Structural Insulated Header for Architectural Features

Abstract

The present invention relates to the construction arts, in particular a modular 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 entry way. The header is modular and can be easily implemented into a variety of architectural structures. A façade can be formed which easily allows complex arches to be created such as round, horseshoe, lancet, ogee, trefoil and so on. The support member can also include an insulation which, when used with a steel beam, serves to increase the insulation value.

1 . A preformed modularized structural header for creating an architectural fa£ade during framing said header comprising:
 (i) an elongated steel beam comprising a web portion and at least one flange portion being substantially encased in an enclosure; 
 (ii) said enclosure comprising;
 a first vertical member having an architecturally pleasing form; a second vertical member spaced from and substantially parallel to said first vertical member and the second vertical member having a substantially matching form to the first vertical member; 
 said vertical members having an elongated edge being oriented with respect to said flange portion of said beam and being in connection with a first horizontal member; 
 the first horizontal member and a second horizontal member spaced from and substantially parallel to said first horizontal member; at least one of said horizontal members being oriented with respect to the flange portion of said beam; 
 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 enclosure for encasing the beam with the vertical members forming an architectural façade. 
 
 
     
     
         2 . A preformed modularized structural header in accordance with  claim 1  wherein the architectural design of said vertical members comprise at least one of; curved, polygon, round, horseshoe, lancet, ogee, trefoil, basket handle and Tudor. 
     
     
         3 . A preformed modularized structural header in accordance with  claim 2  wherein a void is formed between the web portion of the beam and the vertical members, said void being filled with an insulating material at least one of: rock wool, fiberglass, Styrofoam, or polyurethane foam. 
     
     
         4 . A preformed modularized structural header in accordance with  claim 3  wherein said insulating material comprises: open cell, low density, non-ozone depleting polyurethane foam. 
     
     
         5 . A preformed modularized structural header in accordance with  claim 3  wherein said beam has an insulating value of approximately R20. 
     
     
         6 . A preformed modularized structural header in accordance with  claim 3  wherein said beam comprises two flange portions being arranged on substantially opposite sides of the web portion. 
     
     
         7 . A preformed 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. 
     
     
         8 . A preformed modularized structural header in accordance with  claim 8  wherein said vertical members interact with said flange portion to provide support to the vertical member. 
     
     
         9 . A preformed 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. 
     
     
         10 . A preformed 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. 
     
     
         11 . A method for making a preformed modular header having an architectural façade 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 metal beam with an enclosure comprising; a plurality of matching vertical members having an architecturally pleasing form; a first and a second elongated horizontal members; said vertical members having an elongated edge, said first and second elongated horizontal members each having a plurality of elongated edges; said elongated edge of the vertical members being securely connected with said elongated edges of the elongated horizontal members in a predetermined fashion 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 vertical members; 
 (iii) filling the void with insulation. 
 
     
     
         12 . The method for making a preformed modular header in accordance with  claim 13  wherein the wherein the elongated orthogonal enclosure further comprises a modular arch. 
     
     
         13 . The method for making a preformed modular 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. 
     
     
         14 . The method for making a preformed modular header in accordance with  claim 13  wherein the insulation comprises open cell polyurethane foam. 
     
     
         15 . The method for making a preformed modular 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. 
     
     
         16 . 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 substantially wooden box like structure substantially enclosing the steel beam 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, a foam insulating material being added through said injection points in such a way as to substantially fill said void with the insulating material.