Patent Publication Number: US-8117802-B1

Title: Prefabricated structural element

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to structure-forming elements and more particularly pertains to a new prefabricated structural element that facilitates the construction of a building by providing a preformed element that is easily cut to fit differently-sized openings in a building and that facilitate the finishing of the interior of the building after the element is installed. 
     2. Description of the Prior Art 
     In the construction of a building or other structure, it is often desirable to create openings for doors and windows to permit egress and allow for light passage and ventilation. These openings require reinforced structural elements to be positioned above the opening to support the portion of the wall above the opening, and an element typically referred to as a “header” is employed that has greater strength than the usual stud-and-bay arrangement employed in the rest of the wall. Headers are most commonly formed by the wall framers on-site, using two or three 2″×4″ or 2″×6″ (or larger) boards that are nailed or otherwise fastened together and placed on edge above the opening. The on-site construction of the header can be relatively time consuming as compared to other framing done on-site, and fastener placement in the boards may not be optimal for the greatest strength. The fabrication of headers in this manner does not always result in a structural element that is the same thickness as the rest of the wall, which can cause gaps in the interior of the wall. The header formed of boards abutted against each other may also have a relatively lesser insulation characteristic as compared to the rest of the insulation filled wall. 
     Various prefabricated structural members have been proposed for use as headers (or as other structural elements) in buildings, which can eliminate the need to perform on-site fabrication and provide a more uniform quality for the header, but the known designs tend to employ a modified I-beam or box-beam configuration that can form gaps in the resulting walls which in turn may complicate insulation installation in the wall, as well as the finishing of the wall (such as with wall board) and the installation of decorative elements (such as curtain rods that tend to be installed above openings in a structure). 
     For example, U.S. Pat. No. 5,966,894 to Crump, Jr. shows a framing beam assembly that combines a box beam and an I-beam design, but is fabricated out of a multiplicity of parts and only has a limited area on a side which can be securely fastened to due to the positioning of a relatively soft insulation material on the side of the beam assembly. The additional parts complicates the assembly and inevitably makes it more expensive to assemble, and the limited area for secure attachment is positioned more toward one side of the beam assembly and thus requires that the builder make sure at each use that the correct side is positioned downwardly. 
     Therefore, it is believed that an improved prefabricated structural element is needed that can be employed in the construction of buildings, particularly as headers above opening in the building. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing disadvantages inherent in the known types of structure-forming elements now present in the prior art, the present invention provides a new prefabricated structural element wherein the same facilitates the construction of a building by providing a preformed element that is easily cut to fit differently-sized openings in a building and that facilitate the finishing of the interior of the building after the element is installed. 
     To attain this, the present invention generally comprises a structural element for use in forming a structure, with the structural element having opposite longitudinal ends. The structural element includes a first longitudinal member extending between the opposite ends of the structural element, and the first longitudinal member has an inward face, an outward face, and a pair of side faces each extending between the inward and outward faces. The structural element further includes a second longitudinal member extending between the opposite ends of the structural element, with the second longitudinal member having an inward face, an outward face, and a pair of side faces each extending between the inward and outward faces. The element also includes a first lateral member that extends between the first longitudinal member and the second longitudinal member, and the first lateral member having an outer surface. The structural element further includes a second lateral member that extends between the first longitudinal member and the second longitudinal member, and the second lateral member has an outer surface. 
     In some embodiments of the invention, the outer surface of the first lateral member is substantially flush with one of the side faces of the first longitudinal member and one of the side faces of the second longitudinal member to form a substantially planar surface extending across substantially an entirety of a first side surface of the structural element. Similarly, the outer surface of the second lateral member is substantially flush with one of the side faces of the first longitudinal member and one of the side faces of the second longitudinal member to form a substantially planar surface extending across substantially an entirety of a second side surface of the structural element. 
     In some embodiments, a pair of grooves may be formed on the inward face of the first longitudinal member, with each of the grooves being positioned adjacent to and spaced from a respective one of the side faces of the first longitudinal member. Similarly, a pair of grooves may be formed on the inward face of the second longitudinal member, with each of the grooves being positioned adjacent to and spaced from a respective one of the side faces of the second longitudinal member. A tongue may extend from each of the opposite edge faces of the first lateral member, and the tongue on each of the edge faces of the first lateral member is positioned in one of the grooves of one of the longitudinal members. A tongue may extend from each of the opposite edge faces of the second lateral member, with the tongue on each of the edge faces of the second lateral member being positioned in one of the grooves of one of the longitudinal members. 
     There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto. 
     In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. 
     As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention. 
     Advantages of the invention, along with 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 the specific objects attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated preferred embodiments of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be better understood and objects of the invention will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein: 
         FIG. 1  is a schematic perspective view of the new prefabricated structural element according to the present invention. 
         FIG. 2  is a schematic sectional view of the present invention. 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     With reference now to the drawings, and in particular to  FIGS. 1 and 2  thereof, a new prefabricated structural element embodying the principles and concepts of the present invention and generally designated by the reference numeral  10  will be described. 
     The structural element  10  of the invention is highly suitable for use in the construction of a building or other structure, and is especially useful for, although is not limited to, forming the framing elements above openings in the building structure sometimes referred to as a “header”. The structural element  10  has opposite longitudinal ends  12 ,  14  that may be rested on and attached to supporting elements, such as vertical structures in a wall. 
     The structural element  10  of the invention may comprise a first longitudinal member  16  and a second longitudinal member  18 , and a first lateral member  20  and a second lateral member  22 . The members  16 ,  18 ,  20 ,  22  each extend between the opposite longitudinal ends  12 ,  14  of the element  10 . The members  16  through  22  are arranged so that they define an interior channel  24  therebetween, and extend from one end  14  to the other end  16  of the element  10 . The channel  24  may be continuously and uninterruptedly circumscribed by the members  16  through  22 . 
     The first longitudinal member  16  extends between the opposite ends  12 ,  14  of the structural element  10 . The first longitudinal member  16  has an inward face  26  and an outward face  27 . The outward face  27  may form one of the exterior bearing surfaces of the structural element  10 . The first longitudinal member  16  also has a pair of side faces each extending between the inward face and the outward face of the first longitudinal member. 
     A groove  30  is formed on the inward face  26  of the first longitudinal member  16 , and may be positioned at a spaced location from one  28  of the side faces of the member  16 . In some of the most preferred embodiments, a pair of grooves  30  and  32  is formed on the inward face  26  of the first longitudinal member. Each of the grooves  30 ,  32  may thus be positioned adjacent to or relatively proximate to, but spaced from, a respective one of the side faces of the first longitudinal member. 
     The second longitudinal member  18  extends between the opposite ends  12 ,  14  of the element  10 , and includes an inward face  34  and an outward face  35 . The inward face  34  of the second longitudinal member  18  is oriented toward the inward face  26  of the first longitudinal member  16 . The second longitudinal member  18  may be positioned a substantially uniform distance from the first longitudinal member  16  between the opposite ends  12 ,  14  of the structural element  10 . The second longitudinal member  18  has a pair of side faces  36 ,  37  that each extend between the inward face  34  and the outward face  35  of the second longitudinal member. 
     A groove  38  is also formed on the inward face  34  of the second longitudinal member  18 , and may be positioned at a spaced location from one of the side faces  36  of the second longitudinal member  18 . The groove  38  may be positioned in opposition to the groove  30  on the first longitudinal member  16 . Similar to the first longitudinal member, a pair of grooves  38  and  40  is formed on the inward face  34  of the second longitudinal member  18 , and each of the grooves  38  and  40  may be positioned adjacent to and spaced from a respective one of the side faces  36 ,  37  of the second longitudinal member. Each groove  38 ,  40  of the pair of grooves in the second longitudinal member may be positioned in opposition to a respective one of the grooves  30   32  in the in the first longitudinal member  16 . 
     The first lateral member  20  extends between the first  16  and second  18  longitudinal members, and has an outer surface  42  as well as an inner surface  43 . The first lateral member  20  has a pair of opposite edge faces  44 ,  45 . Similarly but not necessarily identically, the second lateral member  22  extends between the first longitudinal member  16  and the second longitudinal member  18 , and has an outer surface  46  as well as an inner surface  47 . The second lateral member  22  also has a pair of opposite edge faces  48 ,  49 . 
     A significant feature of at least some embodiments of the invention is that the outer surface  42  of the first lateral member  20  is substantially flush with one  28  of the side faces of the first longitudinal member  16  and one  36  of the side faces of the second longitudinal member  18  to form a substantially planar surface extending across substantially the entire side surface of the structural element  10 . Similarly, but again not necessarily identically, the outer surface  46  of the second lateral member  22  is substantially flush with one  29  of the side faces of the first longitudinal member  16  and one  37  of the side faces of the second longitudinal member  18  to form a substantially planar surface extending across substantially the entire side surface of the structural element  10 . This relationship between the outer surfaces of the first  20  and second  22  lateral members and the respective side faces of the first  16  and second  18  longitudinal members is significant as it not only provides a substantially flat surface across the entire dimension of the side surface of the element  10  for positioning facing elements (such as wall board) against, but also facilitates fastening of such elements to the side of the element  10  as the entire, or substantially the entire, side surface of the element  10  is formed by the strength providing components (e.g. the members  16  through  22 ), and not by relatively weaker elements such as insulation materials. The members  16  through  22  are preferably formed of a wood-containing material such as, but not limited to, natural form wood, plywood, laminated wood, medium density fiberboard, or virtually any wood fiber-containing material that provides structural strength. Other types of materials that exhibit structural strength may also be used. It will be evident that the strength of the element  10  may be increased by increasing the relative thicknesses of the members, or changing the materials. These types of materials provide an ideal base for placing a wall surface forming material against, such as wall board, and also form a sturdy surface for fastening the wall board to at any location on the side surface of the element  10 . Further, a gap is not formed between the lateral members and the wall board mounted against the element, so the mounting of supports, such as curtain rod supports, may be effected at any location on the wall board as the fastener of the support is highly likely to reach the lateral member of element  10  due to the positioning of the lateral member right behind the wallboard. 
     In another significant aspect of the invention that is employed on at least some embodiments of the invention, a tongue  50 ,  51  extends from each of the opposite edge faces  44 ,  45  of the first lateral member. Each of the tongues may comprise a portion of the member with a reduced width relative to the width of the lateral member between the inner and outer surfaces of the major portion of the lateral member. The tongues of a lateral member may be positioned relative to the inner and outer surfaces in a variety of relationships, but preferably the tongues  50 ,  51  may be spaced from the outer surface  42  of the first lateral member  20 , and optionally may be substantially flush or even with the inner surface of the first lateral member. The tongues  50 ,  51  on each of the edge faces  44 ,  45  of the first lateral member  20  are positioned in respective grooves  30 ,  38  of the longitudinal members  16 ,  18 . Similarly, but not necessarily identically, a tongue  52 ,  53  extends from each of the opposite edge faces  48 ,  49  of the second lateral member  22 . The tongues  52 ,  53  are spaced from the outer surface  46  of the second lateral member  22 . The tongues  52 ,  53  on each of the respective edge faces of the second lateral member are positioned in a respective groove  32 ,  40  of the longitudinal members  16 ,  18 . The positioning of the tongues toward the inner surfaces  43 ,  47  of the lateral members and away from the outer surface  42 ,  46  of the lateral members permits the outer surface  42 ,  46  to be flushed up with the side faces of longitudinal members  16 ,  18 , while also permitting the tongues to be inserted into a full groove with opposite sides that contact, and thus may be adhered to, the tongue that is inserted into the groove. This relationship enhances the strength of the bond between the longitudinal and lateral members formed by the tongue and groove structure. 
     The groove corresponding to a tongue may have a width slightly wider than the width of the tongue, or substantially the same as the width of the tongue, if an interference fit therebetween is desired. It will be appreciated that the spacing of each groove from the adjacent side face of the longitudinal member substantially corresponds to the offset of the tongue (that mates with the groove) from the outer surface of the respective lateral member. 
     Optionally, the width dimension of the tongues  50 ,  51  may be approximately one half of the thickness dimension of the respective lateral member from which it extends, although wider or narrower widths may be employed. In such an illustrative embodiment, the offset of the tongue from the respective outer surface of the respective lateral member is approximately one half of the width of the lateral member. 
     In some embodiments of the invention, an insulation material  60  is located in the interior channel  24  of the element  10  formed by the longitudinal members  16 ,  18  and the lateral members  20 ,  22 . Optionally, the insulation material  60  may be formed exteriorly of the interior channel  24  and then inserted into the channel. For example, pieces of insulation board formed of expanded polystyrene may be slid into the interior channel after the members  16  through  22  of the element  10  are attached together, or may be inserted during the process of assembling the members. As a further option, the insulation material  60  may be foamed into the interior channel by spraying the components of an expanding foam material into the channel  24  allowing the foam to expand. The expanding foam may thus form a bond with at least one of the inner faces of one of the members. 
     The structural element  10  may thus be used as any other header or beam material, and may be supplied to the user in standard lengths that may be measured and cut into the needed length at the construction site using conventional techniques. 
     With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art in light of the foregoing disclosure, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention. 
     Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. 
     
       
         
           
               
             
               
                   
               
               
                 Index of Elements for  
               
               
                 PREFABRICATED STRUCTURAL ELEMENT 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
            
               
                 1. 
                   
               
               
                 2. 
                   
               
               
                 3. 
                   
               
               
                 4. 
                   
               
               
                 5. 
                   
               
               
                 6. 
                   
               
               
                 7. 
                   
               
               
                 8. 
                   
               
               
                 9. 
                   
               
               
                 10. 
                 structural member 
               
               
                 11. 
                   
               
               
                 12. 
                 (first) opposite end of struct. member 
               
               
                 13. 
                   
               
               
                 14. 
                 (second) opposite end of struct. memb. 
               
               
                 15. 
                   
               
               
                 16. 
                 first longitudinal member 
               
               
                 17. 
                   
               
               
                 18. 
                 second longitudinal member 
               
               
                 19. 
                   
               
               
                 20. 
                 first lateral member 
               
               
                 21. 
                   
               
               
                 22. 
                 second lateral member 
               
               
                 23. 
                   
               
               
                 24. 
                 interior channel 
               
               
                 25. 
                   
               
               
                 26. 
                 inward face of first long. member 
               
               
                 27. 
                 outward face of first long. member 
               
               
                 28. 
                 (first) side face of first long. member 
               
               
                 29. 
                 (second) side face of first long. member 
               
               
                 30. 
                 (first) groove in first long. member 
               
               
                 31. 
                   
               
               
                 32. 
                 (second) groove in second long. memb. 
               
               
                 33. 
                   
               
               
                 34. 
                 inward face of second long member 
               
               
                 35. 
                 outward face of second long member 
               
               
                 36. 
                 (first) side face of second long. member  
               
               
                 37. 
                 (second) side face of second long mem 
               
               
                 38. 
                 (first) groove in second long member 
               
               
                 39. 
                   
               
               
                 40. 
                 (second) groove in sec. long. member 
               
               
                 41. 
                   
               
               
                 42. 
                 outer surface of first lat member 
               
               
                 43. 
                 inner surface of first lateral member 
               
               
                 44. 
                 (first) edge face of first lat member 
               
               
                 45. 
                 (second) edge face of first lat member 
               
               
                 46. 
                 outer surface of second lat member 
               
               
                 47. 
                 inner surface of second lat member 
               
               
                 48. 
                 (first) edge face of second lat. memb. 
               
               
                 49. 
                 (second) edge face of second lat memb 
               
               
                 50. 
                 (first) tongue on first lat member 
               
               
                 51. 
                 (second) tongue on first lat member 
               
               
                 52. 
                 (first) tongue on second lat member 
               
               
                 53. 
                 (second) tongue on second lat memb 
               
               
                 54. 
                   
               
               
                 55. 
                   
               
               
                 56. 
                   
               
               
                 57. 
                   
               
               
                 58. 
                   
               
               
                 59. 
                   
               
               
                 60. 
                 insulation material 
               
               
                 61. 
                   
               
               
                 62. 
                   
               
               
                 63. 
                   
               
               
                 64. 
                   
               
               
                 65. 
                   
               
               
                 66. 
                   
               
               
                 67. 
                   
               
               
                 68. 
                   
               
               
                 69. 
                   
               
               
                 70. 
                   
               
               
                 71. 
                   
               
               
                 72. 
                   
               
               
                 73. 
                   
               
               
                 74. 
                   
               
               
                 75. 
                   
               
               
                 76. 
                   
               
               
                 77. 
                   
               
               
                 78. 
                   
               
               
                 79. 
                   
               
               
                 80.