Note: Descriptions are shown in the official language in which they were submitted.
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INSULATION MOUNTING BRACKET
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S. Provisional
Patent
Application No. 63/017,270, filed April 29, 2020, the entire disclosure of
which is incorporated
herein by reference in full.
FIELD
[0002] The general inventive concepts relate to insulation systems and, more
specifically, to
a mounting bracket for use in insulation systems.
BACKGROUND
[0003] High rise buildings are typically constructed with concrete slab floors
that "float"
within an outer skin (i.e., windows and cladding materials interfaced with an
aluminum
framework). In other words, the outer skin does not carry the load of the
floors. The intersection
of the exterior (curtain) walls and these floor slabs provide a gap through
which a fire on one
floor may spread/climb vertically to floors above. Consequently, it is well
known to insulate
these gaps with fire-resistant materials to retard the spread of a fire from
one floor to the next.
This insulation takes the form of curtain wall insulation, safing insulation,
and the like that fit
in and around the framework (e.g., mullions and transoms). For example, U.S.
Pat. No.
10,309,100, the entirety of which is incorporated herein by reference,
describes a conventional
curtain wall insulation system.
[0004] A conventional curtain wall insulation system 100 is shown in FIG. 1.
The curtain
wall insulation system 100 is useful for insulating a curtain wall structure
150 connected to a
building structure (not shown). As one of skill in the art will appreciate, a
curtain wall structure
150 is a type of exterior wall system commonly used on buildings, such as high-
rise buildings,
wherein the curtain wall structure 150 does not bear the load of the building
structure. As see
in FIG. 1, the curtain wall structure 150 is spaced from a floor slab 160 of
the building structure
to define a perimeter void 170. The curtain wall structure 150 includes
framing defined by at
least first and second vertically disposed and parallel mullions 152, at least
one upper
horizontally disposed transom 154, and at least one lower horizontally
disposed transom 156.
The curtain wall insulation system 100 provides thermal insulation and also
provides a barrier
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to inhibit the spread of fire from one floor of a building to an upper
adjacent floor through the
perimeter void 170.
[0005] With continued reference to FIG. 1, the curtain wall insulation system
100 includes a
curtain wall insulation 102. The curtain wall insulation 102 may be formed of
various materials
based on a desired failure temperature of the material such as mineral wool,
which can maintain
its integrity for more than five hours at temperatures of nearly 2,100 F.
Such curtain wall
insulation 102 is commercially available from Thermafiber, Inc. of Wabash,
Indiana. The
curtain wall insulation 102 may have a thickness of 1 inch to 8 inches, and a
density of 4 pounds
per cubic foot to 8 pounds per cubic foot. The curtain wall insulation 102 is
disposed within
the framing and mechanically attached to the framing. Accordingly, the size
and shape of the
curtain wall insulation 102 will typically depend on the size and shape of the
framing into
which the curtain wall insulation 102 is being installed. The curtain wall
insulation 102 may
be mechanically attached to the framing with insulation hangers (not shown),
such as Impasse
insulation hangers available from Thermafiber, Inc. of Wabash, Indiana, or by
other
conventional means used to mechanically attach curtain wall insulation 102 to
the framing,
such as impaling pins or screws.
[0006] As shown in FIG. 1, the curtain wall insulation system 100 also
includes a safing
insulation 104 having a bottom surface 105 and a top surface 106. The safing
insulation 104 is
disposed within the perimeter void 170 and compression fit between the curtain
wall insulation
102 and the floor slab 160. The safing insulation 104 inhibits flames and hot
gases from moving
from a first floor to an adjacent upper floor through the perimeter void 170.
As with the curtain
wall insulation 102, the safing insulation 104 may be formed of various
materials based on a
desired failure temperature of the material. In certain embodiments, the
safing insulation 104
comprises mineral wool. The safing insulation 104 may have a thickness of 1
inch to 8 inches,
and a density of 4 pounds per cubic foot to 8 pounds per cubic foot. Such
safing insulation 104
is commercially available from Thermafiber, Inc. of Wabash, Indiana. When
installed, the
safing insulation 104 is commonly compressed to varying degrees, but normally
it is
compressed to approximately 25%. After installation, the safing insulation 104
provides
fireproof sealing of the perimeter void 170. Because the safing insulation 104
is compressed
when installed, it provides some capability to expand which can seal openings
or cracks that
might otherwise develop in the perimeter void 170. Slight variations in the
size of the perimeter
void 170 due to expansion or other environmental changes are accommodated by
the safing
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insulation 104 since it is compressed when placed in the perimeter void 170,
and thus can
provide an effective seal under various conditions.
[0007] In certain embodiments, the curtain wall insulation system 100 includes
a
reinforcement member 130 attached to and disposed between the mullions 152 and
behind the
curtain wall insulation 102. The reinforcement member 130 is positioned at a
level
corresponding to a level of the safing insulation 104, which level is commonly
referred to as
the safing line. The reinforcement member 130 prevents bowing or deformation
of the curtain
wall insulation 102 due to the compression fit of the safing insulation 104.
The reinforcement
member 130 may have various shapes or configurations. For example, the
reinforcement
member may have a T-shape, as shown in FIG. 1, an L-shape, or may be formed as
a channel
(e.g., C-shaped channel, U-shaped channel). Brackets (not shown) may be used
to attach the
reinforcement member 130 to the mullions 152. The reinforcement member 130 may
be formed
of various materials including, but not limited to, steel, galvanized steel,
ceramics, and other
heat resistant materials.
[0008] As shown in FIG. 1, the curtain wall insulation system 100 includes a
mullion cover
hanger 110 that is attached to the mullions 152 and a mullion cover 120 that
is attached to the
mullion cover hanger 110. The mullion cover 120 protects the mullions 152 from
hot flames
and gases during a fire. The mullion cover 120 may be formed of various
materials based on a
desired failure temperature of the material. In certain embodiments, the
mullion cover 120
comprises mineral wool. The mullion cover 120 may have a thickness of 1 inch
to 8 inches,
and a density of 4 pounds per cubic foot to 8 pounds per cubic foot. Such
mullion covers 120
are commercially available from Thermafiber, Inc. of Wabash, Indiana.
[0009] In certain embodiments, and as shown in FIG. 1, the curtain insulation
system 100
includes a lower mullion cover 121 attached to the mullion cover hanger 110,
and an upper
mullion cover 123 attached to the mullion cover hanger 110. The lower mullion
cover 121 is
installed so that a top surface 122 of the lower mullion cover 121 will abut a
bottom surface
105 of the installed safing insulation 104. Similarly, the upper mullion cover
123 is installed
so that a bottom surface 124 of the upper mullion cover 123 will abut a top
surface 106 of the
installed safing insulation 104. This configuration provides an effective seal
of insulation that
inhibits hot flames and gases from reaching the mullions 152.
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[0010] As discussed above, the mullion cover hanger 110 can be attached to a
mullion 152
(with fasteners, such as screws, or by welding) at a point above a floor slab
160 and at a point
below the floor slab 160, where an installer has relatively open access for
using electric tools,
such as a power drill, electric screwdriver, or welder. After the mullion
cover hanger 110 is
installed on the mullion 152, an installer can easily attach the mullion cover
120 to the mullion
cover hanger 110 without using electric tools, such as a power drill or
electric screwdriver, or
additional fasteners.
[0011] During a fire, there is a lot of turbulence, movement, and
gravitational pull, all of
which can cause the insulation to become dislodged, thereby allowing the fire
to propagate to
the next floor. Accordingly, mechanical fasteners are typically used to secure
the insulation
(e.g., the curtain wall insulation 102) to the building structure (e.g., the
mullions 152 and the
transoms 154, 156).
[0012] A conventional approach to mounting curtain wall insulation relies on
mounting
brackets. As shown in FIGS. 2A, 2B, and 2C, a conventional mounting system 200
includes a
vertical hanger 210, a horizontal hanger 230, and a locking washer 250.
[0013] The vertical hanger 210 includes a body 212, a first leg 214, a second
leg 216, and a
flange 218. The first leg 214 extends from and perpendicular to the body 212.
The second leg
216 extends from and perpendicular to the body 212. The flange 218 extends
from and
perpendicular to an end of the first leg 214. The flange 218 includes an
aperture therethrough
that forms a mounting hole 220. The mounting hole 220 is used to mount the
vertical hanger
210 to a mullion via a fastener (e.g., screw). An end of the second leg 216
includes a pair of
prongs 222, which are separated from one another by a gap. Each of the prongs
222 tapers into
a pointed end.
[0014] The horizontal hanger 230 includes a body 232, a first leg 234, a
second leg 236, and
a flange 238. The first leg 234 extends from and perpendicular to the body
232. The second leg
236 extends from and perpendicular to the body 232. The flange 238 extends
from and
perpendicular to an end of the first leg 234. The flange 238 includes an
aperture therethrough
that forms a mounting hole 240. The mounting hole 240 is used to mount the
vertical hanger
230 to a transom via a fastener (e.g., screw). An end of the second leg 236
includes a pair of
prongs 242, which are separated from one another by a gap. Each of the prongs
242 tapers into
a pointed end.
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[0015] The locking washer 250 includes a body 252 with an aperture
therethrough that forms
a slot 254. The slot 254 has a thickness and width sufficient for the prongs
222 of the vertical
hanger 210 and the prongs 242 of the horizontal hanger 230 to pass
therethrough.
[0016] The conventional mounting system 200 functions as follows. Multiple
vertical
hangers 210 and multiple horizontal hangers 230 are interfaced with a portion
of curtain wall
insulation sized to fit within a curtain wall region (i.e., at least a portion
of a region framed by
a pair of parallel mullions and a pair of parallel transoms). More
specifically, each vertical
hanger 210 is pressed through the insulation so that a rear face of the
insulation abuts the body
212 of the hanger 210, a side of the insulation abuts the first leg 214 of the
hanger 210, and the
prongs 222 extend through the insulation and beyond a front face of the
insulation. Likewise,
each horizontal hanger 230 is pressed through the insulation so that a rear
face of the insulation
abuts the body 232 of the hanger 230, a side of the insulation abuts the first
leg 234 of the
hanger 230, and the prongs 242 extend through the insulation and beyond a
front face of the
insulation. The second leg 216 of each vertical hanger 210 and the second leg
236 of each
horizontal hanger 230 functions as a shelf-like ledge that supports the weight
of the insulation.
[0017] For each pair of prongs 222, 242 extending through the insulation, a
locking washer
250 is manually pressed onto the prongs so that the prongs pass through the
slot 254 of the
locking washer 250, as shown in FIG. 3A. Then, the prongs are manually bent in
opposite
directions, as shown in FIG. 3B, to effectively lock the insulation on the
respective hangers
210, 230. In this manner, the curtain wall insulation is interfaced with the
hangers 210, 230.
[0018] Thereafter, the curtain wall insulation can be positioned and mounted
in the curtain
wall region. More specifically, a fastener (now shown), such as a screw,
passes through the
mounting hole 220 of each vertical hanger 210 to secure the hanger 210 to a
mullion. Likewise,
a fastener (now shown), such as a screw, passes through the mounting hole 240
of each
horizontal hanger 230 to secure the hanger 230 to a transom. In this manner,
the curtain wall
insulation (e.g., curtain wall insulation 102) is mechanically secured within
the curtain wall
region, as shown in the insulation installation 400 of FIG. 4A. Typically, a
piece of insulation
(i.e., the mullion cover 123) is then positioned over the mullion 152 to
protect it in the event of
a fire, as shown in the insulation installation 400 of FIG. 4B. The mullion
cover 123 can be
secured to the curtain wall insulation 102 via fasteners, such as spiral
screws 402 or other
separate mounting hangers/brackets.
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[0019] While effective in mounting insulation within a curtain wall, the
conventional
insulation mounting system 200 requires transport and manual installation of
many pieces (e.g.,
x brackets and x locking washers for a total of 2x pieces), which results in a
relatively lengthy
installation time. Accordingly, there is an unmet need for an improved
insulation mounting
system that requires transport and manual installation of significantly fewer
pieces (e.g., < x
total pieces) and, thus, can result in a significantly reduced installation
time.
SUMMARY
[0020] The general inventive concepts relate to an insulation mounting system,
including an
innovative mounting bracket for use therein. The mounting bracket can support
the insulation
without the use of locking washers. Furthermore, the design of the mounting
bracket allows for
the installation of curtain wall insulation without the use or installation of
a separate reinforcing
member (e.g., T-shaped backer bar). Accordingly, insulation can be mounted
more quickly
using the insulation mounting system, as opposed to conventional insulation
mounting systems.
[0021] In one exemplary embodiment, a mounting bracket is disclosed that
comprises a
bracket body having a middle portion, a first leg, a second leg, and at least
one reinforcing
member, wherein the middle portion extends between and connects the first leg
and the second
leg, wherein the first leg extends from the middle portion in a first
direction, wherein the second
leg extends from the middle portion in the first direction, and wherein the at
least one
reinforcing member extends from the middle portion in a second direction, the
first direction
and the second direction being opposite of one another.
[0022] In some exemplary embodiments, a height of the middle portion is
greater than a depth
of the first leg and a depth of the second leg.
[0023] In some exemplary embodiments, a depth of the middle portion is equal
to a height
of the first leg and a height of the second leg.
[0024] In some exemplary embodiments, a depth of the middle portion is equal
to a height
of the second leg and is less than a height of the first leg.
[0025] In some exemplary embodiments, the first leg is perpendicular to the
middle portion.
[0026] In some exemplary embodiments, the first leg includes at least one
aperture.
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[0027] In some exemplary embodiments, the first leg includes a mounting flange
that extends
from and perpendicular to an end of the first leg. In some exemplary
embodiments, the
mounting flange includes an aperture.
[0028] In some exemplary embodiments, the second leg is perpendicular to the
middle
portion.
[0029] In some exemplary embodiments, a depth of the second leg is greater
than a depth of
the first leg.
[0030] In some exemplary embodiments, a height of the second leg is equal to a
height of the
first leg.
[0031] In some exemplary embodiments, a height of the second leg is less than
a height of
the first leg.
[0032] In some exemplary embodiments, the second leg includes a body having
one or more
barbs and a tapered end. In some exemplary embodiments, the body includes a
plurality of the
barbs. In some exemplary embodiments, the body includes four of the barbs. In
some
exemplary embodiments, a number of the barbs on one side of the body differs
from a number
of the barbs on the opposite side of the body.
[0033] In some exemplary embodiments, the second leg is symmetrical about a
central axis
of the body.
[0034] In some exemplary embodiments, the first leg and the second leg are
parallel to one
another.
[0035] In some exemplary embodiments, the at least one reinforcing member is
perpendicular to the middle portion.
[0036] In some exemplary embodiments, the at least one reinforcing member
extends from
the middle portion at an angle in the range of 45 to 90 .
[0037] In some exemplary embodiments, the bracket body includes two
reinforcing members
space from one another by a distance that is less than or equal to a width of
the middle portion.
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[0038] In some exemplary embodiments, a height of the at least one reinforcing
member is
less than a height of the middle portion, a depth of the first leg, and a
depth of the second leg.
[0039] In some exemplary embodiments, a height of the at least one reinforcing
member is
equal to a height of the middle portion.
[0040] In some exemplary embodiments, a height of the at least one reinforcing
member is
less than or equal to a height of the middle portion and is more than half of
the height of the
middle portion.
[0041] In some exemplary embodiments, a height of the at least one reinforcing
member is
less than a depth of the first leg and is more than half of the depth of the
first leg.
[0042] In some exemplary embodiments, a height of the at least one reinforcing
member is
less than a depth of the second leg and is more than half of the depth of the
second leg.
[0043] In some exemplary embodiments, the at least one reinforcing member is a
flange.
[0044] In some exemplary embodiments, the bracket body is a unitary structure.
[0045] In some exemplary embodiments, the bracket body is made of galvanized
steel.
[0046] In one exemplary embodiment, a curtain wall insulation system is
disclosed that
comprises a plurality of mounting brackets and a curtain wall insulation, each
of the mounting
brackets comprising a bracket body having a middle portion, a first leg, a
second leg, and at
least one reinforcing member, wherein the middle portion extends between and
connects the
first leg and the second leg, wherein the first leg extends from the middle
portion in a first
direction, wherein the second leg extends from the middle portion in the first
direction, and
wherein the at least one reinforcing member extends from the middle portion in
a second
direction, the first direction and the second direction being opposite of one
another. Each of
the mounting brackets may also have any of the other features shown,
described, or otherwise
suggested herein.
[0047] In some exemplary embodiments, the curtain wall insulation system is
free of a
reinforcing member disposed at or in proximity to a safing line of the curtain
wall insulation
system.
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[0048] In some exemplary embodiments, a depth of the second leg is less than a
depth of the
curtain wall insulation.
[0049] Other aspects and features of the general inventive concepts will
become more readily
apparent to those of ordinary skill in the art upon review of the following
description of various
exemplary embodiments in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] The general inventive concepts, as well as embodiments and advantages
thereof, are
described below in greater detail, by way of example, with reference to the
drawings in which:
[0051] FIG. 1 is a side sectional diagram of a representational portion of a
conventional
curtain wall insulation system.
[0052] FIGS. 2A, 2B, and 2C illustrate various components of a conventional
insulation
mounting system. FIG. 2A shows various views of a vertical hanger. FIG. 2B
shows various
views of a horizontal hanger. FIG. 2C shows a locking washer for interfacing
with the vertical
hanger of FIG. 2A and the horizontal hanger of FIG. 2B.
[0053] FIGS. 3A and 3B illustrate the locking washer of FIG. 2C interfacing
with the
horizontal hanger of FIG. 2B.
[0054] FIGS. 4A and 4B illustrate the conventional insulation mounting system
of FIGS. 2A-
2C being used to mount curtain wall insulation.
[0055] FIGS. 5A-5E illustrate an insulation mounting bracket, according to one
exemplary
embodiment. FIG. 5A is a perspective view of the mounting bracket. FIG. 5B is
a plan view of
the mounting bracket. FIG. 5C is a detailed view of a second leg of the
mounting bracket. FIG.
5D is a front elevational view of the mounting bracket. FIG. 5E is a side
elevational view of
the mounting bracket.
[0056] FIG. 6 illustrates a portion of a test setup used to conduct a test in
accordance with
ASTM E2307-19 as described in the example of the present disclosure.
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DETAILED DESCRIPTION
[0057] Several illustrative embodiments will be described in detail with the
understanding
that the present disclosure merely exemplifies the general inventive concepts.
Embodiments
encompassing the general inventive concepts may take various forms and the
general inventive
concepts are not intended to be limited to the specific embodiments described
herein.
[0058] The general inventive concepts relate to an insulation mounting system,
including
innovative mounting brackets for use therein. The mounting brackets are one-
part structures
that replace conventional multi-part structures for mounting insulation, such
as in a curtain wall
space. For example, these unitary mounting brackets can support the insulation
without the use
of locking washers. Furthermore, the design of the unitary mounting brackets
allow for
installation of curtain wall insulation without the use or installation of a
separate reinforcing
member (e.g., T-shaped backer bar) as used in conventional insulation mounting
systems.
Accordingly, insulation can be mounted more quickly using the insulation
mounting system of
the present invention, as opposed to conventional insulation mounting systems.
[0059] A single-piece mounting bracket 500, according to one exemplary
embodiment, is
shown in FIGS. 5A-5E. Although specific dimensions are illustrated in some of
the drawings,
the general inventive concepts are not limited to the disclosed dimensions.
[0060] The mounting bracket 500 includes a bracket body 502 that includes a
middle portion
510, a first leg 520, a second leg 530, and at least one reinforcing member
540. The bracket
500 can be made of any suitable material. In some exemplary embodiments, the
bracket 500 is
made of a metal including, but not limited to, steel, galvanized steel, brass,
and aluminum.
Ceramic materials may also be used to form the bracket 500. In certain
embodiments, the
bracket 500 is formed of galvanized steel, and preferably 20 gauge galvanized
steel.
[0061] As seen in FIG. 5A, the middle portion 510 extends between and connects
the first
leg 520 and the second leg 530 to one another. In some exemplary embodiments,
a height mph
of the middle portion 510 is greater than a depth fld of the first leg 520 and
a depth sld of the
second leg 530. In some exemplary embodiments, a depth mpd of the middle
portion 510 is
equal to a height flh of the first leg 520 and a height slh of the second leg
530. In some exemplary
embodiments, a depth mpd of the middle portion 510 is equal to a height slh of
the second leg
530 and is less than a height flh of the first leg 520.
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[0062] The first leg 520 extends from the middle portion 510 in a direction
forward of the
middle portion 510, as seen in FIGS. 5A and 5E. In some exemplary embodiments,
the first leg
520 is perpendicular to the middle portion 510. In some exemplary embodiments,
the first leg
520 includes at least one aperture 522 therethrough to form a mounting hole.
The at least one
aperture 522 may be used to mount the bracket 500 to a support structure
(e.g., mullion,
transom) via a fastener (e.g., screw). In some exemplary embodiments, the
first leg 520
includes a mounting flange 524 that extends from and perpendicular to an end
of the first leg
520. In some exemplary embodiments, the mounting flange 524 includes an
aperture 522
therethrough to form a mounting hole. In some exemplary embodiments, the
aperture 522
extends through a depth fla of the first leg. In some exemplary embodiments,
the aperture 522
extends through a height fln of the first leg. In some exemplary embodiments,
the first leg 520
includes an aperture 522 that extends through a height fln of the first leg
and a mounting flange
524 having an aperture 522 that extends through a depth fla of the first leg
520.
[0063] As seen in FIGS. 5A and 5E, the second leg 530 extends from the middle
portion 510
in a direction forward of the middle portion 510. In some exemplary
embodiments, (a central
axis ca of) the second leg 530 is perpendicular to the middle portion 510. In
some exemplary
embodiments, a depth sld of the second leg 530 is greater than a depth fla of
the first leg 520.
In some exemplary embodiments, a height sin of the second leg 530 is equal to
a height fln of
the first leg 520 before the mounting flange 524. In some exemplary
embodiments, a height sin
of the second leg 530 is less than a height fln of the first leg 520. The
second leg 530 includes
a body 532 having one or more barbs 534. The body 532 includes a tapered end
536 beyond
the barbs 534. The tapered end 536 facilitates passage of the second leg 530
into a piece of
insulation, while the barbs 534 are operable to hold/secure the insulation on
the second leg 530.
The body 532 of the second leg 530 may function as a shelf-like ledge operable
to support the
weight of the insulation. In some exemplary embodiments, a depth sld of the
second leg 530 is
less than a depth of a piece of insulation with which the mounting bracket 500
is used.
Accordingly, in some exemplary embodiments, the second leg 530 does not extend
completely
through the insulation, which maintains the integrity of a facing of the
insulation, if present.
While the illustrated embodiment shows the same number of barbs 534 on each
side of the
body 532, the general inventive concepts are not so limited. In some exemplary
embodiments,
one or more barbs 534 are only on one side of the body 532. In some exemplary
embodiments,
the number of barbs 534 on one side of the body 532 differs from the number of
barbs 534 on
the other side of the body 532. While the illustrated embodiment shows the
second leg 530 to
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be symmetrical about the central axis ca, the general inventive concepts are
not so limited. In
some exemplary embodiments, the size, shape, and/or positions of the barbs 534
differ on
opposite sides of the central axis ca of the body 532.
[0064] As shown in FIG. 5C, in one specific exemplary embodiment, the body 532
of the
second leg 530 includes four distinct barbs, i.e., a first barb 534-1, a
second barb 534-2, a third
barb 534-3, and a fourth barb 534-4. A size, shape, and angle of the first
barb 534-1 and the
second barb 534-2 are the same. A size, shape, and angle of the third barb 534-
3 and the fourth
barb 534-4 are the same. In this exemplary embodiment, at least one of the
size, shape, and
angle of the first and second barbs 534-1, 534-2 is different from that of the
third and fourth
barbs 534-3, 534-4. In this exemplary embodiment, the angle of at least the
first and second
barbs 534-1, 534-2 is 42 degrees. The general inventive concepts contemplate
that the barbs
534 can have any angle suitable to hold the insulation once it is impaled on
the second leg 530.
[0065] As mentioned above, the bracket body 502 includes at least one
reinforcing member
540. The at least one reinforcing member 540 extends from the middle portion
510 in a
direction rearward of the middle portion 510 (i.e., opposite the
aforementioned forward
direction). In some exemplary embodiments, the at least one reinforcing member
540 is a
flange. In some exemplary embodiments, the at least one reinforcing member 540
extends from
the middle portion 510 in a direction (or from a side) different and/or
opposite than a direction
(or side) that the first leg 520 and the second leg 530 extend from the middle
portion 510. As
seen in FIG. 5A, each of the reinforcing members 540 extend along a height
dimension of the
middle portion 510 and project outward along a depth dimension behind the
middle portion
510, whereas the first leg 520 and the second leg 530 are extend across a
width dimension of
the middle portion 510 and project outward along a depth dimension in front of
the middle
portion 510. In other words, the at least reinforcing member 540 extends
behind the middle
portion 510 and the first leg 520 and the second leg 530 extend in front of
the middle portion
510. In some exemplary embodiments, the at least one reinforcing member 540 is
perpendicular
(i.e., 90 ) to the middle portion 510, as seen in FIG. 5B. In some exemplary
embodiments, the
at least one reinforcing member 540 extends from the middle portion 510 at an
angle of less
than or equal to 90 , such as at an angle in the range of 45 to 90 .
[0066] As shown in FIG. 5B, in one specific exemplary embodiment, the bracket
body 502
includes two reinforcing members 540 extending from and perpendicular to the
middle portion
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510. In this exemplary embodiment, the two reinforcing members 540 are spaced
from one
another by a distance that is less than or equal to a width mp,, of the middle
portion 510. In this
exemplary embodiment, the reinforcing members 540 have a rectangular shape.
The general
inventive concepts contemplate that the bracket body 502 can have additional
reinforcing
members 540 extending from the middle portion 510 or a single reinforcing
member 540
extending from the middle portion 510, preferably along a central axis of the
middle portion.
Furthermore, the general inventive concepts contemplate that the reinforcing
member 540 can
have any suitable shape, such as triangular, that allows the reinforcing
member 540 to function
as described herein.
[0067] In some exemplary embodiments, a height rmh of the reinforcing member
540 is less
than a height mph of the middle portion 510, a depth fld of the first leg 520,
and a depth sld of
the second leg 530. In some exemplary embodiments, a height rmh of the
reinforcing member
540 is equal to a height mph of the middle portion 510. In some exemplary
embodiments, a
height rmh of the reinforcing member 540 is less than or equal to a height mph
of the middle
portion 510 but more than half of the height mph of the middle portion 510
(i.e., 0.5mph < rmh
< mph). In some exemplary embodiments, a height rmh of the reinforcing member
540 is less
than a depth fld of the first leg 520 but more than half of the depth fld of
the first leg 520 (i.e.,
0.5fld < rmh < fld). In some exemplary embodiments, a height rmh of the
reinforcing member
540 is less than a depth sld of the second leg 530 but more than half of the
depth sld of the
second leg 530 (i.e., 0.55ld < rmh <
[0068] In some exemplary embodiments, a depth rmd of the reinforcing member
540 is less
than a height mph of the middle portion 510, a depth fld of the first leg 520,
and a depth sld of
the second leg 530. In some exemplary embodiments, a depth rmd of the
reinforcing member
540 is less than a height rmh of the reinforcing member 540. In some exemplary
embodiments,
a depth rmd of the reinforcing member 540 is equal to a height rmh of the
reinforcing member
540. In some exemplary embodiments, a depth rmd of the reinforcing member 540
is less than
or equal to half of a height mph of the middle portion 510 (i.e., rmd <
0.5mph). In some
exemplary embodiments, a depth rmd of the reinforcing member 540 is less than
or equal to
three-quarters of a depth fld of the first leg 520 (i.e., rmd < 0.75f1d). In
some exemplary
embodiments, a depth rmd of the reinforcing member 540 is less than or equal
to half of a depth
sld of the second leg 530 (i.e., rmd < 0.5s1d).
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[0069] The at least one reinforcing member 540 provides the bracket body 502
with greater
structural integrity to resist deformation when acted on by external forces.
In particular, when
the mounting bracket 500 is used to install insulation (e.g., curtain wall
insulation 102), the at
least one reinforcing member 540 increases a depth of the mounting bracket 500
and provides
at least one additional surface that is operable to bear against a support
structure (e.g., mullion,
transom) and thereby increase resistance to deformation by external forces,
such as external
forces exerted on a curtain wall insulation 102 due to the compression fit of
a safing insulation
104. Accordingly, the mounting brackets 500 disclosed herein having at least
one reinforcing
member 540 can be used in a curtain wall insulation system 100 to prevent
bowing or
deformation of curtain wall insulation 102 due to the compression fit of the
safing insulation
104 without the need for a separate reinforcement member (e.g., T-shaped
backer bar 130) at
or near the safing line.
[0070] In operation, one or more mounting brackets 500 are interfaced with a
support
structure (e.g., the mullion 152, the transoms 154, 156) in proximity to a
location where
insulation (e.g., the curtain wall insulation 102) is to be installed. More
specifically, one or
more mounting brackets 500 are secured to mullion 152 and transoms 154, 156
via fasteners,
such as screws. After attaching the mounting brackets 500 to the mullion 152
and transoms
154, 156, curtain wall insulation 102 can be pressed onto the second leg 530
of each mounting
bracket 500 such that the second leg 530 of each mounting bracket 500
penetrates the curtain
wall insulation 102 such that a rear face of the curtain wall insulation abuts
the middle portion
510 of each mounting bracket 500 and the barbs 534 on each second leg 530
effectively hold
the curtain wall insulation 102 in place. The barbs 534 are suitable to secure
the curtain wall
insulation 102 to the mounting bracket 500 without the need for any additional
structure (e.g.,
locking washers).
[0071] Alternatively, an insulation system incorporating the mounting brackets
500 of the
present disclosure may be installed in a manner similar to an insulation
system that utilizes the
vertical hangers 210 and horizontal hangers 230 shown in FIGS. 2A and 2B. In
particular,
multiple mounting brackets 500 are interfaced with a portion of curtain wall
insulation sized to
fit within a curtain wall region (i.e., at least a portion of a region framed
by a pair of parallel
mullions and a pair of parallel transoms). More specifically, each mounting
bracket 500 is
pressed into the insulation so that a rear face of the insulation abuts the
middle portion 510 of
the mounting bracket 500, a side of the insulation abuts the first leg 520 of
the mounting bracket
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500, and the second leg 530 extends into, but not through, the insulation and
the barbs 534 on
the second leg 530 effectively secure the insulation to the mounting brackets
500. In this
manner, the curtain wall insulation is interfaced with the mounting brackets
500.
[0072] Thereafter, the curtain wall insulation can be positioned and mounted
in the curtain
wall region. More specifically, a fastener (now shown), such as a screw,
passes through the
aperture 522 of each mounting bracket 500 to secure the mounting bracket 500
to a mullion or
a transom. In this manner, the curtain wall insulation (e.g., curtain wall
insulation 102) is
mechanically secured within the curtain wall region. Typically, a piece of
insulation (i.e.,
mullion cover) is then positioned over the mullion to protect it in the event
of afire. The mullion
cover can be secured to the curtain wall insulation via fasteners, such as
spiral screws or other
separate mounting hangers/brackets.
[0073] It will be obvious to one of ordinary skill int the art, that any
suitable number of the
mounting brackets 500 can be used to secure the insulation (e.g., the curtain
wall insulation
102) in the desired spaces.
[0074] Because the mounting bracket 500 operates to effectively install and
affix the
insulation without the need for locking washers and the like, the mounting
bracket 500 allows
for a simpler and quicker installation of fire perimeter insulation.
Furthermore, because the
mounting bracket 500 includes an integrated reinforcing member 540, there is
no need to install
a separate reinforcing member (e.g., T-shaped backer bar) required in
conventional fire
perimeter insulation systems and, thus, the mounting bracket 500 allows for a
simpler and
quicker installation of fire perimeter insulation.
EXAMPLE
[0075] The following example illustrates the performance of mounting brackets
according to
the present disclosure as compared to conventional horizontal Impasse
insulation hangers
("conventional horizontal hangers") available from Thermafiber, Inc. of
Wabash, Indiana,
which are shown in FIG. 2B. This example is for purposes of illustration only
and is not
intended to limit the scope of the present disclosure.
[0076] In this example, a test was conducted in accordance with ASTM E2307-19
"Standard
Test Method for Determining Fire Resistance of Perimeter Fire Barriers Using
Intermediate-
Scale, Multi-story Test Apparatus." This test standard is intended to test for
a system's ability
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to impede vertical spread of fire from a floor of origin to that above through
a perimeter void,
the void between an exterior wall assembly and a floor assembly.
[0077] As shown in FIG. 6, the test setup includes two identical pieces of
mineral wool
insulation 102, 102a (i.e., curtain wall insulation) attached to aluminum
framing including
mullions 152 and transoms 154. One piece of mineral wool insulation 102 was
attached to the
transom 154 using five mounting brackets 500 according to the present
disclosure and two
conventional vertical hangers 210 to attach the mineral wool insulation 102 to
the mullions
152. The other piece of mineral wool insulation 102a was attached to the
transom 154 using
five conventional horizontal hangers 230 and two conventional vertical hangers
210 to attach
the mineral wool insulation 102a to the mullions. The spacing of the five
mounting brackets
500 attached to transom 154 and the spacing of the five conventional
horizontal hangers 230
attached to transom 154 was identical. In addition, the mounting brackets 500
and the
conventional horizontal hangers 230 were made of the same material and had the
same
thickness.
[0078] After conducting the test in accordance with ASTM E2307-19, it was
observed that
the mounting brackets 500 held its insulation 102 in place better than the
conventional
horizontal hangers 230 held its insulation 102a in place. This was observed by
how much each
piece of insulation 102, 102a sagged or drooped after being exposed to the
fire test conditions
at three points. When the insulation 102, 102a sags, gaps can be created in
void material (i.e.,
safing insulation) that, if large enough, may allow flames to pass through
causing the fire to
spread. The first point corresponded to the edges of the mineral wool
insulation 102, 102a
adjacent the center mullion 152, the second point corresponded to the first
mounting bracket
500 and the first conventional horizontal hanger 230 spaced from the center
mullion 152, and
the third point corresponded to the second mounting bracket 500 and the second
conventional
hanger 230 spaced from the center mullion. The sag at the first point for the
mineral wool
insulation 102 attached with the mounting brackets 500 was about 0.4 inches,
whereas the sag
at the first point for the mineral wool insulation 102a attached with the
conventional horizontal
hangers 230 was about 1 inch. The sag at the second point for the mineral wool
insulation 102
attached with the mounting brackets 500 was about 0.4 inches, whereas the sag
at the second
point for the mineral wool insulation 102a attached with the conventional
horizontal hangers
230 was about 0.8 inches. The sag at the third point for the mineral wool
insulation 102 attached
with the mounting brackets 500 was about 0.3 inches, whereas the sag at the
third point for the
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mineral wool insulation 102a attached with the conventional horizontal hangers
230 was about
0.7 inches.
[0079] These results indicate that the mounting brackets 500 of the present
disclosure
maintain their shape and strength under fire exposure conditions better than
the conventional
horizontal hangers 230. In addition, these results indicate that the mounting
brackets 500 of the
present disclosure can provide a safer curtain wall insulation system than the
conventional
horizontal hangers 230 because the insulation is less likely to sag or droop,
which reduces the
ability of a fire to spread.
[0080] The scope of the general inventive concepts presented herein are not
intended to be
limited to the particular exemplary embodiments shown and described herein.
From the
disclosure given, those skilled in the art will not only understand the
general inventive concepts
and their attendant advantages, but will also find apparent various changes
and modifications
to the devices and systems disclosed. For example, while the exemplary
embodiments
described and shown herein relate to fire perimeter insulation, the inventive
mounting brackets
could be used to install other forms of insulation in building cavities. It is
sought, therefore, to
cover all such changes and modifications as fall within the spirit and scope
of the general
inventive concepts, as described and/or claimed herein, and any equivalents
thereof.
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