OPENING IN A STRUCTURE

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No.

63/192,641, filed on May 25, 2021, which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

[0002] The present disclosure generally relates to a method and apparatus for constructing and reinforcing an opening in a structure, and more specifically to pre-construction of new lintels, and repair of existing lintels, above a garage door or other opening.

BACKGROUND

[0003] Lintels are used in the construction industry to support, lift, stabilize, or repair masonry units and are generally used over door, garage, or window openings. Lintels may also be used when removing a wall or portion of a wall to provide reinforcement to the area above the opening. Lintels are typically made from angle iron, but may take other cross-sectional shapes, and can vary significantly in length.

[0004] A post and lintel technique is commonly used to support loads over door, garage, and window openings. This technique is a simple, yet effective construction technique and is thus used by many architects and builders to support a load above an opening. In the post and lintel technique, two vertical members (or the posts) support a horizontal member (or the lintel) at opposing ends of the horizontal member.

[0005] While the conventional post and lintel construction technique is widespread and used considerably, it does suffer from certain drawbacks. Over time, the lintel deflects, or sags, and rotates, resulting in damage to the supporting members and an unsafe positioning of the masonry load, which must be repaired. These repairs are time consuming, labor intensive, and costly.

[0006] In addition, the conventional post and lintel technique may suffer from additional drawbacks in colder climates. In this conventional technique, the two vertical posts may rest, completely or partially, on floating driveway concrete. In colder climates, moisture trapped under the floating driveway concrete may freeze and expand, thereby raising the post to a degree that may damage the lintel or the masonry above the lintel. When the moisture under the floating driveway concrete thaws, the floating driveway concrete may sink back down, which may damage the lintel or result in a lack of adequate support. Accordingly, there is a need for a method and apparatus for constructing and reinforcing an opening in a structure that may address one or more of these drawbacks.

SUMMARY

[0007] According to an aspect of one or more exemplary embodiments, there is provided a system for supporting an existing lintel above a garage door opening of a garage. The system may include first and second support columns configured to be respectively affixed to first and second sides of the garage door opening, first and second foot plates configured to be respectively affixed to first and second portions of a floor of the garage, and a replacement lintel having a horizontal flange with a first end and a second end, said first and second ends of said replacement lintel are configured to be respectively coupled to the first and second support columns, and said horizontal flange is configured to be disposed substantially adjacent to a bottom surface of the existing lintel. The first and second foot plates may be configured to be respectively coupled to the first and second support columns, and may be configured to respectively support the first and second support columns so that bottom portions of the first and second support columns are spaced apart from the floor of the garage.

[0008] According to another aspect of one or more exemplary embodiments, there is provided a method of supporting a pre-construction lintel above a garage door opening of a garage. The method may include respectively affixing first and second support columns to first and second sides of the garage door opening, respectively coupling first and second ends of a support lintel to the first and second support columns so that a horizontal flange of the support lintel is disposed substantially adjacent to a bottom surface of the pre-construction lintel. The horizontal flange may be cambered so that the first and second ends of the support lintel are closer to a floor of the garage than a center portion of the horizontal flange when the support lintel is disposed substantially adjacent to a bottom surface of the pre-construction lintel. The method may also include pulling the center portion of the horizontal flange downward so that the center portion is substantially coplanar with the first and second ends of the support lintel, and is configured to support a structural load above the horizontal flange.

BRIEF DESCRIPTION OF DRAWINGS

[0009] Fig. 1 shows a support column configured to be disposed on the right side of a garage according to an exemplary embodiment.

[0010] Fig. 2 Fig. 1 shows a support column configured to be disposed on the left side of a garage according to an exemplary embodiment.

[0011] Fig. 3 A shows a top-down view of a foot plate configured to receive a support column according to an exemplary embodiment.

[0012] Fig. 3B shows a side view of a foot plate configured to receive a support column according to an exemplary embodiment. [0013] Fig. 3C shows a front view of a foot plate configured to receive a support column according to an exemplary embodiment.

[0014] Fig. 4 shows multiple cross-sectional view of a support column according to an exemplary embodiment.

[0015] Fig. 5 shows a front side view and a bottom view of a replacement lintel according to an exemplary embodiment.

[0016] Fig. 6 shows a jack screw according to an exemplary embodiment.

[0017] Fig. 7A shows an illustration of a method of supporting a pre-construction lintel above a garage door opening of a garage according to an exemplary embodiment.

[0018] Fig. 7B shows an alternative view of a method of supporting a pre-construction lintel above a garage door opening of a garage according to an exemplary embodiment.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0019] Reference will now be made in detail to the following exemplary embodiments, which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. The exemplary embodiments may be embodied in various forms without being limited to the exemplary embodiments set forth herein. Descriptions of well-known parts are omitted for clarity.

[0020] Referring to Figs. 1 and 2, support columns 100 and 200 are configured to be disposed on the right side and left side, respectively (when facing the garage from the driveway) of a garage door opening according to an exemplary embodiment are shown. Support columns 100 and 200 may have a substantially rectangular cross section, and may be substantially hollow. However, the support columns 100 and 200 may have different cross-sectional shapes and may be partially hollow. The support columns 100 and 200 respectively include front faces 105 and 205 and rear faces (not shown), wherein the rear faces may be configured to abut against the side of the garage frame. The front faces 105 and 205 may respectively include a plurality of holes 110 and 210 that are configured to receive lag bolts or other types of coupling mechanisms to affix the support columns 100 and 200 to the sides of the garage door frame, respectively. The support columns 100 and 200 may also include a plurality of foot plate holes 115 and 215 that are configured to receive lag bolts or other types of coupling mechanisms to affix the support columns 100 and 200 to respective foot plates, which are discussed further below. The foot plate holes 115 and 215 are located in respective side faces (not visible in Figs. 1 and 2) of the support columns 100 and 200, which are disposed approximately 90 degrees relative the front faces 105 and 205. Foot plate holes 115 and 215 are configured to receive lag bolts or other coupling mechanisms to couple the support columns 100 and 200 to foot plates, as described further below.

[0021] As shown in Figs. 1 and 2, the support columns 100 and 200 may be affixed to respective portions of the garage frame that are above the floating driveway concrete, and be mounted so that the bottom of the support columns 100 and 200 is located above the floating driveway concrete by a certain threshold distance. The threshold distance may be, for example, two inches, however other distances may be used. In addition, according to an exemplary embodiment, the support columns 100 and 200 may be affixed to respective portions of the garage frame that are above the garage concrete slab, or that partially overlap both the floating driveway concrete and the garage concrete slab.

[0022] Fig. 3 A shows a top down view of a foot plate 300 according to an exemplary embodiment. The foot plate 300 may have a bottom surface 305 that includes a floor mounting hole 310. The bottom surface 305 may be substantially rectangular, however other shapes may be used. The foot plate 300 is configured to support a support column, e.g., support columns 100 or 200, and is configured to be affixed to the ground by inserting a lag bolt or other coupling mechanism through floor mounting hole 310. The foot plate 300 may also include a side face 315 that extends along one of the short sides of the bottom surface 305, and extends upward at approximately a 90 degree angle from the bottom surface 305. The foot plate 300 may also include a front face 320 and a rear face 325 that may partially extend across the long sides of the bottom surface 305, respectively. The front and rear faces 320, 325 may be integrally formed with the side face 315, and may extend upward at approximately a 90 degree angle from the bottom surface 305, to form a substantially U-shaped cross section together with the side face 315.

[0023] Fig. 3B shows a side view of the foot plate 300 according to an exemplary embodiment. As shown in Fig. 3B, the side face 315 may include column mounting holes 330 that are configured to receive mounting bolts to affix the foot plate 300 to a support column, e.g., support column 100. Referring again to Fig. 1, mounting bolts or other coupling mechanisms may be inserted through column mounting holes 330 and foot plate holes 115 to secure the support column 100 to the foot plate 300. The column mounting holes 330 and the foot plate holes 115 may be configured so that when the support column, e.g., support column 100, is affixed to the foot plate 300 using lag bolts through the column mounting holes 330, the support column 100 is suspended above the ground so that the bottom of the support column is not in contact with the ground. For example, the support column 100 may be approximately two inches above the ground when secured to the foot plate 300, however a different distance may be used.

[0024] The front and rear faces 320, 325 may include frame mounting holes 335A and 335B, respectively, that are configured to receive lag bolts or other coupling mechanisms to secure the foot plate 300 to the frame of the garage. The front and rear faces 320, 325 may also include a ratchet holes 340A and 340B, respectively, located across from the frame mounting holes 335B and 335A, respectively, on the opposite face. For example, in Fig. 3B, front face 320 includes a ratchet hole 340A located above a frame mounting hole 335A, and rear face 325 includes a frame mounting hole 335B located above the ratchet hole 340B. In use, the frame mounting hole 335B in the rear face 325 is configured to be located adjacent to the garage frame, and a lag bolt may be inserted into the ratchet hole 340A in the front face 320, through the frame mounting hole 335B in the rear face 325, and into the garage frame. The ratchet holes 340A, 340B may be larger than the frame mounting holes 335A, 335B so that the ratchet holes 340A, 340B may accommodate a ratchet to tighten the bolts when inserted through the frame mounting holes 335.

[0025] Fig. 3C shows a front view of the foot plate 300 according to an exemplary embodiment. As shown in Fig. 3C, the rear face 325 includes a ratchet hole 340B located below a frame mounting hole 335B, whereas the front face 320 (not visible) includes a ratchet hole 340A located above a frame mounting hole 335A. In practice, a lag bolt or other coupling mechanism may be inserted through the ratchet hole 340B in the rear face 325 and the frame mounting hole 335A in the front face 320, and secured to the frame of the garage. The bottom surface 305 may be secured to the garage slab using a lag bolt or other coupling mechanism through floor mounting hole 310. According to an exemplary embodiment, the bottom surface 305 may be mounted partially on the garage slab and partially on the floating driveway concrete (or entirely on the garage slab), such that when the support column 100 or 200 is affixed to the side face 315, the bottom of the support column is located above the floating concrete driveway. Therefore, if the floating concrete driveway is raised due to freezing moisture under the floating concrete driveway, the driveway will not contact the support column.

[0026] Fig. 4 shows multiple cross-sectional views of support column 100 taken at various positions along the support column 100. The top image in Fig. 4 shows the cross- sectional view of the support column 100 in Fig. 1 across the A-A line in the upper portion of Fig. 1, the second image in Fig. 4 shows the cross-section view of the support column 100 across line B-B in Fig. 1, the third image in Fig. 4 shows the cross-section view of the support column 100 across line C-C in Fig. 1, and the bottom image in Fig. 4 shows the cross-section view of the support column 100 across line D-D in Fig. 1. As shown in the cross-sectional view in Fig. 4, the support column 100 may be substantially hollow, which allows lag bolts or other coupling mechanisms to affix the support column 100 to the garage frame and the foot plate 300.

[0027] To install the foot plate 300 and support columns 100, 200 according to an exemplary embodiment, a foot plate 300 may be positioned adjacent to each side of the garage door frame, with either the rear face 325 or the front face 320 adjacent to the side of the garage door frame. A lag bolt or other coupling mechanism may be inserted through floor mounting hole 310 to secure the foot plate 300 to the ground. As discussed above, the ground plate 300 may installed so that the bottom surface 305 may be disposed on the garage concrete slab, a floating driveway directly adjacent to the garage concrete slab, or overlapping both the garage concrete slab and the floating driveway. The support columns 100, 200 may be respectively disposed on top of the foot plates 300 so that front face 320, side face 315, and rear face 325 of the foot plates 300 respectively fit within the hollow interior of the support columns 100, 200. Alternatively, the support columns 100, 200 and the foot plates 300 may be sized and shaped so that one end of the support columns 100, 200 respectively fits within the space formed by front face 320, side face 315, and rear face 325 for each foot plate 300. When the support columns 100, 200 are properly positioned with respect to the foot plates 300, the foot plate holes 115, 215 of the support columns 100, 200 will respectively align with column mounting holes 330 of the foot plates 300. A lag bolt or other coupling mechanism may be inserted through foot plate holes 115, 215 and column mounting holes 330 to couple the support columns 100, 200 to the foot plates 300. According to an exemplary embodiment, the bottom of the support columns 100, 200 may be located a certain distance (e.g., 2 to 3 inches) above the concrete garage slab and/or floating driveway slab. Lag bolts or other coupling mechanisms may be inserted through holes 110, 210 and into the respective sides of the garage frame to couple support columns 100, 200 to the respective sides of the garage frame. Once the support columns 100, 200 are coupled to the foot plates 300 and the sides of the garage frame, they can be coupled to the replacement lintel, as explained below.

[0028] Fig. 5 shows a front side view and a bottom view (i.e., looking upward from the garage floor when installed) of a replacement lintel 500 that is configured to be supported by the support columns 100 and 200, according to an exemplary embodiment. The front side view, shown in the upper portion of Fig. 5, shows a replacement lintel 500 having a horizontal flange 505 and a vertical flange 510, which may be disposed at approximately a 90 degree angle with respect to the horizontal flange 505. In practice, the replacement lintel 500 may be disposed so that the horizontal flange 505 is located substantially adjacent to and underneath an existing lintel. The vertical flange 510 may be located in front of or behind masonry or other structure supported by the existing lintel. According to an exemplary embodiment, the horizontal flange 505 may be cambered, or arched, so that a center portion of the horizontal flange 505 is disposed substantially adjacent to the existing lintel, while the two end portions of the horizontal flange 505 may be spaced apart from the existing lintel. According to an exemplary embodiment, the vertical flange 510 may also be cambered, or arched so that a center portion of the vertical flange 510 is located above two end portions of the vertical flange. According to an exemplary embodiment, the replacement lintel may include the horizontal flange 505, but not the vertical flange 510.

[0029] The bottom view of the replacement lintel 500 is shown in the lower portion of Fig. 5. As shown in the bottom view of the replacement lintel 500, the horizontal flange 505 may include one or more receiving slots 515 on each end of the horizontal flange. The receiving slots 515 may be configured to receive jack screws to raise the end portions of the horizontal flange 505 so that the end portions are substantially coplanar with the center portion of the horizontal flange 505. According to an exemplary embodiment, various lift mechanisms other than jack screws may be used to raise the end portions of the horizontal flange 505. According to an exemplary embodiment in which the horizontal flange 505 is initially cambered, lifting the end portions of the horizontal flange 505 so that they are substantially coplanar with the center portion of the horizontal flange 505 may further strengthen the replacement lintel to support the existing lintel.

[0030] Fig. 6 shows a jack screw 600 according to an exemplary embodiment. The jack screw may include a threaded shank 605 that is configured to engage with a threaded hole within a block 610. The block may include a narrower base with an enlarged flange 615 that is configured to engage the top portion of the support column 100 or 200. However, the enlarged flange 615 is optional, and the block 610 may alternatively have a uniform width that allows the block 610 to rest atop or within the support column 100 or 200. At the end of the threaded shank 605 is located a screw head 625 that is configured to engage receiving slots 515 of the horizontal flange 505. For example, the screw head 625 may include a protrusion that extends upwardly (i.e., opposite of the threaded shank 605) to engage the receiving slots 515. The screw head 625 may also include one or more openings 620 that are configured to receive a tool by which the threaded shank 605 and the screw head 625 are rotated, thereby lifting the screw head 625 with respect to the block 610. As the block 610 remains disposed atop or within the support columns 100, 200, the screw head 625 is raised to engage the receiving slots 515 and raise the end portions of the horizontal flange 505 so that they become substantially coplanar with the center portion of the horizontal flange 505. According to an embodiment in which the horizontal flange 505 is not cambered, the jack screws 600 support the replacement lintel 500 against the existing lintel.

[0031] Figs. 7A and 7B illustrate a method of supporting a pre-construction lintel above a garage door opening of a garage, according to an exemplary embodiment. The method may include using a support lintel 700, which may include a vertical flange 705 and a horizontal flange 710, to support a structure to be built above the support lintel 700. The support lintel 700 may be supported by two support columns 100 and 200 (not shown) affixed to the respective sides of the garage door opening. The support lintel 700 may be initially cambered or arched, so that the two end portions of the horizontal flange 710 are located closer to the garage floor than a center portion of the horizontal flange 710. The center portion of the horizontal flange 710 may be pulled or pushed downward so that the center portion of the horizontal flange 710 is substantially coplanar with the two end portions of the support lintel 700. For example, as shown in Figs. 7 A and 7B, a center bracket 715 may be mounted to a center portion of the horizontal flange 710, and may be configured to receive a hook of a cable pulley device 720.

Two end portions of the cable pulley device 720 may be affixed to the support columns 100, 200 (or to the garage frame itself) using two side brackets 725 mounted to the support columns 100, 200. The cable pulley device 720 may then be used to pull the center portion of the horizontal flange 710 downward (e.g., using a ratchet to increase tension in the cable) so that the center portion of the horizontal flange 710 is substantially coplanar with the end portions of the horizontal flange 710. By making the initially-cambered support lintel 700 substantially straight, the support lintel 700 may experience increased strength to support a heavier load without sagging or breaking.

[0032] Although the inventive concepts of the present disclosure have been described and illustrated with respect to exemplary embodiments thereof, it is not limited to the exemplary embodiments disclosed herein and modifications may be made therein without departing from the scope of the inventive concepts.