Abstract:
A device for providing a flat surface on a deformed wooden stud, joist or rafter where said device has two elongated members where the first member is sized so that the first member is fastened to a surface of a stud, joist or rafter and a second member is fastened to said second member whereby said second member forms a level surface on said stud, joist or rafter.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK 
       [0003]    Not Applicable 
       REFERENCE TO A MICROFICHE APPENDIX 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1) Field of the Invention 
         [0006]    This invention relates to structural support elements for use in connection with wooden structural elements in existing buildings. 
         [0007]    2) Description of Related Art 
         [0008]    The present invention relates generally to a devices and methods that are useful in the construction or reconstruction of wooden framed buildings. Wood is a natural product that is affected by moisture and is subject to movement, particularly when wood in the form of dimensional lumber is stressed by the application of the weight that is typically applied to dimensional lumber that is used in the framing of residential or commercial buildings. 
         [0009]    When buildings are remodeled, it is typical to locate wooden framing members that have become warped over time which results in bowed or sagging floors, out of plumb walls and sagging roof lines. Bowed and sagging structures result from the inability of studs, joists and rafters to provide the desired flat and level surfaces that are required for affixing finishing materials. 
         [0010]    Various methods have been developed to meet and overcome this problem. For example, measurements are taken and string lines placed transversely across a plurality of such support members to deter mine the misalignment that exists for the formation of an application surface by such plurality of studs or joists so that misaligned studs or joists can be shimmed or removed and replaced with new wooden studs, joists or rafters, as the case may be, for a wall, floor or ceiling. Generally, this process is expensive because it requires the services of skilled carpenters using custom fabricated wooden elements with continual checking for a level profile or a plumb surface. 
         [0011]    A traditional method of overcoming the bowed profile of a stud, joist or rafter is the application of a “sister” stud, joist or rafter that is bolted, nailed or screwed to an existing bowed stud, joist or rafter to provide a new surface that is level and corrects the defect of the bowed but structurally sound existing stid, joist or rafter. This method is not always acceptable as it presents cost issues, installation issues when space is tight or there are existing utilities that have been installed in the past. 
         [0012]    U.S. Pat. No. 5,822,942 to Lucia Jr. shows a U-shaped device for straightening warped, twisted, improperly installed or inaccurately aligned studs, joists and rafters which utilizes a plurality of U-shaped devices applied to a corresponding plurality of studs, joists or rafters. In the straightening function of the U-shaped device, for a given stud, joist or rafter, the common reference point for attaching the exterior finishing material is for example the forward corner  56  of the front angled face of the given warped stud  16 ′ shown in  FIG. 3  of the drawings in the Lucia Jr patent. The U-shaped device is adjustably positioned on the stud  16 ′ using this reference point and then fastened to the stud in its adjusted position. However, this does and will not give the desired planar mounting surface in a common plane with a multiplicity of other studs, required for properly affixing the exterior finishing members to the plurality of studs, joists or rafters defining a wall, floor or ceiling in a building. 
         [0013]    Where a plurality of studs, joists or rafters need to be aligned to achieve the required planar mounting surface for the exterior finishing members, Lucia Jr provides an additional bar  60  which is first threadably affixed to the outer sections  34  for each of the respective U-shaped devices for an associated plurality of studs, joists or rafters which in the aligned or plumbed position are then affixed to their associated studs, joists or rafters to establish the planar mounting surface in a common plane required to properly affix the exterior finishing members over a plurality of studs, joists or rafters. This method of achieving the planar mounting surface with a common plane creates the very same problems of the prior art as above described by increasing the steps for establishing the planar mounting surface, the number of people required, the time and the need for calculations to achieve the common plane for the planar mounting surface. More important this method and the device used do not address the problem of a wall with a multiplicity of studs where some studs are misaligned because they are warped from side to side or twisted or bowed into or away from the room or space. 
         [0014]    U.S. Pat. No. 6,523,315 to Ford discloses various L shaped and U shaped metal or plastic elements that are attached to wooden structural elements for the purpose of providing a level surface on a warped or bowed wooden stud, joist or rafter. The Ford elements preferably have pre-positioned holes to allow for the attachment of the L shaped or U shaped metal elements. The Ford patent also contemplates that thinner gauge materials may be used which can be pierced or cut by conventional fastening devices. The difficulty when using thinner gauge materials, the resulting structure may not be able to resist bowing or warping due to the fact that thin gauge materials my bend or distort under load conditions and the result will be a sagging or bowed structure. 
         [0015]    The present invention provides a device having two imperforate members where the first member comprises a U shape having a center section with a flat surface positioned orthogonally to two lateral sections and the second member is also a U shaped member that is sized so that it fits over the first section and comprises a center section with a flat surface and two lateral sections. 
         [0016]    The installed device provides the flat surface in a position that the flat surface becomes a straight or level surface which can be used as a load bearing surface for a floor, ceiling or a wall. 
         [0017]    In another embodiment an S-shaped element comprising a vertical center section and an upper orthogonal section and a lower orthogonal surface that extend in opposite directions from the center section and the device is sized for application to a bowed floor joist so that the floor surface of the joist is provided with a level metal surface that is formed by the upper orthogonal section and the lower orthogonal section forms a level surface for the ceiling of the space below the floor that is supported by the bowed floor joist. This embodiment may be installed over a U shaped element to reinforce the S-shaped shaped element. 
       SUMMARY OF THE INVENTION 
       [0018]    The invention provides a device that provides a flat surface on a deformed, e.g. a bowed wooden stud, joist or rafter. The device provides a flat surface on a deformed wooden stud, joist or rafter where said device comprises two elongated members where the first member is sized so that the first member is fastened to a surface of a stud, joist or rafter and a second member is fastened to said second member whereby said second member forms a level surface on said stud, joist or rafter. 
         [0019]    In a preferred embodiment, the device of the present invention comprises two elongated members each having a U shaped cross sectional profile where the first member and second member comprise a flat center section placed between two laterally arranged side sections where the first member is sized so that the first member fits over a wooden stud, joist or rafter and the second member fits over the firsat member to which it is fastened on both sides. In a preferred embodiment, the U shaped members are imperforate and are sized to fit over a stud, joist or rafter so that the flat center section of the second member actually forms a structurally sound, new level or straight surface on said stud, joist or rafter which is straight or level. 
         [0020]    In another embodiment an elongated S-shaped metal element which comprises an elongated vertically positioned center section having at a top edge, an upper orthogonal section and at a bottom edge, a lower orthogonal section, where said upper and lower sections extend in opposite directions from the vertical center section and the device is sized for application to a bowed floor joist so that the floor engaging surface of the joist is modified so that it has a level metal surface that is formed by the upper orthogonal section while the lower orthogonal section forms a level surface for the ceiling of the space below the floor that is supported by the bowed floor joist. This embodiment may be installed over a U-shaped element previously described as the first U-shaped member. 
         [0021]    It is an object of the invention to provide a low cost, easily installable device for providing a level or substantially flat surface on a wooden stud, joist or rafter. 
         [0022]    It is also an object of the invention to provide a device for providing a level or straight surface on wooden building framing members that does not require the use of any elements having different sizes that are attached to a stud, floor or joist in order to provide a straight surface for mounting wall, floor or ceiling finishing materials. 
         [0023]    It is also an object of this invention to provide a device for providing a level surface for a stud, joist or rafter which can be sized and installed at the job site using carpenters tools. 
         [0024]    It is also an object of this invention to provide a device that when installed on a floor joist will simultaneously provide a level surface on the top and bottom of a floor joist for installation of a floor on the top of the joist and a ceiling on the bottom of the floor joist. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0025]      FIG. 1  is a perspective view of a floor joist which shows a sag between the two ends of the joist. 
           [0026]      FIG. 2  is a perspective view of a floor joist which shows a first U-shaped member installed over the top of the joist. 
           [0027]      FIG. 3  is a perspective view of a floor joist which shows a second U-shaped member installed over a first U-shaped member. 
           [0028]      FIG. 4  is a cross-section of a floor joist with a first U-shaped member installed on the joist. 
           [0029]      FIG. 5  is a cross-section of a floor joist which shows a second U-shaped member installed over a first member. 
           [0030]      FIG. 6  is a cross-section of a floor joist with an S-shaped member installed without a first U-shaped member. 
           [0031]      FIG. 7 . is a cross-sectional view of a floor joist with a first U-shaped member installed under an S-shaped member. 
           [0032]      FIG. 8  is a perspective view of two side-by-side floor joists connected with diagonal bridging where the first and second U-shaped members have been installed with cut-outs to accommodate the bridging. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0033]    The present invention provides an attachable device that forms a straight surface on structural components used in wood framed buildings. As pointed out above, structural framing timbers such as studs, joists or rafters are subject to sagging and deformation due to age, overloading or being cut for plumbing and electrical access. The problem typically arises in older buildings where sagging floors or out of plumb walls require replacement for structural or cosmetic reasons. 
         [0034]      FIG. 1  shows a floor joist which has sagged to an unacceptable degree and requires replacement or leveling in order to provide a base for supporting a level floor.  FIG. 2  shows the sagged floor joist of  FIG. 1  with a first U-shaped member  2  installed over the top surface  4  of the joist. The top surface of a joist is the surface which extends upwardly when the joist is positioned for installation as a structural support for a floor. The first U-shaped member may be made of metal, preferably galvanized steel of 16 to 25 gauge, more preferably 18-22 gauge and most preferably 20 gauge. Other metals may be used such as stainless steel, aluminum, etc. depending on the environment of use and cost. 
         [0035]    As shown in  FIG. 2 , the first U-shaped member  2  is secured with a plurality of screws  6  to the top  4  of the joist which tightly fasten the center section of the first U-shaped member to the top  4  of the floor joist. The first U-shaped member  2  may have one or more cuts  8  on one or both sides to allow the U-shaped member to assume a curved profile so as to conform to the contour of the top surface  4  of the joist.  FIG. 4  is a cross-section of a joist with the first U-shaped member installed on a joist with sides  12  and  16  sized so that they extend downwardly about one quarter to one-third of the distance of the side of the joist. It is preferred that the first U-shaped member be sized so that the top surface  10  is 0.165 inch to 0.5 inch wider than the width of top surface of the joist. The placing and spacing of the screws in the top surface will depend on the size of the joist. For example a 3 by 12 joist may have a double row of 2 to 3 inch screws placed about 0.75 inches from each edge with two screws placed every 8 to 18 inches along the length of the joist. The spacing of the screws is not critical and may vary depending on the degree of sagging and the length of the joist. 
         [0036]    As shown in  FIG. 3 , a second U-shaped member  14  is placed over the first U-shaped member so that the top surface  10  of the U-shaped member forms a new level surface on the joist for receiving a sub-floor member (not shown). Dashed lines  15  show the sloped profile of the top of the installed first U-shaped member which follows the profile of the sagging joist. Dashed line  17  shows the edge of the hidden side  12  of the first U-shaped member. 
         [0037]      FIG. 5  shows a cross-section of a joist on which a first U-shaped member and a second U-shaped member have been installed. The second U-shape member has a top  10 A with sides  12 A and  16 A which extend downwardly along the side of the joist and do not contact the side of the joist. Optionally the second U-shaped member may be sized so that the sides are in contact with the sides of the joist on which the device is installed. 
         [0038]    The positioning of the screws in side  12 A and side  16 A of the second U-shaped member is arranged so that the sides  12  and  12 A as well as sides  16  and  16 A of the U-shaped members are fastened together. The screws may be just long enough to join the sides together It is preferred that the length of the screws will be selected so that the screws do not penetrate into the joist but optionally longer screws can be employed that will penetrate into the joist if additional support is required. In addition, the use of screws is not critical as threaded bolts or rivets may also be used. 
         [0039]    As best shown in  FIG. 6 . an S-shaped device is shown for use on a bowed floor joist where the joist also serves as a ceiling joist for the space below. The purpose of the S-shaped device it to provide top surface  20  which serves as a level surface for the floor above the joist and bottom surface  26  which serves as a level surface for the ceiling in the space below the floor joist. 
         [0040]    The S-shaped device has an elongated vertically positioned center section  30  having at a top edge, an upper orthogonal section  20  which forms the top surface and at a bottom edge, a lower orthogonal section  26 , where said upper and lower sections extend in opposite directions from the vertically positioned center section  30 . The device is sized for application to a bowed floor joist so that the floor engaging surface of the joist is modified so that it has a level metal surface that is formed by the upper orthogonal section while the lower orthogonal section forms a level surface for the ceiling of the space below the floor that is supported by the bowed floor joist. This device may also be used to reinforce a floor joist that has been weakened by being modified for plumbing and/or electrical access. 
         [0041]      FIG. 7  shows the S-shaped device of  FIG. 6  installed over a first U-shaped member as shown in  FIG. 4 . This configuration may be used where additional reinforcement is required. 
         [0042]      FIG. 8  shows two adjoining floor joist that have diagonally connected bridging  34  for stabilizing the joists from moving sideways under heavy floor loads. The first U-shaped member  2  and second U-shaped member  12 A are shown with a cut out  36  which allows the U-shaped members to be fitted in place to avoid having to remove the bridging  34 .