, the socket comprising at least two flange profiles having a surrounding portion remote from the wall plate. Both the surrounding portion and the supporting edge can be configured to interlock with the outer side of the end portion of the mounting rail, thereby inhibiting movement of the inserted end portion parallel to the mounting plate. Alternatively, the surrounding portion can be configured to interlock with the outer side of the end portion of the mounting rail, and the supporting edge can be configured to be inserted into the open end of the mounting rail and interlock with the inner side of the end portion of the mounting rail. Effectively, the bracket provides two-point support for the load. This results in a reinforced load-bearing connection between the bracket and the mounting rail.

[0012] It should also be noted that the bracket is integrally formed, thus being a single piece, comprising the wall plate, two flange profiles, and the supporting edge. This has the advantage that only one component is produced, and no further assembly and / or welding of the bracket itself is required. The lack of welding also means that pre-galvanized materials can be used to manufacture the wall bracket, further simplifying the manufacturing process.

[0013] Another advantage of the integrally formed wall mount is that the material properties are relatively consistent throughout. This results in a load-bearing capacity of consistent quality, as there are no connections between the individual components, which could prove to be a weak link or require specific reinforcement strategies.

[0014] In a possible embodiment, the support edge is formed as a curved edge of the hole in the plate. This allows the support edge to be formed integrally with the wall plate. In addition, this helps to easily manufacture the support edge.

[0015] In a possible embodiment, the flange profile is formed by bending. This allows the flange profile to be formed integrally with the wall panel. In addition, this contributes to easy production of the support edge.

[0016] In a further possible embodiment, the wall bracket is made by casting or moulding. This results in an integrally formed bracket.

[0017] In a possible embodiment, the flange profile tapers from the respective proximal end toward the surrounding portion. The taper of the flange profile results in an increase in the bending stiffness of the socket in the vertical direction. This increase in bending stiffness due to the tapered profile can also be referred to as bracing.

[0018] In a possible embodiment, the flange profiles are inclined towards each other from the proximal end towards the surrounding portion. This inclination provides further support for the socket. Consequently, this also results in increased bending stiffness in the transverse direction.

[0019] In a preferred embodiment, the socket comprises two opposing flange profiles.

[0020] In another embodiment, the enclosure has a U-shaped profile, with the open sides of the U-shaped profile facing each other. Due to the U-shaped profile, the enclosure engages the mounting rail at its upper, left / right, and lower sides. This provides additional support for the connection between the enclosure and the mounting rail. It should be understood that other cross-sectional shapes of the enclosure are contemplated, such as an L-shape.

[0021] In yet another embodiment, the support edge has a rectangular shape. This rectangular shape preferably has a closed profile with rounded corners. The rectangular shape allows the end portions of the mounting rails to be positioned and retained in the bracket. Typically, the outer profile of the cross section of these mounting rails forms a rectangular shape. It should be noted that the support edge and / or the mounting rails may alternatively have other shapes.

[0022] In one possible embodiment, the rim is aligned with the surrounding portion of the flange profile. This results in an effective two-point support of the load. The rim and the surrounding portion effectively share the load, and this prevents torque or bending moments due to out-of-plane sharing of the load.

[0023] In a possible embodiment, the inner side of the supporting rim interlocks with the outer side of the end portion of the mounting rail.

[0024] In a possible embodiment, the outer side of the supporting rim interlocks with the inner side of the end portion of the mounting rail.

[0025] In a practical embodiment, the bracket is formed from a sheet metal blank. In another practical embodiment, the sheet metal blank is pre-galvanized. The latter is beneficial because it results in a cheaper and more efficient manufacturing process.

[0026] The invention also relates to a cantilever assembly comprising a wall-mounted bracket as set out above and comprising a mounting rail, which is inserted with its end portion into a socket of the bracket and which engages a support rim of the bracket. As a result, the end portion of the mounting rail interlocks with the socket and the support rim. The inner contour of the socket, the inner contour or outer contour of the support rim and the outer contour of the end portion of the mounting rail and the dimensions of the possible inner contour are designed to match each other. The interlocking of the socket and the support rim inhibits movement of the inserted rail end portion parallel to the mounting plate. The outer contour and the possible inner contour of the mounting rail can fully or partially match the shape of the cross section of the socket and / or the support rim of the bracket.

[0027] In one possible embodiment, the mounting rail has a C-shaped cross-section. This allows mounting elements, such as pipes and / or machinery, to be securely attached to the mounting rail. It should be noted that this is only one example of a possible mounting rail cross-section. Depending on the application, a mounting rail having another suitable cross-section may be selected.

[0028] The invention also relates to a method for manufacturing a metal wall bracket.

[0029] In particular, the present invention also relates to a method for manufacturing a metal wall bracket, wherein:

[0030] - providing a flat sheet metal blank;

[0031] - punching a central opening with upright edges into the blank;

[0032] - Punching or cutting the outer contour of the unfolded stent from the blank;

[0033] - Punching or cutting one or more mounting holes and one or more fixing holes;

[0034] - bending the flange profile out of the plane of the sheet metal blank;

[0035] - Forming the flange profile as a profile having a U-shaped cross section at its distal end portion.

[0036] In a practical embodiment, the sheet metal blank is made from pre-galvanized metal. This is beneficial because it results in a cheaper and more efficient manufacturing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The present invention will be explained in the following description with reference to the accompanying drawings, wherein like reference numerals refer to like parts.

[0038] Figure 1 A perspective view showing a wall mount according to the present invention;

[0039] Figure 2 Show Figure 1 Front view of the wall mount bracket;

[0040] Figure 3 Shown including Figure 1 a perspective view of the cantilever assembly of the wall mount bracket; and

[0041] Figure 4 Shown through Figure 3 Cross section of a cantilever assembly. DETAILED DESCRIPTION

[0042] exist Figure 1 1 shows a metal wall mount 1 which generally comprises a wall plate 2 and a socket 3. The metal wall mount 1 may be formed from a flat sheet metal blank which is preferably pre-galvanized. Alternatively, the metal wall mount 1 may be formed by casting or molding metal.

[0043] The wall panel 2 has an engagement side 4 to be positioned against a wall or any other supporting surface, and a front side 5 opposite the engagement side 4. The wall panel 2 of this particular embodiment has a generally rectangular shape with rounded corners 6.

[0044] The wall plate 2 further has oblong mounting holes 7 and 8 extending from the front side 5 to the engagement side 4. The mounting holes 7 and 8 are centrally located in the upper and lower halves of the wall plate 2, respectively. The mounting holes 7 and 8 can be used to mount the wall mount bracket 1 to a wall or any other supporting surface with the aid of male fasteners such as screws or bolts. The appropriate male fastener can be selected based on the intended use and / or load of the bracket 1. The mounting holes 7 and 8 each have an oblong shape with a longitudinal axis. The longitudinal axes of the holes 7 and 8 are perpendicular to each other, so that the position and orientation of the bracket 1 can be adjusted when the bracket 1 is attached to the wall.

[0045] The socket 3 is located on the front side 5 and comprises two opposite flange profiles 9 and 10. The flange profiles 9 and 10 are formed at opposite edges of the wall panel 2 and are bent out of the plane of the wall panel 2. The flange profiles 9 and 10 have respective proximal ends 11 and 12 connected to the wall panel 2. The respective bending lines 13 and 14 about which the flange profiles 9 and 10 are bent are located at the sides of the wall panel 2. Figure 1 It is schematically shown in FIG.

[0046] Each flange profile 9 and 10 has a respective distal end 15 and 16 that is remote from the wall panel 2. At the distal ends 15 and 16, the flange profiles 9 and 10 each have a mutually opposing surrounding portion 17 and 18. The surrounding portions 17 and 18 have a U-shaped profile and face each other with the open sides of the U-shape. Thus, the surrounding portions 17 and 18 are arranged and configured to together surround the end portion of the mounting rail 100.

[0047] exist Figure 1In the figure, it can be seen that the flange profiles 9 and 10 taper from their respective proximal ends 11 and 12 towards these surrounding portions 17 and 18. The taper of the flange profiles 9 and 10 results in an increase in the bending stiffness of the socket 3 in the vertical direction. In addition, the flange profiles 9 and 10 are inclined towards each other from the proximal ends 11 and 12 towards the surrounding portions 17 and 18, thereby providing further support for the socket 3.

[0048] Between them, the surrounding parts 17 and 18 define a space 19, which is laterally blocked by the side parts 17A and 18A and vertically blocked by the upper side parts 17B and 18B and the lower side parts 17C and 18C. This space is open at the front and rear sides of the surrounding parts 17 and 18. This space 19 allows the insertion of the end part 100A of the mounting rail 100, as shown in FIG. Figure 3 and Figure 4 When the mounting rail 100 is inserted, the outer side of the mounting rail engages the inner side of the surrounding parts 17 and 18. As a result, movement of the end portion 100A parallel to the wall panel 2 is inhibited.

[0049] It will be appreciated that the surrounding portions 17 and 18 may also have contours of different shapes and define the space therebetween accordingly.

[0050] The surrounding portions 17 and 18 further have fixing holes 20 and 21 arranged in the side portions 17A and 18A, respectively. These fixing holes 20 and 21 can be used to pass male fasteners to fix the end portion 100A of the mounting rail 100, thereby inhibiting the end portion 100A from retracting from the socket 3.

[0051] The support rim 22 is centrally arranged on the front side 5 and is formed as a rim bent from a hole 23 in the wall plate 2. This allows the support rim 22 to be formed integrally with the wall plate 2. The support rim 22 is shown as having a rectangular shape. This is also the typical shape of the outer profile of the mounting rail. However, it should be understood that other shapes are also conceivable.

[0052] The support rim 22 can receive the end portion 100A of the mounting rail in the hole 23. When the end portion 100A is inserted, the outer side of the end portion 100A of the mounting rail 100 interlocks with the inner side of the support rim 22. This prevents displacement of the inserted end portion 100A parallel to the wall panel 2.

[0053] exist Figure 2 Shown in Figure 1A front view of bracket 1 is shown. Support rim 22 can be seen aligned with surrounding portions 17 and 18 extending from flange profiles 9 and 10 of socket 3. Upper side 22A and lower side 22B of rim 22 are visible through the space defined between surrounding portions 17 and 18. When a load is applied to mounting rail 100 inserted into bracket 1, the alignment of support rim 22 and socket 3 provides effective two-point support. Support rim 22 and surrounding portions 17 and 18 effectively share the load and prevent torque or bending moments due to out-of-plane load sharing.

[0054] exist Figure 3 1 shows a cantilever assembly comprising a bracket 1 and a mounting rail 100. The end portion 100A of the mounting rail 100 is inserted into the socket 3 and the support rim 22 of the bracket 1. This causes the outer side of the end portion 100A to interlock with the inner side of the surrounding portions 17 and 18 of the socket 3 and the inner side of the support rim 22, respectively.

[0055] like Figure 3 As shown, screws 25 extend through fixing holes 21 in the surrounding portion 18 and are screwed into or against the side walls of the mounting rail 100. Preferably, the screws are self-tapping screws that are screwed into the side walls of the mounting rail 100. This constrains the mounting rail 100 relative to the socket 3. In this way, for example, retraction of the mounting rail 100 from the socket 3 is inhibited.

[0056] The support rim 22 is shown as having a rectangular shape. The mounting rail 100 is shown as having a C-shaped cross section. The outer contour of the cross section of the mounting rail 100 matches the shape of the support rim 22.

[0057] Figure 4 Shown through Figure 3 As can be seen in this figure, the cantilever assembly is under a vertical load F. The load F is applied to the mounting rail 100 and transferred into the wall panel 2, which in this particular embodiment is fixed to the wall at its joint side 4.

[0058] The enclosing portions 17 and 18 interlocking with the mounting rail 100 form a first load-bearing connection. The supporting edge 22 interlocking with the mounting rail 100 forms a second load-bearing connection. These two separate connections result in a reinforced load-bearing connection between the bracket 1 and the mounting rail 100.

[0059] It will be appreciated that the vertical support provided by the flange profiles 9 and 10 of the bracket 1; Figure 4 The mounting orientation shown in , and the vertical load applied to the mounting rail 100, can be considered a preferred arrangement. However, it should be understood that a cantilever assembly including a wall mount bracket 1 according to the present invention is also capable of handling lateral loads and can be mounted in another orientation.

[0060] exist Figures 1 to 4 In the illustrated embodiment, the support rim 22 has dimensions such that the outer contour of the end portion of the mounting rail 100 fits onto the inner side of the rim 22. When the mounting rail 100 is mounted in the support rim 22, the inner side of the support rim then interlocks with the outer side of the end portion of the mounting rail 100. However, it is also conceivable that the rim 22 has smaller dimensions such that the rim 22 fits within the inner contour of the open end of the mounting rail 100. When the mounting rail 100 is mounted in the support rim 22, the outer side of the support rim then interlocks with the inner side of the end portion of the mounting rail.

[0061] In manufacturing Figures 1 to 4 In the method of the metal wall mount 1 shown, the metal wall mount is formed from a flat sheet metal blank, which is preferably made of pre-galvanized metal. In the steps of the method, a central opening is formed in the flat sheet metal blank, for example by punching it using a punch or by cutting it using a laser cutter. The upright edges can then be bent out of the plane of the sheet metal blank from the outer contour of the central opening; thereby forming the supporting edge 22. The central opening formed now defines the hole 23. The steps of forming the central opening and bending the upright edges can be separate steps as indicated above. Alternatively, the two steps can be combined in a single manufacturing step, for example when a stamping press is used.

[0062] In a further step of the method, the outer contour of the wall mount 1 in its unfolded state is removed from the sheet metal blank. This can be done, for example, by punching, for example using a punch, or by cutting, for example using a laser cutter.

[0063] In a further step of the method, the mounting holes 7, 8 and / or fixing holes 20, 21 are formed. This can be done, for example, by punching or cutting said holes 7, 8, 20, and 21 in a flat sheet metal blank.

[0064] In a further step of the method, the flange profiles 9 and 10 of the bracket 1 are formed by bending the sheet metal blank out of a plane about the bending lines 13 and 14, for example using a press. Figures 1 to 4 In the embodiment shown in , the resulting flange profiles 9 and 10 are tapered, which results in an increased bending stiffness of the socket 3 in the vertical direction. In a further step of the method, the flange profiles 9 and 10 can be bent so that they tilt towards each other from the proximal ends 11 and 12 towards the surrounding portions 17 and 18; thereby also providing further support for the socket in the transverse direction.

[0065] In a further step, the flange profiles 9 and 10 are formed into a profile having a U-shaped cross section at their distal end portions by bending the distal ends 15 and 16 multiple times. This forms enclosed portions 17 and 18, with the open sides of the U-shaped profile facing each other. Thus, the bending of the distal ends 15 and 16 is achieved in opposite directions. The U-shaped profile can be formed by implementing multiple bends using a single, more complex punch-and-die arrangement or a (series of) multiple punch-and-die arrangements.

[0066] The order of the method steps may differ from the order disclosed in the preceding sections.

Claims

1. A metal wall mount for mounting an elongated mounting rail as a cantilever to a wall or other supporting surface, wherein the wall mount is adapted to locate and retain an end portion of the mounting rail in the bracket and to secure the end portion to the bracket by means of at least one mechanical fastener, wherein the wall mount comprises: a wall plate having a wall engaging side for positioning against the wall or other supporting surface and a front side opposite the wall engaging side, wherein mounting holes extend from the front side to the wall engaging side for mounting the bracket to the wall or other supporting surface by means of male fasteners, Characterized in that the bracket further comprises: - a socket located on the front side of the wall plate for inserting the end portion of the mounting rail, the socket comprising at least two flange profiles integrally formed with the wall plate and having a proximal end connected to the wall plate and a distal end remote from the wall plate, wherein the flange profiles have surrounding portions at the distal ends, the surrounding portions being configured to together surround the end portion of the mounting rail so as to interlock with the end portion of the mounting rail to inhibit movement of the inserted end portion parallel to the wall plate, and wherein at least one of the surrounding portions has a fixing hole for passing a male fastener to fix the end portion of the mounting rail to inhibit retraction of the end portion from the socket, - a support rim integrally formed on the front side of the wall panel in the socket, the support rim being configured to interlock with the outside or inside of the end portion of the mounting rail so as to inhibit movement of the inserted end portion parallel to the wall panel.

2. The wall mount according to claim 1, wherein the support edge is formed as a curved edge of the hole in the plate.

3. The wall mounting bracket according to claim 1 or 2, wherein the flange profile is formed by bending. The wall mount bracket according to claim 1 , wherein the bracket is made by molding. 5 . The wall mount bracket according to claim 1 , wherein the flange profile members taper from the respective proximal ends toward the surrounding portion. The wall mount bracket according to claim 1 , wherein the flange profiles are inclined toward each other from the proximal end toward the surrounding portion.

7. The wall mount of claim 1, wherein the socket comprises two opposing flange profiles.

8. The wall mount according to claim 1, wherein the surrounding portion has a U-shaped profile, wherein open sides of the U-shaped profile face each other.

9. The wall mount of claim 1, wherein the support rim has a rectangular shape.

10. The wall mount according to claim 1, wherein the supporting edge is aligned with the surrounding portion of the flange profile.

11. The wall mount of claim 1 , wherein an inner side of the support rim interlocks with an outer side of the end portion of the mounting track.

12. The wall mount of claim 1, wherein an outer side of the support rim interlocks with an inner side of the end portion of the mounting track.

13. The wall mount of claim 1 formed from a sheet metal blank.

14. The wall mount of claim 13, wherein the sheet metal blank is pre-galvanized.

15. The wall mount bracket according to claim 4, wherein the bracket is made by casting.

16. A cantilever assembly comprising a wall mount according to any preceding claim and including a mounting rail which is inserted with an end portion into the socket and supported by the support rim of the bracket.

17. The assembly of claim 16, wherein the mounting rail has a C-shaped cross-section.

18. A method for manufacturing the metal wall mount according to claim 1, wherein: - providing a flat sheet metal blank; - punching a central opening having upright edges into the blank; - punching or cutting the outer contour of the unfolded stent from the blank; - Punching or cutting one or more mounting holes and one or more fixing holes; - bending the flange profile out of the plane of the sheet metal blank; - forming the flange profile as a profile having a U-shaped cross section at its distal end portion.

19. The method of claim 18, wherein the sheet metal blank is made of pre-galvanized metal.

Images