Structural Insulated Header

Abstract

The present invention relates to the construction arts, in particular a new implementation for a structural support member or header for bearing the load of large spans of a floor, wall section above a window, door or garage door. The support member has an insulation which, when used with a steel beam, serves to increase the insulation value. Further the header is modular and can be easily implemented into a variety of architectural structures.

1 . A preformed modularized structural header for forming header structures for framing said header comprising:
 (i) a generally elongated orthogonal enclosure comprising;
 a first vertical member; a second vertical member spaced from and substantially parallel to said first vertical member; said vertical members comprising a plurality of injection points at predetermined intervals along the members for receiving an insulating material, each said first and a second vertical members further comprising a first and second elongated edges and; 
 a first horizontal member; a second horizontal member spaced from and substantially parallel to said first horizontal member; said first and second horizontal members further comprising a first and a second elongated edges and; 
 said vertical members and said horizontal members arranged such that said vertical members and said horizontal members are rigidly connected in a predetermined way along the elongated edges so as to form an elongated orthogonal enclosure having a void, 
   (ii) an insulating material being added through said injection points in such a way as to substantially fill said void with the insulating material.   
   
   
       2 . A modularized structural header in accordance with  claim 1  wherein said vertical and said horizontal members comprise at least one of; wood, oriented strand board (osb), plywood, and hardboard being approximately ½ to 2 inches in thickness. 
   
   
       3 . A modularized structural header in accordance with  claim 1  wherein said insulating material comprises at least one of: rock wool, fiberglass, Styrofoam, or polyurethane foam. 
   
   
       4 . A modularized structural header in accordance with  claim 3  wherein said insulating material comprises: open cell, low density, non-ozone depleting polyurethane foam. 
   
   
       5 . A modularized structural header in accordance with  claim 3  wherein said beam has an insulating value of R20. 
   
   
       6 . A modularized structural header in accordance with  claim 3  wherein said header further comprises a beam. 
   
   
       7 . A modularized structural header in accordance with  claim 3  wherein said beam is made of steel. 
   
   
       8 . A modularized structural header in accordance with  claim 3  wherein said beam comprises a web portion and a plurality of flange portions. 
   
   
       9 . A modularized structural header in accordance with  claim 8  wherein the flange portion is connected with said horizontal members such that said flange portion substantially deflects forces created by expanding the insulating material. 
   
   
       10 . A modularized structural header in accordance with  claim 8  wherein said vertical members interact with said flange portion to provide support to the vertical member. 
   
   
       11 . A modularized structural header in accordance with  claim 10  wherein said vertical members further comprises at least one of; a cleat, a shelf, a projection, a ledge, a sill, a step, or a ridge. 
   
   
       12 . A modularized structural header in accordance with  claim 9  wherein said rigid connection comprises at least one of: dado's, rabbets, lock joints, spline joints, tongue and groove, or mortise and tenon joinery. 
   
   
       13 . A method for making a header comprising the steps of;
 (i) providing an elongated metal beam comprising a web portion rigidly connected with a plurality of flange portions;   (ii) encasing the structural beam with an elongated orthogonal enclosure comprising; a plurality of elongated vertical members; a plurality of elongated horizontal members; said elongated vertical members having a plurality of vertical edges, said elongated horizontal members having a plurality of horizontal edges; said vertical edges being securely connected with said horizontal edges in a predetermined fashion;   (iii) fitting the elongated orthogonal structure to substantially form a tight fit with the elongated metal beam such that a void is formed between the web portion of the beam and the elongated vertical members;   (iv) filling the void with insulation.   
   
   
       14 . The method for making a header in accordance with  claim 13  wherein the elongated metal beam further comprises a steel I beam. 
   
   
       15 . The method for making a header in accordance with  claim 13  wherein the connection between the vertical edges and the horizontal edges comprises at least one of: fasteners, nails, screws, staples, dados, rabbets, lock joints, spline joints, tongue and groove or mortise and tenon. 
   
   
       16 . The method for making a header in accordance with  claim 13  wherein the insulation comprises open cell polyurethane foam. 
   
   
       17 . The method for making a header in accordance with  claim 13  wherein vertical member comprises the at least one of; a cleat, a shelf, a projection, a ledge, a sill, a step, or a ridge for engaging with the flange portion of the beam. 
   
   
       18 . A preformed modularized structural header for forming header structures for framing said beam comprising:
 (i) a steel beam comprising a web portion and a plurality of flange portions;   (ii) a generally elongated orthogonal enclosure comprising;
 a first vertical member; a second vertical member spaced from and substantially parallel to said first vertical member; said vertical members comprising a plurality of injection points at predetermined intervals along the members for receiving an insulating material, each said first and said second vertical member comprising a cleat; each said first and said second vertical members further comprising a first and second elongated edges and; 
 a first horizontal member; a second horizontal member spaced from and substantially parallel to said first horizontal member; said first and second horizontal members further comprising a first and a second elongated edges and; 
 said vertical members and said horizontal members arranged such that said vertical members and said horizontal members are rigidly connected in a predetermined way along the elongated edges so as to form an elongated orthogonal enclosure having a void, 
   (iii) the elongated orthogonal structure substantially fitting with the steel beam such that the flange portions interact with the vertical members to provide support to the vertical members,   (iv) a foam insulating material being added through said injection points in such a way as to substantially fill said void with the insulating material.