U.S. patent application number 12/048058 was filed with the patent office on 2008-07-03 for wall with opening and header arrangement therefore.
Invention is credited to Raymond C. Frobosilo.
Application Number | 20080155912 12/048058 |
Document ID | / |
Family ID | 39133574 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080155912 |
Kind Code |
A1 |
Frobosilo; Raymond C. |
July 3, 2008 |
WALL WITH OPENING AND HEADER ARRANGEMENT THEREFORE
Abstract
In combination with a wall having an opening between opposite
wall portions, a header arrangement has an elongated, lower, and
substantially horizontal flange with a downwardly open U-shape for
embracing the wall portions along at least part of the length of
the lower flange, an elongated, and substantially vertical web
connected along and extending upwardly from the lower flange, and
an elongated, upper, and substantially horizontal flange connected
along an upper edge of the vertical web and also having a U-shape.
Web stiffeners and end stiffeners are engaged to the flanges and
web to brace the header arrangement against static and dynamic
loads.
Inventors: |
Frobosilo; Raymond C.;
(Astoria, NY) |
Correspondence
Address: |
NOTARO AND MICHALOS
100 DUTCH HILL ROAD, SUITE 110
ORANGEBURG
NY
10962-2100
US
|
Family ID: |
39133574 |
Appl. No.: |
12/048058 |
Filed: |
March 13, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11509217 |
Aug 24, 2006 |
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12048058 |
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Current U.S.
Class: |
52/204.2 |
Current CPC
Class: |
E04B 2/58 20130101 |
Class at
Publication: |
52/204.2 |
International
Class: |
E04C 3/06 20060101
E04C003/06; E04B 1/24 20060101 E04B001/24 |
Claims
1. In combination with a wall having an opening (40) and a pair of
wall portions (42) on opposite sides of the opening, a header
arrangement comprising: a pair of connected together, mirror image
members each having an elongated, lower, substantially horizontal
flange (12), an elongated, substantially vertical web (14)
connected along and extending upwardly from the lower flange, and
an elongated, upper, substantially horizontal flange (16) connected
along an upper edge of the vertical web; the lower and upper
flanges of each member having outer elongated edges with a
downwardly extending flange plate (12a, 16a), the flanges, plates
and vertical webs of each member together forming a polygonal
pockets (18) on one side of each vertical web; the vertical webs
(14) of the members being co-extensive and being fixed to each
other so that the flanges (12, 16) and pockets (18) are on opposite
sides of the vertical webs, the lower flanges (12) of the members
together defining a downwardly open U-shape for embracing an upper
end of the wall portions (42) on opposite side of the opening (40)
along at least part of a length of the lower flanges with a
remainder of each lower flange (12) spanning over the opening (40);
and a plurality of web stiffeners (20) in the pockets (18), each
stiffener having an outer plate (22) connected to the flange plates
(12a, 16a) of the upper and the lower flanges (12, 16), each
stiffener (20) having a pair of pocket plates (24) connected on
opposite sides of the outer plate (22) and extending in a pocket
(18) and in close proximity to, or in contact with surfaces of the
flanges and the vertical web in the pocket for bracing the flanges
and the webs of each member; each outer plate (22) being vertically
long enough to span a distance between the flange plates of the
upper and lower flanges, and to engage under and be connect to the
flange plate (16a) of the upper flange, and to engage over and be
connected to the flange plate (12a) of the lower flange.
2. The combination of claim 1, wherein the lower and upper flanges
and the vertical web are made of sheet metal, the webs (14) of the
members being connected to each other by spot welding, and the
outer plate (22) of the stiffeners (20) being connected to the
flange plates (12a, 16a) by screws (30).
3. The combination of claim 1, wherein the lower and upper flanges
and the vertical web of each member together form a rectangular
pocket, the pocket plate (24) of each stiffener (20) being
rectangular to closely engage surfaces of the flanges and web in
each pocket.
4. The combination of claim 1, wherein the lower and upper flanges
and the vertical web of both mirror image members together form a
header beam and together create a pair of polygonal pockets on
opposite sides of the vertical webs, the header arrangement
including at least one substantially U-shaped end stiffener (50)
connected to one end of the header beam and shaped to cover an end
of the pair of pockets, the end stiffener having a pair of spaced
apart vertical rails (52) and a wall plate (54) connected between
the vertical rails.
5. The combination of claim 1, wherein the lower and upper flanges
and the vertical web of both mirror image members together form a
header beam and together create a pair of polygonal pockets on
opposite sides of the vertical webs, the header arrangement
including an L-shaped cover plate (80) connected to at least one of
the upper and lower flanges for covering at least part of one of
the pockets.
6. The combination of claim 1, wherein the header arrangement
extends over a window forming the opening (40) and includes a
downwardly U-shaped sill track (28) for engagement over a lower
wall portion (46) forming a lower end of the window, between the
opposite wall portions (42).
7. The combination of claim 1, wherein the lower and upper flanges
and the vertical web together form a header beam, the header
arrangement including at least one substantially U-shaped end
stiffener (50) connected to one end the header beam and shaped to
cover an end of the pair of pockets (18), the end stiffener having
a pair of spaced apart vertical rails and a wall plate connected
between the vertical rails, the header arrangement further
including a U-shaped jack panel (70) under the header arrangement
and extending along one side of a window forming the opening (40),
the jack panel having a lower end and the header arrangement
including a gusset plate connected to the lower end of the jack
panel for reenforcing the jack panel.
8. The combination of claim 1, including U-shaped floor track (90)
connected under the wall portions (42) and having opposite side
plates (92) with spaced slots (94) in at least one of side plates
for drainage in case water is trapped or condenses inside the wall
portions.
9. In combination with a wall having an opening (40) and a pair of
wall portions (42) on opposite sides of the opening, a header
arrangement comprising: a pair of connected together, mirror image
members each having an elongated, lower, substantially horizontal
flange (12), an elongated, substantially vertical web (14)
connected along and extending upwardly from the lower flange, and
an elongated, upper, substantially horizontal flange (16) connected
along an upper edge of the vertical web; the lower and upper
flanges of each member having outer elongated edges with a
downwardly extending flange plate (12a, 16a), the flanges, plates
and vertical webs of each member together forming a polygonal
pockets (18) on one side of each vertical web; the vertical webs
(14) of the members being co-extensive and being fixed to each
other so that the flanges (12, 16) and pockets (18) are on opposite
sides of the vertical webs, the lower flanges (12) of the members
together defining a downwardly open U-shape for embracing an upper
end of the wall portions (42) on opposite side of the opening (40)
along at least part of a length of the lower flanges with a
remainder of each lower flange (12) spanning over the opening (40);
a plurality of web stiffeners (20) in the pockets (18), each
stiffener having an outer plate (22) connected to the flange plates
(12a, 16a) of the upper and the lower flanges (12, 16) of pockets
(18), each stiffener (20) having a pair of pocket plates (24)
connected on opposite sides of the outer plate (22) and extending
in a pocket (18) and in close proximity to, or in contact with
surfaces of the flanges and the vertical web in the pocket for
bracing the flanges and the webs of each member; each outer plate
(22) being vertically long enough to span a distance between the
flange plates of the upper and lower flanges, and to engage under
and be connect to the flange plate (16a) of the upper flange, and
to engage over and be connected to the flange plate (12a) of the
lower flange; the lower and upper flanges and the vertical web of
both mirror image members together form a header beam and together
create a pair of polygonal pockets on opposite sides of the
vertical webs; and at least one substantially U-shaped end
stiffener (50) connected to one end the header beam and shaped to
cover an end of the pair of pockets, the end stiffener having a
pair of spaced apart vertical rails (52) and a wall plate (54)
connected between the vertical rails; the lower and upper flanges
and the vertical web are made of sheet metal, the webs (14) of the
members being connected to each other by spot welding or screws,
and the outer plate (22) of the stiffeners (20) being connected to
the flange plates (12a, 16a) by screws (30).
10. The combination of claim 9, wherein the lower and upper flanges
and the vertical web of each member together form a rectangular
pocket, the pocket plate (24) of each stiffener (20) being
rectangular to closely engage surfaces of the flanges and web in
each pocket.
11. The combination of claim 9, wherein the lower and upper flanges
and the vertical web of both mirror image members together form a
header beam and together create a pair of polygonal pockets on
opposite sides of the vertical webs, the header arrangement
including an L-shaped cover plate (80) connected to at least one of
the upper and lower flanges for covering at least part of one of
the pockets.
12. The combination of claim 9, wherein the header arrangement is
adapted to extend over a window forming the opening (40) and
including a downwardly U-shaped sill track (28) for engagement over
a lower wall portion (46) forming a lower end of the window,
between the opposite wall portions (42).
13. The combination of claim 9, wherein the lower and upper flanges
and the vertical web together form a header beam, the header
arrangement including at least one substantially U-shaped end
stiffener (50) connected to one end the header beam and shaped to
cover an end of the pair of pockets (18), the end stiffener having
a pair of spaced apart vertical rails and a wall plate connected
between the vertical rails, the header arrangement further
including a U-shaped jack panel (70) under the header arrangement
and extending along one side of a window forming the opening (40),
the jack panel having a lower end and the header arrangement
including a gusset plate connected to the lower end of the jack
panel for reenforcing the jack panel.
14. The combination of claim 9, including U-shaped floor track (90)
connected under the wall portions (42) and having opposite side
plates (92) with spaced slots (94) in at least one of side plates
for drainage in case water is trapped or condenses inside the wall
portions.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation of application Ser. No. 11/509,217
filed Aug. 24, 2006, which is now U.S. patent ______, and which is
incorporated here by reference.
FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates in general to the field of
building components and construction, and in particular to a new
and useful header arrangement for use in metal and non-metal
buildings.
[0003] U.S. patent application Ser. No. 10/801,068 filed Mar. 15,
2004 is incorporated here by reference, and discloses the
inventor's previous invention of a Metal Building Construction.
This prior patent application, among other times, discloses metal
building panels that advantageously interlock at Z-shaped
structures provided at the opposite vertical edges of each
panel.
[0004] Virtually all buildings include openings through their walls
in the form of windows, doors and other needed openings of various
heights and widths.
[0005] Since these openings necessarily weaken the static or
vertical load bearing capacity of the wall, at least in the area of
the opening, measures must be taken to increase the strength of the
wall above each opening. The aforementioned U.S. patent application
Ser. No. 10/801,068, solves this problem by connecting shorter
metal panels that are of similar construction to the longer wall
panels, in a side-by-side arrangement in order to span the to of
each opening. For windows, a similar combination of shorter panels
is also provided below each window.
[0006] In more conventional wooden stud wall and other building
constructions, this problem is solved using headers in the form of
strong, wide and heavy wooden beams that span the top of each
opening and provide the needed load support.
[0007] U.S. Pat. No. 5,117,602 for a Structural Panel for
Pre-fabricated Buildings, discloses a structural member having an
elongated panels with generally Z-shaped portions that nest with
each other. Flanges of the nested panels cooperate to form a
receptacle for a stud or joist to form a wall, floor or ceiling
combination, and U.S. Pat. No. 5,979,136 for a Prefabricated
Structure Panel discloses a structural member having elongated
panels with Z-shaped, nested portions and reinforcing members at
the top and bottom of plural nested panels, along with top and
bottom plates.
[0008] A need remains for a header arrangement that is light in
weight and strong in construction, and particularly although not
exclusively, suited for metal building construction.
SUMMARY OF THE INVENTION
[0009] It is an object of the present invention to provide a header
made of sheet metal that is light yet strong in the vertical
direction for supporting static or vertical load, e.g. the load of
the roof or floors of a building above the header, and which is
strong in the horizontal direction to resist dynamic or horizontal
load, e.g. wind load, as well as resisting twisting loads.
[0010] Accordingly, a further object of the invention is to provide
a header arrangement comprising: an elongated, lower, and
substantially horizontal flange having a downwardly open U-shape
for embracing a wall structured along at least part of the length
of the lower flange; an elongated, substantially vertical web
connected along and extending upwardly from the lower flange; and
an elongated, upper, and substantially horizontal flange connected
along an upper edge of the vertical web and also having a
U-shape.
[0011] According to another object of the invention, the header
arrangement has lower and upper flanges and a vertical web formed
of a pair of mirror members which each have part of each flange and
a vertical web panel, the vertical web panels being coextensive
with respect to each other and being connected to each other to
form the vertical web.
[0012] The lower and upper flanges and the vertical web are
preferably made of sheet metal and the U-shape of the upper flange
is preferably downwardly open.
[0013] The lower and upper flanges and the vertical web together
form a polygonal pocket on at least one side of the vertical web,
and the arrangement may include one or preferably multiple web
stiffeners connected to at least one of the flanges and extending
into the pocket for bracing the flanges and the vertical web.
[0014] Another object of the invention is to provide the header
arrangement with additional metal components to facilitating
assembly of the header arrangement into the remainder of a metal
building construction.
[0015] The various features of novelty which characterize the
invention are pointed out with particularity in the claims annexed
to and forming a part of this disclosure. For a better
understanding of the invention, its operating advantages and
specific objects attained by its uses, reference is made to the
accompanying drawings and descriptive matter in which a preferred
embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In the drawings:
[0017] FIG. 1 is an exploded perspective view of parts of a header
arrangement according to the present invention;
[0018] FIG. 2 is a view similar to FIG. 1 but with some of the
parts assembled;
[0019] FIG. 3 is a perspective view of a section of wall of a metal
building construction including the header arrangement of the
present invention;
[0020] FIG. 4 is a sectional view taken along line 4-4 of FIG.
3;
[0021] FIG. 5 is an exploded view of component parts of the header
arrangement of the present invention;
[0022] FIG. 6 is a vertical sectional view of the header
arrangement of the invention, taken along line 6-6 of FIG. 3;
[0023] FIG. 7 is a view similar to FIG. 6 of another embodiment of
the invention;
[0024] FIG. 8 is a front perspective view of a web stiffener of the
embodiment of FIG. 7; and
[0025] FIG. 9 is a partial, perspective view of a key assembly of
the header arrangement of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] Referring now to the drawings, in which like reference
numerals are used to refer to the same or similar elements, FIGS. 1
to 6 show a header arrangement comprising an elongated, lower, and
substantially horizontal flange 12 having a downwardly open U-shape
for embracing a wall structure along at least part of the length of
the lower flange, for example, on opposite sides of an opening in
the wall to be spanned by the header arrangement. An example of
such a wall structure is the pair of wall panels 42 and 44 shown in
FIG. 3 and similar to the wall panels disclosed in the incorporated
U.S. patent application Ser. No. 10/801,068.
[0027] The header arrangement also includes an elongated,
substantially vertical web 14 connected along and extending
upwardly from the lower flange 12. An elongated, upper, and
substantially horizontal flange 16 is connected along an upper edge
of the vertical web 14 and has a U-shape as well. The lower and
upper flanges 12, 16, each having outer elongated edges with a
downwardly extending flange plates 12a and 16a best shown in FIG.
6, forming at least part of each U-shape. The flanges and the
vertical web together form a pair of polygonal, e.g. substantially
rectangular pockets 18 on opposite sides of the vertical web
14.
[0028] The lower and upper flanges 12, 16, and the vertical web 14
are formed of a pair of mirror image members which each have part
of each flange and a vertical web panel that are back-to-back and
spot welded or otherwise fastened to each other as shown in FIG. 6
at 19, the vertical web panels being coextensive with respect to
each other and being connected to each other to form the vertical
web 14.
[0029] The arrangement includes a plurality of web stiffeners 20
each connected to at least one of the flange plates 12a and/or 16a,
but preferably to both, and each extending into at least one of the
pockets for bracing the flanges and the vertical web. Each
stiffener comprising an outer plate 22 that is vertically long
enough to span the distance between the flange plates 12a and 16a
of the upper and lower flanges 12 and 16 as best shown in FIG. 6,
the flange plates of both of the upper and lower flanges being
connected, e.g. by screws of other fasteners 30 to the outer plate
22. Each stiffener further comprising a pocket plate 24 connected
to each vertical edge of the outer plate and being shaped and sized
to extend into one of the pockets, in close proximity to, or in
contact with inner surfaces of the flanges and the vertical web in
the pocket. Each web stiffener is thus also U-shaped in top plan
view, and the vertical length of the outer plate 22 is greater, at
least downwardly of the pocket plate so that there is enough
extension of the outer plate 22 to overlap the lower flange plate
12a and be connected thereto by screws 30.
[0030] As shown in FIG. 6, the upper end of the outer web plate 22
extends along the inside surface of the flange plate 16a of the
upper flange 16, and is also connected to this upper flange plate
by screws 30 to positively secure both ends of the web stiffener to
the header beam formed of the flanges 12, 16 and web 14.
[0031] Stiffeners are spaced along the header arrangement, e.g.
every 2 feet or as needed depending on the static and dynamic loads
contemplated for the building, and may be staggered or aligned with
respect to each other on opposite side of the vertical web 14.
[0032] The header arrangement of the invention is adapted to extend
over any opening in the wall of a building, such as a door or, as
shown in FIG. 3 for example, a window 40 formed between tall wall
panels or panel assemblies 42 and 44, and a short lower wall panel
or panel assembly 46 under the window opening 40. The header
assembly in this case comprises a header beam made up of the
flanges 12, 16 and web 14 with one or more web stiffeners 20 as
needed to stiffen the beam, the beam extending over the top of the
window 40 and along the tops of the adjacent panels 42 and 44, for
at least some distance.
[0033] In the case of the wall in FIG. 3 being, for example, an 8
foot wall section to be assembled into a final wall of greater
size, the header beam may also advantageously be 8 feet long and
therefore span the entire wall section width.
[0034] The window or door opening 40 may be any width that is
sufficiently less than 8 feet so that at least some part of the
header beam extends over the opposite wall panels, e.g. by at least
6 inches.
[0035] The beam thus extends over part or all of each of the wall
panels 42 and 44, and the panels are each closely embraced over
their top ends by the downwardly U-shaped lower flange 12. The
lower border of window 40 formed by the top ends of the short panel
or panel assembly 46, is also covered and closely embraced by a
downwardly U-shaped sill track 28 for engagement over the lower
wall forming the lower end of the window. Sill track 28 is fastened
in place by screws or other suitable fasteners.
[0036] To further integrate the header beam into the wall, and
especially to resist any side loads on the header such as those
caused by wind or any unevenness in the vertical load that may tend
to twist the header beam out of its required vertical orientation,
the arrangement includes at least one, but preferably two opposite
and substantially U-shaped end stiffeners 50 connected to each
opposite end of the header beam as shown in FIG. 3, and shaped to
cover an end of the pair of pockets 18 on each side of web 14.
[0037] Referring to FIG. 9, the end stiffeners 50 each having a
pair of spaced apart vertical rails 52 and a wall plate 54
connected between the vertical rails.
[0038] The wall plate 54 includes a Z-shaped portion 56 such as
those disclosed in U.S. patent application Ser. No. 10/801,068.
Each end stiffener 50 is vertically long enough to fully cover the
end of the header beam and also to extend downwardly over (as
shown) or under (i.e. inside wall panel 42 as not shown but as
still possible), the wall panel that is itself under that end of
the beam, e.g. panel 42 in FIG. 9. Each panel 42, 44 and even lower
wall panels 46, are U-shaped and have one or two Z-shaped portions
at one or both end of each wall panel. In this way the Z-shaped
portions of the wall panels, at least at one end of the header
beam, engages the Z-shaped portion 56 of the end stiffener 50.
Screws 30 or other fasteners are used to fix the end stiffeners to
the header beam and wall panels. The end stiffener 50 can thus be
outside or inside the panel 42 it extends to, to help prevent
twisting of the header beam. Although shown with the Z-shaped
portion 56, stiffener 50 can be a simple U-shape with a flat or
other shaped wall plate 54, to engage differently shaped wall
panels, wall studs or other wall members that can be used with the
header arrangement of the present invention.
[0039] The end stiffeners 50, which are advantageously 1 to 3 feet
long (preferably about 2 feet long) and wide enough to embrace the
end of the header beam, and, in conjunction with the web stiffeners
for the header beams of over about 2 feet long, have been found by
actual testing to be extremely strong against both vertical and
transverse or side loads, and are well suited for building
construction since they exceed all code requirements.
[0040] The same end stiffener 50 is used at both ends of the header
beam as shown in FIG. 1, with the vertical position of one simply
being inverted with respect to the other.
[0041] To further strengthen the wall as shown in FIG. 3, the outer
wall panels each having a lower end and the arrangement includes a
triangular gusset plate 60 connected to the lower end of the wall
panel for reenforcement.
[0042] One or both vertical side borders of the window 40 are also
reenforced by vertical, U-shaped jack studs 70 that are fastened,
e.g. by screws, to the side portions of the wall panels 42 or 44
that form that border of the window as shown, for example, in FIG.
4.
[0043] An L-shaped cover plate 80 is also fastened, e.g. by screws,
over one or both sides of the header beam to close the outer,
otherwise open pocket at one or both sides of the header beam.
[0044] An upwardly open, U-shaped floor track 90 is also provided
at the bottom of the wall (see FIGS. 3 and 5) and has side plates
92 with spaced slots 94 in at least one of the inside or outside
plate for drainage in case water is trapped or condenses inside the
wall.
[0045] FIGS. 7 and 8 illustrate an embodiment of the invention that
uses an upwardly U-shaped upper flange 17 and modified web
stiffener 20 with outer plate 23 having upper and lower extensions
that go beyond the pocket plates 24 so that they can be fastened,
e.g. by screws 30, to the flange plates of the upper and lower
flanges. This embodiment allows both the upper and lower flanges to
embrace walls extending along the header beam.
[0046] All parts of the header arrangement of the invention are
preferably made of galvanized or otherwise corrosion resistant
sheet metal of appropriate gauge, e.g. 24 to 16 gauge, preferably
22 to 18 gauge and still more preferably 22 or 20 or 18 gauge
steel, as needed for a particular building. Each piece can be cut
to shape and bent into the form called for by this disclosure.
[0047] Although the header arrangement of the present invention is
best suited to metal building construction using panels, it can
equally be used for conventional metal or even wood stud
construction.
[0048] While specific embodiments of the invention have been shown
and described in detail to illustrate the application of the
principles of the invention, it will be understood that the
invention may be embodied otherwise without departing from such
principles.
* * * * *