U.S. patent application number 11/850911 was filed with the patent office on 2008-03-06 for modular metal wall framing system.
Invention is credited to Zev Rosenberg.
Application Number | 20080053035 11/850911 |
Document ID | / |
Family ID | 39149611 |
Filed Date | 2008-03-06 |
United States Patent
Application |
20080053035 |
Kind Code |
A1 |
Rosenberg; Zev |
March 6, 2008 |
Modular Metal Wall Framing System
Abstract
A metal stud assembly includes a stud used in constructing a
metal wall frame between two channel members, and an extender
longitudinally slidably mounted within the stud. The stud includes
a central column portion, two side walls formed on opposite sides
of the central column portion, a retainer, at least one alignment
slot formed in the stud for receiving the retainer formed on one of
the channel members, and an indented portion formed in at least one
of the side walls for receiving a spacer bar. The alignment slot is
formed in at least one end portion of the central column portion.
The extender includes an upper portion having side walls parallel
to the side walls of the stud, and a lower portion having side
walls that join the upper portion side walls at a top end and which
taper at a bottom end to fit within the stud.
Inventors: |
Rosenberg; Zev; (Brooklyn,
NY) |
Correspondence
Address: |
IP STRATEGIES
12 1/2 WALL STREET, SUITE I
ASHEVILLE
NC
28801
US
|
Family ID: |
39149611 |
Appl. No.: |
11/850911 |
Filed: |
September 6, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60824652 |
Sep 6, 2006 |
|
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Current U.S.
Class: |
52/483.1 |
Current CPC
Class: |
E04B 2/7457 20130101;
E04B 2/762 20130101; E04B 2/767 20130101 |
Class at
Publication: |
52/726.3 ;
52/733.2 |
International
Class: |
E04C 3/32 20060101
E04C003/32 |
Claims
1. A metal stud assembly, comprising: a stud adapted to be used in
a metal wall frame between a pair of channel members; and an
extender longitudinally adapted to be slidably mounted within said
stud; wherein the stud includes a longitudinally-extending central
column portion having a pair of opposite end portions, a pair of
side walls formed on opposite sides of said central column portion,
a first retainer, and at least one elongated alignment slot formed
in said stud that is adapted to receive the first retainer formed
on one of said channel members, wherein said alignment slot is
formed in at least one of said end portions of said central column
portion; and wherein the extender includes an upper portion having
side walls that are substantially parallel to the side walls of the
stud, and a lower portion having side walls that join the upper
portion side walls at a top end and which taper to smaller
dimensions at a bottom end, such that the bottom end fits within
the stud.
2. The metal stud assembly of claim 1, wherein the stud further
includes an indented portion formed in at least one of said side
walls that is adapted to receive a spacer bar.
3. The metal stud assembly of claim 2, wherein the stud is a
plurality of studs, and further comprising at least one spacer bar
that is adapted to interconnect adjacent ones of said studs, and is
adapted to couple to respective said indented portions formed in
said studs.
4. The metal stud assembly of claim 1, wherein the lower portion
side walls of the extender taper linearly inward.
5. The metal stud assembly of claim 4, wherein said extender is
formed with a push hole that is adapted to push and slide said
extender within said stud.
6. The metal stud assembly of claim 4, wherein the retainer is a
first retainer, the metal stud assembly further comprising a second
retainer formed on said channel member, wherein said first retainer
has at least one slot formed therein that is adapted to receive the
second retainer.
7. A metal wall frame system, comprising: a series of metal studs
according to the metal stud assembly of claim 1; a metal channel
member having a floor portion and a pair of side walls upstanding
from said floor portion, wherein the series of metal studs is
adapted to interconnect to said channel member; a series of stops
formed at predetermined intervals along said channel member,
wherein each said stud is adapted to be butted against a respective
one of said stops; and a series of retainer members formed at
predetermined intervals along said channel member, wherein each
said stud is adapted to receive a respective one of said retainer
members.
8. The metal wall frame system of claim 7, further comprising a
series of spacer bars, wherein each said spacer bar is adapted to
interconnect adjacent ones of said studs.
9. The metal wall frame system of claim 7, wherein said stops are
formed as upstanding tabs struck from said channel member.
10. The metal wall frame system of claim 9, further comprising a
series of longitudinally spaced crimp portions crimped inwardly
from said side walls and adapted to lock said studs on said channel
member.
11. The metal wall frame system of claim 9, wherein each of said
studs comprises a socket and wherein each said spacer bar comprises
a series of projections adapted to respectively extend into each of
said sockets.
12. The metal wall frame system of claim 7, wherein the metal
channel member is a lower channel member, and further comprising an
upper channel member adapted to interconnect to the extender.
13. The metal wall frame system of claim 12, wherein the extender
includes an elongated slot, and the upper channel member includes a
retainer member that is adapted to engage the elongated slot to
interconnect the upper channel member to the extender.
14. A metal stud assembly, comprising: a stud adapted for
constructing a metal wall frame between a pair of channel members;
and an extender adapted to be longitudinally slidably mounted over
said stud; wherein the stud includes a longitudinally-extending
central column portion having a pair of opposite end portions, a
pair of side walls formed on opposite sides of said central column
portion, a first retainer, at least one elongated alignment slot
formed in said stud that is adapted to receive the first retainer
formed on one of said channel members, and an indented portion
formed in at least one of said side walls that is adapted to
receive a spacer bar, wherein said alignment slot is formed in at
least one of said end portions of said central column portion; and
wherein the extender includes an upper portion having side walls
that are substantially parallel to the side walls of the stud, and
a lower portion having side walls that are adapted to fit over the
stud.
15. The metal stud assembly of claim 14, wherein the lower portion
side walls of the extender taper linearly inward.
16. The metal stud assembly of claim 15, wherein said extender is
formed with a push hole that is adapted to push and slide said
extender within said stud.
17. The metal stud assembly of claim 15, wherein the retainer is a
first retainer, the metal stud assembly further comprising a second
retainer formed on said channel member, wherein said first retainer
has at least one slot formed therein that is adapted to receive the
second retainer.
18. A metal wall frame system, comprising: a series of metal studs
according to the metal stud assembly of claim 14; a metal channel
member having a floor portion and a pair of side walls upstanding
from said floor portion, wherein the series of metal studs is
adapted to be interconnected to said channel member; a series of
stops formed at predetermined intervals along said channel member,
wherein each said stud is adapted to be butted against a respective
one of said stops; and a series of retainer members formed at
predetermined intervals along said channel member, wherein each
said stud is adapted to receive a respective one of said retainer
members.
19. The metal wall frame system of claim 18, further comprising a
series of spacer bars, wherein each said spacer bar is adapted to
interconnect adjacent ones of said studs.
20. The metal wall frame system of claim 18, wherein said stops are
formed as upstanding tabs struck from said channel member.
21. The metal wall frame system of claim 20, further comprising a
series of longitudinally spaced crimp portions crimped inwardly
from said side walls and adapted to lock said studs on said channel
member.
22. The metal wall frame system of claim 20, wherein each of said
studs comprises a socket and wherein each said spacer bar comprises
a series of projections adapted to respectively extend into each of
said sockets.
23. The metal wall frame system of claim 18, wherein the metal
channel member is a lower channel member, and further comprising an
upper channel member adapted to be interconnected to the
extender.
24. The metal wall frame system of claim 23, wherein the extender
includes an elongated slot, and the upper channel member includes a
retainer member that is adapted to engage the elongated slot to
interconnect the upper channel member to the extender.
25. The metal stud assembly of claim 14, wherein the lower portion
of the extender is adapted to join the upper portion side walls at
a top end and tapers to larger dimensions at a bottom end, such
that the bottom end is adapted to fit over the stud.
26. The metal stud assembly of claim 14, further comprising a
tapered section, wherein the lower portion of the extender is
adapted to fit over the stud and join the upper portion side walls
at the tapered section, wherein the tapered section provides a
transition in dimensions between the upper portion and the lower
portion.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is related to, and claims the benefit under 35 USC
.sctn.119(e) of U.S. Provisional Application for Patent No.
60/824,652, which was filed on Sep. 6, 2006.
FIELD OF THE INVENTION
[0002] The present invention relates in general to metal wall
frames, and in particular to such frames which include channels and
studs having integrally formed connectors, locators, and
retainers.
BACKGROUND OF THE INVENTION
[0003] Framing systems have been developed using metal channels and
studs in place of more conventional wood frames. Such systems have
been adapted to construct various structures including residential
and commercial buildings, and particularly the partitions of such
buildings. Although these systems function adequately, they are
sometimes difficult to use and can take longer to assemble than can
conventional wood frames.
[0004] Because of these drawbacks, many builders have been
reluctant to adopt conventional metal framing systems. Moreover,
installers have experienced difficulty in correctly installing some
conventional metal framing systems. Installers also dislike the
snipping and cutting of the metal frame members required in such
systems, as the sharp metal edges can result in cut hands and torn
clothes. For these reasons, wood frames are still commonly used for
residential construction.
[0005] Although wood frames have been widely accepted by builders
and installers, wood frames are not fireproof and wood tends to
buckle, warp, split, shrink, and bend out of shape. Moreover, a
wood stud is heavier and more awkward to work with than a metal
stud, and is currently about twice the price of a metal stud.
[0006] Even with the drawbacks associated with wood frames, wood is
still the material of choice of most builders, particularly since
carpenters are familiar with wood frame construction and can nail
wood frames together with a nail gun faster than they can screw a
fastener into a metal frame with a screw gun.
[0007] The following comparison of existing standard wood and
conventional metal stud applications might be of value in fully
appreciating the advantages of the present invention.
[0008] Installation of a wall partition constructed of wooden
studs, after upper and lower plates have been installed, requires
the following steps for each stud: [0009] 1. Measure 16 inches on
center or 24 inches on center from the previously-installed stud
and appropriately mark the measured distance on the upper and lower
plate. [0010] 2. Measure the distance between upper and lower
plates. [0011] 3. Measure the length of the stud to be installed to
be equal to the measurement in the previous step and mark the stud
where it is to be cut. [0012] 4. Cut the stud. The cut must be cut
square, using a miter box, skill saw guide, etc. [0013] 5. Place
the stud into position between the plates. Adjust the position of
the stud by applying a level to assure that it is plumb, top to
bottom, side to side and front to back. [0014] 6. Nail the bottom
portion of the stud to the lower plate using two nails, either
manually or with a nailing gun. [0015] 7. Climb a ladder or
scaffold and nail the top portion of the stud to the upper plate,
again using two nails. [0016] 8. Usually framers will also install
horizontal wood members to serve as braces and spacers between the
studs. In such case there are the following additional steps:
[0017] A. Measure and mark a piece of stud lumber to fit between
the studs. [0018] B. Cut the piece of lumber square to form a
brace. [0019] C. Nail two nails to one end of the brace and into
one stud. [0020] D. Nail two nails into the other end of the brace
and into the other stud. [0021] 9. When electricians run electrical
cable through the studs, it is necessary for them to first bore a
hole through each stud individually, that is, through those studs
that will have cable going through them.
[0022] It is apparent that wood fame construction requires many
individual time-consuming steps. Moreover, problems associated with
wood studs include: [0023] 1. Wood is not fireproof. [0024] 2. Wood
can buckle, split, shrink, and bend out of shape. [0025] 3. A wood
stud is heavier and clumsier to work with than a corresponding
metal stud. [0026] 4. A wood stud is currently about double the
price of a metal stud, and with continuing depletion of natural
reserves, prices for lumber will likely continue to rise.
[0027] Installation of a partition constructed of conventional
metal studs, after the upper and lower channels have been
installed, requires the following steps for each stud: [0028] 1.
Measure 16 inches on center or 24 inches on center from a
previously-installed stud and appropriately mark the measured
distance on the upper and lower channels. [0029] 2. Measure the
distance between upper and lower channels. [0030] 3. Measure the
length of the stud to be installed to be equal to the measurement
in the previous step and mark the stud where it is to be cut.
[0031] 4. Cut the two side flanges of the stud with a pair of
snippers, and then bend the central backbone of the stud back and
forth until it breaks off. [0032] 5. Place the stud into position
between the channels where previously marked. Adjust the position
of the stud by applying a level to assure that it is plumb, top to
bottom and side to side. [0033] 6. Take two screws and individually
mount each screw onto a screw gun and screw the bottom portion of
the stud into the lower channel. [0034] 7. Climb a ladder, and
again, take two screws and individually mount each onto a screw gun
and screw the upper portion of the stud into the upper channel.
[0035] 8. Many installers also place a horizontal brace and spacing
member that runs through the apertures of several studs. In such
case, there are the following additional steps: [0036] A. Run the
bracing member through the apertures of several studs. [0037] B.
Cut little tabs to connect and fasten each stud to its section of
bracing member. [0038] C. Line up each stud to be properly aligned
and plumb with each corresponding section of bracing member. [0039]
D. Screw into a precut tab to connect the stud to the bracing
member.
[0040] It can be seen that conventional metal frame construction
requires many individual time-consuming steps. Moreover, problems
associated with conventional metal studs include: [0041] 1. There
does not seem to be any installation time savings of metal over
wood. In fact, one can argue that a wooden frame will go up faster
than a metal frame because of the extra time required with metal in
the process of cutting the stud to size and the fumbling required
with screws as opposed to automatic nailing with a nailing gun and
nail cartridges. [0042] 2. Since the conventional installation of
metal frames does not appear to provide real economies of time,
many framing contractors prefer to use wood, the "old-fashioned"
way. [0043] 3. When snipping and breaking off a piece of a metal
stud, hands and clothing tend to get cut very easily. [0044] 4.
Fumbling with the individual placement of a screw onto a screw gun
and screwing into a conventional metal stud is cumbersome,
annoying, and more time-consuming than simply applying a
cartridge-loaded nailing gun to wood. [0045] 5. Tunneling spacing
members through holes in a series of studs and then dealing with
the connection of the tabs between the studs and the spacing
members is cumbersome, awkward, and annoying.
[0046] However, metal stud installation does provide the following
benefits: [0047] 1. Metal is virtually fireproof. [0048] 2. Metal
is lightweight and easier to work with than wood. [0049] 3. Metal
studs remain intact and square and do not warp. [0050] 4. Metal
studs are currently about half the price of wooden studs. [0051] 5.
Metal studs have precut holes for electrical and other cable
running.
[0052] Accordingly, a need exists for a framing system that is easy
to understand and quick to assemble, that does not require
extensive cutting or snipping, and that is cost-effective as
compared to current alternative methods.
[0053] A need also exists for a framing system that is more
economical to use than wood frame systems and that is readily
acceptable to architects, builders, installers, and end users.
[0054] A need also exists for a framing system that provides
accurate spacing between studs and that is available with modular
interchangeable components.
[0055] A need also exists for a framing system that offers a
complete and simple solution rather than a partial solution to the
entire installation process.
BRIEF SUMMARY OF THE INVENTION
[0056] The present invention is a metal framing system for
supporting the walls, floors, and ceilings of various building
structures including residential and commercial buildings. The
invention is an apparatus that is useful, for example, in the
construction industry, and is also useful to end users who are
performing home construction projects.
[0057] This invention provides for much simpler and speedier
installation of wall/partition frames, resulting in greatly reduced
labor costs while at the same time maintaining quality control in
the integrity and accuracy of the installation.
[0058] The construction industry, whose workers are tradition- and
trade-oriented, has been very slow to adopt any innovative
methodologies or technologies. On the other hand, there is always a
desire on the part of builders and consumers to reduce costs in
building. The only way to satisfy both ends of the spectrum is to
present a solution that creates significant cost-savings while at
the same time has certain key ingredients: simple, easy to learn,
practical (makes life easier for the worker), and also provides a
complete solution, rather than incremental benefits.
[0059] The present invention provides ingredients to satisfy the
worker and take away the worker's opposition to innovation. Those
same ingredients have the effect of cutting costs for the builder.
Time is money, and a speedy operation becomes a less expensive
one.
[0060] Previous innovations have in most instances offered a
solution to only a small part of the process, rather than to the
whole thing. The present invention provides a complete solution.
Importantly, the invention does not seek to replace steps in
stud-wall building with a better process. Instead, it just
eliminates some of the steps entirely for the tradesperson.
[0061] While saving money and streamlining operations, the
invention maintains the integrity and accuracy of the installation;
studs are square-plumb and on center for drywall installation.
[0062] The invention also provides a metal framing system that is
easy to use, quick to assemble, and does not require metal cutting
during frame assembly.
[0063] The invention also provides a complete modular framing
system that is simple in form, easy to learn, and easy to use.
[0064] The invention also provides a metal wall framing system that
eliminates some of the steps required to construct a conventional
metal or wood frame, while providing a square, plumb, and on-center
metal frame for supporting drywall or other wall materials.
[0065] The invention also provides a metal framing system that is
significantly faster and more economical to assemble than other
wood and metal framing systems.
[0066] The invention also provides a modular metal framing system
that is easily used by an unskilled, lower-cost worker. The system
is also intended for use by inexperienced do-it-yourself homeowners
lacking the tools, knowledge, and experience of a skilled
professional framer.
[0067] The invention also provides a metal wall framing system that
does not require supplemental hardware, requires no supplemental
fasteners, nails, electric tools or other power tools, or any
measuring devices or cutting devices.
[0068] The invention also provides a modular metal framing system
that can include an optional side spacer or bracer that provides
spacing and alignment of studs and serves as a larger surface for
supporting drywall and into which metal screws can be more
conveniently secured to hold the drywall to the frame.
[0069] The present invention is directed to a modular metal framing
system for constructing wall frames in virtually any type of
building construction. The system is complete insofar as it
requires virtually no additional hardware and can be readily used
by unskilled labor. Metal wall frames constructed in accordance
with the invention can be completed in a fraction of the time and
at much lower cost than wood frames as well as other conventional
metal frame systems.
[0070] In accordance with the invention, upper and lower metal
channels are formed with a series of evenly-spaced locators or
stops that accurately locate a series of metal studs along the
channels. The channels also include retainers or prongs located
adjacent to the locators or stops for fitting within slots formed
in the studs. The channels further include scored or notched areas
located adjacent to the stops and prongs for allowing a portion of
each channel side wall to be crimped inwardly to hold a stud in
place on the channel, or flexible clips that hold the stud in place
along the channel.
[0071] In order to interconnect and mount a stud on a channel, the
stud is simply moved along the channel with a sliding movement
until the stud engages a stop. Just before the stud engages a stop,
one or more locators or prongs slide into mating slots formed in
the stud to hold and guide the stud into alignment with the stop.
Notched or perforated portions in the channel sidewalls are then
crimped inwardly to hold the stud in place within the channel.
Alternatively, flexible clips are bent inward to hold the stud in
place. This provides a bracing system for spacing and leveling.
[0072] According to a particular aspect of the invention, a metal
stud assembly includes a stud adapted for constructing a metal wall
frame between a pair of channel members, and an extender
longitudinally slidably mounted within the stud. The stud includes
a longitudinally-extending central column portion having a pair of
opposite end portions, a pair of side walls formed on opposite
sides of the central column portion, a first retainer, and at least
one elongated alignment slot formed in the stud that is adapted to
receive the first retainer formed on one of the channel members.
The alignment slot is formed in at least one of the end portions of
the central column portion. The extender includes an upper portion
having side walls that are substantially parallel to the side walls
of the stud, and a lower portion having side walls that join the
upper portion side walls at a top end and which taper to smaller
dimensions at a bottom end, such that the bottom end fits within
the stud.
[0073] The stud can also include an indented portion formed in at
least one of the side walls that is adapted to receive a spacer
bar. The metal stud assembly can include a plurality of studs, as
well as at least one spacer bar interconnecting adjacent ones of
the studs, coupled to respective the indented portions formed in
the studs.
[0074] The lower portion side walls of the extender can taper
linearly inward. In this case, the extender can be formed with a
push hole for pushing and sliding the extender within the stud. The
metal stud assembly can also include a second retainer formed on
the channel member, and the first retainer can have at least one
slot formed therein that receives the second retainer.
[0075] According to another aspect of the invention, a metal wall
frame system includes a series of metal studs according to the
metal stud assembly described above. The system also includes a
metal channel member, a series of stops formed at predetermined
intervals along the channel member, and a series of retainer
members formed at predetermined intervals along the channel member.
The metal channel member has a floor portion and a pair of side
walls upstanding from the floor portion. The series of metal studs
is interconnected to the channel member. Each stud is butted
against a respective one of the stops, and each stud receives a
respective one of the retainer members.
[0076] The system can also include a series of spacer bars. Each
spacer bar interconnects adjacent studs.
[0077] The stops can be formed as upstanding tabs struck from the
channel member. In this case, the system can also include a series
of longitudinally spaced crimp portions crimped inwardly from the
side walls and locking the studs on the channel member. Each of the
studs can include a socket, and each spacer bar can include a
series of projections respectively extending into each of the
sockets.
[0078] The metal channel member described above can be a lower
channel member, and the system can also include an upper channel
member interconnected to the extender. The extender can include an
elongated slot, and the upper channel member can include a retainer
member that engages the elongated slot to interconnect the upper
channel member to the extender.
[0079] According to another aspect of the invention, a metal stud
assembly includes a stud adapted to be used in the construction of
a metal wall frame between a pair of channel members, and an
extender longitudinally slidably mounted over the stud. The stud
includes a longitudinally-extending central column portion having a
pair of opposite end portions, a pair of side walls formed on
opposite sides of the central column portion, a first retainer, at
least one elongated alignment slot formed in the stud adapted to
receive the first retainer formed on one of the channel members,
and an indented portion formed in at least one of the side walls
adapted to receive a spacer bar. The alignment slot is formed in at
least one of the end portions of the central column portion. The
extender includes an upper portion having side walls that are
substantially parallel to the side walls of the stud, and a lower
portion having side walls that fit over the stud.
[0080] The lower portion side walls of the extender can taper
linearly inward.
[0081] The lower portion of the extender can join the upper portion
side walls at a top end and taper to larger dimensions at a bottom
end, such that the bottom end fits over the stud.
[0082] The assembly can also include a tapered section. The lower
portion of the extender can fit over the stud and join the upper
portion side walls at the tapered section. The tapered section
provides a transition in dimensions between the upper portion and
the lower portion.
[0083] The extender can be formed with a push hole for pushing and
sliding the extender within the stud.
[0084] The metal stud assembly can also include a second retainer
formed on channel member, and the first retainer can have at least
one slot formed therein that receives the second retainer.
[0085] According to another aspect of the invention, a metal wall
frame system includes a series of metal studs as described above.
The system also includes a metal channel member having a floor
portion and a pair of side walls upstanding from the floor portion,
a series of stops formed at predetermined intervals along the
channel member, and a series of retainer members formed at
predetermined intervals along the channel member. The series of
metal studs is interconnected to the channel member. Each stud is
butted against a respective one of the stops. Each said stud
receives a respective one of the retainer members.
[0086] The metal wall frame system can also include a series of
spacer bars. Each spacer bar is adapted to connect adjacent
studs.
[0087] The stops can be formed as upstanding tabs struck from the
channel member. In this case, the system can also include a series
of longitudinally spaced crimp portions crimped inwardly from the
side walls and locking the studs on the channel member. Each of the
studs can include a socket and each spacer bar can include a series
of projections respectively extending into each of the sockets.
[0088] The metal channel member described above can be a lower
channel member, and the system can also include an upper channel
member interconnected to the extender. In this case, the extender
can include an elongated slot, and the upper channel member can
include a retainer member that engages the elongated slot to
interconnect the upper channel member to the extender.
[0089] The aforementioned features and advantages of the invention
will, in part, be pointed out with particularity, and will, in
part, become apparent from the following more detailed description
of the invention, taken in conjunction with the accompanying
drawings, which form an integral part thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0090] In the drawings:
[0091] FIG. 1 is a perspective view of a portion of a metal wall
framing channel member constructed in accordance with the
invention;
[0092] FIG. 1A is a partial central longitudinal sectional view
taken through a first embodiment of a retainer member;
[0093] FIG. 1B is a view similar to FIG. 1A showing an alternative
embodiment of a retainer member;
[0094] FIG. 2 is a perspective view of a bottom portion of a stud
constructed in accordance with the invention;
[0095] FIG. 2A is a perspective view of the stud of FIG. 2
interconnected to the channel member of FIG. 1;
[0096] FIG. 3 is a top plan view of FIG. 2A;
[0097] FIG. 4 is a perspective view of an alternative embodiment of
the stud of FIG. 2 connected to an alternative embodiment of the
channel of FIG. 1;
[0098] FIG. 4A is a view similar to FIG. 4 showing another
embodiment of the invention;
[0099] FIG. 4B is a top plan view of FIG. 4A;
[0100] FIG. 5 is a schematic perspective view of the stud and
channel of FIG. 2A provided with a vertically sliding extender;
[0101] FIG. 5A is a perspective view of an alternative embodiment
of the extender of FIG. 5;
[0102] FIG. 6 is a partial view of the extender of FIG. 5A
interconnected to an alternative embodiment of an upper channel
member;
[0103] FIG. 7 is a view similar to FIG. 6 showing another
embodiment of an extender connected to an upper channel member
similar to that shown in FIG. 4;
[0104] FIG. 8 is a partial perspective view of a wall frame
constructed in accordance with the invention and showing the use of
a pair of horizontally disposed space bars;
[0105] FIG. 8A is a top plan view of a portion of one of the spacer
bars of FIG. 8;
[0106] FIG. 9 is a partial perspective view of another embodiment
of a stud constructed in accordance with the invention and formed
with a socket struck out from the central column of the stud;
[0107] FIG. 10 is a view similar to FIG. 9 showing another
embodiment of socket construction and a stud having an indented
portion formed along one or both side walls;
[0108] FIG. 11 is a schematic view similar to FIG. 9 showing a
spacer bar interconnected to a stud constructed with an alternative
embodiment of the socket of FIG. 9;
[0109] FIG. 12 is a partial schematic top plan view of a pair of
spacer bars aligned with a channel member having sockets for
receiving each spacer;
[0110] FIG. 13 is a partial perspective view of a spacer bar formed
with an alternative embodiment of a socket;
[0111] FIG. 14 is a partial schematic top plan view of a spacer bar
provided with an alternative tongue configuration for insertion
within the socket of FIG. 13;
[0112] FIG. 15 is a partial perspective view of a series of studs
spaced apart and mutually braced by an alternative embodiment of
spacer bar and an alternative embodiment of sockets formed on the
studs as shown in FIG. 10;
[0113] FIG. 16 is a perspective view of a portion of a metal wall
framing channel member showing a rounded tab stop member
constructed in accordance with the invention;
[0114] FIG. 17 is a perspective view of a portion of a metal wall
framing channel member showing a rounded retainer member
constructed in accordance with the invention;
[0115] FIG. 18 is a perspective view of a portion of a metal wall
framing channel member showing flexible clips constructed in
accordance with the invention;
[0116] FIG. 18A is a top plan view of FIG. 18;
[0117] FIG. 19 shows a tabbed retainer member in an upper channel
member;
[0118] FIG. 20 shows an alternative embodiment of the extender of
FIG. 5A;
[0119] FIG. 21 shows another alternative embodiment of the extender
of FIG. 5A;
[0120] FIG. 22 shows another alternative embodiment of the extender
of FIG. 5A;
[0121] FIG. 23 shows an alternative embodiment of the retaining
member of FIG. 1B;
[0122] FIGS. 24-29 show details of an arrangement that can be used
as an alternative to that shown in FIG. 8;
[0123] FIG. 30 is a perspective view of a portion of a metal wall
framing channel member constructed in accordance with the invention
as an alternative to that of FIG. 1; and
[0124] FIG. 31 provides side, front, and top views of the exemplary
embodiment of FIG. 29.
[0125] In the various figures of the drawings, like reference
characters designate like or similar parts.
DETAILED DESCRIPTION OF THE INVENTION
[0126] The present invention will now be described in conjunction
with the drawings, beginning with FIG. 1, which shows a channel
member 10 constructed in accordance with the invention. The channel
member 10 is adapted to be installed in a known manner on a lower
support surface such as a floor. An identical second or upper
channel member 10 is typically installed in a known manner on an
overhead support surface such as a ceiling. The upper and lower
channel members are aligned parallel with one another and typically
aligned within a common vertical plane.
[0127] The channel member 10 includes a flat,
longitudinally-extending central floor 12 and a pair of upstanding
parallel side walls 14 that are bent upwardly at right angles from
each side of the floor 12. The channel member 10 is formed of a
sheet metal material such as steel. A stud locator or stop member
in the form of a tab 16 is struck or punched upwardly from the
channel floor 12, leaving behind an open aperture 18 in the floor
12. As shown in FIG. 1, the tab is squared-off to provide a large
surface area as a stop member for the stud. Alternatively, as shown
in FIG. 16, the tab 16 can be rounded, so as to make it less likely
that a worker will be cut by the tab or that clothing will be
snagged during installation.
[0128] Preferably, the tab 16 is aligned vertically perpendicular
to the floor 12 and laterally or transversely perpendicular to each
side wall 14. In this manner, the tab 16 is square with both the
floor and side walls of the channel member. A series of
longitudinally-spaced tabs 16 is formed in the channel member 10,
with each tab located at regular intervals. The tabs 16 can be
located at predetermined longitudinal spacings of, for example, 16
and/or 24 inches.
[0129] One or more retaining members 20 are also struck out or
punched up from the channel floor 12, leaving behind an open
aperture 22 in the floor 12. As shown in FIG. 1, a pair of tapered,
pointed retainer members is laterally spaced on each side of the
tab 16. The retainer members can be ramped upwardly from the floor
12 as shown in FIG. 1A, or can be formed in an "L" shape as shown
in FIG. 1B. As shown in FIG. 1, the retainer members are pointed to
provide an easy insertion through slots in the stud. Alternatively,
as shown in FIG. 17, the retainer members 20 can have rounded tips,
so as to make it less likely that a worker will be cut by the
retainer member or that clothing will be snagged during
installation.
[0130] As shown in FIG. 1B, the base 24 of the retainer 20 is
aligned perpendicularly upwardly from the floor 12 of the channel
member 10 and is located at substantially the same longitudinal
position on the floor 12 as is the tab 16. A leg 26 extends from
the base 24 on the retainer 20 and is bent back over the floor 12
and is aligned substantially parallel with the floor 12.
Alternatively, as shown in FIG. 23, the retaining members 20 can be
formed directly above the aperture 22, for example by shearing and
forming the retaining member in a direction straight up from the
channel floor 12.
[0131] As also shown in FIG. 1, a cut, notched, perforated, or
otherwise weakened crimp portion 28 is formed along one or both
sidewalls 14. As shown, a pair of rectangular crimp portions 28 is
formed along the top edge 29 of each side wall 14. Each crimp
portion 28 is longitudinally spaced a predetermined distance away
from each tab 16 to allow the crimp portions 28 to be squeezed or
crimped inwardly toward each other in order to hold a stud in place
within the channel member 10, as described more fully below.
Alternatively, a flexible clip 104 can be used in place of the
crimp portion 28, as shown in FIG. 18 and as described more
completely below.
[0132] As shown in FIG. 2, a stud 30 is formed of a metal material,
such as steel, in accordance with the invention. The stud 30
includes a central column portion 32 and a pair of parallel side
walls 34 projecting perpendicularly from the column portion. An
inturned lip 36 is formed on the outer end portion of each side
wall 34. One or more alignment slots 38 are formed through the end
portion 40 of the stud 30 for receiving and interconnecting with
one or more of the retainer members 20 on the channel member
10.
[0133] As can be appreciated from a review of FIG. 2A, the stud 30
is fitted between the side walls 14 of the channel member 10 with
the bottom edge of the stud making sliding contact against the
channel floor 12 and with the side walls 34 of the stud making
sliding contact against the side walls 14 of the channel member. As
the stud 30 approaches the tab 16 on the channel member 10, the
tips of the retainer members 20 enter the alignment slots 38 in the
stud 30.
[0134] When the stud is fully and properly butted flat against the
tab 16, it is also fully seated against the retainer members 20. In
the example of the retainer member 20 of FIG. 3, the rear face of
the column portion 32 abuts the tab 16 as well as the base 24 of
each retainer member 20. Once this three-position contact has been
achieved, the stud 30 is properly and fully aligned and seated
within the channel member 10.
[0135] At this point, the crimp portions 28 are bent inwardly from
the side walls 14 of channel member 10 to form locking members 44.
An open notch 46 is thus formed in the top edge 29 of each side
wall 14. The locking members 44 can be closely spaced from the lips
36 on the stud 30 or in contact with the lips 36.
[0136] Alternatively, flexible clips 104 can be used in place of
the locking members 44 to hold the stud in place. As shown in FIG.
18, these clips 104 are substantially rectangular in shape, with
one side of the clip defined by the upper edge of the sidewall 14.
The lower side 106, parallel to the upper edge of the sidewall, and
the transverse edge 108, closer to the stud 30, are both at least
partially separated from the sidewall, and bend inward, hinged at
the transverse edge 110 farther from the stud 30. The hinge
functionality of the distal transverse edge 110 can be provided by
the natural bend of the unbroken connection of that edge 110 to the
channel sidewall 14. Alternatively, the distal edge 110 can be
scored or perforated, or can be thinned along a line that is
intended to function as a hinge, or can be modified in any known
fashion to provide an easy bend to the clip 104.
[0137] The edge 108 of the clip 104 encroaching within the channel
member 10 prevents movement of the stud 30 along the longitudinal
direction of the channel in much the same manner as the locking
members 44. FIG. 18A is a top plan view of a section of channel,
clearly showing a bent clip 104, with a leading edge 108 jutting
out within the channel member 10. The flexible clips 104 shown in
FIG. 18 provide advantages over use of the locking members 44 in
that more precise and uniform blocking means is provided, it is
easier to bend the flexible clip than it is to crimp over the
locking members, saving time and effort in assembling the stud
system, and bending the flexible clips into position provides less
opportunity for injury to a person assembling the stud system. It
is intended that any description of the present invention including
the locking members 44 or crimp portions 28 applies correspondingly
to the alternative embodiment of FIG. 18, that is, an embodiment in
which the flexible clips 104 replace the crimp portions 28 and
locking members 44.
[0138] FIG. 29 shows an alternative placement of the clip 104. As
shown, the clip 104a can be struck or otherwise formed from an
intermediate portion of the sidewall, rather than at the upper edge
of the sidewall as described above. Either arrangement of the clip
104, 104a can be used alone, or both can be used at the same area
of the channel 12 if desired. FIG. 30 shows alternative views of
the section of the channel member shown in FIG. 29.
[0139] The general spacing of the interconnected channel member 10
and the stud 30 is shown in FIG. 3 wherein the stud is held in
position vertically by the retainer members 20, held laterally by
contact with the side walls 14 and locked longitudinally by
abutment in one direction with the tab 16 and in the other by
abutment with the locking members 44 or the flexible clips 104.
[0140] A variation of this positioning, locating, aligning, and
locking stud and channel framing system is shown in FIG. 4 wherein
the retainer members 20 are struck out from the side walls 14 of
the channel member 10 and extend inwardly over the floor 12 of the
channel member. The stud 30 is modified to locate the elongated
alignment slots 38 in a vertical orientation in order to receive
and mate with the retainer members 20. The tab 16 is arranged as in
the prior example, and crimp portions 28 or flexible clips 104 are
formed in side walls 14 as in the prior example.
[0141] A further variation of the invention is shown in FIGS. 4A
and 4B wherein the retainer members 20 enter the vertical slots 38
through the inside surface 50 of the channel member 10 rather than
through the outside or back side 52 as shown in FIG. 4. In the
example of FIG. 4, the back side 52 is slid into and against the
retainer members 20 in the direction of the arrow 54. In the
example of FIGS. 4A and 4B, the inside surface 50 is slid into and
against the retainer members 20 in the direction of the arrow
56.
[0142] In the example of FIG. 4A, a cut-out portion 58 can be
formed in each lip 36 for providing clearance for the passage of
the retainer members 20 through the lips 36. Alternatively, as
shown in FIG. 4B, the base 24 of the retainer members can be
dimensioned to extend into the channel member to provide clearance
of the leg 26 over the lip 36. The crimp portions 28 or flexible
clips 104 are formed adjacent to the lips 36 in FIG. 4 and adjacent
to the back surface 52 and to the slots 38 in FIGS. 4A and 4B.
[0143] In each of the prior examples, a pair of identical channel
members 10 is aligned with one channel member directly above
another. One channel member can be attached by fasteners to a floor
and the other similarly attached to a ceiling. The tabs 16 on each
channel member are vertically aligned one directly over the other
and the channel members are carefully plumbed longitudinally
parallel with one another as well.
[0144] The aligned channel members provide for the accurate
vertically-plumbed alignment of the studs when the studs are pushed
against a pair of aligned tabs 16, one tab being on the upper
channel member and one on the lower channel member. In this case,
the alignment slots 38 on each opposite end of the stud 30 are
identical so that both ends of the studs are aligned by sliding the
studs against a pair of stops or tabs 16 and interengaging the
slots 38 with the retainer members 20 on each channel member 10.
The crimp portions 28 or flexible clips 104 are then bent inwardly
as described above.
[0145] A further embodiment of the invention is shown in FIG. 5,
wherein the lower end of the stud 30 is the same as that shown in
any of the prior examples and in this case, as shown in FIG. 2. The
channel member 10 is shown as in FIG. 1 to match the slot pattern
on the stud. What is different about the stud 30 in FIG. 5 is the
addition of an extender member 60, which is telescopically held
within and between the side walls 34 of the top portion 62 of the
stud 30.
[0146] Rather than secure the upper or top portion 62 of the stud
30 directly to an overhead channel member 10, the extender 60 is
adjusted vertically by sliding within the top portion 62 to engage
the tabs 16 and the retainer members 20 on the channel member 10.
The lower side walls 64 on the extender 60 have more compact
dimensions than the upper portion 66, to form a snug sliding
friction-fit against the side walls 34 of the top portion 62. The
area between the lower side walls 64 and the upper portion 66 can
be slightly tapered to provide a suitable transition in dimension.
This prevents the extender from having a loose slack fit within the
stud 30.
[0147] The upper portion 66 of the extender 60 can be transversely
or laterally enlarged along the outwardly tapered portions 68 to
prevent the extender 60 from sliding completely into the stud 30 by
interfering with or abutting against the top edge 70 of the stud
30. As further seen in FIG. 5, the extender 60 is formed with a
pair of upper alignment slots 72 and a pair of lower alignment
slots 74.
[0148] Normally, the lower alignment slots 74 are engaged with the
retainer members 20 on an upper channel member 10 attached to a
ceiling. The retainer members 20 are thus spaced below the ceiling
on which the upper channel member is fastened and spaced below the
floor 12 of the upper channel member 10. With this arrangement, the
top edge 78 of the extender 60 fits snugly against the floor 12 of
the upper channel member. When the upper slots 72 are engaged with
the retainer members 20, the top edge 78 of the extender 60 is
spaced a small distance below the floor 12 of the upper channel
member. This spacing accommodates settling of the ceiling and
floors of the building structure and/or allows for additional
loading which can compress and lower a ceiling.
[0149] When a stud 30 is attached directly to an upper channel
member without an extender 60, it is suitable for use in
load-bearing walls, providing the gauge of the metal stud meets the
strength requirements for a load-bearing partition. However, when
the extender 60 is used, it is loosely telescopically positioned
within the stud and as such is not suitable for use in load-bearing
walls.
[0150] As shown in FIG. 5A, the pairs of upper and lower alignment
slots 72, 74 of FIG. 5 can each be replaced with a single elongated
slot 72, 74. This single slot concept can also be used in place of
the alignment slots 38 formed on the stud 30. In these cases, the
retainer members 20 can be replaced with a single wider retainer
that extends across substantially the entire width of each single
elongated alignment slot. As shown in FIG. 19, a tab can be struck
out of the upper channel member 10 and bent over, to be used as a
retainer member 20. Alternatively, as shown in FIGS. 32 and 33, the
tab can be struck up and out from the channel member 10.
[0151] The extender 60 of FIG. 5A is shown in FIG. 6 mounted to an
upper channel member 10 having a large single retainer member
struck out from the floor 12 of the channel member and inserted
through the upper alignment slot 72 on the extender 60. The
extender 60 is formed with a push hole 80 to allow an installer to
push the extender 60 upwardly with a rod or the like engaged within
the hole 80 while pushing the lower end of the stud 30 against a
tab 16 as shown in FIG. 5 and inserting the retainer members 20
through the stud slots 38. This can be done without the use of a
ladder, with an installer standing on the floor.
[0152] In an alternative embodiment, shown in FIG. 20, the extender
60 can fit over the stud 30 rather than into the stud. In this
embodiment, the wall system may be able to bear heavier loads than
the embodiment of FIG. 5A. Similar to the previous embodiment, the
extender 60 is adjusted vertically by sliding over the top portion
62 to engage the retainer members 20 on the upper channel member
10. The upper portion 66 on the extender 60 has more compact
dimensions than the lower side walls 64, to form a snug sliding
friction-fit over the side walls 34 of the top portion 62. The
section between the lower side walls 64 and the upper portion 66
can be slightly tapered to provide a suitable transition in
dimension.
[0153] In another alternative embodiment, shown in FIG. 21, the
extender 60 again fits into the stud 30. The extender 60 is
adjusted vertically by sliding into the top portion 62 to engage
the retainer members 20 on the upper channel member 10. The lower
side walls 64 on the extender 60 can be slightly tapered,
preferably in a regular transition over substantially the length of
the lower side walls 64 to form a snug sliding friction-fit within
the side walls 34 of the top portion 62. The tapering of the
sidewalls 64 provides a small enough dimension at the bottom such
that the extender 60 can be inserted within the stud 30.
Preferably, the upper portion 66 is not tapered, and is
substantially parallel to the side walls 34 of the top portion
62.
[0154] In another alternative embodiment, shown in FIG. 22, the
extender 60 fits over the stud 30. In this embodiment, the wall
system may be able to bear heavier loads than the embodiment of
FIG. 5A. The extender 60 is adjusted vertically by sliding into the
top portion 62 to engage the retainer members 20 on the upper
channel member 10. The lower side walls 64 on the extender 60 can
be slightly tapered, preferably in a regular transition over
substantially the length of the lower side walls 64 to form a snug
sliding friction-fit over the side walls 34 of the top portion 62.
The tapering of the sidewalls 64 provides a large enough dimension
at the bottom such that the extender 60 can fit over the stud 30.
Preferably, the upper portion 66 is not tapered, and is
substantially parallel to the side walls 34 of the top portion
62.
[0155] A variation of the horizontally- or transversely-elongated
alignment slots 72, 74 of FIG. 5 is shown in FIG. 7 wherein the
alignment slots 72, 74 are elongated vertically and the mating
retainer members 20 are formed as in FIG. 4. Alternatively, push
holes 80 can be formed in the side walls 64 of extender 60.
[0156] In each of the embodiments discussed above, the upper and
lower portions of each stud 30 are secured in place between the
upper and lower channels 10 and held in place by stops such as tabs
16 which are accurately positioned on, for example, 16-inch or
24-inch spacings. An alternative embodiment of this arrangement is
to secure the bottom portion of each stud 30 as described in any of
the examples above, but to allow the upper portion of each stud to
slide longitudinally within the upper channel member without being
locked in place.
[0157] This can be achieved by eliminating the tabs 16 from the
upper channel member 10. One or more "L" shaped retainer members 20
as shown in FIG. 1B serve as the stop against which the stud is
positioned. The base 24 of the retainer member 20 acts as a
stop-like tab 16, and the leg 26 of the retainer member 20 acts as
a longitudinally-extending guide over which the top portion of the
stud 30 or the extender 60 freely slides.
[0158] In this embodiment, the upper channel member 10 need not be
accurately aligned horizontally from wall to wall with the lower
channel member 10. The lower channel member 10 is spaced and
positioned where desired and the upper channel member 10 is simply
approximately located above the lower channel member. Although the
upper and lower channel members are aligned vertically in a common
plane, they are not necessarily spaced and aligned accurately on
16-inch or 24-inch centers with one another. This allows for wall
variations that may be wider on top than at the bottom or vice
versa.
[0159] In this case, the lower ends of the studs 30 are secured
within a channel member 10 as discussed in connection with the
previous embodiments. The upper ends of the studs 30 (or the
extenders 60) are simply slid onto the retainer members 20 and left
to freely slide or "float" along the length of the retainer legs
26. Accurate spacing of the studs 30 can still be achieved,
however, by the use of one or more central spacer or bracer bars 84
as shown in FIG. 8. It is important to note that the use of such
spacer bars is advantageous when constructing load-bearing walls,
or in commercial applications. However, for residential,
non-load-bearing applications, these spacer bars are not necessary,
although they can be optionally provided.
[0160] In FIG. 8, the upper ends of the studs 30 are provided with
extenders 60 that are free to slide longitudinally or "float" along
the retainer members 20 as noted above. The lower end of each stud
30 is positioned and locked in place as in FIG. 2A. After two or
three of the studs 30 are so arranged and placed in the upper and
lower channel members 10, one or more spacer bars 84 are connected
to the central or middle portion 86 of each stud 30.
[0161] As shown in FIGS. 8 and 8A, each spacer bar 84 has a series
of accurately-spaced tongue members 88 struck out of the sheet
metal spacer material, leaving behind an opening 90. The tongue
members are spaced apart, for example, on 16-inch and/or 24-inch
centers, and are dimensioned to fit or snap within receiving
members or sockets formed on the studs 30.
[0162] FIGS. 24-29 show details of arrangements that can be used as
alternatives to the arrangement shown in FIG. 8. As shown,
connections of the spacer bar 84 to the studs 30 and of the studs
30 to the upper and lower channel members 10 are made differently.
For example, tabs struck out and over from the horizontal spacer
bar at measured intervals can be inserted into vertical slots in
the studs. Likewise, tabs struck down and back from the upper
channel can be inserted into horizontal slots at the tops of the
studs. It will be apparent to those of skill in the art that other
alternative connections and coupling arrangements can be utilized
without departing from the spirit and scope of the invention as
described and claimed herein, and the exemplary embodiments shown
in FIGS. 24-29 are non-limiting examples. Further, some exemplary
dimensions are shown in these drawings, which are included to
provide an exemplary idea of scale and are not intended to be
limitations on the useful dimensions contemplated for these or
other disclosed or undisclosed embodiments.
[0163] One example of such receiving members is shown in FIG. 9
wherein a vertically, elongated receiving slot 92 is punched
through the side wall 34 of the stud 30 directly and immediately
adjacent to the inner surface 50 of the channel member 10.
Arched-shaped bands or loops 94 are punched through the central
column portion 32 of the stud 30 from the outer surface or back
side 52 toward the inner surface 50 to form a socket 96 that
receives the free end 98 of the tongue members 88.
[0164] The socket 96 is dimensioned to receive each tongue member
88 with a tight locking fit or a snap fit. While the tongue members
in FIGS. 8 and 8A are shown having a rectangular shape, they can
also be formed having a triangular shape similar to the retainer
members 20 shown in FIG. 1. Although only one spacer bar 84 is
required, two can be used, as shown in FIG. 8, attached to opposite
side walls 34 of each stud 30.
[0165] A further variation of the spacer bar assembly is shown in
FIG. 10, wherein a rectangular indented or recessed portion 100 is
formed in the side wall 34 of the stud 30 adjacent to a pair of
sockets 96. The recessed portion 100 receives the flat spacer bar
84 with a flush fit so that the spacer bar does not extend
outwardly from the plane of the side wall 34, or extends only
slightly outwardly. In either case, the spacer bar 84 will not
interfere with the placement of drywall.
[0166] A variation of the socket 96 of FIG. 9 is shown in FIG. 11,
wherein one or more loops or bands 94 are struck out from the
central column portion 32 from the inner face 50 of the stud 30
toward its outer face 52. In this manner, the bands 94 project from
the outer face 52 and therefore the receiving slot 92 of FIG. 9 is
not required.
[0167] In FIG. 12, a pair of spacers 84 is shown aligned for
insertion within two pairs of sockets 96 formed on the outer side
or backside 52 of the column portion 32. In FIGS. 13 and 14 the
spacer bar 84 is formed with an L-shaped tongue member 88 and the
stud 30 is formed with a single elongated slot 102 for receiving
the tongue member 88.
[0168] As shown in FIG. 15, two triangular tongue members 88 are
struck out perpendicularly from the spacer bar 84 to enter a pair
of receiving slots formed in the sidewalls 34 in the same manner as
the receiving slots 92 shown in FIG. 9.
[0169] There has been disclosed heretofore the best embodiment of
the invention presently contemplated. However, it is to be
understood that the various changes and modifications may be made
thereto without departing from the spirit and scope of the
invention as set forth in the appended claims.
* * * * *