Note: Descriptions are shown in the official language in which they were submitted.
CA 02538649 2006-03-03
PATENT
040241 CI PCI P
TITLE
BUILDING CONSTRUCTION COMPONENTS
INVENTOR
Larry Randall Daudet, a U.S. citizen residing at 271 Stone Ridge Court,
Chesterton, Indiana 46304.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part application of U.S. Patent
Application
Serial No. 11/093,804, entitled Building Construction Components, filed March
30, 2005
which is a continuation-in-part of U.S. Patent Application Serial No. 1
OI981,868, entitled
Building Construction Components, filed November 5, 2004, the disclosures of
which
are herein incorporated by reference.
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
(0001 The invention relates to building construction components and, more
particularly, to building construction components fabricated from metal such
as headers,
sills, trusses, girders and support posts.
DESCRIPTION OF THE INVENTION BACKGROUND
[0002] Traditionally, the material of choice for new residential and
commercial
building framing construction has been wood. However, over the years, the
rising costs
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PI-1245483 v2 0174010-0182
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of lumber and labor required to install wood framing components have placed
the dream
of owning a newly constructed home out of the economic reach of many families.
Likewise, such increasing costs have contributed to the slowing of the
development and
advancement of urban renewal plans in many cities. Other problems such as the
susceptibility to fire and insect damage, rotting, etc. are commonly
associated with
wood building products.
(0003] In view of the foregoing problems and shortcomings of wood
construction,
steel is rapidly gaining acceptance among homebuilders and homeowners alike
due to
its cost effectiveness, dimensional stability, noncombustibility, insect
resistance,
durability, high strength-to-weight ratio and recycleability. These advantages
have long
been recognized by the commercial construction industry wherein steel has been
the
material of choice for several decades.
[0004] Regardless of whether a building comprises a multistory commercial
structure or a single story residence, C-shaped metal studs and tracks are
commonly
used in their construction. Figure 1 illustrates a conventional C-shaped metal
stud 10
that has a web 12 and a pair of flanges 14. A lip 16 is also formed on the end
of each
flange 14 to further strengthen the stud. Such studs 10 are commonly
fabricated from
cold-formed steel utilizing conventional rollforming techniques. Similarly,
the
conventional tracks 20 that are employed by the building trades each have a
web 22
and a pair of flanges 24. The tracks 20 are similar in construction as the C-
shaped
studs, but lack the lack the lips that are commonly formed on the ends of the
stud
flanges. See Figure 2.
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[0005] In most construction applications, walls are constructed by attaching a
series of C-shaped studs between a top track and a bottom track. The bottom
track is
usually attached to the floor structure by screws or other fasteners and the
top track is
usually attached to the ceiling joists. The ends of the studs are inserted
into the top and
bottom tracks and are attached thereto by screws, welds, etc. After the wall
frame is
constructed, then the desired wallboard material is attached to the flanges of
the studs
and tracks utilizing screws or other fasteners to complete the wall assembly.
[0006] In those walls that require door and/or window openings to be framed
therein, a header is constructed to transfer loads occurring above the opening
to the
vertically extending studs adjacent the opening. The studs that define the
vertical
boundaries of the opening are often referred to as the "jamb" studs. Figures 3-
5
illustrate one prior header and jamb stud arrangement that is formed utilizing
conventional C-shaped studs and tracks. As can be seen in Figures 3 and 4, the
header 30 is formed by attaching a first C-shaped stud 32 to a track 40 such
that the
flanges 36 of the stud 32 are received between the flanges 42 of the track 40.
A second
upwardly facing piece of track 46 is then attached to the web 34 of the first
stud 32.
Such header 30 is commonly fabricated by attaching these components together
with
fasteners such as screws 49 or the like. The use of such screws, however,
creates
undesirable buildups which can lead to drywall finishing problems. In the
aftemative,
the components may be welded together which adds to assembly time and expense.
[0007] Likewise, the jamb studs 50 are each commonly formed by attaching a C-
shaped stud 52 to another piece of track 60 such that the flanges 56 of the
stud 52 are
received between the flanges 64 of the track 60 and then attaching the web 72
of
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another stud 70 to the web 64 of the track 60. These components are also
commonly
coupled together with screws 49 which can lead to drywall finishing problems.
In the
alternative, they may be welded together to form the jamb stud 50. Such
assembly
approach requires additional skilled labor. These combinations of components
have
been found to provide the jamb stud with a sufficient amount of strength to
receive the
loads from the header without failing or buckling.
[0008] To complete the header assembly, the header 30 is then attached to each
jamb stud 50 by corresponding L-shaped clips 80. The clips 80 are welded or
screwed
to each jamb stud 50. In addition, sections of studs 82 are attached between
the track
60 and the section of upper track (not shown) to which the upper ends of the
jamb studs
50 are attached. Such stud segments 82 are often referred to in the industry
as "cripple
studs» and further transfer loads from the upper structures to the header.
[0009] Figure 6 illustrates a prior truss chord 90 that is fabricated
utilizing
conventional C-shaped studs. By way of background, trusses are used to form
the
support frame for a roof or, in some applications, are used to form the
support for an
upper floor. The upper and lower portions of the truss are known as the
"chords" and
the members that extend between the chords are called "webs°. As can be
seen in
Figure 6, a typical method employed to form a truss chord 90 is to weld two C-
shaped
studs 92 together as shown. The truss webs are formed from other pieces of C-
shaped
studs 94 that are fastened to the chord 90 by screws, bolts etc. This
arrangement,
however, is labor intensive because studs have to be welded together to form
the
necessary chords.
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(00010] Conventional C-shaped studs and tracks are also used to form support
posts for supporting loads from the structures located above the posts. Figure
7
illustrates a prior method of constructing a support post. As can be seen in
that Figure,
a total of 3 C-shaped studs 102 and two tracks 104 are employed. The studs 102
and
tracks 104 may be connected together by a collection of screws or by welding.
Both
fastening methods, however, are time consuming and attribute to higher labor
costs
associated with their fabrication.
[00011 Floors are also constructed utilizing components that are somewhat
identical to C-shaped studs and tracks utilized to form the wall frames for
the structure.
However, the tracks and C-shaped members used to form the floor structure can
be
larger than those like-shaped components used to form wall structures. The
floor of a
structure is commonly formed from a series of C-shaped members that span the
distance between support structures or support walls. These C-shaped members
are
commonly referred to as floor joists. The ends of the joists are coupled to
tracks
referred to as joist rims that are either supported on a wall or other
structure by one of
their flanges or have their webs attached to the wall or structure. The joists
are
commonly attached to the joist rims by conventional L-shaped clips or by tabs
that are
integrally formed in the web of the joist rim.
[00012] In those instances wherein the span is too long or loading conditions
require it, beams known as girders are employed. The girders serve as points
of
attachments for the ends of adjacent floor joists as shown in Figure 8. In the
past, many
floor girders 110 were fabricated utilizing a conventional stud 112 nested in
a
conventional track 118. The flanges of the track 118 and stud 112 were
attached
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together utilizing screws 119 or welds. The floor joists 120 were then
attached to the
girder 110 by means of L-shaped clips 122 and screws. Such approach required
extra
labor to assembly the girders. In addition, when screws are used to assemble
the
girder, the screws cause the flooring material to be raised up or bulge in the
area
around each screw head.
[00013] Figure 8A illustrates a prior method of constructing a load bearing
header
arrangement. As can be seen in that Figure, the header 130 was formed from two
conventional studs or C-shaped members 140 that were retained in spaced-apart
relationship relative to each other between a piece of upper track 150 and a
piece of
lower track 160. The pieces are held together by a collection of screws 162 or
by
welding. Both fastening methods, however, are undesirably time consuming.
[00014 Thus, as can be appreciated from the forgoing discussion, a variety of
difFerent components utilized in constructing residential and commercial
buildings from
steel are fabricated from conventional C-shaped studs and tracks. While the
use of
such components affords a host of advantages over the use of wood beams and
the
like, the added labor and materials required to fabricate such components
undesirably
lead to increased construction costs.
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SUMMARY
[00015] In accordance with one embodiment of the present invention, there is
provided a header and jamb stud arrangement that includes a jamb stud assembly
that
comprises a jamb stud that has a substantially planar jamb stud web and first
and
second jamb stud flanges that protrude from the substantially planar jamb stud
web. A
first jamb stud leg protrudes from the first jamb stud flange and is
substantially parallel
to the substantially planar jamb stud web. A second jamb stud leg protrudes
from the
second jamb stud flange and is substantially parallel to the substantially
planar jamb
stud web. A first jamb stud return is formed on an end of the first jamb stud
leg and a
second jamb stud return is formed on an end of the second jamb stud leg. The
header
and jamb stud arrangement further includes another jamb stud that has the
attributes of
the above-mentioned jamb stud. The web of the another jamb stud is adjacent to
the
substantially planar jamb stud web of the first jamb stud. A third jamb stud
is supported
in spaced-apart relationship with respect to the jamb stud assembly. A first C-
shaped
connector is attached to the jamb stud assembly and has a pair of spaced first
flanges
that define a first header-receiving area therebetween. A C-shaped track is
attached to
a portion of the jamb stud assembly that is located beneath the first C-shaped
connector. A second C-shaped connector is attached to the third jamb stud and
has a
pair of spaced second flanges that define a second header-receiving area
therebetween. A first end of at least one header is received in the first
header-receiving
area of the first C-shaped connector. A second end of the header is received
in the
second header-receiving area of the second C-shaped connector. The header
spans
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between the jamb stud assembly and the third jamb stud to define an upper
boundary of
an opening therebetween.
[00016] Another embodiment of the present invention comprises a header and
jamb stud arrangement that includes a first jamb stud and a second jamb stud
supported in spaced-apart relationship with respect to the first jamb stud. A
first C-
shaped connector is attached to the jamb stud assembly. The first C-shaped
connector
has a pair of spaced first flanges that define a first header-receiving area
therebetween.
A second C-shaped connector is attached to the third jamb stud and has a pair
of
spaced second flanges that define a second header-receiving area therebetween.
A
first end of a first header is received in the first header-receiving area of
the first C-
shaped connector. A second end of the first header is received' in the second
header-
receiving area of the second C-shaped connector and spans between the first
and
second jamb studs. A second header is adjacent to the first header and has one
end
thereof received in the first header-receiving area of the first C-shaped
connector and
another end thereof is received in the second header-receiving area of the
second C-
shaped connector. The second header spans between the first and second jamb
studs.
[00017] Another embodiment of the present invention comprises a truss assembly
that includes a first truss chord that has a substantially planar first truss
cord web and a
first truss chord flange that protrudes from the substantially planar first
truss chord web.
A second truss chord flange protrudes from the substantially planar first
truss chord web
and is spaced from the first truss chord flange. A first truss chord leg
protrudes from the
first truss chord flange and is substantially parallel to the substantially
planar first truss
chord web. A second truss chord leg protrudes from the second truss chord
flange and
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is substantially parallel to the substantially planar first truss chord web
and is
substantially coplanar with the first truss chord leg. A first truss chord
return is on an
end of the first truss chord leg and a second truss chord return is on an end
of the
second truss chord leg. The truss assembly further includes another truss
chord that
has another substantially planar truss chord web. Another first truss chord
flange
protrudes from the another substantially planar truss chord web. Another
second truss
chord flange protrudes from the another substantially planar truss chord web
and is
spaced from the another first truss chord flange. Another first truss chord
leg protrudes
from the another first truss chord flange and is substantially parallel to the
another
substantially planar truss chord web. Another second truss chord leg protrudes
from
the another second truss chord flange and is substantially parallel to the
another
substantially planar truss chord web and further is substantially coplanar
with the
another first truss chord leg. Another first truss chord return is provided on
another end
of the another first truss chord leg. Another second truss chord return is
provided on
another end of the another second truss chord leg. The another truss chord
stud is
retained in abutting contact with the first truss chord to form a truss chord
assembly. At
least one web assembly is attached to the truss chord assembly.
(00018] Another embodiment of the present invention comprises a truss that is
supported between two support structures. One embodiment of the truss
comprises at
least one first truss stud that extends between the support structures and is
received
thereon. The first truss stud includes a substantially planar first truss stud
web and a
first truss stud flange that protrudes from the substantially planar first
truss stud web. A
second truss stud flange protrudes from the substantially planar first truss
stud web and
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is spaced from the first truss stud flange. A first truss stud leg protrudes
from the first
truss stud flange and is substantially parallel to the substantially planar
first truss stud
web. A second truss stud leg protrudes from the second truss stud flange and
is
substantially parallel to the substantially planar first truss stud web and is
substantially
coplanar with the first truss stud leg. A first truss stud return is on an end
of the first
truss stud leg and a second truss stud return is on an end of the second truss
stud leg.
At least two other chord studs form a peak of the truss and are coupled to the
first truss
stud. Each chord stud includes another substantially planar chord web and a
first chord
flange that protrudes from the substantially planar chord web. A second chord
flange
protrudes from the substantially planar chord web and is spaced from the first
chord
flange. A first chord leg protrudes from the first chord flange and is
substantially parallel
to the substantially planar chord web. A second chord leg protrudes from the
second
chord flange and is substantially parallel to the substantially planar chord
web and is
substantially coplanar with the first chord leg. A first chord return is on an
end of the
first chord leg and a second chord return is on an end of the second chord.
[00019] Yet another embodiment of the present invention comprises a header and
jamb stud arrangement that includes a header that has two ends and a height. A
jamb
stud corresponds to each end of the header wherein at least one of the jamb
studs
comprises a substantially planar jamb stud web. A first jamb stud flange
protrudes from
the substantially planar jamb stud web. A second jamb stud flange protrudes
from the
substantially planar jamb stud web and is spaced from the first jamb stud
flange. A first
jamb stud leg protrudes from the first jamb stud flange and is substantially
parallel to the
substantially planar jamb stud web. A second jamb stud leg protrudes from the
second
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jamb stud flange and is substantially parallel to the substantially planar
jamb stud web.
A first jamb stud return is on an end of the first jamb stud leg and a second
jamb stud
return is on an end of the second jamb stud leg. A bearing plate is on an
upper end of
at least one of the jamb studs for receiving an end of the header thereon. A
stud is
attached to the jamb stud that supports the bearing plate and extends beyond
the
bearing plate a distance that substantially con-esponds to the height of the
header.
(00020] Another embodiment of the present invention comprises a jamb stud
arrangement for attachment to a structure and a track that is attached to the
structure.
The track has a web and a pair of flanges. The jamb stud includes a
substantially
planar jamb stud web and a first jamb stud flange that protrudes from the
substantially
planar jamb stud web. A second jamb stud flange protrudes from the
substantially
planar jamb stud web and is spaced from the first jamb stud flange. A first
jamb stud
leg protrudes from the first jamb stud flange and is substantially parallel to
the
substantially planar jamb stud web. A second jamb stud leg protrudes from the
second
jamb stud flange and is substantially parallel to the substantially planar
jamb stud web.
A first jamb stud return is on an end of the first jamb stud leg and a second
jamb stud
return is on an end of the second jamb stud leg. At least one L-shaped
connector that
has one leg attached to the jamb stud and the other leg attached to the track
is included
to affix the jamb stud to the track.
(00021] Another embodiment of the present invention comprises a jamb stud
arrangement for attachment to a track that is attached to a structure. The
track has a
web and a pair of flanges. This arrangement also includes a jamb stud that has
a
substantially planar jamb stud web and a first jamb stud flange that protrudes
from the
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substantially planar jamb stud web. A second jamb stud flange protrudes from
the
substantially planar jamb stud web and is spaced from the first jam stud
flange. A first
jamb stud leg protrudes from the first jamb stud flange and is substantially
parallel to the
substantially planar jamb stud web. A second jamb stud leg protrudes from the
second
jamb stud flange and is substantially parallel to the substantially planar
jamb stud web.
A first jamb stud return is on an end of the first jamb stud leg and a second
jamb stud
return on an end of the second jamb stud leg. At least one hold-down is
attached to the
jamb stud and the track.
(00022) Another embodiment of the present invention comprises a support post
that includes a post stud that has a substantially planar post stud web and a
first post
stud flange that protrudes from the substantially planar post stud web. A
second post
stud flange protrudes from the substantially planar post stud web and is
spaced from
the first post stud flange. A first post stud leg protrudes from the first
post stud flange
and is substantially parallel to the substantially planar post stud web. A
second post
stud leg protrudes from the second post stud flange and is substantially
parallel to the
substantially planar post stud web. A first post stud return is on an end of
the first post
stud leg and a second post stud return is on an end of the second post stud
leg. The
support post further includes another post stud that has another substantially
planar
post stud web. The another substantially planar post stud web is attached to
the
substantially planar post stud web of the post stud. Another first post stud
flange
protrudes from the another substantially planar post stud web. Another second
post
stud flange protrudes from the another substantially planar post stud web and
is spaced
from the another first post stud flange. Another first post stud leg protrudes
from the
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another first post stud flange and is substantially parallel to the another
substantially
planar post stud web. Another second post stud leg protrudes from the another
second
post stud flange and is substantially parallel to the another substantially
planar post stud
web. Another first post stud return is formed on an end of the another first
post stud leg.
Another second post stud return is formed on an end of the another second post
stud
leg.
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BRIEF DESCRIPTION OF THE DRAWINGS
[00023] In the accompanying Figures, there are shown present embodiments of
the invention wherein like reference numerals are employed to designate like
parts and
wherein:
[00024] FIG. 1 is a perspective view of a prior art C-shaped stud;
[00025] FIG. 2 is a perspective view of a prior art track;
[00026] FIG. 3 is a partial perspective view of a prior header and jamb stud
arrangement;
[00027] FIG. 4 is a partial end view of the prior header arrangement depicted
in
Figure 3;
[00028] FIG. 5 is a partial end of the prior jamb stud arrangement depicted in
Figure 3;
[00029] FIG. 6 is a partial perspective view of a prior truss chord assembly;
[00030) FIG. 7 is a partial perspective view of a prior art post arrangement;
[00031) FIG. 8 is a partial perspective view of a prior floor girder and floor
joist
arrangement;
[00032] FIG. 8A is a perspective view of a portion of a prior header assembly;
[00033] FIG. 9 is an elevational view of a wall frame that employs a header
embodiment, a sill embodiment and a jamb stud embodiment of the present
invention;
[00034] FIG. 9A is an elevational view of another wall frame that employs
other
header and jamb stud arrangements of the present invention;
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[00035] FIG. 9B is an elevational view of another wall frame that employs
other
header and jamb stud arrangements of the present invention;
[00036] FIG. 9C is an elevational view of another wall frame that employs
other
header and jamb stud arrangements of the present invention;
[00037] FIG. 10 is an end view of a stud embodiment of the present invention;
[00038] FIG. 11 is a perspective view of a portion of a header and jamb stud
embodiment of the present invention;
[00039] FIG. 11 A is a perspective view of the header and jamb stud embodiment
depicted in Figure 11 with a conventional stud attached to the jamb stud;
[00040] FIG. 11 B is a perspective view of a portion of another header and
jamb
stud embodiment of the present invention;
[00041] FIG. 11C is a perspective view of a portion of another header and jamb
stud embodiment of the present invention;
[00042] FIG. 11 D is a partial front elevational view of the header and jamb
stud
assembly of Figure 11 C;
[00043] FIG. 12 is a partial cross-section view of the header and jamb stud
embodiment of the Figure 11 taken along line 12-12 in Figure 11;
[00044] FIG. 13 is a perspective view of one embodiment of an attachment clip
of
the present invention;
[00045] FIG. 14 is a partial cross-sectional view of the sill and jamb stud
embodiment of Figure 9 taken along line 14-14 in Figure 9;
[00046] FIG. 15 is a partial perspective view of another header and jamb stud
embodiment of the present invention;
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[00047] FIG. 16 is a perspective view of another attachment clip of the
present
invention;
[00048] FIG. 17 is a perspective view of a portion of a truss chord embodiment
of
the present invention;
[00049] FIG. 18 is a perspective view of a portion of a truss embodiment of
the
present invention;
[00050] FIG. 18A is an elevational view of a truss that employs various truss-
related embodiments of the present invention;
[00051] FIG. 18B is a perspective view of a portion of the truss peak of the
truss
depicted in Figure 18A;
[00052] FIG. 18C is a perspective view of a portion of one of the truss heal
details
of the truss depicted in Figure 18A;
[00053] FIG. 18D is an elevational view of another truss that employs a truss
chord
and web arrangement of one embodiment of the present invention;
[00054] FIG. 18E is a perspective view of a portion of a chord and web
arrangement of one embodiment of the present invention employed in the truss
of
Figure 18D;
[00055] FAG. 19 is a perspective view of a portion of a support post of the
present
invention;
[00056] FIG. 19A is a perspective view of a portion of another support post of
the
present invention;
[00057] FIG. 19B is a perspective view of a portion of another support post
arrangement of the present invention;
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[00058] FIG. 20 is a portion of a cross-sectional view of the support post
embodiment of Figure 19 taken along line 20-20 in Figure 19;
[00059] FIG. 21 is a perspective view of a portion of a floor girder
embodiment of
the present invention;
[00060] FIG. 22 is an end view of another stud embodiment of the present
invention;
[00061] FIG. 23 is a perspective view of a portion of the stud of Figure 22;
[00062] FIG. 24 is a perspective view of a portion of other stud embodiments
of the
present invention;
[00063] FIG. 25 is a perspective view of a portion of a conventional header
assembly attached to a portion of a conventional jamb stud assembly utilizing
a pair of
connection plates of one embodiment of the present invention;
[00064] FIG. 26 is a perspective view of one embodiment of a connection plate
of
the present invention;
(00065] FIG. 27 is a plan view of a squared-shaped hole through the connection
plate depicted in FIG. 26;
[00066] FIG. 28 is a plan view of a triangular-shaped hole through the
connector
plate of FIG. 26;
(00067] FIG. 29 is a cross-section al view of the header assembly and jamb
stud
arrangement depicted in Figure 25 taken along lines 29-29 in Figure 25;
[00068] FIG. 30 is a perspective view of a portion of one embodiment of a
header
assembly of the present invention attached to a portion of a conventional jamb
stud
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assembly utilizing a pair of connection plates of one embodiment of the
present
invention;
[00069] FIG. 30A is another perspective view of the header assembly
arrangement
of Figure 30 attached to a header track and cripple studs;
[00070] FIG. 31 is a cross-sectional view of the header assembly depicted in
Figure 30 taken along line 31-31 in Figure 30;
[00071] FIG. 31A is a cross-sectional view of the header assembly of Figure
30A
taken along line 31A-31A in Figure 30A;
[00072] FIG. 32 is a perspective view of a portion of one embodiment of
another
header assembly of the present invention attached to a portion of a
conventional jamb
stud assembly utilizing a pair of connection plates of one embodiment of the
present
invention;
[00073] FIG. 33 is a cross-sectional view of the header assembly depicted in
Figure 32 taken along line 33-33 in Figure 32;
[00074] FIG. 34 is a perspective view of a portion of one embodiment of
another
header assembly of the present invention attached to a portion of a
conventional jamb
stud assembly utilizing a pair of connection plates of one embodiment of the
present
invention;
[00075] FIG. 35 is a cross-sectional view of the header assembly depicted in
Figure 34 taken along line 35-35 in Figure 34;
[00076] FIG. 36 is a perspective view of a portion of one embodiment of a
header
assembly of the present invention attached to a portion of a jamb stud of the
present
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invention utilizing a pair of connection plates of one embodiment of the
present
invention;
[00077] FIG. 37 is a cross-sectional view of the header assembly depicted in
Figure 36 taken along line 37-37 in Figure 36;
[00078] FIG. 38 is a perspective view of a portion of one embodiment of
another
header assembly of the present invention attached to a portion of a jamb stud
of the
present invention utilizing a pair of connection plates of one embodiment of
the present
invention;
[00079] FIG. 39 is a cross-sectional view of the header assembly depicted in
Figure 38 taken along line 39-39 in Figure 38;
[00080] FIG. 40 is a perspective view of a portion of one embodiment of
another
header assembly of the present invention attached to a portion of a jamb stud
of the
present invention utilizing a pair of connection plates of one embodiment of
the present
invention;
[00081] FIG. 41 is a cross-sectional view of the header assembly depicted in
Figure 40 taken along line 41-41. in Figure 40;
[00082] FIG. 42 is a perspective view of a portion of a load bearing jack post
assembly and header arrangement of one embodiment of the present invention;
[00083] FIG. 43 is a front elevational view of the portion of the load bearing
jack
post assembly and header arrangement of Figure 42;
[00084] FIG. 44 is a perspective view of a method for attaching a jamb stud
embodiment of the present invention to a portion of a bottom track;
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[00085] Figure 45 is a perspective view of a jamb stud embodiment of the
present
invention attached to a portion of an upper track that is attached to a
structure;
[00086] Figure 46 is a perspective view of one embodiment of a slide bracket
for
fastening a jamb stud of the present invention to an upper track;
[00087] Fig. 47 is an elevational view of the jamb stud and bracket of Figure
46;
[00088] FIG. 48 is a perspective view of a stud of the present invention
slidably
affixed to an I beam;
[00089] FIG. 49 is a perspective view of one embodiment of a bracket for
slidably
attaching a stud of the present invention to an I beam;
[00090] FIG. 50 is a top view of the stud and I beam connection depicted in
Figure
48;
[00091] FIG. 51 is a perspective view of a portion of a stud of the present
invention
slidably attached to an I beam;
[00092] FIG. 52 is a top view of the stud and I beam connection depicted in
Figure
51;
[00093] FIG. 53 is a perspective view of a shearwall post embodiment of the
present invention attached to a structure;
[00094] FIG. 54 is a perspective view of another shearwall post embodiment of
the
present invention attached to a structure;
[00095] FIG. 55 is a perspective view of a stud of the present invention
attached to
a structure;
[00096] FIG. 56 is a perspective view of one embodiment of a bracket for
attaching a stud of the present invention to a structure;
CA 02538649 2006-03-03
[00097] FIG. 57 is another perspective view of a stud of the present invention
attached to a structure; and
[00098] FIG. 58 is another perspective view of a stud of the present invention
attached to a structure.
21
CA 02538649 2006-03-03
DETAILED DESCRIPTION OF THE INVENTION
[00099] Any patent, publication, or other disclosure material, in whole or in
part,
that is said to be incorporated by reference herein is incorporated herein
only to the
extent that the incorporated material does not conflict with existing
definitions,
statements, or other disclosure material set forth in this disclosure. As
such, and to the
extent necessary, the disclosure as explicitly set forth herein supersedes any
conflicting
material incorporated herein by reference. Any material, or portion thereof,
that is said
to be incorporated by reference herein, but which conflicts with existing
definitions,
statements, or other disclosure material set forth herein will only be
incorporated to the
extent that no conflict arises between that incorporated material and the
existing
disclosure material.
[000100] Referring now to the drawings for the purposes of illustrating the
present
embodiments of the invention only and not for the purposes of limiting the
same,
Figures 9, 11 and 12 illustrate one embodiment of a header assembly 219 of the
present invention utilized to form a window opening 201 in a wall frame
structure 200.
As can be seen in Figure 9, the wall frame structure 200 may be fabricated
from a lower
track 202 and an upper track 206. The lower track has a web 203 and a pair of
upstanding flanges 204. Similarly, the upper track 206 has a web 207 and a
pair of
flanges 208. A plurality of studs 210 are connected between the lower track
202 and
the upper track 206 utilizing screws or other suitable fastening methods. The
studs 210
are conventional in nature and have a web 211, a pair of flanges 212 and a lip
formed
on the end of each flange 212.
22
CA 02538649 2006-03-03
[000101] In this embodiment, the header assembly 219 is formed from a uniquely
shaped header stud 220, one embodiment of which is depicted in Figure 10. As
can be
seen in Figure 10, stud 220 includes a substantially planar header web 222, a
first
header flange 224 and a second header flange 226. The first and second header
flanges (224, 226) protrude outwardly from the substantially planar header web
222. A
first header leg 228 protrudes from the first header flange 224 such that the
first header
leg 228 is substantially parallel to the substantially planar header web 222.
Likewise, a
second header leg 230 protrudes from the second header flange 226 such that it
is
substantially parallel to the substantially planar header web 222. A first
header return
232 protrudes from the first header leg 228 and a second header return 234
protrudes
from the second header leg 230.
[000102] In one embodiment, the stud 220 is rollformed from steel sheet by
utilizing
conventional rollforming methods and equipment. For example, the stud 220 may
be
fabricated from 12, 14, 16, 18, 20, etc. gage steel or other metal or
material. Although
the size of the stud 220 and the material from which it is formed may vary
depending
upon the application and loading conditions, in one embodiment for example,
the web
222 may be made in various widths of, for example, 3 5/8 inches, 6 inches and
eight
inches (distance "A"). The first and second flanges (224, 226) may be
fabricated with a
variety of different heights ranging from, for example, 2 inches- 3.5 inches
(distance
"B"). The widths of the first and second legs (228, 230) of a stud that has a
web width
of 3 5/8 inches may be 1 1/16 inches (distance "C"). Thus in this embodiment,
the
distance between the ends of the first and second legs (228, 230) is 1 1/2
inches
(distance "D"). The widths of the first and second legs (228, 230) of a stud
that has a
23
CA 02538649 2006-03-03
web width of six inches would be, for example, 2'/ inches. The widths of the
first and
second legs (228, 230) of a stud that has a web width of eight inches would
be, for
example, 3'/ inches. In various embodiments, the length of each return portion
(232,
234) may be 3/4 inches (distance "E"). It will be appreciated, however, that
other sizes
of stud 220 could be used depending upon the specific application.
[000103] In the embodiment depicted in Figures 9 and 11, a header stud 220 is
used to form the header assembly 219 and studs 220' are used to form the jamb
studs
which form the vertical boundaries of the opening 201. Studs 220' are
identical to studs
220 and are identified herein with the ""' symbol to distinguish between the
use of a stud
220 as a header and as a jamb stud. For example, each jamb stud 220' has a
substantially planar jamb stud web 222', a first jamb stud flange 224' and a
second jamb
stud flange 226' that protrude from the jamb stud web 222'. A first jamb stud
leg 228' is
attached or otherwise formed on the first jamb stud flange 224' and a second
jamb stud
leg 230' is formed on or attached to the second jamb stud flange 226'. A first
jamb stud
return 232' is formed on the end of the first jamb stud leg 228' and a second
jamb stud
return 234' is formed on the end of the second jamb stud leg 230'. See Figure
11. In
this embodiment, the stud 220 is interposed between the jamb studs 220 and may
be
quickly coupled to the jamb studs 220' by connector clips 240.
[000104] As can be seen in Figure 13, in this embodiment, one connector clip
embodiment has a clip web 242 and a pair of clip flanges 244 protruding from
the clip
web 242. The clip flanges 244 define a header-receiving space 245
therebetween. The
clip web 242 of the clip 240 is fastened to the jamb stud web 222' of the
corresponding
jamb stud 220' by appropriately sized fasteners such as sheet metal screws or
the like
24
CA 02538649 2006-03-03
and one end of the header stud 220 is inserted between the clip flanges 242 as
shown
in Figure 11. Each end of the header stud 220 is attached to the clip 240
utilizing
threaded fasteners 246 such as sheet metal screws or the like. However, header
stud
220 could be welded to the clip 240.
[000105] As shown in Figure 11, in this embodiment, a header track 260 is
supported on and attached to the first and second legs (228, 230) of the
header stud
220. Header track 260 has a header track web 262 and a pair of upstanding
header
track flanges 264. The web 262 of the header track 260 is attached to the
first and
second header legs (228, 230) of the header stud 220 by fasteners 246 which
may
comprise conventional sheet metal screws or the like. In addition, pieces of
studs 270,
which may be conventional in nature, may be attached to the track header 260
and the
upper track 206. Studs 270 may each have a web 272, pair of flanges 274 and a
return
276 formed on the end of each flange 274. The flanges 274 of the studs 270 are
attached to the header flanges 264 and the upper track flanges 208 by
fasteners such
as sheet metal screws or the like. Studs 270 serve as the cripple studs for
the header
arrangement. For window or door openings that require additional support due
to their
width, an additional conventional stud 210 could be attached to the jamb stud
220' as
shown in Figure 11A.
(000106 Figures 9A and 11 B illustrate the use of alternate header and jamb
stud
arrangements to form a window opening 201 in a wall frame structure 200. As
can be
seen in Figure 11 B, two jamb studs 220' are employed to form a jamb stud
assembly
221'. In this embodiment, the web portions 222' of the jamb studs 220' may be
attached
in back-to back fashion by a plurality of screws 289 through the web portions
222'. For
CA 02538649 2006-03-03
example, No. 10-16 screws may be employed and spaced at 12 inches on center to
attach the two web portions 222' together. In alternative embodiments, the
jamb studs
220' could be welded together or other fastener arrangements employed. To lend
further support to the jamb stud assembly 221', a C-shaped piece of track 291
may be
attached to the one jamb stud 220' as shown in Figure 11 B. The track 291 has
a web
portion 293 and a pair of flanges 295 and would extend down to the sill. The
flanges
295 may be attached to the corresponding flanges 224', 226' of the jamb stud
220' by
screws 297 or by welding. In one example, No. 10-16 screws that are 24 inches
on
center may be employed. The track 291 may be located such that the connector
clip
242 is attached immediately above the track 291 as shown. The track 291 may be
employed or may not be employed depending upon how the window is attached to
the
jamb. The track serves to better facilitate attachment of the window assembly
to the
jamb. For example, for some windows, the inside face of the jamb will have to
provide
an attachment surface through the web depth. For other windows, the window can
be
secured to the jamb without adding track 291. One end of a header stud 220 of
the type
and construction described above is connected to the jamb stud assembly 221'
by
connector clip 242 in the manner described above.
[000107] Also in this embodiment, a header track 260 is supported on and
attached
to the first and second legs (228, 230) of the upper header stud 220. Header
track 260
has a header track web 262 and a pair of upstanding header track flanges 264.
The
web 262 of the header track 260 is attached to the first and second header
legs (228,
230) of the header stud 220 by fasteners 246 which may comprise conventional
sheet
metal screws or the like. For example, in one embodiment, fasteners 246
comprise No.
26
CA 02538649 2006-03-03
10-16 screws. However, other fasteners and fastener arrangements could be
employed. In addition, studs 270, which may be conventional in nature, may be
attached to the header track 260 and the upper track 207. Studs 270 may each
have a
web 272, pair of flanges 274 and a return 276 formed on the end of each flange
274.
The flanges 274 of the studs 270 are attached to the header flanges 264 and
the upper
track flanges by fasteners such as sheet metal screws or the like.
[000108] Figure 9B illustrates use of the jamb stud assembly 221' embodiment
described above to form one vertical side of opening 201 and a "third" jamb
stud 220' to
form the other vertical side of opening 201.
(000109] Figures 9C, 11 C and 11 D illustrate the use of a pair of header
studs 220
for forming a header assembly 219'. Studs 220' and 210 are used to form a jamb
stud
assembly 221 which forms the vertical boundaries of the opening 201' in the
manner
described above. In this embodiment, the webs 222 of the header studs 220 may
be
interconnected by appropriately sized fasteners 223. In one embodiment,
fasteners 223
comprise No. 10-16 screws spaced at 12 inches on center. However, other
suitable
fasteners and fastener arrangements may be employed. For example, the studs
220
may be welded together. It is also conceivable that, depending upon the load
requirements, the upper stud 220 may be positioned on the lower stud 220 such
that the
legs (228, 230) of the upper stud 220 are received on the web 222 of the lower
stud
220.
[000110] As can be seen in Figure 11 C, a connector clip 240' is attached to
the web
222' of the jamb stud 220' and is oriented to receive the two header studs 220
therein
as shown in Figure 11 D. The connector clip 240' has a web 242' and a pair of
flanges
27
CA 02538649 2006-03-03
244' and is oriented such that the flanges 244' extend vertically to receive
the header
studs 220 therebetween. The connector clip 240' may be attached to the web of
the
jamb stud by appropriate fasteners 225' and/or welded thereto. In one
embodiment,
fasteners 225' comprise four No. 10-16 screws. However, other fasteners and
fastener
arrangements may be employed. The header studs 220 may be attached to the
flanges
244' by appropriate fasteners 227' and/or be welded thereto. In one embodiment
three
No.10-16 screws may be employed through each flange 244'. See Figure 11 D.
However, other fasteners and fastener arrangements may be employed.
[000111] Also in this embodiment, a header track 260 is supported on and
attached
to the first and second legs (228, 230) of the upper header stud 220. Header
track 260
has a header track web 262 and a pair of upstanding header track flanges 264.
The
web 262 of the header track 260 is attached to the first and second header
legs (228,
230) of the header stud 220 by fasteners 246 which may comprise conventional
sheet
metal screws or the like. For example, in one embodiment, fasteners 246
comprise No.
10-16 screws. However, other fasteners and fastener arrangements could be
employed. In addition, studs 270, which may be conventional in nature, may be
attached to the header track 260 and the upper track 207. Studs 270 may each
have a
web 272, pair of flanges 274 and a return 276 formed on the end of each flange
274.
The flanges 274 of the studs 270 are attached to the header flanges 264 and
the upper
track flanges by fasteners such as sheet metal screws or the like. However,
studs 270
could also be welded to the header track 260. Studs 270 serve as the cripple
studs for
the header arrangement.
28
CA 02538649 2006-03-03
[000112] As can also be seen in Figures 9 and 14, sill studs 220" may be used
to
form a windowsill designated as 280. Sill studs 220" are identical to header
studs 220
and are identified herein with the " symbol to distinguish between the use of
a stud 220
as a header and as a sill stud. For example, each sill stud 220" has a
substantially
planar sill stud web 222", a first sill stud flange 224" and a second sill
stud flange 226"
that protrude from the sill stud web 222". See Figure 14. A first sill stud
leg 228" is
attached or otherwise formed on the first sill stud flange 224" and a second
sill stud leg
230" is formed on or attached to the second sill stud flange 226". A first
sill stud return
232" is formed on the end of the first sill stud leg 228" and a second sill
stud return 234"
is formed on the end of the second jamb stud leg 230'.
[000113] In this embodiment, the sill stud 220" is oriented with the flanges
224" and
226" extending toward the lower track 202 and is coupled to the jamb studs
220' by
connector clips 240 in the manner described above. Also in this embodiment, a
sill
track 260" is supported on and attached to the first and second legs (228",
230") of the
sill stud 220". Sill track 260" has a sill track web 262" and a pair of
upstanding sill track
flanges 264". The sill track web 262" of the sill track 260" is attached to
the first and
second sill track legs (228", 230") of the sill stud 220" by fasteners 246"
which may
comprise conventional sheet metal screws or the like. In addition, pieces of
studs 270",
which may be conventional in nature, may be attached to the sill track 260"
and the
lower track 202. Studs 270" may each have a web 272", pair of flanges 274" and
a
return 276" formed on the end of each flange 274". The flanges 274" of the
studs 270"
are attached to the sill track flanges 264" and the lower track flanges 208 by
fasteners
29
CA 02538649 2006-03-03
246" such as sheet metal screws or the like. Studs 270" serve as the cripple
studs for
the sill 280.
[000114] Such header, jamb stud and sill arrangements of the present invention
require less labor and material to assemble than the prior header
configurations. It will
also be appreciated, however, that the uniquely shaped studs 220, 220', 220"
could be
used in a variety of other applications and combinations. For example, the
header
studs 220 and the sill studs 220" could be used to form headers and sills,
respectively
as described above in connection with conventional jamb stud arrangements.
Likewise,
the studs 220' could be used to form jamb studs that are used in connection
with
conventional header and sill assemblies. Thus, it will be appreciated that the
header
studs 220 and/or sill studs 220" do not have to be used in connection with
jamb studs
220' if use of other jambs stud arrangements is more preferable and visa-
versa. It will
be also appreciated that the studs (220, 220', 220") could be used in
connection with
wood studs and wood framing assemblies.
[000115] In another header assembly embodiment of the present invention, a
connector clip 290 of the type illustrated in Figures 15 and 16 is employed.
As can be
seen in Figure 16, the connector clip 290 has a pair of clip attachment tabs
292 and a
raised central portion 296. The clip attachment tabs 292 are substantially
coplanar with
each other. The central portion 296 is substantially parallel to the clip
attachment tabs
292 and is attached thereto by a pair of clip legs 294. The clip attachment
tabs 292 are
attached to the jamb stud web 222' of the jamb stud 220' by fasteners 299 such
as
sheet metal screws and the end of the header stud 220 is inserted over the
central
portion 296 such that the central portion 296 is received in the area between
the first
CA 02538649 2006-03-03
and second header flanges (224, 226) and the first and header second legs
(228, 230).
As can be seen in Figures 15 and 16, a pair of return-receiving slots 298 are
provided in
a portion of the central portion 296 and one of the clip legs 294 for
receiving the first and
second header returns (232, 234) when the ends of the header stud 220 is
inserted over
the raised central portion 286. The header stud 220 is then attached to the
connector
clip 290 by conventional fasteners such as such metal screws or the like. The
header
stud 220 could also be attached to the connector by welding or other fastener
arrangements. Such connector clip arrangement may provide further torsional
stability
to the header stud 220 when installed in this manner. Connector 290 could also
be
used to attach the sill studs 220" to the jamb studs 220' in the above-
described
manners.
[000116] Figure 17 illustrates a unique and novel truss chord arrangement 300
of
one embodiment of the present invention. In this embodiment, a chord stud 310,
which
is essentially identical in construction as the header stud 220, is employed
to form the
truss chord. The chord stud 310 has a substantially planar chord web 312 and a
first
chord flange 314 and a second chord flange 316 protruding therefrom. A first
chord leg
318 protrudes from the first chord flange 314 and a second chord leg 320
protrudes
from the second chord flange 316. A first chord return 322 is formed on the
end of the
first chord leg 318 and a second chord return 324 is formed on the end of the
second
chord leg 320. Pieces of studs 330 which are conventional in nature are
attached to the
first and second chord legs (314, 316) and the chord web 312 of the chord stud
310
utilizing fasteners 340 such as sheet metal screws. The studs 330 each have a
web
332, a pair of flanges 334 and a lip 336 formed on the end of each flange 334.
These
31
CA 02538649 2006-03-03
studs 330 form the webs of the truss. Such arrangement eliminates labor
required to
weld two pieces of stud together to form the truss chord.
[000117] Figure 18 illustrates another truss assembly 300' of the present
invention.
In this embodiment, the truss webs are formed from truss studs 310' which are
each
essentially identical in construction as the chord stud 310. Each truss stud
310' has a
substantially planar chord web 312' and a first chord flange 314' and a second
chord
flange 316' protruding therefrom. A first chord leg 318' protrudes from the
first chord
flange 314' and a second chord leg 320' protrudes from the second chord flange
316'.
A first chord return 322' is formed on the end of the first chord leg 318' and
a second
chord return 324' is formed on the end of the second chord leg 320'. In this
embodiment, the truss studs 310" are attached to the chord stud 310 by one or
more
gusset plates 350' and fasteners 354' such as sheet metal screws. The gusset
plates
350' may be fabricated from steel or other suitable material.
[000118] Figure 18A illustrates a portion of a truss 2000 that employs various
truss-
related embodiments of the present invention. In one embodiment, two chord
studs 310
of the type and construction described above form the upper chords of the
truss 2000.
The studs 310 are cut to form a pitch break 2010 of the truss 2000. The chord
studs
310 are interconnected by one and preferably two gusset plates 2012 and
fasteners
2014 of the type described above. See Figure 18B.
[000119] Figure 18C illustrates a truss heal detail 2020 that employs two
truss
chords 310 of the present invention that are coupled together utilizing gusset
plates
2012 and fasteners 2014. As can be seen in the Figure, the stud 310 forming
the lower
truss chord is supported on a structure such as an I beam 2030 or the like.
32
CA 02538649 2006-03-03
[000120] Figure 18D illustrates another truss assembly 3000 that employs
another
chord and web arrangement of the present invention. In this embodiment, the
upper
chords 3010 of the truss 3000 are each formed from a pair of chord studs 310.
As can
be seen in Figure 18E, the chord legs 318, 320 of one chord stud 310 abut the
chord
stud legs 318, 320 of the other chord stud 310. The truss assembly 3000
further
includes web assemblies 370 that each may comprise a pair of truss studs 310'
which
are each essentially identical in construction as the chord stud 310. Each
truss stud
310' has a substantially planar chord web 312' and a first chord flange 314'
and a
second chord flange 316' protruding therefrom. A first chord leg 318'
protrudes from the
first chord flange 314' and a second chord leg 320' protrudes from the second
chord
flange 316'. A first chord return 322' is formed on the end of the first chord
leg 318' and
a second chord return 324' is formed on the end of the second chord leg 320'.
The
chord webs 312' of the chord studs 310' are arranged to abut each other to
form a
single web assembly 370. The web assemblies 370 are then attached to the chord
assembly 360 by one or more gusset plates 350" and fasteners 354" such as
sheet
metal screws. The gusset plates 350" may be fabricated from steel or other
suitable
material.
[000121] Figures 19 and 20 illustrate a support post 400 embodiment of the
present
invention that is formed utilizing a post stud 410 which is identical to the
header stud
220 described above. The post stud 410 has a substantially planar post stud
web 412
and a first post stud flange 414 and a second post stud flange 416 protruding
from the
post stud web 412. A first post stud leg 418 protrudes from the first post
stud flange
414 and a second post stud leg 420 protrudes from the second post stud flange
416. A
33
CA 02538649 2006-03-03
first post stud return 422 is formed on the end of the first post stud leg 418
and a
second post stud return 424 is formed on the end of the second post stud leg
420. See
Figure 19.
[000122] In this embodiment, the post stud 410 is used in connection with two
studs
430. The studs 430 each have a web 432 and two flanges 434. A lip 436 is
formed on
the end of each flange 434. The post 400 is formed by attaching the web 432 of
one of
the studs 430 to the post stud 412 of the post stud 410 with fasteners 438
such as sheet
metal screws or the like and the web 432 of the other stud 430 is attached to
the first
and second post stud legs (418, 420) of the post stud 410 by sheet metal
screws 438 or
the like. I have discovered that such arrangement provides an equivalent
amount of
structural support as prior post arrangements that employ three conventional
studs and
two pieces of conventional track. Thus, this embodiment of the present
invention
reduces the amount of material needed and also the amount of labor needed to
assemble it when compared to prior post assemblies. It will be appreciated,
however,
that the post stud 410 may also be used in connection with one stud 430 or
more than
two studs 430 without departing from the spirit and scope of the present
invention.
[000123] Figure 19A illustrates a support post 400' embodiment of the present
invention that is formed utilizing a pair of post studs 410 which are each
identical to the
header stud 220 described above. Each post stud 410 has a substantially planar
post
stud web 412 and a first post stud flange 414 and a second post stud flange
416
protruding from the post stud web 412. A first post stud leg 418 protrudes
from the first
post stud flange 414 and a second post stud leg 420 protrudes from the second
post
stud flange 416. A first post stud return 422 is formed on the end of the
first post stud
34
CA 02538649 2006-03-03
leg 416 and a second post stud return 424 is formed on the end of the second
post stud
leg 420. In this embodiment, the post studs 410 are arranged such that the
post stud
webs 412 are back-to back and interconnected by an appropriate number of
appropriately sized fasteners 401 and/or be attached together by welding. In
one
embodiment, fasteners 401 comprise No. 10-16 screws that are arranged at 12
inches
on center. However, other types and arrangements of fasteners may be used. In
alternative embodiments, depending upon the application and load requirements,
the
post stud legs 418, 420 of one post stud 410 may be attached to the post stud
web 412
of the other post stud 410 or the post stud legs 418, 420 of one post stud 410
may be
attached to the post stud legs 418, 420 of the other post stud 410. In
addition, as
shown in Figure 19B, additional studs 430 of the type and construction
described above
may be attached to the pair of post studs 410 to form a support post 400" as
shown. In
that embodiment, the webs 432 of each of the studs 430 are attached to the
legs 418,
420 of the corresponding stud by fasteners 403. !n one embodiment, fasteners
403
comprise No. 10-16 screws arranged in pairs that are spaced at 24 inches on
center.
However, other fasteners and fastener arrangements could be employed. For
example,
the studs 430 may be welded to the respective post studs 410.
[000124] The unique and novel studs of the present invention may also be used
as
a floor girder 502 in a floor system 500. More particularly and with reference
to Figure
21, a single girder stud 510 serves as a floor girder for attaching
conventional floor joists
530 thereto. The girder stud 510 is identical in construction when compared to
the
header stud 220 described above. In one embodiment, the girder stud 510 has a
substantially planar girder web 512 and a first girder flange 514 and a second
girder
CA 02538649 2006-03-03
flange 516 protruding from the girder web 512. A first girder leg 518
protrudes from the
first girder flange 514 and a second girder leg 520 protrudes from the second
girder
flange 516. A first girder return 522 is formed on the end of the first girder
leg 518 and a
second girder return 524 is formed on the end of the second girder leg 520.
[000125] The floor joists 530 may have a joist web 532 and a first joist
flange 534
and a second joist flange 536. A first joist lip 538 is formed on the end of
the first joist
flange 534 and a second joist lip 540 is formed on the end of the second joist
flange
536. One series of joists 530 are attached to the first and second girder legs
(518, 520)
of the girder stud 510 by conventional L-shaped clips 550 and sheet metal
screws 552
or the like. The joists 530 protruding from the other side of the girder stud
510 are
attached to the girder web 512 of the girder stud 510 by L-shaped clips 550
and
fasteners 552. Such improved arrangement eliminates the need to assemble the
girder
from a conventional stud and track and the labor associated with making such
girder. It
will be further appreciated that the girder of the present invention may find
utility in non-
floor applications without departing form the spirit and scope of the present
invention.
[000126] Figures 22 and 23 illustrate an alternative stud embodiment 620 of
the
present invention. Stud 620 includes a web 622, a first flange 624 and a
second flange
626. The first and second flanges (624, 626) protrude outwardly from the web
622. A
first leg 628 protrudes from the first flange 624 such that the first leg 628
is substantially
parallel to the web 622. Likewise, a second leg 630 protrudes from the second
flange
626 such fihat it is substantially parallel to the web 622. A first return 632
protrudes from
the first leg 628 and a second return 634 protrudes from the second header leg
630.
See Figure 22.
36
CA 02538649 2006-03-03
[000127] In one embodiment, the stud 620 is rollformed from steel sheet by
utilizing
conventional rollforming methods and equipment. For example, the stud 620 may
be
fabricated from 12, 14, 16, 18, 20, etc. gage steel or other metal or
material. In this
embodiment, the stud 620 may further include a series of stiffener ribs. More
particularly and with reference to Figure 22, the web 622 may have one or more
web
stiffener ribs 623 therein. Web stiffener ribs 623 may continuously extend the
entire
length of the web 622 or they may, for example, be provided in an intermittent
manner
along the web 622. Similarly, flange stiffener ribs may be provided in the
flanges 624
and/or 626. For example, at least one first flange stiffener rib 625 may be
provided in
the first flange 624. The first flange stiffener rib 625 may continuously
extend the entire
length of the first flange 624 or it may be intermittently provided therein.
At least one
second flange stiffener rib 627 may be provided in the second flange 626. The
second
flange stiffener rib 627 may extend the entire length of the second flange 626
or it may
be intermittently provided therein. In addition, at least one first leg
stiffener rib 629 may
be provided in the first leg 628. The first leg stiffener rib 629 may
continuously extend
the entire length of the first leg 628 or it may be intermittently provided
therein. At least
one second leg stiffener rib 631 may be provided in the second leg 630. The
second
leg stiffener rib 631 may extend the entire length of the second leg 630 or it
may be
intermittently provided therein. Various stud embodiments may include one or
more
web stiffener ribs, flange stiffener ribs and leg stiffener ribs or any
combination thereof
depending upon the specific application. For example, one embodiment may only
include at least one stiffener rib in the web of the stud. Another embodiment
may only
include at leas one stiffener rib in each flange. Another embodiment may
include at
37
CA 02538649 2006-03-03
least one stiffener rib in each of the legs. Still another embodiment may
include at least
one stiffener rib in the flanges, but not in the web. Another embodiment may
include at
least one stiffener rib in each leg, but nowhere else in the stud. Another
embodiment
may include at least one stiffener rib in each leg and at least one stiffener
rib in the web,
but not in the flanges. The present disclosure is meant to encompass all
permutations
and combinations of stiffener ribs without departing from the spirit and scope
of the
present invention.
[000128] In yet another embodiment, one or more access holes 700 may be
provided through the webs of studs 220, 220', 220", 620 disclosed herein. See
Figure
24. The access holes may be formed in the webs of the respective studs such
that a
flange 702 extends around the perimeter of the hole 700. Studs containing such
holes
could be used in any of the above-described embodiments to form, for example,
headers, sills, jamb studs, truss chords, posts, and girders.
[000129] Figure 25 illustrates a portion of a lintel arrangement 800 that is
spaced
between conventional jamb studs 50 of the type and construction described
above to
form the top of a door or window opening 804. As was described above, the jamb
studs
50 are each commonly formed by attaching a C-shaped stud 52 to another piece
of
track 60 such that the flanges 56 of the stud 52 are received between the
flanges 64 of
the track 60 and then attaching the web 72 of another stud 70 to the web 64 of
the track
60. These components are also commonly coupled together with screws 49 or, in
the
alternative, they may be welded together to form the jamb stud 50. This
embodiment
employs unique and novel connectors 810 to fasten a conventional header 130 of
the
type and construction depicted in Figure 8A to the jamb studs 50.
38
CA 02538649 2006-03-03
[000130] As described above, the conventional header 130 is formed from two
conventional studs or C-shaped members 140 that are retained in spaced-apart
relationship relative to each other between a piece of upper track 150 and a
piece of
lower track 160. The pieces are held together by a collection of screws 162 or
by
welding.
[000131] One embodiment of the unique and novel connectors 810 of the present
invention is depicted in Figure 26. As can be seen in that Figure, the
connector 810
comprises a substantially planar connection plate 812 that is fabricated from
suitable
material that is capable of withstanding the anticipated loading conditions in
accordance
with the relevant building codes and design requirements. For example, the
connection
plate 812 may be fabricated from 12, 14 or 16 gauge metal or other suitable
material. In
one embodiment, the connection plate 812 is substantially rectangular in
shape. For
example, in the embodiment depicted in Figure 26, the plate 812 may be
approximately
8.5 inches long (distance "F") and approximately 6 inches high (distance "G")
However, other plate sizes may be employed.
[000132] The connection plate 812 may be provided with a collection of
fastener
holes collectively designated as 820. In one embodiment, the holes 820 may all
have
the same dimensions and shape. For example, the holes 820 may all be round and
sized to accommodate the appropriate size of fastener. In alternative
embodiments. If
different sizes of fasteners are desirable, the holes may have like shapes by
have
different sizes to accommodate different sizes of fasteners.
[000133] In the embodiment depicted in Figure 26, however, a unique and novel
fastener hole arrangement is employed. In one embodiment, at least two
different
39
CA 02538649 2006-03-03
shapes of holes are employed. In the embodiment depicted in Figure 26, for
example,
three different shapes of holes are employed. As can be seen in Figure 26, two
rows
830, 832 of linearly aligned first holes 834 are provided through the
connection plate
812. Row 830 of first holes 834 is adjacent the upper edge 814 of the
connection plate
812. In this embodiment, the distance from the upper edge 814 to the
centerlines of the
holes 834 in row 830 is approximately 0.5 inches (distance "K"). Row 832 of
first holes
834 is adjacent the lower edge 816 of the connection plate 812. In this
embodiment,
the distance from the lower edge 816 to the centerlines of the first holes 834
in the row
832 is approximately 0.5 inches (distance "L"). As can be seen in Figures 26
and 27,
the first holes 834 are square-shaped. The square-shaped first holes 834 are
sized to
accommodate the desired fasteners that are to be installed through those
holes. For
example, the square-shaped first holes 834 may be approximately 3/32 inch
square
(distance "M" in Figure 27) to accommodate No. 10-16 screws. However other
sizes
and types of fasteners may be employed
[000134] Also in this embodiment, a collection of second holes 844 are
provided
through connection plate 812. Second holes 844 each have a second shape that
differs
from the shape of the first holes 834. More particularly in this embodiment,
rows 840,
842 of linearly aligned second holes 844 are provided through the connection
plate 812
in the locations shown in Figure 26. That is, row 840 is adjacent to the row
830 and row
842 is adjacent to row 832. In this embodiment, the centerlines of the second
holes 844
in the row 840 are spaced approximately 1.0 inches from the centerlines of the
first
holes 834 in the row 830. Likewise, the centerlines of the second holes 844 in
the row
842 are approximately 1.0 inches from the centerlines of the first holes 834
in row 832.
CA 02538649 2006-03-03
In this embodiment, the second holes 844 are triangular-shaped and sized to
accommodate the desired fasteners. In one embodiment, the sides of the second
holes
844 may be approximately 1/8 inch long (distance "N" in Figure 28) to
accommodate
No. 10-16 screws. However other types and sizes of fasteners may be employed.
[000135] As can also be seen in Figure 26, in this embodiment, two rows 850,
852
of linearly aligned third holes 854 are provided through the connection plate
812. The
shape of each of the third holes 854 differs from the "first" shape of each of
the first
holes 834 and the "second" shape of second holes 844. In this embodiment, the
centerline of the linearly aligned third holes 854 in row 850 is spaced
approximately 1.0
inch from the centerline of linearly aligned second holes 844 in row 840.
Likewise, the
centerline of the linearly aligned third holes 854 in row 852 is approximately
1.0 inch
from the centerline of the linearly aligned second holes 844 in row 842 and
also
approximately 1.0 inch from the centerline of the linearly aligned third holes
854 in row
850. The third holes 854 in this embodiment are round and sized to accommodate
the
desired fasteners. In one embodiment, for example, the third holes 854 are
approximately 5/32 inches in diameter and may accommodate No. 10-16 screws.
However, other types and sizes of fasteners may be employed.
[000136] In this embodiment, the first holes 834, second holes 844 and third
holes
854 are further aligned to form a first column of linearly aligned holes
designated as first
column 860, a second column of linearly aligned holes designated as second
column
862, a third column of linearly aligned holes designated as third column 864,
a fourth
column of linearly aligned holes designated as fourth column 866 and a fifth
column of
linearly holes designed as fifth column 868.
41
CA 02538649 2006-03-03
[000137] Each particular hole shape has a load capacity associated with it.
That is,
by filling all of the first holes 834 with appropriately sized fasteners that
correspond to
those holes, a first predetermined load capacity for the connection may be
attained. By
filling all of the second holes 844 with appropriately sized fasteners that
correspond to
those holes, a second predetermined load capacity for the connection may be
achieved.
By filling all of the third holes 854 with appropriately sized fasteners that
correspond to
those holes, a third load capacity may be achieved for the connection. By
filling only all
of the first and second holes 834, 844 with appropriately sized fasteners
corresponding
to those holes, a fourth predetermined load capacity may be achieved. By
filling only all
of the first and third holes 834, 854 with appropriately sized fasteners con-
esponding to
those holes, a fifth predetermined load capacity may be achieved. By filling
only all of
the second and third holes 844, 854 with appropriately sized fasteners
corresponding to
those holes, a sixth predetermined load capacity for the connection may be
achieved.
By filling all of the first, second and third holes 834, 844, 854 with
corresponding
fasteners, a seventh predetermined load capacity for the connection may be
achieved.
[000138] The following chart provides an example of the loading
characteristics that
may be achieved using conventional connectors:
FramingFraming10 Screws 20 Screws 30 Screws
ConnectorGauge Fy Jamb Header Jamb Header Jamb Header
(Mils) (ksi) Ca aci Ca acitCa aci Ca acit Ca aci Ca acit
20 33 33 561 307 1121 507 1361 637
18 43 33 8 455 1361 753 1361 945
32
H436 16(54) 33 __ 455 1361 753 1361 945
Using 50 _ 455 1361 753 1361 945
832
832
#12-16 14 (68)33 832 455 1361 753 1361 945
Screws 50 832 455 1361 753 1361 945
12 (97)33 832 455 1361 753 1361 945
50 832 455 1361 753 1361 945
20 33 33 561 307 1121 507 1682 637
18 43 33 832 455 1664 753 2496 945
H546 16(54) 33 1172 641 2345 1061 2634 1332
Using 50 1682 919 2634 1522 2634 1910
42
CA 02538649 2006-03-03
Framing Framing10 Screws 20 Screws 30 Screws
ConnectorGauge Fy Jamb Header Jamb Header Jamb Header
(Mils) (ksi) Ca acitCa acitCa acit Ca acitCa acitCa acit
#10-16 14 (68) 33 1655 905 2634 1498 2634 1880
Screws 50 1682 919 2634 1522 2634 1910
12(97) 33 1682 919 2634 1522 2634 1910
50 1682 919 2634 1522 2634 1910
20 33 33 630 344 1260 570 1890 716
18 43 33 935 511 1870 846 2805 1062
H686 16 (54) 33 1318 720 2635 1193 3821 1497
Using 50 1997 1091 3821 180 3821 2268
7
'/-14 14 (68) 33 1860 1017 3720 _ 3821 2113
Screws 50 2818 1541 3821 _ 3821 3201
1684
2551
12(97) 33 2818 1541 3821 2551 3821 3201
50 2818 1541 3821 2551 3821 3201
(000139] The skilled artisan will appreciate that the unique and novel
fastener hole
arrangement of the connection plate embodiment of the present invention may be
adapted to assist the installer in quickly attaining the desired load capacity
when
coupling a header 130 to a jamb stud 50. By locating the holes in the
necessary
locations and providing the installer with information indicating: (i) the
type and size of
fastener associated with each shape of hole and (ii) an indication of the load
capacity
attainable by employing fasteners through particular shapes of holes, the
installer will be
able to quickly achieve a connection that will have the desired load capacity
characteristics. It will be further appreciated that particular shapes and
orientations of
the fastener holes depicted in Figure 26 are merely illustrative of one
embodiment of the
connection plate of the present invention. The numbers, locations and
particular
shapes of holes may vary with the size of the plate employed and the load
capacity
required. For example, the rows of square holes may be provided where the rows
of
round holes are located and the rows of round holes may be provided where the
rows of
square holes are located, ect. Thus, the scope of protection afforded to the
connection
plate of the present invention should not be limited to the particular shape
and
43
CA 02538649 2006-03-03
arrangements of holes depicted in Figures 26-28 and described above. A myriad
of
different shapes, sizes and arrangements of holes are contemplated.
[000140] To aid in the quick positioning of the connection plate 812 such that
it
properly spans between the jamb stud 50 and the header 130 and the fastener
holes
are oriented in desired positions to facilitate fastening of the plate 812 in
the desired
position, a locator tab 890 is formed on the lower parametrical edge 816 of
the
connection plate 812. In one embodiment, the locator tab 890 is substantially
planar
and substantially rectangular in shape and protrudes outward from the
connection plate
such that it is substantially perpendicular thereto. For example, the locator
tab 890 may
be approximately 2 inches long (distance "O") and approximately 1.5 inches
wide
(distance "P"). For use in connection with conventional jamb stud assemblies,
the
locator tab 890 may be located approximately 3.25 inches from the end of the
connection plate 812 (distance "Q")
[000141] Figures 25 and 29, illustrate use of one embodiment of the connector
810
of the present invention to connect a conventional header 130 to a
conventional jamb
stud 50. As can be seen in those Figures, the installer places the locator tab
890 under
the header 130 and moves it into abutting contact with the jamb stud 50. The
locator
tab 890 serves to position the connector 810 such that the first and second
columns
860, 862 of holes are aligned to permit fasteners 892 to be installed through
the holes of
those columns and into the jamb stud 50. Likewise, the columns 864, 866, 868
of holes
are located to permit fasteners to be inserted therethrough into the header
130. The
reader will appreciate that two connectors 810 may be employed to attach one
end of
the header 130 to the corresponding jamb stud 50. Thus, four connectors 810
may be
44
CA 02538649 2006-03-03
employed to attach the ends of the header 130 to two spaced jamb studs 50 to
form a
window, door or other opening. Such unique and novel arrangement of the
connector
810 enables the connector 810 to be used on either side and either end of the
header
for attachment purposes. This is can be a very useful advantage when compared
with
other types of connector arrangements employed to connector headers to jamb
studs.
Such connector arrangements require different connectors for connecting left
and right
ends of the header to the jamb stud. This undesirable feature requires the
installer to
have both types of connectors on hand during the construction process.
Whereas,
when using the connector 810 of the present invention, only one type of
connector is
required.
[000142] The connector 810 of the present invention may also be effectively
used in
connection with header studs 220 of the type and construction described above.
In
particular and with reference to Figures 30 and 31, a header assembly
embodiment
1000 of the present invention is depicted for use in connection with a
conventional jamb
stud 50. In this embodiment, header assembly 1000 includes a pair of header
studs
220 that are arranged such that the first leg 228 of one header stud 220 is in
abutting
contact with the first leg 228 of the other header stud 220. Likewise, the
second leg 230
of the one header stud 220 is in abutting contact with the second leg 230 of
the other
header stud 220 as shown in Figures 30 and 31.
[000143] A pair of connector plates 810 is used on each end of the header
assembly 1000 to attach one end of the header assembly 1000 to the
corresponding
jamb stud 50. Fasteners 892 such as 10-16 screws, etc. are inserted through
the holes
in the connector plate 812 of the connectors 810. Figures 30 and 31 illustrate
use of
CA 02538649 2006-03-03
fasteners 892 through all of the holes in the connector plate 812. The reader
will
appreciate that the number and types of fasteners 892 employed may vary
depending
upon the load capacity desired and the corresponding hole shapes that must be
filled
with a corresponding fastener 892. The locator tab 890, when abutted against
the jamb
stud 50, serves to locate the columns 866 and 868 of holes through the
connector plate
812 along the jamb stud 50 for attachment of the plate 812 thereto. The header
studs
220 in this embodiment may or may not be attached to each other by other
fasteners
(screws) or by welding. In those embodiments wherein the header studs 220 are
not
independently attached to each other, they are simply sandwiched together at
their
respective ends between the corresponding pairs of connectors 810.
[000144] Figures 30A and 31A illustrate the use of a header track 260 and
cripple
stud arrangement of the type and construction described with the embodiment of
Figures 30 and 31. As can be seen in Figures 30A and 31A, a header track 260
is
supported on and attached to the flanges 224 of the header studs 220. Header
track
260 has a header track web 262 and a pair of upstanding header track flanges
264.
The web 262 of the header track 260 is attached to the flanges 224 of the
header studs
220 by fasteners 246 which may comprise conventional sheet metal screws or the
like.
In addition, pieces of studs 270, which may be conventional in nature, may be
attached
to the header track 260 and the upper track (not shown). Studs 270 may each
have a
web 272, pair of flanges 274 and a return 276 formed on the end of each flange
274.
The flanges 274 of the studs 270 are attached to the header flanges 264 and
the upper
track flanges 208 by fasteners 269 such as sheet metal screws or the like.
Studs 270
serve as the cripple studs for the header arrangement. A pair of L-shaped clip
angles
46
CA 02538649 2006-03-03
271 may be employed as shown to complete the connection. As can be seen in
Figures
30A and 31A, one leg of the upper L-shaped clip angle 271 is attached to the
web 222'
of the jamb stud 220' and the other leg of the clip angle 271 may be attached
to the web
262 of the header track 260 and underlying flanges 224 of the header studs 220
by
appropriate fasteners 273. In one embodiment No. 10-16 screws are employed.
However, other fasteners may be employed. The legs of the L-shaped clip angle
271
may be welded to the webs, if desired. Similarly, on leg of the lower L-shaped
clip
angle 271 is attached to the web 222' of the jamb stud 220' and the other leg
of the clip
angle 271 is attached to the flanges 226 of the header studs 220 by other
fasteners
273. See Figure 31 A.
[000145] Figures 32 and 33 illustrate the use of the connector plates 810 of
the
subject invention in connection with an alternative header assembly 1100 of
the present
invention which also employs a pair of header studs 220 of the type and
construction
described above. In this embodiment, the web 222 of one of the header studs
220 is in
abutting contact with the web 222 of the other header stud 220 as shown in
Figure 32.
In one embodiment, the webs 222 may be interconnected by fasteners such as
screws
892 or the like. See Figure 33.
[000146] A pair of connector plates 810 is used on each end of the header
assembly 1100 to attach the header assembly 1100 to the corresponding jamb
stud 50.
Fasteners 892 such as 10-16 screws, etc. are inserted through the holes in the
connector plate 812 of the connectors 810. Figure 32 illustrates use of
fasteners 892
through all of the holes in the upper two rows 830, 840 of holes and the lower
two rows
832, 842 of holes in the connector plate 812. The reader will appreciate that
the
47
CA 02538649 2006-03-03
number and types of fasteners 892 employed may vary depending upon the load
capacity desired and the corresponding hole shapes that must be filled with a
corresponding fastener 892. The locator tab 890 when abutted against the jamb
stud
50 serves to locate the columns 866 and 868 along the jamb stud 50 for
attachment of
the plate 812 thereto. The header studs 220 in this embodiment may or may not
be
attached to each other by other fasteners (screws) or by welding. In those
embodiments wherein the header studs 220 are not attached to each other, they
are
simply sandwiched together at their respective ends between the corresponding
pairs of
connectors 810.
(000147] Figures 34 and 35 illustrate the use of the connector plates 810 of
the
subject invention in connection with an alternative header assembly 1200 of
the present
invention which also employs a pair of header studs 220 of the type and
construction
described above. In this embodiment, the first leg 228 and the second leg 230
of one of
the header studs 22 are in abutting contact with the web 222 of the other
header stud
220 as shown in Figures 34 and 35.
(000148] A pair of connector plates 810 is used on each end of the header
assembly 1200 to attach the header assembly 1200 to the corresponding jamb
stud 50.
Fasteners 892 such as 10-16 screws, etc. are inserted through the holes in the
connector plate 812 of the connectors 810. Figure 35 illustrates use of
fasteners 892
through all of the holes in the connection plate 812 that is abutted against
the web 222
of one of the header studs 220. That Figure also illustrates fasteners 892
through all of
the holes in the upper two rows 830, 840 of holes and the lower two rows 832,
842 of
holes in the connector plate 812 that is abutted against the first leg 228 and
the second
48
CA 02538649 2006-03-03
leg 230 of the other header stud 220. The reader will appreciate that the
number and
types of fasteners 892 employed may vary depending upon the load capacity
desired
and the corresponding hole shapes that must be filled with a corresponding
fastener
892. The locator tab 890, when abutted against the jamb stud 50, serves to
locate the
columns 866 and 868 along the jamb stud 50 for attachment of the plate 812
thereto.
The header studs 220 in this embodiment may or may not be attached to each
other by
other fasteners (screws) or by welding. In those embodiments wherein the
header
studs 220 are not attached to each other, they are simply sandwiched together
at their
respective ends between the corresponding pairs of connectors 810.
[000149] Figures 36 and 37 illustrate use of an embodiment of the connector
plates
810 of the present invention to connect an end of a header assembly 1000 of
the type
and construction described above to a jamb stud 220' embodiment of the present
invention. As can be seen in those Figures, the header assembly 1000 includes
a pair
of header studs 220 that are arranged such that the first leg 228 of one
header stud 220
is in abutting contact with the first leg 228 of the other header stud 220.
Likewise, the
second leg 230 of the one header stud 220 is in abutting contact with the
second leg
230 of the other header stud 220. As was described above, an embodiment of the
jamb stud 220' has a substantially planar jamb stud web 222', a first jamb
stud flange
224' and a second jamb stud flange 226' that protrude from the jamb stud web
222'. A
first jamb stud leg 228' is attached or otherwise formed on the first jamb
stud flange 224'
and a second jamb stud leg 230' is formed on or attached to the second jamb
stud
flange 226'. A first jamb stud return 232' is formed on the end of the first
jamb stud leg
49
CA 02538649 2006-03-03
228' and a second jamb stud return 234' is formed on the end of the second
jamb stud
leg 230'.
[000150] A pair of connector plates 810 is used on each end of the header
assembly 1000 to attach one end of the header assembly 1000 to the
corresponding
jamb stud 220'. Fasteners 892 such as 10-16 screws, etc. are inserted through
the
holes in the connector plate 812 of the connectors 810. Figures 30 and 31
illustrate use
of fasteners 892 through all of the holes in the connector plate 812. The
reader will
appreciate that the number and types of fasteners 892 employed may vary
depending
upon the load capacity desired and the corresponding hole shapes that must be
filled
with a corresponding fastener 892. The locator tab 890 when abutted against
the web
222' of the jamb stud 220' serves to locate the columns 866 and 868 of holes
through
the connector plate 812 along one of the corresponding the flanges 224', 226'
(whatever
the case may be) of the jamb stud 220' for attachment of the plate 812
thereto. The
header studs 220 in this embodiment may or may not be attached to each other
by
other fasteners (screws) or by welding. In those embodiments wherein the
header
studs 220 are not attached to each other, they are simply sandwiched together
at their
respective ends between the corresponding pairs of connectors 810.
[000151] Figures 38 and 39 illustrate use of an embodiment of the connector
plates
810 of the present invention to connect an end of a header assembly 1100 of
the type
and construction described above to a jamb stud 220' embodiment of the present
invention. As can be seen in those Figures, the header assembly 1100 includes
a pair
of header studs 220 that are arranged such that the web 222 of one header stud
220 is
in abutting contact with the web 222 of the other header stud 220. As was
described
CA 02538649 2006-03-03
above, an embodiment of the jamb stud 220' has a substantially planar jamb
stud web
222', a first jamb stud flange 224' and a second jamb stud flange 226' that
protrude from
the jamb stud web 222'. A first jamb stud leg 228' is attached or otherwise
formed on
the first jamb stud flange 224' and a second jamb stud leg 230' is formed on
or attached
to the second jamb stud flange 226'. A first jamb stud return 232' is formed
on the end
of the first jamb stud leg 228' and a second jamb stud return 234' is formed
on the end
of the second jamb stud leg 230'.
(000152] A pair of connector plates 810 is used on each end of the header
assembly 1100 to attach one end of the header assembly 1100 to the
corresponding
jamb stud 220'. Fasteners 892 such as 10-16 screws, etc. are inserted through
the
holes in the connector plate 812 of the connectors 810.
[000153] Figures 38 and 39 illustrate use of fasteners 892 through all of the
holes in
the upper two rows and lower two rows of holes in the connector plate 812. The
reader
will appreciate that the number and types of fasteners 892 employed may vary
depending upon the load capacity desired and the corresponding hole shapes
that must
be filled with a corresponding fastener 892. The locator tab 890 when abutted
against
the web 222' of the jamb stud 220' serves to locate the columns 866 and 868 of
holes
through the connector plate 812 along one of the corresponding the flanges
224', 226'
(whatever the case may be) of the jamb stud 220' for attachment of the plate
812
thereto. The header studs 220 in this embodiment may or may not be attached to
each
other by other fasteners (screws) or by welding. In those embodiments wherein
the
header studs 220 are not attached to each other, they are simply sandwiched
together
at their respective ends between the corresponding pairs of connectors 810.
51
CA 02538649 2006-03-03
[000154] Figures 40 and 41 illustrate use of an embodiment of the connector
plates
810 of the present invention to connect an end of a header assembly 1200 of
the type
and construction described above to a jamb stud 220' embodiment of the present
invention. As can be seen in those Figures, the header assembly 1200 includes
a pair
of header studs 220 that are arranged such that the first leg 228 and the
second leg 230
of one header stud is in abutting contact with the web 222 of the other header
stud 220.
As was described above, an embodiment of the jamb stud 220' has a
substantially
planar jamb stud web 222', a first jamb stud flange 224' and a second jamb
stud flange
226' that protrude from the jamb stud web 222'. A first jamb stud leg 228' is
attached or
otherwise formed on the first jamb stud flange 224' and a second jamb stud leg
230' is
formed on or attached to the second jamb stud flange 226'. A first jamb stud
return 232'
is formed on the end of the first jamb stud leg 228' and a second jamb stud
return 234'
is formed on the end of the second jamb stud leg 230'.
[000155] A pair of connector plates 810 is used on each end of the header
assembly 1200 to attach one end of the header assembly 1200 to the
corresponding
jamb stud 220'. Fasteners 892 such as 10-16 screws, etc. are inserted through
the
holes in the connector plate 812 of the connectors 810.
[000156] Figure 41 illustrates use of fasteners 892 through all of the holes
in the
connection plate 812 that is abutted against the web 222 of one of the header
studs
220. That Figure also illustrates fasteners 892 through all of the holes in
the upper two
rows and lower two rows of holes in the connector plate 812 that is abutted
against the
first leg 228 and the second leg 230 of the other header stud 220. The reader
will
appreciate that the number and types of fasteners 892 employed may vary
depending
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upon the load capacity desired and the corresponding hole shapes that must be
filled
with a corresponding fastener 892. The locator tab 890 when abutted against
the web
222' of the jamb stud 220' serves to locate the columns 866 and 868 of holes
through
the connector plate 812 along one of the corresponding the flanges 224', 226'
(whatever
the case may be) of the jamb stud 220' for attachment of the plate 812
thereto. The
header studs 220 in this embodiment may or may not be attached to each other
by
other fasteners (screws) or by welding. In those embodiments wherein the
header
studs 220 are not attached to each other, they are simply sandwiched together
at their
respective ends between the corresponding pairs of connectors 810.
[000157] The reader will appreciate that a variety of other connectors could
also be
employed to couple the various header assemblies 1000, 1100, 1200 described
above
to convention jamb stud assemblies 50 or to jamb studs 220' of the types
described
herein without departing from the spirit and scope of the present invention.
[000158] Figures 42 and 43 illustrate a load bearing jack post assembly 1300
that
employs a post stud 410 described above and depicted in Figure 19. The post
stud 410
has a substantially planar post stud web 412 and a first post stud flange 414
and a
second post stud flange 416 protruding from the post stud web 412. A first
post stud leg
418 protrudes from the first post stud flange 414 and a second post stud leg
420
protrudes from the second post stud flange 416. A first post stud return 422
is formed
on the end of the first post stud leg 418 and a second post stud return 424 is
formed on
the end of the second post stud leg 420. See Figure 19.
[000159] In this embodiment, the post stud 410 is used in connection with a
single
stud 430. The stud 430 has a web 432 and two flanges 434. A lip 436 is formed
on the
53
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end of each flange 434. The first and second post stud legs 416 and 420 are
attached
to the web 432 of the stud 430 by screws 421 and/or by welding. In the
embodiment
shown in Figures 42 and 43, the load bearing jack post assembly 1300 is used
in
connection with a header assembly 1310 that comprises an I-section header
1320.
[000160] The header 1320 may comprise a separately fabricated I-beam beam or
it
may be fabricated from two joists 1330 that are interconnected in back-to-back
fashion.
The reader will appreciate that in such an-angement, each joist 1330 has a web
portion
1332 and an upper flange 1334 and a lower flange 1336 that protrude from the
web
portion 1332. An upper return 1338 is formed on the end of the upper flange
1334 and
a lower return 1340 is formed on the end of the lower flange 1336. The web
portions
1332 are arranged in back-to-back fashion and may be attached to each other by
welding or other suitable fasteners such as screws. A conventional C-shaped
web
stiffener 1350 may be affixed to the web portion 1332 of one or both of the
joists 1330
as shown to reinforce the I-section with a collection of screws 1352 such as
No: 10-16
screws or the like.
(000161] The end of the header assembly 1310 is arranged to be supported on a
bearing plate 1360 that is supported on the upper end of the post stud 410. In
one
embodiment, the bearing plate 1360 comprises a steel plate and is sized to
completely
cover the upper end of the post stud 410 and protrude therefrom to form a
header
attachment portion 1362 that cantilevers therefrom. The bearing plate 1360 is
constructed to be welded to the end of the post stud 410 and/or the stud 430.
The end
of the header assembly 1310 is then supported on the bearing plate 1360 and
attached
thereto by welding or screws 1364.
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[000162] The header assembly 1320 has a height "H" and the stud 430 extends
beyond the end of the post stud 410 a distance "H'" that is substantially
equivalent to
the height of the header assembly 1320. See Figure 43. The assembly 1300 is
formed
by attaching the web 432 of the stud 430 to the post stud web 412 of the post
stud 410
with fasteners 438 such as sheet metal screws or the like and the web 432 of
the other
stud 430 is attached to the first and second post stud legs (418, 420) of the
post stud
410 by sheet metal screws 438 or the like. I have discovered that such
arrangement
provides an equivalent amount of structural support as prior post arrangements
that
employ three conventional studs and two pieces of conventional track. Thus,
this
embodiment of the present invention reduces the amount of material needed and
also
the amount of labor needed to assemble it when compared to prior post
assemblies. It
will be appreciated, however, that the post stud 410 may also be used in
connection
with one stud 430 or more than two studs 430 without departing from the
.spirit and
scope of the present invention.
[000163] Figure 44 illustrates one method for attachment of a jamb stud 220'
of the
type and construction described above to a conventional section of bottom
track 1400.
The bottom track has a web 1402 and a pair of upstanding flanges 1404. The web
1402 of the bottom track 1400 is attached to floor decking 1410 or other
support
structure. The floor decking 1410 illustrated in Figure 44 comprises concrete
material.
However, other types of floor decking materials may be employed. The web 1402
is
attached to the floor decking material utilizing appropriate conventional
fasteners.
[000164] As can be seen in Figure 44, the bottom end of the jamb stud 220' is
received between the upstanding flanges 1404 and the flanges 224' and 226' may
be
CA 02538649 2006-03-03
attached to the upstanding flanges 1404 by fasteners 1412 and/or by welding.
In one
embodiment, fasteners 1412 comprise No. 10-16 screws. However other suitable
fasteners could be employed. To further support the end of the jamb stud 220'
and
attach it to the bottom track 1400, an L-shaped clip angle 1420 may be
employed. In
one embodiment, the clip angle 1420 has a first leg 1422 that is attached to
the web
1402 of the bottom track 1400 and a second leg 1424 that is attached to the
first leg
224' and the second leg 226' of the jamb stud 220' by fasteners 1412 and/or by
welding.
[000165] To provide additional support to the jamb stud 220', a second L-
shaped
clip angle 1430 is employed. The clip angle 1430 may be identical to the clip
angle
4120 and have a first leg 1422 that is attached to the web 1402 of the bottom
track 1400
and a second leg 1434 that is attached to the web 222' of the jamb stud 220'
by
fasteners 1412 and/or by welding. The reader will also understand that the
upper end
of the jamb stud 220' may be attached to an upper track (not shown) in a
similar
manner.
[000166] Figures 45 and 47 illustrate another method of attaching a jamb stud
220'
to a conventional upper track 1500 that is attached to a support structure
1506. The
upper track 1500 has a web 1502 and a pair of upstanding flanges 1504. The web
1502 is attached to the support structure 1506 (concrete, steel or wood
framing, etc.)
utilizing appropriate conventional fasteners. The method and components
illustrated in
Figure 45 serves to affix the end of the jamb stud 220' to the upper track
1500 such that
it can move relative to the upper track 1500 in the directions illustrated by
arrows 1511
and 1513.
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CA 02538649 2006-03-03
[000167] More particularly and with reference to Figures 45-47, in this
embodiment,
the upper end of the jamb stud 220' is attached to the upper track 1500
utilizing a
slotted bracket 1520 which may be of the type disclosed in U.S. Patent No.
6,688,069 to
Zadeh, the disclosure of which is herein incorporated by reference. As can be
seen in
Figures 46 and 47, one embodiment of the bracket 1520 includes a first
connector plate
1522 and a second connector plate 1530 that forms a right angle juncture with
the first
connector plate 1522. The first connector plate 1522 may be provided with
prepunched
fastener holes 1524 and/or it may be provided with a score line 1526 and/or
dimples
(not shown) for locating fasteners as described in the above-mentioned patent.
In one
embodiment, the first connector plate 1522 is attached to the web 1502 of the
upper
track 1500 by fasteners 1526. In one embodiment, fasteners 1526 may comprise
No.
10-16 screws or other appropriate fasteners.
[000168] In this embodiment, the second connector plate 1530 is provided with
at
least one and preferably at least two vertically extending slots 1532. The
slots 1532
may be provided in embossed stiffener regions 1534 and fastener locating
indicia 1536
may also be provided adjacent each slot 1532. As can be seen in Figure 47, a
fastener
1526 is installed through one slot 1532 into the leg 228' of the jamb stud
220' and
another fastener 1526 is provided through another slot 1532 into the leg 230'.
To
achieve the desired amount of vertical deflection, the slots 1532 may be
provided such
that the upper ends of the slots 1532 are located a first distance 1540 from
the web
1502 of the upper track 1500 when the bracket 1520 is installed as shown in
Figure 47
and the fasteners 1526 may be located a second distance 1550 away from the
upper
ends of the slots 1532. See Figure 47.
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CA 02538649 2006-03-03
[000169] Figures 48 and 50 illustrate one method of attaching a stud 220 of
the type
and construction described above to an I beam 1600 or other structure such
that the
stud 220 can move relative to the I beam 1600 in the directions represented by
arrows
1601 and 1603. The I beam 1600 may comprise a conventional I beam that has an
upper flange 1602 and a lower flange 1604 that are interconnected by a web
1608. In
one embodiment, the stud 220 may be affixed to the I beam 1600 by a piece of
conventional angle 1610 that is welded to or otherwise attached to the I beam
1600 and
a connection bracket 1620 of the type described in U.S. Patent No. 6,688,069.
[000170] As shown in Figure 49, the bracket 1620 has a first connector plate
1630
and a second connector plate 1650 that is arranged relative to the first
connector plate
1630 to form a right angled juncture 1632 therewith. At least one stiffener
channel 1634
may be formed in the right angled juncture 1632 to stiffen the bracket 1620.
Also, one
or more linear stiffener channels 1636 may be provided in the first connector
plate 1630.
A plurality of fastener locating dimples or holes 1638 and/or a score line
1640 may be
provided in the first connector plate 1630 to assist the installer with
positioning the
fastener screws 1642.
[000171] The second connector plate 1650 is provided with at least one and
preferably at least two slots 1652 that each may be located within an embossed
stiffener region 1654. Fastener locating indicia 1656 may be provided in one
or more
stiffener regions. The bracket 1620 is then attached to the leg 230 of the
stud with
fastener screws 1642 that are installed through the slots 1652 and into the
leg 230. As
can be seen in Figure 50, a second bracket 1620 may be attached to the web 222
of the
stud 220 by screws 1642 extending through the slots 1652 in the bracket 1620.
As can
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CA 02538649 2006-03-03
be seen in Figure 50, in one embodiment, a gap 1670 is provided between the
leg 226
of the stud 220 and the upstanding leg of the angle 1610. In one embodiment,
that gap
1670 may be a maximum of one inch. Other gap sizes may be employed depending
upon the application.
[000172] Figures 51 and 52 illustrate the slidable attachment of a stud 220 to
the
lower flange 1604 of an I beam 1600 utilizing brackets 1720 that are somewhat
longer
and have more slots than bracket 1620. Bracket 1720 is essentially identical
to bracket
1620 except that, in the embodiment depicted in Figures 51 and 52, the bracket
1720
lacks the stiffener channels 1634 and 1636 and it may have more slots. It will
be
understood, however, that bracket 1720 may be formed with stiffener channels
similar
to those in bracket 1620 without departing from the spirit and scope of the
present
invention. As can be seen in Figure 51, the bracket 1720 has a first connector
plate
1722 and a second connector plate 1730 that is oriented at a right angle with
respect to
the first connector plate 1722. In the embodiment depicted in Figure 51, the
first
connector plate 1722 is provided with a score line 1724 to assist the
installer in locating
fasteners 1728 for connecting the first connector plate 1722 to the lower
flange 1604 of
the I- beam 1600. However, the first connector plate 1722 may be provided with
prepunched holes and/or dimples.
[000173] The second connector plate 1730 is provided with a plurality of slots
1732
that may each be located in a corresponding embossed stiffener region 1734.
Fastener
locating indicia 1738 may be associated with one or more slots 1732 may be
provided in
the second connector plate 1730. As can be seen in Figure 52, the second
connector
plate 1730 is attached to the first and second legs 228, 230 by screws or
other suitable
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CA 02538649 2006-03-03
fasteners 1728 extending through the slots 1732 corresponding thereto. A
second
bracket 1720 may be employed and attached to the web 222 of the stud 220 with
fasteners 1728 as illustrated in Figure 52.
[000174] Figure 53 illustrates a shearwall post arrangement 1800 that employs
a
post stud 410 of the type and construction described above. As can be seen in
that
Figure, the bottom end of the post stud 410 is supported on and attached to a
conventional bottom track 1810 that has a web 1812 and a pair of upstanding
flanges
1814. The bottom end of the post stud 410 may be attached to the flanges 1814
of the
bottom track 1810 by welding or other suitable fastening means. The bottom
track 1810
may be attached to the floor structure 1802 by conventional fasteners 1805
such as, for
example, conventional shear anchors or the like.
[000175] To provide additional support to the post stud 410, a device 1820
known in
the industry as a "hold-down" may be employed. In on embodiment, the hold-down
1820 has a base portion 1822 and a vertically extending strut portion 1824
that is
arranged at a right angle to the base portion 1822. The strut portion 1824 is
attached to
the web 412 of the post stud 410 by welding or other suitable fastening means.
The
base portion 1822 is configured to receive a bolt 1825 or other suitable
fastener for
attaching the base portion 1822 to the underlying floor structure 1802. In
addition,
depending upon the application, a strap 1830 or straps 1830 may be attached to
the
post stud 410 and/or hold-down 1820. In one embodiment, the straps are metal
and
welded to the hold-down 1820 and the post stud 410.
[000176] Figure 54 illustrates the use of two post studs 410 in back-to back
relationship to form another shearwall post embodiment of the present
invention. In this
CA 02538649 2006-03-03
embodiment, the webs 412 of the post studs 410 may be attached by a series of
appropriately sized fasteners 1850 or the post studs 410 may be welded
together. In
one embodiment, No. 10-16 screws, spaced 12 inches on center, are employed to
affix
the webs 412 of the post studs 410 together. The posts studs 410 are attached
to the
flanges 1814 of the base track 1810 by suitable fasteners or by welding. A
hold-down
1820 of the type and construction described above may be attached to one of
the post
studs 410 by welding and bolted to the floor structure 1802 with a suitable
anchor bolt
1825. One or more straps 1830 may be welded or other wise attached to the post
studs
410.
[000177] Figure 55 illustrates the attachment of a stud 220 of the present
invention
attached to a structure such as a piece of angle 1900 that may be affixed to
other
structures such as I beams, girders, posts, etc. (not shown). In this
embodiment, at
least one, and preferably two, connector brackets 1910 which may be of the
type
disclosed in U.S. Patent No. 6,688,069 to Zadeh are used to rigidly affix the
stud 220 to
the angle 1900.
[000178] As can be seen in Figure 56, one embodiment of the bracket 1910
includes a first connector plate 1920 and a second connector plate 1930 that
forms a
right angle juncture1932 with the first connector plate 1920. At least one
stiffener
channel 1934 may be formed in the right angled juncture 1932 to stiffen the
bracket
1910. Also, one or more linear stiffener channels 1925 may be provided in the
first
connector plate 1920. The first connector plate 1920 may be provided with
prepunched
fastener holes and/or it may be provided with a score line 1926 and/or dimples
(not
shown) for locating fasteners as described in the above-mentioned patent. In
one
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embodiment, the first connector plate '1920 is attached to the leg 1902 of the
angle 1900
by fasteners 1928. In one embodiment, fasteners 1928 may comprise No. 10-16
screws or other appropriate fasteners.
[000179] The second connector plate 1930 is provided with at least one row
1932 of
fastener holes 1935 therethrough. The row 1932 of fasteners holes 1934 may be
located within an embossed stiffener region 1936. The bracket 1910 is then
attached to
the leg 230 of the stud 220 with fastener screws 1942 that are installed
through the
holes 1934 and into the leg 230. As can be seen in Figure 55, a second bracket
1910
may be attached to the web 222 of the stud 220 by screws 1942 extending
through the
fastener holes 1935 in the bracket 1910.
[000180] Figure 57 illustrates non-movable attachment of a stud 220 to the
angle
1900 by an angle clip 1960 that is affixed to the angle 1900 and the leg 230
of the stud
220 by fasteners 1962 and/or by welding. Also in this embodiment, a second
angle clip
1960 may be attached to the leg 1902 of the angle 1900 and the web 222 of the
stud
222 by fasteners 1962 and/or by welding.
[000181] Figure 58 illustrates non-movable attachment of a stud 220 to the
angle
1900 by another angle clip 1970 that is affixed to the angle 1900 and the leg
230 of the
stud 220 by fasteners 1972 and/or by welding. Also in this embodiment, a
second angle
clip 1970 may be attached to the leg 1902 of the angle 1900 and the web 222 of
the
stud 222 by fasteners 1972 and/or by welding.
[000182] As can be appreciated from the foregoing description, the unique and
novel header assemblies and connection plates of the present invention may
have a
variety of advantages over prior header arrangements and connectors. The
unique and
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CA 02538649 2006-03-03
novel connector of the present invention eliminates the need for "left" and
"right"
connectors for attaching header assemblies to jamb studs or when connecting
other
types of components. In addition, the unique fastener hole arrangement
employed in
such connector plates enables the installer to easily attain the desired load
capacity for
the connection. The reader will also appreciate the connectors of the subject
invention
may be employed with conventional headers and jamb studs. It will be further
appreciated that the connectors of the present invention may also be used to
connect
wooden header arrangements to wood jamb studs or, if desired, to connect a
metal
header assembly to a wooden jamb stud or a wooden header to a metal jamb stud.
The
various embodiments of the subject invention depicted in Figures 30-58 may
also be
constructed utilizing studs 620 of the type and construction described above.
[000183] The present invention also addresses the problems associated with
fabricating headers from metal or the like. The unique and novel header
assemblies of
the present invention may be quickly assembled together without the need to
employ
several pieces of studs and track and fasteners to couple them together. In
applications
wherein it is desirable to install insulation inside of the header assemblies,
the installer
should find it easier to install insulation in at least some of the header
assemblies of the
present invention when compared to installing insulation in prior header
arrangements.
[000184] The invention which is intended to be protected is not to be
construed as
limited to the particular embodiments disclosed. The embodiments are therefore
to be
regarded as illustrative rather than restrictive. Variations and changes may
be made by
others without departing from the spirit of the present invention.
Accordingly, it is
expressly intended that all such equivalents, variations and changes which
fall within
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the spirit and scope of the present invention as defined in the claims be
embraced
thereby.
64
