Patent Application
20190048589
This disclosure relates generally to an extendable beam methods and systems for masonry use in spanning and carrying a load of an opening. These systems relate more specifically to the use of a single beam over two vertical supports to create an opening, such as a window or doorway or other architectural element.
In masonry, forms are often used to create windows, doorways or openings. These forms can be called many different things such as frames, bucks, headers, girders, joists and the like. These forms are often made of simple wood (2×4s or 2×6s) and built to hopefully fit within the space needed. Many times the wood frames are not the right size and have to be cut, fit, worked and reworked until the proper dimensions of the frame is made. After the frame is constructed then a mason or other construction worker may begin building the next layer of block over the frame, maintaining the opening.
These frames are costly and are typically limited to a one time, single use because of the opening size. Often installation and removal these frames require block repair and in interrupts a mason's job. A wood frame may also leave rough finishings and limit access through the opening while the frame is in place and are not considered a very environmentally sensitive (or “green”) practice.
Other devices include lintels. These lintels are supported by other support beams made of wood or metal that extends from the base of an opening to the lintel. These lintels may also include a single extendable portion that slides from a single side of the lintel so that the lintel may be used for different size openings. In one instance a lintel may include a first fixed shoulder that sits on one wall then a second extendable shoulder that sits on a different wall. The lintel rests on the two walls over an opening. These devices are only intended to telescope from a single side and may allow the lintel to nearly double its size.
This disclosure, at least in one aspect, relates to a system or device with a longitudinal housing, which may be comprised of steel, or steel alloy, or other metal, or strong structure capable of holding significant weight (i.e. carbon fiber). The housing may be elongated with a U-shaped or C-shaped cross-section. The housing may hold, or may be capable of encompassing at least one extendable member. The at least one extendable member may be two extendable members that each extend from the housing in opposite directions.
The housing may be forged, bent, milled, extruded or the like from a single piece of metal and may be forged with multiple bends (which bends may be 90°). The housing may also be welded with multiple pieces of metal at 90° angles or bends (or nearly 90° angels or bends) as well. The housing may include a first longitudinal wall that extends the length of the housing, a pair of second longitudinal walls that may be perpendicular to the first longitudinal wall and extend the length of the housing. A pair of third longitudinal walls, or pair of lips, that may be perpendicular to the pair of second longitudinal walls. The pair of lips may extend at least partially toward a longitudinal axis of the housing and the pair of lips may be parallel or close to parallel to the first longitudinal wall. At least one cross support post may extend between the pair of lips across a void in the housing securing the one lip to the second lip. The cross support post may be welded, forged or the like.
The system may comprise multiple configurations. In a first configuration the two extendable members may reside entirely within the housing. The two extendable members may be held within the housing by the pair of lips of the housing. Alternatively the two extendable members may be held by at least one support member which may be welded inside the housing. The at least one support member may be a plurality of support members. The plurality of support members may be secured, welded, formed, etc. to the pair of second longitudinal walls. The plurality of support members may be positioned opposite one another on the pair of second longitudinal walls. The plurality of support members may extend longitudinally at least partially along the pair of second longitudinal walls.
The extendable members may be similar in shape and size and may be interchangeable. The extendable members may be forged or welded and are separate from the housing. The extendable members may be substantially rectangular in shape and from one perspective may resemble a tray or open top box. Each extendable member may comprise a longitudinal axis, a first wall, a pair of second walls opposite each other, which may be parallel to each other, extending from the first wall at a 90° angle, and a pair of third walls opposite each other, and which may be parallel to each other, extending from the first wall at a 90° angle and connected to the pair of second walls.
The pair of second walls may be different lengths extending from the first wall. The distal wall of the pair of second walls, may be shorter in length than the proximal wall. The proximal wall may be longer and may engage the plurality of support members of the housing to act as a stop such that the extendable members may not extend out of the housing beyond a predetermined or predesignated distance or amount. An extendable member flange, or tab, may extend distally from the distal wall of the pair of second walls. The extendable flange may be configured to engage a wall or support for the system to rest on.
The pair of third walls may be substantially parallel and may be substantially the same length and width. The pair of third walls may provide a slide or guide to glide along the plurality of support members while the extendable members are manipulated at different positions relative to the housing.
A second configuration may be both extendable members extending beyond the housing exposing each flange of each extendable member to engage the construction element, walls or supports, that traverses an opening of the construction element. In a third configuration at least one of the extendable members may extend at least partially beyond the housing, exposing at least one flange from the extendable member to engage a wall or support of the construction while the other extendable member only protrudes from the housing far enough to expose a flange to engage the construction element.
The system may comprise or resemble a lintel or header and may be configured to traverse an opening of a structure, such as a door or window for a building that is being constructed.
In the drawings:
The housing 12 may include a first wall 16, which may be substantially planar, extending a length and a width of the housing 12. The first wall 16 may be substantially flat and configured to allow other flat elements (i.e. bricks, blocks, etc.) to easily reside on the first wall 16. The first wall 16 may include bends or curves toward each width end of the first wall 16. A pair of second walls 18, 18′ may extend from the first wall 16, or the bends of the first wall 16, in a direction substantially perpendicular to the first wall 16. Extending from the pair of second walls 18, 18′ are a pair of third walls 20, 20′ that may extend from separate bends in the second walls 18, 18′. The pair of third walls 20, 20′ may extend toward each other and the longitudinal axis 14, or midline, of the longitudinal housing 12. A channel 25 may be positioned between the pair of third walls 20, 20′ and run the length of the housing 12. The third walls 20, 20′ may be substantially parallel to the first wall 16. The channel 25, or passage, or void, may run the length of the housing. A cross-sectional shape of the housing 16 may resemble a C-shape or U-shape.
The housing 12 may include a first opening 24 toward one end of the housing 12 and a second opening 26 toward a second end of the housing 12 with the channel running from the first opening 24 to the second opening 26.
The housing may be comprised of a single piece of metal or steel and may be forged of a single piece of metal. The single piece of metal is forged with the bends in the walls as described earlier and allows for greater strength of the housing rather than welding the walls together at weld points. However, it will be appreciated that the system 12 may be welded together will multiple metal pieces. In the instance of welding the “bends” may be sharper and more defined and not as curved, or the welds may be ground or sanded down to form similar bends as though the housing 12 was forged from a single piece of metal.
Referring to
A plurality of support members 30 may be positioned and secured to the housing on the interior of the second walls 18, 18′ within the channel 25. Securing of the support members 30 may be accomplished by welding the pieces into place. The plurality of support members 30 may be positioned opposite one another on the pair of second walls 18, 18′ and at multiple locations along the pair of second walls 18, 18′. For example, support members 30 may be secured at different longitudinal positions along the interior of the second walls 18, 18′. The plurality of support members 30 may extend longitudinally at least partially along the pair of second walls 18, 18′ and provide additional support and may operate as a guide or track for extendable members. The support members 30 may also be planar, or flat, with the plan of the support members running substantially parallel to the first wall 16 of the housing.
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The proximal wall 38 may extend further from the planar first wall 34 than the distal wall 40. The proximal wall 38 may extend further than the extendable member second walls 36, 36′ as well. The proximal wall 38 may provide a stop against a proximal end of the support members 30, so that the first extendable member 32 does not extend too far out of the housing 12. The distal wall 40 may include a distal tip 42 which may include a flange 44, or tab, which extends longitudinally from the distal wall 40 in the same plane or parallel plane as the planar first wall 34. The distal tip 42 may be integrated into the body of the first extendable member 32 or may be a separate piece that may be secured, or welded, to the distal wall 40. The distal tip 42 may include a right angle piece, or elbow, that on one plane sits flush against the distal wall 40 and a separate plane, perpendicular to the one plane sitting flush against the distal wall, extending in a same plane, or substantially the same plane, or parallel plane to the first planar wall 34, which may be the flange 44. The flange 44 engages a construction element 50, which may be a wall or support, and rests on that construction element which holds up the system 10. Each extendable member 32, 31 may extend from the housing 12 at least as far as half of the length of the extendable members 32, 31. Each extendable member 32, 31 may extend just far enough for the flange 44 to protrude from the housing 12 to engage one edge of an opening (see
The first extendable member 32 may be manufactured, or forged, from a single metal piece or it may be welded from multiple metal pieces. Additionally the first extendable member 32 may complementary fit within the housing 12 such that the curved edges/corners of the housing 12 between the first wall 16 and the second walls 18, 18′ may correspond to similar curvatures in the first extendable member 32 between the planar first wall 34 and the extendable member second walls 36, 36′. This complementary fit may allow for ease in sliding the first extendable member 32 out of the housing 12 as well as retracting the first extendable member 32 back into the housing 12.
The second extendable member 31 may be substantially identical to the first extendable member 32. The same elements are utilized in the second extendable member 31 with the same features other than the second extendable member 31 extends from the opposite side of the housing 12 than the first extendable member 32.
The extendable members 32, 31 may extend from a fraction of one inch to up to 12 inches from the housing 12. The length of the entire system 10 may vary from 1.5 feet (18 inches) up to 42 feet and perhaps even longer. The housing 12 may be the majority of the length while the extendable members 32, 31 remain roughly the same size, regardless of the housing 12 size; however, it is contemplated that the extendable members size 32, 31 may increase proportionately to the housing size.
Depending on the length of the system 10 utilized, for the system to traverse an opening in a construction element, posts, or post shores, or props may be required to engage the system 10 at one or more locations. The posts may engage the system 10 on a bottom side, or within the channel 25 side of the housing 12 at strategic locations in the opening of the construction element 50.
Referring to
The dimensions of the system may vary as well. The housing 12 may be anywhere from 2 feet (or roughly 0.6 meters) to 42 feet (or roughly 13 meters) in length. The width of the housing 12 may be 4 to 8 inches (or roughly 10 cm to 21 cm). The height of the housing 12 may be 2 to 4 inches (or roughly 5 cm to 11 cm). The length of the extendable members 31, 32, may vary but may be in the range of 12 to 18 inches (or roughly 30 cm to 46 cm), with the extendable members 31, 32 being capable of extending 6 to 9 inches (or roughly 15 cm to 23 cm).
A user may then use building materials, bricks, blocks, etc., to build across and on top of the system 10 utilizing the system 10 to stabilize the materials. The user may then remove the system 10 by simply retracting the extendable members 31, 32 at least enough to release the flange(s) from the edges of the construction element 50 opening.
It will be appreciated that the housing 12, or shell, may be comprised of 12-14 Gauge C Channel purlin which is a commonly used beam to extend over a roof or other constructive element. The extendable memebers 31, 32 (or trays) may be one-quarter inch milled steel (it may also be cast, forged, extruded, welded, etc.). Other metals and materials may be used with a similar construct and even wood, plastics and carbon-fiber are contemplated.
Although the foregoing disclosure provides many specifics, these should not be construed as limiting the scope of any of the ensuing claims. Other embodiments may be devised which do not depart from the scopes of the claims. Features from different embodiments may be employed in combination. The scope of each claim is, therefore, indicated and limited only by its plain language and the full scope of available legal equivalents to its elements.
