A carrier construction

Abstract

 A carrier assembly for mounting a member such as an exterior wall panel to a wall surface, said assembly comprising an elongate channel section carrier (10) securable to a wall surface with its axis generally vertical. The channel section including a web (12) and two spaced apart side flanges (14) connected thereto, with inturned beads (16) on the free edges of the side flanges. At least one guide surface (18) is provided on the interior of the channel section carrier and mounting elements (20) are longitudinally slidable within the channel section carrier in abutting relation to the guide surface (18). Grooves (24) on the mounting element (20) engage the guide surfaces (18). When the mounting element (20) has been moved to a desired longitudinal position in the carrier, it is rotated about its axis using a tool, thereby permanently deforming a portion of the guide surface (18) to retain the mounting element in that position.

Description

[0001] The present invention relates to a carrier assembly for mounting a member on a wall surface. While the assembly of the present invention can be used for mounting any member, such as a shelf or the like, on a wall surface, it is especially for use with mounting a wall panelling system, particularly an exterior architectural panelling system, to the outside of a building. However, it can be used for many other purposes.

[0002] Various proposals have been made for mounting a member on a wall surface and these often include generally vertically extending channel or other cross section carriers provided with a number of apertures, notches, tongues or the like at spaced locations along the length of the carrier. These elements are used to mount a hanger or other member at specific locations. Most of these assemblies utilise two and often several carriers which are mounted essentially vertically and it is often quite difficult to ensure that the notches, apertures or tongues of all of the carriers of a set are at exactly the same level because, in mounting the carriers against the wall surface, errors can occur.

[0003] It is an object of the present invention to overcome such a problem.

[0004] According to the present invention there is provided a carrier assembly for mounting a member on a wall surface, said assembly comprising an elongate channel section carrier, means to secure said carrier to said wall surface, with the longitudinal axis of the carrier generally vertical, said channel section including a web, two spaced apart side flanges connected to said web, with inturned beads on the free edges of said side flanges, at least one guide surface on the interior of said channel section carrier, mounting elements longitudinally slidable within said channel section carrier in abutting relation to said at least one guide surface and means on said mounting element which can permanently deform said at least one guide surface at any longitudinal location thereon to define a position in which said mounting elements may be retained.

[0005] With such an arrangement, no preset locations are provided. One simply slides the mounting element longitudinally within the channel section carrier to the desired location and then carries out a movement on said mounting element which permanently deforms the guide surface or surfaces at that longitudinal location. If a series of carriers are provided, having set one such mounting element at a particular height one can readily set another mounting element on an adjacent carrier by use of a spirit level or the like.

[0006] The means on said mounting element which can permanently deform said at least one guide surface can take many forms. In one particularly preferred arrangement according to the present invention, the mounting element is rotatable about an axis substantially perpendicular to the longitudinal axis of the carrier. With such an arrangement, rotation of the mounting element is such as to cause the permanent deformation of the guide surface at a particular longitudinal location.

[0007] The rotation of the mounting element can be about an axis extending substantially perpendicular to the web of the channel in which case the circumferential surfaces of the mounting element can have projections which can engage and bite into guide ribs on the interior surface of the side flanges. It is important, in all structures according to the invention, of course, that the mounting element which should be made of a material which is significantly harder than the material of the carriers. It is contemplated that the carriers themselves could be formed of a plastics material; however, they are preferably formed as an extrusion of an aluminium or aluminium alloy, in which case the mounting elements can be formed of an somewhat harder metal, most commonly mild steel.

[0008] Preferably, however, the mounting element is generally cylindrical, the axis of the cylinder being parallel to the web of the carrier and n faces of the carrier have means slidable relative to the guide surface(s), rotation of said mounting element rupturing a portion of the guide surface(s). It is contemplated that the cylindrical mounting element could have a tongue projecting from each axial end, this tongue passing in a groove formed on the inner face of the flanges of the channel carrier. Rotation of the mounting element will then cause deformation of this groove.

[0009] However, in a preferred structure, the guide surface(s) comprise a longitudinally extending rim on the inner face of at least one of said side flanges and said means slidable relative thereto comprise a co-operating slot in the adjacent end face(s) of said cylindrical mounting element, rotation of said mounting element deforming the longitudinal rib(s), thereby restraining any further longitudinal movement of said mounting element.

[0010] Where the mounting element is required to rotate, it is preferably provided with tool engaging portion whereby it may be used to rotate said mounting element. For example, the mounting element may be provided with an aperture for the insertion of a tommy bar or may be provided with flats for engagement by a spanner.

[0011] The invention also contemplates a rather different arrangement in which said guide surfaces comprise a plurality of longitudinally extending ridges of the inner faces of said inturned beads, said mounting elements each comprise a plate slidable in said channel section, these having a plurality of horizontally extending ridges slidable relative to the ridges of the carrier and a screw connection is provided to urge the horizontal ridges on the mounting element plate to bite into and permanently deform the ridges on the inner of the beads of the carrier. With such a structure, advantageously there is further provided a holding plate associated with each mounting element this having a protuberance engageable between the inturned beads of the carrier, the mounting plate having an aperture therein for the passage of a bolt forming part of said screw connection.

[0012] The invention also contemplates hangers which may be hooked over the mounting element.

[0013] The means to secure the carriers to the wall surface may include a first bracket securable to the wall surface, a second bracket securable to the carrier and means to mount the second bracket adjustably on the first bracket. Such an arrangement allows one to the alter the angle and disposition of the carrier to take into account any irregularities in the wall surface

[0014] With such a structure, the first bracket may comprise a base securable to a wall surface, two spaced arms extending outwardly from the base and horizontal slots in the arms, and the second bracket may comprise a clamp portion clampable to the carrier and two spaced apart legs positionable adjacent to the two arms of the first bracket, locking bolts passing through the slots and being threadably engaged in the legs of the second bracket.

[0015] Desirably the outer surfaces of the arms of the first bracket are formed with vertically extending ridges and holding plates are provided through which the bolts pass, said holding plates also having vertically extending ridges cooperable with the ridges of the arms to define selected positions of said holding plate, and thus of the bolts and second bracket relative to the ridges of the arms and thus of the first bracket.

[0016] In order that the present invention may more readily be understood, the following description is given, merely by way of example, reference being made to the accompanying drawings in which;

Figure 1 is a schematic perspective exploded view showing a portion of one embodiment of carrier assembly according to the invention;

Figure 2 a section taken on the line II-II of Figure 1;

Figure 3 is a perspective view similar to Figure 1, showing a portion of a second embodiment.

Figure 4 is a section taken along the line IV-IV of Figure 3;

Figures 5a and 5b are perspective schematic views of two forms of hanger for use with the carrier and mounting element of Figures 1-4;

Figure 6 is a schematic plan view, in section, of a portion of a wall cladding arrangement employing a carrier assembly according to the invention;

Figure 7 is a schematic perspective view, showing the panelling system of Figure 6;

Figures 8a and 8b are cross sections, to reduced scale, of one embodiment of second bracket used in the arrangement of Figures 6 and 7, before and after, respectively, tightening of the securing bolts.

Figure 9 is a view similar to Figure 6 of a second embodiment of panelling arrangement; and

Figure 10 is a view similar to Figure 7 of the arrangement of Figure 9.

Figure 11 is an enlarged perspective exploded view of a mounting plate used in the embodiment of Figures 9 and 10.

[0017] Referring now first to Figure 1 there is illustrated therein a carrier 10 of generally channel cross-section including a web 12, two side flanges 14 and inturned beads 16 extending generally parallel to the web 12.

[0018] Projecting inwardly parallel to the web 12 and beads 16, are two longitudinally extending ribs 18. Associated with the channel section carrier 10 is a generally cylindrical mounting element 20 which has a diameter slightly less than the spacing between the inner surfaces of the web 12 and beads 16. The length of the element 20 is again slightly less than the spacing between the inner surfaces of the side flanges 14. In order to accommodate the longitudinally extending ribs 18, the end portions 22 of the element 20, which may be, as shown, of reduced diameter, are provided with diametrically extending aligned slots 24 having a width slightly greater than the width of the ribs 18. The cylindrical outer surface of the element 20 is provided with two opposed flat portions 26 to receive a spanner (not shown) or other suitable tool.

[0019] In use, the carrier 10 is mounted (as will be described later) on a wall surface and mounting elements 20 are slid into the end of the channel 10 with the slots 24 accommodating the ribs 18. As is apparent from the description of the dimensions above, the mounting element 20 is a sliding fit within the channel 10. When the mounting element has reached a desired level, that is a desired longitudinal position in the channel 10, the spanner is applied to the flats 26 and the mounting element 20 is rotated about its axis, thereby snapping off a portion of the two ribs 18 as shown in Figure 2. With an appropriate adaptation of the length of element 20 and/or with suitable diameter end portions 22, it is also possible to manoeuvre the elements in position as shown at the top of Figure 1. It will be appreciated that the mounting element 20 needs to be made of a far harder material than the channel section and for this reason it is preferred to use a mild steel mounting element 20 and an aluminium alloy carrier 10. It will be appreciated that once the mounting element has thus been twisted, it is thereafter not practical to move the mounting element in either direction.

[0020] In use, one will position several of these mounting elements along the length of the carrier 10 as shown in Figure 1 so that the mounting elements 20 thus form the rungs of a ladder, these rungs being positioned at the desired longitudinal locations along the carrier 10. In carrying this out one will start at one end, for example the bottom, having slid the mounting element down from the top of the carrier. This mounting element is then twisted to locate it and the next mounting element is then introduced and twisted at its desired location and so on. Having thus located the mounting elements at the desired positions, then these may be used to support any suitable form of hanger, for example a shelf support hanger of the type illustrated very schematically in Figure 5a in which it will be seen that a hook portion 28 of the hanger 30 can be engaged over a mounting element 20.

[0021] In Figure 1 the carrier channel section 10 includes central portion 34 attached to a T-shaped centre flange 36 and two side channel webs 38, from which extend the webs 12, side flanges 14 and inturned beads 16, the inner faces of the beads being provided with longitudinally extending serrations 40.

[0022] Figures 3 and 4 show a structure which is very similar to that of Figures 1 and 2 and like parts have been indicated by like reference numerals. The main difference is that the webs 12 have, associated therewith, longitudinally extending ridges 19 which extending towards the inturned beads 16 and form a continuation of webs 38. The cylindrical mounting elements shown more clearly in Figure 3 have, spaced from their ends, circumferential annular grooves 23 so positioned as to cooperate with the ridges 19. Thus the annular grooves 23 are axially spaced by the same spacing as exists between the ridges 19.

[0023] Extending outwardly from the annular grooves 23 are flat portions 25. While only one set of flat portions, which extend in planes parallel to the axis of the mounting element 20, need to be provided, the structure illustrated shows two such flats at each end.

[0024] It will be appreciated that the arrangement is such that the mounting elements can thus be mounted as shown at the top in Figure 3, left hand side, and twisted so that they then extend horizontally, the flats 25 allowing the end parts of the mounting elements to pass inside the ridges 19. However, when one starts to turn the mounting elements about their axes, the annular grooves and the ridges will cooperate to lock the side channel webs 38 in position, thereby inhibiting any outward flexing thereof caused by turning of the mounting element or subsequently by wind conditions.

[0025] The carrier channel 10 is illustrated used in the panel supporting structure shown in Figure 6. One of the mounting elements 20 is illustrated therein and this cooperates with two hangers in the form of hook members 50 lockingly engaged in grooves 53 provided in edge profiles 57 of panels 54. This form of hanger 50 is shown in Figure 5B and includes a hook forming recess 48, and longitudinal ridges 51 having a threaded aperture 52. The ridge 51 on each hanger 50 is slid into a groove 53 in the edge profile 57 of each panel 54 and is secured at a desired position therein by a bolt 55 passing through the threaded aperture 52 in ridge 51.

[0026] Figure 7, which is a perspective view of the assembly of Figure 6 also illustrates one method of mounting the channel section profile 10. A first bracket 60 is secured to a wall surface in any suitable way. This first bracket 60 comprises a base 62 securable to the wall surface and two spaced arms 64 each having a slot 66 therein and vertically extending serrations 68 on their outer surfaces. The first bracket 60 cooperates with a second bracket 70 which is illustrated in more detail in Figures 8a and 8b. This has two side walls 72 with aligned internally threaded bosses 74, the side wall 72 being joined by a cross-wall 76. Spaced from the cross-wall 76 are two jaws 80 which, together with the cross-wall 76, define a T-shaped groove 82 shaped and sized to accommodate the T-shaped flange 36 of the carrier 10. In their relaxed state, the side walls 72 converge towards one another slightly, as shown in Figure 8a.

[0027] Bolts 84 are passed through apertures in holding plates 86 which are provided with vertically extending ridges matching the ridges 68 on arms 64 of the first bracket 60. Bolts 84 are screwed into the threaded bosses 74 of the second bracket and the relative positions of the two brackets can be determined by sliding the bolts further and less distances into the slots 66 and when the vertically extending ridges of the holding plates and the arms 64 are inter-engaged at a desired location, the bolts 84 are then fully tightened. As the bolts are tightened, the side walls 72 are deformed so that they extend parallel, until they abut the arms 64 of the first bracket. This, in turn, deforms jaws 80, reducing the size of the T-shaped groove 82, thereby securely clamping the T-shaped flange 36 of carrier 10.

[0028] Figure 7 in particular shows that the panels 54 are sandwich panels and also show how the hook members 50 are secured in place to the edge profile 57. The panels shown in Figure 6 are rectangular, the longer dimension of the rectangle being vertical, as an example.

[0029] Figures 9 and 10 show an arrangement in which the longer dimension of the rectangular panels is horizontal. Like parts in Figures 9 and 10 have been indicated by like reference numerals. In this structure, however, instead of the hangers 50 and mounting elements 20, a mounting plate 90 is used which has a central protuberance 92 engaged in the gap between the inturned beads 16 of the carrier 10. Mounted within the carrier 10, between the side flanges 14 is a holding plate 94 having a plurality of horizontally extending ridges 96. If reference is again made to Figures 1 and 3 it will be noted that the inturned beads 16 have, on their inner face, a plurality of longitudinally (that is to say vertically in this instance) extending serrations 40 formed in the relatively soft metal of the extrusion of the carrier 10.

[0030] A countersunk head bolt 98 passes through the mounting plate 90 and is screwed into the holding plate 94. As this screw is tightened up, the relatively hard ridges on the holding plate 94 dig into the relatively soft serrations 40 of the extrusion 10 and permanently deform these serrations to provide a desired location of the holding plate, and thus of the mounting plate 90.

[0031] If reference is again made to Figure 10, it will be seen that the mounting plate 90 has a plurality of apertures 100 into which are threaded bolts 102 passing apertures 100 into which are threaded bolts 102 passing through part circular locking plates 104 provided with grooves 106. These grooves 106 may be engaged over rims of the end flanges 108 of the panels 110 and serve to lock these panels against the mounting plate 90. The panels can be introduced into place with the plates 104 oriented while still slightly loose with the cut off portion horizontal, whereafter the plates 104 are rotated so that the grooves engage the end flanges 108. This mounting system corresponds substantially to that described in EP-A-549215 which is hereby incorporated by reference.

[0032] As can be seen more particularly in Figure 11, spring washers 107 are positioned adjacent the plate 90 and the bolts 102 pass therethrough. The spring washers 107 allow a certain amount of resilience thereby facilitating rotation of the plates 104, while still untightened or upon loosening thereof. Of course the mounting arrangement shown in Figures 9, 10 and 11 can be used in combination with the mounting arrangement shown in Figures 6, 7, 8a and 8b, thereby to provide further support which may be necessary in some circumstances.

Claims

1. A carrier assembly for mounting a member (54,110) on a wall surface, said assembly comprising an elongate channel section carrier (10), means (60-86) to secure said carrier to said wall surface with the longitudinal axis of the carrier generally vertical, said channel section including a web (12,34) and two spaced apart side flanges (14) connected to said web, with inturned beads (16) on the free edges of said side flanges, at least one guide surface (18,40) on the interior of said channel section carrier, mounting elements (20,90) longitudinally slidable within said channel section carrier in abutting relation to said at least one guide surface and means (24,96) on said mounting element which can permanently deform said at least one guide surface at any longitudinal location thereon, to define a position in which in the mounting elements may be retained.

2. An assembly according to claim 1, wherein each mounting element (20) is rotatable about an axis substantially perpendicular to the longitudinal axis of the carrier (10).

3. An assembly according to claim 2, wherein each mounting element (20) is generally cylindrical, the axis of the cylinder being parallel to the web of the carrier, end faces (22) of the carrier having means (24) slidable relative to said guide surface(s) (18), rotation of said mounting element deforming a portion of the guide surface(s) (18).

4. An assembly according to claim 3, wherein said guide surface, comprise a longitudinally extending rib (18) on the inner face of at least one of said side flanges (14) and wherein said means slidably relative thereto comprise a cooperating slot (24) in the adjacent end face(s) of said cylindrical mounting element (20), rotation of said mounting element (20) deforming the longitudinal rib(s) thereby restraining any further longitudinal movement of said mounting element.

5. An assembly according to claim 2, 3 or 4, wherein a tool engaging portion (26) is provided on said mounting element, whereby a tool maybe used to rotate said mounting element.

6. An assembly according to claim 2, 3, 4 or 5, wherein the mounting element comprises a circumferential groove (23), axially spaced from each end of the element (20) and wherein the elongate channel section carrier includes a longitudinally ridge (19) engageable in each said groove (23) to guide the mounting element longitudinally of the elongate channel section carrier.

7. An assembly according to claim 6, wherein the end parts of said mounting element (20) further comprise at least one flat portion (25) arranged in a plane parallel to the axis at each end, extending from the associated end to the circumferential groove, to enable the mounting element to be introduced past the ridge (19) on the carrier.

8. An assembly according to claim 1, wherein said guide surfaces comprise a plurality of longitudinally extending serrations (40) on the inner faces of said inturned beads (16), wherein said mounting elements each comprise a plate (94) slidable in said channel section and having a plurality of horizontally extending ridges (96) slidable relative to the serrations (40) of the carrier and wherein a screw connection (98) is provided to urge the horizontal ridges (96) on the mounting element plate (94) to bite into and permanently deform the serrations (40) on the inner surface of the beads of the carrier.

9. An assembly according to claim 8, and further comprising a holding plate (90) associated with each mounting element (94) and having a protuberance (92) engageable between the inturned beads of the carrier, the mounting plate having an aperture therein for the passage of a bolt forming part of said screw connection (98).

10. An assembly according to any preceding claim and further comprising hangers (30,50) which may be hooked over said mounting element (20).

11. An assembly according to any preceding claim, wherein said means to secure said carriers include a first bracket (60) securable to the wall surface, a second bracket (70) securable to the carrier (10) and means (74,87,86) to mount the second bracket (70) adjustably on the first bracket (60).

12. An assembly according to claim 11, wherein the first bracket (60) comprises a base (62) securable to a wall surface, two spaced arms (64) extending outwardly from the base and horizontal slots (66) in said arms, wherein the second bracket (70) comprises a clamp portion (80) clampable to the carrier and two spaced apart legs (72) positionable adjacent the two arms (64) of the first bracket and wherein locking bolts (84) pass through the slots and threadably engage (at 74) in the legs of the second bracket.

13. An assembly according to claim 12, wherein the outer surfaces of the arms (64) of the first bracket (60) are formed with vertically extending ridges (68) and further comprising holding plates (86) through which said bolts pass, said holding plates having vertically extending ridges cooperable with the ridges (68) of the arms to define a selected position of said holding plate and thus of the bolts and second bracket relative to the ridges of the arms and thus of the first bracket.

14. An assembly according to claim 12 or 13, wherein the two spaced apart legs (72) of the second bracket are inclined towards one another, in the relaxed state, and wherein tightening of the locking bolts (84) deforms said arms (72) until they abut the two spaced apart arms of the first bracket, such deformation causing deformation of the clamp portions (80), thereby to clamp the clamp portion (36) on the carrier.

Drawing