Metal wall frame construction

Abstract

This invention provides a metal frame for wall constructions and the like, which frame is easily assembled to provide a substantially fireproof frame to which paneling may be easily attached. Saw slots are provided in upper and lower extruded plate members into which are inserted the web portions of upright extruded studs which in a preferred embodiment are secured in place by means of tapered pins driven into holes formed in the web portions of the studs. The tapered pins engage wing portions formed in the plate extrusion to retain the studs in a locked condition. In an alternate construction the stud may be mounted in the slot and with upper and lower plates in a secured condition the stud is retained within only limited and reasonable end movement which disappears when paneling is fastened to both the outer faces of the plate and stud members.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

With reference to the classification of art as established in the United States Patent Office the present invention pertains to the general Class entitled, "Static Structures" (Class 52) and more particularly to the subclasses entitled, "panel or panel edging directly clamped or adhered to barrier" (subclass 208). Pertinent or associated art is also found in the subclass entitled, "panel held by pre-assembled or pre-positioned frame of shaft" (subclass 474) and some further subclasses under this general subclass.

2. Description of the Prior Art

The use of aluminum for framing houses, sheds, etc., is, of course, well known. The increased cost of wood and the problem of shrinkage of so-called "dried" structural lumber makes quality construction at reasonable prices difficult if not impossible at times. The use of metal extrusions as both plate and stud members is seen in U.S. Pat. No. 3,732,660 to BYSSING as issued on May 15, 1973. In this patent and many similar devices particular extruded forms are formed and after cutting to length intermediate shapes or cuts are used to secure one member to the other. Screws or rivets are most often the securing means and are usually applied from the outside. These and similar arrangements utilize metal extrusions for inexpensive structural members particularly where partitions are to be provided and panels attached thereto. The present invention provides a plate and stud construction which is easy to use and requires very little assembly effort and the assembly can be accomplished by one worker or as a do-it-yourself structural assembly.

SUMMARY OF THE INVENTION

This invention may be summarized at least in part with respect to its objects.

It is an object of this invention to provide, and it does provide, an efficient means of providing readiy erected wall frames of extruded metal in which the studs are retained in slots formed in the extruded plate. The plates, in a preferred embodiment, have upstanding rib members which are sized to engage inner flange portions formed on the studs so that the studs when mounted in the slots are retained both transversely and longitudinally.

It is a further object of this invention to provide, and it does provide, a wall frame system which is easily erected from lengths of extruded metal such as aluminum. The plate is formed with outer ribs providing a support for the ends of the extruded studs and from the base of the plate there extends a pair of inner or intermediate ribs which extend further upwardly from the base than do the outer ribs. The stud member fits in slots formed in these inner ribs. The stud member is generally of an I-beam shape and has inwardly extending ribs which are sized to engage the inner ribs of the plate. When the stud is to be secured to the plate, holes are formed in the web of the stud and by tapered pins driven into these holes the stud is locked to the plate.

Extruded plate and stud members are of metal and are formed with the plate member generally channel-shaped with both flange end portions having their ends inwardly turned to form shelf supporting surfaces. Upstanding intermediate ribs extend from the plate back member to and beyond the plane of the flange end portions. Each intermediate rib in the preferred embodiment is formed with a right-angled leg end. The stud member is I-beam shaped with the web having end flanges each having inwardly extending ribs. For assembly purposes transverse slots are formed in the intermediate rib portions of the plate member. Precisely positioned holes are formed in the web of the stud member with these holes sized for accepting and retaining tapered metal pins which are driven in place to lock the stud to the plate after the ends of the stud are mounted in the slot in the plate.

In addition to the above summary the following disclosure is detailed to insure adequacy and aid in understanding of the invention. This disclosure, however, is not intended to prejudice that purpose of a patent which is to cover each new inventive concept therein no matter how it may later be disguised by variations in form or additions of further improvements. For this reason there has been chosen a specific embodiment of the metal wall frame construction as adopted for use with buildings and the like and showing a preferred means for assembly of the members. This specific embodiment has been chosen for the purposes of illustration and description as shown in the accompanying drawings wherein:

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 represents a fragmentary sectional view showing the method of joining the stud member to the plate member of the metal wall construction assembly;

FIG. 2 represents an exploded isometric view showing the constructional details of the members of FIG. 1;

FIG. 3 represents an exploded isometric view similar to that of FIG. 2 and showing one end of a stud end cut so as to be assembled with both upper and lower plate members in secured position;

FIG. 4 represents a fragmentary plane view showing a right angle corner assembly of the wall;

FIG. 5 represents a fragmentary isometric view of an alternate plate configuration, and

FIG. 6 represents a fragmentary isometric view of an alternate stud configuration of a generally Z-shape.

In the following description and in the claims various details will be identified by specific names for convenience. These names, however, are intended to be generic in their application. Corresponding reference characters refer to like members throughout the several figures of the drawings.

The drawings accompanying, and forming part of, this specification disclose certain details of construction for the purpose of explanation of the broader aspects of the invention, but it should be understood that structural details may be modified in various respects without departure from the concept and principles of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring now in particular to the preferred embodiment as seen in FIGS. 1 through 4, there is depicted a metal wall frame system in which the plate member is generally indicated as 10 and the stud member is generally indicated as 12. The plate member is generally channel-shaped with a base 20 having like ends 22 and 24 extending at right angles therefrom. These ends are turned inwardly to provide support shelf portions 26 and 28 with their upper support surfaces laying in a plane generally parallel with the outer or bottom support surface of base 20. Assuming that plate 10 is shown substantially full size, about five-eighths of an inch in from end 22 is an upstanding rib 30 and a like distance in from end 24 is another upstanding rib 32. Ribs 30 and 32 are integrally attached to base 20 and have their distal or free ends turned outwardly at substantially right angles to the ribs to form retaining and positioning ears 34 and 36. The outer faces of ears 34 and 36 are precisely defined by the extrusion die so that the distance between these outer surfaces is substantially identical on all members.

Stud member 12 as best seen in FIGS. 2, 3 and 4 is also an extrusion and includes a web 40 to which flanges 42 and 44 are integrally attached. In the embodiment shown each flange has a pair of inwardly extending ribs. Ribs 46 and 48 are carried on and extend inwardly from flange 42 and ribs 50 and 52 are carried on and extend inwardly from flange 44. The distance between the ends of ribs 46 and 50 and ribs 48 and 52 are substantially identical with this established distance being a sliding fit between the outer faces of the outwardly extending ends of ears 34 and 36.

CORNER MEMBER OF FIG. 4

Referring next to FIG. 4, there is depicted a corner stud 60 which includes a center web 62 which has its outer end attached at a forty-five degree angle to legs 64 and 66 which are at right angles to each other. The end of leg 64 is turned inward at right angles to form and provide ear 68. In like manner the end of leg 68 is turned inward at right angles to form and provide ear 70. The other or opposite end of web 62 is attached to legs 72 and 74 which form a right angle to each other and with web 62 are at an angle of 135.degree..

Extending inwardly from leg 72 is short rib 76 and a short distance outwardly from rib 76 is longer rib 78 which also extends inwardly. In a like manner there is formed on leg 74 a short rib 80 and adjacent thereto is leg 82.

ASSEMBLY OF METAL WALL FRAME

To install the metal wall frame of this invention requires the use of a metal cutting saw and a drill. The plate member 10 is cut to the desired length of the wall to be provided. Two like plate members 10 are required, one for the ceiling and one for the floor. For every stud to be used, as seen in FIG. 2, there are made saw cuts 86 and 87. These cuts are made of a width so that web 40 of the stud 12 is a sliding or slip fit in each of the cuts. The depth of the cuts are to a point which is on a line with the top surface of ears 34 and 36. For every stud 12 to be installed, aligned cuts 86 and 87 need be made in the upper and lower plate member. Of course, slots 86 and 87 may be formed by punching dies and the like but where these slots are to be made on the job sawing is found easy and fast.

Where the sutds are to be installed vertically in a normal room wall both ends of each stud are cut square and at right angles with the web. At a determined distance from each end of the stud 12 two holes 90 and 91 are drilled through the web when the stud is to be secured to the plate. As seen in FIG. 1, these holes are positioned so that when the stud end is fully inserted into the cuts 86 and 87 these holes are tangent to the sides of ribs 30 and 32 and at the same time to the underside of ears 34 and 36. A tapered drive pin 92 when inserted into a hole 90, for example, and driven home engages these surfaces of rib 30 and ear 34 to retain and lock the stud 12 in slot 86. A like pin 92 driven into hole 91 will lock the other side of stud 12 into slot 87 as the pin engages both the inner wall of rib 32 and the underside of the ear 36.

Where the stud 12 is to be swung into place with the upper and lower plates 10 secured to floor and ceiling portions it has been found that a stud 12 altered as in FIG. 3 permits ready installation. The upper end of this stud identified as 12a in FIG. 3 has a portion of flange 42 and ribs 46 and 48 removed. The removed portion is greater than the extent of projection of rib 32 beyond end 24. Holes 90a and 91a as well as holes 90 and 91 are formed in stud 12a which is of a length sufficient to extend between opposing faces of ends 26 and 28 and 28 and 26 of the lower and upper plates. The bottom of the stud 12a is placed in slots 86 and 87 of the floor plate 10 and then swung upwardly into upper slots 86 and 87 in ceiling plate 10. With the flange portions 42, 46 and 48 removed from the left side of the upper stud the stud is moved into position with web 40 entering and sliding in slots 86 and then 87. Four pins 92 then secure the stud 12a in place with the pins being driven into holes 90, 91, 90a and 91a.

The plate 10 may be secured to the floor or ceiling by means of nails, screws, adhesive or any other desired means. Where right-angled corner joints are to be made as in FIG. 4, the plates are cut at a 45.degree. bevel as shown. At a determined distance from this beveled end slots 86 and 87 are formed in these plates. Holes similar to holes 91 are accurately formed in longer ribs 78 and 82 of corner stud 60. Pins 92 are inserted into and are driven into these holes to lock these ribs to the plate.

In the several figures the slot 86 and 87 are shown substantially wider than web 40. The inner ends of 46, 48, 50 and 52 are shown as disengaged from the outward faces of ears 34 and 36. The ends of stud 12 are shown as a slight distance above the upper surfaces of shelf portions 26 and 28. The inner ends of ears 68, 70, 76 and 80 are shown spaced a short distance from the outer faces of retaining ears 34 and 36.

This spacing in the drawings has been deliberately made to enable the several portions to be more easily identified whereas in actual practice web 40 is a slip fit in slots 86 and 87. The inner ends of ribs 46 and 48 engage the outer face of ear 34 and the inner ends of ribs 50 and 52 engage the outer face of ear 36. The end of stud 12 rests on the upper surfaces of shelf portions 26 and 28. Longer ribs 78 and 82 of corner stud 60 are a slip fit in slots 87. The inner ends of ears 68 and 70 engage the outer faces of ears 34 and the inner faces of ears 76 and 80 engage the outer face of ear 36.

In its assembled condition the frame is light, easily assembled, substantially shakeproof, is fireproof within reasonable limits and presents flat surfaces for securing thereto selected wall members. For example, as seen in FIGS. 1 and 4 in phantom outline, wall board 100 may be secured to the outer facing surfaces of the frame by drilling holes for metal screws 102 in any of the outer facing portions of the studs or plates. These screws may have their head exposed or countersunk and covered. As to whether the plates and studs are of extruded aluminum, magnesium or other suitable alloy it is only necessary that the extending portions of the legs and ribs be sufficiently deflectable so that a snug slightly tight mating fit be made so that a secure wall may be provided. The spacing of the studs is merely a matter of choice although the stud, if desired, may be made to support a portion of the wall load. The size and thickness of the various member portions is merely a matter of design requirements.

Although ears 34 and 36 are shown as extending outwardly from ribs 30 and 32, of course, they may be made to turn inwardly with the ribs 30 and 32 engaging the inner ends of the ribs 46, 48, 50 and 52 whereupon holes 90 and 91 would be made on the inside portion of the web so as to engage the ear and rib to effect the engagement. The stud 12 may be as a simple I-beam absent ribs 46, 50 and 52. When this change is made ribs 30 and 32 and ears 34 and 36 are moved outwardly so as to engage the inner faces of flanges 42 and 44.

It is, of course, recognized that where this metal wall construction is to be used in new or a remodeling assembly where the upper and lower plates are to be secured to the floor and ceiling portions after the stud members have been mounted in slots the use of holes 90 and 91 and pins 92 may be omitted. The saw slots retain the studs longitudinally along the plate and ears 34 and 36 retain the studs against sideway displacement. Care in cutting the stud member to length prevents any excessive up and down movement or "play" of the stud in the slots as the stud is retained between upper and lower shelf portions 26 and 28 on upper and lower plates 10. Adhesive also may be used to secure the studs in the slots formed in the plate member 10. When the wall board has been secured to the outer facing portions of the stud and plate members the several studs are well secured in a fixed condition in the wall.

Where the plate 10 and studs 12 are to be used in stair construction or roof construction and one or both of the plates are disposed at a slope the saw slots 86 and 87 are made transverse to the axis of the plate but at a selected angle to the base 20. The ends of the studs are likewise cut at a corresponding beveled angle so that the ends of the flanges 42 and 44 of the stud mate with the angle of the plate so as to rest on the shelf portions 26 and 28 of the plate 10.

ALTERNATE PLATE AND STUD CONSTRUCTIONS

In FIG. 5 is depicted an alternate plate member 110 which although channel-like in its general configuration is formed with two outer flange portions 112 and 114. From these flange portions side walls 116 and 118 extend upwardly to a joining web member portion 120. Saw slots 122 extend through web member 120 and the side walls 116 and 118 to a point at the top surface of flanges 112 and 114 whereat a stud web mounted in the slot 122 will slide downwardly to the bottom of the slots or until the stud flange portions engage and rest on the top surfaces of flanges 112 and 114. Their ribs 46, 48, 50 and 52 of the stud 12 engage the outer faces of side walls 116 and 118 to position the stud on this alternate plate 110. Plate 110, of course, as it rests on the floor is supported by flanges 112 and 114. These flanges also engage the ceiling when the plate is mounted thereto.

In FIG. 6 is shown an alternate stud member generally identified as 130. As depicted this stud is a Z-member having legs 132 and 134 which extend at right angles to web 136. The web 136, when this alternate member is used as a stud, is of a thickness to be slidably retained in the saw slots and the inner faces of legs 132 and 134 are spaced so as to engage mating outer faces in either plate 10 or 110.

Instead of a Z form this stud, if desired, could be a channel-shape having both legs extending from the web on the same side.

As a do-it-yourself assembly unit it is contemplated that the plates will have the slots preformed and positioned as, for example, on sixteen inch centers. The studs may be precut to lengths such as seven, seven and one-half and eight feet lengths with holes 90 and 91 prepunched or drilled. Production tooling and equipment will enable slots and holes to be inexpensively provided even if they are not all used at a particular installation of a wall.

Terms such as "left," "right," "up," "down," "bottom," "top," "front," "back," "in," "out" and the like are applicable to the embodiments shown and described in conjunction with the drawings. These terms are merely for the purposes of description and do not necessarily apply to the position in which the metal wall frame construction may be constructed or used.

While a particular embodiment of the plate and stud and a corner attachment and an alternate plate and stud have been shown and described it is to be understood the invention is not limited thereto since modifications may be made within the scope of the accompanying claims and protection is sought to the broadest extent the prior art allows.

Claims

What is claimed is:

1. A metal wall frame construction for assembly and providing a frame support for wall panel members, said assembly including: (a) a plate member of metal and having a generally channel-like configuration with the base portion of a substantially flat exterior support surface and with two substantially like edge portions extending at substantially right angles to the base exterior surface, each of said edge portions forming an outwardly facing supporting surface for a wall panel member, each edge portion at its upper distal end formed with a continuous shelf supporting surface, these supporting surfaces laying in a common plane parallel to the base portion support surface; (b) at least two intermediate rib portions intergrally attached to the base and extending from the same side of the base as the edge portions, each intermediate rib extending further from the base support surface than the outer end portions, each intermediate rib formed with an outwardly facing underlip engaging surface a short distance above the plane of the supporting surfaces of the end portion; (c) a stud member of generally I-beam like configuration with each of the ends of the web joined to a flange, the outwardly facing surfaces of the flanges substantially parallel to each other and spaced at a distance which coincides with the apart spacing of outwardly facing supporting surfaces of the edges of the plate member, each flange also having an inwardly facing surface with the space between the opposed facing surfaces sized to slidably engage and pass the outwardly facing engaging surface of the intermediate rib portions of the base; (d) a plurality of slots transverse of and formed only in the intermediate rib members of the plate and of a depth sufficient to permit the entrance of the web of the stud into the slot until said transversely cut end of the stud engages and is supported by the upper edges of the end portions of the plate member, said slots having a width sufficient to slidably engage and retain the web of the stud, and (e) means formed in the web of the stud so that with the web mounted in the slots in the ribs of the plate member and the flanges of the stud resting on the edge portions of the plate member, cooperative means is used to engage the means in the web and the underlip engaging surface of the intermediate rib to lock the stud to the plate member and causing the outer surfaces of the edge portions of the plate member and the outwardly facing surfaces of the stud to form two planes parallel to each other and supporting surfaces for the mounting of panels thereto.

2. A metal wall frame structure as in claim 1 in which a rib is formed on the inner surface of each of the flange portions, the inner faces of these ribs forming opposed engaging planes which are spaced so as to engage outwardly facing portions on the plate members.

3. A metal wall frame as in claim 1 in which there is at least one hole formed in the end of the web of the stud, said hole sized to accept and retain a tapered pin, each hole positioned so that when the stud is inserted into the slot of the intermediate ribs the hole lays adjacent one of the underlip securing means formed on the distal end of the intermediate rib of the plate member.

4. A metal wall frame as in claim 1 in which the continuous shelf support provided on each side of the plate member are inwardly turned ears extending from upwardly extending end portions which are attached to a flat base portion of the plate.

5. A metal wall frame as in claim 1 in which each flange extension of the stud member is formed with a rib extending inwardly to provide at least four support surfaces establishing two parallel planes which slidably engage the two outwardly facing engaging surfaces of the intermediate rib portions of the plate member.

6. A metal wall frame as in claim 5 in which the formed ribs on the flanges of the studs are disposed with one rib on each side of the web.