U.S. patent application number 10/630389 was filed with the patent office on 2005-02-17 for metal stud wall packaging system.
Invention is credited to DeFranscesco, Frank, Palumbo, Joseph.
Application Number | 20050034408 10/630389 |
Document ID | / |
Family ID | 34135533 |
Filed Date | 2005-02-17 |
United States Patent
Application |
20050034408 |
Kind Code |
A1 |
Palumbo, Joseph ; et
al. |
February 17, 2005 |
Metal stud wall packaging system
Abstract
A stud wall framing system having a number of studs, and a floor
and a ceiling track that are marked at spaced intervals to indicate
the location of the studs when erected.
Inventors: |
Palumbo, Joseph; (Bolton,
CA) ; DeFranscesco, Frank; (Palgrave, CA) |
Correspondence
Address: |
Thomas N. Young
YOUNG & BASILE P.C.
Suite 624
3001 West Big Beaver Road
Troy
MI
48084
US
|
Family ID: |
34135533 |
Appl. No.: |
10/630389 |
Filed: |
July 30, 2003 |
Current U.S.
Class: |
52/633 |
Current CPC
Class: |
E04B 2/7457 20130101;
B65D 2571/00111 20130101; B65D 2571/00925 20130101; E04B 2002/7488
20130101 |
Class at
Publication: |
052/633 |
International
Class: |
E04B 001/00 |
Claims
What is claimed is:
1. A method of distributing framing materials for a wall section of
predetermined dimensions, the method including the steps of: (a)
providing a plurality of elongate framing studs each having a
length that is at least sufficient for a height of the wall
section; (b) providing a plurality of elongate ceiling and floor
tracks, each track defining a channel for receiving and securing
ends of the framing studs to form the wall section; (c) selecting,
from the plurality of framing studs, at least a number of elongate
framing studs required for framing the wall section using a
predetermined stud spacing; (d) selecting, from the plurality of
ceiling and floor tracks, at least an amount of ceiling and floor
track required for the wall section; and (e) securing the selected
framing studs and floor and ceiling tracks together unassembled in
a transportable bundle.
2. The method of claim 1 including, prior to step (e), providing a
plurality of visible markings at spaced intervals along a length of
at least one of the ceiling and floor tracks for indicating desired
locations for the framing studs.
3. The method of claim 2 wherein the visible markings are selected
from the group consisting of adhesive stickers, permanent dye,
paint, and embossed dimples.
4. The method of claim 2 including providing and using a marking
table for applying the visible markings to the track, that table
having means for securing the track in a stationary location, and
marking means movable relative to the track for applying the
visible markings at the spaced intervals.
5. The method of claim 1 including providing a plurality of
stiffening channels for stiffening the wall section, and selecting
from the plurality of stiffening channels at least an amount of
stiffening channel required for the wall section, and step (e)
includes securing the selected amount of stiffening channel
together with the framing studs and floor and ceiling tracks in the
transportable bundle.
6. The method of claim 1 including providing a plurality of framing
stud fasteners for securing the framing studs to the ceiling and
floor tracks, and selecting from the plurality of framing stud
fasteners at least a number of framing stud fasteners required to
complete the wall section, and step (e) includes securing the
selected number of framing stud fasteners in the transportable
bundle.
7. The method of claim 6 including providing a plurality of wall
board fasteners for securing wall board to the wall section, and
selecting from the plurality of wall board fasteners at least a
number of wall board fasteners required to complete the wall
section according to predetermined criteria, and step (e) includes
securing the selected number of wall board fasteners in the
transportable bundle.
8. The method of claim 7 including providing a plurality of track
fasteners for securing the floor and ceiling tracks to support
surfaces, and selecting from the plurality of track fasteners at
least a number of track fasteners required to complete the wall
section according to predetermined criteria, and step (e) includes
securing the selected number of track fasteners in the
transportable bundle.
9. The method of claim 1 including providing a plurality of
instruction sheets providing instructions for assembly of the wall
section and step (e) includes securing one of the instruction
sheets to the transportable bundle.
10. The method of claim 1 including, after step (e): (f) providing
the bundle to a commercial outlet for sale to an end user.
11. The method of claim 1 wherein steps (a) and (b) include
acquiring the framing studs and ceiling and floor tracks from a
third party supplier, and including, after step (e): (f) providing
the bundle to the third party supplier.
12. The method of claim 11, including after step (f): (g) providing
the bundle to a commercial outlet for sale to an end user.
13. A stud wall framing kit of unassembled components for framing a
predetermined wall section, including: a predetermined number of
elongate framing studs, the predetermined number being at least the
number of framing studs required for framing the predetermined wall
section using a predetermined stud spacing; and an elongate ceiling
track and an elongate floor track each having channels for
receiving ends of the framing studs, at least one of the ceiling
track and floor track having a plurality of visible markings along
a length thereof at spaced intervals for indicating desired
locations for the framing studs.
14. The framing kit of claim 13 wherein the framing studs and
ceiling and floor tracks are arranged substantially parallel to
each other and secured together in a bundle.
15. The framing kit of claim 14 wherein the framing kit includes an
instruction sheet providing instructions for assembly of the
predetermined wall section.
16. The framing kit of claim 14 wherein the instruction sheet is
provided on a wrapper that surrounds a portion of the bundle.
17. The framing kit of claim 14 wherein the visible markings are
provided on both the ceiling and floor tracks.
18. The framing kit of claim 14 wherein a container containing a
predetermined number of framing fasteners for securing the framing
studs to the ceiling and floor tracks is secured to the bundle, the
predetermined number of framing fasteners being at least the number
required for completing the predetermined wall section.
19. The framing kit of claim 18 wherein a predetermined number of
wall board fasteners are included with the bundle, the
predetermined number of wall board fasteners being at least the
number required for securing wall board to the predetermined wall
section according to predetermined criteria.
20. The framing kit of claim 13 wherein the tracks and studs are
steel.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to wall structures, and more
particularly to stud wall frames.
BACKGROUND OF THE INVENTION
[0002] Due to their ease of assembly and wide availability in
various standard sizes, metal wall frames are quickly becoming the
product of choice for most "do-it-yourself" handymen and wall
installers. Metal wall frames provide an ideal and economical
alternative to the wood wall frames, as they are more robust,
lightweight, non-combustible, and easy to install. In addition,
each metal wall frame is consistently manufactured and does not
deviate from the standard manufacturing guidelines, which in turn
translates into lesser imperfections and straighter finished
walls.
[0003] An example of commonly available metal stud framing system
is the CORUS STEEL FRAMING SYSTEM.TM. available from Corus Metal
Profiles of Brampton, Ontario, Canada. Metal stud framing systems
that are sold by manufacturers such as CORUS are typically
distributed in packs of identical components to wholesalers and
distributors. For example, the wall components will be distributed
in 10 pieces of identical floor/ceiling tracks, 10 pieces of studs,
etc.
[0004] Such distribution system could be inconvenient for the
"do-it-yourself" handymen and the home supply or hardware stores
that offer these products, as they frequently require less than all
the parts found in a pack. This often results in the packs being
broken open in the stores, and sometimes results in damaged and
unusable products.
[0005] Another difficulty associated with existing wall frames is
the time spent at the supplier store by the customer to find
various components such as the floor and ceiling tracks, wood or
metal studs, and various fasteners required for erecting the wall
frame, as well as determining the number of these required
components. An average handyman must therefore determine exactly
what and how many components to retrieve and purchase for the wall
framing project. This may require a novice wall installer an
excessive amount of time spent to locate the components, and
sometimes numerous trips to the hardware store in order to gather
all of the necessary components for erecting the wall frame. The
customer may end up with excess and unwanted components. Moreover,
although these items are generally found in hardware and home
supply stores, they may be stocked or shelved in different areas of
the store which makes the task of retrieving the required
components even more difficult.
[0006] Yet another difficulty associated with existing wall
structures is that it is often required for a wall installer to
constantly measure and mark the distance between the studs in order
to ensure that the wall frame is properly supported. This is not
only cumbersome, but also quite time consuming as it requires the
wall installer to place down his or her wall framing tools, measure
and mark the location of the next stud on the floor or ceiling
track, pick up his or her wall framing tools and proceed with
securing the subsequent stud. The task of marking the location of
the studs is more tedious in extreme weather conditions.
[0007] Accordingly, there is a need for a wall framing system
whereby the components are sized and conveniently regrouped for the
customer. There is also a need for a wall framing system in which
the need for the customer to make measurements is minimized.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides a wall framing packaging
system for metal stud walls which addresses the shortcomings
associated with known systems.
[0009] In one aspect, the present invention provides a
multi-component modular system which includes all the essential
components for use in construction of metal stud wall frames of a
predetermined size, namely, a floor track, a ceiling track, a
plurality of studs and fasteners. The floor and/or ceiling tracks
may be marked to indicate the location of the studs for fast
construction of the wall frame.
[0010] In another aspect, the present invention provides a method
of distributing framing materials for a wall section of
predetermined dimensions, including the steps of:
[0011] (a) providing a plurality of elongate framing studs each
having a length that is at least sufficient for a height of the
wall section;
[0012] (b) providing a plurality of elongate ceiling and floor
tracks, each track defining a channel for receiving and securing
ends of the framing studs to form the wall section;
[0013] (c) selecting, from the plurality of framing studs, at least
a number of elongate framing studs required for framing the wall
section using a predetermined stud spacing;
[0014] (d) selecting, from the plurality of ceiling and floor
tracks, at least an amount of ceiling and floor track required for
the wall section; and
[0015] (e) securing the selected framing studs and floor and
ceiling tracks together unassembled in a transportable bundle.
[0016] In yet another aspect, the present invention provides a stud
wall framing kit of unassembled components for framing a
predetermined wall section. The kit includes a predetermined number
of elongate framing studs, the predetermined number being at least
the number of framing studs required for framing the predetermined
wall section using a predetermined stud spacing. The kit further
includes an elongate ceiling track and an elongate floor track each
having channels for receiving ends of the framing studs, at least
one of the ceiling track and floor track having a plurality of
visible markings along a length thereof at spaced intervals for
indicating desired locations for the framing studs.
[0017] Other aspects and features of the present invention will
become apparent to those ordinarily skilled in the art upon review
of the following description of specific embodiments of the
invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Reference will now be made to the accompanying drawings,
which show, by way of example, a representative embodiment of the
present invention, and in which:
[0019] FIG. 1 is a perspective view of a typical wall which has
been partially framed using the metal stud wall packaging system of
the present invention;
[0020] FIG. 2 is a perspective view of a metal stud wall packaging
system according to the present invention;
[0021] FIG. 3 is a flow chart showing the sequence of steps
involved in assembling a metal stud wall packaging kit according to
the present invention;
[0022] FIG. 4 is a side elevational view of a table for marking the
tracks to indicate the locations of the studs according to the
present invention; and
[0023] FIG. 5 is a top elevational view of a table incorporating a
press for marking the tracks to indicate the locations of the studs
according to the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0024] The present invention is now described with reference to
accompanying drawings, wherein like constituent elements are
designated by like reference numerals throughout the drawings.
[0025] Reference is now made to FIG. 1 which shows a perspective
view of a typical wall which has been framed using the metal stud
wall packaging system. As well known in the art, the metal stud
wall frame 10 includes a ceiling track 14, a floor track 16, and
spaced metal framing studs 11 vertically secured therebetween. The
studs 11 are generally C-shaped channeled members and come into
intimate contact with the sidewalls of typically U-shaped ceiling
track 14 and floor track 16. Fasteners 12 (shown on the ceiling
track 14 only) such as framing screws are used to secure the studs
11 to the ceiling track 14 or floor track 16. The sidewalls of
studs 11 may also define knurled flanges to securely hold screws
fastening a wall panel 15 to the stud wall frame 10.
[0026] As shown in FIG. 1, the studs 11 are transversely spaced at
spaced intervals 17 measured between the center of the studs 11.
The spaced intervals 17 are generally 16" or 24", however, their
actual length depends on the wall framing application. According to
a novel aspect of the present invention, for ease of installation,
at least one sidewall of the floor track 16 is marked uniformly at
spaced intervals 17 to indicate to the wall installer the
intermittent spacing between the studs 11. This in turn eliminates
the need to manually measure the location of each stud 11, thereby
allowing rapid construction in even inclement weather conditions
and reducing construction project time. The markings 19 indicating
the spaced intervals 17 between the studs 11 are made using
adhesive stickers, dye, painting, making dimples on either the
ceiling track 14 or the floor track 16, or other similar means for
marking sheet metal. Although the ceiling track 14 can also include
markings 19, preferably only the floor track 16 has the markings
19. However, even if both the ceiling track 14 and floor track 16
include the markings 19, they can still be perfectly aligned upon
leveling of one stud located on both indicators.
[0027] The studs 11 are preferably sized to dimensionally match
wood studs and are typically available in 1{fraction
(5/8)}".times.3{fraction (5/8)}", 1{fraction
(5/8)}".times.2{fraction (1/2)}" or 1{fraction
(5/8)}".times.1{fraction (5/8)}" thickness and width dimensions
corresponding to 2.times.4, 2.times.3 or 2.times.2 wood studs
respectively, depending on the application. Other
4".times.1{fraction (5/8)}", 6".times.1{fraction (5/8)}" or
8".times.1{fraction (5/8)}" can also be available corresponding to
2.times.4, 2.times.6, 2.times.8 wood studs. The ceiling track 14
and floor track 16, as well as the studs 11, are made of
corrosion-resistant, galvanized steel sheet or like materials. A
stiffening channel (not shown in FIG. 1) can be employed to improve
the structural rigidity of the metal stud wall frame 10. The
stiffening channel can pass through one of the rows of aligned
apertures 24 provided on the studs 11. The apertures 24 can also be
conveniently used for passage of electrical wiring, pipes, or other
structural members (not shown) through the studs 11.
[0028] The studs 11 may be implemented using regular metal wall
studs, however, other types of studs such as cripple studs, jack
studs, king studs or any other kinds may also be used.
[0029] According to preferred embodiments of the invention, all the
component parts required by an installer to install a predetermined
size of framing may be packaged together as a kit. Referring now to
FIG. 2, there is shown a metal stud wall packaging system indicated
generally by reference 30, which when assembled, would result in
the wall frame 10 of FIG. 1 according to the present invention. The
metal stud wall packaging system 30 is in a kit format and includes
a ceiling track 14, a floor track 16, and a plurality of metal
studs 11. In particular, the packaging system 30 includes the
amount of metal framing required to frame a wall section of a
predetermined size. For example, each system 30 could include one
10' ceiling track 14, one 10' floor track 16 and eight 8' metal
studs 11, for framing a wall section having an appropriate size of
8' high by 10' long, with 16" stud spacing 17. The metal stud wall
packaging system 30 preferably also includes framing screws 12 for
attaching the studs 11 to the tracks 14,16. Other types of
fasteners such as rivets may also be used to connect the studs 11
to the tracks 14,16.
[0030] The framing screws 12 may be put in a container such as a
bag 40 or other package which is secured by tape or adhering to one
of the metal framing components in the packaging system 10. The bag
40 will include at least the number of framing screws 12 required
to assemble the wall section. Other fasteners, for example at least
a screw 13 to fasten the ceiling track 14 to the ceiling joists, or
at least a screw 18 required to secure the floor track 16 in place,
may also be included in packaging system 30. In a similar fashion,
screws 20 for attaching the wall panel 15 to the stud 11 may also
be provided in the packaging system 30. Advantageously, the various
components of the metal stud wall packaging system 30 can be
packaged together by nylon straps 32, 34 or other means of
packaging such as cable ties, metal wraps, plastic bags or the
like.
[0031] The packaging system 30 may also include a stiffening
channel 36, and preferably also include an instruction sheet 38
which outlines the steps necessary for erecting the wall frame. The
instruction sheet 38 may also serve as a label for the metal stud
wall packaging system 40. For example, the instruction sheet 38 may
include marketing information in one portion of an outer side, and
the instructions in another portion or on the inner side.
[0032] In a preferred embodiment, the instruction sheet may contain
instructions advising the installer to take the following steps for
erecting the wall frame structure: For installation, the wall
installer must first mark the location for the ceiling track 14 and
floor track 16 on a floor and ceiling respectively. The installer
must then cut the ceiling track 14 and floor track 16 at the
appropriate length. The next step involves attaching the ceiling
track 14 to the ceiling joist using a fastener such as 1{fraction
(1/4)}" drywall screws at 2 ft. intervals. In a similar fashion,
the installer must also attach the floor track 16 to the floor
using a fastener such as 1{fraction (1/4)}" screws at every 2 ft.
interval for wood floors. For concrete floors, the floor track 16
is attached to the floor using concrete fasteners or nail drive
anchors located at 2 ft. intervals on the floor track 16. The
installer must then retrofit the studs at the spaced intervals 17.
This is achieved by first cutting the studs 11 approximately
{fraction (1/2)}" shorter than the distance L between the ceiling
track 14 and floor track 16. The studs 11 are positioned at the
spaced intervals 17 as indicated by markings 19, between the
ceiling track 14 and floor track 16 by twisting and friction
fitting. A close but not necessarily tight fit is desirable in
order to permit slight movement of the studs 11 for adjustment. A
level is used to level one stud 11. The studs 11 are then secured
onto the ceiling track 14 and floor track 16 by framing screws in
accordance with the indicator markings 19. The wall frame 10 can
then be subsequently covered with a wall panel 15 made of drywall,
wood, plastic or other similar paneling materials.
[0033] Referring now to FIG. 3, there is shown the sequence of
steps involved in assembling a metal stud wall packaging system 30
of FIG. 2 in a modular kit according to the present invention. A
first step of assembling the metal stud wall packaging system 30 of
the present invention involves the step of obtaining from one or
more wall frame component suppliers various fasteners, as well as
bundles of pre-packed studs 11, ceiling or floor tracks 14,16 or
stiffening channels 36 (Step S1). These various components are then
separated, sorted (if required) and regrouped in individual
quantities for kits (Step S2). For instance, a typical kit may
include ten studs 11, a ceiling track 14, a floor track 16, a
stiffening channel 36, and a bag 40 containing fastener means as
required for erecting the wall frame structure 10 as shown in FIG.
1. The fastener means may include 11/4" screws for securing the
ceiling and floor tracks 14, 16 to a ceiling and floor, as well as
{fraction (7/16)}" pan head framing screws to secure the studs 11
to the ceiling and floor tracks 14, 16.
[0034] The next step involves the marking of the ceiling track 14
and floor track 16 to indicate the locations of the spaced
intervals 17 by way of markings 19 (Step S3). The location of the
markings 19 corresponds to the designated positions of the studs 11
when erected. The various components of the kit are then packaged
together (Step S4) for distribution (Step S5). Accordingly, the
ceiling track 14, floor track 16, metal studs 11, stiffening
channel 36, and bag 40 are then packed together and wrapped using
nylon wrappers 32, 34. Preferably, the instruction sheet 38 wraps
around a portion of the entire kit.
[0035] The kits may be directly delivered to home hardware stores
or home supply retailers (Step S7), or in the alternative, sent
back to the wall frame supplier (Step S6) to be eventually
delivered and distributed to the home hardware stores or home
supply retailers (Step S7).
[0036] Reference is now made to FIGS. 4 and 5 wherein a table 50
for marking spaced intervals 17 on a ceiling track 14 or a floor
track 16 (as shown in FIG. 1) is illustrated. The table 50 includes
a tabletop 52 having a first recessed area 54 for supporting the
ceiling track 14 or the floor track 16 therein. The first recessed
area 54 includes rails 56 at transversely spaced locations along
the bottom wall 58 of the first recessed area 54 to allow the
ceiling or floor track 14, 16 to freely move along the length of
the tabletop 52. The tabletop also includes a second recessed area
64 wherein an indicator press 60 therein can move longitudinally
along the length of the tabletop 52 and parallel to the first
recessed area 54. The second recessed area 64 also comprises rails
66 to allow longitudinal movement of the indicator press 60 along
the length of the tabletop 52. The indicator press 60 is secured to
the tabletop 50 by movable securing means 70 such as a vise clamp,
brace, clip or the like, and includes a position indicator 72. The
position indicator 72 comes in registry with the reference ruler 68
to show the exact position of the indicator press 60.
[0037] The tabletop 52 is also provided with a reference ruler 68
for accurate positioning of the press 60 when marking the ceiling
track 14 or the floor track 16. To mark the ceiling or floor tracks
14, 16, a track 16 is inserted in the first recessed area 54. Using
the reference ruler 68, the location of the first marking 19 (as
shown in FIG. 1) is determined, and the indicator press 60 is
secured to the tabletop 52. The indicator press 60 is then
mobilized in order to make the marking 19 on the rail 16. The
indicator press 60 is then positioned at the desired location of
the second marking 19, secured to the tabletop 52 and triggered in
order to mark the position of the second marking 19. The foregoing
steps are repeated until the track 16 has been marked.
[0038] It should be noted that in an alternative embodiment, the
indicator press 60 and the recessed area 52 may be located on top
on the tabletop 52.
[0039] The present invention may be embodied in other specific
forms without departing from the spirit or essential
characteristics thereof. Certain adaptations and modifications of
the invention will be obvious to those skilled in the art. For
instance, in some embodiments wood studs instead of metal studs
could be used. Therefore, the presently discussed embodiments are
considered to be illustrative and not restrictive, the scope of the
invention being indicated by the appended claims rather than the
foregoing description, and all changes which come within the
meaning and range of equivalency of the claims are therefore
intended to be embraced therein.
* * * * *