CONSTRUCTION CRIPPLES AND STRUCTURES INCORPORATING THE SAME

Description

BACKGROUND

Window openings and door openings are defined in construction using studs, headers, footers and cripples. Specifically, as shown in FIG. 1A, cripples 10 are used to interconnect headers 12 to corresponding header tracks 14 and footers 16 to corresponding footer tracks 18, defining upper 20 and lower 22 boundaries of a window or door opening, respectively. End studs 24 may be used to define the side boundaries 25 of the window or door opening. The headers and footers are typically studs or C-channels. Each cripple 10 may have flaps 24 that extend over opposite sides 26, 28 of the header 12 or footer 16 as for example shown in FIG. 1B. These flaps are fastened to the header or footer using fasteners 29. The other ends of the cripples have similar flaps 32 that extent over their corresponding header track or footer track which are typically channel structures. These flaps are fastened to their corresponding header track or footer track using fasteners 33. The end studs 24 also have flaps 34 that extend from their opposite ends and over their corresponding header tracks and footer tracks. The flaps 34 are fastened using fasteners 36 to their corresponding header tracks and footer tracks. The header 12 and footer 16 also have end flaps 38 that extend from their opposite ends. These flaps 38 are fastened using fasteners 40 to the end studs 24. Wall finishes, such as plaster board or sheet rack are mounted over the headers, footers and cripples surrounding the window or door opening defined by the header, footer and end studs. However, the end flaps and fasteners protrude creating an uneven surface that make leveling of the mounted wall finishes more difficult. Better systems are desired the provide for surfaces for fostering a better interface for the finishes.

SUMMARY

In an example embodiment, a cripple includes a web, a first leg extending transversely from the web, and a second leg extending transversely from the web. The web, the first leg and the second leg define a channel. A flange extends transversely from the web. In a further example embodiment, the flange extends in a direction opposite the legs. In another example embodiment, first leg and the second leg extend perpendicularly from the web and the flange extends perpendicularly from the web and relative to the first and second legs. In yet another example embodiment, the cripple also includes a first lip extending transversely from the first leg and a second lip extending transversely from the second leg, such that the first lip extends in a direction towards the second leg and the second lip extends in a direction towards the first lip. In a further example embodiment, the cripple is formed from a single sheet of material.

In an example embodiment, a structure for defining an opening for accommodating a window or a door includes a header track, a footer track below the header track, a first end member coupled to the header track and the footer track defining a first boundary of the opening, and a second end member coupled to the header track and the footer track, such that the second end member is spaced apart from the first end member and defines a second boundary of the opening spaced apart from the first boundary of the opening. The structure also includes a header spaced apart and below the header track and coupled to the first end member and to the second end member and defining a third boundary of the opening extending from the first boundary to the second boundary. The structure further includes a first plurality of spaced apart cripples connected to the header to the header track, such that an outer surface of each of the first end member, second end member, header and first plurality of spaced apart cripples extends along a first plane. In another example embodiment, the header is a stud including a web, two spaced apart legs extending generally perpendicularly from the web, and two spaced apart lips each extending from a corresponding leg of the two spaced apart legs and extending generally parallel to the web. Each of the cripples includes a web and two spaced apart legs extending generally perpendicularly from the cripple web, and a first flange extending generally perpendicularly from the cripple web and relative to the cripple first and second legs. The first flange is attached to the header lips. In one example embodiment, the first flange of each cripple of the first plurality of spaced apart cripples extends in a direction away from the legs of each cripple of the first plurality of spaced apart cripples. In yet another example embodiment, the structure also includes a footer spaced apart and above the footer track and below the header. The footer is coupled to the first end member and to the second end member. The footer defines a fourth boundary extending from the first boundary to the second boundary and spaced from the third boundary, such that the first, second, third and fourth boundary define the opening. The structure further includes a second plurality of spaced apart cripples connected to the footer and to the footer track. An outer surface of the footer and an outer surface of each of the second plurality of spaced apart cripples extend along the first plane. In a further example embodiment, the header and footer are studs, each including a web, two spaced apart legs extending generally perpendicularly from the footer web and two spaced apart lips each extending from a corresponding leg of the footer two spaced apart legs and extending generally parallel to the footer web. In addition, each of the first plurality and second plurality of spaced apart cripples includes a web and two spaced apart legs extending generally perpendicularly from the cripple web, and a first flange extending generally perpendicularly from a first end of each of the cripple webs and relative to the first and second legs of the cripple. With this example embodiment, the first flanges of the first plurality of spaced apart cripples are attached to the lips of the header, and the first flanges of the second plurality of spaced apart cripples are attached to the lips of the footer. In yet a further example embodiment, each of the first and second pluralities of cripples includes a second flange extending from a second end opposite the first end of each web of the first and second plurality of spaced apart cripples. With this example embodiment, the second flange of each of the first plurality of spaced apart cripples is attached to the header track, and the second flange of each of the second plurality of spaced apart cripples is attached to the footer track, and an outer surface of each the footer track and header track extends along the first plane. In one example embodiment, a flap extends generally perpendicularly from first and second ends of the web and relative to the spaced apart legs of the header and from first and second ends of the web and relative to the spaced apart legs of the footer, such that the flap at the first end of each of the header and footer is attached to the first end member and the flap at the second end of each of the header and footer is attached to the second end member. In another example embodiment, the header track and the footer track each define a channel and an end portion of each of the first plurality of spaced apart cripples opposite its corresponding first flange is received within the channel defined by the header track.

In addition, an end portion of each of the second plurality of spaced apart cripples opposite its corresponding first flange is received within the channel defined by the footer track. In yet another example embodiment, each of the first plurality of spaced apart cripples is formed from a single piece of material.

In an example embodiment, a structure for defining an opening for accommodating a window or a door includes a header track, a first end member defining a first boundary of the opening, a second end member defining a second boundary of the opening, a header spaced apart and below the header track and connected to the first end member and to the second end member and defining a third boundary of the opening extending from the first boundary to the second boundary, and a plurality of spaced apart cripples connected to the header and to the header track, such that an outer surface of each of the first end member, second end member, header and plurality of spaced apart cripples extends along a first plane. In another example embodiment, the header is a stud including a web, two spaced apart legs extending generally perpendicularly from the web, and two spaced apart lips each extending from a corresponding leg of the two spaced apart legs and extending generally parallel to the web. Each of the plurality of spaced apart cripples includes a web and two spaced apart legs extending generally perpendicularly from the cripple web, and a first flange extending generally perpendicularly from a first end of the cripple web and relative to the cripple first and second legs. In one example embodiment, the first flange of each cripple of the plurality of spaced apart cripples extends in a direction away from the legs of each cripple of the plurality of spaced apart cripples. The first flange is attached to the header lips. In yet another example embodiment, each of the plurality of cripples includes a second flange extending from a second end opposite the first end of the web of each cripple, and the second flange of each of the plurality of spaced apart cripples is attached to the header track. With this example embodiment, an outer surface of each the header track extends along the first plane. In a further example embodiment, the header track defines a channel, and an end portion of each of the plurality of spaced apart cripples opposite its first flange is received within the channel defined by the header track. In yet a further example embodiment, each of the plurality of spaced apart cripples is formed from a single piece of material.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view of a prior art structure defining a window opening.

FIG. 1B is a partial cross-sectional view of a connection between a cripple and a footer along 1A-1A shown in FIG. 1A.

FIG. 2 is an example embodiment structure defining a window opening and a door opening.

FIG. 3A is a cross-sectional view of an example embodiment cripple.

FIG. 3B is a cross-sectional view of another example embodiment cripple.

FIG. 4 is a partial perspective view of an example embodiment cripple connected to a footer.

DESCRIPTION

In an example embodiment, cripples 110 that are channels or studs are used, as for example shown in FIG. 2. Channels 112 include a web 114 and two opposite legs 116 extending perpendicularly, or generally perpendicularly, from the web defining a channel, as for example shown in FIG. 3A. Studs 118 include a web 120 and two opposite legs 122 extending perpendicularly, or generally perpendicularly, from the web, as for example shown in FIG. 3B. A lip 124 extends from a distal end of each leg and extends towards the other lip. The lips are parallel, or generally parallel to the web defining the stud. Example embodiment cripples have a flange 126 that extends perpendicularly from the web 120 (whether the cripple is a stud or a channel) in a direction opposite the legs of the channel or stud, as for example shown in FIG. 4. In another example embodiment, the flange extends perpendicularly from the cripple web in the same direction as the legs. For illustrative purposes the embodiments herein are described using a cripple that is a stud 118 as shown in FIG. 4. However, the cripple can also be a channel. In an example embodiment, the ends 128 of the legs 122 and the end surface 130 of the flange extend along the same plane, as for example shown in FIG. 4. In the example embodiment shown in FIG. 4, the flange 126 is integral with the web 120. In example embodiment as shown in FIG. 4, the entire cripple is formed from a single sheet of material. In another example embodiment the flange is part of an angle having a first side connected to the web and a second side extending perpendicularly from the web defining the flange.

In an example embodiment, each header 132 and footer 134 are also studs 118. Typically, they are mounted to define a window opening 136 or a door opening 138 with their webs 120 defining the window or door boundaries 140. In this example embodiment, the flange 126 of each cripple is connected to the lips 124 of its corresponding stud defining either the header or footer. In an example embodiment as shown in FIG. 4, the flange is connected to the lips of a header or footer using fasteners 142. In example embodiments, where the lips 124 of the studs defining the header or footer are used to form the horizontal boundaries 140 of a door or window, the flange 126 of each cripple is fastened to the web 120 of its corresponding header or footer. The end portions 143 of each cripple opposite the flange 126 are received within the channels defining each cripple's corresponding header track 144 or footer track 146. In an example embodiment, the end potion 143 of each cripple is fastened to its corresponding header of footer track using fasteners 148. End members 150 which in example embodiments may be studs or channels are used to define the vertical boundaries 152. The end members have end portions 154 that are received in their corresponding header track and footer track which are channels. In an example embodiment the end portions are fastened to their corresponding header track and footer track using fasteners 156.

In another example embodiment, the header track 144 and footer track 146 may be a stud 118. In such case, the end of each cripple opposite the flange 126 may be formed to have a second flange extending perpendicularly from its web 120 that is fastened to its corresponding header track or footer track. With such embodiment, each end member also has flanges extending perpendicularly relative to its web from opposite ends of its web that allows it to be fastened to its corresponding header track and footer track.

In an example embodiment the webs 120 of each header 132 and footer 134 extend beyond the legs 122 and are bent perpendicularly to the web 120 to define an end flap 150 at each end of the header or footer, as for example shown in FIGS. 2 and 4. In an example embodiment, fasteners 154 are used to fasten the end flaps 150 of each header and footer to their corresponding end member 150 for connecting the headers and footers to the end member as for example shown in FIG. 2.

The example embodiment connections of the cripples to the headers and footers and the headers and footers to the end members forming a frame defining window and/or door openings place the surfaces of legs 122 of the cripples, headers, footers, and end members extend along the same plane. As such these surfaces provide for level surfaces for the attachment of end finishes such as plaster board, sheet rack, etc. For example, these surfaces extend along the same plane without having protrusions extending therefrom that may be defined by using fasteners extending perpendicularly to such plane for connecting the cripples to the header and footer, and the header and footer to the end members.

In another example embodiment, an opening such as a door opening 138 may be bounded by a header, the two end members, and by the footer track, as for example shown in FIG. 2

Each of the fasteners described herein can be any type of fastener, as for example a screw. Other methods of fastening may also be used. In an example embodiment each cripple is unitary structure formed for a single piece of sheet metal. In other example embodiments each of the header, footer, and end members is a unitary structure formed from a single piece of sheet metal.

While this invention has been described in detail with particular references to exemplary embodiments thereof, the exemplary embodiments described herein are not intended to be exhaustive or to limit the scope of the invention to the exact forms disclosed. Persons skilled in the art and technology to which this invention pertains will appreciate that alterations and changes in the described structures and methods of assembly and operation can be practiced without meaningfully departing from the principles, spirit, and scope of this invention, as set forth in the following claims. Although relative terms such as “outer,” “inner,” “upper,” “lower,” “below,” “above,” and similar terms have been used herein to describe a spatial relationship of one element to another, it is understood that these terms are intended to encompass different orientations of the various elements and components of the invention in addition to the orientation depicted in the figures. Additionally, as used herein, the term “substantially,” “about,” and similar terms are used as terms of approximation and not as terms of degree, and are intended to account for the inherent deviations in measured or calculated values that would be recognized by those of ordinary skill in the art. Furthermore, as used herein, when a component is referred to as being “on” another component, it can be directly on the other component, or components may also be present therebetween. Moreover, when a component is component is referred to as being “coupled” to another component, it can be directly attached to the other component, or intervening components may be present therebetween.