U.S. patent application number 11/451185 was filed with the patent office on 2007-06-14 for sheet metal intersection studs.
Invention is credited to Lawrence W. Gorham, Matt F. Surowiecki, Tadeusz (Ted) Wrobel.
Application Number | 20070130856 11/451185 |
Document ID | / |
Family ID | 38123525 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070130856 |
Kind Code |
A1 |
Surowiecki; Matt F. ; et
al. |
June 14, 2007 |
Sheet metal intersection studs
Abstract
A corner stud (40) has a four-sided post portion (42) that sits
into a corner region of a framing wall. The post portion includes a
pair of flanges (92, 96) which form a right angle inside corner at
the inside corner of the framing wall. Edge portions of wallboard
panels (108, 110) connect to the flanges (92, 96). A post portion
112 of an intersection stud (110) fits within the tracks at a
location between the corners. Inside corners are formed by flanges
(148, 160) and (154, 166) against which edge portions (180, 182) of
wallboard panels (184, 186) and (188, 190) are connected. The edge
portions (180, 182, 188, 190) of the wallboard are connected to and
backed up by the flanges (148, 160, 154, 166).
Inventors: |
Surowiecki; Matt F.;
(Seattle, WA) ; Gorham; Lawrence W.; (Vancouver,
WA) ; Wrobel; Tadeusz (Ted); (Auburn, WA) |
Correspondence
Address: |
BARNARD INTELLECTUAL PROPERTY LAW, INC.
P.O. BOX 58888
SEATTLE
WA
98138-1888
US
|
Family ID: |
38123525 |
Appl. No.: |
11/451185 |
Filed: |
June 12, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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11296115 |
Dec 7, 2005 |
|
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11451185 |
Jun 12, 2006 |
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Current U.S.
Class: |
52/287.1 |
Current CPC
Class: |
E04B 2/7457 20130101;
E04B 2/789 20130101; E04C 2003/0421 20130101; E04C 2003/046
20130101; E04C 3/07 20130101; E04C 2003/0473 20130101; E04C
2003/0439 20130101; E04B 2002/725 20130101; E04C 2003/0465
20130101; E04C 2003/0478 20130101; E04C 2003/0413 20130101 |
Class at
Publication: |
052/287.1 |
International
Class: |
E04B 2/00 20060101
E04B002/00 |
Claims
1. An intersection stud for a framing wall, comprising: a post
portion having an upper end adapted to be fitable between the
flanges of an upper track and a lower portion adapted to be fitable
between the flanges of a lower track; and a pair of flanges on said
post portion forming an inside corner that is adapted to be
positioned to provide a backing for wallboard edges that meet at
the corner.
2. The intersection stud of claim 1, wherein the post portion of
the stud has four sides and four corners and the two flanges extend
perpendicular to each other from a common corner.
3. The intersection stud of claim 1, wherein the post portion of
the stud has three sides, a pair of co-planar flanges projecting
inwardly from two of the sides, and a pair of parallel second
flanges projecting perpendicularly from the first two flanges and
forming two inside corners for backing up edge portions of
wallboard members that meet at the corners.
4. A sheet metal corner stud, comprising: a first wall; a second
wall; a third wall; a fourth wall; said first wall having a first
edge and a second edge; said second wall having a first edge and a
second edge; said third wall having a first edge and a second edge;
said fourth wall having a first edge and a second edge; said second
edge of said first wall being connected to the first edge of the
second wall and forming a right angle corner with the second wall;
said second edge of the second wall being connected to the first
edge of the fourth wall and forming a right angle corner with the
third wall; said second edge of the third wall being connected to
and forming a right angle corner with the fourth wall; a first
flange having a first edge connected to the first edge of the first
wall and forming a right angle corner with the first wall; said
first flange extending away from the first wall in a direction
opposite from the direction that the second wall extends from the
first wall; a second flange having a first edge connected to the
second edge of the fourth wall and forming a right angle corner
with the fourth wall; said second flange extending from the fourth
wall in a direction opposite from the direction that the third wall
extends from the fourth wall; said first flange having an outer
surface; said second flange having an outer surface; and said outer
surface of said first flange extending substantially perpendicular
to the outer surface of the second flange.
5. The sheet metal corner stud of claim 4, wherein the first flange
has a second edge and said corner stud further includes a web
having a first edge connected to the second edge of the first
flange and forming a right angle corner with the first flange, and
having a second edge; and said corner stud also including a third
flange having a first edge connected to the second edge of the web,
and forming a right angle corner with said web and extending in
spaced parallelism with the first flange, from said web towards the
fourth wall of the stud.
6. The sheet metal corner stud of claim 4, wherein the second
flange has a second edge and said corner stud further includes a
web having a first edge connected to the second edge of the second
flange and forming a right angle with the second flange, and having
a second edge; and said corner stud also including a third flange
having a first edge connected to the second edge of the web, and
forming a right angle corner with said web and extending in spaced
parallelism with the first flange, from said web towards the first
wall of the stud.
7. The sheet metal corner stud of claim 5, wherein the second
flange has a second edge and said corner stud further includes a
web having a first edge connected to the second edge of the second
flange and forming a right angle with the second flange, and having
a second edge; and said corner stud also including a third flange
having a first edge connected to the second edge of the web, and
forming a right angle corner with said web and extending in space
parallelism with the first flange, from said web towards the first
wall of the stud.
8. A sheet metal framing assembly, comprising first and second
lower channels meeting at a corner, each said channel having a
bottom web including first and second edges and a pair of laterally
spaced apart connected to and extending upwardly from said edges,
said channels having a first pair of flanges coming together and
defining an inner corner and a second pair of flanges coming
together and forming an outer corner; a sheet metal corner stud at
the corner, comprising: a first wall; a second wall; a third wall;
a fourth wall; said first wall having a first edge and a second
edge; said second wall having a first edge and a second edge; said
third wall having a first edge and a second edge; said fourth wall
having a first edge and a second edge; said second edge of said
first wall being connected to the first edge of the second wall and
forming a right angle corner with the second wall; said second edge
of said second wall being connected to the first edge of the third
wall and forming a right angle corner with the third wall; said
second edge of said third wall being connected to the first edge of
the fourth wall and forming a right angle corner with the fourth
wall; a first flange having a first edge connected to the first
edge of the first wall and forming a right angle corner with the
first wall; said first flange extending away from the first wall
and in a direction opposite from the direction that the second wall
extends from the first wall; a second flange having a first edge
connected to the second edge of and forming a right angle corner
with the fourth wall; said second flange extending from the fourth
wall in a direction generally opposite from the direction that the
third wall extends from the fourth wall; said first flange having
an outer surface; said second flange having an outer surface; said
outer surface of said first flange extending substantially
perpendicular to the outer surface of the second flange; said sheet
metal corner stud including a lower end portion that sets down into
the corner region formed by the lower channel members; wherein the
second and third walls of the corner stud are inside bottom track
flanges that meet and form an outside corner; and wherein the first
and second flanges of the corner stud are contiguous bottom track
flanges that meet and form an inside corner.
9. A sheet metal intersection stud, comprising: a first wall having
a first edge and a second edge; a second wall having a first edge
and a second edge; a third wall having a first edge and a second
edge; said second edge of the first wall being connected to the
first edge of the second wall, said second wall extending
perpendicular from the first wall; said second edge of the second
wall being connected to the first edge of the third wall, said
third wall extending perpendicular from the second wall and in
spaced apart parallelism with the first wall; a first flange having
a first edge and a second edge, said first edge being connected to
the first edge of the first wall, said first flange extending
perpendicular from the first wall; a second flange having a first
edge and a second edge, said first edge being connected to the
second edge of the third wall, said second flange extending
perpendicular from the third wall towards and in co-planar
parallelism with the first flange; a third flange having a first
edge and a second edge, said first edge being connected to the
second edge of the first flange, said third flange extending
perpendicular from the first flange in a direction opposite the
direction that the first wall extends from the first flange; a
fourth flange having a first edge and a second edge, said first
edge being connected to the second edge of the second flange, said
fourth flange extending perpendicular from the second flange in a
direction opposite from the direction that the third side wall
extends from the second flange; said third flange and said fourth
flange extending in spaced apart parallelism with each other; said
intersection stud having a width dimension extending between the
outside surface of the second wall and the outside surfaces of the
first and second flanges which is substantially equal to the width
dimension between the outside surface of the third flange and the
outside surface of the fourth flange.
10. For use with a corner stud that fits into L-shaped corner
portions of upper and lower tracks, a corner comprising: an
L-shaped web having perpendicular first and second legs having
intersecting first and second inner edges and intersecting third
and fourth outer edges; first and second flanges extending from the
inner edges of the web perpendicular to the web and to each other;
third and fourth flanges extending from the third and fourth edges
of the web, in the same direction as the first and second flanges,
and extending perpendicular to the web and to each other; and said
first leg of the web and said first and third flanges forming one
end of the corner fitting and said second leg of the web and said
second and fourth flanges forming a second and fourth corner
fitting.
11. For use with an intersection stud that intersects upper and
lower tracks at a location between two corners, a T fitting
comprising: a T-shaped web having an elongated first portion and a
second stem portion intersecting the first portion between the ends
of the first portion, said web having first and second edges that
are perpendicular to each other, a third and fourth edges that are
perpendicular to each other and a fifth edge that is parallel to
the first and fourth edges and perpendicular to the second and
third edges; first and second flanges connected to the first and
second edges of the web and extending perpendicular to the web and
to each other; third and fourth flanges connected to the third and
fourth edges of the web and extending perpendicular to the web and
to each other; a fifth flange connected to the fifth edge of the
web and extending perpendicular to the web and the second and third
flanges and extending parallel with the first and fourth flanges;
said first and fifth flanges and the web forming a first end of the
member; said second and third flanges and the web region between
them forming a second end of the member; and said fourth and fifth
flanges and the web region between them forming a third end of the
member; whereby straight sections of track may be positioned in
line with the first and third ends of the member and a
perpendicular section of track may be positioned in line with the
second end of the member.
12. A sheet metal corner stud, comprising: a first wall; a second
wall; a third wall; a fourth wall; a fifth wall; said first wall
having a first edge and a second edge; said second wall having a
first edge and a second edge; said third wall having a first edge
and a second edge; said fourth wall having a first edge and a
second edge; said fifth wall having a first edge and a second edge;
said second edge is said first wall being connected to the first
edge of the second wall and forming a right angle corner with the
second wall; said second edge of the second wall being connected to
the first edge of the third wall and forming a right angle corner
with the third wall; said first edge of the first wall being
connected to the first edge of the fourth wall and forming a right
angle corner with the fourth wall; said second edge of the fourth
wall being connected to the first edge of the fifth wall and
forming a right angle corner with the fifth wall; a first flange
having a first edge connected to the second edge of the third wall
and forming a right angle corner with the third wall; a second
flange having a first edge connected to the second edge of the
fifth wall and forming a right angle corner with the fifth wall;
and said fourth and fifth walls forming an inside corner region at
which edge portions of perpendicular wallboard members are
received, each of which is backed up by one of said fourth and
fifth walls.
13. The sheet metal corner stud of claim 12, comprising a first lip
connected to the first flange and a second lip connected to the
second flange.
14. A sheet metal intersection stud, comprising: a first wall
having a first edge and a second edge; a second wall having a first
edge and a second edge; a third wall having a first edge and a
second edge; a fourth wall having a first edge and a second edge; a
fifth wall having a first edge and a second edge; a sixth wall
having a first edge and a second edge; a seventh wall having a
first edge and a second edge; an eighth wall having a first edge
and a second edge; a ninth wall having a first edge and a second
edge; said first edge of first wall being connected to the first
edge of the second wall, said second wall extending perpendicular
to the first wall; said first edge of the third wall having a first
edge connected to the second edge of the second wall, said third
wall extending perpendicular to the second wall and parallel with
the first wall; said second edge of the third wall being connected
to the first edge of the fourth wall, said fourth wall extending
perpendicular to the third wall; said second edge of the fourth
wall being connected to the first edge of the fifth wall, said
fifth wall extending perpendicular to the fourth wall; said fifth
wall having a second edge connected to the first edge of the sixth
wall, said sixth wall extending perpendicular to the fifth wall and
parallel with the fourth wall; said sixth wall having a second edge
connected to the first edge of the seventh wall, said seventh wall
extending perpendicular to the sixth wall and parallel to the first
wall, the third wall and the fifth wall; said seventh wall having a
second edge connected to the first edge of the eighth wall, said
eighth wall extending perpendicular to the seventh wall and
parallel with the second wall, the fourth wall and the sixth wall;
said third and fourth walls forming an inside corner where edge
portions of perpendicular wallboard panels meet; and said sixth
wall and said seventh wall forming an inside corner where edge
portions of perpendicular wallboard panels meet and are backed up
by said stud walls.
15. A sheet metal intersection stud, comprising a first wall having
a first edge and a second edge; a second wall having a first edge
and a second edge; a third wall having a first edge and a second
edge; a fourth wall having a first edge and a second edge; a fifth
wall having a first edge and a second edge; a sixth wall having a
first edge and a second edge; a seventh wall having a first edge
and a second edge; first edge of first wall being connected to the
first edge of the second wall, extending perpendicular to the first
wall; said second edge of the second wall being connected to the
first edge of the third wall, said third wall extending
perpendicular to the second wall; said second wall of the third
wall being connected to the first edge of the fourth wall, said
fourth wall extending perpendicular to the third wall; said second
edge of the fourth wall being connected at the first edge of the
fifth wall, said fifth wall extending perpendicular to the fourth
wall; said second edge of the fifth wall being connected to the
first edge of the sixth wall, said sixth wall extending
perpendicular to the fourth wall; said second and third walls
forming an inside corner where edge portions of perpendicular
wallboard panel meet; said fifth and sixth walls forming an inside
corner where edge portions of perpendicular wallboard panels meet;
and said third, fourth and fifth walls forming a channel portion
having opposite ends that fit into upper and lower tracks.
16. The sheet metal stud of claim 15, wherein the first edge of the
first wall connects to a flange that extends perpendicular to the
first wall, and the second edge of the sixth wall connects to a
second flange that extends perpendicular to the sixth wall, and
wherein the first and second flanges are parallel and extend
towards each other.
17. An elongated sheet metal stud, comprising: a first corner
portion including adjacent unitary walls set at an angle to each
other; a second corner portion including adjacent unitary walls set
at an angle to each other; and a body portion interconnecting the
first and second corner portions, said body portion and said first
and second corner portions being parts of a unitary structure;
wherein the first corner portion is adapted to provide a backing
for edge portions of wallboard panels that meet at the corner
formed by said first corner portion; and wherein the second corner
portion is adapted to provide a backing for edge portions of
wallboard panels that meet at the corner formed by said second
corner portion.
18. The stud of claim 17, wherein the first corner portion forms an
inside corner and said second corner portion forms an inside
corner.
19. The stud of claim 17, wherein the first corner portion forms an
inside corner and the second corner portion forms an outside
corner.
Description
RELATED APPLICATION
[0001] This application is a continuation-in-part application based
on Ser. No. 11/296,115, filed Dec. 7, 2005, and entitled Sheet
Metal Intersection Studs.
TECHNICAL FIELD
[0002] This invention relates to sheet metal framing walls. More
particularly, it relates to the provision of studs usable where two
walls intersect, for facilitating the connection together of the
two walls.
BACKGROUND OF THE INVENTION
[0003] Building walls intersect each other at corners and at
locations between the corners. U.S. Pat. No. 4,689,930, granted
Sep. 1, 1987, to Robert J. Menchetti, discloses a corner stud to
which two standard studs are connected. U.S. Pat. No. 3,363,377,
granted Jan. 16, 1968, to Melvin H. Beckman, and U.S. Pat. No.
4,283,892, granted Aug. 18, 1981, to Larry B. Brown disclose studs
constructed to be usable at an intersection of a first wall with a
second wall between its corners. FIG. 1 of the drawing herein shows
a prior art use of two standard studs where two walls intersect at
a corner. FIG. 3 of the drawing herein shows the use of two
standard prior art studs at an intersection of two walls between
the corners.
[0004] There is a need for intersection studs for use at the
corners and between the corners that facilitates construction of
the walls while reducing both material and labor. It is the primary
object of the present invention to fill this need.
BRIEF SUMMARY OF THE INVENTION
[0005] It is an object of the invention to provide an elongated
sheet metal stud that includes a first corner portion including
adjacent unitary walls set at an angle to each other, a second
corner portion including adjacent unitary walls set an angle to
each other, and a body portion interconnecting the first and second
corner portions. The body portion and the first and second corner
portions are parts of a unitary structure. The first corner portion
is adapted to provide a backing for edge portions or wallboard
panels that meet at the corner formed by said corner portion. The
second corner portion is adapted to provide a backing for edge
portions of wallboard panels that meet at the corner formed by said
second corner portion. In some embodiments, the first corner
portion forms an inside corner and the second corner portion forms
an inside corner. In other embodiments, the first corner portion
forms an inside corner and the second corner portion forms an
outside corner.
[0006] It is another object of the invention to provide a corner
stud that has a generally tubular post portion which fits into the
corner regions of the upper and lower tracks where they meet at the
corners and which includes flanges forming a right angle inside
corner to which edge portions of wallboard panels are secured.
[0007] It is also an object of the invention to provide an
intersection stud which fits into the upper and lower tracks
between the corners of a wall and which includes a pair of flanges
that project into the upper and lower tracks of an intersecting
wall, and to which edge portions of wallboard panels are
secured.
[0008] A sheet metal corner stud incorporating the invention
comprises a first wall, a second wall, a third wall and a fourth
wall. The first wall has a first edge and a second edge. The second
wall had a first edge and a second edge. The third wall has first
edge and a second edge. The fourth wall has a first edge and a
second edge. The second edge of the first wall is connected to the
first edge of the second wall. The second edge of the second wall
is connected to the first edge of the fourth wall. The second edge
of the third wall is connected to the first edge of the fourth
wall. A first flange is provided that has a first edge that is
connected to the first edge of the first wall. The first flange
extends from the first wall in a direction opposite from the
direction that the second wall extends from the first wall. A
second flange is provided that has a first edge that is connected
to the second edge of a fourth wall. The second flange extends from
the fourth wall in a direction opposite from the direction that the
third wall extends from the fourth wall. The first flange has an
outer surface and the second flange has an outer surface. The first
flange extends substantially perpendicular to the second
flange.
[0009] The between-the-corners intersection stud preferably
comprises a first wall having a first edge and a second edge, a
second wall having a first edge and a second edge, and a third wall
having a first edge and a second edge. The second edge of the first
wall is connected to the first edge of the second wall. The second
wall extends perpendicular from the first wall. The second edge of
the second wall is connected to the first edge of the third wall.
The third wall extends perpendicular from the second wall and in
spaced apart parallelism with the first wall. The stud includes a
first flange having a first edge and a second edge. The first edge
is connected to the first edge of the first wall. The first flange
extends perpendicular from the first wall. The stud includes a
second flange having a first edge and a second edge. The first edge
is connected to the second edge of the third wall. The second
flange extends perpendicular from the third wall towards and in
co-planar parallelism with the first flange. A third flange has a
first edge and a second edge. The first edge is connected to the
second edge of the first flange. The third flange extends
perpendicular from the first flange in a direction opposite the
direction that the first wall extends from the first flange. A
fourth flange has a first edge and a second edge. The first edge is
connected to the second edge of the second flange. The fourth
flange extends perpendicular from the second flange in a direction
opposite from the direction that the third sidewall extends from
the second flange. The third flange and the fourth flange extend in
spaced apart parallelism with each other. The intersection stud has
a width dimension extending between the outside surface of the
second wall and the outside surfaces of the first and second
flanges which is substantially equal to the width dimension between
the outside surface of the third flange and the outside surface of
the fourth flange.
[0010] Another object of the present invention is to provide an
intersection stud positionable at a corner where two walls meet
which has a first sided post portion that fits inside end portions
of upper and lower tracks, and flanges which project from the post
portion perpendicular to each other inside the upper and lower
tracks adjacent the corner post.
[0011] Another object of the invention is to provide an
intersection stud between the corners which has a post portion that
fits into upper and lower tracks at a location between corners and
includes a pair of flanges which project from the post into end
portions of upper and lower tracks that intersect the tracks in
which the post portion is situated.
[0012] Other objects, advantages and features of the invention will
become apparent from the description of the best mode set forth
below, from the drawings, from the claims and from the principals
that are embodied in the specific structures that are illustrated
and described.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] Like reference numerals are used to designate like parts
throughout the several views of drawing, and:
[0014] FIG. 1 is a cross sectional view taken at a corner formed
where two walls meet, showing a prior art arrangement of
conventional studs at such corner;
[0015] FIG. 2 is a cross sectional view of a corner stud embodying
the present invention;
[0016] FIG. 3 is a cross sectional view of a prior art intersection
construction between corners;
[0017] FIG. 4 is a cross sectional view of an intersection stud of
the present invention that is utilized at an intersection between
corners;
[0018] FIG. 5 is an exploded pictorial view of the corner stud
shown by FIG. 2, showing the lower portion of the stud within the
intersecting lower tracks and showing the intersecting upper tracks
spaced above the corner stud;
[0019] FIG. 6 is a fragmentary pictorial view of the
between-the-corner intersection stud shown by FIG. 4, showing its
lower portion within the intersecting tracks of the two walls which
intersect between corners;
[0020] FIG. 7 is an exploded pictorial view of two corner
components for the upper and lower tracks, performed for
installation at a corner between two perpendicular sections of the
track;
[0021] FIG. 8 is an exploded pictorial view of track components
usable at an intersection between the corners, such components
being adapted to be used with three straight sections of track that
meet the three ends of the components that is illustrated;
[0022] FIG. 9 shows the use of miter cuts at the ends of two
lengths of track for making a right angle at a corner where the
lengths of tracks meet;
[0023] FIG. 10 is a view like FIG. 5 of another embodiment of the
corner stud;
[0024] FIG. 11 is a view like FIGS. 5 and 10 of a further
embodiment of the corner stud;
[0025] FIG. 12 is a view like FIGS. 5, 10 and 11 of another
embodiment of the corner stud, such corner stud being adapted to
back up a door jam;
[0026] FIG. 13 is a view like FIG. 4 of a second embodiment of a
between-the-corners intersection stud;
[0027] FIG. 14 is a view like FIG. 13, showing the
between-the-corners intersection stud backing up a door jam;
[0028] FIG. 15 is a view like FIGS. 5, 10 and 11 but of a corner
stud adapted to be used at a corner where two walls intersect at an
angle larger than 90 degrees;
[0029] FIG. 16 is a view like FIGS. 6 and 13 showing an
intersection stud adapted to mate with an outwardly opening end
stud at the end of a framing wall into which the plug portion of
the between-the-corner stud projects;
[0030] FIG. 17 is a view like FIG. 1 showing a four-way
intersection and a prior art arrangement of conventional studs at
the intersection;
[0031] FIG. 18 is a view like FIG. 17, but showing a single stud
embodiment of the invention at the intersection; and
[0032] FIG. 19 is a view like FIG. 18, but showing a two-stud
embodiment of the invention at the intersection.
DETAILED DESCRIPTION OF THE ILLUSTRATED INVENTION
[0033] For background purposes, FIGS. I and 3 show prior art
assemblies where one wall intersects another wall. FIG. 1 shows an
intersection at a corner. FIG. 3 shows an intersection between
corners. Referring to FIG. 1, a first stud 10 is provided at the
end of a first wall 12. A second stud 10 is shown at the end of a
second wall 14. Stud 10 includes a flange 16. A wall board panel 18
is attached to the wall 12 in the manner shown. End portion 20 of
the panel 18 is connected to the stud flange 16. Then, the web 22
is positioned against wall board panel 18, in the manner
illustrated. Web 22 is suitably secure to the stud 10. Then, wall
board panel 24 is connected to stud flange 26, in the manner
illustrated.
[0034] Referring to FIG. 3, a first framing wall 28 is constructed
from upper and lower tracks and a plurality of studs 30, in
known-fashion. Then, a wallboard wall panel 32 is connected to one
side of the framing wall. Then, a stud 34 at one end of an
intersecting wall 36 is connected to stud flange 38. Wall 36
comprises upper and lower tracks and a plurality of studs
interconnecting the tracks.
[0035] In the prior art arrangements shown by FIGS. 1 and 3, the
metal framing members of the two walls are separated by wall board
12, 32.
[0036] Referring to FIGS. 2 and 5, the corner intersection stud 40,
exemplifying an aspect of the invention, comprises a four-sided
corner post 42 having upper and lower ends that fit within upper
and lower tracks 44, 46, between the webs 48, 50 and 52, 54, as
illustrated. The post portion 42 of corner stud 40 has a first wall
56 having a first edge 58 and a second edge 60. A second wall 62
has a first edge 64 and a second edge 66. A third wall 68 has a
first edge 70 and a second edge 72. A fourth wall 74 has a first
edge 76 and a second edge 78. The second edge of the wall 56 is
connected to the first edge of wall 62. The second edge 66 of wall
62 is connected to the first edge 70 of wall 68. The second edge 72
of wall 68 is connected to the first edge 76 of wall 74. As best
illustrated by FIG. 2, the post portion 42 of wall 40 is positioned
between the opposite flanges 80, 82 of lower track 84 for wall 86.
In a perpendicular direction, the post portion has a dimension
substantially equal to the distance between flanges 52, 54 of track
56. In the same direction, the post portion 42 fits between flanges
48, 50 of track 44. The width of wall 56 allows wall 56 to fit
between flanges 88, 90 of track 92.
[0037] Corner stud 40 includes a first flange 92 having a first
edge 94 connected to the first edge 58 of first wall 56. Flange 62
and wall 56 form a right angle corner with each other. A second
flange 96 has a first edge 98 connected to the second edge 78 of
fourth wall 42. Flange 96 and wall 74 together form a right angle
corner, as shown in FIG. 2. Flange 92 may be provided with an end
flange 100 and a return flange 102. In similar fashion, flange 98
may be provided with an end flange 104 and a return flange 106. End
flange 100 is perpendicular to flange 92 and is perpendicular to
return flange 102. End flange 104 is perpendicular to flange 96 and
is perpendicular to end flange 106. Flanges 92, 102 are parallel
and flanges 96, 106 are parallel.
[0038] As best shown by FIG. 5, the post portion 42 of corner stud
40 is positioned at the corner of the wall, with its lower end
portion within the intersecting tracks 46, 84. Flange 96 is
positioned inwardly adjacent flange 52. Flange 92 is positioned
inwardly adjacent flange 80. At the top of the stud wall 40, flange
96 is inwardly adjacent flange 48 and flange 92 is inwardly
adjacent flange 86. As shown by FIG. 2, wallboard panel 108 is
connected to flange 92 and wallboard panel 110 is connected to
flange 96. Accordingly, there is solid backing for the wallboard
panels 108, 110 at the corner where they meet.
[0039] The between-the-corner intersection stud 110 comprises a
post portion 112 that fits at its bottom into a lower track and at
its top into an upper track. FIG. 6 shows a lower track 114 having
a web 116 and a pair of flanges 118, 120 that project upwardly from
the opposite edges of the web 116. An intersecting track 122 has a
web 124 and a pair of flanges 126, 128 that project upwardly from
the side edges of the web 124. A portion of the flange 116 is cut
away at the end of the track 124. If FIG. 6 is inverted, it would
show intersecting upper tracks and the upper end portion of the
stud 110. The post portion 112 of stud 110 comprises a first wall
130 having a first edge 132 and a second edge 134. A second wall
136 has a first edge 138 and a second edge 140. A fourth wall 142
has a first edge 144 and second edge 146. The second edge 134 of
the first wall 130 is connected to the first edge 138 of the second
wall 136. The second edge 140 of the second wall 136 is connected
to the first edge 144 of the third wall 142. A first flange 148 has
a first edge 150 and a second edge 152. A second flange 154 has a
first edge 156 and a second edge 158. The first edge 150 of flange
148 is connected to the first edge 132 of wall 130. Flange 148
extends perpendicular to wall 130 and is in co-planar parallelism
with flange 154. The second edge 146 of wall 142 is connected to
the first edge 158 of flange 154. Flange 154 is perpendicular to
the third wall 132. A third flange 160 has a first edge 162 and a
second edge 164. Edge 162 of flange 160 is connected to edge 152 of
flange 148. A fourth flange 166 has a first edge 168 that is
connected to the second edge 156 of flange 154. Flange 166 includes
a second edge 168. Flanges 160, 166 are parallel to each other and
are perpendicular to the flanges 148, 154. End flanges 170, 172 may
be connected to the edges 164, 168 of the flanges 160, 166. Return
flanges 174, 176 may be connected to the end flanges 170, 172.
[0040] The outside dimension measured from the outer surfaces of
flanges 148, 154 and the outer surface of second wall 36 is
substantially equal to the inside dimension between the flanges
118, 120 of the track 114. The distance between the outside
surfaces of the flanges 160, 166 is substantially equal to the
distance between the inside surfaces of flanges 126, 128. The post
portion 112 of the stud 110 is wider than the distance between the
inside surfaces of the flanges 126, 128.
[0041] FIG. 4 is a sectional view in a mid portion of the stud 110.
It shows edge portions 180, 182 of wallboard panels 184, 186 being
outwardly adjacent the flanges 148, 154. Preferably the wallboard
is connected to the flanges 148, 154. Wall board edge portions 186,
188 are outwardly adjacent the flanges 160, 166. Preferably, these
wallboard edges 186, 188 are connected to the flanges 160, 166,
such as by use of screws. As shown by FIG. 4, the wallboard edges
180, 186 and 182, 188 are backed up where they meet by the flanges
148, 160 and 154, 166.
[0042] Both forms of intersection studs 40, 110 can be easily and
quickly installed in the upper and lower tracks and then the
wallboard can be applied to the framing members.
[0043] FIG. 7 shows a pair of corner members 200, 200' usable at a
corner between two perpendicular tracks. Corner member 200, 200'
comprises an
[0044] L-shaped web 202 and flanges 204, 206, 208, 210. All four
flanges 204, 206, 208, 210 extend perpendicular to the web 202.
Flanges 204 and 208 meet and form a right angle corner and flanges
206 and 210 meet and form a right angle corner. The corner member
200 is positioned at a corner between two perpendicular straight
sections of track that are leading into the corner. The ends of the
straight sections of the track may butt up against the ends of the
corner member 200. Corner member 200' is a mirror image of corner
member 200.
[0045] FIG. 8 shows members 212, 212' that are each usable at an
intersection of two walls between corners. It comprises a T-shaped
web 214 and flanges 216, 218, 220, 222, 224. All of the flanges
216, 218, 220, 222, 224 extend perpendicular to the T-shaped web
214. Flanges 216, 218 extend perpendicular to each other and meet
at a right angle corner. Flanges 222, 224 extend perpendicular to
each other and meet at a right angle corner. Flange 220 extends
along the outside of a straight section of the member 212 which is
positioned between the ends of two collinear straight sections of
track. The stem portion of the member 212 includes the flanges 218,
224 adapted to be collinear with an intersecting perpendicular
section of track. Member 212' is a mirror image of member 212.
[0046] In place of using the corner member shown by FIG. 7, the
ends of the two straight section of track may be cut at a 45 degree
angle as shown by FIG. 9. Then the cut ends 230, 230', 232, 232' of
the two sections 234, 234', 236, 236' can be brought together so
that the two sections will meet and form a right angle.
[0047] The construction shown by FIGS. 7-9 can all be used with
both the top tracks and the bottom tracks.
[0048] FIG. 10 shows upper and lower corner members 240, 242 which
may be like corner members 200, 200' shown in FIG. 7. FIG. 10 also
shows a modified embodiment of the corner stud which is designated
244. It has upper and lower ends that fit within upper and lower
track sections 240, 242. Stud 234 has a first wall 246 having a
first edge 248 and a second edge 250. A second wall 252 has a first
edge 254 and a second edge 256. A third wall 258 has a first edge
260 and a second edge 262. A fourth wall 264 has a first edge 266
and a second edge 268. First edge 248 of wall 246 is connected to
first edge 266 of wall 264. Second edge 250 of wall 246 is
connected to first edge 254 of second wall 252. The second edge 256
of wall 252 is connected to first edge 260 of wall 258. Second edge
262 of wall 258 is connected to a flange 270. Second edge 268 of
wall 264 is connected to a second flange 272. The second edge of
flange 262 is connected to a third flange 274. Upper track 242 has
a first pair of opposite flanges 276, 278 and a second pair of
opposite flanges 280, 282. The lower track section 242 has a first
pair of opposite flanges 284, 286 and a second pair of opposite
flanges 288, 290. When the upper and lower ends of the stud 246 are
in the track sections 240, 242, wall 264 is inwardly adjacent
flanges 280, 288 and wall 256 is inwardly adjacent flanges 276,
284. Wall 252 is inwardly adjacent flanges 282, 290. Flange 272 is
inwardly adjacent the flanges 278, 286.
[0049] The wallboard members are not shown in FIG. 10. However, as
shown in FIG. 2, one wallboard member will rest against flanges
280, 288 and wall 264. The second wallboard member rests against
flanges 278, 286 and against the wall 272. Accordingly, at the
inside corner, the intersecting wallboard members are each backed
up by a sheet metal wall 264, 272.
[0050] The flanges 270, 272 may be in co-planar parallelism. They
extend perpendicular to walls 258 and 272, providing them with
stiffness.
[0051] The embodiment of FIG. 11 is similar to the embodiment of
FIG. 10. The only difference is that wall 258' is narrower. Also,
flanges 274' and 270' have perpendicular lips 292, 294.
[0052] The corner structure shown by FIG. 12 is like the corner
structure shown by FIG. 11 but shows shortened flanges 288', 290',
the outer ends of which are substantially flush with the outer
surface of wall 246. A door jam stile 300 is provided outwardly
adjacent wall 246.
[0053] FIG. 13 should be compared to FIG. 6. A lower track 114 is
illustrated. It has a bottom 116 and a pair of side flanges 118,
120. A second lower track 122 may intersect track 114 in the manner
shown in FIG. 6. Or the two tracks may be joined together to form a
member such as disclosed in FIG. 8. The upper track may be like
track 114 or it may be constructed together with the intersecting
track as shown in FIG. 8. In this embodiment, the stud 310
comprises a first wall 312, a second wall 314, a third wall 316, a
fourth wall 318, a fifth wall 320, a sixth wall 322, a seventh wall
324, an eighth wall 326 and a ninth wall 328. Wall 312 is provided
with a flange 330. In like fashion, wall 328 is provided with a
flange 332. The flanges 330, 332 are spaced apart and are in
co-planar parallelism with each other and with the walls 314, 318,
322, 326. Wall 314 is interconnected between and perpendicular to
walls 312, 316. In similar fashion, wall 326 extends between and is
perpendicular to the walls 324, 328. Walls 318, 322 are spaced
apart and are perpendicular to walls 316, 324 and wall 320. The
upper and lower ends of the stud 310 extend into the upper and
lower tracks. The wall 318, 322 are inwardly adjacent the flanges
on the track in which member 318, 320, 322 is placed. The
relationship is like the relationship shown in FIG. 6 with respect
to the member 160, 166, 170, 172, 174, 176. The upper and lower
ends of the stud 310 also fit into the tracks 116 between the
flanges 118, 120. This arrangement is shown by FIG. 6.
[0054] The relationship of the wallboard members to the stud 310
are as shown in FIG. 4. Wallboard panels 184, 186 that extend
lengthwise of tracks 114 are outwardly adjacent the walls 316, 324.
The perpendicular wallboard panels 188, 190 are outwardly adjacent
the stud walls 318, 322. Accordingly, the edge portions of the
wallboard panels 184, 186 and 188, 190 are backed up by the walls
316, 324 and 318, 322 of the stud 310.
[0055] FIG. 14 shows an assembly that is like the assembly of FIG.
13 except that a door jam stile 300 is positioned outwardly
adjacent stud wall 320. Thus, in this embodiment, stud wall 320
forms one side boundary of a door opening in the wall that extends
perpendicular to the wall that includes tracks 114.
[0056] FIG. 15 shows a corner stud 350 for a diagonal corner. This
stud 350 includes a first wall 352 having a first edge 354 and a
second edge 356. It includes a second wall 356 having a first edge
360 and a second edge 362. It also includes a third wall 364 having
a first edge 366 and a second edge 368. It further has a fourth
wall 370 having a first edge 372 and a second edge 374. It further
has a fifth wall 376 having a first edge 378 and a second edge 380.
Walls 352, 376 are spaced apart and are parallel to each other.
Walls 358, 370 are spaced apart and are parallel to each other.
Wall 364 is perpendicular to walls 358, 370. The first edge 354 of
wall 352 is connected to a first edge 380 of a first flange 382.
Flange 382 includes a second edge 384 that is connected to a flange
386. Flange 386 extends perpendicular to flange 282 and includes a
lip 388. Edge 380 of wall 376 is connected to a flange 390. Flange
390 is perpendicular to wall 376 and is co-planar parallelism with
flange 382. Flange 390 is connected to a flange 392 and flange 392
is connected to a lip 394. Flange 392 is perpendicular to flange
390 and is parallel to flange 386 and walls 352 and 376. Lip 394 is
perpendicular to flange 392 and is in co-planar parallelism with
lip 388. Both lips 388, 392 are in spaced parallelism with flanges
282, 390.
[0057] Corner stud 350 is basically like corner stud 349 shown by
FIG. 10 except that in FIG. 10 the two portions of the stud 244 are
perpendicular to each other and the stud 244 fits into tracks 240,
242 that are perpendicular to each other. In the embodiment of FIG.
15, the two portions of stud 350 are separated by an angle x that
is larger than 90 degrees and smaller than 180 degrees. The corner
is formed where true tracks meet at a line 400. Two straight track
sections may be cut at an angle to form ends that meet at line 400.
Or, a track fitting 420 may be used at the corner. Track fitting
420 has opposite ends 422, 424 which are adapted to a butt against
the ends of straight sections of track (not shown) that extend away
and opposite directions from corner fitting 420. The intersecting
tracks or track fitting 420, whichever is used, includes flanges
426, 428, 430, 432 which extend perpendicular from a bottom web
434. The upper and lower ends of the stud 420 fit into the corner
region of the upper and lower tracks. Wall 376 is closely adjacent
flanges 426. Wall 370 is closely adjacent flanges 432. Wall 352 is
closely adjacent flanges 428. Wall 358 is closely adjacent flanges
432. In this embodiment, the edges of the wallboard panels are
preferably beveled and the wallboard panels meet each other at the
corners. Specifically, one pair of wallboard members are positioned
against walls 352, 358 are secured to them by sheet metal screws.
Another pair of wall members are against walls 376, 370 and are
secured to them by sheet metal screws.
[0058] FIG. 16 is a view like FIG. 4 with one modification. The
walls 160', 166' are spaced closer together so that the flanges
500, 502 of a channel member 504 can be positioned outwardly
adjacent the walls 160', 166' and the wallboard members 188, 190
will be positioned outwardly adjacent the flanges 500, 502. Channel
504 is a vertical member at the end of a framing wall that includes
upper and lower tracks and horizontally spaced apart studs. Sheet
metal screws are used to secure the flanges 500, 502 to the walls
160', 166'.
[0059] FIG. 17 shows a four-way intersection of framing walls 550,
552, 554, 556 in which four conventional studs 558, 560, 562, 564
are used at the intersection. This is prior art. FIGS. 18 and 19
show intersection studs of the present invention that constitute a
significant improvement over the prior art arrangement shown by
FIG. 17.
[0060] FIG. 18 shows four bottom tracks meeting at the
intersection. The bottom track for wall 550 includes a web 556 and
a pair of flanges 568, 570. The bottom track for framing wall 554
includes a web 572 and a pair of flanges 574, 576. The bottom track
for framing wall 554 includes a web 578 and a pair of flanges 580,
582. The bottom track for framing wall 556 includes a web 584 and a
pair of flanges 586, 588. The intersection stud 590 has the cross
sectional configuration that is shown in FIG. 18. It has four
parts, each extending perpendicular to the parts on both sides of
it. Part 1 comprises a first wall 592 and a first flange 594 that
extends perpendicular to wall 592, towards the center of the track
for framing wall 554. Part 1 also has a second wall 596 and a
second flange 598. Flange 596 is spaced from and parallel with wall
592. Flange 598 is spaced from and in co-planar parallelism with
flange 594. Stud wall 592 is inwardly adjacent the flanges 580 of
the bottom track in which the first part is situated. Wall 596 is
inwardly adjacent flange 582 of the same bottom track. Wall 592
makes a right angle or perpendicular corner with wall 600. Wall 600
makes a right angle or perpendicular corner with wall 502. Wall 502
makes a right angle or perpendicular corner with wall 604. Walls
600, 602, 604 form a second part of the stud 590 that fits in the
upper and lower tracks of framing wall 556.
[0061] Stud wall 602 makes a right angle or perpendicular
connection to stud wall 606. Stud wall 606 makes a right angle or
perpendicular connection to stud wall 608. Stud wall 608 makes a
right angle or perpendicular connection to stud wall 610. Walls
606, 610 are spaced apart and parallel to each other and
perpendicular to wall 608. Walls 606, 608, 610 form the third part
of the stud 590, the upper and lower ends of which are in the upper
and lower tracks for framing wall 550.
[0062] Stud wall 610 makes a right angle or perpendicular corner
with stud wall 612. Stud wall 612 makes a right angle or
perpendicular corner with stud wall 614. Stud wall 614 makes a
right angle or perpendicular corner with stud wall 616. Stud wall
612, 616 are spaced apart and parallel to each other and
perpendicular to wall 614. Stud walls 612, 614, 616 form the fourth
part of the stud 590. At its upper and lower ends, this four part
sets into the upper and lower tracks for framing wall 552.
[0063] As illustrated in FIG. 18, edge portions of wallboard walls
620, 622, 624, 626, 628, 630, 632, 634. The intersecting edge
portions of wallboard panels 620, 624 are screwed to the stud walls
604, 606 by the use of screws which are commonly used for securing
wallboard to sheet metal framework. The edge portions of
intersecting wallboard panels 622, 626 are in like fashion
connected to the stud walls 612, 610 by the use of sheet metal
screws. The edge portions of intersecting wallboard panels 630, 632
are secured to stud walls 616, 596 by the use sheet metal screws.
The edge portions of intersecting wallboard panels 628, 632 are
secured to stud walls 600, 592 by sheet metal screws. As can be
seen, at the four inside corners formed at the intersection of the
framing walls 550, 554 and 552, 556 are backed up by sheet metal
walls which are connected together at the corners and to the rest
of the stud 590 between the corners.
[0064] FIG. 19 shows the use of two identical studs 590' at a
four-way intersection. One of the studs 590' can be used by itself
at a T-intersection. For example, imagine that the upper and lower
tracks each form a T as illustrated in FIG. 8. Let it also be
assumed that there is no stud wall 554 and the track flanges 588,
574 constitute a single flange like flange 220 in FIG. 8. In this
embodiment, the upper stud 590' can be used at the intersection
between framing wall 550 and the perpendicular framing wall which
would exist in place of the framing walls 552, 556. Stud 590
includes a wall 602' which connects at a right angle or
perpendicular to stud wall 604. Also stud wall 612 makes a right
angle or perpendicular connection to stud wall 614'. Flanges 603,
605 make right angle or perpendicular connections to the stud walls
602', 614'. Sheet metal screws extend through the track flanges
568, 570 and 576, 586 and screw into the stud walls 610, 608 and
screw into the stud walls 604, 612. Sheet metal screws extend
through the track flanges 568, 570 and screw into the stud walls
610, 608. Then, when the wallboard panels 620, 622, 624, 626 are
applied, sheet metal screws are used to screw the edge portions of
panels 620, 622 to stud walls 608, 612 and to connect the edge
portions of panels 624, 626 to stud walls 608, 610. This
construction provides a solid sheet metal wall backing at the
inside corners formed where the wallboard panels 620, 624 meet and
the wallboard panels 622, 626 meet.
[0065] In the embodiment of FIGS. 4 and 6, walls 148, 160 form a
first corner portion. Walls 154, 166 form a second corner portion.
Walls 130, 136, 142 (FIG. 6) form a body portion that interconnects
the first and second corner portions. In the embodiment of FIGS.
10, 11 and 12, walls 264, 272 form a first corner portion which is
an inside corner. Walls 252, 258 form a second corner that is an
outside corner. Walls 264, 246, 252 form a body portion that
interconnects the two corner portions. In the embodiment of FIGS.
13 and 14, walls 316, 318 form a first corner portion. Walls 322,
324 form a second corner portion. Walls 318, 320, 322 form a body
portion that interconnects the two corner portions. In these
embodiments, both corner portions are inside corners. In the
embodiment of FIG. 15, walls 370, 378 form a first corner portion.
Walls 352, 358 form a second corner portion. Walls 358, 362, 370
form a body portion that interconnects the two corner portions. In
this embodiment, the first corner portion forms an outside corner
and the second corner portion forms an inside corner.
[0066] In the embodiment of FIG. 18, walls 592, 600 form a first
wall portion. Walls 604, 606 form a second wall portion. Walls 600,
602, 604 form a body portion that interconnects the first and
second corner portions. This embodiment includes two more corner
portions 610, 612 and 596, 616. It includes a body portion 606,
608, 610 connecting corner portions 604, 606 and 610, 603. It also
includes a body portion 612, 616, 6 - - - connecting corner portion
610, 612 and corner portion 596, 616.
[0067] The illustrated embodiments are only examples of the present
invention and, therefore, are non-limitive. It is to be understood
that many changes in the particular structure, materials and
features of the invention may be made without departing from the
spirit and scope of the invention. Therefore, it is my intention
that my patent rights not be limited by the particular embodiments
that are illustrated and described herein, but rather are to be
determined by the following claims, interpreted according to
accepted doctrines of patent claim interpretation, including use of
the doctrine of equivalents and reversal of parts.
* * * * *