Note: Descriptions are shown in the official language in which they were submitted.
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PATENT
CASE J834-010US
METAL STUD ARRANGEMENT
FIELD AND BACKGROUND OF THE INVENTION
1[] The present invention relates generally to the field of building
components, and in particular to a new and useful metal stud arrangement.
2[] A wide variety of metal stud arrangements are known. See for
example, U.S. Patents 5,685,121 to Defrancesco et al; 5,040,345 to Gilmour;
6,929,226 to Philistine; 5,628,598 to Hoefle; 6,122,871 to Russell et al; and
5,655,344 to Moen et al.
3[] These arrangements usually include top and bottom U-shaped tracks
which receive metal studs that are also U-shaped in cross section. Often it is
difficult to at least momentarily fix the studs in their respective positions
in the
top and bottom tracks, for example, on 16 inch centers. For this reason
various clips and anchors have been developed for securing at least the top
end of the stud in its top track. None of these systems are satisfactory,
however, and few permit easy longitudinal movement of the stud along the
top track. Such lateral movement is necessary, however, to line up each
stud when a gypsum board is to be fastened to the studs, for example, using
screws. In particular, where a pair of gypsum boards meet, the stud must be
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placed to overlap the edges of both boards so that both can be screwed in
place.
4[] Another problem associated with metal studs is that if they cut exactly
to the floor to ceiling length, they cannot accommodate movement, for
example, downward movement of the ceiling or irregularities in the ceiling or
floor. If a gypsum board is installed on such systems and the ceiling moves
downwardly even slightly, for example, because of settling, the gypsum
board will crack or its seams will open.
5[] Accordingly, a need remains for a solution to the problems described
above.
SUMMARY OF THE INVENTION
6[] It is an object of the present invention to provide a metal stud
arrangement comprising: a metal top track having a track web with opposite
side edges and a pair of track flanges connected along the respective
opposite side edges of the top track to form a downwardly facing trough; a
support rail fixed to the track web, extending between the track flanges and
into the trough, the support rail having an enlarged hanger portion spaced
downwardly from the track web, the hanger portion having a maximum width
in a direction extending between the track flanges; and a metal stud having a
stud web with a top end, a pair of side edges and a stud flange connected
along at least one of the side edges of the stud, the web including a support
rail receiving opening near the top end of the stud web, the support rail
receiving opening having an entry passage with a width that is smaller than
the maximum width of the hanger portion, the passage being adapted to
receive the support rail, the opening including an enlarged portion that is
larger than the maximum width so that with the hanger portion in the
enlarged portion of the support rail receiving opening, the stud hangs from
the top track.
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7[] A further object of the invention is to provide such an arrangement
where the stud includes a pair of stud flanged connected along the opposite
side edges of the stud web, an outside dimension of the stud between the
stud flanges being substantially equal to an inside dimension of the top track
between the track flanges so that the top end of the stud sits movably in the
trough when the stud web is substantially perpendicular to the track flanges.
8[] A further object of the invention is to provide a metal stud arrangement
which permits a single worker, without a ladder, to install studs which hang
and permit vertical displacement between each stud and the top and bottom
tracks and lateral movement along the tracks. Despite this freedom of
movement each stud is held sufficiently securely in place to permit
attachment of the gypsum boards.
9[] Although any suitable metal can be used, it is contemplated that
galvanized steel or steel which is otherwise coated to reduce rust be used.
The metal forming the components of the invention can be bent to shape or
formed to shape and made of single pieces or multiple pieces. In general, 30
to 12 gauge steel can be used or steel that is anywhere from about 0.015 to
0.096 inches in wall thickness. Steel or other metals outside this range are
also appropriate for the invention depending on its application.
10[] In general the present invention is particularly suited to non-bearing,
interior walls, particularly in view of the vertical displacement permitted
between the studs and their attached gypsum boards and the top and bottom
tracks. Other applications of the invention may also be appropriate,
however.
11 [] The various features of novelty which characterize the invention are
pointed out with particularity in the claims annexed to and forming a part of
this disclosure. For a better understanding of the invention, its operating
advantages and specific objects attained by its uses, reference is made to
the accompanying drawings and descriptive matter in which preferred
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embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
120 In the drawings:
130 Fig. 1 is a perspective view of a metal stud arrangement according to
the present invention and including examples of gypsum board
to be fastened to the arrangement;
140 Fig. 2 is a perspective view of the arrangement;
150 Fig. 3 is a plan view of the arrangement;
160 Fig. 4 is a side, exploded view of a multi-part embodiment of the top
track of the invention;
170 Fig. 5 is a side elevation of the arrangement to show how the hanging
stud of the invention provides advantageous clearances; and
180 Fig. 6 is a composite view of alternate, non-limiting embodiments for
the shape of the support rail enlargement and stub web
opening.
DESCRIPTION OF THE PREFERREDEMBODIMENTS
190 Referring now to the drawings, in which like reference numerals are
used to refer to the same or similar elements, Fig. 2 shows the metal stud
arrangement of the invention which includes a metal top track 10 having a
track web 14 with opposite side edges and a pair of track flanges 16 and 18
connected along the respective opposite side edges of the top track to form
a downwardly facing trough. A support rail 20 is fixed to the track web,
extends between the track flanges and is at least partly or can be entirely in
the trough. The support rail 20 has an enlarged hanger portion or
enlargement 22, spaced downwardly from the track eb 14. Enlarged hanger
portion 22 can, for example, be an enlargement of a support flange 24 formed
as one piece with the web 14 and flanges 16, 28, or formed of separate
pieces. Fig. 4, for example, illustrates a top track 10, formed of two
symmetrical mirror image parts 10a and 10b that each have one of the flanges
16 or 18, and half or a portion of the track web 14a and 14b, as well as half
or
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a portion of the support rail 20a and 20b. The two parts can be connected,
e.g. by spot welding the support flanges 24a and 24b to each other. The
lower converging edged of the enlargement halves 22a and 22b, may simply
be brought close to each other when the flanges 24a and 24b are fixed to
each other, as they will eventually be held in proper association with each
other when they are inside a support rail receiving opening in the stud.
200 Returning to Fig. 2, the hanger portion 22, regardless of how it is made,
has a maximum width W in a direction extending between the track flanges 16
and 18.
210 Fig. 2 also shows the arrangement of the invention to include a metal
stud 30 having a stud web 34 with a top end illustrated in Fig. 2, a pair of
side
edges and one or two stud flanges 36 and 38 connected along at least one or
preferably both of the side edges of the stud. The web 34 includes a support
rail receiving opening 32 near the top end of the stud. This opening has an
entry passage 33 with a width that is smaller than the maximum width W of the
enlarged hanger portion 22 of the support rail 20. The passage is adapted to
receive the support rail and the opening 32 includes an enlarged portion 35
that is large enough in width (i.e. at least as large as the maximum width W)
and height, so that with the enlarged hanger portion 22 of the support rail
received in the enlarged portion of the opening, the stud hangs from the top
track 10.
220 An outside dimension of the stud 30, between the stud flanges 36 and
38, is substantially equal to an inside dimension of the top track between the
track flanges 16 and 18, so that the top end of the stud stis in, but is also
movable in the trough, when the stub web is substantially perpendicular to the
track flanges as shown in Fig. 3.
230 It will be seen in Figs. 2, 5, and 6, that the support rail receiving
opening
32, in particular at the upper end of passage 33, is funnel shaped or tapers
from a large dimension to a smaller dimension. This allows a funnel effect as
the studs 30 are pushed up into the trough of the top track 10, rotated into
positoin as will be explained in connection with Fig. 3, and allowed to fall
into
their hanging position illustrated in Fig. 5.
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240 To achieve this hanging effect, at the top of the enlarged portion 35 of
the opening 32, and on opposite sides of the passage 33, a shoulder 37 is
provided. Each shoulder 37 is advantageously horizontal or at least
substantially transverse to insure a proper support on the enlarged hanger
portion 22 of the support rail 20.
250 Turning to Fig. 3, the invention is practiced by first attaching the top
track 10 to the ceiling surface or ceiling joists or beams designed to carry
the
track. Each stud is then held with its opening 32 up and the entry of the
passage 33 (see Fig. 2) is raised so that it begins to receive the enlarged
hanger portion 22 of the support rail 20. Although the support rail 20 and the
associated opening 32 are shown at the center of the respective track 10 and
stud 30, and this is the preferred position, the rail and associated opening
can
be off-center. The central position is advantageous since it allows the studs
to be installed with their flanges extending in either direction. It is
important
that the side flanges 36 and 38 of each stud 30 face the same direction, then
it may be advantageous to provide off-center rail and openings to ensure the
proper positioning of each stud.
260 In any case when the stud is lifted into place and the enlargement 22
is well inside the enlarged portion 35 of opening 32, the stud is rotated in
the
direction of arrows R-R, in Fig. 3 and, in effect, snapped into place. The
transverse final position of each stud is shown in solid line in Fig. 2 with
the
rotating position in phantom line. Some slight deformation of one or both
flanges of the stud are permitted to accommodate this rotation and to ensure
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a snug fit of the stud flanges inside the track flanges. This installation can
be
done by one person and without a ladder.
27[] Fig. 5 shows that after the stud has been rotated into place it can be
allowed to drop or pulled down in the direction of the vertically extending
double arrows. This also provides a top clearance TC between the top edge
of each stud and the inside surface of the track web. A clearance BC can
also be provided at the bottom between the bottom edge of the stud 30 and a
bottom track 60. In this way a shorter stud than the wall height is used and
clearance is available for uneven ceilings and settling.
28[] A piece of gypsum board 70 is then put into place. While the bottom
edge of the board can rest on the floor, its top edge should be spaced below
the ceiling surface to take advantage of the vertical movement permitted
between the stud 30 and the top track 10. Fasteners such as screws 72 are
then used to attach the board to the stud 30, and the bottom screw may also
pass through the bottom track or channel flange 60. It is important that the
top screw 72 not pass through the flange of the top track 10, however, to
make sure that the gypsum can still rise in the direction of the upwardly
facing arrow in Fig. 5. Such relative movement between the stud and track
may be necessary to accommodate irregularities in the ceiling or even
downward movement of the ceiling due to settling of the building. This will
effectively avoid cracking of the gypsum board.
29[] Fig. I also illustrates the use of fasteners or screws 72 to attach
adjacent edges of gypsum boards 72 to a single stud. The invention permits
lateral movement of the stud in the direction of arrow S in Fig. 1, to line up
each stud with the mating edges of the boards or otherwise properly place
each stud.
300 As it is known in the prior art, the stud web can also include other
openings for electrical lines, plumbing and the like, and these are not
illustrated in the drawings as they are known in the prior art. This insertion
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step also contemplates some defection of the stud web material around the
opening 32, the metal material around being resilient to spring back into
place.
31[] Fig. 6 shows that the enlargement 22 of the support rail need not be in
the shape of a downwardly directed arrowhead as in Figs. 2, 4, and 5, but
maybe other shapes such as cylindrical or oval in the upper part of Fig. 6, or
diamond-shaped in the lower part of Fig. 6. Any other enlarged shape is also
acceptable as long as the shape of the passage 33 in the opening of 32 of
each stud web is shaped so that it can be pushed up to bring the support rail
enlargement into the enlargement of the opening.
32[] While specific embodiments of the invention have been shown and
described in detail to illustrate the application of the principles of the
invention, it will be understood that the invention may be embodied otherwise
without departing from such principles.
