The present invention relates to the general field of construction, and is more specifically concerned with an adjustable lintel and a wall including the same.
In a brick wall construction, there is a need to provide a structure to support the bricks above any opening, such as along the upper edge of door and window openings. This is for example achieved by positioning a lintel across the top of the opening. One problem that often occurs is that the bricks on both sides of the opening may present a small difference in height between the two corresponding upper brick layers on each side thereof. The situation gets worse if this difference starts to manifests itself only after a few brick layers have been laid down on top of a lintel support member provided above the opening due, for example, to the quality or a varying density in the mortar used during the construction thereof. When such a difference occurs, the lintel support structure ends up not at level and may put pressure on one side of the door or window frame. To correct the situation, the construction worker often has to remove some brick layers and start anew including some measurements and compensations in mortar thickness between selected brick layers.
Experienced construction workers may be aware in advance of such possible differences in height between the two upper brick layers on each side of a wall opening as the last few brick layers are laid down before reaching the upper edge thereof. These experienced construction workers generally measure the expected difference and compensate with a suitable thickness of mortar on one side or the other accordingly. But even once such compensations have been used, a true level lintel is not necessarily guaranteed due to different factors such as mortar quality and temperature, for example.
In the end, all these corrections, measurements and/or compensations during the construction of a brick wall around a wall opening inevitably induce delays which, in turn, may result in significant time and budget overruns in large construction sites defining multiple wall openings in brick walls.
Against this background, there exists a need in the construction industry to provide an improved device for supporting construction blocks above an opening. An object of the present invention is therefore to provide such an improved device.
In a broad aspect, there is provided an adjustable lintel.
In another broad aspect, there is provided a wall of construction blocks including the adjustable lintel.
In yet another broad aspect, there is provided a lintel for use in supporting construction blocks over an aperture in a wall including the construction blocks, the lintel comprising: a substantially horizontally elongated lintel body defining substantially longitudinally opposed end sections and an intermediate section extending therebetween, the lintel body defining a block supporting element in the intermediate section for supporting the construction blocks over the aperture; and a pair of end elements each mounted to a respective one of the end sections, each of the end elements defining a lintel supporting element for supporting the lintel in the wall between adjacent rows of the construction block on a respective side of the aperture. Each of the end elements is securable to a respective end section at upper and lower positions relative thereto.
There may also be provided a lintel wherein the block supporting element defines a substantially horizontal block supporting surface facing substantially upwardly and the lintel supporting elements are each substantially plate-shaped and substantially horizontal.
There may also be provided a lintel wherein the intermediate portion has a substantially L-shaped transversal cross-sectional configuration.
There may also be provided a lintel wherein the relative position between each of the end sections and the end element mounted thereto is continuously adjustable between the upper and lower positions.
There may also be provided a lintel wherein the end sections each define a substantially vertically extending end section mounting plate and the end elements each define a substantially vertically extending end element mounting plate, wherein, with the end elements operatively mounted to the end sections, the end element mounting plate and end section mounting plate abut against each other in a substantially parallel relationship relative to each other.
There may also be provided a lintel wherein the end section mounting plate is provided with a threaded bore and the end element mounting plate is provided with a substantially vertical slot extending therethrough, the lintel further comprising a threaded fastener inserted through the slot and threadedly engaging the threaded bore.
There may also be provided a lintel wherein the slot is narrower adjacent the end section mounting plate than opposed to the end section mounting plate.
There may also be provided a lintel further comprising a pair of substantially vertical lead screws each supported by a respective one of the end sections and threadedly engaging a threaded aperture extending vertically in a respective one of the end elements, wherein rotating the lead screws moves the end elements between the upper and lower positions.
There may also be provided a lintel wherein in the upper and lower positions, the lintel supporting element is respectively higher and lower than the block supporting element.
In yet another broad aspect, there is also provided a wall structure, comprising: a plurality of superposed rows, each row including a plurality of constructions blocks, the construction blocks delimiting an aperture in the wall structure; and a lintel provided adjacent and above the aperture, the lintel including a substantially horizontally elongated lintel body defining substantially longitudinally opposed end sections and an intermediate section extending therebetween, the intermediate section extending above and across the aperture, the lintel body defining a block supporting element in the intermediate section supporting the construction blocks topping the aperture; and a pair of end elements each mounted to a respective one of the end sections, each of the end elements defining a lintel supporting element embedded in the wall on a respective side of the aperture. Prior to construction of the wall, each of the end elements is securable to a respective end section at upper and lower positions relative thereto.
There may also be provided a wall structure wherein the block supporting element defines a substantially horizontal block supporting surface facing substantially upwardly supporting the construction blocks topping the aperture and the lintel supporting elements are each substantially plate-shaped and substantially horizontal, each of the lintel supporting element being inserted between adjacent rows.
There may also be provided a wall structure wherein the intermediate portion has a substantially L-shaped transversal cross-sectional configuration.
There may also be provided a wall structure wherein the relative position between each of the end sections and the end element mounted thereto is continuously adjustable between the upper and lower positions.
There may also be provided a wall structure wherein the end sections each define a substantially vertically extending end section mounting plate and the end elements each define a substantially vertically extending end element mounting plate, wherein the end element mounting plate and end section mounting plate abut against each other in a substantially parallel relationship relative to each other.
There may also be provided a wall structure wherein the end section mounting plate is provided with a threaded bore and the end element mounting plate is provided with a substantially vertical slot extending therethrough, the lintel further comprising a threaded fastener inserted through the slot and threadedly engaging the threaded bore.
There may also be provided a wall structure wherein the slot is narrower adjacent the end section mounting plate than opposed to the end section mounting plate.
There may also be provided a wall structure further comprising a pair of substantially vertical lead screws each supported by a respective one of the end sections and threadedly engaging a substantially vertical threaded aperture extending in a respective one of the end elements, wherein rotating the lead screws moves the end elements between the upper and lower positions.
There may also be provided a wall structure wherein in the upper and lower positions, the lintel supporting element is respectively higher and lower than the block supporting element.
There may also be provided a wall structure further comprising one of a window frame and a door frame in the aperture, the lintel being configured, sized and positioned so that the weight of the wall above the aperture is substantially entirely supported by the lintel to prevent excessive loads on the window or door frame.
Advantageously, in some embodiments, the various components of the proposed lintel and wall structure including the same may be manufactured using readily available materials, such as for example stock right angle, plate and screw members made of a sufficiently rigid metal such as steel, aluminum or a combination thereof.
Also, the proposed lintel and wall structure may facilitate the construction of a level lintel structure above the aperture, which may result, in some embodiments, to a significant reduction in the time, and thus the cost, usually spent by construction workers in constructing walls.
The present application claims benefit from UK request application 1616974.0 filed Oct. 6, 2016, the contents of which is hereby incorporated by reference in its entirety.
Other objects, advantages and features of the present invention will become more apparent upon reading of the following non-restrictive description of some embodiments thereof, given by way of example only with reference to the accompanying drawings.
The term “substantially” is used throughout this document to indicate variations in the thus qualified terms. These variations are variations that do not materially affect the manner in which the invention works and can be due, for example, to uncertainty in manufacturing processes or to small deviations from a nominal value or ideal shape that do not cause significant changes to the invention. These variations are to be interpreted from the point of view of the person skilled in the art.
Directional terminology, such as right, left, top, bottom, forward and backward, among others, refers to the orientation relative to an upstanding wall on level ground. This terminology is used for clarity reasons and should not be used to restrict the scope of the claims unless explicitly claimed.
The lintel 10 includes a substantially horizontally elongated lintel body 12. The lintel body defines substantially longitudinally opposed end sections 14 and an intermediate section 16 extending therebetween, as better seen in
In some embodiments, the relative position between each of the end sections 14 and the end element 22 mounted thereto is continuously adjustable between the upper and lower positions. However, discrete positioning between the end sections 14 and the end elements 22 is also within the scope of the present invention. Such discrete positioning could be achieved for example by mating horizontally extending grooves in the end sections 14 to ridges in the end element 22, and vice-versa, among other possibilities. Typically, but not necessarily, in the upper and lower positions, the lintel supporting element 23 is respectively higher and lower than the block supporting element 17.
In some embodiments, the intermediate section 16 has a length dimension that is at least slight greater than the width of the aperture 100. For example, for a 48 inches (or about 123 cm) wide aperture 100, the length dimension of the intermediate section 16 may be about 49 inches (about 124.5 cm). In other words, the length dimension of the intermediate section 16 exceeds about ½ inch on each side of the aperture 100. Other length values for the intermediate section 16, relative to the width of the aperture 100, are also possible, including length values that are substantially equal or slightly lower than the width of the aperture 100.
The end elements 22 may have any shape that allow mounting of the end elements 22 at various vertically spaced apart locations along the end sections 14. For example, as seen in
The block supporting element 17 and the lintel supporting element 23 each includes a forwardly extending portion 36 and 38 respectively. Each one of the forwardly extending portions 36 and 38 defines a top surface portion 40 sufficiently sized for supporting at least one construction block 108 thereon. Therefore, the block supporting element 17 defines a substantially horizontal block supporting surface, in the form of the top surface portion 40, facing substantially upwardly, and the lintel supporting elements 23 are each substantially plate-shaped and substantially horizontal. Thus, the forwardly extending portion 38 of each one of the end elements 22 defines an underside surface portion 48 that is configured for stably resting on a top surface portion of a construction block 108.
The lintel 10 further comprises at least one adjustment element 30. The at least one adjustment element 30 is provided between each one of the end elements 22 and a corresponding one in the pair of end sections 14. Furthermore, the at least one adjustment element 30 is configured for user selectively adjusting the vertical position of each one of the end elements 22 relative to the corresponding one in the pair of end sections 14.
Thus, each one of the end elements 22 is user vertically adjustable between an upper position, wherein each end element 22 is relatively closer to an upper edge 32 of its corresponding end section 14, and a lower position, wherein each end element 22 is relatively closer to a lower edge 34 of its corresponding end section 14.
In some embodiments, each end section 14 defines at least one threaded bore 42. For example each end section 14 includes a series of threaded bores 42. Each threaded bore 42 extends at least partially inwardly through a front surface portion 44 of the end section mounting plate 26, and may in some embodiments extend through the end section 14. The threaded bores 42 in each series are vertically distributed in a spaced apart relationship therealong.
Furthermore, each one of the end elements 22 defines at least one generally elongated slot 46 extending vertically through the end element mounting plate 24 thereof. Furthermore, each one of the at least one generally elongated slot 46 extends in register with each one of the at least one series of threaded bores 42 of the corresponding end section 14.
In some embodiments, each one of the at least one adjustment element 30 is a threaded fastener, such as a headed screw 50, suitably sized and configured for extending through the front opening of the at least one vertically extending slot 46 of each one the end elements 22, and threadedly engaging a threaded bore 42 along the corresponding end section 14.
In some embodiments, as in the presently described embodiment of the invention, and as best illustrated in
In some embodiments, as illustrated in
In some embodiments, referring for example to
Thus, the vertically extending rear portion 25 of the intermediate section 16, along with the stock plate members representing the end sections 14 cooperatively define a back wall surface 18 that is typically extending vertically coplanarly relative to the construction support structure 104, as illustrated in
In some embodiments, the end elements 22 may also be made out of stock right angle members.
In some embodiments, each one of the top surface portions 40 of the intermediate section 16 and end elements 22 extends a forward distance that is at least slightly less than the transversal dimension one of the construction blocks so as to allow an application of mortar or sealant caulking along the front interstitial space between two adjacent construction elements 108.
Furthermore, each one of the forwardly extending portions 36 and 38 of the intermediate section 16 and end elements 22 has for example a same vertical thickness dimension that is equal to, or less than, the typical mortar thickness or brick sealant used between two superposed rows 107 of the construction block 108 surrounding the aperture 100. Other thickness dimensions are also possible.
In some embodiments of the present invention, the intermediate section 16, the end elements 22, and the at least one adjustment element 30, are suitably configured such that the upper position corresponds to a position wherein the top surface portion 40 of the end elements 22 is at least substantially at level, or slightly higher than, the top surface portion 40 of the intermediate section 16. The lower position corresponds to a position wherein the top surface portion 40 of the end elements 22 is at least slightly lower than the top surface portion 40 of the intermediate section 16. For example, the lower position corresponds to a position wherein the top surface portion 40 of the end elements 22 is located below the top surface portion 40 of the intermediate section 16 a vertical dimension that is roughly equivalent to the vertical thickness of a construction block 108. Other upper and lower positions for the end elements 22, relative to the intermediate section 16, are also possible.
The lintel body 12, the end elements 22 and the at least one attachment element 30 are each made of a sufficiently sized and rigid material for supporting a predefined load represented by the construction blocks 108. Furthermore, the various elements of the present invention described above may be made of a steel metal, aluminum, a suitable metal alloy, or a combination thereof.
Now referring more particularly to
Advantageously, in a first step, a plurality of lintel bodies 12 corresponding to the number of apertures 100 in a given construction site may have their intermediate section 16 pre-dimensioned to correspond to the width of each apertures 100 requiring the lintel 10 on the construction site, followed with welding the end sections 14 on each opposed ends thereof. It should be noted that in alternative embodiments, the lintel bodies 12 are entirely factory manufactured.
In a second step, once the rows 107 of construction blocks 108 assembled on each side of a given aperture 100 have reached a height that is at least slightly lower than the upper horizontal edge of the aperture 100, the lintel body 12 is positioned in a saddle-like configuration there across, with the underside surface portion 48 of end elements 22 stably resting on the top surface of the upper construction blocks 108 on each side of the aperture 100.
In
In a third step, using a proper tool, the end elements 22 and associated adjustment elements 30 are set and tightened at a user selected vertical position along each end section 14 such that the underside surface portion 20 of the intermediate section 16 extends substantially horizontally parallelly a predetermined distance above the bottom aperture 100 or, alternatively, a predetermined distance above the window or door frame 106 mounted in the aperture 100. For example, the predetermined distance in this latter case may be between roughly ⅛ and a quarter inch distance (3 mm to 6 mm). Other predetermined distance values are also possible.
In a fourth step, additional layers of construction blocks and mortar are laid down on each sides and above the lintel 10 to form a complete wall 102 around the aperture 100. Thus, each of the lintel supporting elements 23 are embedded in the wall 102 on a respective side of the aperture 100, between adjacent rows 107. Finally, mortar or a suitable sealant may be applied to fill the interstitial space between the construction blocks 108 in order to cover the forward edges of the forwardly extending portions 36 and 38 of the intermediate section 16 and end elements 22. As would be obvious to someone familiar with house constructions in general, the steps described above may be slightly altered for a same end result.
Thus, there is provided a level lintel structure above an aperture 100 in a wall 102 including construction blocks 108. The lintel 10 may significantly reduce the time, and thus the cost, usually spent by construction workers to erect the wall 102 by avoiding the usual measurements, work corrections and/or mortar compensations often involved during the installation of prior art lintel members and systems in brick wall constructions.
An alternate embodiment of a lintel 10′ according to the present invention, is illustrated in
More specifically, referring to
Each one of the end elements 22 includes a generally elongated member 66 protruding vertically parallelly along a rear surface portion thereof. The elongated member 66 is configured for freely slidably engaging the elongated slot 62 so as to allow at least a vertical movement therein. The elongated member 66 further defines a threaded aperture 68 that extends vertically throughout the elongated member 66.
The adjustment element 30′, in the presently described embodiment, is represented by the lead screw 50′, taking for example the form of a generally elongated headed screw configured for extending through the axially corresponding pair of bores 64 and threadedly engaging the threaded aperture 68 of the elongated member 66 axially located there between. A nut 70 may lock the elongated headed screw 50 into the assembly.
Thus, each one of the end elements 22′ is vertically adjustable at a user selected position relative to the corresponding end section 14 by suitably rotating clockwise or counter clockwise each one of the lead screws 50′.
Advantageously, as exemplified in side elevational view in
In some embodiments, as illustrated in cross-sectional view in
The present embodiment of the invention requires only one screw to be rotated in order to adjust the vertical position of the end elements 22. Furthermore, the present embodiment avoids the possibility of an inadvertent vertical slippage of an end element 22 relative to the lintel body 12 due to a screw that has not been tightened enough since the structure configuration thereof inherently does not allow this type of error.
Although the present invention has been described hereinabove by way of exemplary embodiments thereof, it will be readily appreciated that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, the scope of the claims should not be limited by the exemplary embodiments, but should be given the broadest interpretation consistent with the description as a whole. The present invention can thus be modified without departing from the spirit and nature of the subject invention as defined in the appended claims.
Number | Date | Country | Kind |
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1616974.0 | Oct 2016 | GB | national |