U.S. patent application number 14/973613 was filed with the patent office on 2016-06-30 for adjustable joist hanger.
The applicant listed for this patent is Darrell Meyer. Invention is credited to Darrell Meyer.
Application Number | 20160186424 14/973613 |
Document ID | / |
Family ID | 56163547 |
Filed Date | 2016-06-30 |
United States Patent
Application |
20160186424 |
Kind Code |
A1 |
Meyer; Darrell |
June 30, 2016 |
Adjustable Joist Hanger
Abstract
An easily-stackable joist support structure is provided having
prefabricated tabs embedded within the main plane of the support
structure to allow the tabs to be bent during construction. The
tabs typically have both slot screw holes and fixed screw holes.
Once the tabs are bent (typically to a 90 degree angle), a screw
partially engaged through the slot and the joist can hold the joist
in place while the joist is adjusted before the screw is fully
engaged. Then screws can be engaged through the fixed screw holes
to fully hold the joist in place. The support structure can be
Z-shaped so that one ledge lays on top of the ceiling track before
the support structure is attached to the track, and the other ledge
is used to support the joist before the joist is attached to the
support structure.
Inventors: |
Meyer; Darrell; (Anaheim,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Meyer; Darrell |
Anaheim |
CA |
US |
|
|
Family ID: |
56163547 |
Appl. No.: |
14/973613 |
Filed: |
December 17, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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62093320 |
Dec 17, 2014 |
|
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Current U.S.
Class: |
52/702 ;
52/745.21 |
Current CPC
Class: |
E04C 2003/0482 20130101;
E04B 5/10 20130101; E04B 1/24 20130101; E04B 2001/2457 20130101;
E04B 2001/2484 20130101; E04B 2001/2448 20130101 |
International
Class: |
E04B 1/26 20060101
E04B001/26; E04B 1/38 20060101 E04B001/38 |
Claims
1. A joist support structure, comprising: a support body; a first
tab disposed on a side of the support body that couples the support
body to a joist, the first tab comprising (a) a first adjustment
slot and (b) a first plurality of holes; and wherein the first tab
has (1) a first flat configuration wherein the first tab is
coplanar with the side of the support body and (2) a first bent
configuration wherein the first tab is bent to a first angle
greater than zero relative to the side of the support body.
2. The joist support structure of claim 1, wherein the support body
has a Z-shaped cross-section providing an upper flange configured
to abut and a top surface of a track and a lower flange configured
to abut and a bottom surface of the joist.
3. The joist support structure of claim 2, wherein upper flange is
further configured to couple to the top surface of the track and
the lower flange is further configured to couple to the bottom
surface of the joist.
4. The joist support structure of claim 1, wherein the support body
has a C-shaped cross-section providing an upper flange configured
to abut a top surface of the joist and a lower flange configured to
abut a bottom surface of the joist.
5. The joist support structure of claim 1, wherein the first tab is
formed with the support body by at least one of machining or
casting.
6. The joist support structure of claim 1, wherein the first tab in
the first bent configuration is oriented at substantially a 90
degree angle to the side of the support body.
7. The joist support structure of claim 1, further comprising a set
of perforated holes along a folding line of the first tab to
facilitate bending of the first tab to the first bent
configuration.
8. The joist support structure of claim 1, comprising a second tab
configured to attach to the side of the support body.
9. The joist support structure of claim 8, wherein the second tab
has (1) a second flat configuration wherein the second tab is
coplanar with the side of the support body and (2) a second bent
configuration wherein the second tab is bent to a second angle
greater than zero relative to the side of the support body.
10. The joist support structure of claim 9, wherein the first tab
is configured to bend in a first direction to fasten to the joist
and the second tab is configured to bend in a second direction to
fasten to the joist, wherein the first direction is different from
the second direction.
11. The joist support structure of claim 8, wherein the second tab
couples the support body to the joist via (a) a second adjustment
slot and (b) a second plurality of holes.
12. The joist support structure of claim 1, further comprising a
slot screw to couple the joist support structure via the first
adjustment slot and a set of screws configured to further couple
the joist support structure to the joist via the first plurality of
holes.
13. The joist support structure of claim 12, wherein a
cross-sectional area of the slot screw is larger than a
cross-sectional area of any of the set of screws.
14. A method of fastening a joist to a joist support structure,
where the joist support structure has a first tab having an
adjustment slot and a plurality of holes, the method comprising the
steps of: placing the joist support structure in a desired location
relative to the joist; bending the first tab such that a portion of
the first tab is at a first angle greater than zero relative to the
side of the joist support structure on which the first tab is
disposed; positioning the joist such that a side of the joist is
substantially parallel to the first tab and an end of the joist is
near the first tab; loosely fastening the joist to the first tab
using a fastener that passes through the adjustment slot of the
first tab and into the side of the joist; upon loosely fastening
the joist to the first tab, repositioning the joist relative to the
joist support structure; and upon repositioning the joist, firmly
fastening the joist to the first tab using a plurality of fasteners
and the plurality of holes on the first tab.
15. The method of claim 14, wherein the fastener comprises a
screw.
16. The method of claim 14, wherein the plurality of fasteners
comprise screws.
17. The method of claim 14, wherein the first tab is substantially
perpendicular to the joist after the step of bending.
18. The method of claim 14, further comprising the steps of:
bending a second tab having a second adjustment slot and a second
plurality of holes, where the second tab is also disposed on the
joist support structure, such that a portion of the second tab is
at a second angle greater than zero relative to the side of the
joist support structure on which the second tab is disposed;
positioning the joist such that a side of the joist is
substantially parallel to the second tab and the end of the joist
is near the second tab; loosely fastening the joist to the second
tab using a second fastener that passes through the second
adjustment slot of the first tab and into the side of the joist;
upon loosely fastening the joist to the second tab, repositioning
the joist relative to the joist support; and upon repositioning the
joist, firmly fastening the joist to the first tab using a second
plurality of fasteners and the plurality of holes on the second
tab.
19. The method of claim 14, wherein the step of bending the first
tab is performed using a bending tool provided with the joist
support structure.
20. The method of claim 14, wherein the step of bending the first
tab is performed by bending the first tab along a first row of
perforation holes along a side of the first tab.
Description
[0001] This application claims priority to U.S. Provisional
Application Ser. No. 62/093,320, filed Dec. 17, 2014. This and all
other extrinsic materials identified herein are incorporated by
reference in their entirety.
FIELD OF THE INVENTION
[0002] The field of the invention is joist support structures.
BACKGROUND
[0003] The background description includes information that may be
useful in understanding the present invention. It is not an
admission that any of the information provided in this application
is prior art or relevant to the presently claimed invention, or
that any publication specifically or implicitly referenced is prior
art.
[0004] All publications identified in this application are
incorporated by reference to the same extent as if each individual
publication or patent application were specifically and
individually indicated to be incorporated by reference. Where a
definition or use of a term in an incorporated reference is
inconsistent or contrary to the definition of that term provided in
this application, the definition of that term provided in this
application applies and the definition of that term in the
reference does not apply.
[0005] Construction of a building begins with a solid foundation
and a solid frame upon which holds the building infrastructure
together. Proper attachment mechanisms and placement of wall studs
relative to one another is imperative. While studs can be directly
attached to tracks and ceiling joists, intermediary support
structures are preferred to improve the connection and placement of
the framing elements.
[0006] CA 2,525,416 to Hall teaches a C-shaped track apparatus that
helps guide joist placement in between the top and bottom rims of
the C-shape during construction. Hall's attachment apparatus,
however, requires a joist to be inserted in between the top and
bottom of the C-shape, which requires precise control over the
heavy joist during placement. In addition, Hall's track apparatus
requires a separate connector bracket to be used to connect the
joist and the track to one another, which can be easily lost,
misplaced, or misaligned during construction.
[0007] U.S. Pat. No. 7,240,459 to Daudet also teaches a C-shaped
joist rim apparatus with an integrated attachment tab that helps to
attach the joist to the ceiling. Since the attachment tab is
integrated into the ceiling track, the separate connector bracket
is not needed, and the construction process is simplified. But
Daudet's ceiling track is difficult to stack, since the integrated
attachment tabs are perpendicular the C-shaped rims. In addition,
Daudet's joist rim still uses C-shaped tracks, which requires
precise control over the heavy joist. Such precise control is very
difficult, even when using large construction machinery to help
support the joist.
[0008] U.S. Pat. No. 8,091,316 to Beck teaches a Z-shaped ceiling
track apparatus with integrated tabs that allow a construction
worker to lay the joist on top of the ceiling track apparatus
without needing such precise control to wedge a joist between top
and bottom lips of a C-shaped apparatus. Beck's ceiling track
apparatus, however, are even more difficult to stack since the
Z-shape encourages stacked multiple apparatus to lean to the side
and fall over. In addition, Beck's ceiling track apparatus fails to
account for joists that are placed slightly out of alignment and
need to be repositioned using mechanical means to make last-minute
adjustments.
[0009] Thus, there is still a need for improved joist support
structures that are easier to stack and provide additional
adjustment mechanisms.
SUMMARY OF THE INVENTION
[0010] The inventive subject matter provides apparatuses, systems
and methods in which a joist support structure has bending tabs
with adjustment slots and fixed holes to enable adjustable joist
placement prior to more permanent fixation of a joist to the joist
support structure. A user can partially engage a screw through the
slot to hold a joist in place along one axis while the user slides
the joist along the main axis to make final adjustments. Once the
slot screw is fully engaged, substantially holding the joist in
place, fastening screws can be engaged through the fixed screw
holes. The tabs lie in the plane of the main body of the support
structure during shipping to allow for easy stacking, and are
preferably perforated along the edge where the tabs bend to improve
the ability to bend the tabs. The joist support structure is
preferably Z-shaped to allow a prefabricated deck to be easily set
on top of the lower ledge of the support structure before screws
are set in place.
[0011] In one aspect of the inventive subject matter, the inventors
contemplate a joist support structure that includes a support body
and a tab disposed on the side of the support body. The tab couples
the support body to a joist. The tab has an adjustment slot and a
number of holes on it that are used to fasten the support body to
the joist. Preferably, the tab has two key configurations: a flat
configuration where the tab is coplanar with the side of the
support body and a bent configuration where the tab is bent to an
angle greater than zero (e.g., a 90 or 45 degree angle) relative to
the side of the support body.
[0012] In some embodiments, the support body has a Z-shaped
cross-section with an upper flange that is designed to abut a top
surface of a track or other surface and a lower flange that is
designed to abut a bottom surface of a joist (e.g., the support
body rests on a track while simultaneously supporting a joist).
Generally, the support body is configured to couple the upper
flange to a top surface of the track and couple the lower flange to
the bottom surface of the joist, for example using screw holes or
other fastener support mechanisms. In other embodiments, the
support body has a C-shaped cross-section having an upper flange
that is designed to abut a top surface of a joist and a lower
flange that is designed to abut a bottom surface of the same
joist.
[0013] In preferred embodiments, the tab is formed with the support
body (e.g., by machining, casting, forging, cutting, or the like).
To facilitate bending, the tab can be formed in the side of the
support body such that there are structural weaknesses along a line
where the bend is intended to occur compared to other portions of
the support body. For example, perforation holes could be formed
along the line, or a groove could be worn away along the line.
[0014] The inventors additionally contemplate that more than one
tab per joist can be preferable to increase the strength of the
coupling between the joist and the support body. In embodiments
having two tabs, for example, the tabs can bend outward from the
side of the support body in different directions (e.g., opposite
directions). Outside of bending direction, multiple tabs on a
particular support body are generally the same in terms of size,
shape, and hole/slot configuration.
[0015] In some embodiments, the joist support structure also
includes a fastener (e.g., a screw or a nut and bolt) to couple the
support body to a joist via the adjustment slot, and a plurality of
fasteners (e.g., screws or nuts and bolts) to further couple the
support beam to the joist via the first plurality of holes. In
these embodiments, it can be preferable for the screw passing
through the adjustment slot to have a larger cross section than any
of the other screws.
[0016] In another aspect of the inventive subject matter, the
inventors contemplate a method of fastening a joist to a joist
support structure using a tab as described above (e.g., a tab
having an adjustment slot and a plurality of holes). To fasten a
joist to the joist support structure, the first step is to place
the joist support structure in a desired location (e.g., put it
into place in a construction site). The second step is to bend the
tab such that a portion of the tab is at an angle relative to the
side of the joist support structure (e.g., substantially
perpendicular to the joist). The third step is to position the
joist such that a side of the joist is substantially parallel to
the tab and an end of the joist is near the tab. The fourth step is
to loosely fasten the joist to the tab using a fastener (e.g., a
screw or nut and bolt) that passes through the adjustment slot of
the tab and into the side of the joist. The fifth step is to
repositioning the joist to be level, and the last step is to firmly
fasten the joist to the tab using a number of fasteners (e.g.,
screws or nuts and bolts) and the holes on the tab. Although
described in a particular order, these steps do not all necessarily
have to occur in the order described above.
[0017] In some embodiments, the steps of bending the tab,
positioning the joist, loosely fastening the joist to the tab,
repositioning the joist, and firmly fastening the joist can all be
completed with a second, separate tab in conjunction with the first
tab. The inventors contemplate that any number of tabs can be used
without departing from the inventive concepts described in this
application.
[0018] Various objects, features, aspects and advantages of the
inventive subject matter will become more apparent from the
following detailed description of preferred embodiments, along with
the accompanying drawing figures in which like numerals represent
like components.
BRIEF DESCRIPTION OF THE DRAWING
[0019] FIG. 1 is a perspective view of an inventive joist support
structure
[0020] FIGS. 2A-2C are a plan views of exemplary tab sizes and
measurements
[0021] FIG. 3 shows a perspective view of the inventive joist
support structure of FIG. 1 as used with a stud, track, and
joist
[0022] FIG. 4 shows a perspective view of the stud, track, and
joist of FIG. 3 having a corrugated deck laying on top of the
joist.
[0023] FIG. 5A shows a side view of several tabs in the joist
support structure of FIG. 1
[0024] FIG. 5B shows a blown-up view of the tabs of FIG. 5A.
[0025] FIG. 6 shows a top-down view of an exemplary corrugated deck
being mounted on inventive joist support structures of the present
invention.
[0026] FIG. 7 shows a perspective view of an alternative inventive
Z-shaped joist hangar having numbered labels.
[0027] FIG. 8 shows an embodiment of a tab bending tool.
DETAILED DESCRIPTION
[0028] The following description includes information that may be
useful in understanding the present invention. It is not an
admission that any of the information provided in this application
is prior art or relevant to the presently claimed invention, or
that any publication specifically or implicitly referenced is prior
art.
[0029] In some embodiments, the numbers expressing quantities of
ingredients, properties such as concentration, reaction conditions,
and so forth, used to describe and claim certain embodiments of the
invention are to be understood as being modified in some instances
by the term "about." Accordingly, in some embodiments, the
numerical parameters set forth in the written description and
attached claims are approximations that can vary depending upon the
desired properties sought to be obtained by a particular
embodiment. In some embodiments, the numerical parameters should be
construed in light of the number of reported significant digits and
by applying ordinary rounding techniques. Notwithstanding that the
numerical ranges and parameters setting forth the broad scope of
some embodiments of the invention are approximations, the numerical
values set forth in the specific examples are reported as precisely
as practicable. The numerical values presented in some embodiments
of the invention may contain certain errors necessarily resulting
from the standard deviation found in their respective testing
measurements.
[0030] Unless the context dictates the contrary, all ranges set
forth in this application should be interpreted as being inclusive
of their endpoints and open-ended ranges should be interpreted to
include only commercially practical values. Similarly, all lists of
values should be considered as inclusive of intermediate values
unless the context indicates the contrary.
[0031] As used in the description in this application and
throughout the claims that follow, the meaning of "a," "an," and
"the" includes plural reference unless the context clearly dictates
otherwise. Also, as used in the description in this application,
the meaning of "in" includes "in" and "on" unless the context
clearly dictates otherwise.
[0032] The recitation of ranges of values in this application is
merely intended to serve as a shorthand method of referring
individually to each separate value falling within the range.
Unless otherwise indicated in this application, each individual
value is incorporated into the specification as if it were
individually recited in this application. All methods described in
this application can be performed in any suitable order unless
otherwise indicated in this application or otherwise clearly
contradicted by context. The use of any and all examples, or
exemplary language (e.g. "such as") provided with respect to
certain embodiments in this application is intended merely to
better illuminate the invention and does not pose a limitation on
the scope of the invention otherwise claimed. No language in the
specification should be construed as indicating any non-claimed
element essential to the practice of the invention.
[0033] Groupings of alternative elements or embodiments of the
invention disclosed in this application are not to be construed as
limitations. Each group member can be referred to and claimed
individually or in any combination with other members of the group
or other elements found in this application. One or more members of
a group can be included in, or deleted from, a group for reasons of
convenience and/or patentability. When any such inclusion or
deletion occurs, the specification is in this application deemed to
contain the group as modified thus fulfilling the written
description of all Markush groups used in the appended claims.
[0034] One should appreciate that the disclosed techniques provide
many advantageous technical effects including the ability to stack
tabbed joist support structures for shipping where the tabs are
unified with the main body of the joist support structure, the
ability to slide the joist along a slot of the tab before fixing
the joist in place, and the ability to easily stack prefabricated
ceilings on top of a joist support structure.
[0035] The following discussion provides many example embodiments
of the inventive subject matter. Although each embodiment
represents a single combination of inventive elements, the
inventive subject matter is considered to include all possible
combinations of the disclosed elements. Thus if one embodiment
comprises elements A, B, and C, and a second embodiment comprises
elements B and D, then the inventive subject matter is also
considered to include other remaining combinations of A, B, C, or
D, even if not explicitly disclosed.
[0036] As used in this application, and unless the context dictates
otherwise, the term "coupled to" is intended to include both direct
coupling (in which two elements that are coupled to each other
contact each other) and indirect coupling (in which at least one
additional element is located between the two elements). Therefore,
the terms "coupled to" and "coupled with" are used
synonymously.
[0037] FIG. 1 shows an exemplary joist support structure 100 having
a first tab 102 and second tab 104 that are unified with the main
body 106 of the joist support structure 100. As used in this
application, a tab that is "unified" with the main body 106 of the
joist support structure 100 is one that is permanently attached to
the joist support structure 100 in such a way that the only way to
remove the tab is to rip or cut the tab away from the main body
106. Such tabs can be welded or glued onto the main body 106, but
are preferably molded as a single contiguous piece with the main
body 106. In some embodiments, the main body 106 can be cast into a
Z-shaped support structure without a tab, and the tab, slot, and
screw holes, and perforated holes can then be cut (e.g., machined,
lasered, water cut) out of the main body 106.
[0038] As shown, both the first tab 102 and the second tab 104 are
flat and lay substantially flat within the main body 106 of the
joist support structure 100 prior to bending the tabs 102 and 104.
"Substantially flat within the main body" for purposes of this
application means that the tab is coplanar with the main body of
the joist support structure and it does not deviate more than 5
degrees in any direction from the plane of the main body 106.
[0039] In the embodiment shown in FIG. 1, both the first tab 102
and the second tab 104 are configured to bend along the vertical
perforation holes 124. Either the first tab 102 or the second tab
104 can be bent to any angle (e.g., 45-50, 50-55, 55-60, 60-65,
65-70, 75-80, 80-85, 85-90 degrees) relative to the main body 106
of the joist support structure 100, but preferably both tabs 102
& 104 are bent to substantially 90 degree angles so as to abut
a surface of a joist (not shown in FIG. 1). As used in this
application, a "substantially 90 degree angle" is an angle that is
at most 5 degrees away from a 90 degree angle. In addition, any
angle measurement that is "substantially" close to a desired angle
should be at most 5 degrees away from that desired angle.
Preferably, first tab 102 and second tab 104 are configured to bend
in opposing directions, to increase the stability of the attachment
junctures. In some embodiments, however, the tabs can bend in the
same direction. An outside edge of the joist support structure 100
opposing the bending vertex of the tab can be slightly sloped to
assist in "gripping" the edge of the tab to help bend it in
place.
[0040] In other embodiments, a bending tool can be provided that
helps to bend the tab into a desired position. Typically such tab
unbending tools increase a force applied to the tab to assist in
bending the tab. An exemplary bending tool 800 can be seen in more
detail in FIG. 8. The bending tool 800A & 800B fits around both
major sides of a bendable tab, and increases an effective length of
a lever arm used to bend the tab. As applied to the joist support
structure shown in FIG. 1, a construction worker can position the
bending portion 804 of the bending tool 800 against the tab 102 and
bend the tab 102 upwards to a substantially 90 degree angle more
easily than without using the tool 800. While the bending tool 800
in FIG. 8 is shown as two parts that are joined together (a handle
802 and a bending portion 804), the entire bending tool 800 can be
cast of a single piece without departing from the scope of the
invention. In some embodiments, a single bending tool could be
provided along with a plurality of joist support structures having
bendable tabs.
[0041] As shown in FIG. 1, each tab 102 & 104 has a single
adjustment slot 108 & 110 and four pre-drilled screw holes 112
& 114 to assist in attaching each tab 102 & 104 to a joist
(not shown), although more or fewer adjustment slots 108 & 110
and/or holes 112 & 114 can be implemented without departing
from the scope of the invention. In fact, more than two tabs can be
configured to attach to a joist. In preferred embodiments, each tab
is at least 1.5 inches in height to provide enough support for a
joist. The main body 106, upper flange 116, and lower flange 118 of
the joist support structure 100 also have holes 120 & 122 to
help attach the joist support structure 100 to a track (not shown)
or other parts of the joist (not shown). The functionality of these
adjustment slots 108 & 110 and holes 112 & 114 are shown in
greater detail in FIG. 3.
[0042] In FIGS. 2A, 2B, and 2C, various tab configurations are
shown for three different exemplary support structures 200A, 200B,
& 200C. Each joist support structure is shown having a Z-shaped
cross-sectional area with both tabs bent to a substantially
90-degree angle relative to the side of the respective joist
support structures. Each joist support structure has an upper
flange that faces left and a lower flange that faces right. Each
upper flange is configured to rest on a top of a surface, such as a
track (not shown) or bearing wall (not shown), to assist in
attaching each corresponding joist support structure to the track.
Once a joist support structure is fully attached to a track, a
lower flange can be used to help support the weight of an end of a
joist before the joist has been attached to the joist support
structure using the tabs. Because the joist support structure is
Z-shaped, it is reversible and can be used on any side of a
load-bearing wall.
[0043] FIG. 2A shows exemplary measurements for a joist support
structure 200A configured to attach to a joist having a height of
about 12 inches by its tabs 202A. The upper flange 204A and lower
flange 206A extend from the support body 208A of the joist support
structure 200A by 2 inches, and the total height of the support
body 208A is 12 inches. Each of the tabs 202A is substantially
square-shaped, having 3-inch perimeters, and are spaced from one
another by 3 inches. The tabs have a smaller spacing from the
flanges, each being 1.5 inches from the upper and lower flanges
204A & 206A, respectively.
[0044] FIG. 2B shows a similar configuration for a joist support
structure 200B having a height of the support body 208B of about 10
inches. The flanges 204B & 206B still have 2-inch widths, and
the tabs 202B are still shaped as 3-inch squares, but the tabs 202B
are separated from one another by 2 inches, and each tab is spaced
from the upper flange 204B and lower flange 206B by 1-inch,
respectively. FIG. 2C shows a configuration for a joist having a
height of the support body 208C of about 8 inches. The tabs 202C
are rectangular in shape, having a 2-inch height and a 2.5-inch
width, and are separated from one another by only 1.5 inches. Each
tab 202C is spaced from the upper flange 204C and lower flange 206C
by 1.25 inches, respectively.
[0045] FIG. 3 shows a joist support structure 300 as used with a
C-shaped stud 302, a C-shaped floor track 304, and joist 306. A
C-shaped stud 302 is shown on top of the C-shaped floor track 304,
which in turn is on top of a C-shaped ceiling track 308, which sits
on top of a lower C-shaped stud 310. The Z-shaped joist support
structure 300 is shown with the upper flange 312 sandwiched in
between the C-shaped floor track 304 and the C-shaped ceiling track
308. The joist support structure 300 is attached to the C-shaped
ceiling track 308 using large screws. In some embodiments, the
screws are course grade and self-tapping, so that they can
penetrate any portion of the ceiling track without needing to
properly align screw holes beforehand. The threads of the screws
are also preferably shaped to hug threads within each of the pilot
holes to increase traction between the screws and the joist support
structure. In other embodiments, nuts and/or washers and bolts are
provided to couple to the other side of the screws where the pilot
holes are not threaded. While not shown, screws can also penetrate
the C-shaped ceiling track 308, the upper flange 312 of the joist
support structure, and the C-shaped floor track 304, which helps to
hold the upper flange 312 in place with respect to both the
C-shaped floor track 304 and the C-shaped ceiling track 308. There
can also be screws coupling the joist support structure 300 to the
lower C-shaped vertical stud 310.
[0046] Once the joist support structure 300 is properly attached to
the C-shaped floor track 304 and C-shaped ceiling track 308 (and
preferably the C-shaped vertical studs 302 & 310), the joist
306 can be laid on top of the lower flange 314 of the joist support
structure 300. Preferably there is also another joist support
structure opposite the one shown that is holding the other side of
the joist 306 during installation. A user of this system can then
use a fastener (e.g., a screw, a nut and bolt, or any other
appropriate fastener) to partially fasten the joist 306 to the
joist support structure 300. This can be accomplished, for example,
by hand-tightening a nut and bolt to hold the joist 306 to the
joist support structure 300. Once the fastener is partially engaged
in the adjustment slot, the joist 306 is held in contact with the
joist support structure 300. When held in contact with the joist
support structure 300, the joist 306 can move slightly in a
direction parallel to the angle of the tabs 316 the joist 306 is
connected to. Such limited movement allows for adjustments without
the danger of the joist moving drastically (e.g., falling). Once
the joist 306 has been positioned correctly, the fastener can be
fully engaged (e.g., tightened) in the adjustment slot, and
additional fasteners (e.g., screws, nuts and bolts, and the like)
can be engaged into the four holes surrounding the slot (these
slots and holes are best seen in FIGS. 1-2C). In some embodiments,
the fastener used in the adjustment slot is stronger than the other
fasteners (e.g., has a larger cross sectional area, is made from a
stronger material, or is otherwise designed to endure high amounts
of shear force), since the fastener used in the adjustment slot
needs to hold more initial weight before the other fasteners become
fully engaged (e.g., tightened).
[0047] In FIG. 4, a corrugated floor structure is laid on top of
the installed joist (which is fastened to the joist support
structure by the use of fasteners and the bent tabs), and concrete
is laid on top of the corrugated structure. In some embodiments,
the entire floor structure, including the joists, can be
prefabricated and easily laid on top of the joist support
structure, allowing for quick assembly of prefabricated parts. Such
an installation procedure is shown more fully in FIGS. 5-7.
[0048] FIG. 6 shows a top view of a prefabricated corrugated deck
600, having joists 602 run vertically in the drawing and a
rectangular corrugated deck 600 overlaying the joists 602. Other
contemplated decking material includes plywood structocrete or
9/16'' corrugated steel. The corrugated deck 600 is generally
attached to the joists 602 using screws or other known fasteners.
Once the prefabricated deck 600 has been assembled, in some
embodiments, eye-nuts 604 can be screwed into the joists 602 as
shown, and straps can be tied to each eye nut to lift the
prefabricated deck and set it on top of the bearing wall support
structures. The top of FIG. 6 shows the lower flange 606 of a first
joist support structure 608 along one wall and the bottom of FIG. 6
shows the lower flange 610 of a second joist support structure 612
along another wall. Once the deck 600 is resting on the support
structures 608 & 612, the joists can be attached to the tabs
via the tab adjustment slots, adjusted, and then finally fixed in
place using fasteners engaged in the holes of the tabs on the sides
of the joist support structures 608 & 612.
[0049] FIGS. 5A and 5B shows a plan view of the top joist support
structure of FIG. 6, having a plurality of C-shaped joists attached
to each tab. The holes left by each tab are shown on either side of
the joist, a hole on the left for the upper tab and a hole on the
right for the lower tab. A blown-up view of two of the joists of
FIG. 5A are shown in FIG. 5B.
[0050] FIG. 7 shows a perspective view of an exemplary Z-shaped
joist hangar 700 having a web 702 (e.g., a side having a vertical
dimension of 12'') and an upper flange 704 and lower flange 706
(each having a 2'' width). Each flange 704 & 706 has two pilot
holes 708 which are disposed as part of a coupling mechanism for
joist hangar 700 to attach to structural objects (e.g., ceiling or
floor tracks, or other structural objects). Pilot holes 708 on
upper flange 704 are used to couple joist hangar 700 to a track
(not shown) while pilot holes 708 on lower flange 706 are used to
couple joist hangar 700 to a joist (not shown). Pilot holes 710 on
web 702 are also used to couple joist hangar 700 to a track. Each
tab 712 has a slot 714 and several pilot holes 716 that are used to
couple a joist (not shown) to joist hangar 700 via the tab 712.
[0051] Joist hangars of the inventive subject matter are stackable
for easy transport (due in large part to their level profiles and
lack of protruding components since the tabs begin in an unbent
configuration), and are reversible to ensure that a single Z-shaped
joist hangar can be used on either the left or right side of a
track. Joist hangars can be made from a variety of materials
including, steel, aluminum, iron, and metal alloys. In embodiments
using steel, the steel is preferably 18 or 20 gage to facilitate
tab bending, but smaller gages like 16 and 14 gage steel can also
be used to form the joist hangars.
[0052] In preferred applications, the Z-shaped hangar is placed
over a bearing wall track and is screwed into the track (and
possibly other structural elements, such as studs) using pilot
holes. Once the Z-shaped joist hangar is in place and the tabs are
unfolded to a desired angle from the web of the joist hangar (e.g.,
90, 45, or 60 degrees), joists can be laid on top of the lower
flange of the joist hangar. A fastener (such as a screw or nut and
bolt) can be partially engaged in the slot to ensure the joist
remains moveably in place while the joist is positioned properly,
and once the joist is positioned properly, the joist can be firmly
held in place by using fasteners with the remaining holes.
[0053] This is particularly useful where an entire prefabricated
floor panel is used. Lift bolts with eye nuts (as seen in FIG. 6 as
element 604) can be screwed into the top of the floor panel deck
and can then be used to lift the entire floor panel up to the track
to rest on the lower flange of the Z-shaped joist hangar. Since
aligning an entire floor panel properly can be difficult, a builder
can partially engage screws in many of the tab adjustment slots to
hold portions of the floor panel in place relative to a ceiling
track while adjusting other portions of the floor panel deck. Once
the entire floor panel deck is properly positioned, screws can be
fastened in the pilot holes.
[0054] It should be apparent to those skilled in the art that many
more modifications besides those already described are possible
without departing from the inventive concepts in this application.
The inventive subject matter, therefore, is not to be restricted
except in the spirit of the appended claims. Moreover, in
interpreting both the specification and the claims, all terms
should be interpreted in the broadest possible manner consistent
with the context. In particular, the terms "comprises" and
"comprising" should be interpreted as referring to elements,
components, or steps in a non-exclusive manner, indicating that the
referenced elements, components, or steps may be present, or
utilized, or combined with other elements, components, or steps
that are not expressly referenced. Where the specification claims
refers to at least one of something selected from the group
consisting of A, B, C . . . and N, the text should be interpreted
as requiring only one element from the group, not A plus N, or B
plus N, etc.
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