Patent Application
20180274235
This invention relates to the manufacture and use of a prefabricated structural framing system.
Timber framing is a routine method for construction of structures. Timber framing construction typically uses solid dimensional lumber, joined with nails to form framing structures. This method includes cutting of dimensional lumber at a construction site.
Difficulties of this prior art may include imperfection in positioning, orientation, and the dimensions of the pre-sawn lumber. During the construction of a structure, there are typically stages of significant instability of components requiring temporary bracing during assembly and construction. This is inconvenient, time consuming and adds to the cost of framing the structure. Bracing can introduce safety hazards and restrict the movement of people or materials at a construction site.
Cutting dimensional lumber at a construction site can also introduce hazards including injury during cutting, accumulation of dust, debris, and off-cut pieces, and tripping hazards associated with power cables. Generally, cutting equipment such as table saws may require sheltering from the elements, which may add to the cost of the construction.
Moreover there are limits on the size and height of structures framed using traditional dimensional lumber. Larger structures may require significantly different construction materials, equipment and techniques.
The production of traditional dimensional lumber includes growing, harvesting, sawing, drying and planing. All these steps have environmental impacts as they involve handling systems that produce waste products.
Embodiments of the present disclosure relate to an engineered lumber framing system for construction of prefabricated structures comprising: a first top plate comprising an end, the end including corners at variable angles forming a first stepped construct; and a second top plate comprising an end, the end including corners at variable angles forming a second stepped construct; wherein the first stepped construct fits into the second stepped construct forming a corner connection; and wherein the first top plate and the second top plate each include a plurality of sheet layers. The corner connection comprises a haunched stub tenon-like corner joint.
In another embodiment of the present disclosure, an engineered lumber framing system comprising: a corner post including an end, a first side, a second side, a first end edge between the end and the first side and a second end edge between the end the second side, and a corner wall; and a corner end wall including a first wall portion protruding beyond the end along the first end edge; and a second wall portion protruding beyond the end along the second end edge.
These and other features of the present disclosure will become more apparent in the following detailed description in which reference is made to the appended drawings:
Engineered lumber such as plywood or oriented strand board (OSB) can have a reduced environmental impact due to the decreased footprint of natural resources required to make these products, for example there is a decrease in energy consumption and of exhaust gas emission. Engineered lumber can be produced with greater consistency than traditional solid dimensional lumber, which can also lead to less material waste. Additionally, engineered lumber can achieve larger dimensions than traditional solid dimensional lumber.
The framing system of the present invention includes prefabricated OSB or similar engineered beam assemblies including corner posts and top plate assemblies. In another embodiment, the system further includes top plate locking plates, posts with varying dimension including 2×4 posts, 2×6 posts, etc., window headers, window sills, door headers, or door sills. The system can be used to build garages, houses, condominiums, and similar structures that would otherwise be framed using traditional dimensional lumber framing techniques and materials.
In one aspect of the invention, the framing system of the present invention includes a kit of all the pre-fabricated components made to fit certain dimensions of a construction project with instruction manuals or videos. The kit may be shipped to a construction site for ease of use and timely construction.
In one embodiment of the present invention, the engineered framing system includes a corner post box structure made up of OSB walls enclosing an insulated core. The box structure gives the corner post compression, torsion and flexion strength. In another embodiment, the tight enclosure of an expanded insulation, for example polystyrene (EPS) foam, can provide some additional compressive strength. Corner post sidewalls are cut to size for a desired application and may be connected together using a fastener, such as glue and staples. The insulation is configured to fit tightly within the cavity of the box structure. The corner post may be formed of straight walls with square corners and is stable. The corner post includes an end, a first side, a second side, a first end edge between the end and the first side and a second end edge between the end the second side, a corner wall and insulation. There is a corner end wall including a first wall portion protruding axially beyond the end along the first end edge, and a second wall portion protruding axially beyond the end along the second end edge. The protruding portions are referred to as the wings of the corner post. The wings are vertical extensions of two adjacent corner post sidewalls. These wings form an axially projecting outside corner, which provides top plates accurately aligned into the corner post.
In another embodiment, the engineered framing system further comprises a support element protruding outwardly from a third side and extending axially along the corner and another support element protruding outwardly from a fourth side and extending axially along the corner. With reference to
In one embodiment, the system further includes a top plate assembly supported on a corner post. Each end of a top plate assembly includes connectors, providing stable and accurate engagement of two adjacent top plate assemblies with the corner post. A corner post includes wings that extend up vertically beyond the end edge of the corner post when installed. With reference to
In an example configuration, the beam assembly is a glued and stapled assembly of eight sheets of OSB with the individual sheets oriented vertically (i.e. a plurality of sheets positioned face to face in parallel planes with their fiber strands oriented and aligned with the longitudinal axis of the sheets, for example in the orientation of a laminate) and an additional locking strip of OSB oriented horizontally (i.e. a sheet positioned flat over the edges of one side of a plurality of sheets) and spanning the assembly. This provides an added flexion strength in the vertical direction, when the beam is installed.
In another embodiment, the engineered lumber framing system includes a recess also referred to as a cavity or a depression on the surface of the top plate. A top plate locking plate in an L or elbow shape made from OSB may be inserted into said recess. The top plate locking plate is attached to the top of the corner joint once two adjacent top plate assemblies are attached to the corner post. The top plate assembly includes a recess proximal the ends into which the top locking plate may be installed for a substantially flush arrangement with the corner post. In one embodiment, for example, the recess may be formed proximal to the terminating end of the top plate assembly. The top plate locking plate may be fastened using screws. The top plate locking plate gives additional load and torque support to the structure and provides a flat top surface, suitable for further construction of roofing, support joints, flooring or higher wall structures.
With reference to
During assembly of the structure fasteners such as screws, nails, glue, staples etc. may be used. Compared to traditional nailed assembly, screws can provide greater strength, avoiding fatigue and workout. The shape of the connectors allows for the beam assembly in either order, left then right or right then left.
The orientation and shape of the top plate assembly and the top plate locking plate provides a structure where the majority of the cut edges of the OSB are covered and the majority of the outer exposed structure comprises of a laminate face of the OSB. Additionally, the orientation and shape of the components is such that all fasteners can pass through and abut the laminate face of the OSB. Therefore, fasteners entering the edges of the OSB are avoided.
The cut edges of OSB may be weak and susceptible to damage and delamination. The present invention hides the majority of the cut edges of the corner post/beam assembly and avoids screws that go through the cut edges.
Assembly posts for example 2×4 posts, 2×6 posts and other traditional lumber dimensions are formed as fastened stacks or boxes of OSB in similar dimensions as traditional dimensional lumber. Posts can also be cut to non-traditional lumber dimensions. Any post can include internal insulation. The posts may also include internal bracing for greater strength.
In another embodiment, the engineered lumber framing system includes corner posts, 2×4 posts, and 2×6 posts with mortise-like recesses to quickly, accurately, and securely attach to horizontal components.
With reference to
The framing system provides improved loading strength and insulation relative to traditional framing with dimensional lumber. In addition, the worksite may be safer by avoiding cutting, saw cabling, dust and off-cut debris as well as providing stable and free-standing framing at all stages of construction, which avoids the need for temporary bracing and additional construction workers.
On a construction site where additional structural requirements may be needed, for example earthquake resistance or hurricane resistance, the framing system of the present invention may include additional materials for example anchoring to prevent shear or roof-lift. In addition, the framing system components may be treated before shipping, for example treatment may include coatings such as fire-resistant, moisture-resistant, or insect-resistant coatings. Coating of the framing structure components can occur after fabrication and cutting providing a complete barrier covering the entire surface of the component.
Holes for conduits for electrical or plumbing may be drilled into framing system components before or after assembly. Drilling before assembly can facilitate a complete coating barrier if coating is required.
Example walls were built and tested to structural failure.
The framing system components used for testing were 8 ft×10 ft walls for racking shear tests and 4 ft×10 ft walls for axial and transverse load tests.
The walls were manufactured using 7/16 inches thick OSB fastened 6 inch on center (o/c) around a perimeter and 12 inches o/c elsewhere with 2 inches long wire weld nails.
| Number | Date | Country | |
|---|---|---|---|
| 62477225 | Mar 2017 | US |
