U.S. patent application number 11/149786 was filed with the patent office on 2006-12-14 for track member for wall and soffit construction.
Invention is credited to Frederick J. Majusiak.
Application Number | 20060277841 11/149786 |
Document ID | / |
Family ID | 37522816 |
Filed Date | 2006-12-14 |
United States Patent
Application |
20060277841 |
Kind Code |
A1 |
Majusiak; Frederick J. |
December 14, 2006 |
Track member for wall and soffit construction
Abstract
An improved track member for use in stud and track wall
construction, particularly with metal structural members, that
comprises a generally U-shaped track member with a plurality of
measurement lines and/or measurement designations along the base or
flange portion of the track member to assist in the positioning of
the studs in the channel of the track member. In the preferred
embodiment, the track member is divisible by both sixteen and
twenty-four inches. If vertically disposed slots are utilized, they
are positioned evenly along the track member with or without
measurement lines or designations. The track member ends have an
improved mechanism, having notches and tabs for interlocking
engagement, for longitudinally connecting two adjacent track
members. A soffit track member comprises two attached track members
having their lateral axis in orthogonal relation. The soffit track
member can incorporate the measurement lines and/or designations
and the connecting mechanism.
Inventors: |
Majusiak; Frederick J.;
(Bakersfield, CA) |
Correspondence
Address: |
RICHARD A. RYAN;ATTORNEY AT LAW
8497 N. MILLBROOK AVENUE
SUITE 101
FRESNO
CA
93720
US
|
Family ID: |
37522816 |
Appl. No.: |
11/149786 |
Filed: |
June 9, 2005 |
Current U.S.
Class: |
52/105 ; 52/241;
52/481.1 |
Current CPC
Class: |
E04B 2/7457 20130101;
E04B 2/767 20130101; E04B 2/789 20130101; E04B 2/825 20130101 |
Class at
Publication: |
052/105 ;
052/241; 052/481.1 |
International
Class: |
E04B 1/00 20060101
E04B001/00; E04C 2/34 20060101 E04C002/34 |
Claims
1. A wall construction, comprising: a stud member having a lower
end and an upper end; and a track member having a generally
elongated, rectangular base and two longitudinally extending,
substantially parallel flanges perpendicularly disposed at the
sides of said base to form a generally U-shaped transverse
cross-section channel configured to receive either said lower end
or said upper end of said stud, said track member having a
longitudinal axis and a perpendicular lateral axis, said track
member having a preferred length to facilitate construction of said
wall construction.
2. The wall construction according to claim 1, wherein said
preferred length is evenly divisible by both sixteen inches and
twenty-four inches.
3. The wall construction according to claim 2, wherein said
preferred length is twelve feet.
4. The wall construction according to claim 1, wherein said track
member further comprises a plurality of measurement lines in spaced
apart relation substantially along the length of said track
member.
5. The wall construction according to claim 4, wherein said track
member further comprises a plurality of measurement
designations.
6. The wall construction according to claim 5, wherein at least one
of said measurement designations is utilized to designate the
position of said stud member in said channel.
7. The wall construction according to claim 1, wherein said flange
of said track member comprises a plurality of vertically disposed
slots, said vertically disposed slots positioned in substantially
uniform spaced apart relation along the length of said track
member.
8. The wall construction according to claim 7, wherein said
vertically disposed slots are spaced apart two inches.
9. The wall construction according to claim 7, wherein said flange
of said track member further comprises a plurality of measurement
lines positioned in conjunction with said vertically disposed
slots.
10. The wall construction according to claim 1, wherein said wall
construction comprises a first track member and a second track
member disposed in longitudinal relation, each of said first track
member and said second track member having a first end and a second
end, said first end and said second end of each of said first track
member and said second track member configured with a connecting
mechanism, said connecting mechanism configured for interlockingly
engagement of said first track member and said second track member
to substantially join said first track member and said second track
member.
11. The wall construction according to claim 10, wherein said
connecting mechanism comprises a center notch, a side notch, a
first tab member and a second tab member at said first end and said
second end of each of said first track member and said second track
member.
12. The wall construction according to claim 11, wherein said
center notch of said first track member is configured to be engaged
by said center notch of said second track member and said first tab
and said second tab of each of said first track member and said
second track member are configured for slidable engagement.
13. The wall construction according to claim 12, wherein said
center notch at said second end of said first track member is
configured to be engaged in said center notch at said first end of
said second track member, said first tab member of said second end
of said first track member is configured to be slidably disposed
relative to said second tab member of said first end of said second
track member and said second tab member of said second end of said
first track member is configured to be slidably disposed relative
to said first tab member of said first end of said second track
member.
14. The wall construction according to claim 12, wherein said first
tab member is upwardly offset and said second tab member is
downwardly offset.
15. The wall construction according to claim 1, wherein said wall
construction further comprises a soffit track member comprising two
of said track members, said flange of one of said track members
attached to said base of the other of said track members, said
lateral axis of each of said track members orthogonally disposed
relative to each other, wherein said channel of one of said track
members is generally vertically disposed and said channel of the
other of said track members is generally horizontally disposed.
16. The wall construction according to claim 15, wherein said
soffit track member further comprises a plurality of measurement
lines and/or a plurality of measurement designations.
17. The wall construction according to claim 15, wherein the ends
of said soffit track member are configured with a connecting
mechanism, said connecting mechanism comprising a center notch, a
side notch, a first tab member and a second tab member.
18. A wall construction, comprising: a stud member having a lower
end and an upper end; and a track member having a generally
elongated, rectangular base and two longitudinally extending,
substantially parallel flanges perpendicularly disposed at the
sides of said base to form a generally U-shaped transverse
cross-section channel configured to receive either said lower end
or said upper end of said stud, said track member having a
longitudinal axis and a perpendicular lateral axis, said track
member having a preferred length to facilitate construction of said
wall construction, said track member having a plurality of
measurement lines in spaced apart relation substantially along said
length of said track member, said track member having a first end
and a second end, each of said first end and said second end
configured with a connecting mechanism having one or more notches
and one or more tab members.
19. The wall construction according to claim 18, wherein said track
member further comprises a plurality of measurement
designations.
20. A wall construction, comprising: a stud member having a lower
end and an upper end; a track member having a generally elongated,
rectangular base and two longitudinally extending, substantially
parallel flanges perpendicularly disposed at the sides of said base
to form a generally U-shaped transverse cross-section channel
configured to receive either said lower end or said upper end of
said stud, said track member having a longitudinal axis and a
perpendicular lateral axis, said track member having a preferred
length to facilitate construction of said wall construction, said
track member having a plurality of measurement lines in spaced
apart relation substantially along said length of said track
member, said track member having a first end and a second end, each
of said first end and said second end configured with a connecting
mechanism having one or more notches and one or more tab members;
and a soffit track member comprising two of said track members,
said flange of one of said track members attached to said base of
the other of said track members, said lateral axis of each of said
two track members orthogonally disposed relative to each other,
wherein said channel of one of said two track members is generally
vertically disposed and said channel of the other of said two track
members is generally horizontally disposed.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] None.
BACKGROUND OF THE INVENTION
[0002] A. Field of the Invention
[0003] The field of the present invention relates generally to
structural framing members utilized in building construction. More
particularly, the present invention relates to stud and track
structural members specially configured for use as wall members in
metal frame construction. Even more particularly, the present
invention relates to improved track members that are configured to
reduce the amount of time and materials necessary for installation
of wall members in metal frame construction.
[0004] B. Background
[0005] The use of metal frame members in commercial and residential
building construction has increased somewhat in recent years due to
a number of factors that make the use of metal, particularly light
gauge steel and the like, a more preferred framing material than
wood. These factors include the somewhat diminishing supply of good
quality lumber, environmental concerns regarding the cutting of
trees for lumber, the recyclable nature of most metals, the general
resistance of metals to rotting, warping, splitting, cracking or
other common wood problems, the relatively consistent quality of
metal members, the lack of expansion/contraction due to moisture,
the invulnerability to termites, fungi or other organisms, the
general non-combustible nature of metals and the improved weight to
strength nature of most metals. Due to these factors, as well as
others, many building owners and designers are selecting metal as
the material for their supporting structural members, particularly
structural framing members such as the vertical wall studs and the
floor and ceiling plates which attach to the opposite ends of the
studs. In metal construction, the vertical metal wall studs are
typically configured as C-shaped members having a center web
portion with outwardly extending flanges at the opposing ends
thereof and a lip at the end of each flange that is directed
towards the lip on the opposite flange. Typically, the floor and
ceiling plates, which are more commonly referred to as tracks, are
configured as a generally U-shaped channel member that is disposed
in a generally horizontal manner and sized and configured to
receive an end of the vertical stud member inside the open channel.
The lower track member is generally configured to attach to the
floor of the structure and the upper track member, disposed at the
opposite end of the vertical stud, is configured to support and/or
attach to the ceiling or roof of the structure. Typically, the
studs and tracks are assembled into a wall frame, with the studs
usually spaced sixteen or twenty-four inches on center, that is
then covered with wall panels, such as drywall panels or other
types of wall board, to form the interior rooms of the
structure.
[0006] An important consideration with regard to all construction
activities is the speed by which the construction progresses. As is
well known, the amount of time it takes to construct a structure
substantially affects the overall cost of the structure. One
important factor in any construction project is the cost of labor
required to accomplish the desired objectives. Naturally, the
longer it takes to accomplish a task or group of tasks associated
with a component or feature of the structure, the more that
particular component or feature will impact the overall cost of the
structure. In addition, most construction projects have relatively
narrow timing goals, often with bonuses given for early completion
and meeting of cost objectives and, conversely, penalties imposed
for delays and cost overruns. As a result, building owners,
designers and contractors are always looking for materials,
equipment and processes that will reduce the amount of time and,
therefore, cost of building a particular structure. However, as is
also well known, it is very important or critical that the quality
and integrity of the finished structure is not sacrificed in order
to complete the project in a timely manner.
[0007] One known disadvantage of the use of the aforementioned
metal stud and tracking system for structural wall components is
the increased amount of time and labor associated with the
metal-to-metal positioning and fastening of the stud to track
connection and with joining the ends of two adjacent track members
together. In fact, the positioning/fastening problem is referred to
some in the industry as a key factor in why light-gauge steel
framing takes up to seventy-fiver percent longer to position and
fasten than wood studs and wood upper/lower plate members. Although
equipment such as automatic feed screw guns, pneumatic sheathing
pin nailers and portable plasma torches have resolved some of the
problems with metal studs and track wall systems, there are still a
number of known problems that limit the complete acceptance for the
use of metal structural members in commercial or residential
building construction. One such problem is determining where to
place the stud members in the channel of the track member. This is
presently accomplished by using a measuring tape or other
measurement tool to locate the spacing between adjacent stud
members, a process that can be both time consuming and subject to
errors in measurement.
[0008] Various improvement to frame structures and systems for
constructing walls from metal stud and track members are known in
the art. For instance, U.S. Pat. No. 4,805,364 to Smolik describes
a wall construction that utilizes track members configured with a
plurality of serrations which are bent inward toward the channel on
either side of the vertical stud member to confine an end of the
stud in the channel. U.S. Pat. No. 5,203,132, also to Smolik,
describes a wall assembly that utilizes a ratchet type of
engagement between the end of the stud and the channel of the track
member to secure the stud in the track member. U.S. Pat. No.
5,325,651 to Meyer, et al. describes a wall frame structure that
utilizes eyelets in the sides of the track flanges which are
configured to project through the flanges of the stud and then be
engaged by a clip that holds the stud in place. U.S. Pat. No.
5,797,233 to Hascall describes an improved track for wall
construction that utilizes a plurality of tabs placed at
predetermined intervals on the flanges of the track which are bent
inward around the lips of the stud members to mount the studs to
the track. U.S. Pat. No. 5,222,335 to Petrecca describes an
improved track for building wall construction that includes a
plurality of sets of spaced apart inward protrusions or dimples in
which the flanges of the studs are snapped into so as to
interconnect the studs and tracks. U.S. Pat. No. 5,274,973 to Liang
describes a stud spacer and mounting system that has a plurality of
upwardly extending flanges on the web or base portion of the track
configured to be secured to an end of the stud to secure the stud
in the channel formed by the track. Although the foregoing patents
describe various improved track members and mechanisms for
interconnecting the end of a stud in the channel of the track
member, they have not been generally widely accepted or have
experienced only limited acceptance by those in the industry.
[0009] An improved upper track member or header which is suitable
for use in areas subject to environmental stress loading from the
weight of upper floors, snow, earthquakes and similar types of
vertical loading is described in U.S. Pat. No. 5,127,760 to Brady
(the "'760 Patent"). The vertically slotted header of the '760
Patent, owned by Slip Track Systems, Inc., utilizes the slots to
secure the upper end of the vertical studs to the header in a
manner that allows the header to rise and fall in response to
environmental forces applied to the floor or roof. Once the stud is
perpendicularly placed in the header's channel, the stud and header
are joined by an attachment mechanism, such as a self-tapping
screw. Another seismic resistant wall structure is disclosed in
U.S. Pat. No. 5,127,203 to Paqueffe (the "'203 Patent"), owned by
Metal Lite, Inc. In the '203 Patent, the upper track member is
provided with a plurality of slotted openings in the flange
portions of the track to interconnect with the upper end of the
stud in a manner that allows the upper track to move in response to
seismic or other vertical loading. Although the configuration of
the track members set forth in the '760 Patent and '203 Patent are
widely utilized, neither patent discloses beneficial placement of
the slotted openings for use in determining where to locate a stud
along the track.
[0010] One component of stud and track wall construction that
remains a particular problem is the joining of the ends of adjacent
track members along the floor and ceiling/roof of the structure. A
current method of joining two adjacent track members involves
placing a small U-shaped joining member that is sized and
configured to fit snugly into the channel of the track members over
the joint and slightly into both adjacent track members. The
joining member is then fixedly attached to the end area of both
track members by using appropriate attachment mechanisms, such as
screws, or by welding it in place. Another method of joining
adjacent track members involves cutting a small V-shaped groove
into the ends of both track members, sliding the track members
together at the groove and then connecting the two track members
together. Unfortunately, this latter method results in a double
thick wall in the flange, which is where the drywall or other
planar wall board members are attached. This typically creates an
undesirable, unattractive bulge in the wall board. In addition, the
double thick wall makes it more difficult for the installer as he
or she must screw through two pieces of metal to attach the track
members together.
[0011] Another component of stud and track wall construction that
remains a particular problem for the contractor and his or her
framing subcontractors or employees is the soffit. Many buildings,
particularly residential structures, have a projecting edge or eave
with a short vertical portion, referred to as the fascia, at the
outward end thereof. The area under the eave is typically covered
with plywood or other planar mater that is attached to horizontal
or nearly horizontal members of the support structure on the
underside of the eave. The covering is usually referred to as the
soffit. In stud and track wall construction, configuration of the
soffit requires installation of a section of the track in a
generally horizontal configuration (i.e., the channel facing in a
horizontal direction as opposed to the usual vertical disposition)
with a horizontally disposed stud and then attachment of a second
track member to the first track member and stud so as to provide
for the vertical portion of the soffit. This process is known to be
time consuming and labor intensive due to the fact that each stud
has to be screwed into twice and squared. Problems arise with
having to twist each stud into position. If any stud is not to the
correct length, the track has to be removed, the stud cut and then
the track has to be reinstalled at an additional cost to the
contractor or subcontractor.
[0012] A particular problem with each of the foregoing patents and
the presently available track apparatuses and systems is that they
have limited ability for varied placement of the stud in the track,
they do not beneficially locate the attachment devices for stud
placement, they do not adequately provide for soffit installation
and they fail to address the problems associated with connecting
the ends of two adjoining track members together. What is needed,
therefore, are structural members that reduce the amount of time
and labor necessary to position and install structural members for
use in wall and soffit construction. In particular, what is needed
is an improved track member that simplifies and speeds up the
layout and placement of metal studs in the open channel of the
track members, the connection of the ends of adjoining track
members and the construction of soffit and like structural
components used in the building. The improved track members will be
configured to reduce the amount of time necessary for installation
of the wall and soffit components and, therefore, reduce the cost
of such construction.
SUMMARY OF THE INVENTION
[0013] The improved track members for wall and soffit construction
of the present invention provides the benefits and solves the
problems identified above. That is to say, the present invention
discloses an improved track member for use in stud and track wall
construction that is configured to substantially reduce the amount
of time necessary for laying out the location of the studs in the
upper and lower track members. The improved track member of the
present invention provides additional installation flexibility for
the studs with regard to the location of windows, doors and other
wall items. The improved track member of the present invention
reduces the cost and time associated with joining the ends of two
adjacent track members by facilitating the interconnection of the
two abutting ends. In one embodiment of the track member of the
present invention, an improved soffit track member is provided to
reduce the time and cost of installing a soffit in a building using
stud and track wall construction. The track member of the present
invention allows for all layout to be done at the floor or
floor/ground level. The track layout will be predetermined, cut and
installed to match the floor track. In addition, the length of the
track with the connections allows for the layout of each track
member to maintain layout of any length of wall or soffit.
[0014] In one general aspect of the present invention, the improved
track members for wall and soffit construction of the present is
utilized in a wall construction having one or more stud members
engaged with one or more track members. The typical wall
construction comprises a plurality of stud members having a lower
end disposed in a lower track member and an upper end disposed in
an upper track member to form a wall section between the floor and
ceiling and suitable for attaching drywall or other wall board
material. The improved track member has a generally elongated,
rectangular base and with a pair of longitudinally extending,
substantially parallel flanges that are perpendicularly disposed at
the sides of the base to form a generally U-shaped transverse
cross-section channel. The channel is sized and configured to
receive either the lower end or the upper end of the stud. The
track member has a longitudinal axis and a perpendicular lateral
axis. In the improved embodiment, the track member has a preferred
length, such as twelve feet or other length that is divisible by
both sixteen and twenty-four inches to facilitate construction of
the wall construction, where studs are typically positioned on
sixteen or twenty-four inch centers. The improved track member also
has a plurality of measurement lines that are in spaced apart
relation substantially along the length of the track member in some
evenly spaced amount, such as two inches apart. The improved track
member also has a plurality of measurement designations that are
utilized to designate the position of the stud members in the
channel. In some uses, the upper track member will have a plurality
of vertically disposed slots to allow for loading on the wall
section. For the improved track member, these vertically disposed
slots are positioned in substantially uniform spaced apart relation
along the length of the track member, for instance at every two
inches. The measurement lines and/or measurement designations can
be placed in conjunction with the vertically disposed slots. The
improved track member also has a connecting mechanism that is
configured for interlockingly engagement of two longitudinally
adjacent track members so as to substantially join the two track
members. In the preferred embodiment, the connecting mechanism has
a center notch, side notch, first tab member and second tab member
at the first and second ends of each track member. With this
configuration, the center notches of the two track members engage
each other and the first tab and second tabs of the track members
are configured for slidable engagement with each other. To
facilitate the slidable engagement of the tabs, the first tab
member is upwardly offset and the second tab member is downwardly
offset. Two of the track members described above can be utilized as
a soffit track member, with the flange of one of the track members
attached to the base of the other track member. The lateral axis of
each of the track members are orthogonally disposed relative to
each other, such that the channel of one of the track members is
generally vertically disposed and the channel of the other of the
track members is generally horizontally disposed. The measurement
lines, measurement designations, preferred length and connecting
mechanism described above can also be utilized with the soffit
track member for improved use thereof.
[0015] Accordingly, the primary objective of the present invention
is to provide an improved track member for use in wall and soffit
construction that provides the advantages discussed above and that
overcomes the disadvantages and limitations which are associated
with presently available track members and stud/track wall and
soffit systems.
[0016] It is also an important objective of the present invention
to provide a track member for use in wall and soffit construction
which is sized to be more useful and which comprises a plurality of
pre-measured track markings that are configured to better
facilitate placement of the stud member in the upper and lower
track member.
[0017] It is also an important objective of the present invention
to provide a track member for use in wall and soffit construction
that beneficially places the vertically slotted openings along the
flange portion of the track to allow the installer to utilize the
openings to assist him or her with placement of the studs in the
channel portion of the track.
[0018] It is also an important objective of the present invention
to provide a track member for use in wall and soffit construction
that comprises an improved mechanism for joining the abutting ends
of adjacent track members which reduces the cost and time of such
construction.
[0019] It is also an important objective of the present invention
to provide a track member for use in wall and soffit construction
that comprises an interlocking mechanism for joining the abutting
ends of adjacent track members that provides a flatter surface on
which to install drywall or other planar members and which does not
result in a change in operative length for the track member.
[0020] It is also an important objective of the present invention
to provide a single piece soffit track member that comprises a
fixedly joined pair of alternating disposed track members that
reduces the cost and time associated with installing soffits in
stud and track construction.
[0021] The above and other objectives of the present invention will
be explained in greater detail by reference to the attached figures
and the description of the preferred embodiment which follows. As
set forth herein, the present invention resides in the novel
features of form, construction, mode of operation and combination
of processes presently described and understood by the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] In the drawings which illustrate the preferred embodiments
and the best modes presently contemplated for carrying out the
present invention:
[0023] FIG. 1 is a fragmentary side perspective view of a wall
constructed utilizing the improved track member of the present
invention with portions thereof removed for purposes of
illustration;
[0024] FIG. 2 is a top perspective view of a lower track member
configured according to the present invention with two stud members
connected thereto;
[0025] FIG. 3 is a top view of a lower track member configured
according to the present invention;
[0026] FIG. 4 is a side perspective view of a vertically slotted
upper track member configured according to the present
invention;
[0027] FIG. 5 is a top view of the ends of a pair of adjacent track
members shown spaced apart to illustrate a mechanism for
interconnecting the members together according to the present
invention;
[0028] FIG. 6 is a top view of the illustration of FIG. 5 showing
the two track members in interlocking cooperation;
[0029] FIG. 7 is an end view of the mechanism of FIGS. 5 and 6;
[0030] FIG. 8 is a side view of a soffit member configured
according to the principles of the present invention; and
[0031] FIG. 9 is a end perspective view of the soffit member of
FIG. 8 showing the notched end thereof for interconnecting adjacent
soffit members together.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] With reference to the figures where like elements have been
given like numerical designations to facilitate the reader's
understanding of the present invention, and particularly with
reference to the embodiment of the improved track member for wall
and soffit construction of the present invention illustrated in the
figures, various preferred embodiments of the present invention are
set forth below. The enclosed description and drawings are merely
illustrative of one or more preferred embodiments and represent at
least one of several different ways of configuring the present
invention. Although specific components, materials, configurations
and uses of the present invention are illustrated and set forth in
this disclosure, it should be understood that a number of
variations to the components and to the configuration of those
components described herein and in the accompanying figures can be
made without changing the scope and function of the invention set
forth herein. For purposes of this disclosure, references are
generally to use of the present invention with metal stud framing,
however, it is understood that the disclosure herein is likely
applicable to other types of framing systems.
[0033] A track member that is manufactured out of the components
and configured pursuant to the concepts and principles of the
present invention is shown generally as 10 in the figures. As shown
in FIG. 1, track member 10 is an elongated member that is utilized
in wall construction 12 that comprises a lower track member 14 and
an upper track member or header 16 that are spaced apart by a
plurality of stud members 18 so as to generally span the distance
between the floor 20 and ceiling or roof 22. The framework formed
by lower track member 14, upper track member 16 and stud members 18
is generally covered by wall construction material, such as drywall
panels or other wall board 24 on one or both sides of the framework
so as to form interior walls 26. As well known in the art, the
drywall panels 24 are attached to lower track member 14, upper
track member 16 and/or stud members 18 using drywall screws (not
shown) or other connecting mechanisms appropriate for the
particular drywall panels 24 and materials utilized for members 14,
16 and 18. As also known in the art, and best shown in FIGS. 2
through 4, track member 10 is formed in a generally U-shaped
transverse cross-section configuration, formed in an elongated
rectangular shape with a longitudinal axis 27 and lateral axis 29
(shown in FIG. 3), having a web or base 28 with a pair of
longitudinally extending, substantially parallel flanges 30 that
are generally perpendicularly disposed at the ends of base 28. In
the embodiment shown in FIG. 1, lower 14 and upper 16 track members
are configured the substantially the same, just disposed in
opposite facing directions. Stud member 18 also comprises a base or
web 32 with a pair of generally parallel, outwardly extending
flanges 34 that are generally perpendicularly disposed at the ends
of web 32. Unlike track member 10, however, stud member 18 is
typically configured with a generally C-shaped transverse
cross-section having a pair of inwardly facing lip members 35 to
better support stud members 18 in the channel 36 formed between the
pair of flanges 30 of track member 10. The width of web 32 of stud
member 18, including flanges 34, is typically sized to be
approximately the same as the width of channel 36 between flanges
30 of track member 10 such that the lower end 38 of stud member 18
fits within channel 36 of lower track member 14 (shown in FIG. 3)
and the upper end 40 of stud member 18 fits within channel 36 of
upper track member 16 (shown in FIG. 4). Typically, a self tapping
screw or like connecting mechanism, shown as 42, is used to secure
stud member 18 in the channel 36 of track members 10. Stud members
18 usually have one or more apertures 44 on web 32 for receiving
electrical and/or plumbing conduits.
[0034] In a preferred embodiment of the present invention, track
member 10, which can be utilized for both lower track member 14 and
upper track member 16, is improved to include one or more marking
devices, such as measurement lines 46 and measurement designations
48 thereon to assist in the fast and correct installation of track
members 14 and 16 and stud member 18. In one embodiment,
measurement lines 46 are placed on the base 28 and flanges 30 of
track members 10, as shown, at an interval of every two inches so
as to facilitate the placement of stud members 18 on the standard
sixteen or twenty-four inch centers. As those familiar with the
relative placement of stud members 18 to lower 14 and upper 16
track members are very aware, it can be somewhat difficult and time
consuming to ensure that stud member 18 is properly placed at the
desired location along the track members 10. With measurement lines
46, the installer can effectively utilize the track member 10
itself as the tape measure or other measuring device to match up
the positioning of stud member 18 on the lower 14 and upper 16
track members, thereby improving productivity with regard to
installation of wall construction 12. If desired, various different
configurations of measurement lines 46 can be utilized for periodic
(such as at every four or eight inches) or at specific positions
(such as at every sixteen and/or twenty-four inches) to further
assist the installer with regard to the placement of stud member 18
in channel 36 of track member 10. For instance, the measurement
lines 46 at these locations can be made wider, deeper, of different
color and/or different shape so that the user can quickly have an
idea where he or she is relative to the previously placed stud
member 18. In conjunction with or as an alternative to specially
configured measurement lines 46, track member 10 can include
measurement designations 48 placed at every measurement line 46 or
at various measurement lines 46 (i.e., periodic or specific) to
distinguish the measurement lines 46 from each other. In one
embodiment, shown in FIG. 2, measurement designations 48 are
numerical designations of the distance measured from a prior
reference point, which can be the end of track member 10 or some
other location on track member 10, such as the previous sixteen or
twenty-four inch marking. In an alternative embodiment, measurement
designations 48 can be symbols or any other type of distinguishing
mark that will assist the installer in matching up the position of
stud member 18 on lower 14 and upper 16 track members. Use of track
member 10 configured as described above will increase productivity
and, therefore, reduce cost of framing for wall construction 12.
With the use of measurement lines 46 and measurement designations
48, the framing installer will be able to more quickly and
accurately adjust the placement of stud members 18 on track members
14 and 16, particularly around areas in the interior walls 26 where
windows, doors and the like will be located.
[0035] In addition to the above, the preferred embodiment the
length of track member 10, shown as "L" in FIGS. 2 and 3, is
selected to be beneficial for the quick and easy layout of stud
members 18 relative to lower 14 and upper 16 track members. The
presently configured standard length of track members is ten feet.
While ten feet is easily divided into equal segments of twenty-four
inches, that length is not easily divided into equal segments of
sixteen inches. For the track member 10 of the present invention,
the preferred effective length L, the distance between first end 50
and second end 52, is twelve feet, which is divisible by both
sixteen and twenty-four. Alternatively, track member 10 can be made
into other lengths which are divisible by both sixteen and
twenty-four, such as eight feet or sixteen feet. When combined with
measurement lines 46, the preferred twelve foot length L of track
member 10 becomes much easier to utilize with regard to matching
the placement of stud member 18 at lower track member 14 and upper
track member 16. For additional improvement, measurement
designations 48 can also be utilized with track member 10 of length
L (preferably twelve feet). Although heretofore such lengths have
not been available, it is believed that they can be provided a
reasonable additional cost compared to existing ten foot lengths of
track members.
[0036] In another embodiment of the present invention, shown in
FIG. 4, the features described above are combined into a vertically
slotted upper track member 16 that can be used in wall construction
12 in configurations where vertical loading is a consideration
(i.e., earthquake prone areas). As described in the '760 Patent and
'203 Patent, upper track member 16 includes a plurality of
vertically disposed slots 54 in the flange 30 of track member 16
which are configured to receive connecting mechanism 42 to attach
upper track member 16 to stud member 18. The vertically slotted
upper track member 16 is improved over the track members disclosed
in the '760 Patent and '203 Patent by including measurement lines
46 thereon at the desired spacing intervals (i.e., every two
inches) along the length of flange 30 and/or base 28 (not shown).
In addition, also not shown, the improved vertically slotted upper
track member 16 can include measurement designations 48 to further
assist the framer with properly locating stud member 18 relative to
upper track member 16. In one embodiment, the vertically slotted
upper track member 16 does not utilize either measurement lines 46
or measurement designations 48, but instead strategically places
slots 54 at a predetermined spacing (shown as being at measurement
lines 46 in FIG. 4) to be useful as a measuring device. For
instance, slots 54 can be placed on flange 30 such that they are
two inches on center. In this manner, the user of upper track
member 16 can merely count over the number of slots 54 and multiply
that number by two to obtain the distance in inches. As such, the
slotted upper track member 16 is itself a measuring tool.
[0037] In the embodiment of the present invention shown in FIGS. 5
through 7, track member 10 is shown with an improved connecting
mechanism 56 for connecting two adjacent track members 10 together,
such as the second end 52 of first track member 10a and the first
end 50 of second track member 10b. As stated above, the present
mechanisms for connecting the ends 50 and 52 of two adjacent track
members generally results in an undesirable and unsightly bulge in
the drywall or other wall board 24 and/or requires too much time to
configure and then attach stud member 18 thereto. The improved
connecting mechanism 56 comprises one or more notches, such as
center notch 58 and side notch 60 and one or more outwardly
projecting members, such as first tab member 62 and second tab
member 64 at each end 50 and 52 of track members 10a and 10b, as
best shown in FIG. 5. As will be understood by those skilled in the
art, notches 58 and 60 and tab members 62 and 64 are cooperatively
configured for interlocking engagement (as best shown in FIG. 6) of
second end 52 of first track member 10a and first end 50 of second
track member 10b so as to provide a substantially continuous track
for use as lower track member 14 and/or upper track member 16.
Connecting mechanism 56 at each of first end 50 and second end 52
of adjacent track members 10a and 10b are cooperatively configured
such that center notch 58 of each end 50 and 52 slide against each
other and first tab member 62 slides over second tab member 64, as
shown in FIG. 6, to join first 10a and second 10b track members. To
accomplish this connection, first tab member 62 is disposed in a
slightly upward offset position relative to the plane through the
generally planar surface of base 28 and second tab member is
disposed in a slightly downward offset position relative to the
plane through base 28, as shown in FIG. 7. The amount of the offset
for first tab member 62 and second tab member 64 is preferably only
enough to allow first tab member 62 to pass over second tab member
64, such that the two members 62 and 64 are slidably disposed
relative to each other, and place these members in a generally
adjacent engagement. Although having both first 62 and second 64
tab member both be offset relative to base 28 is preferred, those
skilled in the art will recognize that the aforementioned slidable
engagement can be accomplished by having only one of the members 62
or 64 be offset relative to base 28 and the other be substantially
in the same plane as base 28. An advantage of both tab members 62
and 64 being offset is that less of hump or lump is created at the
junction of adjacent first 10a and second 10b track members. In the
preferred embodiment of connecting mechanism 56, side notches 60
are cut away portions of the side of base 28 and a portion of
flange 30 of track members 10a and 10b and are configured to join
the opposing uncut area of the adjoining track member 10a or 10b.
Use of side notches 60 as part of connecting mechanism 56
facilitates first tab member 62 sliding over second tab member 64
and provides additional structural support to the area of
connecting mechanism.
[0038] In the preferred embodiment, connecting mechanism 56 is
combined with the measurement features described above, namely
measurement lines 46, as shown in FIGS. 5 and 6, and measurement
designations 48. Also in the preferred embodiment connecting
mechanism 56 is utilized with track member 10 of length L
(preferably twelve feet). To maintain the desired length L when
connected with another adjacent track member (such as 10a and 10b),
it is preferred that the overall length of the track member 10 be
adjusted to allow for connecting mechanism 56 by providing an
overall length that is equal to the desired length L plus the
amount of outward extension, shown as E in FIG. 5, by first 62 and
second 64 tab members at both ends of track member 10. The overall
length for track members 10a and 10b is the desired length L plus
twice the length E of the outward projection of first 62 and second
64 tab members, or L+(2.times.E). For instance, in one exemplary
configuration, first tab member 62 and second tab member 64 can
each have a outward projection of one-half an inch, requiring an
overall length (in the preferred embodiment) of twelve feet and one
inch. Side notch 60 is cut back into first end 50 and second end 52
an amount equal to the total length of the tab members 62 and 64
for the track member 10a or 10b, for a total cut of twice E. In the
example configuration provided above, the length of side notch 60
would be one inch. Although it is preferred that the connecting
mechanism 56 be configured such that first 50 and second 52 ends
closely interconnect, those skilled in the art will recognize that
the notches and tabs to not have to be exactly the same (i.e., the
measurements can be approximate). In a preferred method of making
the track member 10 of the preferred embodiment having connecting
mechanism 56 described above, track member 10 is made with an
overall length of L+(2.times.E) and then center notch 58 is cut
into first 50 and second 52 ends at a depth desired for length of
tab members 62 and 64, represented by E, and then side notch 60 is
cut into first 50 and second 52 ends for a length of twice E
(2.times.E). In this configuration and with the tab members 62 and
64 offset as described above, first end 50 of second track member
10b will lockingly engage second end 52 of first track member 10a
to provide a substantially continuous section track for use in wall
construction 12.
[0039] In another preferred configuration of the present invention,
the principles set forth above are also incorporated into a soffit
track member, shown as 66 in FIGS. 8 and 9. As set forth above,
currently soffits are configured with a horizontally disposed track
member that is attached at the end of a horizontally disposed stud
or eave to which is then attached another track member that is
faced in a substantially vertical direction. This requires
installer to attach two separate track members at the end of the
same horizontally disposed stud or eave. In the preferred
embodiment, soffit track member 66 comprises two track members
configured as described above and designated as third track member
10c and fourth track member 10d, each having the base 28, flanges
30 and channel 36 discussed above. For soffit track member 66, the
bottom side of base 28 of fourth track member 10d is fixedly joined
to the outside of one of the flanges 30 of third track member 10c,
as best shown in FIG. 8, such that the lateral axis of third 10c
and fourth 10d track members are generally orthogonally disposed to
each other. This configuration can be accomplished by welding or
otherwise connecting flange 30 of third track member 10c to the
bottom side of base 28 of fourth track member 10d. As will be
recognized by those skilled in the art, various other connecting
mechanisms can be utilized to connect third track member 10c and
fourth track member 10d, such as appropriate adhesives and/or
connecting members, including rivets, screws, bolts and the like.
The connection of these third 10c and fourth 10d track members will
result in the channels 36 of third 10c and fourth 10d track members
being orthogonally disposed to face open in a vertical direction
and a horizontal direction to receive the generally vertical fascia
stud and the generally horizontal edge or eave stud, respectively.
The width of channels 36 in third track member 10c and fourth track
member 10d can be the same (i.e., each being three and five-eights
inch) or different (i.e. one being three and five-eights inch and
one being six inches). The actual sizes will depend on the stud
members used for the eave and fascia sections of the soffit. Use of
soffit track member 66 of the present invention will substantially
reduce the amount of time necessary to construct the soffit portion
of the building by reducing the amount of time necessary to attach
the various members forming the soffit.
[0040] As best shown in FIG. 9, soffit track member 66 can also
incorporate the measurement features, namely measurement lines 46
and measurement designations 48, the preferred length L and the
connecting mechanism 56 components described above. As with the
single channel 36 configuration of track members 10a and 10b, use
of the measurement features 46 and 48 with the double channel 36
configuration of soffit track member 66 will enable the installer
to essentially utilize soffit track member 66 as a measuring tool
when placing stud members 18 therein and attaching them thereto.
The use of the preferred length of L, preferably twelve feet, will
further facilitate installation of the soffit component. Use of
connecting mechanism 56 described, with the one or more notches,
such as center notch 58 and side notch 60, and tabs, such as first
tab member 62 and second tab member 64, above will reduce the
amount of time necessary to interconnect the ends of two adjacent
soffit track members 66.
[0041] In use, track member 10 having measurement lines 46 and/or
measurement designations 48 is laid out as the lower track member
14 and the lower end 38 of stud members 18 are placed in channel 36
at the appropriate marking places (typically at sixteen or
twenty-four inches on center). A second track member 10, configured
as upper track member 16, is positioned such that the upper end 40
of stud members 18 is placed in channel 36 thereof at the locations
that correspond to those of lower track member 14. Measurement
lines 46 and/or measurement designations 48 will facilitate
matching up the locations of stud members 18 in the channels 36 of
lower track member 14 and upper track member 16. If desired, upper
track member 16 can comprise the vertically disposed slots 54 of
the prior art patents described above. Preferably, the slots 54 are
evenly positioned along flange 30 and placed in conjunction with
any measurement lines 46 or measurement designations 48 to further
assist the installer in matching up the location of the lower 38
and upper 40 ends of the various stud members 18. Use of connecting
mechanism 56 will facilitate joining first 50 and second 52 ends of
longitudinally disposed adjacent track members, such as first track
member 10a and second track member 10b, as shown in FIG. 5.
Preferably, connecting mechanism 56 is configured to interlockingly
connect first 50 and second 52 ends of track members 10a and 10b to
provide a substantially continuous track member for use in wall
construction 12. In the preferred embodiment, the center notches 58
engage each other and the first tab member 62 is slidably disposed
with regard to second tab member 64 of the adjacent track member
10a and 10b. Side notches 60 are configured to facilitate first tab
member 62 sliding over second tab member 64. Preferably, the
overall length of track member 10 is adjusted to allow for the
lengths E of tab members 62 and 64 in order to obtain the desired
length L, which is typically twelve feet. Soffit track member 66 is
configured with a two connected track members, such as third 10c
and fourth 10d track members, which have their lateral axis being
orthogonally disposed relative to each other. Preferably, soffit
track member 66 incorporates the measurement and connecting
features to facilitate installation of the soffit component of the
building.
[0042] While there are shown and described herein certain specific
alternative forms of the invention, it will be readily apparent to
those skilled in the art that the invention is not so limited, but
is susceptible to various modifications and rearrangements in
design and materials without departing from the spirit and scope of
the invention. In particular, it should be noted that the present
invention is subject to modification with regard to the dimensional
relationships set forth herein and modifications in assembly,
materials, size, shape, and use. For instance, there are numerous
components described herein that can be replaced with equivalent
functioning components to accomplish the objectives of the present
invention.
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