bracket

Abstract

A mounting bracket (10) of sheet material form comprises a spacer arm (24) spacing apart a foot region (12a) comprising apertures (20a, 20b), and a head region (12b) comprising apertures (14a). The mounting bracket (10) comprises a profiled sheet portion comprising corrugations (32, 34) comprising plateau regions extending in the extension of the spacer arm (24) from the foot region (12a) to the head region (12b). The plateau regions define a floor span perpendicular to the extension of the spacer arm. The corrugations (32, 34) comprise obtusely angled side walls (35) separating the plateau regions, and adjacent corrugations (32, 34) have a floor span of no less than 10 mm, providing a clearance region for location of fastener heads in a floor of a plateau region. The obtusely angled walls (35) enable nested stacking of two sheet profiles.

Description

[0001] Bracket

[0002] Field of the Invention

[0003] The present invention relates to mounting brackets, specifically to mounting brackets formed from sheet material, as used in fapade and roof cladding. Aspects of the invention relate to mounting brackets suitable for multiple different mounting systems. In some embodiments, the present invention relates to brackets that have been designed to be produced with less material, compared to a solid sheet material bracket, to provide a lower mass bracket.

[0004] Background

[0005] Mounting brackets for fagade and ceiling walls are used in great numbers within an installation, often using the same type of bracket, to support the load of cladding and other structures of a building.

[0006] The present invention seeks to provide improvements to the design and manufacture of such mounting brackets, and to provide a bracket that is more versatile for a wider range of applications.

[0007] Summary of the Invention

[0008] In accordance with a first aspect of the invention, there is provided a mounting bracket as defined in claim 1 , of sheet material form, comprising a spacer arm spacing apart a foot region and a head region opposite the foot region, wherein the head region comprises an arrangement of one or more apertures, and wherein the foot region comprises an arrangement of one or more apertures, wherein the mounting bracket comprises a profiled sheet portion comprising corrugations comprising plateau regions extending in the extension of the spacer arm from the foot region to the head region, the plateau regions defining a floor span perpendicular to the extension of the spacer arm, wherein the corrugations comprise obtusely angled side walls separating the plateau regions, and wherein at least two adjacent corrugations each have a floor span of no less than 10 mm.

[0009] The mounting bracket may be for use in horizontal and / or vertical support systems such as roof support systems and / or cladding systems.

[0010] The arrangement of apertures may be part of a fastening system using fasteners such as bolts, selfdrilling screws or self-tapping screws. Such apertures will be understood to be fastener apertures, whether or not they are used in an installation, and are typically of round or of obround shape, comprising either a circular perimeter or a perimeter comprising two parallel edges to provide a slot.

[0011] The apertures will be understood as extending through the thickness of the sheet material, open to both faces of the sheet material for receipt of a fastener structure of a fastener, such as a shaft. The

[0012] Version 2025-09-02 arrangement of apertures may comprise two or more spaced apart apertures. In some variants, a single aperture may provide multiple fastener locations, e.g. in the form of an elongate slot or other suitable aperture. The fastener locations and / or apertures may be spaced apart in the extension of the spacer arm, and / or perpendicularly to the extension of the spacer arm.

[0013] The corrugations may be made up of ridges and grooves, respectively, in the form of ribs, making up a profiled sheet portion extending along the length of the bracket. The profiled sheet portion, or at least a portion thereof, may extend into the foot region and into the head region. The corrugations may be rounded, in the manner of undulations, or polygonally profiled, in the manner of castellations, or combinations thereof including rounded side walls with plateaued surfaces.

[0014] The corrugations may be of a width defining a plateaued apex profile. The plateaued profile may provide an abutment surface for another member or component, such as a fastener, tool, and / or for a bracket-reinforcing structure. The floor of a corrugation will be understood as an inner surface of a corrugation, at the bottom thereof. The floor span, herein, is the free space between adjacent side walls, defining a distance transverse to the extension of the spacer arm, and may be considered the width of an inner plateau region.

[0015] The side walls, or web portions, will be understood as wall portions, viewed in profile or section, that extend along the sides of ridges and grooves and make up corrugations.

[0016] By obtusely angled, it is meant that the side walls are arranged with an open angle relative to each other, flaring outwardly. The obtusely angled walls are such that a like profiled sheet portion may be stacked onto the bracket, in a manner allowing a corrugation ridge formation of one profile to nest within a corresponding corrugation groove formation of another bracket of the same profile. This allows two sheet profiles to be used by nesting one sheet profile in another sheet profile, e.g., a reinforced sheet profile and a reinforcing sheet profile, to provide a double-profile reinforcement.

[0017] The corrugations are sufficiently open to permit nested stacking, by way of the obtusely angled profile, that a groove profile of one bracket may fit at least partially between two ridge profiles of another bracket, and, likewise, a ridge profile of one bracket may fit between two groove profiles of another bracket. The expressions “groove” and “ridge” are understood to encompass plateaued structures. Likewise, it will be appreciated that a corrugation formation providing a groove on one face of a bracket profile also provides a corresponding ridge or rib on the opposite face of the bracket profile.

[0018] Such stacked configurations may be used for reinforcing purposes, to make up a bracket from a reinforced sheet portion and a reinforcing sheet portion. The reinforced sheet portion may be a bracket of the invention. As will be appreciated, a reinforcing sheet profile may have the same profile shape as the reinforced sheet portion, although being of shorter configuration and often without head portion, to avoid interference with the head portion of the reinforced sheet portion.

[0019] Version 2025-09-02 Adjacent corrugations, herein, are two corrugations extending next to and parallel to each other. The plateau regions of the at least two adjacent corrugations are understood to lie on two different planes, e.g. one higher and one lower plane. The plateau regions of the adjacent corrugations may be parallel to each other.

[0020] In some embodiments, at least three adjacent corrugations each have a floor span of no less than 10 mm.

[0021] Three adjacent corrugations are understood as a group of three corrugations that extend parallel to each other with one central corrugation between two immediately lateral corrugations. The plateau regions of the three corrugations are understood to lie on two different planes, e.g. one central corrugation on a higher plane and two lateral corrugations on a lower plane. The plateau region of the central corrugation may be parallel to the two laterally adjacent corrugations.

[0022] In some embodiments, the corrugations are provided in the form of alternating ridges and grooves providing the plateau regions, wherein transition regions between adjacent ridges and grooves provide the side walls.

[0023] In some embodiments, the adjacent corrugations have a floor span of no less than 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, or no less than 16 mm.

[0024] An appreciation underlying the embodiment was that the floor span effectively defines a clearance on, and also on the underside of, a plateau region. A suggestion made in this disclosure is that corrugations are shaped with a sufficiently flat base or plateau floor, and dimensioned such that a fastener or bolt head may be attached. Specifically, the floor span may be chosen to accommodate a fastener head and a fastening tool. As such, the floor span is designed to provide a flat plateau as abutment for a fastener head between adjacent side walls. While it is appreciated that the required span may depend on the type of fastener and may also depend on the type of fastening tool, it was found that a span of at least 10 mm can accommodate for practical purposes a wide range of fastener systems. As such, the bracket arm may be formed without reinforcing “V” shaped ribs, and may be comprised only of trapezoidally profiled corrugations.

[0025] As such, fastener apertures may be located within a plateau region. The plateau regions may be wider than the cross-sections of the apertures in the valley span direction. In this manner, the one or more apertures of a connector system are surrounded by material of the plateau region, the plateau regions providing sufficient surface to accommodate a head of a fastener.

[0026] In some embodiments, the corrugations have a floor span of no more than 30 mm, 29 mm, 28 mm, 26 mm, 25 mm, 24 mm, 23 mm, 22 mm, 21 mm, or no more than 20 mm.

[0027] Version 2025-09-02 For instance, in some embodiments, the corrugations comprise three adjacent corrugations in the form of a valley-ridge-valley, each comprising a floor span in the region of 10-30 mm, e.g. a floor span of 15 mm, or each comprising a floor span of 20 mm, or each comprising a floor span of 25 mm.

[0028] In some embodiments, adjacent corrugations comprise a floor span differing by no more than 5 mm, 4 mm, 3 mm, 2 mm, or no more than 1 mm.

[0029] The group of adjacent corrugations may be two, three, four, five or more corrugations. The floor span of a group of adjacent corrugations may be the same. Thereby, adjacent plateau regions can be expected to have the same width, or practically the same width.

[0030] In some embodiments, a group of at least three adjacent corrugations comprises the same floor span.

[0031] In some embodiments, the mounting bracket comprises three corrugations between two opposite lateral edges.

[0032] A bracket in accordance with the embodiment may be understood as comprising only two grooves and a ridge between the grooves, wherein the ridge may provide a central spine. It will be appreciated that depending on orientation, the embodiment may be considered as having two ridges and one groove between the ridges. A bracket of this form may comprise three valley plateaus, one in the central corrugation (in the “underside” of the ridge) and one each in the two grooves (in the “floor” of the valleys).

[0033] As such, the mounting bracket may comprise no more than three plateau-region-providing corrugations between the lateral edges of the mounting bracket. The lateral regions may comprise a flange or rail along the lateral edge.

[0034] In some embodiments, the corrugations comprise a valley depth, the valley depth measured from ridge crest to trough floor, of no less than 3 mm, 4 mm, or no less than 5 mm.

[0035] The valley depth is defined as the vertical distance between the highest crest surface of a ridge and the floor surface of a valley.

[0036] In some embodiments, the corrugations comprise a valley depth, the valley depth measured from ridge crest to trough floor, of no more than 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or no more than 15 mm.

[0037] In some embodiments, adjacent corrugations comprise a valley depth differing by no more than 3 mm, 2 mm, or no more than 1 mm.

[0038] Version 2025-09-02 In some embodiments, a group of at least three adjacent corrugations comprises the same valley depth.

[0039] The plateau regions of the corrugations may be described as lying on two planes. As will be appreciated, the or each plateau region of each ridge may be on a first plane, and the or each plateau region of each valley may be on a second plane. The first and second planes may be parallel to each other.

[0040] In some embodiments, the bracket comprises an arrangement of one or more helping-hand clips.

[0041] In accordance with a second aspect of the invention, there is provided a mounting bracket of sheet material form, comprising a spacer arm spacing apart a foot region and a head region opposite the foot region, wherein the mounting bracket comprises a profiled sheet portion comprising corrugations extending in the extension of the spacer arm from the foot region to the head region, wherein the head region comprises an arrangement of one or more apertures, and wherein the bracket comprises an arrangement of one or more helping-hand clips, and wherein the corrugations comprise obtusely angled side walls suitable for nested stacking with a like profiled sheet portion.

[0042] In some embodiments, one or more helping-hand clips are located in valley regions of the corrugations, wherein, optionally, at least two helping-hand clips are located in two different valleys spaced apart by a ridge region.

[0043] In some embodiments, the helping-hand clips extend beyond plateau regions of their adjacent ridge regions.

[0044] In this manner, a ridge region or plateau region between helping-hand clips may be used as abutment surface, to temporarily hold a member such as a profiled beam between a helping-hand clip and a ridge apex region, or plateau. For instance, a central ridge and two flange portions may provide contact lines with the helping-hand clips.

[0045] In some embodiments, the head region comprises one or more connector elements of a first connector system and one or more connector elements of a second connector system, wherein the connector elements of the first connector system comprise recess structures on opposite edges of the sheet material, and wherein the connector elements of the second connector system comprise a plurality of spaced apart apertures.

[0046] In accordance with a third aspect of the invention, there is provided a mounting bracket of sheet material form, comprising a spacer arm spacing apart a foot region and a head region opposite the foot region, wherein the head region comprises one or more connector elements of a first connector system and one or more connector elements of a second connector system, wherein the connector

[0047] Version 2025-09-02 elements of the first connector system comprise recess structures on opposite edges of the sheet material, and wherein the connector elements of the second connector system comprise one or more apertures.

[0048] The first connector system and the second connector system are understood to provide different configurations, e.g. differently shaped connector elements. The presence of connector elements of a first connector system and connector elements of another, second connector system provides the mounting bracket with a multi-purpose capability. A bracket may comprise connector elements of one or more further connection systems, i.e. elements of a third connector system and so on.

[0049] The arrangement of apertures may be fastener apertures, and as such part of a fastening system using fasteners such as bolts, self-drilling screws or self-tapping screws. The fastener apertures may comprise at least two spaced apart apertures. The recess structures on opposite edges of the sheet material may be part of a snap-on system.

[0050] The recess structures on opposite edges may be offset in the extension of the spacer arm, e.g. a recess on one edge may be closer or further, relative to the foot region, than the opposite recess. Such recesses may be used with a snap-on rail connection system such as the Applicant’s Ashgrid (RTM) system described in United Kingdom patent publication GB2240558. The Ashgrid system provides a connection with a hollow profiled beam member comprising in-turned flanges providing a rail portion along a recessed track. The head region of the bracket can be inserted into the recessed track of such a hollow profiled member and levered such that the opposite recesses engage the inturned rail portions, by snapping in or clicking in.

[0051] In some embodiments, the mounting bracket comprises at least one central corrugation in the form of one of a ridge and groove, providing a spine structure flanked by two lateral corrugations in the form of the other of a ridge and groove, extending in the extension of the spacer arm from the foot region to the head region.

[0052] In such embodiments, the central corrugation, or the rib or groove making up the spine structure, respectively, may be a solid sheet structure, free of apertures, between the head region and the foot region.

[0053] In some embodiments, at least some of the one or more fastener apertures are located on a central corrugation.

[0054] The apertures may be located on a plateau region of the head end and of the foot end, surrounded by flats of the plateau region to provide an abutment for a fastener head. To this end, many embodiments will comprise apertures in a front region of the head end. In many embodiments, the apertures of the foot end are located centrally on the foot end between the bracket arm and the free foot end edge opposite the bracket arm.

[0055] Version 2025-09-02 The fastener apertures may be fastener apertures of a connector system, e.g. of the second connector system. For instance, the fastener apertures, being part of a second connector system, may be positioned between the recess structures of the first connector system.

[0056] In some embodiments, the mounting bracket comprises flange structures extending along lateral edges in the extension of the spacer arm from the foot region to the head region.

[0057] In most embodiments, flange structures are provided on opposite, outer edges of the bracket sheet structure. However, in some embodiments, a flange structure may be provided on only one outer edge of a bracket sheet.

[0058] The flange structures may be provided each in the form of a continuous rail structure extending along the bracket, extending from the foot region to the head region. The flange structures may extend along the length of the foot region. In embodiments comprising lateral recesses, e.g. to provide a snap-on connector arrangement, the flange structure may be interrupted by the recesses and / or may extend only from the foot region to the head region, and stop short of the recesses of the snap-on connector arrangement.

[0059] In some embodiments, the mounting bracket comprises a plurality of mass-reducing apertures along the spacer arm in a region without fastener apertures between the foot region and the head region.

[0060] The mass-reducing apertures are distinguished from apertures of connector elements in that they are incorporated to reduce the overall mass of the bracket.

[0061] In some embodiments, the plurality of mass-reducing apertures is located in plateau regions laterally of a central corrugation, wherein, optionally, the central corrugation is constituted by a continuous sheet between the fastener apertures.

[0062] In some embodiments, the mounting bracket comprises a network of beams along the spacer arm between the foot region and the head region.

[0063] In some embodiments, individual beams of the network of beams are located laterally of a central corrugation.

[0064] The beams may extend between the lateral flange portions and the spine structure. A such, the mass-reducing apertures may be located between the flange portions and the one or more spine structures. In this manner, reinforcing structures such as the spine or spines, and the flanges where present, are not provided with mass-reducing apertures, and are provided with apertures that may serve as connector element.

[0065] Version 2025-09-02 The brackets of the present disclosure may be made from solid, continuous sheet. Alternatively, brackets of the present disclosure may incorporate mass-reducing apertures, which are understood as apertures incorporated merely for the purpose of reducing the overall mass of the bracket. For instance, mass-reducing apertures may comprise irregular shapes and / or may be located in regions of the spacer arm between head end and foot end, i.e. shapes and / or regions a skilled person will recognise are not suited for accommodating a fastener or for affixing the bracket to a surface.

[0066] For a better understanding of a mass-reduced variants, the disclosure includes a method for defining a bracket shape producible by a sheet forming operation, the method comprising defining a bracket envelope volume defining the outer dimensions and a sheet thickness of a bracket; defining fixing regions of the bracket and a bracket arm region between the fixing regions; defining a sheet material shape comprising the fixing regions and the bracket arm region between the fixing regions; defining load conditions for the bracket; defining a termination criterion for iterative optimisation; performing iterative optimisation to modify the sheet material shape at least until the termination criterion is met, determining if the sheet material shape is a lattice structure, wherein, if the sheet material shape is a lattice structure, the method comprises proceeding to form a two-dimensional profile for a sheet material bracket; and wherein, if the sheet material shape is not a lattice structure, the method comprises altering the sheet thickness for the load condition until the sheet material shape is a lattice structure.

[0067] The method is intended for the design and manufacture of brackets formed from a sheet material, e.g. aluminium, steel, other suitable metal material sheets or suitable non-metal material sheets. Such a bracket will be understood to comprise fixing regions, at the head end and at the foot end, via which the bracket is mounted to an article or surface. Typically, the fixing regions are spaced apart by the spacer arm and comprise holes in the form of round or elongate apertures to receive a shaft of a fastener. The fixing regions may be one or more fastener apertures, and / or recesses of a connector system. However, the fixing region may also comprise clips, or so-called “helping-hand” structures, and may be used for temporary alignment and / or final fastening. One fixing region may comprise connector elements of two or more different fastening systems.

[0068] The bracket is understood to comprise a body between the fixing regions, herein referred to as bracket arm or spacer arm. For sheet material brackets, the bracket arm is of typically elongate form, comprising a flat or angled profile along its length, to space apart fixing regions of opposing ends of the arm. Being of sheet material, the bracket and arm are understood to have two opposite faces, the face-to-face distance defining the sheet thickness. The bracket thickness typically corresponds to the sheet thickness. The bracket or spacer arm may comprise, extending along its extension, reinforcing ribs, corrugations or the like.

[0069] The bracket is a unitary body comprising the arm spacing apart the fixing regions on opposite ends of the arm.

[0070] Version 2025-09-02 A bracket envelope, herein, is understood to be a perimeter or three-dimensional outer silhouette of a bracket volume, wherein no part of the bracket extends beyond the envelope. For a method defining a bracket shape, the envelope may define the maximum desired dimensions of a bracket. The bracket envelope may be a cuboid geometric shape, or may be a more complex shape. The method also defines a sheet thickness of the bracket structure within the bracket envelope. For a bracket formed to comprise corrugations or ribs, the method may define a sheet thickness of a flat structure, prior to forming corrugations, and may also take into account a bracket thickness after forming corrugations, e.g. the valley-to-ridge thickness.

[0071] By performing an iterative design process, the shape of the bracket may be altered, e.g. by altering a lattice of trusses, thickness and length of material, and / or size and shape of apertures, etc. In addition, the outer dimensions of the shape may be altered, by reducing and increasing them. It will be understood that increasing outer dimensions may be permitted provided the bracket dimensions remain within the bracket envelope. The method may add, move and / or replace material, iteratively, within the bracket envelope.

[0072] The method may comprise defining preserve regions, such as the fixing regions, that are not permitted to be reshaped by the iterative process. For instance, position, shape and size of fixing regions may be defined as preserve regions. Likewise, a minimum perimeter thickness of solid material around fixing regions may be defined as preserve region. Preserve regions may include regions defining sufficient material, and / or one or more sufficiently large sheet areas, for ribs or bends to be formed.

[0073] For instance, preserve regions may comprise elements of a first connector system and elements of a second connector system, such as recess structures on lateral edges of the bracket and / or apertures within the plane of the bracket shape. Preserve regions may include ribs, spine formations and / or lateral flange structures, that are to be formed without lattice structure. For instance, a central rib or spine formation, and / or wide walls of corrugations, may be defined as a preserve region.

[0074] A lattice structure, herein, is understood to be a structure comprising less material than a solid block, e.g., comprising regions without material and / or from which material was removed, by incorporating holes or apertures. The presence of a lattice structure can be determined by identifying the presence of a beams or trusses separated by holes or apertures. In some embodiments, determining the presence of a lattice structure comprises determining the presence of beams that intersect in the manner of involutes. In some embodiments, determining the presence of a lattice structure comprises determining the presence of curved beams. The step of determining the presence of a lattice structure may comprise determining if the lattice structure is a low compliance structure, such as a Michell structure or cantilever truss structure.

[0075] As will be appreciated, the shape of load-bearing lattice structure may be defined computationally by an iterative design process, with reference to load conditions or stress conditions.

[0076] Version 2025-09-02 It was found that an iterative optimisation process may yield considerably different results for similar input parameters. A further observation by the inventors was that iterative optimisation may often lead to the formation of characteristic low mass load-bearing structures, such as Michell structures, however that this is not always the case. In simplified terms, it is possible that an optimisation is ‘stuck’ on a wrong path, producing a sub-optimal candidate result.

[0077] An observation leading to designs used in some embodiments was that shapes for brackets defined by iterative design methods often tend to result in a lattice structure, typically a so-called low compliance or so-called lowest compliance shape. Such shapes comprise a characteristic pattern, or lattice, of trusses or beams, often including intersecting beams, curved involute structures, and apertures of triangular and / or quadrilateral form, the quadrilaterals typically of rhomboid or diamond shaped form, with curved sides, between the vertices of intersecting trusses.

[0078] It was found that a good lower mass lattice result often evolves into lower mass structures comprising curved trusses, or truss segments that are straight and arranged, as a series of segments, to follow a curve, intersecting with other curved trusses at angles close to a right angle, in the manner of involutes. The method may be carried out until at least one two-dimensional profile has been generated that comprises a lattice structure comprising involutes, wherein the involutes may be present in the form of a series of straight segments.

[0079] An appreciation underlying the development of some embodiments was that for certain load conditions and bracket envelopes, an iterative design process may result in shapes that do not resemble a lattice, for instance may result in a solid body sheet with complex outer contours. In that case, adjusting the sheet thickness for the same load conditions was found to be more likely to lead to a lattice structure.

[0080] The sheet thickness is understood as the face-to-face distance between two opposite faces of a bracket body, prior to formation of ribs or corrugations.

[0081] For the purpose of an iterative design process, a design method may define a starting shape as starting point, and a termination condition. The termination condition will be understood to be a parameter defining when an iterative process may be stopped, upon fulfilling the termination condition. To provide illustrative examples, the termination condition may be a maximum or minimum bracket mass, minimum width of trusses, and others.

[0082] The method may comprise repeating the optimisation to create different candidate profiles for the load conditions; and selecting a candidate profile as the two-dimensional profile.

[0083] Version 2025-09-02 The method may comprise creating a two-dimensional stencil from the sheet material shape, the two- dimensional stencil suitable for incorporation as the two-dimensional profile of a sheet material bracket.

[0084] An iterative design process of the method may result in the creation of a three-dimensional shape, specifically a shape with varying profile in the face-to-face orientation perpendicular to the planar extension of the arm. It has been observed that currently available software packages tend to create a three-dimensional shape. Even if forced to create a two-dimensional shape, existing software packages tend to design a three-dimensional shape extending in two dimensions, in the form of a lattice of trusses that, while not overlapping, tend to comprise a rounded cross-section, rather than a rectangular profile.

[0085] In order to facilitate the use of the bracket shape as a stencil for the manufacture of a sheet material bracket, the method may comprise a step of re-shaping the bracket material shape, if necessary, e.g. by flattening, to create a two-dimensional stencil that can be reproduced by an axial sheet forming operation, such as laser cutting or pressing.

[0086] It will be appreciated that the stencil may be suitable for a predetermined sheet thickness, or range of sheet thicknesses. As such, the bracket shape may be presented in the form of an output comprising a nominal sheet thickness. The output may be provided in the form of metadata or other suitable format.

[0087] The method may comprise defining a candidate lattice structure between the fixing regions; and using the candidate lattice structure as starting point for iterative optimisation of the bracket arm region of the sheet material shape.

[0088] Iterative design processes can be successful in defining a lattice structure. However, such iterations can be time consuming with present computational resources, particularly if the computation has to be repeated several times until a suitable sheet thickness has been identified. The issue can be exacerbated when it is desired to calculate optimum shapes for a range of brackets. In this regard, it is not unusual that brackets of one application type may be provided by a supplier in several different lengths, e.g. 12cm, 14am, 16cm, 18cm, 20cm, 22cm, 24cm, etc, each length resulting in a different low compliance structure.

[0089] During the development of embodiments, it was found that an iterative process to define a bracket shape can be shortened by using, as a starting point for the iterative process, a lattice structure.

[0090] For instance, a candidate lattice structure may be an estimated lowest compliance structure for a similar shape, e.g. a known lowest compliance structure of a 12 cm (arm length) bracket, stretched (computationally) in one dimension to conform to a 20 cm (arm length) bracket. Such a “stretched” shape, used as a starting point, is less likely to be found via iterative design directly. However, the

[0091] Version 2025-09-02 inventors found that this can nonetheless serve as a better starting point than a solid sheet material starting point.

[0092] Furthermore, the starting point may be an estimated low compliance structure with a three- dimensional lattice, e.g., calculated with one software package, and to be used as the starting point for an iterative design process in another software package.

[0093] The candidate lattice structure may comprise an estimated lowest compliance structure between the fixing regions. In relation to a load bearing bracket, it will be understood that compliance refers to a bracket’s ability to withstand stress, a lower compliance resulting in better load bearing properties.

[0094] The candidate lattice structure may comprise a Michell structure. Michell structures, sometimes also referenced as so-called Prager trusses, are structures that aim to utilise the minimum material necessary for a frame or truss structure compared to other structures under the same applied forces.

[0095] The candidate lattice structure may comprise a cantilever truss structure.

[0096] The candidate lattice structure may be selected from a database of pre-calculated minimum compliance structures.

[0097] The method may comprise using multiple candidate lattice structures to generate multiple candidate two-dimensional stencils. The use of a termination criterion may result in multiple different shapes, which may be generated for presentation to a user to select a preferred shape.

[0098] Iterative optimisation may comprise generative design optimisation and / or topology optimisation.

[0099] Iterative optimisation may comprise thinning, within the two-dimensional plane, one or more truss structures of the lattice structure. The thinning is understood to affect the truss width for a given sheet thickness, while maintaining the sheet thickness of the truss.

[0100] Iterative optimisation may be carried out with criteria requiring the maintaining of a minimum truss width.

[0101] The method may comprise, if a minimum truss width of a candidate truss cannot be maintained, removing the candidate truss and permitting widening of remaining truss structures, within the two- dimensional plane.

[0102] Iterative optimisation may comprise widening, within the two-dimensional plane, one or more truss structures. The widening is understood to affect the truss width for a given sheet thickness, while maintaining the sheet thickness of the truss.

[0103] Version 2025-09-02 The lattice structure may comprise symmetry. The lattice structure may comprise an axis of symmetry extending along the arm of the bracket. The axis of symmetry may extend centrally along the arm of the bracket.

[0104] Iterative optimisation may comprise removing symmetry to create an asymmetric sheet material shape.

[0105] The lattice structure may be a two-dimensional profile extending perpendicularly through a face-to- face thickness of the sheet material shape.

[0106] Iterative optimisation may comprise maintaining a two-dimensional profile extending perpendicularly through the face-to-face thickness of the sheet material shape.

[0107] Iterative optimisation may comprise creating at least two candidate outputs, each candidate output comprising a different two-dimensional stencil. The different outputs may be presented to a user for user selection. The different outputs may be used as an input for further analytical processes.

[0108] A method of forming a bracket may comprise providing a sheet material; incorporating, in the sheet material, a lattice structure corresponding to a sheet material shape defined by the methods described before; and forming the sheet material to provide a bracket.

[0109] The lattice structure may be a minimum compliance structure, may comprise a Michell structure and / or may comprise a cantilever truss structure. The bracket formed by the method may be characterised by curved arms intersecting with other curved arms in the manner of involutes. The bracket formed by the method may be characterised by a network of straight beam segments arranged in series to follow a curvature. A feature of such beam segments following a curvature is that the included angle between two straight beam segments is less than 180°.

[0110] The bracket may have a sheet thickness determined by the method of defining a lower mass bracket.

[0111] The step of forming a lattice structure may comprise removing material from the sheet material, which may optionally comprise laser cutting and / or press forming.

[0112] A bracket so formed is understood to comprise a lattice structure incorporated in the form of a two- dimensional profile extending between fixing regions of the bracket, and the two-dimensional profile may thereby incorporate one of a Michell structure and a low compliance cantilever structure.

[0113] The bracket may have a sheet thickness at which the Michell structure or low compliance structure are prominent. The lattice structure may be characterised by the presence of curved beams, and / or curved and / or straight or beam segments following a curvature, intersections of such beams and / or

[0114] Version 2025-09-02 beam segments, and beams joining other beams in the form of involutes. As such, the bracket may be distinguished from brackets with solid sheet faces.

[0115] In accordance with a fourth aspect of the invention, there is provided a building structure comprising a walling system or roof system mounted using a plurality of brackets, according to any one of the embodiments of the first aspect, second aspect, and / or third aspect.

[0116] Any one or more features described in relation to the embodiments of the first aspect, second aspect, and third aspect may be combined with any one or more features of the respective other aspects to form embodiments thereof. Any one of the features of the first, second and third aspect, and combinations of such features, may be incorporated in embodiments of the fourth aspect.

[0117] Description of the Figures

[0118] Exemplary embodiments of the invention will now be described with reference to the Figures, in which:

[0119] Figure 1 is an isometric view illustrating a multi-purpose bracket;

[0120] Figure 1 A shows a schematic cross-section 1 A of Figure 1 ;

[0121] Figure 1 B illustrates depth and width dimensions of plateau regions of corrugations;

[0122] Figure 2 is an isometric view illustrating another side of the Figure 1 bracket;

[0123] Figure 3 is an isometric view illustrating a helping-hand bracket;

[0124] Figure 3A shows a schematic cross-section 3A of Figure 3;

[0125] Figure 3B illustrates, schematically, a nested arrangement of two sheet profiles;

[0126] Figure 4 is an isometric view of a lower-mass version of the Figure 1 bracket;

[0127] Figure 5A illustrates a reference Michell structure;

[0128] Figure 5B is a schematic visualisation of a bracket incorporating a Michell structure;

[0129] Figure 6 is an isometric view of a lower-mass version of the Figure 3 bracket;

[0130] Figure 7 is an isometric view illustrating a low-compliance bracket shape;

[0131] Figure 8 is a side view illustrating the Figure 7 shape;

[0132] Figure 9 is a first bracket shape created via an iterative design process;

[0133] Figure 10 is a second bracket shape created via an iterative design process;

[0134] Figure 11 is two-dimensional stencil created from the Figure 9 shape;

[0135] Figure 12 is two-dimensional stencil created from the Figure 10 shape; and

[0136] Figure 13 is a flow chart of an exemplary method of forming a bracket.

[0137] Description

[0138] Figures 1 and 2 show a mounting bracket 10 of sheet material form, comprising a foot region 12a, a head region 12b, and a spacer arm 24, the head region 12b being opposite the foot region 12a. The head region 12b, the spacer arm 24 and the foot region 12a are integral parts of a unitary bracket 10.

[0139] Version 2025-09-02 The head region 12b and the foot region 12a are examples of fixing regions of the bracket 10, and the spacer arm 24 is an example of a bracket arm region between the fixing regions.

[0140] Being of sheet material form, the bracket 10 comprises a planar extension defining the extension of the spacer arm 24. The foot region 12a is provided by a bent end portion of the of the bracket 10, here bent perpendicularly to the planar extension of the spacer arm 24. The foot region 12a comprises an arrangement of, here, three mounting holes 14a, constituting an example of a fixing region.

[0141] The head region 12b comprises a configuration permitting attachment of different connection arrangements, including holes and a snap-on profile, the connection arrangements allowing one of several (here: two) connection systems to be attached to the head region 12b.

[0142] A first connector arrangement 16 is provided by a snap-on profile, comprising two recesses 16a, 16b on opposite edges of the sheet material. The snap-on profile comprises a first recess 16a, here a proximal recess 16a located proximal with reference to the foot region 12a. Further, the snap-on profile comprises a second recess 16b, here a distal recess 16b located distally of the foot region 12a. The recesses 16a, 16b are each located adjacent a tapering wing 18a, 18b, the tapering wings 18a, 18b extending perpendicularly to a plane of the mounting bracket 10 and being thinner at the distal end of the head region 12b. One of the recesses 16a, 16b (here the first recess 16a) comprises an undercut 17 extending underneath the tapering wing, here into the wing 18a, to provide a rotation-inhibiting feature for a beam to be provided. The recesses 16a, 16b and the tapering wing formation 18a, 18b provide a snap-on or lock-on arrangement for roof rails such as the Applicant’s Ashgrid (RTM) mounting system, described in United Kingdom patent publication GB2240558, and constitute herein an example of connector elements of a first connector system.

[0143] A second connector arrangement 20 is provided in the form of a plurality of, here, two spaced apart mounting holes 20a, 20b, providing here an example of connector elements of a second connector system. The mounting holes 20a, 20b may be used as mounting locations to receive fasteners to attach a vertically extending component such as a rail or other cladding component. The mounting holes 20a, 20b are between the recesses 16a, 16b.

[0144] The connector elements of the first and second connector systems are different from each other, and / or for different mounting systems. A skilled person familiar with different roof and wall cladding systems will recognise that the mounting holes 20a, 20b are not part of a connection formed using the recesses 16a, 16b, and vice versa, the recesses 16a, 16b or wing formations 18a, 18b are not part of a connection relying on the mounting holes 20a, 20b. A skilled person will appreciate that the presence of the holes 20a, 20b and of the recesses 16a, 16b indicate that the bracket 10 is to be used with different mounting systems, the holes 20a, 20b being suited for fastener systems, such as bolts, self-drilling screws or self-tapping screws, and the recesses 16a, 16b being suited for a snap- on connection systems. Connector elements such as the tapering wings 18a, 18b and / or the

[0145] Version 2025-09-02 undercut 17 may be recognised as stabilising features or anti-rotation features to engage a corresponding beam profile, such as an open box profile.

[0146] The presence of both a first connector arrangement 16, here in the form of a snap-on or lock-on head region comprising two opposite recesses 16a, 16b, and a second connector arrangement 20, here in the form of an arrangement of mounting holes 20a, 20b in a planar portion provided by a plateau region of the head region 12b, provides a more versatile bracket.

[0147] Figure 1A illustrates, schematically, a profile section of a plane 1A through the spacer arm 24, corresponding to the plane 1A in Figure 1. The bracket 10 comprises an arrangement of corrugations 30 formed from a castellated profile, here plateaued corrugations 30 profiled in the manner of ridges 32 and grooves 34 separated by side walls 35. The bracket 10 comprises at least one main ridge 32, here a central ridge, flanked, by two grooves 34, the ridge 32 and the grooves 34 extending along the length of the bracket 10 from the foot region 12a to the head region 12b in the extension of the spacer arm 24. The main ridge 32 provides a spine 36 extending into the head region and extending, here, between the two opposite recesses 16a, 16b. The ridge 32 and groove 34 have the same valley span, i.e. a span between adjacent side walls 35, in a direction perpendicular to the extension of the bracket. The span of each corrugation structure is, here, 20 mm, although in some embodiments the span may be a value from the range from no less than 10 mm to no more than 30 mm, or from a range of 15 mm to 25 mm. The depth of each valley, measured from ridge crest to valley floor, is, in this example, 5 mm. The depth may be a value from 3 mm to 15 mm. In this manner, each corrugation top of a ridge, and each floor of a groove, can be used as abutment surface for a fastener head, to be engaged from either side. Specifically, the arrangement of plateaued valley floors allows fastener heads to be accommodated within the floor span of a corrugation. In the illustrated embodiment, the depth of each corrugation structure is the same. In this manner, the apertures located on a plateau region are surrounded by a flat plateau structure, permitting a wide range of fasteners to be affixed. The span is preferably chosen such that a wide range of fastener heads can be attached either on top of a ridge or, likewise, within a valley.

[0148] Furthermore, the bracket comprises two lateral ridges at the lateral edges, providing two flange portions 33. The ridges 32 are of even height, relative to the grooves 34. Correspondingly, the plateaus of the flange portions 33 are level with the plateau of the spine 36. In this manner, plateaus or faces of the flange portions 33 and of the main ridge 32 may be used as spaced-apart abutment surfaces for a planar structure such as a beam profile.

[0149] Figure 1 B illustrates a valley depth and floor span of a single corrugation. A valley depth D is defined as difference between ridge crest C, corresponding to the plane of the plateaued regions 32, and the valley floor or through floor F. A floor span W is defined as the width defined by a plateau region (in Figure 1 B, the plateau region 34) between two adjacent side walls 35. The floor span W is intended to accommodate a fastener head in a manner allowing the fastener head to abut the floor of the plateau region. The floor spans Wi and W2of two adjacent corrugations may be the same or differ

[0150] Version 2025-09-02 by no more than a few millimetres. The valley depths Di and D2of two adjacent corrugations may be the same, albeit the valleys are open to opposite sides, or differ by no more than a few millimetres.

[0151] The mounting holes 20a, 20b are arranged in spaced-apart formation in a plateau region of the spine 36. As will be appreciated, a reference to grooves or ridges depends on the orientation of the bracket, but for a given face, the presence of corrugations results in the presence of valleys or ridges. For instance, a structure located in a valley is understood to be located on the ‘underside’ of the corresponding ridge on the other face. The corrugations comprise side walls 35 between the grooves and ridges that are obtusely angled, relatively to the adjacent flats or apex regions, thereby providing a nestable profile. With reference to Figure 3B, which schematically shows two profiles 40 and 41 , the obtusely angled side walls permit a nested stacking of two like profiles 40, 41 if desired, e.g., to reinforce a bracket. As will be appreciated, a reinforcing bracket profile, such as a profile 41 , may not necessarily comprise a head portion.

[0152] The spine 36 provided by a central ridge 32 serves to reinforce the head region 12b in the region of the mounting holes 20a, 20b. To this end, the sidewalls 35 of the central ridge 32 or spine 36 also extend in the head region 12b. As illustrated in Figures 1 and 2, the central ridge 32 or spine 36 and its immediate sidewalls 35 extend into the head region 12b, between the recess 16a, 16b and the apertures 20a, 20b. Each of the mounting holes 20a, 20b is surrounded by a flat, planar portion of the plateau of the spine 36. As will be appreciated, the bracket 10 may be used as snap-on bracket using the first connector arrangement 16. In that case, the mounting holes 20a, 20b may not be used throughout the service life of the bracket 10, and so the presence of a strengthening formation such as the spine 36 is believed to improve the load rating of the bracket for a wider range of application scenarios despite the presence of an unused fixing location such as the unused connector elements.

[0153] Figure 3 illustrates a mounting bracket 40 of sheet material form, comprising a foot region 42a, a head region 42b, and a spacer arm 54, the head region 42b being opposite the foot region 42a. The head region 42b, the spacer arm 54 and the foot region 42a are integral parts of a unitary bracket 40. The head region 42b and the foot region 42a are further examples of fixing regions of a bracket, and the spacer arm 54 is an example of a bracket arm region between the fixing regions.

[0154] The spacer arm 54 defines a planar extension of the bracket 40 and the foot region 42a is formed by a portion bent perpendicularly to the planar extension. The foot region 42a comprises an arrangement of holes 44a providing fastener locations.

[0155] The head region 42b is formed in the manner of a cladding support system, comprising a main mounting region 50 comprising an arrangement of mounting holes 50a, 50b, 50c, including elongate slots 50b, 50c permitting some degree of movement for adjusting a fastener position. The elongate slots 50b, 50c extend, here, in a direction perpendicular to the extension of the spacer arm 54. For a bracket arm 54 installed to project horizontally, the sheet oriented vertically, the slots 50b, 50c are

[0156] Version 2025-09-02 understood to permit vertical repositioning. The bracket 40 comprises, as a further part of the head region 42b, a helping-hand arrangement 46 comprising two helping-hand clips 46a, 46b. A skilled person will recognise helping-hand clips as temporary mounting locations for, usually, temporarily holding rails in a manner permitting repositioning before fastening in a final position using the mounting holes 50a, 50b, 50c of the main mounting region 50. The helping-hand clips will typically be expected to be open in the direction of the corresponding mounting holes 50a, 50b, 50c, although the clips may be set further back from the head region of the bracket. It will be understood that the arrangement of three mounting holes 50a, 50b, 50c is exemplary and any other number of mounting apertures of round or elongate form may be provided.

[0157] Figure 3A illustrates, schematically, a profile section through the spacer arm 54, corresponding to the plane 3A in Figure 3. The bracket 40 comprises an arrangement of corrugations 60, here plateaued corrugations 60 profiled in the manner of ridges 62 and grooves 64. The side walls 65 between the ridges 62 and grooves 64 are obtusely angled, permitting a nested stacked arrangement, as illustrated in Figure 3B. Figure 3B shows, schematically, a first sheet profile, corresponding to a bracket 40, to be reinforced, and a second sheet profile 41 , being a profile of identical to the first sheet profile and used as a reinforcing profile for the first sheet profile.

[0158] The bracket 40 comprises at least one main ridge 62 flanked by two grooves 64, the ridge 62 and the grooves 64 extending along the length of the bracket 10 in the extension of the spacer arm 54. The main ridge 62 provides a spine 66 or rib extending into the head region 42b and extending, here, between two helping-hand clips 46a, 46b. One of the mounting holes 50a is located on a plateau region of the spine 66. At least one helping-hand clip, and here each helping-hand clip 46a, 46b, is located in a groove 64 and flanked by a ridge 62 either in the form of a spine or rib, or in the form of a lateral flange. The helping-hand clips 46a, 46b protrude sufficiently from the grooves 64 to allow a sheet member to be clamped between the clips 46a, 46b and a plane defined by the plateau regions of the spine 66 and the lateral flange portions 62. The ridge 62 and each groove 64 have the same span in a direction perpendicular to the extension of the bracket, and their dimensions, as well as variations thereof, may correspond to the dimensions and ranges described above in relation to the ridge 32 and grooves 34 of Figures 1 A and 1 B.

[0159] The spine 66 provided by a central ridge 62 serves to reinforce the head region 42b in the region of the helping-hand clips 46a, 46b.

[0160] The spacer arm 54 and the foot region 42a of the bracket 40 may be of the same design as the spacer arm 24 and the foot region 12a of the bracket 10. As such, the brackets 10 and 40 may be manufactured from a corrugated sheet of the same design. An aspect underlying the development of the bracket was that a common bracket profile, such as a profile illustrated schematically in Figures 1A, 1 B, and 3A, may be used in the manufacture of different brackets types, such as the multiconnector system bracket of Figure 1 , or a helping hand bracket of Figure 3.

[0161] Version 2025-09-02 Figure 4 illustrates a bracket 10a incorporating mass-reducing apertures to reduce the overall mass of the bracket. The bracket 10a is similar to the bracket 10, comprising a foot region 12a and a head region 12b constituting fixing regions, and a spacer arm 24a constituting a bracket arm region between the fixing regions. The mass-reducing apertures provide a lower-mass bracket compared to the bracket 10. As will be appreciated, mass-reducing apertures are distinguished from functional fixing regions and unused fixing regions, such as the above-mentioned fastener apertures, as having been formed for the purpose of reducing the overall mass of the bracket 10, and are not intended to provide mounting locations. As such, mass-reducing apertures are characterised by irregular shapes other than round holes or oblong slots, and by their location partway along a spacer arm.

[0162] The head region 12b comprises a first a connector arrangement 16 comprising lateral recesses 16a, 16b, as described in relation to the bracket 10, and a second connector arrangement 20 comprised of a plurality of apertures 20a, 20b. The first and second connector arrangements may allow the bracket 10a to be used with a snap-on mounting system and alternatively with a fastener-based mounting system.

[0163] The bracket 10a incorporates a lower-mass structure 70 along a portion 71 of the spacer arm 24a. The foot region 12a and the head region 12b are for the purposes of this description the same as those of the bracket 10 and so the description thereof is not repeated. The lower mass structure 70 is provided by an arrangement of apertures 72 defined as the holes defined by the interstitial spaces, free of sheet material, in a network or lattice of beam structures 74, the beam structures constituting trusses or truss segments.

[0164] The beam structures 74 are, here, straight arms that are aligned in a sequence of beam portions, or as a series of truss segments, arranged to follow a curvature. The curvature is illustrated in Figure 4 in the example of one of the beam structures 74a, which comprises a first beam portion 74a1 located between the spine 36, and a lateral flange 33. The beam structure 74a comprises a second beam portion 74a2 extending between the spine 36 and another lateral flange 33, the first beam portion 74a1 and the second beam portion 74a2 being arranged in end-to-end arrangement along a beam curvature indicated by a dashed line in Figure 4. The individual beam portions, e.g. 74a1 and 74a2, are angled relative to each other at less than 180 degrees.

[0165] The beam structures 74 have been defined computationally by determining low-compliance beam structures. To provide a visual illustration, Figure 5A shows a generic Michell structure 80 as an example of a load-optimised or stress-optimised cantilever structure. The Michell structure 80 comprises curved beams 84 defining a lattice and free regions 82 between the beams 84. The beams 84 are curved and their intersections arranged in the form of involutes. The free regions 82 provide quadrilateral and sometimes triangular apertures having irregular geometry as defined by the beams 84.

[0166] Version 2025-09-02 Figure 5B illustrates a Michell structure 80a in which curved beams are replaced by straight beam segments 84a, or truss segments, arranged in an end-to-end series such as the beam 74a of Figure 5B, and aperture regions 82a are defined between the beam segments 84a. The free spaces 82a define a pattern, locations and / or shapes of irregularly shaped apertures 72 to be incorporated in the bracket 10a. In this manner, the bracket 10a incorporates a lower mass structure, here a Michell structure, by way of apertures 72 and beam segments 74. In this example, the lateral flanges 33 and the spine 36, have been defined as preserve regions, such that the apertures 72 are formed only in the valleys 34, between the lateral flanges 33 and the spine 36. The bracket 5B is characterised by the presence of irregularly shaped quadrilateral apertures and / or triangular apertures, and by the presence of beam segments, which may be curved or, as illustrated, straight and arranged along a curvature. The spine 36 and the flanges 33 are provided as solid structures interrupting the apertures of the lower mass structure.

[0167] Figure 6 illustrates a bracket 40a, here in the form of a helping-hand bracket, incorporating massreducing apertures to reduce the overall mass of the bracket. Similarly to the bracket 40, the bracket 40a comprises a foot region 42a, a head region 42b, constituting fixing regions, and a spacer arm 54a, constituting a bracket arm region, the head region 42b comprising a main mounting region 50 and a helping-hand arrangement 46.

[0168] The bracket 40a corresponds to the helping-hand bracket 40, and so only modifications in a lower- mass region 70a along a portion 75 of the spacer arm 54a are described for Figure 6. The spacer arm 54a incorporates apertures 76 that result in a lower mass of the bracket 40a compared to the bracket 40. The apertures are defined as locations between beam structures 78 or truss segments. The beam structures are, here, straight beams segments that are aligned in a sequence of beam portions, or as a series of truss segments, arranged to follow a curvature. As illustrated in Figure 6, a first beam portion 78a1 is located between the central rib, constituted by the spine 66, and an external flange. Another beam structure is provided by a second beam portion 78b1 and a third beam portion 78b2, the second beam portion and the third beam portion being arranged in end-to- end arrangement along a beam curvature indicated by a dashed line. A further beam structure is provided by a fourth beam portion 78c1 and a fifth beam portion 78c2, the fourth and fifth beam portions being arranged as series in end-to-end arrangement, following another beam curvature indicated by a dashed line.

[0169] The beam structures 74 (Figure 4) and 78 (Figure 6) may have been defined computationally by determining a low-compliance beam structure, here designed to correspond to a Michell structure, or by determining regions selected from a Michell structure, as described above in relation to Figures 5A and 5B. As illustrated in Figures 4 and 6, the beam structures 74, 78 are arranged as a lattice or network of intersecting truss segments, and the apertures 72, 76 are provided by irregularly shaped apertures in the free spaces defined between the lattice beams. The apertures 72, 76 have irregular geometric shapes, e.g. irregular triangular shapes and / or irregular quadrilateral shapes. The central rib, in the form of a spine 36, 66, and the lateral flanges 33, 62, are not provided with apertures in the

[0170] Version 2025-09-02 region of the spacer arm. Likewise, in the illustrated embodiments, the sidewall structures 35, 65 are not provided with mass-reducing apertures. At least a few of the beam structures 74,78 intersect with other beam structures 74,78 to provide an improved load-bearing capacity.

[0171] Exemplary methods for determining a lattice or network of a lower mass structure are described below with reference to Figures 7 to 13.

[0172] Figures 7 and 8 illustrate an isometric view and a side view, respectively, of a bracket 110 comprising a first end 112a and a second end 112b, the first end 112a comprising fixing regions 114a, the second end comprising fixing regions 114b, and an arm 116 between the fixing regions 114a, 114b. The arm 116 will be understood to be a load-supporting structure. To provide an illustrative example, the bracket 110 may be a mounting bracket to support a fagade component, such as a cladding panel, an upright beam or a transverse beam, such as mullions or transoms, and other fagade and roof structures. As illustrated in Figures 7 and 8, the fixing regions comprise connector elements of a first connection system, here in the form of lateral recesses, and connector elements of second connection system, here in the form of two apertures.

[0173] The fixing regions 114a and 114b allow the bracket 110 to be connected to an article or to a surface, such as an existing building structure. The bracket 110 comprises a lattice structure 120 as an example of a lower-mass structure, here in the form of a so-called Michell structure. The Michell structure comprises a first outermost truss 122a, a second outermost truss 122b, a lattice of trusses 124 with intersections and involutes defining apertures 126 between the trusses.

[0174] The bracket 110 is a sheet material bracket, such as a sheet metal bracket formed from aluminium or other suitable materials. The bracket 110 may be formed by providing a sheet material, cutting the shape of the bracket from the sheet material, and forming the cut material, for instance by bending, to create a three-dimensional bracket shaped from a planar sheet of material. Alternatively, and / or in addition, a sheet material may be formed to a three-dimensional shape before a lattice shape is cut into it. Cutting operations may be performed before, during, and after a forming process.

[0175] The lattice structure 120 of the arm 116 fits within an envelope 128 (see Figure 8) defining an outer perimeter of the bracket 110. Relative to the outer perimeter of the envelope 128, the lattice structure 120 comprises less material due to the apertures 126 and the smaller silhouette of the body within the outermost trusses 122a, 122b.

[0176] The lattice structure 120 between the fixing regions 114a and 114b comprises mirror symmetry along the cantilever axis of the arm 116, however this is not necessarily a requirement of all embodiments.

[0177] The lattice structure 120 may have been determined using iterative optimisation, for instance using generative design, to determine a lowest compliance structure for a given pre-determined load condition, fixing regions 114a, 114b and given envelope 128. The inventors observed that a good

[0178] Version 2025-09-02 result tended to be created when the lattice structure so created resembled a Michell structure, or low-compliance cantilever structure.

[0179] During the development of embodiments of the invention that incorporate a lower mass structure, it was found that iterative optimisation may not always lead to a low compliance structure for a predetermined load condition. Without wishing to be bound by theory, it is believed that a larger sheet thickness, in relation to a given load, allows such algorithms to create single-beam structures, whereas a thinner sheet, in relation to a given load, tends to result in sheet bodies with little material reduction.

[0180] By altering the sheet thickness, as part of iterative optimisation and / or as part of different optimisation runs, for a given load condition, the inventors were able to improve the likelihood that an iterative optimisation would create a low compliance lattice structure such as a Michell structure.

[0181] A further suggestion is to use a lattice structure such as that illustrated in Figure 8 as a starting point for an iterative design process to create a new low compliance bracket shape. As will be appreciated, one group of fixing regions, here the fixing regions 114b, may be exposed to a nominal load or stress values, for instance as part of a head region of a bracket. Another group of fixing regions, here the fixing regions 114a, may be the back-fixing region of the bracket 110, for instance as part of a foot region of a bracket.

[0182] The shape of the bracket 110 may have been defined by an iterative design process. However, the shape of the bracket 110 may have been defined for a different set of parameters, e.g. different arm length, different load characteristics, different sheet material thickness and / or different material, and others. For instance, the shape of bracket 110 may be iteratively optimised for a particular nominal load, and it may be desired to alter the load condition defining the nominal load.

[0183] Figures 9 and 10 show different results, a first output 130a and a second output 130b, each derived from an iterative design process using the bracket shape 110 as an input to define a starting point of the iterative design process. As will be appreciated, the first and second outputs 130a, 130b may be representative of different termination conditions. For the purpose of the present disclosure, the first and second outputs 130a, 130b may be representative of the same load condition calculated for two different sheet thicknesses. In this example, both outputs 130a and 130b comprise a lattice structure, but for different load parameters, and sheet thickness parameters, the result may not be a lattice structure.

[0184] Each output 130a, 130b constitutes a sheet material shape comprising a bracket arm 132a, 132b, respectively, a first end 134a, 134b and a second end 136a, 136b between which the bracket arm 132a, 132b extends. For the purpose of this disclosure, the outputs 130a, 130b constitute different candidate shapes obtained by an iterative design process, and from which a two-dimensional stencil can be created.

[0185] Version 2025-09-02 As a result of iterative analysis, the first and second outputs 130a, 130b provide a bracket arm comprising a generally flat lattice structure, or two-dimensional lattice structure, characterised in that the beams and trusses of the lattice structure might intersect at vertices, but do not extend in a third dimension to overlap each other. However, in several software packages, the lattice structure of the first and second outputs 130a, 130b comprises trusses and branches, that, while not necessarily arranged in a three-dimensional network, are themselves of rounded cross section, such that the shape of the first and second outputs 130a, 130b, is a three-dimensional shape, varying in the face- to-face direction. To provide an illustrative example, Figure 9 shows a cross section 135 through one of the trusses of the first output 130a, and its profile 138, which is generally round.

[0186] Figures 11 and 12 show two-dimensional stencils, a first stencil 140a created from the first output 130a, and a second stencil 140b created from the second output 130b. Each stencil 140a, 140b is a two-dimensional shape that can be incorporated as a lattice structure into a sheet material, e.g. by a laser cutting process, by pressing, and other suitable processes. The stencils 140a, 140b comprise a first stencil end 144a, 144b, a second stencil end 146a, 146b, and a stencil arm portion 142a, 142b, respectively.

[0187] In contrast to the rounded profile 138 of the first and second outputs 130a, 130b, the profile of the stencils 144a, 144b is constant in the face-to-face direction. As will be appreciated, the stencil itself may have no thickness dimension. E.g., an illustrative section 145 through a truss region of the first stencil 140a, if incorporated into a sheet material structure, might have a flat profile 148, as illustrated in Figure 11 . The stencils 144a, 144b may each be created for a particular nominal load, determined by a load condition, and for a sheet thickness.

[0188] Furthermore, the first and second stencil ends 144a, 144b, and 146a, 146b, which are the ends corresponding to areas comprising the fixing regions 114a, 114b, have been unfolded to provide a flat, two-dimensional stencil shape.

[0189] The individual beams of the stencils 140a, 140b follow a curvature, and beams are made up of segments 431 a, 432a, 433a, 434a, 431 b, 433b, 434b, extending between intersections. The beam segments 431 a, 432a, 433a, 434a, 431 b, 433b, 434b of a beam may be at least partially straightened, such that some or all of the beams are made up of a series of straight beam segments 431 a, 432a, 433a, 434a, 431 b, 433b, 434b, aligned to follow a curvature. Some of the beam segments may widen at intersections or vertices. As such, the stencils comprise beams with straightened segments and wider intersection regions 147a, 147b.

[0190] As will be appreciated, the stencils 140a, 140b may be used as a cutting pattern to incorporate a lattice structure into a bracket. The cutting pattern may be converted into machine readable instructions. Several methods of cutting a bracket shape from sheet material will be known to a skilled person and are not disclosed in detail herein.

[0191] Version 2025-09-02 The stencils 140a, 140b are handed, comprising a top side and an underside. The stencils 140a, 140b may be used to create a symmetric bracket, by mirroring the lattice shape about a horizontal axis to become a symmetry axis. The resulting symmetric shape can be installed as both left-hand bracket and as right-hand bracket. However, the symmetric stencil shape is not necessarily a requirement of all embodiments.

[0192] Figure 13 illustrates steps of a method 150 of designing a bracket shape suitable as a two- dimensional stencil to be incorporated as a bracket profile into a bracket body.

[0193] In step 152, a bracket envelope is volume is defined that defines the outer dimensions and a sheet thickness of a bracket. For instance, the envelope may be a region such as the envelope 128 illustrated in Figure 8.

[0194] In step 154, fixing regions of the bracket are defined, and a bracket arm region between the fixing regions. The fixing regions may be slots, holes, clips and the like that will be required as functional regions, e.g. for receiving fasteners. The fixing regions and the outer dimensions may be considered preserve regions, and the fixing regions may be used as reference points for stress calculations and load paths.

[0195] Preserve regions defined in step 154 may comprise one or more spine structures, such as the spines 36 or 66, extending along the extension of the bracket arm, and / or one or more flange structures, such as the flange structures 33 or 62, extending along the edge region of the bracket arm. The preserve regions may require that the spine structure and / or lateral flange structures, or at least plateau regions thereof, remain solid without mass-reducing apertures.

[0196] In step 156, a sheet material shape is defined that is sufficiently dimensioned to comprise the fixing regions and the bracket arm region. The sheet material shape may be flat, and / or may comprise bent portions.

[0197] In step 158, the method comprises defining load conditions for the bracket. A load condition may be a nominal load applied to and / or carried at an end of a bracket arm, and may be applied via the fixing regions. The load condition may be applied symmetrically, i.e. in-use upward an in-use downward, for the design of a bracket for both left-handed and right-handed installations.

[0198] In an optional step 160, the method comprises defining a lattice structure between the fixing regions as a starting point for optimisation. The lattice structure will be understood to comprise a network of trusses, which may intersect. The lattice structure may be a low compliance structure, such as an estimated lowest compliance structure, a Michell structure, a Prager truss, or a low compliance truss structure. The lattice structure may be a two-dimensional shape fitting in the sheet material shape defined in step 156. The iterative processing may identify regions of the bracket, specifically but not

[0199] Version 2025-09-02 necessarily only, of the bracket arm within the bracket envelope, that can be removed while maintaining minimum load bearing characteristics or other termination conditions of the bracket.

[0200] In the optional step 160, the lattice structure is used as a starting point for iterative optimisation of the sheet material shape. In that case, it is the lattice structure, and not merely any sheet material shape, that is used as starting point and subject to iterative remodelling.

[0201] In step 162, a termination criterion is defined. As will be appreciated, some of the steps 152 to 162 may be carried out in a different order than that illustrated in Figure 13. Likewise, some or all of the steps 152 to 162 may be carried out simultaneously. E.g., the load conditions and termination criterion may be defined in one step.

[0202] In step 164, an iterative optimisation method is carried out to iteratively modify the sheet material shape at least until the termination criterion is met. The method may apply multiple different termination criteria. In that case, iterations may be carried out until at least one of the termination criteria is met. Alternatively, iterations may be carried out until some or all of the termination criteria are met.

[0203] A termination criterion may be that a sheet material shape may be incorporated into two or more bracket shapes, and / or into bracket variants of different lengths. For instance, a sheet material shape may be designed to be incorporated into a bracket arm comprising head regions of different lengths.

[0204] In step 166, a determination is made whether or not the sheet material shape is a lattice structure, such as a low-compliance structure, or a Michell structure, comprising a lattice of continuous, curved trusses or beams with curve-on-curve intersections and connections comprising involute junctions, or consisting of practically only involutes.

[0205] If, in step 166, the sheet material shape is not a lattice structure, the sheet thickness is modified and the iterative optimisation is continued, or repeated, as the case may be. For instance, the method may modify the sheet thickness only, or may modify the sheet thickness and other parameters. Parameters such as sheet thickness may be modified until all beams of a lattice structure are within a common plane, in which the beams may intersect, without overlaps or bridge structures extending in a third dimension.

[0206] If, in step 166, the sheet material shape is a lattice structure, such as a low compliance structure or lowest compliance structure, then the method may proceed to subsequent steps, such as step 168, step 170, and / or step 172.

[0207] In an optional step 168, a two-dimensional stencil is created from the optimised sheet material shape, wherein the optimised sheet material shape is understood to be a sheet material shape

[0208] Version 2025-09-02 meeting the termination criteria. Creating a two-dimensional stencil may comprise flattening, or bending into a planar shape, portions of the sheet material shape. Creating a two-dimensional stencil may comprise reshaping truss structures of the lattice to a planar shape. In step 168, it may be ensured that the stencil shape is a unitary shape.

[0209] The sheet material or two-dimensional shape may be used as a stencil, or blueprint, for a bracket. To incorporate a lower-mass structure, only part of a stencil may be used, to define a lower-mass structure. For instance, a stencil may have been designed to allow it to be incorporated in bracket arms of different lengths, such that a larger (longer) portion of the stencil is used for a longer bracket variant, and a smaller (shorter) portion of the same stencil is used for a relatively shorter bracket variant. The stencil may be incorporated in some regions of a bracket. For instance, the stencil may be incorporated as lower mass structure in regions other than reinforcing ribs, spines and / or flanges, i.e. between flanges and / or spines.

[0210] In an optional step 170, a sheet material is provided, for instance a sheet metal such as aluminium, and the two-dimensional shape is incorporated. E.g., the two-dimensional stencil may be incorporated by a laser cutting or press forming operation.

[0211] In an optional step 172, the sheet material is formed, e.g. by bending, to form a bracket. When incorporated into a bracket, it will be understood that the stencil is incorporated as a lattice extending in the face-to-face thickness as a uniform, constant profile, even though some of the uniformity may be lost in subsequent forming operations, e.g. when bending angles of the bracket.

[0212] For some optimisation parameters, depending on load parameters and sheet thickness, the method may require several attempts to produce suitable lattice structures, such as a Michell structure. In that case, it was found that the use of a lattice structure, such as depicted in Figures 4, 5A, 5B, 6, 7, and / or 8, as a starting point, rather than an end point, may speed up iterative bracket design processes. For instance, this may allow a larger number of reduced-mass bracket shapes to be designed in shorter time. To provide exemplary situations in which the method may be applied, different brackets may have different length arms, or a different number of mounting points, and / or may be designed for a different type of mounting system.

[0213] Different lattice designs may be provided as reference starting points, for instance in the form of a database of reference structures for use as a starting point.

[0214] While some of the illustrated brackets show a single central spine or rib region of plateaued profile, some embodiments may comprise an arrangement of multiple spines or ridges. Likewise, example helping-hand brackets described herein comprise two helping-hand clips. The brackets of the invention may comprise any number of helping hand clips, including a single clip, three clips, or any other number of helping-hand clips.

[0215] Version 2025-09-02 The brackets may be formed from a suitable sheet material, such as sheet metal, including aluminium, steel, and aluminium alloys and steel alloys, including stainless steel. The brackets may be galvanised. The brackets may be coated, alloy coated or otherwise treated depending on required use. The forming operation may comprise roll-forming a sheet material to incorporate a bracket profile such as corrugations and / or ribs along the length of a bracket precursor, and incorporating fixing regions and / or mass-reducing apertures of a lower-mass structure by a suitable operation such as pressing or laser-cutting, or other suitable forming operations.

[0216] The invention is thought to be useful particularly in the manufacture of load support brackets, such as mounting brackets or grid support brackets for wall and / or roof cladding and twin skin installations and the like. Such installations cover significant areas and require a large number of support brackets. In such installations with a large number of brackets, different bracket types may be needed to attach to different materials and / or for different load requirements. The provision of a bracket with multiple plateau regions, including in rib regions, shaped to facilitate nesting if required, facilitates the use of the same bracket type for a wide range of connections. The use of a lower- mass bracket, where incorporated, reduces the overall load on underlying structures. The aspects individually and combined facilitate logistics, on-site handling and pre-installation of a large number of brackets.

[0217] Whilst the principle of the invention has been illustrated using exemplary embodiments, it will be understood that the invention is not so limited, and that the invention may be embodied by other variants defined within the scope of the appended claims.

[0218] Version 2025-09-02

Claims

CLAIMS:1 . A mounting bracket of sheet material form, comprising a spacer arm spacing apart a foot region and a head region opposite the foot region, wherein the head region comprises an arrangement of one or more apertures, and wherein the foot region comprises an arrangement of one or more apertures, wherein the mounting bracket comprises a profiled sheet portion comprising corrugations comprising plateau regions extending in the extension of the spacer arm from the foot region to the head region, the plateau regions defining a floor span perpendicular to the extension of the spacer arm, wherein the corrugations comprise obtusely angled side walls separating the plateau regions, and wherein at least two adjacent corrugations each have a floor span of no less than 10 mm.

2. The mounting bracket according to claim 1 , wherein at least three adjacent corrugations each have a floor span of no less than 10 mm.

3. The mounting bracket according to claim 1 or 2, wherein the corrugations are provided in the form of alternating ridges and grooves providing the plateau regions, wherein transition regions between adjacent ridges and grooves provide the side walls.

4. The mounting bracket according to any one of the preceding claims, wherein the adjacent corrugations have a floor span of no less than 11 mm, 12 mm, 13 mm, 14 mm, 15 mm, or no less than 16 mm.5 The mounting bracket according to any one of the preceding claims, wherein the adjacent corrugations have a floor span of no more than 30 mm, 29 mm, 28 mm, 26 mm, 25 mm, 24 mm, 23 mm, 22 mm, 21 mm, or no more than 20 mm.

6. The mounting bracket according to any one of the preceding claims, wherein adjacent corrugations comprise a floor span differing by no more than 5 mm, 4 mm, 3 mm, 2 mm, or no more than 1 mm.

7. The mounting bracket according to any one of the preceding claims, wherein a group of at least three adjacent corrugations comprises the same floor span.

8. The mounting bracket according to any one of the preceding claims, comprising three corrugations between two opposite lateral edges.Version 2025-09-029. The mounting bracket according to any one of the preceding claims, wherein the corrugations comprise a valley depth, the valley depth measured from ridge crest to trough floor, of no less than 3 mm, 4 mm, or no less than 5 mm.

10. The mounting bracket according to any one of the preceding claims, wherein the corrugations comprise a valley depth, the valley depth measured from ridge crest to trough floor, of no more than 7 mm, 8 mm, 9 mm, 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or no more than 15 mm.11 . The mounting bracket according to any one of the preceding claims, wherein adjacent corrugations comprise a valley depth differing by no more than 5 mm, 4 mm, 3 mm, 2 mm, or no more than 1 mm.

12. The mounting bracket according to any one of the preceding claims, wherein a group of at least three adjacent corrugations comprises the same valley depth.

13. The mounting bracket according to any one of the preceding claims, wherein the bracket comprises an arrangement of one or more helping-hand clips.

14. A mounting bracket of sheet material form, comprising a spacer arm spacing apart a foot region and a head region opposite the foot region, wherein the mounting bracket comprises a profiled sheet portion comprising corrugations extending in the extension of the spacer arm from the foot region to the head region, wherein the head region comprises an arrangement of one or more apertures, and wherein the bracket comprises an arrangement of one or more helping-hand clips, and wherein the corrugations comprise obtusely angled side walls suitable for nested stacking with a like profiled sheet portion.

15. The mounting bracket according to claim 13 or 14, wherein one or more helping-hand clips are located in valley regions of the corrugations, wherein, optionally, at least two helping-hand clips are located in two different valleys spaced apart by a ridge region.

16. The mounting bracket according to any one of claims 13 to 15, wherein the helping-hand clips extend beyond plateau regions of their adjacent ridge regions.

17. The mounting bracket according to any one of claims 1 to 12, wherein the head region comprises one or more connector elements of a first connector system and one or more connector elements of a second connector system, wherein the connector elements of the first connector system comprise recess structures on opposite edges of the sheet material, and wherein the connector elements of the second connector system comprise a plurality of spaced apart apertures.Version 2025-09-0218. A mounting bracket of sheet material form, comprising a spacer arm spacing apart a foot region and a head region opposite the foot region, wherein the head region comprises one or more connector elements of a first connector system and one or more connector elements of a second connector system, wherein the connector elements of the first connector system comprise recess structures on opposite edges of the sheet material, and wherein the connector elements of the second connector system comprise one or more apertures.

19. The mounting bracket according to claim 17 or 18, comprising at least one central corrugation in the form of one of a ridge and groove, providing a spine structure flanked by two lateral corrugations in the form of the other of a ridge and groove, extending in the extension of the spacer arm from the foot region to the head region.

20. The mounting bracket according to any one of the preceding claims, wherein the one or more apertures are located on a central corrugation.21 . The mounting bracket according to any one of the preceding claims, comprising flange structures extending along lateral edges in the extension of the spacer arm from the foot region to the head region.

22. The mounting bracket according to any one of the preceding claims, comprising a plurality of mass-reducing apertures along the spacer arm in a region without fastener apertures between the foot region and the head region, wherein, optionally, the plurality of mass-reducing apertures is located in plateau regions laterally of a central corrugation, wherein, further optionally, the central corrugation is constituted by a continuous sheet between the fastener apertures.

23. The mounting bracket according to any one of the preceding claims, comprising a network of beams along the spacer arm between the foot region and the head region, wherein, optionally, beams of the network of beams are located laterally of a central corrugation.

24. A building structure comprising a walling system or roof system mounted using a plurality of brackets according to any one of the preceding claims.Version 2025-09-02

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