Adjustable Support System for a Building Structure and a Wall Structure Having an Adjustable Support System

This present application is a continuation of U.S. patent application Ser. No. 18/426,332, filed Jan. 29, 2024, entitled “Adjustable Support System For A Building Structure And A Wall Structure Having An Adjustable Support System,” which is a continuation of U.S. patent application Ser. No. 18/092,900, filed Jan. 3, 2023, entitled “Adjustable Support System For A Building Structure And A Wall Structure Having An Adjustable Support System,” which is a continuation of U.S. patent application Ser. No. 17/149,668, filed Jan. 14, 2021, entitled “Adjustable Support System For A Building Structure And A Wall Structure Having An Adjustable Support System,” which is a continuation-in-part of U.S. patent application Ser. No. 16/912,575, filed Jun. 25, 2020, entitled “Adjustable Support System For A Building Structure And A Wall Structure Having An Adjustable Support System,” the entire specification of which is hereby incorporated by reference in its entirety.

The disclosure relates in general to building structures, and more particularly, to an adjustable support system for building walls.

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.

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.

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 sot 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.

As such, providing structures which have high thermal insulative properties while also correcting for imperfections, undulations and other problems associated with building substrates so that cladding can be uniformly installed is highly desirable.

The disclosure is directed an adjustable support system comprising a base bracket member, at least one clip member, and an outer bracket. The base bracket member has a first end wall structurally configured to overly a substrate, a body wall extending outwardly from the first end wall and a second end wall opposite the first end wall. The at least one clip member has a base bracket member coupling, and a projecting arm. The clip member has a protruding stop directed at the base bracket, at a distal end thereof. The base bracket member coupling is attached to the first end wall and overlies a portion of the body wall. the outer bracket has an outwardly directed flange at a distal end thereof. The projecting arm is spaceable apart from the body wall of the base bracket member. The outer bracket comprises a spanning wall with an inner side and an outer side. An outer end wall extends from the outer side of the outer bracket. The spanning wall of the outer bracket is slidably positionable between the body wall of the base bracket member and the at least one clip member. As such, the body wall and the at least one clip member sandwich the spanning wall therebetween. 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.

In some configurations, the system further comprises at least one fastener coupling the spanning wall to the body wall.

In some configurations, the projecting arm of the at least one clip member is biased against the spanning wall to force the spanning wall against the body wall.

In some configurations, the first end wall includes a base mounting member positioned so as to overly the first end wall on a side opposite a facing side of the first end wall.

In some configurations, the first end wall further includes a channel disposed on an outward side thereof, with the base mounting member being slidably positionable therealong.

In some configurations, the base bracket member coupling of the at least one clip member is slidably positioned within the channel of the first end wall so as to abut the base mounting member.

In some configurations, the at least one clip member comprises a pair of clip members. A clip member is slidably positioned within the channel of the first end wall on opposite sides of the base mounting member.

In some configurations, a distal mounting member overlies at least a portion of at least one of the second end wall and the body wall.

In some configurations, the distal mounting member overlies an inward side of the second end wall and the body wall.

In some configurations, the second end wall includes a channel, with the distal mounting member having a distal slot engaging member slidably positionable within the channel, and a support arm overlying a portion of the body wall.

In some configurations, the body wall is substantially perpendicular to the second end wall. The distal slot engaging member is substantially perpendicular to the support arm.

In some configurations, the base bracket member comprises a polymer with fiber reinforcement. The distal mounting member comprises a metal or alloy thereof.

In some configurations, the system further comprises a distal coupling member overlying an inner surface of the outer end wall.

In some configurations, the outer end wall further includes a channel disposed on the inner surface thereof. The distal coupling member is slidably insertable within the channel.

In some configurations, the distal coupling member comprises a metal or alloy thereof.

In come configurations, assembly, the outer end wall overlies the second end wall, while being distally spaced therefrom.

In some configurations, the outer bracket is positionable relative to the base bracket member so that the outer end wall and the second end wall are oblique relative to each other, while the spanning wall and the body wall are parallel to each other.

In another aspect of the disclosure, the disclosure is directed to a wall. The wall comprises a substrate, a first base bracket system assembly, a second base bracket assembly, and at least one outer bracket. The substrate has an outer surface. The first base bracket system assembly and the second base bracket assembly each have a base bracket member and at least one clip member. The base bracket member has a first end wall, a body wall extending from the first end wall and a second end wall opposite the first end wall. Each of the at least one clip members are attached to the first end wall and overlie a portion of the body wall. The at least one outer bracket member has a spanning wall and an outer end wall. The spanning wall of the at least one outer bracket is slidably positionable between the base bracket member and the at least one clip of at least one of the first base bracket system and the second base bracket system and fastened thereto. Additionally, the first end wall of the base bracket member is attached to the substrate. Further, a cladding is attached to the second end wall opposite the substrate.

In some configurations, the wall further comprises insulation positioned between the substrate and the cladding.

In yet another aspect of the disclosure, the disclosure is directed to a method of assembling an adjustable support system comprising the steps of: providing a base bracket system assembly, the base bracket system assembly comprising: a base bracket member with a first end wall, a body wall extending from the first end wall and a second end wall opposite the first end wall; at least one clip member attached to the first end wall and overlying a portion of the body wall; providing an outer bracket member having a spanning wall and an outer end wall; slidably positioning the spanning wall between the body wall and the at least one clip member, so that the at least one clip member and the body wall sandwich the spanning wall therebetween; and coupling the spanning wall to the body wall after the step of slidably positioning.

Other systems and methods are likewise contemplated, including the formation of a wall comprising a plurality of base bracket system assemblies and outer brackets that cooperatively are coupled to a wall substrate, with a cladding assembly attached to the outer brackets.

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.

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.

Referring now to the drawings and in particular to, the adjustable support system is shown generally at. The adjustable support systemforms a structure between substrateand cladding assembly. The substrate may comprise a 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. Typically, such an outer surface may be planar, may include surface imperfections, surface variations as well as a plurality of different surfaces.

The cladding assemblyincludes cladding sheetwhich may be attached to the adjustable support system opposite the substrate. In some configurations, rails, such as railsmay extend between adjacent portions of the adjustable support system and the cladding sheet. 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.

The adjustable support systemas is shown incomprises base bracket member, base mounting member, clip member, distal mounting member, outer bracket, distal coupling member, base fastenersand bracket fasteners. The assembled base bracket member, base mounting member, clip member, and distal mounting member collectively define a base bracket system assembly.

The base bracket memberis shown inas comprising first end wall, body walland second wall. The base member may comprise a polymer and fiber composite based material that may be pultruded. One such configuration is disclosed in U.S. Pat. No. 8,826,620 issued to Krause, the entire specification of which is hereby incorporated by reference in its entirety. Of course, other configurations are contemplated as well, including other configurations of the present assignee, among others. It will be understood therefore, that the cross-sectional configuration of the base bracket member is substantially uniform along the length thereof, preferably, as the formation is completed by pultrusion through a pultrusion die. It will be understood that variations may be formed along the length of the base bracket member. It is additionally contemplated, and as will be explained below, a multitude of the base bracket members can be utilized in a single installation, and also to cooperate with a single outer bracket.

In the configuration shown, the first end wallincludes top edge, bottom edge, first side edge, second side edge. The first end wallincludes facing sideand outward sideopposite the facing side. In the configuration shown, the facing sideoverlies the substrate. The first end wall comprises a first leg regionextending one direction from the body wall and a second leg regionextending in the opposite direction from the body wall. In the configuration shown, the width of the first leg region is larger than the width of the second leg region, while variations are contemplated. In the configuration shown, the first leg region and the second leg region define the substantially planar facing side.

A channelis defined on the outward sideof the first leg region. The channelincludes first side slotand a second side slotopposite the first side slot, with a central openingtherebetween exposing the basebetween the first side slot and the second side slot. In the configuration shown, the first side slot and the second side slot are generally mirror images of each other about a line that extends along the longitudinal axis of the channel. It will be understood and explained below that the channel is configured to receive the base mounting memberand the clip memberin mating engagement. It is contemplated which include tab-like features that extend into the first side slot and the second side slot. In other configurations, the first end wallmay include tab-like features with the base mounting memberand the clip membercomprising slot like features for mating slidable engagement. In still other configurations, the outward sidemay comprise a planar structure, with structures adhered or otherwise coupled thereto.

The body wallextends from the first end wall, and generally defines the delineation between the first leg regionand second leg region. In the configuration shown, the body wall is generally perpendicular to the first end wall and includes first sideand second sidedefining a thickness. The perimeter is typically defined by the top edge, bottom edge, inner edgeand outer edge.

The second end wallis positioned at the outer edgeof the body wall opposite the first end wall. The second wall is generally defined by the top edge, bottom edge, first side edgeand second side edge.

The second end wallfurther includes an inward sideand a cladding side. The inward side generally faces toward the substrate of the building, with the cladding side facing the cladding (while variations are contemplated, and the term cladding side is not to be deemed limiting as to contact with, facing or otherwise being associated with the cladding side). In the configuration shown, the second end wall is parallel with the first end wall and perpendicular to the body wall. Variations, however, are contemplated where the walls may be oblique to each other.

The inward sideincludes first side slot, second side slotopposite the first side slot, which is spaced apart by baseopposite of which is central opening. The configuration of the inward side is much like the channel of the first leg region of the first end wall. In the configuration shown, the second end wall meets the body wall at the first side edge of the second end wall so that the second end wall terminates at the body wall. Additionally, in the configuration shown, the second end wall extends in the same direction as the second leg region of the base bracket member, and opposite of the first leg region.

The base mounting memberis shown inas comprising elongated bar memberthat is positioned within the channelof the first end wall. Due to the configuration of the channel, the base mounting member is configured to be slidably positionable therein, and includes upper surface, lower surface, first end, second end, first slot edgeand second slot edge. In the configuration shown, the clip membersare likewise positioned within the channelso that the length of the elongated bar member and the pair of clip members generally matches the length of the base bracket member. It will be understood that the elongated bar member may comprise a single member or multiple members that are positioned in an end to end configuration. Furthermore, it is contemplated that the elongated bar member may comprise a substantially rectangular configuration of uniform thickness. Variations are contemplated to the size and shape thereof, as will be understood by one of skill in the art. Furthermore, the elongated bar member may include a plurality of openings or may include indentations or other markings to identify appropriate regions for the extension of fasteners therethrough.

The clip memberis shown in(and assembled in) as comprising base bracket member coupling, projecting armand distal flange. The base bracket member couplingand the distal flange are generally perpendicular to each other with the projecting arm being oblique to each or perpendicular to each. In certain configurations, the distal flangeand the projecting armmay 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 wallof the base bracket member when installed, so as to provide a biasing force against the distal mounting member toward the body wall of the base bracket member. 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).

In an alternate configuration, and with reference to, the clip memberfurther includes an inwardly protruding stoppositioned at the distal end thereof which faces the outer bracket. At the same time, the outer bracketincludes an outwardly directed flangethat is positioned at the distal endthereof. As will be understood, the inwardly protruding stopprecludes removal of the outer bracket from the sandwiched configuration as the protruding stopcatches the outwardly directed flangeand 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 bracketand the outwardly directed flange to move beyond the protruding stop to separate the same.

This can be helpful as inadvertent disengagement of the structures is precluded if, for example, the outer bracketexperiences a separating force. It will be understood that the outwardly directed flangecan be formed during pultrusion, or may comprise a folded over portion wherein the outer bracketis 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.

The base bracket member couplingincludes slot engaging memberwhich includes first slot side, second slot side, upper surfaceand lower surface. 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.

The projecting armextends from the base bracket member couplingat the proximal end(coupling through the notch) to distal end, and include inner surfacethat generally faces the body walland outer surfaceopposes the inner surface. In the configuration shown, the projecting armcomprises a substantially planar configuration, and of substantially uniform thickness, while variations are contemplated. In the configuration shown, the notchfacilitates the projecting armto be positioned closer to the body wall than would otherwise be possible due to the configuration of the first side slotof the first end wall.

The distal flangeis shown inas comprising proximal end, distal end, with an inner surfaceand an outer surfaceopposite 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, which, as explained is positioned so as to interface with insulation or the like.

In the configuration shown, the projecting arm is longer than either one of the base bracket member coupling or the distal flange, with the distal flange being shorter than the base bracket member. As will be explained in greater detail below, the projecting arm is shorter than the width of the body wall 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.

The distal mounting memberis shown in(and inassembled) as comprising distal slot engaging memberand support arm. In the configuration shown, the distal mounting member comprises a substantially uniform member (which may be formed through an extrusion of a metal or alloy thereof, while not being limited thereto). The distal mounting member extends from first endto second end. In the configuration shown, the distal mounting member has a length that generally corresponds to the base bracket member. Of course, other configurations are likewise contemplated.

The distal slot engaging memberof the distal mounting member includes first slot side, second slot side, upper surfaceand lower surface. As will be understood and explained in greater detail below, the distal slot engaging member is slidably positionable within the channelof the second end wall, so as to be slidably movable therewithin. The support armextends from the distal slot engaging member so as to be positioned along the second side of the body wall, and includes proximal end, distal end, inner surfaceand outer surface. The proximal end includes notchwhich facilitates the attachment of the support arm to the distal slot engaging member around the side slot of the channel. The inner surfaceabuttingly overlies the second sideof the body wall. As will be explained, the distal mounting member provides additional stability to the fastenersthat couple the base bracket member to the outer bracket.

In other configurations, it will be understood that the distal slot engaging member may comprise a pair of members, one of which is positioned on the inward side of the second end wall in overlying fashion with the second end wall and a separate member which is positioned in overlying fashion over the second side of the body wall. In still other configurations, it is contemplated that the distal mounting member may comprise a single member that is adhered or otherwise placed in such an overlying configuration. In still other configurations, the distal mounting member may be molded (or pultruded, or otherwise incorporated) into the construction of the second end of the base bracket member. Similarly, the base mounting member may similarly be molded (or otherwise) into the construction of the first end of the bracket member. That is, the configuration and mating of the base mounting member and the distal mounting member may share commonality in construction (while variations and differences are likewise contemplated).