Abstract:
Devices and methods are disclosed for framing openings for doors, windows, store fronts, air conditioning units and other purposes, in walls formed of cast-in-place concrete. The devices include a jamb member having attached first and second inner flanges with angled guide surfaces for guiding placement of a wall forming system in alignment and engagement therewith and for anchoring the jamb member following hardening of the poured concrete. A method includes use of the disclosed jamb member to frame an opening in a building wall.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of priority of the filing date of prior provisional application Ser. No. 60/867,611, filed Nov. 29, 2006, which is incorporated by reference herein for all purposes. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to devices and methods for framing openings in building walls, and more particularly, devices and methods for framing openings for doors, windows, storefronts, air conditioner unit installations, and other purposes in walls constructed of cast-in-place concrete. 
       BACKGROUND 
       [0003]    Embodiments of the present invention relate to a system that may be used to frame openings in walls. Such openings may include, but are not limited to, those for windows, doors, air conditioning units, store fronts, curtain walls, etc. In the present example, a framing system is used with an “Insulated Concrete Form” wall system provided by Nudura Corporation of Barrie, Ontario. 
         [0004]    While the framing system of the present example will be described herein in the context of the Nudura wall system, it will be appreciated that the framing system of the present example (including variations thereof) may be used with a variety of other wall systems. Accordingly, it is contemplated that the Nudura wall system is simply one merely illustrative example of a wall system with which the framing system of the present example may be used; and that various other wall systems with which the framing system of the present example may be used will be apparent to those of ordinary skill in the art. 
         [0005]    The Nudura wall system of the present example comprises a pair of insulating wall members and a plurality of webs or brackets positioned between the pair of insulating wall members. The brackets are configured to hold the pair of insulating wall members apart at a certain distance, and to receive and hold lengths or portions of reinforcing rods or other reinforcing members. With the wall members, brackets, and reinforcing members in place, concrete is poured in the space between the wall members, such that the wall members provide a form for the concrete. The wall members, brackets, and reinforcing members are left in place after the concrete has been poured and has cured. 
         [0006]    It will be appreciated that certain situations may call for a window, doorway, storefront, curtain wall, or other opening to be formed in a cast concrete wall. For instance, in a Nudura wall system, it may be desirable to provide such openings before the concrete is poured. Such openings may be defined by a framing system such as the framing system of the present example. In particular, a framing system may be engaged with a Nudura wall system to define an opening, facilitate the alignment of the wall, and/or to prevent poured concrete from flowing into the opening. Furthermore, such a framing system may be left in place after the concrete has been poured, to form a framed opening ready to receive a door or a window, hardware associated therewith, or other members, structures or hardware which the opening is intended to accommodate. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]    The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown. In the drawings, like reference numerals refer to like elements in the several views. In the drawings: 
           [0008]      FIG. 1  depicts perspective, plan, and end views of an exemplary framing member; 
           [0009]      FIG. 2  depicts a cross-sectional view of an exemplary framing member engaged with a wall system; 
           [0010]      FIG. 3  depicts a cross-sectional view of another exemplary framing member engaged with a wall system; 
           [0011]      FIG. 4  depicts a cross-sectional view of yet another exemplary framing member engaged with a wall system; 
           [0012]      FIG. 5  depicts a perspective view of exemplary framing members forming an exemplary framing system; 
           [0013]      FIG. 6  depicts perspective, plan, and end views of an alternative framing member; 
           [0014]      FIG. 7  depicts a perspective view of alternative framing members forming an alternative framing system; and 
           [0015]      FIG. 8  depicts a partial cross-sectional view of another alternative framing member; 
           [0016]      FIG. 9  is a perspective view of an example of a wall system component with which a framing system described herein may be used; 
           [0017]      FIG. 10  is a cross-sectional view of another alternative, exemplary framing member used as a sill member in a window opening; 
           [0018]      FIG. 11  is a cross-sectional view of another alternative, exemplary framing member used as a jamb member in a window opening; 
           [0019]      FIG. 12  is a cross-sectional view of another alternative, exemplary framing member used as a header member in a window opening; 
           [0020]      FIG. 13  is a cross-sectional view of another alternative, exemplary framing member used as a header member in a door opening; 
           [0021]      FIG. 14  is a cross-sectional view of another alternative, exemplary framing member used as a jamb member in a door opening; 
           [0022]      FIG. 15  is a cross-sectional view of another alternative, exemplary framing member used as a jamb member in a door opening; 
           [0023]      FIG. 16  is a cross-sectional view of another alternative, exemplary framing member used as a header member in a door opening; and 
           [0024]      FIG. 17  is a cross-sectional view of another alternative, exemplary framing member used as a header member in a door opening. 
       
    
    
       [0025]    Reference will now be made in detail to various embodiments of the invention, examples of which are illustrated in the accompanying drawings. To the extent that specific dimensions are shown in the accompanying drawings, such dimensions should be regarded as merely illustrative and not limiting in any way. Accordingly, it will be appreciated that such dimensions may be varied in any suitable way. 
       DETAILED DESCRIPTION OF EMBODIMENTS 
       [0026]    The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive. 
         [0027]      FIG. 9  depicts an example of a wall system component  150  with which the framing system described herein may be used. The component  150  may include first and second panels such as wall members  102 , having length L, height H and thickness T, and having vertical edges  170 . Wall members  102  may be connected by a plurality of brackets  108  or other suitable connecting members having ends attached to each of wall members  102 . Brackets  108  or other suitable connecting members hold wall members  102  in a uniformly spaced-apart relationship, with inner surfaces  121  defining space  160  therebetween. Wall system components such as depicted in  FIG. 9  are available from Nudura Corporation of Barrie, Ontario, in varying dimensions and specifications. A typical component  150  may have panels having height H=18″, length L=96″, and thickness T=2⅝″, with varying widths for space  160  depending upon the overall thickness of the wall required. The top and bottom edges  171 ,  172  of members  102  may be formed with respectively mating features so that a plurality of components  150  may be interlockably stacked to form a section of a wall form, whereby concrete may be poured into space  160  to form a wall section having a concrete core and outer panels comprising wall members  102 . Wall members  102  may be formed of, for example, expanded polystyrene, which has insulating properties. Wall members  102  also may be formed with vertical grooves along the inner surfaces  121  thereof, into which concrete may flow when poured into space  160 , providing for interlocking and bonding of the concrete core with wall members  102  after the concrete hardens. 
         [0028]    As shown in  FIG. 1 , an exemplary framing member  10  comprises a first member  12 , a second member  14 , a third member  16 , a first outer flange  18 , a second outer flange  20 , a first inner flange  22 , and a second inner flange  24 . Each of the first inner flange  22  and second inner flange  24  has an anchor portion  26 . As shown, the second member  14  and third member  16  are each joined to a respective end of the first member  12 . The first outer flange  18  and first inner flange  22  extend from the second member  14 ; and the second outer flange  20  and second inner flange  24  extend from the third member  16 . The anchor portion  26  of the first inner flange  22  is oriented at an angle of approximately 135° relative to the first inner flange  22 . Similarly, the anchor portion  26  of the second inner flange  24  is oriented at an angle of approximately 135° relative to the second inner flange  24 . It will be appreciated, however, that each anchor portion  26  may be oriented at any other suitable angle relative to its corresponding inner flange  22 ,  24 . For instance, first inner flange  22  and its anchor portion  26  may form an angle anywhere between approximately 1° and approximately 90°; anywhere between approximately 90° and approximately 179°; or any other suitable angle. 
         [0029]    In the present example, first outer flange  18  terminates in an inwardly curling portion  28 . Inwardly curling portion  28  is oriented inward toward first inner flange  22 , then toward second member  14 . Similarly, second outer flange  20  terminates in an inwardly curling portion  30 . Inwardly curling portion  30  is oriented inward toward second inner flange  24 . Of course, as with any other component described herein, inwardly curling portions  28 ,  30  may be configured in any other suitable way, or may be omitted altogether. 
         [0030]    As is also shown in  FIG. 1 , first outer flange  18  and first inner flange  22  are spaced to receive a first wall portion  100  and facilitate the alignment of the wall. In this example, first wall portion  100  comprises a wall member  102  and one or more sheets of drywall  104  positioned adjacent to the wall member  102 . Similarly, second outer flange  20  and second inner flange  24  are spaced to receive a second wall portion  106 , which also comprises a wall member  102 . Wall members  102  are separated by brackets  108 . In the present example, first wall portion  100  is provided as an interior wall for a structure; while second wall portion  106  is provided as an exterior wall for a structure. Of course, various structures or materials may be added to or near each wall portion  100 ,  106 , including but not limited to paneling, masonry, stucco, Exterior Insulation and Finish Systems (EIFS), insulation, siding, etc. 
         [0031]    When framing member  10  of the present example is engaged with wall portions  100 ,  106 , the first inner flange  22  is adjacent to the inner surface of the wall member  102  of the first wall portion  100 ; while the inwardly curling portion  28  is adjacent to the outer surface of the drywall  104 . The second inner flange  22  is adjacent to the inner surface of the wall member  102  of the second wall portion  106 ; while the inwardly curling portion  30  is adjacent to the outer surface of the wall member  102  of the second wall portion  106 . It will be appreciated, however, that framing member  10  may engage wall portions  100 ,  106  in a variety of alternative ways. It will also be appreciated that framing member  10  may engage a variety of other types of wall members. 
         [0032]      FIG. 2  shows an alternative configuration for framing member  10 . In this variation, inner flanges  22 ,  24  extend from first member  12 . Second member  14  extends outwardly from an end of first member  12 ; while third member  16  extends outwardly from the other end of first member  12 . First outer flange  18  and curling member  28  of this variation are configured similar to the configuration of these components  18 ,  28  described above with respect to  FIG. 1 . Second outer flange  20  of this variation is configured similar to the configuration of second outer flange  20  described above with respect to  FIG. 1 ; while curling member  30  of this variation extends away from first member  12  after extending toward second inner member  24 . While curling member  28  is configured to engage drywall  104  (or any other interior wall covering), curling member  30  is configured to engage wall member  102  and brick  108  (or any other exterior building facade material). As is also shown, a gap  40  is provided between wall member  102  of first wall portion  100  and first member  12 . Another gap  42  is provided between first outer member  18  and drywall  104 . It will be appreciated that the orientation angles of anchor portions  26  with respect to inner flanges  22  can enable anchor portions  26  to serve to guide and ease engagement of wall members  102  with framing member  10 , or vice versa, during installation of framing member  10 . With framing member  10  engaged with first and second wall portions  100 ,  106 , concrete  110  is poured between first and second wall portions  100 ,  106 . As shown, poured concrete  110  abuts first member  12 , inner flanges  22 ,  24 , and anchor portions  26 . It will be appreciated that inner flanges  22 ,  24  serve both to help secure wall members  102  in proper position and also to prevent concrete from flowing into gaps or spaces  31 ,  40  during pouring, which may be desired if these spaces are preferably kept open to facilitate, for example, installation of hardware, wiring, etc. Anchor portions  26  are configured such that framing member  10  will be held securely in place after poured concrete  10  hardens. 
         [0033]      FIG. 3  shows another alternative configuration for framing member  10 . In this variation, second member  14  may be regarded as either eliminated or integral with first member  12 . In other words, first outer flange  18  extends directly from first member  12 . As shown, this variation eliminates gap  40 , such that wall member  102  of first wall portion  100  abuts first member  12 . Similarly, drywall  104  abuts first member  12 . The configuration shown in  FIG. 3  is otherwise similar to the configuration shown in  FIG. 2 . 
         [0034]      FIG. 4  shows yet another alternative configuration for framing member  10 . In this variation, the spacing between first outer flange  18  and first inner flange  22  is reduced relative to the spacing between such components  18 ,  22  shown in  FIG. 3 . Due to the reduction in this spacing, curling portion  28  abuts wall member  102  of first wall portion  100 , with a gap  44  being provided between first outer flange  18  and wall member  102  of first wall portion  100 . Curling portion  28  also abuts drywall  104 , but at an end of drywall  104  instead of at the inner surface of drywall  104 . Furthermore, curling portion  28  is configured such that, when framing member  10  and wall portions  100 ,  106  are installed in place, the outer surface of drywall  104  will be substantially flush with first outer flange  18 . The configuration shown in  FIG. 4  is otherwise similar to the configuration shown in  FIG. 3 . 
         [0035]    The various configurations for framing member  10  shown in  FIGS. 1-4  are not intended to be exhaustive. It will therefore be appreciated that components of framing member  10  may be modified in a variety of ways. For instance, various components may be reconfigured, substituted, supplemented, or omitted. Similarly, relationships between such components relative to one another, and relationships between such components and wall portions  100 ,  106 , may be varied in a variety of alternative ways. 
         [0036]      FIG. 5  shows an example of how framing members  10  may be joined together to form a door frame  200 . In particular, ends of framing members  10  may be joined to define a door frame  200 , such as by welding, mechanical fastening, abutment, or using any other suitable technique, materials, or structures. Framing members  10  forming a door frame  200  may be engaged with wall portions  100 ,  106  in any suitable fashion, including but not limited to such engagement as described above. 
         [0037]      FIG. 6  shows yet another alternative framing member  50 . Framing member  50  of this example is similar to framing member  10  shown in  FIG. 1 , except that an anchor strap assembly  52  is provided in lieu of anchor members  26 . Anchor strap assembly comprises an anchor strap mount  54  secured to first member  12 . An anchor strap  56  is secured to anchor strap mount  56  and extends away from first member  12 . The other components of framing member  50  are similar to those of framing member  10  shown in  FIG. 1 . Framing member  50  is also configured to engage wall portions  100 ,  106  in a manner similar to framing member  10  shown in  FIG. 1 . When framing member  50  is engaged with wall portions  100 ,  106 , and when concrete  10  is poured between wall portions  100 ,  106 , anchor strap  56  is configured to engage poured concrete  10 . Accordingly, anchor strap  56  may secure framing member  50  in place in a manner similar to anchor members  26 . 
         [0038]      FIG. 7  shows an example of how framing members  50  may be joined together to form a door frame  200 . In particular, ends of framing members  50  may be joined to define a door frame  200 , such as by welding, mechanical fastening, abutment, or using any other suitable technique, materials, or structures. Framing members  50  forming a door frame  200  may be engaged with wall portions  100 ,  106  in any suitable fashion, including but not limited to such engagement as described above. As is also shown in  FIG. 7 , a plurality of anchor strap assemblies  52  may be secured to each first member  12 . 
         [0039]      FIG. 8  shows another variation of a framing member  60 . In this variation, framing member  60  comprises a thermal break  62  for reducing heat transfer through the framing member  60  when installed, for example, in an exterior wall, in which one portion of framing member  60  will be inside a climate controlled building and the other portion will be outside the building. Framing member  60  may be configured similar to, for example, framing member  10  shown in  FIG. 1 , except that first member  12  is longitudinally separated into two portions—a first portion  64  and a second portion  66 . First portion  64  and second portion  66  each have cooperating joining features, such that the first and second portions  64 ,  66  may be joined, for example, in an “S”-like configuration as shown. An insulating material  68  is provided between the cooperating joining features of first and second portions  64 ,  66 . Insulating material  68  may comprise any suitable material, including but not limited to a foam, a caulking material, a rubber or plastic, or any other suitable material. Material  68  also may be comprised by a pre-formed, for example, extruded, strip, trim piece or fitting suitably designed to cooperate with the cooperating joining features of first and second portions  64 ,  66  and effect, facilitate and/or secure the joining thereof. In one embodiment, insulating material  68  has lower thermal conductivity than the material of which first and second portions  64 ,  66  are formed. Other suitable properties for material  68 , and substances of which material  68  may be comprised, will be apparent to those of ordinary skill in the art. It will also be appreciated that first and second portions  64 ,  66  may be provided in various alternative configurations in lieu of or in addition to the “S”-like configuration shown in  FIG. 8 , to effect a joining of first and second portions of a framing member and create a thermal break. 
         [0040]      FIG. 10  shows a cross section of another variation of a framing member  70  configured to serve as a sill member, and in place atop wall members  102  and poured concrete  10 . Framing member  70  has first and second outer flanges  18 ,  20 , and first and second inner flanges  22 ,  24 . As shown, flange pairs  18 ,  22  and  20 ,  24 , respectively, position and hold respective wall members  102  and framing member  70  in suitable final installation position with respect to each other. Framing member  70  also has sill surface portion  76 , on which a window unit W may rest in installed position as shown. Alternatively, framing member  70  may be configured to accept installation of a door threshold (not shown) or any other component, depending upon the purpose of the framed opening. Particularly when a member such as framing member  70  is used as a sill member to frame a large horizontal opening such as, for example, a window or storefront opening over 3 feet wide, it may be desirable to provide a way to pour and/or vibrate concrete  110  beneath surface portion  76 , to eliminate the necessity for pouring and/or vibrating concrete before installation of framing member  70 , or moving framing member  70 , or making one or more access holes in wall members  102 . Accordingly, surface portion  76  may have one or more access holes  72  therethrough, of a suitable size and placement along the length of framing member  70  to permit pouring of concrete therethrough, into the space between wall members  102 . Additionally or alternatively, one or move access holes such as access hole  72  may be located on framing member  70  and used as access point(s) for insertion and use of a concrete vibrator. Following pouring and/or vibrating of concrete  10  through access hole  70 , an access plate  74  may be installed to cover access hole  72 , and may be fixed in place on framing member  70  via screws at its edges or any other suitable attachment or fastening means. 
         [0041]    Those of ordinary skill in the art will appreciate that framing members  10 ,  50 ,  60 ,  70  described herein may be formed to have the features depicted in the drawings, or other features, to accommodate various purposes. For example, referring to  FIG. 3 , third member  16  may be formed so as to provide a framed opening and stop surfaces  17  for installation of a door (see, for example,  FIGS. 13-17 ), including accompanying hardware. In the examples shown, door hinges H (see, for example,  FIGS. 14 ,  15 ) may be affixed to third member  16  by screws (not shown) driven through third member  16  and into the space  31  therebehind. Weather stripping or cushioning members may be installed against stop surfaces  17 . It will be appreciated, then, that a door stop member may be incorporated into a framing member at locations other than as shown in, for example,  FIG. 3 . See, for example,  FIGS. 13-17 . Similarly, various types of window tracks and other features of window frames may be incorporated into a framing member. Additionally, referring to  FIG. 2 , it will be appreciated that outer flanges  18 ,  20  may be incorporated to provide a finished appearance to walls. By way of example in  FIG. 2 , and also  FIGS. 16 and 17  first outer flange  18  is situated so as to cover and provide a finished appearance to drywall  104  installed around the opening, functioning in the manner of casing; and second outer flange  20  is situated so as to abut, provide a caulking surface, and provide a finished frame appearance where the frame meets masonry such as brick work  108 , functioning in the manner of brick molding. Alternatively, second outer flange  20  may be configured to engage, conceal edges, and provide a finished appearance when used in conjunction with, for example, siding, stucco or other exterior finishes. Alternatively, both first and second outer flanges  18 ,  20  may be configured to engage, conceal edges and provide a finished appearance for drywall  104 , functioning as casing. See, e.g.,  FIGS. 13-15 . It will be appreciated, thus, that a framing member as described herein may be formed to include members to serve the functional and aesthetic purposes of door stops, window tracks or grooves to accommodate fixed or movable windows, moldings, sills, jambs, casings and the like. 
         [0042]    Those of ordinary skill in the art will appreciate that framing members  10 ,  50 ,  60 ,  70  described herein may be formed in a variety of ways. By way of example only, framing members  10 ,  50 ,  60 ,  70  may be formed by cutting and bending sheet or roll stock, by extrusion, or by any other suitable method. Flanges, curling portions, anchor members and any other included members may be formed to be integral with framing members, or may be affixed thereto by welding, adhesives, bonding, mechanical fastening such as screwing or riveting, cooperating joining features or any other suitable method. 
         [0043]    Framing members  10 ,  50 ,  60 ,  70  described herein may be formed using a variety of materials. Various metals may be used, for example, steel, stainless steel, aluminum, etc. Alternatively, vinyl, fiberglass, fiberglass reinforced plastic (FRP), other plastics or other materials may be used, including combinations of materials. For instance, in one variation, a steel framing member  10 ,  50 ,  60 ,  70  may be reinforced with fiberglass. Similarly, any suitable process other than extrusion may be used to produce framing members  10 ,  50 ,  60 ,  70 . 
         [0044]    It will also be appreciated that framing members  10 ,  50 ,  60 ,  70  may be subject to various forms of surface treatment. For instance, if protection from corrosion is required, all or part of a framing member  10 ,  50 ,  60 ,  70  may be coated with paint, primer, rust inhibitor, or other coating(s), including combinations thereof. Framing members  10 ,  50 ,  60 ,  70  may also be pre-finished, painted, varnished, anodized, galvanized, metal-coated, brushed, blasted or subject to any other suitable surface treatment for functional or aesthetic purposes. 
         [0045]    An example of a method of constructing a building wall having an opening framed by a framing system of the present invention will now be described. By way of example, and referring to  FIGS. 2 and 5 , a door frame  200  having, for example, framing members  10  such as member  12  serve as side door jamb members, may be prefabricated to specifications and delivered to the project site. The door frame assembly may then be placed in position as required by the building plans, affixed or anchored at the bottom upon a foundation wall, floor or other base as required, and adjusted to and held in vertical, plumb position by suitable temporary bracing. Thereafter, components of a suitable wall forming system such as wall members  102 , having vertical edges, may be moved toward framing member  10 , guided into alignment and engagement with inner flanges  22 ,  24  using the angled guiding surfaces of anchor portions  26 . With wall members  102  in position abutting framing member  10 , concrete may be poured into the space between wall members  102 , and into the respective channels formed by member  12 , flanges  22 ,  24  and anchor portions  26 , as shown in  FIG. 2 . It will be appreciated that when the concrete hardens, framing member  10  will be securely held in place as a result of flanges  22 ,  24  and anchor portions  26  thereof being encased by the hardened concrete. 
         [0046]    Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of whatever claims recite the invention, and is understood not to be limited to the details of structure and operation shown and described in the description.