KNEE WALL SUPPORT ASSEMBLY

Description

CROSS REFERENCES AND PRIORITIES

This application claims priority from U.S. Provisional Application No. 63/682,949 filed Aug. 14, 2024, the teachings of which are incorporated in their entirety herein.

BACKGROUND

Knee Walls, Pony Walls, Half Walls, and Hip Walls all refer to a wall that does not stretch from the floor to the ceiling.

These walls are typically used as room dividers within spaces of a larger open room. These walls are often framed and sheathed the same as full-height walls.

A knee wall is usually less than 3 feet high (falling below the knee), and is typically used to support something else, such as a countertop or attic rafters.

Pony walls are more of an interior design choice to separate a room.

Knee walls need additional structural support to prevent the unsupported top of the smaller wall from flexing and failing. These are typically called knee wall assemblies.

The additional support is typically in the form of a support bracket consisting of a base plate that is bolted to the floor and a framing member that is a heavier gauge than the rest of the knee wall framing members.

There is always the need for a stronger support made with less material.

SUMMARY

This specification discloses a knee wall support assembly which comprises a framing member having a framing member first end with a framing member first end profile, a framing member second end with said framing member comprising a web, a first flange extending from a web first edge, and a second flange extending from a web second edge (1350).

The specification further describes that knee wall support assembly will also comprise a base plate having a base plate width, a base plate length, a base plate thickness, a base plate top parallel to a plane defined by the base plate width and the base plate length, a base plate bottom end opposite the base plate top end, with a plurality of base plate mounting holes, and a base plate groove having a base plate groove wall wherein the framing member first end is disposed within the base plate groove and a weld joins the framing member and the base plate.

It is further disclosed that the framing member is in frictional contact with one of the first flange, the second flange, and the web.

It is also disclosed that the framing member is in frictional contact with the first flange, the second flange and the web.

It also discloses the case where there is no frictional contact and there is a gap between the base plate groove wall and the framing member having a distance between the base plate groove wall and the framing member.

It is disclosed that there may be a first lip extending from the first flange and a second lip extending from the second flange.

The framing member may also be a unitary piece of cold rolled steel.

A framing assembly comprising the knee wall support assembly is disclose with the framing assembly having a wall face, and the knee wall support assembly is oriented so that the web is perpendicular to the wall face.

It is also disclosed that the framing assembly comprising the knee wall support assembly further comprising a vertical stud, wherein the framing assembly has a wall face, and the knee wall support assembly is oriented so that the web is parallel to the wall face.

It is also disclosed that when the web is perpendicular to the wall, the framing assembly needs only one stud per knee wall assembly per vertical stud

BRIEF DESCRIPTION OF FIGURES

FIG. 1 depicts an embodiment of a knee wall support assembly.

FIG. 2 depicts a perspective view of a framing member.

FIG. 3 depicts the dimensions of a framing member.

FIG. 4 is an end profile view of an embodiment of a framing member.

FIG. 5 is an end profile view of an embodiment of a framing member.

FIG. 6A is top drawing view of a first embodiment of a base plate.

FIG. 6B is a top view of a second embodiment of a base plate.

FIG. 7 is a top view of an actual base plate.

FIG. 8 is a view of an embodiment of a knee wall support assembly with a weld.

FIG. 9A depicts the prior art orientation of with a prior art knee wall support assembly.

FIG. 9B depicts the orientation of an embodiment of the invented knee wall support assembly.

DETAILED DESCRIPTION

1000 depicts a framing member.

1100 depicts a framing member length.

1110 depicts a framing member width.

1120 depicts a framing member height.

1130 depicts a framing member channel.

1150 depicts a framing member channel width.

1160 depicts a framing member channel height.

1170 depicts a framing member first end.

1180 depicts a framing member second end.

1200 depicts a framing member profile.

1210 depicts a framing member outer perimeter.

1220 depicts a framing member inner perimeter.

1300 depicts a framing member web.

1310 depicts a framing member web length.

1320 depicts a framing member web width.

1330 depicts a framing member web thickness.

1340 depicts a framing member web first edge.

1350 depicts a framing member web second edge.

1400 depicts a framing member first flange.

1410 depicts a framing member first flange first edge.

1420 depicts a framing member first flange second edge.

1430 depicts a framing member first flange length.

1440 depicts a framing member first flange thickness.

1450 depicts a framing member first flange outer height.

1460 depicts a framing member first flange inner height.

1500 depicts a framing member second flange.

1510 depicts a framing member second flange first edge.

1520 depicts a framing member second flange second edge.

1530 depicts a framing member second flange length.

1540 depicts a framing member second flange thickness.

1550 depicts a framing member second flange outer height.

1560 depicts a framing member second flange inner height.

1600 depicts a framing member first lip.

1700 depicts a framing member second lip.

2000 depicts a base plate.

2010 depicts a base plate length.

2020 depicts a base plate width.

2030 depicts a base plate thickness.

2040 depicts base plate mounting holes.

2050 depicts a base plate top end.

2060 depicts a base plate bottom end.

2070 depicts a base plate groove.

2080 depicts a base plate groove wall.

3000 depicts a weld.

4000 depicts a knee wall support assembly installation.

4500 depicts a prior art knee wall assembly installation.

As shown in FIG. 1, the knee wall support assembly (4000) of this specification comprises a framing member (1000) welded (3000) to a base plate (2000).

As shown in FIG. 2, the framing member has a web (1300) with a first flange (1400) extending from the web first edge (1340) and a second flange (1500) extending from the web second edge (1350). The first flange has a first flange first edge (1410) and a first flange second edge (1420). The web first edge is attached to the first flange first edge. The second flange has a second flange first edge (1510) and a second flange second edge (1520). The web second edge is attached to the second flange first edge.

Also shown is the framing member first end (1170) and the framing member second end (1180).

While the flanges could be welded to the web, it is more preferable that the framing member be formed from a coil or sheet of steel. In this manner the framing member could be a unitary piece of cold rolled steel.

As shown in FIG. 3, the framing member has a framing member length (1100). The first flange has a first flange length (1430) and the second flange has a second flange length (1530). The framing member has a web width (1320).

This framing member can be made from cold rolled steel where steel coil or steel sheet is fed into rollers that form the shape. As shown in FIGS. 2, 3, and 4 the web and two flanges form a channel, often referred to as a C shape or a U shape.

As shown in FIGS. 4 and 5, the framing member will have a framing member first end profile (1200) which shows the two flanges and web inside the dashed line to indicate the end profile. The two flanges and web are filled in with horizontal lines.

As shown in FIG. 4, there is a framing member width (1110) and a framing member height (1120). As shown in FIG. 4, there is a framing member channel (1130) formed by the web and the two flanges. There is a framing member channel width (1150). There is also a framing member channel height (1160). Also shown in FIG. 4 is the web thickness (1330) and the first and second flange thicknesses (1440 and 1540, respectively.

As shown in FIG. 5, there may also be a first lip (1600) extending from the first flange and second lip (1700) extending from the second flange. As shown in FIG. 5, the lips extend from the edge of the respective flange at a substantially 90 degree angle. Other angles are possible in the range of 10 degrees to 170 degrees measured from the inside of the flange to the lip. Also shown in FIG. 5 is the first flange inner height (1460) and the second flange inner height (1560). The same arrows are used to show the inner heights because the first flange inner height is the same as the second flange inner height in this embodiment. The flange inner heights do not have to be the same. A preferred embodiment has return lips that fold and point to the flange from which the lip extends.

Also shown in FIG. 5 is the first flange outer height (1450) and the second flange outer height (1550). The same arrows are used to show the outer heights because the first flange outer height is the same as the second flange outer height in this embodiment. The flange outer heights do not have to be the same. The framing profile has an inner perimeter (1220) and an outer perimeter (1210).

As shown in FIGS. 6A, 6B, 7 and 8, the knee wall support assembly will have a base plate (2000). The base plate will have a base plate width (2020), a base plate length (2010), and a base plate thickness (2030). There is a base plate top end (2050) which is parallel to a plane defined by the base plate width and the base plate length, a base plate bottom end (2060) opposite the base plate top end. There is also a plurality of base plate mounting holes (2040) that when used with screws or bolts secure the base plate to the floor, stud, or concrete block.

As also shown in FIG. 6A, and 6B, the base plate will have a base plate groove (2070). This groove could pass all the way through the base plate. The base plate groove will have a base plate groove wall (2080) which is the trace around the groove. The base plate groove wall should be perpendicular to the base plate top end. The trace of the groove wall forms a groove outline. The dimensions of the groove are such that the framing member first end profile can enter the groove and pass below the plate top end and into the groove. At this point, the framing member first end is disposed within the base plate groove. The groove wall defines the space into which the framing member end is inserted.

As shown in FIGS. 6A and 6B, the framing member can be oriented so that the web or parallel with the base plate length (FIG. 6A) or parallel with the base plate width (FIG. 6B).

The base plate groove may be dimensioned so that it is in frictional contact with at least one of the first flange, second flange, and web. The base plate groove may be dimensioned so that it is in frictional contact with each of the first flange, the second flange, and the web. Frictional contact means that a force greater than the weight of the framing member is required to place the framing member into the groove.

It is recognized that there could be a gap between the framing member and the groove wall. One of ordinary skill would recognize that it is preferable that the base plate groove be dimensioned so that there is no gap between the groove wall and the framing member inside the groove. However, small gaps are permissible.

It is preferred that the largest distance of any gap between the framing member and groove wall be less than or equal to 1 inch. One of ordinary skill will recognize that the maximum gap occurs when one side of the framing member touches a groove wall, and the gap exists from the opposite side of the framing member. Were the framing member equidistant from the groove wall at all points, the largest gap would be ½ inch.

Using the same methodology, a maximum gap of less than or equal to 0.75 inches is more preferred, with a maximum gap of less than or equal to 0.5 inches or less than or equal to 0.25 inches, being even more preferred. Most preferred is a maximum gap of less than or equal to 0.125 inches which would result in the gap being 0.0625 inches ( 1/16 inch) when the groove wall is equidistant from the framing member. The grove in the working example was laser cut to 0.074 inch +/−0.004 inch.

In some embodiments, the groove will pass through the base plate and the framing member first end will be flush with the base plate bottom.

The knee wall support assembly (4000) also has a weld (FIG. 1, (3000)) joining the framing member and the base plate. The groove cut into the base plate aligns the framing member and helps reduce welding set up time. This weld can be a series of spot welds or a continuous weld running along the base plate outline. The weld could also be discontinuous with multiple welds running along the base plate outline. The weld can be of various types. For example, the weld could be a gas metal arc (MIG), gas tungsten arc (TIG), shielded metal arc, a flux cored arc. The preferred weld is continuous following the outer perimeter (1210) of the framing member profile with no welds on the interior perimeter (1220) as shown in FIG. 8.

The welded base plate to the framing member assembly will be referred to as a knee wall support assembly.

The knee wall support assembly can be made of steel, with the framing member being made of 12, 14, or 16 gauge structural grade steel with a preferred thickness of 14 gauge. The base plate can be made of steel with a preferred thickness (2030) between ⅜″ to ½″.

The knee wall support assembly is also installed in a unique way. Currently these types of pony walls or knee walls are installed as part of a framing assembly. The framing assembly has studs running vertically from the floor to the top track of the knee wall. The base of the studs may be located in an upward facing channel. The studs form a horizontal wall line where the wall sheathing, typically gypsum board, is attached to the studs. The wall face is the plane defined by the horizontal wall line and the vertical wall line which is parallel with the studs as they extend from the floor to the ceiling. Prior art framing assemblies have the knee wall support assembly oriented with the web parallel to the wall face. This places the load from the wall at the web.

The knee wall support assembly is also installed in a unique way. It has been surprisingly discovered and confirmed through testing of physical parts that the invented knee wall support assembly can be installed with the web perpendicular to the wall face. This places the load on both of the flanges with one flange in compression and the opposite flange in tension.

This orientation is shown in FIGS. 9A and 9B. FIG. 9A shows the orientation of the web being parallel with the wall face. FIG. 9B shows the web of the knee wall support assembly being perpendicular with the wall face.

FIG. 9A shows a prior art knee wall support assembly (4500) without the groove in the base plate. As shown in 9A, the knee wall support assembly is parallel with the wall supporting two constructions studs. In contrast, the improved knee wall support assembly with the groove taught herein can be oriented perpendicular to the wall face as shown in FIG. 9B and only needs to support one construction stud, thus saving time and materials.

The instant knee wall support assembly was evaluated in a framing assembly against a prior art knee wall support assembly. The prior art framing member was 350S162-97, 12 gauge steel. The prior art base plate was 8 inches by 3.375 inches and 0.5 inches thick without a groove. Typically, these are installed with two pony or knee wall studs per prior art framing member, thus the reason it is oriented with the web parallel to the wall face. The wall force load is on the web.

The working example of the instant knee wall support assembly had a framing member of 300S162-68 14 gauge steel. The working example base plate was 8 inches by 3.375 inches and 0.375″ inches thick with a groove with the framing member inserted into the groove. While the prior art requires two mating studs per knee wall support assembly as shown in FIG. 9A, it was surprisingly discovered that this knee wall support assembly is strong enough to require only one knee wall support assembly when the new knee wall support assembly is oriented perpendicular to the wall face in the framing assembly. As shown in FIG. 9B, being perpendicular to the wall face places the wall force load on the flange of the knee wall assembly framing member.

Both the prior art example and the working example were evaluated by placing a load at the wall face. In the prior art example, the load was placed on the web of the knee wall support assembly. In the working example, the load was placed on of the flanges. Up to 58% more force was required to deform the working example, proving that the new design and orientation allowed for a stronger wall with less material in the base plate and knee wall support assembly stud, and less installation labor by using 1 mating stud versus 2 mating studs.