Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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Title: METAL $TU~ WALL P~CI~CIIVC $IfSTEIYI
Field of the Invention
[0001] The present invention relates to wall structures, and more particularly
to stud wall frames.
Background of the Invention
[0002) Due to their ease of assembly and wide aivailability in various
standard
sizes, metal wall frames are quickly becoming the product of choice for most
"do-
it-yourself' handymen and wall installers. Metal wall frames provide an ideal
and
economical alternative to the wood wall frames, as 'they are more robust,
lightweight, non-combu~;tible, and easy to install. In addition, each metal
wall
frame is consistently manufactured and does not deviate from the standard
manufacturing guidelines, which in turn translates into lesser imperfections
and
straighter finished walls.
[0003) An example of commonly available metal stud framing systern is the
CORUS STEEL FRAMING SYSTEMT~" available from Corus Metal Profiles of
Brampton, Ontatrio, Canada. Metal stud framing systems that are sold by
manufacturers such as CORUS are typically distributed in packs of identical
components to wholesalers and distributors. For example, the vval9 components
will be distributed in 10 pieces of identical floorlceiling tracks, 10 pieces
of studs,
etc.
[0004.] Such distribution system could be inconvenient for the "do-it-
yourself'
handymen and the home supply or hardware stores that offer these products,
as they frequently require less than all the parts found in a pack. This often
results in the packs being broken open in the stores, arid sometimes results
in
damaged and unusable products.
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(0005] Another difficulty associated with existing wall frames is the time
spent
at the supplier store by the customer to find various components such as the
floor and ceiling tracks, aNOOd or metal studs, and various fasteners required
for
erecting the wall frame, as well as determining the number of these required
components. An average handyman must therefore determine exactly ~nrhat and
how many components to retrieve and purchase for tile wall framing project.
This may require a novice wall installer an excessive amount of time spent to
locate the components, and sometimes numerous trips to the hardware store in
order to gather all of the necessary components for erecting the wall frame.
The
customer may end up with excess and unwanted components. Moreover,
although these items are generally found in a hardware and home suppl,r
stores,
they maybe be stocked or shelved in different areas of the store whichy makes
the task of retrieving the required components even more difficult.
[0006] 1°et another difficulty associated with existing wall structures
is that it is
often required for a wall installer to constantly measure and mark the
distance
between the studs in order to ensure that the wall frame is properly
supported.
This is not only cumbersome, but also quite time consuming as it requires the
wall installer to place down his or her wall framing tools, measure and nnark
the
location of the next stud on the floor or ceiling track, pick up his or Iher
wall
framing tools and proceed with secure the subsequent stud. The task of
marking the location of the studs is more tedious in extreme weather
conditions.
[0007] Accordingly, there is a need for a wall framing system whereby the
components are sized and conveniently regrouped for the customer. There is
also a need for a wall 'framing system in which the need for the customer to
make measurements is minimized.
Brief Summaryr of the Invention
(0008] The present invention provides a wall framing packaging system for
metal stud walls which addresses the shortcomings associated with known
systems.
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[0009] In one aspect, the present invention provides a mufti-component
modular system which includes all the essential components for use in
construction of metal stud wall frames of a predetermined size, namely, a
floor
track, a ceiling track, a ~>lurality of studs and fasteners. The floor andlor
ceiling
tracks may be marked to indicate the location of the studs for fast
construction
of the wall frame.
[0010] In another aspect, the present invention provides a method of
distributing framing ma~:erials for a wall section of predetermined
dimensions,
including the steps ofo
(a) providing a plurality of elongate framireg studs each having a length
that is at least sufficient for a height of the wall section;
(b) providing a plurality of elongate ceiling and floor tracks, each track
defining a channel for r~;ceiving and securing ends of the framing studs to
form
the wall section;
(c) selecting, from the plurality of framincl studs, at least a number of
elongate framing stuck required for framingi the wall section using a
predetermined stud spacing;
(d) selecting, from the plurality of ceiling and floor tracks, at least an
amount of ceiling and floor track required for the wall section; and
(e) securing the selected framing studs and floor and ceiling tracks
together unassembled in a transportable bundle.
[0011] In yet another aspect, the present invention provides a stud wall
framing
kit of unassembled components for framing a predetermined wall section. The
kit includes a predetermined number of elongate framing studs, the
predetermined number being at least the number of framing studs required for
framing the predetermined wall section using a predetermined stud :apacing.
The kit further includes am elongate ceiling track and an elongate floor track
each
having channels for receiving ends of the framing studs, at least one of the
ceiling track and floor track having a plurality of visible markings along a
length
thereof at spaced intervals for indicating desired locations for the framing
studs.
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[0012] Other aspects and features of the piresent invention will become
apparent to those ordinarily skilled in the art upon review of the following
description of specific embodiments of the invention in conjunction with the
accompanying figures.
Brief Description of the Drawing
[0013] Reference will now be made to the accompanying drawings, which
show, by way of examplE;, a representative embodiment of the present
invention,
and in which:
[0014.] Fig. 1 is a perspective view of a typical wall which has been
partially
framed using the metal stud wall packaging system of the present invention;
[0015) Fig. 2 is a perspective view of a metal stud wall packaging system
according to the present invention;
[0016] Fig. 3 is a flow chart showing the sequence of steps involved in
assembling a metal stud wall, packaging kit according to the present
invention;
[0017] Fig. 4 is a side elevational view of a table for marking the tracks to
indicate the locations of the studs according to the present invention; and
[001 ~] Fig. 5 is a top elevational view of a table incorporating a press for
marking the tracks to indicate the locations of the studs according to the
present
invention
Detailed Description of the Er~nbodiment~
[0019) The present invention is now described with reference to accompanying
drawings, wherein like constituent elements are designated by like reference
numerals throughout the drawings.
[0020] Reference is now made to Fig. 1 which shows a perspective view of a
typical wall which has been framed using the metal stud wall packaging system.
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As well known in the art, the metal stud wall frame 10 includes a ceiling
track 14,
a floor track 16, and spaced metal framing studs 11 vertically secured
therebetween. The studs 11 are generally C-shaped channeled members and
come into intimate contact with the sidewalls of t,opicalBy U-shaped ceiling
track
14 and floor track 16. Fasteners 12 (shown on the ceiling track 14 only) such
as
framing screws are used to secure the studs 11 to the ceiling track 14 or
floor
track 16. The sidewalls of studs 11 may also define knurled flanges to
securely
hold screws fastening a wall panel 15 to the stud wall frame 10.
(0021' As shown in Fig. 1, the studs 11 are transversely spaced at spaced
intervals 17 measured between the center of the studs 11. The spaced intervals
17 are generally 16" or 24", however, their actual length depends on the wall
framing application. According to a novel aspect of the present invention, for
ease of installation, at (e;ast one sidewall of the floor track 16 is marked
uniformly
at spaced intervals 17 to indicate to the wall installer the intermittent
spacing
between the studs 11. This in turn eliminates the need to manually mea sure
the
location of each stud 11, thereby allowing rapid construction in even
inclement
weather conditions and reducing construction project ~:ime. The markings 19
indicating the spaced intervals 17 between the studs 11 are made using
adhesive stickers, dye, painting, making dimples on either the ceiling track
14 or
the floor track 16, or othc;r similar means for marking sheet metal. Although
the
ceiling track 14 can also include markings 19, preferably only the floor track
16
has the markings 19. However, even if both the ceiling track 14 and floor
track
16 include the markings 19, they can still be perfectly aligned upon leveling
of
one stud located on both indicators.
[0022] The studs 11 are preferably sized to dirraensionally match wood studs
and are typically available in 1 5I8"x3 5/8", 1 518"x2 112"' or 1
5/8°'x1 5I8"
thickness and width dimensions corresponding to 2x4, 2x3 or 2x2 wood studs
respectively, depending on the application. ~ther 4°'x 1 5/8°',
6"x 1 5/8" or 8°'x 1
5/8" can also be available corresponding to 2x4, 2x6, 2x8 wood studs. The
ceiling track 14 and floor track 16, as well as the studs 11, are rr,ade of
corrosion-resistant, galvanized steel sheet or like materials. A stiffening
channel
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(not shown in Fig. 1 ) can be employed to improve the structural rigidity of
the
metal stud wall frame 10. The stiffening channeB can pass through one of the
rows of aligned apertures 24 provided on the studs 11. The apertures 24 can
also be conveniently used for passage of electrical wiring, pipes, or other
structural members (noi: shown) through the studs 11.
[0023] The studs 11 may be implemented using regular metal wall studs,
however, other types of studs such as cripple studs, jack studs, king studs or
any
other kinds may also be used.
[0024] According to preferred embodiments of the invention, all the cornponent
parts required by an installer to install a predetermined size of framing may
be
packaged together as a kit. Referring now to Fig. 2, there is shown a metal
stud
wall packaging systerra indicated generally by reference 30, which when
assembled, would result in the wall frame 10 of Fig. 1 according the present
invention. The metal stud wail packaging system 30 is in a kit format and
includes a ceiling track "14, a floor track 16, and a plurality of metal studs
11. In
particular, the packagirag system 30 includes the amount of metal framing
required to frame a wall section of a predetermined size. For example, each
system 30 could include one 10° ceiling track 14, one 10° floor
track 16 and eight
8' metal studs 11, for framing a wall section having an appropriate size of
8° high
by 10' long, with 16'° stud spacing 17. The metal stud wall packaging
system 30
preferably also includes framing screws 12 for attaching the studs 11 to the
tracks 14,16. Other types of fasteners such as rivets may also be used to
connect the studs 11 to the tracks 14,16.
[0025] The framing screws 12 maybe be put in a container such as a bag 40
or other package which is secured bvy tape or adhering to ~ne of the metal
framing components in the packaging system 10. The bag 40 will include at
least the number of framing screws 12 required to assemble the wall section.
Other fasteners, for exarnpie at least a screw 13 to fasten the ceiling track
14 to
the ceiling joists, or at least a screw 18 required to secFare the floor track
16 in
place, may also be included in packaging system 30. In a similar fashion,
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screws 20 for attaching the wall panel 15 to the stud 11 may also be provided
in
the packaging system 30. Advantageously, the various components of the metal
stud wall packaging system 30 can be packaged together by nylon straps 32, 34
or other means of packaging such as cable ties, metal wraps, plastic bags or
the
like.
(0026] The packaging system 30 may also include a stiffening channel 36, and
preferably also includE; an instruction sheet 38 which outlines the sfieps
necessary for erecting the wall frame. The instruction sheet 38 may also serve
as a label for the metal stud wall packaging system 40. For example, the
instruction sheet 38 may include marketing information in one portion and an
outer side, and the instructions in another portion or on the inner side.
(0027] In a preferred embodiment, the instruction sheet may contain
instructions advising the installer to take the following steps for erecting
the wall
frame structure: For installation, the wall installer must first mark the
location for
the ceiling track 14 and floor track 16 on a floor .and ceiling respectively.
The
installer must then cut the ceiling track 14 and floor track 16 at the
appropriate
length. The next step involves attaching the ceiling track 14 to the ceiling
joist
using a fastener such as 1'l" drywall screws at 2 ft. intervals. In a similar
fashion, the installer must also attach the floor track 16 to the floor using
a
fastener such as 1'/" screws at every 2 ft. interval for wood floors. For
concrete
floors, the floor track 16 is attached to the floor using concrete fasteners
or nail
drive anchors located at 2 ft. intervals on the floor track 16. The installer
must
then retrofit the studs at the spaced intervals 17. This is achieved by first
cutting
the studs 11 approximately'/Z" shorter than the distance L between the ceiling
track 14 and floor track 16. The studs 11 are positioned at the spaced
intervals
17 as indicated by markings 19, between the ceiling track 14 and floor track
16
by twisting and friction fitting. A close but not necessarily tight fit is
desirable in
order to permit slight movement of the studs 11 far adjustment. A level is
used
to level one stud 11. The studs 11 are then secured onto the ceiling track 14
and floor track 16 by framing screws in accordance with the indicator markings
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19. The wall frame 10 can then be subsequently covered with a wall panel 15
made of drywall, wood, plastic or other similar parceling materials.
[0028] Referring now to Fig. 3, there is shown the sequence of steps involved
in assembling a metal stud wall packaging system 30 of Fig. 2 in a modular kit
according to the present invention. A first step of assembling the metal stud
wall
packaging system 30 of the present invention involves the step of obtaining
from
one or more wall frame component suppliers variou:~ fasteners, as well as
bundles of pre-packed studs 11, ceiling or floor tracks 14,16 or stiffening
channels 36 (Step S1 ). These various components are then separated, sorted
(if required) and regrouped in individual quantities for kits (Step S2). For
instance, a typical kit may include ten studs 11, a ceiling track 14, a floor
track
16, a stiffening channel 36, and a bag 40 containing fastener means as
required
for erecting the wall frame structure 10 as shown Fig. 'i . The fastener means
may include 1'/" screws for securing the ceiling and floor tracks 14, 16 to a
ceiling and floor, as well as 7/16" pan head framing screws to secure the
studs
11 to the ceiling and floor tracks 14, 16.
[0029] The next step involves the marking of the ceiling track 14 and floor
track
16 to indicate the locations of the spaced intervals 17 by way of markings 19
(Step S3). The location of the markings 19 corresponds to the designated
positions of the studs 11 when erected. The various components of the kit are
then packaged together (Step S4) for distribution (Step S5). Accordingly, the
ceiling track 14, floor track 16, metal studs 11, stiffening channel 36, and
bag 40
are then packed together and wrapped using nylon wrappers 32, 34. Preferably,
the instruction sheet 38 wraps around a portion of the entire kit.
[0030] The kits may be directly delivered to horne hardware stores or home
supply retailers (Step S~l), or in the alternative, sent back to the wall
frame
supplier (Step S6) to be eventually delivered and distributed to the home
hardware stores or home supply retailers (Step S7).
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[0031] Reference is now made to Figs. 4 and 5 wherein a table 50 for marking
spaced intervals 17 on a ceiling track 14 or a floor track 16 (as shown in
Fig. 1 )
is illustrated. The table 50 includes a tabletop 52 having a first recessed
area
54 for supporting the ceiling track 14 or the floor track 16 therein. l-he
first
recessed area 54 includes rails 56 at transversely spaced locations along the
bottom wall 58 of the firs>t recessed area 54 to allow the ceiling or floor
is°ack 14,
16 to freely move along l:he length of the tabletop 52. The tabletop also
includes
a second recessed area 64 wherein an indicator press 60 therein can move
longitudinally along the length of the tabletop 52 and parallel to the first
recessed
area 54. The second recessed area 64 also comprises rails 66 tv allow
longitudinal movement of the indicator press 60 along thse length of the
tabletop
52. The indicator press 60 is secured to the tabletop 50 by movable securing
means 70 such as a vise clamp, brace, clip or the like, and includes a
position
indicator 72. The position indicator 72 comes in registry with the reference
ruler
68 to show the exact position of the indicator press 60.
[0032] The tabletop 52 is also provided with a reference ruler 68 for accurate
positioning of the press 60 when marking the ceiling track 14 or the floor
track
16. To mark the ceiling ~or floor tracks 14, 16, a track 16 is inserted in the
first
recessed area 54. Using the reference ruler 68, the location of the first
marking
19 (as shown in Fig. 1 ) is determined, and the indicator press 60 is secured
to
the tabletop 52. The indicator press 60 is then mobilized in order to make the
marking 19 on the rail 16. The indicator press 60 is then positioned at the
desired location of the second marking 19, secured to the tabletop 52 and
triggered in order to mark the position of the second marking 19. The
foiregoing
steps are repeated until the track 16 has been marked.
[0033] It should be noted that in an alternative embodiment, the indicator
press
60 and the recessed area 52 may be located on top on the tabletop 52.
[0034] The present invention may be embodied in other specific forms without
departing from the spirit or essential characteristics thereof. Certain
adaptations
and modifications of the invention will be obvious to those skilled in the
art. For
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instance, in some embf~diments wood studs instead of metal studs could be
used. Therefore, the presently discussed embodiments are considered to be
illustrative and not restriictive, the scope of the invention being indicated
by the
appended claims rather' than the foregoing description, and all changes which
come within the meaning and range of equivalency of the claims are therefore
intended to be embraced therein.
