Patent Abstract:
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.

Full Description:
TECHNICAL FIELD 
       [0001]    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 
       [0002]    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. 
         [0003]    As shown in  FIG. 1 , a primary wall A having a lower plate  12  intersects with an intersecting wall B having a lower plate  14 . During construction, a 2×6 backing stud  16  is position on lower plate  12  and provided for corner nailing. Moreover, a 2×4 end stud  18  is then attached to the 2×6 backing stud  16  and positioned on lower plate  14 . The combination of the two studs (i.e., 2×6 backing stud  16  and 2×4 end stud  18 ) forms the frame support for the T-intersection between primary wall A and intersecting wall B. 
         [0004]    As further shown in  FIG. 2 , a primary wall A having a lower plate  12  again intersects with an intersecting wall B having a lower plate  14 . In this design, a 2×4 backing stud  20  is positioned during construction on lower plate  12  and a 2×4 end stud  22  is then attached to the 2×6 backing stud  20  and positioned on lower plate  14 . A pair of additional 2×4 studs  24   a  and  24   b  are secured to the respective sides of backing stud  20  and serve as a means for corner nailing. 
         [0005]    There are numerous disadvantages and drawbacks to these types framing assemblies for T-intersections. First, the basic approaches illustrated in  FIGS. 1 and 2  require 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 
       [0006]    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. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  illustrates a conventional design for framing assemblies interposed between two wall sections adjoining one another at a T-shaped intersection. 
           [0008]      FIG. 2  illustrates another conventional design for framing assemblies interposed between two wall sections adjoining one another at a T-shaped intersection. 
           [0009]      FIG. 3  illustrates a perspective of two wall sections connected to one another by the frame structure in accordance with an exemplary embodiment. 
           [0010]      FIG. 4  illustrates a cross-sectional view of the frame structure in accordance with an exemplary embodiment. 
           [0011]      FIG. 5  illustrates a side partial view of the frame structure interposed between the two wall sections in accordance with an exemplary embodiment. 
           [0012]      FIG. 6  illustrates a cross-sectional view of the frame structure in accordance with an exemplary embodiment. 
           [0013]      FIG. 7  illustrates a side partial view of the frame structure interposed between the two wall sections in accordance with another exemplary embodiment. 
           [0014]      FIG. 8  illustrate an advantageous shipping configuration of T-intersection frame structures in accordance with an exemplary embodiment. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0015]      FIG. 3  illustrates a perspective  100  of 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 structure  110  is interposed between first wall section  120  and second wall section  130 . Wall section  120  further includes lower plate  122 , upper plate  124  and a plurality of studs  140  connected between lower plate  122  and upper plate  124 . 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 studs  140  that are provided are approximately the desired height of the wall of the building being constructed. Moreover, wall section  130  further includes lower plate  132 , upper plate  134  and a plurality of studs (not shown) connected between lower plate  132  and upper plate  134 . As will be explained in more detail below, frame structure  110  is interposed between the two wall sections  120 ,  130  to facilitate construction of the wall intersection. 
         [0016]      FIG. 4  illustrates a cross-sectional view of frame structure  200  in accordance with an exemplary embodiment. It should be understood that frame structure  200  provides a cross-sectional view of frame structure  110  illustrated in  FIG. 3 . As shown, frame structure  200  comprises a first support panel  210  having two opposing sides  212  and  214  and two outer edges  216   a  and  216   b.  In the exemplary embodiment, first support panel  210  is substantially rectangular in shape. Furthermore, frame structure  200  comprises two individual second support panels  220 ,  230  that protrude from side  214  of first panel  210  at an approximately 90° angle. As such, the pair of individual second support panels  220 ,  230  are positioned substantially parallel to one another. In the exemplary embodiment, the pair of second support panels  220 ,  230  are also substantially rectangular in shape. Moreover, the pair of second support panels  220  and  230  each have respective outer sides  222   a  and  232   a,  respective inner sides  222   b  and  232   b,  as well as respective ends  224  and  234 . In the exemplary embodiment, frame structure  200  is therefore formed with a recess  218  between inner sides  222   b  and  232   b  of second support panels  220  and  230 . It should be clear that while the exemplary embodiment is illustrate with second support panels  220  and  230  being secured to first support panel  210  at 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. 
         [0017]    In implementation, the pair of second support panels  220  and  230  are secured to first support panel  210  by any applicable means. For example, second support panels  220 ,  230  can be secured to first support panel  210  by nails, adhesive, screws, a combination of these materials, or any other suitable means. In an alternative implementation, second support panels  220 ,  230  are manufactured as a single piece of material with first support panel  210 . Frame structure  200  can be manufactured from recycled material, plywood, chipboard, or any other suitable material. In one embodiment, the individual support panels,  210 ,  220  and  230  of frame structure  200  can be milled out of plywood and connected with a suitable adhesive. 
         [0018]    As explained above and illustrated in  FIG. 3 , frame structure  200  is interposed between wall section  120  and wall section  130  during construction. It is appreciated that frame structure  200  is inserted between lower plates  122 ,  132  and upper plates  124 ,  134  of walls sections  120  and  130 , respectively. Accordingly, in implementation, frame structure  200  will be substantially the same length as the plurality of studs  140  shown in  FIG. 3 . 
         [0019]      FIG. 5  illustrates a side partial view of frame structure  200  interposed between the two wall sections in accordance with an exemplary embodiment. As shown, frame structure  200  is coupled to the upper surface  124  of lower plate  122  of wall section  120  by connector bracket  310 . It should be appreciated that connector bracket  310  can be any conventional bracket capable of connecting frame structure  200  and lower plate  122  and is not limited to the design illustrated in  FIG. 5 . Furthermore, frame structure  200  is secured to lower plate  122  such that the inner sides  214   a,    214   b  of frame structure  200  are in substantially the same plane as side edge  126  of lower plate  122 . Furthermore, the pair of second support panels  220 ,  230  of frame structure  200  are secured to first support panel  210  with a premeasured width such that outer sides  222   a  and  232   a  are in substantially the same plane as the side edges  134   a,    134   b  of lower plate  132  of wall section  130 . Alternatively, second support panels,  220  and  230  can be positioned closer together (e.g., 1 inch apart). Finally, while not shown, it should be appreciate that the opposite end of frame structure  200  is secured to the upper plates  124 ,  134  of wall sections  120 ,  130  in a substantially similar manner. 
         [0020]    Once secured between wall sections  120  and  130 , frame structure  200  is 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 panel  210  as well as the pair of second support panels  220 ,  230  are designed so as to assume the principal load carrying function. 
         [0021]    To facilitate construction and design of the particular building, it is appreciated that the inner sides  214   a,    214   b  of first support panel  210  serve to receive the inner wall structure of the house for wall section  120 , such as sheetrock, paneling, etc. Similarly, in the exemplary embodiment, the outer sides or edges  212  of first support panel  210  can server to receive the outer side wall structure of the building such as exterior paneling, siding, etc. Moreover, the outer sides  222   a  and  232   a  of the pair of respective second support panels  220  and  230  serve to receive the inner wall structure of the house for wall section  130 , 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. 
         [0022]      FIG. 6  illustrates a cross-sectional view of frame structure  600  in which specific dimensions are provided in accordance with an exemplary embodiment. As shown, first support panel  610  has a length of approximately 6½ inches and a width of approximately ¾ inches. Moreover, the pair of second support panels  620  and  630  have a length of approximately 1½ inches. Further, second support panels  620  and  630  are secured to first support panel  610  such that their respective outer surfaces  622   a  and  632   a  are positioned approximately 1½ inches from the respective outer edges  616   a  and  616   b  of first support panel  610 . As a result, there is sufficient space provided by frame structure  600  enabling sheetrock, paneling, and the like to be secured to inner sides  614   a  and  614   b  of first support panel  610  as well as to the respective outer surfaces  622   a  and  632   a  of second support panels  620  and  630 . It should be appreciated, however, that the second support panels  620  and  630  can 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 in  FIG. 6 , the invention is by no means intended to be limited by these dimensions. 
         [0023]      FIG. 7  illustrates a side partial view of frame structure  700  interposed between two wall sections  120 ,  130  in accordance with another exemplary embodiment. In contrast to the embodiments described above, frame structure  700  comprises a pair of first support panels  710   a,    710   b.  Moreover a pair of second support panels  720  and  730  are secured, respectively, to the pair of first support panels  710   a,    710   b.  Additionally, a third support panel  740  can be secured between the pair of second support panels  720  and  730 . As such, a recess  750  is provided between second support panels  720  and  730 . In one embodiment, second support panels  720  and  730  as well as third support panel  740  are prefabricated as a single piece of material. In any event, it should be appreciated that frame structure  700  comprises similar functional aspects as frame structure  200 . For example, in a similar manner as shown in  FIG. 5 , the pair of first support panels  710   a  and  710   b  are coupled to the upper surface  124  of lower plate  122  of wall section  120  by a pair connector bracket  310   a,    310   b.  Furthermore, frame structure  700  is secured to lower plate  122  such that the respective inner sides  714   a  and  714   b  of the pair of first support panels  710   a  and  710   b  are in substantially the same plane as side edge  126  of lower plate  122 . Furthermore, the pair of second support panels  720 ,  730  are secured to the pair of first support panels  710   a  and  710   b  with a premeasured width such that outer sides  722   a  and  732   a  are in substantially the same plane as the side edges  134   a,    134   b  of lower plate  132  of wall section  130 . 
         [0024]    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. 
         [0025]    Finally,  FIG. 8  illustrates an advantageous shipping configuration of the frame structures in accordance with an exemplary embodiment. As shown, a plurality of frame structures  810   a - 810   d  can be stacked in an efficient manner are shown in  FIG. 8 . It should be clear that the plurality of frame structures  810   a - 810   d  employ the same design as the exemplary structure described above with respect to  FIG. 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. 
         [0026]    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. 
         [0027]    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.

Technology Classification (CPC): 4