Bracket assembly

Abstract

A bracket assembly that includes a first bracket, a base member, optionally an insulator member, optionally a cross bracket member and a clip member. The first bracket is attachable to an outer bracket. In some configurations, the cross bracket and insulator member may be optionally utilized, with the outer bracket being attached to one of the base member and the cross bracket.

Description

TITLEBRACKET ASSEMBLY CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims priority from U.S. Patent App. Ser. No. 63 / 761,408 field February 21, 2025, entitled “Bracket Assembly”, the entire specification of which is hereby incorporated by reference.

[0002] The present application is related to, but does not make any claim priority from, U.S. Patent Nos. 11,566,421, entitled “Adjustable Support System For A Building Structure And A Wall Structure Having An Adjustable Support System” and 11,542,702, entitled “Adjustable Support System For A Building Structure And A Wall Structure Having An Adjustable Support System”, the entire disclosure of each of which is hereby incorporated by reference in their entirety.BACKGROUND OF THE DISCLOSURE1. Field of the Disclosure

[0003] The disclosure relates in general to building structures, and more particularly, to an adjustable support system for building walls.2. Background Art

[0004] With the cost of energy ever increasing, addressing building thermal losses has become more and more important. In building assembly, cladding and insulation are applied to the outside of a building substrate. Thermal isolation of the cladding from the substrate has increasing been a focus due to the large thermal losses due to heat conduction between the cladding and the building substrate.

[0005] While there have been advances in thermal protection and insulation, there are typically connectors and structural members between the substrate and the cladding which have exhibit high thermal conductivity. For example, many such structures have continuous metal portions that form a path between the substrate and the cladding. Many thermal losses are attributed to this highly thermally conductive conduit.

[0006] Additionally, and somewhat separately, in many instances, the outer surface of the building substrate is uneven or has imperfections. It is desired to correct these imperfections when applying the cladding so that the cladding is both uniform and generally free of undulations, and imperfections. Often, undulations in cladding, are unsightly, and can contribute to deterioration of the cladding which can then compromise the insulation and other structures.

[0007] As such, providing structures which have high thermal insulative propertieswhile also correcting for imperfections, undulations and other problems associated with building substrates so that cladding can be uniformly installed is highly desirable.SUMMARY OF THE DISCLOSURE

[0008] The disclosure is directed to a bracket assembly comprising a first bracket, a base member, and a cross bracket. The first bracket has a base wall and a body wall being one of orthogonal and oblique to each other. The base wall is positionable onto the base member. The cross bracket member has a base portion that is sandwiched between the base member and the base wall, and a support portion with a tab member and a slot being defined therebetween.

[0009] In another aspect of the disclosure, the disclosure is directed to a bracket assembly having a first bracket, a base member and at least one clip member. The first bracket has a base wall and a body wall being one of orthogonal and oblique to each other. The base wall is positionable onto the base member. The at least one clip member is attached to the base wall of the first bracket. The at least one clip member is interfaceable with the body wall so as to retain an outer bracket therebetween.

[0010] In either configuration, among other configurations as described in detail, the bracket assembly further includes an insulator member positioned on the base member on a side opposite the first bracket.

[0011] In some configurations, an outer bracket can be coupled to the bracket assembly.

[0012] In another aspect of the disclosure, the disclosure is directed to a system comprising a plurality of bracket assemblies as described herein, wherein the multiple bracket assemblies are attached to a substrate and at least one outer bracket interfaces with at least two of the plurality of bracket assemblies.

[0013] In yet another aspect of the disclosure, the disclosure is directed to a method of assembling the bracket assemblies set forth herein.

[0014] In another aspect of the disclosure, the disclosure is directed to a bracket assembly comprising a first bracket, a base member and a clip member. The first bracket has a base wall and a body wall being one of orthogonal and oblique to each other. The base wall has a clip retaining assembly comprising an inner clip channel and an outer clip channel. The first bracket is of a metal material. The base member is releasably attachable to the first bracket so that the base member overlies at least a portion of a bottom surface of the base wall of the first bracket. The base member comprises a polymer. The clip member has a base bracket member slidably positionable between the inner lip channeland the outer lip channel. The clip member has a projecting arm extending from the base bracket member, with the distal end of the projecting arm being biased against the body wall of the first bracket.

[0015] In some configurations, the base member further includes a biasing tab on an upper surface of the base member. The biasing tab exerts a force against the first bracket between the inner clip channel and the outer clip channel so as to resist slidable movement of the clip member between the inner lip channel and the outer lip channel.

[0016] In some configurations, the base member further includes an entry tab on the upper surface of the base member and extending through an entry opening in the base wall. The entry tab is movable between a first orientation wherein the entry tab blocks a region between the inner clip channel and the outer clip channel, and, a second orientation wherein the entry tab can be depressed so that the entry tab does not block a region between the inner clip channel and the outer clip channel.

[0017] In some configurations, the base member further includes a stop tab positioned on a side opposite the entry tab. The stop tab extends from the upper surface of the base member through an opening in the base wall. The entry tab and the stop tab define the limits of slidable movement of the clip member along the inner clip channel and the outer clip channel.

[0018] In some configurations, the base member is releasably attachable to the first bracket through an inner attachment member and an outer attachment member. The inner attachment member is positioned on an inner side of the base member engageable with an inner side of the body wall and the outer attachment member positioned on an outer side of the base member engageable with an outer side of the body wall.

[0019] In some configurations, the bracket assembly further comprises an insulator member, wherein the base member is positioned on the insulator member on a side opposite the body wall of the first bracket, the insulator member comprising a resilient material.

[0020] In some configurations, the body wall of the first bracket further includes at least one spike member. The spike member has a base, a body and a tip, with the at least one spike member being bendable relative to the first bracket into an orientation that is one of oblique and orthogonal thereto.

[0021] In some configurations, the base member overlies a portion of a bottom surface of the base wall.

[0022] In some configurations, the base wall further includes a plurality of alignment openings.

[0023] In some configurations, the plurality of alignment openings of the base wall are alignable with a plurality of alignment openings of the base member, with the base member having a ridge around the alignment openings extendable into the alignment openings of the base wall.

[0024] In some configurations, the base member further includes an inner upstanding wall extending from an inner side thereof, with an inner flange extending from the inner upstanding wall in a direction away from a top surface of the base member.

[0025] In some configurations, the inner upstanding wall is perpendicular to the top surface of the base member and perpendicular to the inner flange.

[0026] In some configurations, the base member further includes an outer upstanding wall extending from an outer side thereof, with an outer flange extending from the outer upstanding wall in a direction away from the top surface of the base member.

[0027] In some configurations, the outer upstanding wall is perpendicular to the top surface of the base member and perpendicular to the outer flange.

[0028] In some configurations, the base member further includes an alignment indicator adapted to align the bracket member with a substrate.

[0029] In some configurations, the alignment indicator includes a body having a first wing and a second wing spaced apart from the first wing, forming a cavity therebetween. The cavity has a V-shaped entry, with an indicator member positioned within the cavity.

[0030] In some configurations, the alignment indicator is aligned with at least one alignment opening of the base wall of the first bracket.

[0031] In some configurations, the first bracket further includes a second end wall opposite the base wall, the first bracket extending in a direction opposite the base wall.

[0032] In some configurations, the bracket assembly further comprises a secondary insulator member positionable over an outer side of the second end wall.

[0033] In some configurations, the secondary insulator member includes opposing channels that are configured to slidably engage opposing side edges of the second end wall.

[0034] In another aspect of the disclosure, the disclosure is directed to a system comprising a plurality of bracket assemblies as disclosed herein and an outer bracket coupled to at least a plurality of the plurality of bracket assemblies.BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The disclosure will now be described with reference to the drawings wherein:

[0036] Figure 1 of the drawings is a perspective view of a configuration of the bracket assembly, in an installed configuration wherein multiple bracket assemblies attached to the substrate (in this case spaced apart studs) and also coupled to outer brackets which are substantially parallel to the spaced apart studs) with insulation positioned between adjacent outer brackets;

[0037] Figure 2 of the drawings is a perspective view of a configuration of the bracket assembly attached to a substrate (in this case a studs) and also coupled to an outer bracket with insulation installed as well;

[0038] Figure 3 of the drawings is perspective view of a configuration of the bracket assembly with an outer bracket attached thereto, and with fasteners extended through the first bracket, the base member and the insulator member;

[0039] Figure 4 of the drawings is a perspective view of a configuration of the bracket assembly having a clip member and having fasteners extended through the first bracket, the base member and the insulator member;

[0040] Figure 5 of the drawings is a perspective view of the first bracket of the bracket assembly of the present disclosure;

[0041] Figure 6 of the drawings is a bottom plan view of the first bracket of the bracket assembly of the present disclosure;

[0042] Figure 7 of the drawings is a back elevational view of the first bracket of the bracket assembly of the present disclosure;

[0043] Figure 8 of the drawings is a perspective view of the first bracket of the bracket assembly, showing in particular, the spike members after being bent such that they are no longer parallel to and / or coplanar with the remainder of the body wall;

[0044] Figure 9 of the drawings is a perspective view of the base member of the present disclosure;

[0045] Figure 10 of the drawings is a perspective view of the base member of the present disclosure;

[0046] Figure 11 of the drawings is a bottom plan view of the base member of the present disclosure;

[0047] Figure 12 of the drawings is a perspective view of the insulator member of the present disclosure;

[0048] Figure 13 of the drawings is a perspective view of the clip member of the present disclosure;

[0049] Figure 14 of the drawings is a side elevational view of the clip member of the present disclosure;

[0050] Figure 15 of the drawings is a perspective view of another configuration of the bracket assembly shown in an assembled environment, wherein multiple bracket assemblies are attached to a substrate (in this case a plurality of spaced apart studs) with outer brackets spanning thereacross, and generally perpendicular to the studs);

[0051] Figure 16 of the drawings is a perspective view of the bracket assembly attached to a stud, with an outer bracket coupled to the cross bracket member;

[0052] Figure 17 of the drawings is a perspective view of the bracket assembly having an outer bracket coupled to the cross bracket member, and with fasteners extending through the first bracket, the base member and the insulator member;

[0053] Figure 18 of the drawings is a perspective view of the first bracket, the base member, the insulator member and the cross bracket;

[0054] Figure 19 of the drawings is another perspective view of the first bracket, the base member, the insulator member and the cross bracket;

[0055] Figure 20 of the drawings is a perspective view of the base member and the insulator member with the cross bracket member being positioned thereon prior to attachment of the first bracket;

[0056] Figure 21 of the drawings is a perspective view of the cross bracket member of the present disclosure;

[0057] Figure 22 of the drawings is a cross sectional view of the base member and the insulator member, showing, in particular, the coupling therebetween;

[0058] Figure 23 of the drawings is a cross-sectional view of the first bracket, the base member and the insulator member, showing, in particular, the coupling therebetween;

[0059] Figure 24 of the drawings is a perspective view of another installation showing a substrate (comprising a plurality of spaced apart studs) with a plurality of bracket assemblies coupled thereto, of the type having a second end wall, with a plurality of outer brackets coupled to a plurality of bracket assemblies, and insulation positioned between adjacent outer brackets, with the outer brackets being substantially parallel to the underlying studs;

[0060] Figure 25 of the drawings is a perspective view of another configuration of the bracket assembly, showing, in particular, a first bracket having a second end wall, with a secondary insulation member being attached to the second wall of the first bracket;

[0061] Figure 26 of the drawings is a perspective view of the bracket assembly of Figure 25;

[0062] Figure 27 of the drawings is a bottom perspective view of the secondary insulation member;

[0063] Figure 28 of the drawings is a top perspective view of the secondary insulation member;

[0064] Figure 29 of the drawings is a perspective view of another configuration of the bracket assembly of the present disclosure;

[0065] Figure 30 of the drawings is a perspective view of the first bracket of the bracket assembly of the present disclosure;

[0066] Figure 31 of the drawings is a perspective view of the base member of the bracket assembly of the present disclosure;

[0067] Figure 32 of the drawings is a top plan view of the base member of the bracket assembly of the present disclosure;

[0068] Figure 33 of the drawings is a perspective view of the base member of the bracket assembly of the present disclosure;

[0069] Figure 34 of the drawings is a bottom plan view of the base member of the bracket assembly of the present disclosure;

[0070] Figure 35 of the drawings is a perspective view of the insulator member of the bracket assembly of the present disclosure;

[0071] Figure 36 of the drawings is a top plan view of the secondary insulator member of the bracket assembly of the present disclosure;

[0072] Figure 37 of the drawings is a bottom plan view of the secondary insulator member of the bracket assembly of the present disclosure;

[0073] Figure 38 of the drawings is a cross-sectional perspective view of the secondary insulator member of the bracket assembly of the present disclosure;

[0074] Figure 39 of the drawings is a perspective view of another configuration of the base member of the bracket assembly of the present disclosure;

[0075] Figure 40 of the drawings is a top plan view of the base member of the bracket assembly of the present disclosure; and

[0076] Figure 41 of the drawings is a bottom plan view of the base member of the bracket assembly of the present disclosure.DETAILED DESCRIPTION OF THE DISCLOSURE

[0077] While this disclosure is susceptible of embodiment in many different forms, there is shown in the drawings and described herein in detail a specific embodiment s) with the understanding that the present disclosure is to be considered as an exemplification and is not intended to be limited to the embodiment s) illustrated.

[0078] It will be understood that like or analogous elements and / or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of the invention, and some of the components may have been distorted from actual scale for purposes of pictorial clarity.

[0079] Referring now to the drawings and in particular to Figures 4, 18, and 25, different configurations of the bracket assembly is shown generally at 10. With reference to Figures 1, 15 and 24, the bracket assembly can be utilized in association with a substrate 1000 and a cladding assembly (not shown). The substrate may comprise a wall surface which is attached to a plurality of wall studs or wall surface which is attached to a plurality of wall studs or the like (wood, metal or composite, for example, and without limitation). Alternatively, the substrate may comprise a concrete or block wall. Of course, other substrates are likewise contemplated. The substrate includes an outer surface 1002. Typically, such an outer surface may be planar, may include surface imperfections, surface variations as well as a plurality of different surfaces.

[0080] The cladding assembly may a cladding sheet which may be attached to the adjustable support system opposite the substrate. A number of different cladding materials are contemplated for use, including, but not limited to metal sheeting (flat, corrugated, or otherwise), siding, composite sheet material, fiberboard, just to name a few. The adjustable support system is not limited to any particular substrate or cladding, and the foregoing is merely exemplary.

[0081] In a configuration of the bracket assembly, the bracket assembly is shown in Figures 2 through 4 as comprising first bracket 100, base member 200, insulator member 300, cross bracket 400 and clip member 500. It will be understood that the bracket assembly is attachable to the substrate by way of fasteners 1400 that extend through the first bracket, the base member and the insulator member. With reference to Figures 1 and 2, it will be understood that a plurality of such bracket assemblies areattached in a desired orientation (typically a vertically aligned, horizontally aligned, or otherwise aligned) on the substrate, with an outer bracket 600 being coupled to one or more bracket assemblies.

[0082] With reference to Figures 5 through 8, first bracket 100 is shown as comprising base wall 102 and body wall 104. In the configuration shown, the base wall and the bracket wall are formed from a single sheet metal material which is bent and otherwise stamped or machined with each of the structures described. As will be understood, therefore, the thickness and the width of the first bracket is generally uniform between the base wall 102 and the body wall 104. Of course, variations are contemplated.

[0083] In greater detail, the base wall 102 includes inner side 110, outer side 112, first end 114, second end 116, top surface 118 and bottom surface 120. The inner side is opposite the outer side, the first end is opposite the second end, the top surface is opposite the bottom surface. In the configuration shown, the base wall 102 further includes a plurality of alignment openings 122, through which fasteners may be extended so as to attach to a substrate. In the configuration shown, the base wall is substantially rectangular in configuration.

[0084] The base wall further includes base retaining assembly 126, clip retaining assembly 128 and cross bracket coupling 130. The base retaining assembly 126 facilitates the attachment (typically releasable) of the base member 200 to the base wall 102 of the first bracket 100. The base retaining assembly includes inner tab 132 positioned at the inner side 110 of the base wall and outer tabs 134 which are positioned at the outer side 112 of the base wall. The outer tabs are defined by opposing channels 136 with raised end 138 that curves upwardly away from the top surface 118 of the base wall.

[0085] The clip retaining assembly 128 is shown as comprising outer clip channel 140, inner clip channel 142, entry opening 144, stopper opening 146 and central opening 148. As will be explained below, the outer clip channel 140 and the inner clip channel 142 are spaced apart from each other, while facing each other. The channels cooperate to retain the clip member in slidable retention, allowing the clip member to slidably move along the clip channels from one end to the other end thereof. In the configuration shown, the clip channels are formed from the sheet metal that forms the body wall, and thereby forming openings through the base wall corresponding, in the configuration shown, to the lip channels. As will further be explained with respect to the operation, the entry opening 144 and the stopper opening 146 correspond with structures of the base member 200 (in particular, the clip engagement system 216 thereof, as shown in Figures 9-11) so as tofacilitate insertion and retention of the clip member in a desired releasable engagement with the clip retaining assembly. Similarly, the central opening corresponds to the opening 228 of the base member 200.

[0086] The cross bracket member coupling 130 is shown as comprising a slot, which, in the configuration shown, comprises a T-shaped slot configured to receive and retain the base portion retention tab 418 of the cross bracket member 400. In some configurations, such a coupling may be omitted, or may comprise a different structure, such as a tab which cooperates with a slot on the cross bracket member 400. In other configurations, such a cross member coupling 130 may be fully eliminated, relying instead on, for example, the cross bracket body wall coupling 169 or the alignment screws, and the configuration thereof between the base wall and the base portion 402 of the cross bracket member 400.

[0087] The body wall 104 is shown as comprising inner side 150, outer side 152, first end 154, second end 156, inner surface 158 and outer surface 160. As with the base wall (which is substantially planar), the body wall 104 may be substantially planar, and may be orthogonal (or oblique + / - 20° of orthogonal, for example) to the base wall. As with the base wall, the body wall is substantially rectangular, while, in the configuration shown, being larger in at least one dimension.

[0088] The body wall 104 further includes central void assembly 162 and spike member 164, as well as slots 166, openings 168 and cross bracket body wall coupling 169. In the configuration shown, the body wall may include a plurality of each, for example, a plurality of central void assemblies 162, 162’ which are substantially mirror images of each other (while variations are contemplated), each having a spike member 164, 164’. One central void assembly and spike member will be explained with the understanding that the other is a substantial mirror image thereof (while variations may exist between the various central voids and spike members on the first bracket). It is also contemplated that while a pair of central void assemblies are shown, each with a single spike member, there may be a greater or lesser number of central void assemblies present, with any number of spike members interfacing therewith.

[0089] Each central void includes outer edge 170 and inner edge 172. The inner edge is positioned on the side proximate the inner side 150 of the body wall, with the outer edge 172 being positioned on the side proximate the outer side 152 of the body wall. In the configuration shown, the central void assembly has an appearance of a rectangular configuration with filleted corners, while other configurations, such as,circular, oval, elliptical, polygonal, and arbitrary, are likewise contemplated. The spike member is shown as comprising base 174, body 176 and tip 178. In the configuration shown, the base is narrower than the body, typically, so, when the spike member is bent (as in Figure 8), a bend generally starts or occurs along the base of the spike member. Opposite the base is tip 178 which narrows, so as to facilitate entry into insulation or the like. In some configurations, the spike member may have a uniform configuration, or a consistent configuration, such as a narrowing spike from the base to the tip. In still other configurations, a number of different shapes may be configured between the base and the tip, with the body having areas which are as small as, for example, the base or the tip. I other configurations, a single central void assembly may include multiple spike members positioned therealong.

[0090] The slots 166 and openings 168 are configured to receive various different fasteners. For example, the elongated slots allow for relative slidable movement between the first bracket and the substrate once the fasteners are inserted. As such, the slots 166 can be utilized for initial coupling with further fasteners extended through the various openings 168. The cross bracket body wall coupling is shown as comprising two slots spaced apart from each other and extending along the second edge, spaced apart therefrom. In the configuration shown, the openings comprise rectangular configurations with the longer sides being parallel with the second edge. As will be explained below, these slots cooperate with the retaining pegs 428 of the support portion 404.

[0091] The base member 200 is shown in greater detail in Figure 9 through 11 as comprising inner side 202, outer side 204, first edge 206, second edge 208, top surface 210 and bottom surface 212. In the configuration shown, the base member underlies the base wall 102 and substantially corresponds dimensionally to the footprint of the base wall. In other configurations, the base wall may be larger or smaller, in footprint to the base wall. Additionally, the base member may comprise a polymer member, that may, for example, be molded or otherwise formed.

[0092] Additionally, the top surface may include cross bracket region 220 which is configured to receive the base portion 402 of the cross bracket member 400. In the configuration shown, the portion of the base member that includes the cross bracket region has a thickness that is less than that of the remainder of the base member.

[0093] A plurality of alignment openings 314 extend through the base member, positioned so as to correspond with the alignment openings 122 of the base wall 102. As can be seen, the alignment openings include an outward flange and an upstand so as tofacilitate isolation between the fastener and the base wall, so as to improve the thermal isolation therebetween.

[0094] With further reference to Figures 22 and 23, the bracket attachment coupling 216 is shown as comprising inner member 230, inner void 232, outer member 234, outer void 236, stem 238, and head 240. The bracket attachment interfaces with the base retaining assembly 126 to assemble the two structures in releasable engagement. In particular, the inner member 230 interfaces with (and is movable relative to the base member due to the configuration thereof and including inner void) the inner tab 132 so as to couple the two structures together. It will be understood that in other configurations more than a single inner member may be utilized depending on the configuration.

[0095] At the same time, the outer member 234interface with the outer tabs 134, 134’ as that the inner portion 244of the head 240so as to capture the outer tabs 134, and the raised ends 138between the top surface of the base member and the inner portion of the head (and outwardly by the stem 238). As will be explained, the outer portion 242 of the respective head of the bracket attachment coupling can help facilitate release of the base member from the base wall, or may be utilized for purposes of alignment or coupling to other structures (such as, for example, insulation). In the configuration, two outer members are shown, with the understanding that in different configurations, a greater or lesser number of outer members may be utilized.

[0096] With reference to Figures 4 in cooperation with Figures 9 and 10, the clip engagement system 218 is shown as comprising entry tab 222, stop tab 224 and biasing tab 226. The entry tab is configured to extend through the entry opening 144 of the base wall, and can be pushed from above the base wall so as to limit protrusion or the like. As can be seen, the entry tab 222 is formed on a cantilever so that it is generally configured to extend through the entry opening. A user can push the entry tab back through the entry opening, and the cantilever will exert a biasing force to return to an orientation wherein the entry tab extends through the entry opening.

[0097] The stop tab 224 is configured to extend through the stopper opening 146 of the base wall so as to be engageable with a clip member that is slid along the clip retaining assembly so as to define a distal end of slidability of the clip member therewithin. The biasing tab 226 comprises a centrally located member that forms a cantilever configuration, such that the biasing tab extends slightly above the top surface of the base member, such that the biasing tab exerts a biasing force against the base wall, so as to generally preclude slidable movement therebetween, and also to direct the clipmember into engagement with the clip retaining assembly so as to limit inadvertent and / or undesirable slidable movement of the clip member therealong. The biasing tab 226 may include an opening 228 that corresponds to the central opening 148 of the clip retaining assembly.

[0098] The insulator member is shown in Figure 12 as comprising inner side 302, outer side 204, first edge 306, second edge 308, top surface 310 and bottom surface 312. The top surface 310 is configured to be overlayed by the bottom surface 212 of the base member. The insulator member generally comprises a resilient polymer material that can form a seal between the base member and the cladding. As such, the alignment openings 314 can be sealed so as to preclude the passage of fluid (such as water and the like) from penetrating from the outside into the alignment openings and, in turn, into the substrate through the fasteners that extend through the alignment openings. In some configurations, the insulator member may be omitted or may be co-molded with the base member.

[0099] The clip member 500 is shown in Figures 4, 13 and 14 as comprising base bracket member coupling 520, projecting arm 522 and distal flange 524. The base bracket member coupling 520 and the distal flange are generally parallel (+ / - 20°) to each other with the projecting arm being oblique (+ / - 40°) to each or perpendicular to each. In certain configurations, the distal flange 524 and the projecting arm 522 may be perpendicular to each other with the base bracket member coupling being oblique to each so that the projecting arm is inclined toward the body wall 104 of the base bracket member when installed, so as to provide a biasing force against the distal mounting member toward the body wall of the first bracket 100. While two clip members are shown, it is contemplated that a single clip member, or in excess of three clip members may be utilized (without limitation).

[0100] The clip member 500 further includes an inwardly protruding stop 551 positioned at the distal end thereof which faces the outer bracket 600. At the same time, the outer bracket 600 may include an outwardly directed flange (not shown) that is positioned at a distal end thereof. As will be understood, the inwardly protruding stop 551 precludes removal of the outer bracket from the sandwiched configuration as the protruding stop 551 catches the outwardly directed flange and precludes the same from passing therebeyond. A user can pull the distal end of the clip member so as to provide sufficient clearance for the outer bracket 600 and the outwardly directed flange to move beyond the protruding stop to separate the same.

[0101] This can be helpful as inadvertent disengagement of the structures is precluded if, for example, the outer bracket 600 experiences a separating force. It will be understood that the outwardly directed flange can be formed during pultrusion, or may comprise a folded over portion wherein the outer bracket 600 is formed from a metal member, such as a steel or aluminum member. In other words, the interface between the protruding stop and the outwardly directed flange precludes separation of the outer bracket from between the base bracket and the at least one clip member.

[0102] The base bracket member coupling 520 includes slot engaging member 526 which includes first slot side 530, second slot side 532, upper surface 534 and lower surface 536. As will be explained below in greater detail the slot engaging member slidably positionable and movable within the channel of the first end wall of the base bracket member.

[0103] The projecting arm 522 extends from the base bracket member coupling 520 at the proximal end 538 to distal end 542, and include inner surface 544 that generally faces the body wall 104 and outer surface 546 opposes the inner surface 544. In the configuration shown, the projecting arm 522 comprises a substantially planar configuration, and of substantially uniform thickness, while variations are contemplated.

[0104] The distal flange 524 is shown as comprising proximal end 548, distal end 550, with an inner surface 554 and an outer surface 556 opposite the inner surface. The distal flange is generally oblique or perpendicular to the projecting arm, and substantially planar. In the configuration shown, the distal flange is of substantially uniform cross-sectional configuration. The distal flange terminates at a distal edge 552, which, as explained is positioned so as to interface with insulation or the like.

[0105] In the configuration shown, the projecting arm is longer than the base bracket member coupling or the distal flange, with the distal flange being longer than the base bracket member. As will be explained in greater detail below, the projecting arm is shorter than the height of the body wall 104 so that the distal end of the projecting arm is spaced apart from the outer edge of the body wall. It is contemplated that the clip member may comprise a polymer and fiber composite member which is likewise pultruded. As such, the cross-sectional configuration may be substantially uniform as a result of such pultrusion, while molded polymer members are likewise contemplated. In other configurations, the member may be formed from a metal or alloy thereof through a stamping, casting or forging process.

[0106] The outer bracket 600 is shown in Figure 3 as comprising spanning wall 602 and outer end wall 604. It is contemplated that the outer wall comprises a polymer and fiber based composite that is pultruded or otherwise formed. In other configurations, it is contemplated that the outer bracket may comprise a metal member. In the instance of a metal member, the distal coupling member can be eliminated.

[0107] The spanning wall 602 includes outer side 610 and inner side 612. The outer bracket is further defined by the upper edge 614, the lower edge 616, the inner surface 618 and the outer surface 620. The spanning wall 602 is substantially uniform in thickness and may comprise a substantially planar sheet like configuration. As explained above, and as will further be detailed below, the outer bracket may be larger than the base bracket member, and may span and be coupled to multiple base brackets.

[0108] The outer end wall includes outer surface 630 and inner surface 632. The outer surface 630 my include outer longitudinal notch 634 (or other indicative structure) which provides a visual indication as to a location wherein fasteners can be extended. Other demarcations and the like are likewise contemplated.

[0109] In operation, the operation will be described with respect to an installation shown in Figures 1 and 2. The user may be provided with any number of bracket assemblies for attachment to the substrate. It will be understood that the bracket assemblies are each attached in substantially the same manner, and as such, the attachment of one bracket assembly can be repeated for each of the bracket assemblies, for example, through the use of fasteners, such as fasteners 1400. Additionally, once a number of bracket assemblies are coupled to the substrate, the user can attach an outer bracket 600 to one or more of the bracket assemblies.

[0110] More specifically, the user prepares one of the bracket assemblies.Specifically, the base member 200 can be coupled to the first bracket 100 by snapping the bracket attachment coupling 216 components to the base retaining assembly 126.

[0111] Once the base member is attached to the first bracket, or prior thereto, the insulator member 300 can be snapped onto the bottom surface of the base member. In some configurations, the insulator member can be omitted.

[0112] Next, one or more clip members 500 can be attached to the first bracket 100. Specifically, a clip member 500 is directed so that the slot engaging member 526 is aligned with the clip retaining assembly 128. As these are aligned, eventually the slot engaging member 526 reaches the entry tab 222 of the clip engagement system 218 that is extending through entry opening 144 of the base wall 102. The user can use the slotengaging member 526 to press the entry tab 222, to push it back through the entry opening 144 so as to allow the slot engaging member 526 to be slid into the outer clip channel 140 and the inner clip channel 142.

[0113] The clip member 500 can be slid along the inner clip channel and the outer clip channel from one end to the other end. The stop tab 224 precludes removal of the clip member from the clip retaining assembly 128 at the end opposite the entry tab. Further the entry tab, once returned to the initial configuration precludes removal of the clip member in the direction opposite the stop tab. Thus, the clip member is captured within the clip retaining assembly between the entry tab 222 and the stop tab 224. It will be understood that the clip retaining assembly of the base wall of the first bracket is of sufficient side to receive and retain multiple clip members.

[0114] Once assembled, the bracket assembly with the clip member(s) can be attached to the substrate. To assemble, the bracket assembly is positioned as desired on the substrate. Once positioned, fasteners are directed through the alignment openings and into the substrate. In greater detail, the fasteners can be driven through the alignment openings of the base wall 102, the alignment openings of the base member 200, and where desired, the alignment openings of the insulator member 300 and into the substrate. It will be understood that the particular type of fastener may be varied depending on the particular application.

[0115] Once sufficiently attached to the substrate, the outer bracket can be installed by sliding the spanning wall between the base wall and the clip member so as to be slidably maintained therebetween. Once positioned, fasteners can be driven through the slots and / or openings in the body wall and through the spanning wall. Due to the angled nature of the clip member, preferably, the outer bracket can be maintained through the biasing force applied by the clip member.

[0116] Once the bracket assembly and the outer bracket are attached, the spike members may be bent so as to be orthogonal or oblique to the body wall. The spikes can be used for purposes of retention of insulation and / or the like. Next, insulation 700 can be installed. This process can be repeated to form the entire wall, with the understanding that the steps may happen in a different order (i.e., all of the bracket assemblies may first be assembled, or may come pre-assembled). The user may mount all of the bracket assemblies onto the substrate prior to the outer brackets and the insulation. Indeed, the disclosure is not limited to any particular order of assembly operations.

[0117] In another configuration of the bracket member and installation, as is shown in Figures 15 through 23, instead of or in addition to the use of the clip members 500, cross bracket member 400 can be utilized with the first bracket, in which case the outer bracket is attached to the cross bracket member 400.

[0118] With reference to Figures 15 through 23, and in particular, Figures 18 through 23, cross bracket member 400 is shown as comprising base portion 402, support portion 404, tab member 406 and slot 408 defined between the support portion 404 and the tab member. The cross bracket is generally formed from a single sheet metal member that can be formed into the desired configuration. The cross bracket member 400 can optionally be utilized to capture the outer bracket 600 and the like in a direction that is perpendicular to the body wall, and generally parallel to the support portion of the cross bracket member. Thus, in many instances, when the cross bracket member 400 is utilized, typically, clip members are omitted from use, such as with the installation of Figures 15 and 16.

[0119] In greater detail, the base portion 402 includes top surface 410, bottom surface 412, proximal end 414, distal end 416 and base portion retention tab 418. In the configuration shown, the base portion matches the configuration of the cross bracket region 330 of the top surface, such that when installed the thickness of the base portion plus the cross bracket region match the thickness of the remainder of the base member 200. In the configuration shown, a pair of alignment openings are disposed on the base portion which align with the alignment openings of the base member and the base wall of the first bracket.

[0120] The support portion 404 includes proximal end 420, distal end 422, inner side 424 and outer side 426, as well as, outer surface 423 and inner surface 425. The proximal end 420 of the support portion meets the proximal end 414 of the base portion. The support portion is generally orthogonal (and / or oblique + / - 20°) to the base portion and also, when installed, similarly disposed relative to the body wall 104 of the first bracket 100. The inner side of the support portion includes retaining pegs that are configured to interface with the cross bracket body wall coupling (i.e., the slots) 169 of the body wall 104 of the first bracket.

[0121] The tab member 406 is offset from the support portion so as to be substantially parallel (and / or oblique + / - 20°) thereto while creating a spacing therebetween in two dimensions, and forming slot 408 therebetween. The tab member includes inner side 430 and outer side 432, along with outer surface 434 and inner surface436. As will be understood the outer bracket 600 positioned through the slot 408 can overlie the outer surface of the support portion, and the inner surface of the tab member 406.

[0122] In operation of the assembly of Figures 15 through 23, prior to attaching the base member to the first bracket, the cross bracket member is installed onto the base member, and then to the body wall and the base wall of the first bracket. Once installed, fasteners can be extended through alignment openings in the first bracket, the base member, optionally the insulator member, and in some instances through the base portion of the cross bracket member to attach the bracket assembly to the substrate.

[0123] Once installed onto the substrate, the outer bracket can be positioned so as to extend through the slot formed between the support portion 404 and the tab member 406 of the cross bracket member. Fasteners may be extended through both to couple the structures to each other. Once fully installed, again, the spike members can be bent so as to be orthogonal or oblique to the respective body wall so as to allow for attachment of insulation thereto.

[0124] In such a configuration, in many instances, but not limited thereto, the outer brackets may be oriented so as to be substantially perpendicular to the direction of the studs, with the insulation being elongated and substantially perpendicular to the direction of the studs.

[0125] In another configuration of the bracket assembly, and with reference to Figures 24 through 28, the first bracket may have a “Z” configuration, such that a second end wall 106 may extend from the outer side 152 of the body wall, with a secondary insulation member 350. In such a configuration, the second end wall includes inner side 180, outer side 182, first end 184, second end 186, top surface 187, bottom surface 188 and receiving slots 189.

[0126] The second end wall is generally perpendicular or oblique (+ / - 20°) to the body wall, and parallel or oblique (+ / - 20°) to the base wall. Additionally, whereas the base wall extends from an inner side of the body wall, the second end wall extends (in the configuration shown, and not being limited thereto) from the outer side of the body wall. In the configuration shown, the base wall and the second end wall are substantially the same size, while variations are contemplated.

[0127] The secondary insulation member 350 is positioned to overlie the top surface 187 and includes inner side 352, outer side 354, first edge 356, second edge 358, top surface 360, bottom surface 362 and clips 364. The clips 364 interface with thereceiving slots 189 of the second end wall so as to be releasably joined together. In the configuration shown, the secondary insulation member and the second end wall are dimensionally corresponding. It will be understood that the secondary insulation member, as with the base member, is formed from a polymer or composite member having a greater insulative value than the first bracket or the cross bracket member.

[0128] The installation of the bracket member of Figures 15 through 23 is substantially identical to that of the other configurations. As will be understood, and as is shown, the second end wall 106 overlies the upper surface of insulation 700 (and may abuttingly engage the insulation, or may be spaced apart therefrom).

[0129] In another configuration, shown in Figures 29 through 38, additional features are disclosed, some of which may be incorporated into other configurations shown in Figures 1 through 23. With reference to Figure 29, a bracket assembly is shown that includes a first bracket 100, a base member 200, an insulator member 300, and a secondary insulator member 350. It will be understood that clip members, such as clip member 500 (Figures 13 and 14) may be coupled to the first bracket 100 of the configuration shown. Additionally, it is contemplated that additional variations are provided which can further include a cross bracket member 400 (Figure 21). Of course, similar features will be identified with the same reference numbers.

[0130] In such a configuration, as with the configurations above, preferably, the first bracket comprises a metal member, preferably steel or stainless steel (while other metals, such as aluminum, magnesium, titanium are contemplated). The first bracket may be formed through a stamping operation, for example, while other methods of manufacturing are contemplated. The base member and the secondary insulating member comprise polymer members, and preferably, structures which include fiber reinforced polymers, among other materials. The insulator member preferably comprises a resilient polymer member which can provide a substantially watertight seal between the base member and a substrate.

[0131] In the configuration shown, the body wall 104 is shown to be substantially larger than that of other configurations. It is contemplated that differently sized first bracket members may be provided. Additionally, in some configurations, a plurality of sizes may be provided for the body wall, wherein the base wall is dimensionally the same across the plurality of sizes. For example, such different sizes of body walls allow for differently sized insulation to be utilized, or to have different spacing between thesubstrate and the cladding. Variations throughout each of the configurations is contemplated.

[0132] With further reference to Figure 30, the inner tab 132 may be wider than in the other configurations, while variations are contemplated. Additionally, in such a configuration, the second end wall 106 may include openings, such as openings 181 which are extend through the inner tab. In the configuration shown, the openings are disposed proximate the comers of the generally rectangularly shaped second end wall. Of course, variations in the size, position and number of openings through the second end wall are contemplated. In the configuration shown, receiving slots 189 remain on the outer side 182 of the second end wall so as to positively receive corresponding structures of the secondary insulation member 350 (Figure 29).

[0133] In this configuration, the base member 200 is shown in Figures 31 through 34, and is inclusive of structures which correspond to those disclosed above, some of which may be modified in configuration, and, in addition features not shown in the previous configurations (some of which may be added to the prior configurations). For example, the inner member 230 which is to capture the tab 132 (Figures 29 and 30) is correspondingly wider than that shown above. In addition, the inner void 232 is correspondingly larger as well.

[0134] The base member 200 may further include an inner upstanding wall 250 which extends upwardly from the inner side 202 of the base member, with inner flange 252 at an upper terminal end thereof extending away from the base member. In the configuration shown, the inner upstanding wall 250 is perpendicular to each of the top surface 210 of the base member and the inner flange 252. The inner flange 252 may include a cavity, or recessed region, that corresponds to the inner member (or tab), in some configurations.

[0135] Similarly, the base member 200 may further include an outer upstanding wall 254 having an outer flange 256. In the configuration shown, the outer upstanding wall 254 includes a pair of posts being spaced apart so as to define an opening. In other configurations, the outer upstanding wall 254 may be void of an opening. An outer flange 256 extends outwardly from the outer upstanding wall 254 in a direction away from the top surface of the base member. In the configuration shown, the outer upstanding wall 254 is perpendicular to each of the outer flange 256 and the top surface 210 of the base member 200.

[0136] The inner flange and the outer flange, among other purposes, may provide a structure that can engage insulation on opposing sides of the bracket. It will be understood that in some configurations, one of the inner and the outer flanges may be utilized, or both of the inner and outer flanges. Furthermore, the width and the height of the upstanding walls, as well as the width of the inner and outer flanges is likewise variable, in that they may be smaller or larger than that which is shown in the Figures.

[0137] The base member 200 may further include alignment indicators, such as alignment indicators 260 which are positioned on opposing side edges 206, 208. The alignment indicators provide a visual cue to assist the placement of the bracket assembly so as to facilitate attachment on-center relative to a stud or an underlying substrate. In the configuration shown, each alignment indicator is substantially identical and a mirror image of the other about an axis bisecting the base member. Each alignment indicator includes body 262 and indicator member 264 (which is generally in a contrasting or highly visible color). The body 262 generally comprises first wing 265 and second wing 266 which are spaced apart from each other and which extend outwardly from the respective side edge.

[0138] The first wing 265 and the second wing 266 are spaced apart from each other so as to define a cavity 267 therebetween with a V-shaped entry 269 leading to the cavity 267. In the configuration shown, the first wing and the second wing are mirror images of each other the cavity 267 and the V-shaped entry 269 are configured to align with the openings 214 which are configured to receive fasteners therethrough and into the stud or wall substrate. The indicator member 264 can be positioned within the cavity 267 of the body 262. In the configuration contemplated, the indicator member 264 comprises a highly visible red or orange member (although different highly visible colors as well as photo luminescent colors) that can easily be seen by the installer. It is contemplated that the opposing alignment indicators define a line which can help align the bracket relative to the substrate (i.e., so as to be on-center on a stud, for example). In other configurations, the alignment indicator may be an appendage that includes a painted section, or may comprise a small appendage that is, itself painted, for example. In still other configurations, the alignment member may comprise a notch made in each of the opposing edges.

[0139] Additionally, in the configuration shown in Figures 36 through 38, the secondary insulator member 350 is shown in greater detail. The secondary insulator member 350 is shown as additionally including opposing slots 370, 371 which extendfrom a perimeter wall 375. The perimeter wall 375 extends about outer side 354, and the first and second edges 356, 358. The slot 370 is formed proximate the first edge 356, with the slot 371 being formed proximate the second edge 358. The slots are configured to slidably receive the second end wall 106 in slidable engagement. It is contemplated that the slots are sized so as to maintain the connection with the second end wall through an interference fit. A pair of corresponding opposing windows 372, 373 extend through the secondary insulator member along side of the opposing slots 370, 371, and generally parallel thereto as well as inboard thereof.

[0140] The extending tabs 377 emanate outwardly from the inner side 352 of the secondary insulator member 350. The extending tabs 377 facilitate the retention of insulation once installed on the substrate through an interference fit. In the configuration shown, a pair of spaced apart extending tabs are shown with the tabs being generally coplanar with the secondary insulation member. It is contemplated, however, that the extending tabs may be oblique to the secondary insulation member, and that the tabs may be different from each other.

[0141] Yet another configuration of the base member 200 is shown in Figures 39 through 41. These figures disclose a configuration of the base member that includes a plurality of voids such that the footprint of the base member is smaller than the base wall of the first bracket. In particular, voids are defined centrally on the inner side and the outer side (with each having a different configuration). Additionally, voids are defined at each of the intersections (i.e., corners) defined by the inner side, the outer side, the first end and the second end). Such placement and configuration improves the insulative performance of the base member while providing sufficient strength and support to the base wall. It will be understood that such a configuration may further include thinner regions (that define inner cavities) which are outlined by reinforcing ribs. It will be understood that openings for fasteners may be provided in the base member, or the preferred location may be provided, with the user driving fasteners to define the openings therein. In such a configuration, it is believed that the interface between the fastener and the base member is improved by the fastener providing the opening. In other configurations, openings may be provided. Additionally, a notch 251 may be present in the inner flange 252.

[0142] The foregoing description merely explains and illustrates the disclosure and the disclosure is not limited thereto except insofar as the appended claims are solimited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the disclosure.

Claims

1. WHAT IS CLAIMED IS:

1. A bracket assembly comprising:- a first bracket having a base wall and a body wall being one of orthogonal and oblique to each other, the base wall having a clip retaining assembly comprising an inner clip channel and an outer clip channel, and the first bracket being of a metal material;- a base member releasably attachable to the first bracket so that the base member overlies at least a portion of a bottom surface of the base wall of the first bracket, the base member comprising a polymer; and- a clip member having a base bracket member slidably positionable between the inner lip channel and the outer lip channel, the clip member having a projecting arm extending from the base bracket member, with the distal end of the projecting arm being biased against the body wall of the first bracket.

2. The bracket assembly of claim 1 wherein the base member further includes a biasing tab on an upper surface of the base member, the biasing tab exerting a force against the first bracket between the inner clip channel and the outer clip channel so as to resist slidable movement of the clip member between the inner lip channel and the outer lip channel.

3. The bracket assembly of claim 2 wherein the base member further includes an entry tab on the upper surface of the base member and extending through an entry opening in the base wall, the entry tab being movable between a first orientation wherein the entry tab blocks a region between the inner clip channel and the outer clip channel, and, a second orientation wherein the entry tab can be depressed so that the entry tab does not block a region between the inner clip channel and the outer clip channel.

4. The bracket assembly of claim 3 wherein the base member further includes a stop tab positioned on a side opposite the entry tab, the stop tab extending from the upper surface of the base member through an opening in the base wall, wherein the entry tab and the stop tab define the limits of slidable movement of the clip member along the inner clip channel and the outer clip channel.

5. The bracket assembly of claim 1 wherein the base member is releasably attachable to the first bracket through an inner attachment member and an outer attachment member, the inner attachment member positioned on an inner side of the base member engageable with an inner side of the body wall and the outer attachment member positioned on an outer side of the base member engageable with an outer side of the body wall.

6. The bracket assembly of claim 1 further comprising an insulator member, wherein the base member is positioned on the insulator member on a side opposite the body wall of the first bracket, the insulator member comprising a resilient material.

7. The bracket assembly of claim 1 wherein the body wall of the first bracket further includes at least one spike member, the spike member having a base, a body and a tip, with the at least one spike member being bendable relative to the first bracket into an orientation that is one of oblique and orthogonal thereto.

8. The bracket assembly of claim 1 wherein the base member overlies a portion of a bottom surface of the base wall.

9. The bracket assembly of claim 1 wherein the base wall further includes a plurality of alignment openings.

10. The bracket assembly of claim 9 wherein the plurality of alignment openings of the base wall are alignable with a plurality of alignment openings of the base member, with the base member having a ridge around the alignment openings extendable into the alignment openings of the base wall.

11. The bracket assembly of claim 1 wherein the base member further includes an inner upstanding wall extending from an inner side thereof, with an inner flange extending from the inner upstanding wall in a direction away from a top surface of the base member.

12. The bracket assembly of claim 1 wherein the inner upstanding wall is perpendicular to the top surface of the base member and perpendicular to the inner flange.

13. The bracket assembly of claim 1 wherein the base member further includes an outer upstanding wall extending from an outer side thereof, with an outer flange extending from the outer upstanding wall in a direction away from the top surface of the base member.

14. The bracket assembly of claim 13 wherein the outer upstanding wall is perpendicular to the top surface of the base member and perpendicular to the outer flange.

15. The bracket assembly of claim 1 wherein the base member further includes an alignment indicator adapted to align the bracket member with a substrate.

16. The bracket assembly of claim 15 wherein the alignment indicator includes a body having a first wing and a second wing spaced apart from the first wing, forming a cavity therebetween, the cavity having a V-shaped entry, with an indicator member positioned within the cavity.

17. The bracket assembly of claim 15 wherein the alignment indicator is aligned with at least one alignment opening of the base wall of the first bracket.

18. The bracket assembly of claim 1 wherein the first bracket further includes a second end wall opposite the base wall, the first bracket extending in a direction opposite the base wall.

19. The bracket assembly of claim 18 further comprising a secondary insulator member positionable over an outer side of the second end wall.

20. The bracket assembly of claim 19 wherein the secondary insulator member includes opposing channels that are configured to slidably engage opposing side edges of the second end wall.

21. A system comprising:- a plurality of bracket assemblies of claim 1;- an outer bracket coupled to at least a plurality of the plurality of bracket assemblies.

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