Apparatus and methods for modifying a stress skin panel

Abstract

A modified stress skin panel includes a stress skin panel and at least two substantially vertical studs which are molded into the stress skin panel during manufacture or inserted after manufacture. An opening is formed between two substantially vertical studs for insertion of a window, door, or other item. A header stud may also be attached to two of the at two substantially vertical studs to support a load above the opening. A stress skin panel stud inserter includes a stud guide assembly, a heater element, a heater controller, a pair of rails, and a pair of clamps. A second embodiment of a stress skin panel stud inserter utilizes a stud heater element which is attached to a bottom of the stud. A third embodiment of a stress skin panel stud inserter includes a hot air shroud and an alignment jig. The hot air shroud is attached to a bottom of the stud and the alignment jig is used to guide the stud during insertion thereof into the stress skin panel.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This is a continuation-in-part patent application taking priority from, Ser. No. 09/663,432 filed on Sep. 16, 2000.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates generally to stress skin panels and more specifically to an apparatus and methods for modifying a stress skin panel.

[0004] 2. Discussion of the Prior Art

[0005] A stress skin panel, also known as a structural insulated panel is a structural member used to fabricate buildings. The stress skin panels are joined together to form walls of a building instead of wood studs and wood panels. For example, to create openings for a window, the stress skin panel must be routed out to accept two vertical studs, and then may be routed out to accept a stud which is attached in between the two vertical studs above the window structure. The process of routing out the stress skin panel for the studs is very time consuming.

[0006] Accordingly, there is a clearly felt need in the art for apparatus and methods for modifying stress skin panel to easily install a window, door, or any other appropriate item.

SUMMARY OF THE INVENTION

[0007] The primary objective of the present invention is to provide an apparatus and methods for modifying a stress skin panel to easily accept a window, door, or any other item. A modified stress skin panel includes a stress skin panel and at least two substantially vertical studs which are horizontally spaced apart for the insertion of a window, door, or other structure. A stress skin panel includes an inner layer fabricated from a foam material such as polystyrene which is sandwiched between two outer layers of oriented strand board. The at least two substantially vertical studs are either molded into the inner layer during manufacture, or inserted after manufacture. A header stud may be fastened to the vertical studs in an area above a potential opening to support the load above the potential opening. The header stud could be attached to the two vertical studs before molding or after cutting out the potential opening. A support member could also be placed in or over the stress skin panel with an opening instead of using the header stud. Multiple substantially vertical studs may be molded or inserted into the stress skin panel to increase the load bearing ability or structural integrity thereof.

[0008] Either wood or metal studs may be used. It is preferably to use standard wood studs, because carpenters are more accustomed to working with wood studs. The metal studs are preferably fabricated from a galvanized steel or a noncorrosive metal. Preferably, each substantially vertical stud extends from the bottom of the stress skin panel to the top thereof. The header stud may be attached to the at least two substantially vertical studs with any suitable assembly method. The header stud is not needed, if a support member is placed in or over the stress skin panel.

[0009] A stress skin panel stud inserter includes a stud guide assembly, a heater element, a heater controller, a pair of rails, and a pair of clamps. The thickness of the stress skin panel fits between the pair of support rails. A clamp is slidably attached to each end of each rail. A slidable base rests on the top of each rail. The slidable base is secured to at least one rail. A stud guide is attached to the base with a gusset structure. The heater element is contained inside a heater cover which is fastened to the slidable base. The heater controller ensures that a metal stud is exposed to a substantially constant temperature of heat for later insertion into the stress skin panel.

[0010] A metal stud is inserted into the stress skin panel by placing the stress skin panel stud inserter on top of the stress skin panel. The stress skin panel stud inserter is secured to the stress skin panel by closing the clamps on the stress skin panel. The metal stud is placed in the stud guide. The sliding base is moved such that the metal stud will be aligned with a position which will later define a vertical perimeter of the window opening. The heater controller is turned on so that the heater element may reach the desired temperature. The heater element heats the metal stud so that it may be pushed through the thickness of the stress skin panel. The heated metal stud will melt the inner layer of the stress skin panel to allow insertion of the stud.

[0011] The metal stud will act as an integral member of the stress skin and will improve the amount of weight that may be placed on top of the stress skin panel. As many vertical studs as are required for rigidity and strength are inserted by the stress skin panel stud inserter. The gauge and cross section of the metal stud can also be varied to meet specific structural criteria.

[0012] A second embodiment of a stress skin panel stud inserter utilizes a stud heater element which is attached to a bottom of a metal stud instead of the heater element in the heater cover. A heater controller is used to supply electrical current to the stud heater element through a pair of wires. The metal stud is forced into the stress skin panel utilizing a stud guide. The metal stud is forced through the stress skin panel until the heater element is fully exposed. The heater element is then removed from the bottom of the metal stud and the wires may be pulled out of the stress skin panel or left inside the metal stud.

[0013] A third embodiment of a stress skin panel stud inserter includes a hot air shroud and an alignment jig. The hot air shroud is attached to a bottom of a wood stud. The hot air shroud includes a tube with an inside perimeter which is sized to be received by the bottom of the wood stud. An air inlet is formed on at least one side of the hot air shroud. A single air hose is attached to the air inlet. Hot air is forced through the air hose and hot air exits through an open bottom in the hot air shroud. The alignment jig is attached to a top of the stress skin panel. The alignment jig ensures that the wood stud with the hot air shroud attached thereto is inserted substantially perpendicular to a top of the stress skin panel.

[0014] Accordingly, it is an object of the present invention to provide a stress skin panel stud inserter which allows a stud to be inserted into a stress skin panel to facilitate the easy installation of a window, door, or any other structure.

[0015] Finally, it is another object of the present invention to provide a stress skin panel which may have its structural integrity increased by the inclusion of substantially vertical studs.

[0016] These and additional objects, advantages, features and benefits of the present invention will become apparent from the following specification.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1 is a perspective view of a stress skin panel with at least two substantially metal vertical studs, and a header stud molded into thereof during manufacture in accordance with the present invention;

[0018] FIG. 1a is a perspective view of a stress skin panel with a at least two wood vertical studs, and a header stud molded into thereof during manufacture in accordance with the present invention;

[0019] FIG. 2 is a front view of a stress skin panel after an opening has been formed therein for the insertion of a window in accordance with the present invention;

[0020] FIG. 3 is a perspective view of a load above a stress skin panel being supported by a metal support member placed over a top of the stress skin panel in accordance with the present invention;

[0021] FIG. 3a is a perspective view of an inner layer of a stress skin panel being routed out to receive a wood support member in accordance with the present invention;

[0022] FIG. 4 is a perspective view of the stress skin panel stud inserter in accordance with the present invention;

[0023] FIG. 5 is a top view of the stress skin panel stud inserter in accordance with the present invention;

[0024] FIG. 6 is a cross-sectional view of a heater cover of the stress skin panel stud inserter in accordance with the present invention;

[0025] FIG. 7 is an enlarged cross-sectional view of a clamp arm retained by a bracket in accordance with the present invention;

[0026] FIG. 8 is an enlarged cross-sectional view of a support rail with a bracket attached thereto in accordance with the present invention;

[0027] FIG. 9 is a cross-sectional view of a slidable base secured to a pair of support rails in accordance with the present invention;

[0028] FIG. 10 is an end view of a stud guide of the stress skin panel stud inserter in accordance with the present invention;

[0029] FIG. 11 is a perspective view of an insertion tool which is used to push a stud in to the stress skin panel in accordance with the present invention;

[0030] FIG. 11a is an enlarged partial sectional view of a bottom end of an arm of the insertion tool in accordance with the present invention;

[0031] FIG. 11b is a top view of an insertion tool disposed in a stud guide in accordance with the present invention;

[0032] FIG. 12 is a perspective view of a header stud with a tab extension which facilitates the attachment to a vertical stud with screws in accordance with the present invention;

[0033] FIG. 13 is perspective view of an adjustable stud guide which accommodates studs of varying widths in accordance with the present invention;

[0034] FIG. 14 is a rear view of an adjustable stud guide which accommodates studs of varying widths in accordance with the present invention;

[0035] FIG. 15 is a perspective view of a stud with a heating element attached to a bottom thereof in accordance with the present invention;

[0036] FIG. 16 is an enlarged cross-sectional view of stud heater element attached to a bottom of a stud with spring clips;

[0037] FIG. 17 is a perspective view of an alignment jig attached to a stress skin panel with a stud inserted therein in accordance with the present invention;

[0038] FIG. 18 is a perspective view of a hot air shroud for insertion of a stud into a stress skin panel in accordance with the present invention; and

[0039] FIG. 19 is a cross sectional view of a hot air shroud for insertion into a stress skin panel in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] With reference now to the drawings, and particularly to FIG. 1, there is shown a perspective view of a modified stress skin panel. The modified stress skin panel 1 includes a stress skin panel 10 and at least two metal substantially vertical studs 12 which are horizontally spaced apart for insertion of a window, door, or other item. The at least two metal substantially vertical studs 12 are molded into the inner layer 16 during manufacture or inserted after manufacture. A metal header stud 14 may also be attached to each metal substantially vertical stud 12 such that the metal header stud 14 is above the window, door, or other item. The metal header stud 14 supports the load above the window, door, or other item. Multiple metal substantially vertical studs 12 may be molded into the stress skin panel during manufacture or inserted into the stress skin panel after manufacture to increase the load bearing ability or structural integrity thereof.

[0041] With reference to FIG. 1a, the at least two metal substantially vertical studs 12 are replaced with at least two wood substantially vertical studs 13. The metal header stud 14 is replaced with a wood header stud 17. A combination of wood and metal studs may also be used.

[0042] With reference to FIG. 2, inclusion of the header stud 14, 17 at manufacture would eliminate the need for attaching thereof after an opening 18 is cut. The metal studs are preferably fabricated from a galvanized steel or a noncorrosive metal. Preferably, the at least two substantially vertical studs 12, 13 extend from the bottom of the stress skin panel 10′ to the top thereof. The header stud 14, 17 may be attached to the at least two substantially vertical studs 12, 13 with any suitable assembly method. With reference to FIG. 3, the metal header stud 14 may not be needed to support the load above an opening 18, if a metal support member 20 is placed on top of the stress skin panel 10′. The metal support member 20 will support a load 21 placed on top of the stress skin panel 10. The metal support member 20 preferably has a U-shaped cross section with an inner width that is sized to receive a top of the stress skin panel.

[0043] With reference to FIG. 3a, the at least two substantially metal vertical studs 12 are replaced with at least two wood substantially vertical studs 13. The metal support member 20 is replaced with at least one wood member support 25. The at least one wood support member 25 is preferably a wood stud. A combination of wood and metal studs and support members may also be used.

[0044] FIGS. 4 and 5 show a stress skin panel stud inserter 2 which includes a stud guide assembly 22, a heater element 24, a heater controller 26, a pair of support rails 28, and a pair of clamps 30. The thickness of the stress skin panel fits between the pair of support rails 28. The stud guide assembly 22 includes a slidable base 34, a stud guide 23, and a gusset structure 38. With reference to FIGS. 7 and 8, an arm 31 of the clamp 30 is slidably attached to each end of each support rail 28. It is preferably to use a Quick-Grip clamp purchased from the American Tool Companies of Hoffman Estates, Ill. Clamps manufactured from other companies may also be used. The support rail 28 is preferably an aluminum extrusion which may be purchased from 8020, Inc. of Columbia City, Ind. Support rails manufactured by other companies may also be used.

[0045] A clamp arm bracket 32 is preferably attached to the support rail 28 with cavity nuts and bolts. The clamp arm bracket 32 has a clamping pad 33 which extends therefrom. The clamping pad 33 provides a larger contract area than the clamp 30 to prevent damage to the stress skin panel during clamping. The slidable base 34 rests on top of each support rail 28.

[0046] FIG. 9 shows that the slidable base 34 may be secured to at least one support rail 28 with a clamp lever 36. A cavity nut 39 fits inside a lengthwise cavity 41 in the support rail 28. The clamp lever 36 is tightened to prevent the slidable base 34 from moving in relation to at least one support rail 28. The stud guide 23 is fastened to the slidable base 34 with the gusset structure 38. The gusset structure 38 preferably includes at least one guide support 45, at least one bottom support 47, and at least one gusset member 40. Each guide support 45 is fastened to the stud guide 23 and each bottom support 47 is fastened to the slidable base 34. One end of each gusset member 40 is attached to at least one bottom support 47 and the other end thereof is attached to at least one guide support 45.

[0047] FIG. 6 shows at least one heater element 24 retained inside a heater cover 42. The heater cover 42 is fastened to the slidable base 34. The heater element 24 is preferably attached to the heater cover 42. The heater controller 26 ensures that a metal stud 100 is exposed to a substantially constant temperature of heat for insertion into the stress skin panel. The heater cover 42 has an insulating layer 44 to retain the heat produced by the at least one heater element 24 and to protect a user from accidentally burning them self. It is preferable to use an infra-red heater element for cost and performance concerns. Other types of heaters besides electrically powered elements may be used, such as a flame heater. The flame heater would preferably include a flame tip, and a supply of combustible gas. Preferably, a thermocouple would be mounted inside the heater cover 42 to monitor the heat with a flame heater. The thermocouple would close a gas shut-off valve if the temperature is too high and open the gas shut-off valve when the temperature decreases below a particular temperature.

[0048] FIG. 10 shows an end view of the stud guide 23 with a pair of guides 46. The stud 100 is captured between a spacer 48 and the pair of guides 46. The spacer 48 is fastened to the stud guide 23. The spacer 48 is used to provide support to a back of the metal stud 100. As the metal stud 100 is fed into the stress skin panel 102, the pair of guides 46 prevent the stud 100 from falling out of the stud guide 23.

[0049] The metal stud 100 is inserted into the stress skin panel 102 by placing the stress skin panel stud inserter 2 on top of the stress skin panel 102. The stress skin panel stud inserter 2 is secured to the stress skin panel 102 by closing the clamps 30 on the thickness of the stress skin panel 102. The metal stud 100 is placed in the stud guide 23. The sliding base 34 is moved such that the stud 100 will be aligned with a position which will later define a vertical perimeter of a window opening. The heater controller 26 is turned on so that the at least one heater elements 24 reaches the desired temperature. The at least one heater element 24 heats the metal stud 100 so that it may be pushed through the stress skin panel 102. The heated metal stud 100 will melt the styrene material inside the stress skin panel.

[0050] FIG. 11 shows an insertion tool 50 which may be used to push the metal stud 100 into the stress skin panel 102. The insertion tool 50 includes a pair of arms 52, and at least two sets of telescoping support tubes 54. Each set of telescoping support tubes 54 are preferably pressed or welded into holes formed in the pair of arms 52. Insertion of a locking pin 56 into each set of telescoping support tubes determines the width of the insertion tool 50. The insertion tool 50 may be simplified to accommodate a single width of metal studs by replacing each set of telescoping support tubes 54 with a single support tube which is preferably pressed or welded into a hole in the pair of arms 52.

[0051] FIG. 11a shows that the end of each arm 52 has a tongue 57 which slidably fits inside the metal stud 100. A pushing slot 58 is formed in substantially a front edge 59 to accommodate the insertion of the metal stud 100. With reference to FIG. 11b, the front edge 59 of each arm 52 is supported by the stud guide 23 to prevent excess wobbling when the insertion tool is used to push the stud 100 into the stress skin panel 102. As the insertion tool 50 is pushed through the stud guide 23 the front edge 59 is supported by the guide support 23 and a rear edge 51 is supported by the guides 46.

[0052] The inserted metal stud 100 will act as an integral member of the stress skin panel 102 and will improve the amount of weight that may be placed on top of the stress skin panel 102. At least two metal substantial vertical studs 12 are inserted using the stress skin panel stud inserter 2. The opening 18 is formed between the at least two metal substantial vertical studs 12 for attachment of a metal header stud 14.

[0053] FIG. 12 shows a metal header stud 14′ fastened to a metal substantially vertical stud 12′ with at least one screw 19. At least one tab 15 extends from each end of the metal header stud 14′. A screw 19 is driven through the at least one tab 15 into the metal substantially vertical stud 12′ to fasten the metal header stud 14′ to the metal substantially vertical stud 12′. The wood header stud 17 may be attached between two wood substantially vertical studs by nailing or any other suitable process. A wood header stud 17 may be attached to two metal substantially vertical studs 12 or a metal header stud 14 may be attached to two wood substantially vertical studs 12.

[0054] FIGS. 13 and 14 show an adjustable stud guide 68 which accommodates studs of varying widths. The adjustable stud guide 68 preferably includes a first guide member 70, a second guide member 72, a slide plate 76, and a plurality of lever clamps 74. A plurality of guides 46 are attached to the first and second guide members. A spacer 48 is retained against the first and second guide members with the plurality of lever clamps 74. The guide supports 49 must be attached to the slide plate 76. The first guide member 70 meshes with the second guide member 72 to help maintain parallelism between thereof. The slide plate 76 acts as a back support for the first and second guide members. A slot 78 is formed in the slide plate 76 for each lever clamp 74. The slot 78 allows the distance between the first and second members to be adjusted to accommodate studs of varying widths. The lever clamps 74 are tightened to maintain an inside dimension for a particular stud width.

[0055] FIG. 15 shows a second embodiment of a stress skin panel stud inserter 3 utilizing a stud heater element 60 which is attached to a bottom of the stud 100 instead of the heater element 24. A heater controller 62 is used to supply current to the stud heater element 60 through a pair of wires 64. The metal stud 100 is forced into the stress skin panel 102 utilizing the stud guide 23 and the insertion tool 50. The stud heater element 60 melts an outline in the inner layer of the stress skin panel 102 for insertion of the metal stud 100. The metal stud 100 is forced through the stress skin panel 102 until the stud heater element 60 is fully exposed. The stud heater element 60 is removed from the metal stud 100 and the pair of wires 64 may be pulled out of the stress skin panel 102 or let inside thereof. With reference to FIG. 16, the stud heater element 60 may be attached to the end of the stud 100 with spring clips 66.

[0056] FIGS. 17-19 show a third embodiment of a stress skin panel stud inserter 4. The third embodiment of the stress skin panel stud inserter includes a hot air shroud 80 and an alignment jig 82. The alignment jig 82 is attached to a top of the stress skin panel 102. The alignment jig 82 includes two guide plates 84 and an attachment yoke 86. The attachment yoke 86 includes two side plates 88 which are spaced apart to receive the width of the stress skin panel 102. The two guide plates 84 extend upward from a top of the attachment yoke 86. An inside perimeter of the two guide plates 84 are sized to receive a wood stud 104. The alignment jig 82 ensures that the wood stud 104 with the hot air shroud 80 attached thereto is inserted substantially perpendicular to a top of the stress skin panel 102.

[0057] The hot air shroud 80 includes a square tube with at least two attachment projections 90 which extend upward. The distance between a pair of attachment projections 90 are sized to firmly fit over the end of the wood stud 104. At least one air inlet 92 is attached to a side of the hot air shroud 80. An air hose 94 is attached to an open end of each air inlet 92. Hot air from any suitable source is forced through the at least one air hose 94. The hot air travels through the at least one air inlet 92, a wall of the hot air shroud 80, and exits through an open bottom in the hot air shroud 80. The hot air melts an opening in the inner layer of the stress skin panel 102 as the wood stud 104 is pushed through the stress skin panel 102.

[0058] Other heating devices may be used to facilitate the insertion of a stud besides the first, second, or third embodiments of the stress skin panel stud inserters.

[0059] While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention.

Claims

1. A method for modifying a stress skin panel comprising the steps of:

(a) providing said stress skin panel having an inner layer sandwiched between two outer layers;

(b) inserting at least two substantially vertical studs into said inner layer; and

(c) forming an opening in said modified stress skin panel for the insertion of a single item between two of said at least two substantially vertical studs, at least one header stud being attached to two of said at least two substantially vertical studs.

2. The method for modifying a stress skin panel of claim 1, further comprising the steps of:

(d) providing a heating device which is attachable to a bottom of each said substantially vertical stud that facilitates insertion thereof into said inner layer of said stress skin panel.

3. The method for modifying a stress skin panel of claim 1, further comprising the steps of:

(d) heating said at least two vertical studs as thereof are being inserted into said inner layer of said stress skin panel.

4. The method for modifying a stress skin panel of claim 1, wherein:

at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.

5. The method for modified a stress skin panel of claim 1, wherein:

a support member being placed on top of said modified stress skin.

6. The method for modified a stress skin panel of claim 1, wherein:

a top of said inner layer being routed out to receive a support member, said support member being placed on top of said inner layer.

7. The method for modified a stress skin panel of claim 1, wherein:

each said substantially vertical stud being fabricated from wood.

8. The method for modified a stress skin panel of claim 1, wherein:

each said substantially vertical stud being fabricated from metal.

9. A method for modifying a stress skin panel comprising the steps of:

(a) providing said stress skin panel having an inner layer sandwiched between two outer layers;

(b) inserting at least two vertical studs into said inner layer; and

(c) forming an opening in said modified stress skin panel for the insertion of a single item between two of said at least two substantially vertical studs, a support member being placed on top of said modified stress skin panel.

10. The method for modifying a stress skin panel of claim 9, further comprising the steps of:

(d) providing a heating device which is attachable to a bottom of each said substantially vertical stud that facilitates insertion thereof into said inner layer of said stress skin panel.

11. The method for modifying a stress skin panel of claim 9, further comprising the steps of:

(d) heating said at least two vertical studs a s thereof are being inserted into said inner layer of said stress skin panel.

12. The method for modifying a stress skin panel of claim 9, wherein:

at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.

13. The method for modified a stress skin panel of claim 9, wherein:

a top of said inner layer being routed out to receive said support member, said support member being placed on top of said inner layer.

14. The method for modified a stress skin panel of claim 9, wherein:

each said substantially vertical stud being fabricated from wood.

15. The method for modified a stress skin panel of claim 9, wherein:

each said substantially vertical stud being fabricated from metal.

16. The method for modifying a stress skin panel of claim 9 wherein:

at least one header stud being attached to two of said at least two substantially vertical studs.

17. A method for modifying a stress skin panel comprising the steps of:

(a) providing said stress skin panel having an inner layer sandwiched between two outer layers;

(b) molding at least two substantially vertical studs into said inner layer;

(c) forming an opening in said modified stress skin panel for the insertion of a single item; and

(d) attaching at least one header stud to two of said at least two substantially vertical studs.

18. The method for modifying a stress skin panel of claim 17, wherein:

at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.

19. The method for modified a stress skin panel of claim 17, wherein:

a support member being placed on top of said modified stress skin.

20. The method for modified a stress skin panel of claim 17, wherein:

a top of said inner layer being routed out to receive a support member, said support member being placed on top of said inner layer.

21. The method for modified a stress skin panel of claim 17, wherein:

each said substantially vertical stud being fabricated from wood.

22. The method for modified a stress skin panel of claim 17, wherein:

each said substantially vertical stud being fabricated from metal.

23. A method for modifying a stress skin panel comprising the steps of:

(a) providing said stress skin panel having an inner layer sandwiched between two outer layers;

(b) molding at least two vertical studs into said inner layer;

(c) forming an opening in said modified stress skin panel for the insertion of a single item; and

(d) placing a support member on top of said modified stress skin panel.

24. The method for modifying a stress skin panel of claim 23, wherein:

at least one tab being formed on each end of a single said header stud, the single said header stud being joined to each said substantially vertical stud by driving screws through said at least one tab and each said substantially vertical stud.

25. The method for modified a stress skin panel of claim 23, wherein:

a top of said inner layer being routed out to receive a support member, said support member being placed on top of said inner layer.

26. The method for modified a stress skin panel of claim 23, wherein:

each said substantially vertical stud being fabricated from wood.

27. The method for modified a stress skin panel of claim 23, wherein:

each said substantially vertical stud being fabricated from metal.

28. The method for modifying a stress skin panel of claim 23 wherein:

at least one header stud being attached to two of said at least two substantially vertical studs.