Prefabricated frame support

A support frame for supporting an intersection between a first wall section and a second wall section. The support frame including a first support panel having a top edge and a bottom edge, which are configured to be positioned between respective upper and lower plates of the first wall section. Moreover, the support frame has a pair of second support panels affixed to the first panel, and each second support panel has a top edge and a bottom edge configured to be positioned between respective upper and lower plates of the second wall section.

TECHNICAL FIELD

The present invention relates generally to wall framing, and more particularly to a prefabricated frame support structure designed to be interposed between two wall sections intersecting one another at approximately a 90° angle.

BACKGROUND OF THE INVENTION

During construction of residential homes and similar buildings, it is common practice to construct framing assemblies for intersecting walls at the site of the construction.FIGS. 1 and 2, for example, illustrate conventional designs for framing assemblies interposed between two wall sections adjoining one another at a T-shaped intersection.

As shown inFIG. 1, a primary wall A having a lower plate12intersects with an intersecting wall B having a lower plate14. During construction, a 2×6 backing stud16is position on lower plate12and provided for corner nailing. Moreover, a 2×4 end stud18is then attached to the 2×6 backing stud16and positioned on lower plate14. The combination of the two studs (i.e., 2×6 backing stud16and 2×4 end stud18) forms the frame support for the T-intersection between primary wall A and intersecting wall B.

As further shown inFIG. 2, a primary wall A having a lower plate12again intersects with an intersecting wall B having a lower plate14. In this design, a 2×4 backing stud20is positioned during construction on lower plate12and a 2×4 end stud22is then attached to the 2×6 backing stud20and positioned on lower plate14. A pair of additional 2×4 studs24aand24bare secured to the respective sides of backing stud20and serve as a means for corner nailing.

There are numerous disadvantages and drawbacks to these types framing assemblies for T-intersections. First, the basic approaches illustrated inFIGS. 1 and 2require more material than is necessary to carry the imposed loads. Furthermore, fabrication of these framing assemblies at the construction site is quite inefficient and time consuming. Virgin lumber and scraps are often used to construct these frame assemblies during construction. Consequently, due to the extra material used and the labor required at the construction site, one can expect the total cost of such framing assemblies to be relatively high.

SUMMARY OF THE INVENTION

Accordingly, the present invention presents a prefabricated or premanufactured T-intersection frame structure that is designed to overcome the disadvantages and drawbacks of conventional on-site constructed T-intersection framing assemblies. Generally in the design disclosed herein, the present invention provides a support frame for supporting an intersection between a first wall section and a second wall section. The support frame including a first support panel having a top edge and a bottom edge, which are configured to be positioned between respective upper and lower plates of the first wall section. Moreover, the support frame has a pair of second support panels affixed to the first panel, and each second support panel has a top edge and a bottom edge configured to be positioned between respective upper and lower plates of the second wall section.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 3illustrates a perspective100of two wall sections connected to one another by the frame structure in accordance with an exemplary embodiment of the present invention. It should be readily apparent that the two wall sections can represent any intersecting wall sections in any building. In the exemplary embodiment, the intersection is a T-intersection where the pair of wall sections intersect at an approximately 90° angle. Specifically, as shown, frame structure110is interposed between first wall section120and second wall section130. Wall section120further includes lower plate122, upper plate124and a plurality of studs140connected between lower plate122and upper plate124. One skilled in the art would appreciate that the lower and upper plates are typically conventional 2×4 studs or 2×6 studs. It should also be clear that the studs140that are provided are approximately the desired height of the wall of the building being constructed. Moreover, wall section130further includes lower plate132, upper plate134and a plurality of studs (not shown) connected between lower plate132and upper plate134. As will be explained in more detail below, frame structure110is interposed between the two wall sections120,130to facilitate construction of the wall intersection.

FIG. 4illustrates a cross-sectional view of frame structure200in accordance with an exemplary embodiment. It should be understood that frame structure200provides a cross-sectional view of frame structure110illustrated inFIG. 3. As shown, frame structure200comprises a first support panel210having two opposing sides212and214and two outer edges216aand216b. In the exemplary embodiment, first support panel210is substantially rectangular in shape. Furthermore, frame structure200comprises two individual second support panels220,230that protrude from side214of first panel210at an approximately 90° angle. As such, the pair of individual second support panels220,230are positioned substantially parallel to one another. In the exemplary embodiment, the pair of second support panels220,230are also substantially rectangular in shape. Moreover, the pair of second support panels220and230each have respective outer sides222aand232a, respective inner sides222band232b, as well as respective ends224and234. In the exemplary embodiment, frame structure200is therefore formed with a recess218between inner sides222band232bof second support panels220and230. It should be clear that while the exemplary embodiment is illustrate with second support panels220and230being secured to first support panel210at a 90° angle, the application is in no way intended to be limited to such implementation. It is envisioned that alternative angles are possible pending on the particular design of the building being constructed.

In implementation, the pair of second support panels220and230are secured to first support panel210by any applicable means. For example, second support panels220,230can be secured to first support panel210by nails, adhesive, screws, a combination of these materials, or any other suitable means. In an alternative implementation, second support panels220,230are manufactured as a single piece of material with first support panel210. Frame structure200can be manufactured from recycled material, plywood, chipboard, or any other suitable material. In one embodiment, the individual support panels,210,220and230of frame structure200can be milled out of plywood and connected with a suitable adhesive.

As explained above and illustrated inFIG. 3, frame structure200is interposed between wall section120and wall section130during construction. It is appreciated that frame structure200is inserted between lower plates122,132and upper plates124,134of walls sections120and130, respectively. Accordingly, in implementation, frame structure200will be substantially the same length as the plurality of studs140shown inFIG. 3.

FIG. 5illustrates a side partial view of frame structure200interposed between the two wall sections in accordance with an exemplary embodiment. As shown, frame structure200is coupled to the upper surface124of lower plate122of wall section120by connector bracket310. It should be appreciated that connector bracket310can be any conventional bracket capable of connecting frame structure200and lower plate122and is not limited to the design illustrated inFIG. 5. Furthermore, frame structure200is secured to lower plate122such that the inner sides214a,214bof frame structure200are in substantially the same plane as side edge126of lower plate122. Furthermore, the pair of second support panels220,230of frame structure200are secured to first support panel210with a premeasured width such that outer sides222aand232aare in substantially the same plane as the side edges134a,134bof lower plate132of wall section130. Alternatively, second support panels,220and230can be positioned closer together (e.g., 1 inch apart). Finally, while not shown, it should be appreciate that the opposite end of frame structure200is secured to the upper plates124,134of wall sections120,130in a substantially similar manner.

Once secured between wall sections120and130, frame structure200is properly positioned to support the load imposed upon the intersection areas of the respective wall structure. In this regard, it is appreciated that first support panel210as well as the pair of second support panels220,230are designed so as to assume the principal load carrying function.

To facilitate construction and design of the particular building, it is appreciated that the inner sides214a,214bof first support panel210serve to receive the inner wall structure of the house for wall section120, such as sheetrock, paneling, etc. Similarly, in the exemplary embodiment, the outer sides or edges212of first support panel210can server to receive the outer side wall structure of the building such as exterior paneling, siding, etc. Moreover, the outer sides222aand232aof the pair of respective second support panels220and230serve to receive the inner wall structure of the house for wall section130, such as sheetrock, paneling, etc. It should be appreciated that sheetrock, paneling, siding, etc. are attached to the support panels by, screws, nails, adhesive, or any other suitable means.

FIG. 6illustrates a cross-sectional view of frame structure600in which specific dimensions are provided in accordance with an exemplary embodiment. As shown, first support panel610has a length of approximately 6½ inches and a width of approximately ¾ inches. Moreover, the pair of second support panels620and630have a length of approximately 1½ inches. Further, second support panels620and630are secured to first support panel610such that their respective outer surfaces622aand632aare positioned approximately 1½ inches from the respective outer edges616aand616bof first support panel610. As a result, there is sufficient space provided by frame structure600enabling sheetrock, paneling, and the like to be secured to inner sides614aand614bof first support panel610as well as to the respective outer surfaces622aand632aof second support panels620and630. It should be appreciated, however, that the second support panels620and630can be shorter than 1½ inches (e.g., 1 inch) or longer as needed, so long as sufficient space is provided for finishing materials, such as sheetrock, to be attached. It is reiterated that while these dimensions are provided for the embodiment illustrated inFIG. 6, the invention is by no means intended to be limited by these dimensions.

FIG. 7illustrates a side partial view of frame structure700interposed between two wall sections120,130in accordance with another exemplary embodiment. In contrast to the embodiments described above, frame structure700comprises a pair of first support panels710a,710b. Moreover a pair of second support panels720and730are secured, respectively, to the pair of first support panels710a,710b. Additionally, a third support panel740can be secured between the pair of second support panels720and730. As such, a recess750is provided between second support panels720and730. In one embodiment, second support panels720and730as well as third support panel740are prefabricated as a single piece of material. In any event, it should be appreciated that frame structure700comprises similar functional aspects as frame structure200. For example, in a similar manner as shown inFIG. 5, the pair of first support panels710aand710bare coupled to the upper surface124of lower plate122of wall section120by a pair connector bracket310a,310b. Furthermore, frame structure700is secured to lower plate122such that the respective inner sides714aand714bof the pair of first support panels710aand710bare in substantially the same plane as side edge126of lower plate122. Furthermore, the pair of second support panels720,730are secured to the pair of first support panels710aand710bwith a premeasured width such that outer sides722aand732aare in substantially the same plane as the side edges134a,134bof lower plate132of wall section130.

It is appreciated that the frame structures of the present invention can be particularly designed and dimensioned for walls of various thickness. For example, the frame structures of the present invention can include pre-drilled holes to facilitate easy installation during building construction. In addition, it is further contemplated that the exemplary frame structures of the present invention can easily and conveniently be prefabricated or premanufactured from various suitable materials as discussed above. It is therefore appreciated that the frame structure inserts or assemblies have the capability of reducing both material and the labor cost over conventional construction techniques for the T-intersection framing structure used within framed walls of residential structures and the like as well as any other structure/wall that can utilize the T-intersection framing design. In addition, the design of the present invention enables the T-intersection to be easily insulated and in fact improves the resistance of the wall structure by reducing heat losses and gains to the interior of the structure. Also, as explained above, the frame structures of the present invention provide an attachment surface for the full height of inside and outside wall coverings about the framed intersection.

Finally,FIG. 8illustrates an advantageous shipping configuration of the frame structures in accordance with an exemplary embodiment. As shown, a plurality of frame structures810a-810dcan be stacked in an efficient manner are shown inFIG. 8. It should be clear that the plurality of frame structures810a-810demploy the same design as the exemplary structure described above with respect toFIG. 3-5. Accordingly, in addition to the foregoing advantages described above, the exemplary frame structure enables this further benefit to aid the construction of a building.

While the foregoing has been described in conjunction with an exemplary embodiment, it is understood that the term “exemplary” is merely meant as an example, rather than the best or optimal. Accordingly, the application is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention.

Additionally, in the preceding detailed description, numerous specific details have been set forth in order to provide a thorough understanding of the present invention. However, it should be apparent to one of ordinary skill in the art that the inventive test circuit may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the application.