Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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TRACK SYSTEM FOR SUPPORTING WALL STUDS
BACKGROUND OF THE INVENTION
1. Field of Invention
The present invention relates generally to construction and in particular to a
method and apparatus for supporting a plurality of parallel spaced apart wall
studs.
2. Description of Related Art
Metal wall studs are commonly Osed in the construction trade for framing
walls and other structures. The studs are installed at spaced intervals to
provide a framework for installation of drywall panels and the like.
Various track systems are known in the prior art for supporting wall studs at
the desired location. Such systems typically comprise a top track secured to
the ceiling and a bottom track secured to the floor in alignment with the top
track. Each wall stud is positioned between the top and bottom tracks and
secured in place with screws or crimping. In the case of "slip track" systems,
the wall studs may be cut to a length less than the overall vertical distance
between the top and bottom tracks. This permits some movement of the top
track relative to the bottom track after installation of the wall studs. Slip
track
systems can thus accommodate deflection in the ceiling position relative to
the wall and floor, for example due to changes in applied loads or temperature
fluctuations. In some prior art'syAtems an outer track and a movable inner
track are provided to achieve the slip track functionality.
In conventional wall construction systems each stud is secured to the top and
bottom tracks with fasteners, such as metal screws. This typically requires
installers to use a ladder and a screw gun to secure the top end of each stud
to the top track and building frame. The bottom end of each stud is secured to
the bottom track in a similar manner. In some cases, inexperienced
tradesmen may install the studs at incorrect track locations, resulting in
inconsistent spacing between the studs or off-vertical positioning. In such
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cases it is time-consuming and labour-intensive to remove the fasteners from
the tracks and reinstall the wall studs in the correct orientation.
Some fastener-less stud alignment systems are known in the prior art where
wall studs are held in place with clips or tabs formed in the tracks rather
than
by separate fasteners. Such systems avoid the need for screw guns or other
tools for driving fasteners. However, in some cases the track clips are not
designed to receive standard wall studs and custom studs must be used. In
other cases, studs cannot be easily extracted from the clips after
installation,
particularly in the case of heavier gauge studs.
U.S. Pat. No. 6,647,691, Becker et al., exemplifies the prior art in this
field.
Becker describes a track arrangement for supporting wall studs where the
studs are held in place in the tracks with opposed clips. Each clip consists
of a
portion of track sidewall bent inwardly to form a cam surface and a stud ridge
receiver. The studs may or may not be bottomed-out in the tracks depending
on whether or not the wall is load bearing.
One drawback of the Becker et al. track arrangement is that, once installed,
the wall studs cannot be easily decoupled from the tracks. Rather, significant
force would be required to extract the stud side flanges from the track clips.
Also, the Becker et al. arrangement requires that each stud be inserted within
the top and bottom tracks in the same orientation, i.e. with stud side flanges
projecting in one direction only, Furthermore, the Becker et al. system
requires punching the tabs from the track itself which disadvantageously
compromises the continuity of the track and may be prohibited by some
building codes.
U.S. Pat. No 8,615,959 B2, Ferguson et al. also describes a track
arrangement for supporting wall studs where the studs are held in place with
tabs and slots formed in the tracks by use of a metal press. Similar to Becker
et al., a drawback of this arrangement is that in some jurisdictions building
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code specifies that cuts or notches through the flanges of the tracks are not
permitted.
SUMMARY OF THE INVENTION
According to a first embodiment of the present invention there is disclosed an
apparatus for supporting and retaining a plurality of parallel spaced apart
wall
studs. The apparatus comprises a longitudinally extending base having first
and second side edges and first and second opposed sidewalls extending
generally perpendicular to the base from the first and second side edges,
wherein the base and sidewalls together define a trough for receiving and
retaining an end portion of the plurality of wall studs. The apparatus further
comprises a plurality of clips sized to fit within and extend transversely
across
the trough, each of the plurality of clips having first and second tabs
extending
from the base wherein the first and second tabs each define a slot with a
corresponding of the first and second sidewalls sized to receive a portion of
the wall studs therein.
The clip may include a bottom portion extending between the first and second
tabs. The bottom portion of the clip may be substantially planar. The bottom
portion of the clip may be secured to the base. The first and second tabs may
extend substantially parallel to the first and second side walls.
Each of the first and second tabs may include a bottom portion proximate to
the base portion and a top portion 'distal from the base portion of the clip.
The
bottom and top portions may have a bend angle therebetween. The bottom
portion may be angled towards the first or second side wall and wherein the
top portion is angled away from the first or second side wall.
Each of the plurality of clips may be formed from a substantially planar
unitary
sheet of material. The plurality of clips may be spaced along the trough at
regular intervals. The slots may be adapted to restrain horizontal movement
of the stud located therein in the engaged position. The slots may be adapted
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to permit vertical movement of the stud located therein between engaged and
disengaged positions by sliding the stud vertically.
According to a first embodiment of the present invention there is disclosed a
kit
for forming a wall comprising at least one top track, at least one bottom
track
and a plurality of metal wall studs having sidewalls sized to be received
within
the slots of the top and bottom tracks. Each of the top and bottom tracks
comprises a longitudinally extending base having first and second side edges
and first and second opposed sidewalls extending generally perpendicular to
the base from the first and 'seCond side edges, wherein the base and
sidewalls together define a trough for receiving and retaining an end portion
of
the plurality of wall studs. Each of the top and bottom tracks further
comprises a plurality of clips sized to fit within and extend transversely
across
the trough, each of the plurality of clips having first and second tabs
extending
from the base wherein the first and second tabs each define a slot with a
corresponding of the first and second sidewalls sized to receive a portion of
the wall studs therein. The kit further comprises
The base of the top track may extend along a plane parallel to the base of the
bottom track at a distance greater than a length of the plurality of metal
studs
to permit the relative sliding movement of the plurality of metal studs. The
trough of the top track may have a depth exceeding a depth of the trough of
the bottom track. The tabs of the top track may have a length exceeding a
length of the tabs of the bottol'-n track to define corresponding larger slots
in
the top track.
According to a first embodiment of the present invention there is disclosed a
method for forming a wall comprising securing a bottom track to a floor
surface and securing a top track to a ceiling surface. Each of the bottom top
tracks comprises a longitudinally extending base having first and second side
edges and first and second opposed sidewalls extending generally
perpendicular to the base from the first and second side edges, wherein the
base and sidewalls together define a trough for receiving and retaining an end
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portion of the plurality of wall studs. Each of the bottom and top tracks
further
comprise a plurality of clips sized to fit within and extend transversely
across
the trough, each of the plurality of clips having first and second tabs
extending
from the base wherein the first and second tabs each define a slot with a
corresponding of the first and second sidewalls sized to receive a portion of
the wall studs therein. The method further comprises providing a plurality of
metal wall studs, engaging a top end of each of the plurality of metal wall
studs within the slots of the top track, rotating each of the plurality of
metal
studs into alignment with the slots of the bottom track and vertically moving
each of the plurality of metal sludt into engagement with the bottom slots of
the bottom track.
Other aspects and features of the present 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 DRAWINGS
In drawings which illustrate embodiments of the invention wherein similar
characters of reference denote corresponding parts in each view,
Figure 1 is a perspective view of an assembly for forming a wall
according
to a first embodiment of the present invention.
Figure 2 is a perspective view of a top track of the assembly of
Figure 1.
Figure 3 is a cross-sectional ;'/iew of the top track of Figure 2 as
taken
along section lines 3-3.
Figure 4 is a plan view of a cut sheet for forming a clip for use in
the top
track of Figure 2.
Figure 5 is a front view of the bent top track clip of Figure 4.
Figure 6 is a perspective view of a bottom track of the assembly of
Figure
1.
Figure 7 is a cross-sectional view of the bottom track of Figure 6
taken
along section 7-7.
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Figure 8 is a plan view of a cut sheet for forming a clip for use in
the bottom
track of Figure 6.
Figure 9 is a front view of the bent bottom track clip of Figure 8.
Figure 10 is a fragmented, perspective view of the track assembly
showing
steps for releasably coupling a wall stud to the top and bottom
tracks.
Figure 11 is a detailed, cross-sectional view showing a lower end of
a wall
stud disposed above a track slot.
Figure 12 is a detailed, cross-sectional view showing a lower end of
a wall
stud seated within' a tack slot.
DETAILED DESCRIPTION
Referring to Figure 1, a track assembly 10 for supporting wall studs 9 is
generally illustrated at 10. Track assembly 10 includes a top track 14
attached
to the ceiling framework of a building and a bottom track 40 attached to the
floor of a building. The top track 14 includes a horizontal base 18 and a pair
of
opposed vertical sidewalls 20 extending generally perpendicular to base 18.
The bottom track 40 includes a horizontal base 42 and a pair of opposed
vertical sidewalls 44 extending generally perpendicular to the base 42. Base
18 with sidewalls 20 and base 42 with sidewalls 44 together define generally
U-shaped top and bottom troughs 22 and 41. As described further below,
each top and bottom trough 22 and 41 is sized to receive an end 6, 5 of a stud
9 therein. The height of sidewall 20 and hence the depth of top trough 22 may
be larger in the top track 14 Figs. 2-3) than the height of sidewall 44 and
hence the depth of bottom trough 41 of the bottom track 40 (Figs. 6-7).
As shown best in Figure 10, each stud 9 includes a base 8 and opposed
flanges or sidewalls 7 extending in parallel planes perpendicular to base 8.
Studs 9 are conventional in structure and are typically constructed of 12-25-
gauge steel. Studs 9 can be cut to the desired length by any commonly known
means or selected to have the desired length.
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As shown in Figure 2, a plurality of clips 30 are laterally attached to the
base
18 or sidewall 20 of the top track 14 at regular intervals. Slots 31, as shown
in
Figure 3, between opposed sidewalls 20 and clips 30 are preferably aligned.
In one embodiment of the invention, each slot 31 is defined between a clip 30
and an adjacent portion of sidewall 20. Each clip 30 includes a fixed base
portion 32 attachable to base 18 and a free side tab 34 extending distal from
base portion 32 (Figures 2-3). As described further below, in one embodiment
of the invention each clip 30 may consist of a bent metal piece attached to
base 18 or sidewall 20.
Clips 30 are preferably attached to base 18 at regular, spaced-apart
longitudinal intervals, with clip spacing distance 24. For example, the clip
spacing distance 24 between clips 30 may be selected to correspond to the
desired wall stud spacing. At respective ends of top track 14, clips 30 are
attached at half of the clip spacing distance 24 from the end, as indicated at
half clip spacing distance 26. End clips placed at half clip spacing distance
26
form a full clip spacing distance 24 when end portions of two top tracks 14
are
longitudinally aligned. Clips 30 may be attached to base by any known
method.
Referring to Figure 4, clips 30 may be made from any gauge sheet metal or
any other suitable material. The clip material is bent at fold line 36,
forming a
base portion 32, and a pair of side tabs 34. Base portion 32 is sized to have
a
length between fold lines 36 less than the width of top trough 22, to allow
for a
slot 31 between the side tabs 34 and the sidewall 20, as shown on Figure 3.
The width of base portion 32 may be of any size to be received within the
opening of the selected wall studs. Side tabs 34 may be bent along the fold
line 36 to form the at tab angle 35 equal to or greater than 900. When tab
angle 35 is greater than 90 , a portion of the side tabs 34 on clip 30 may
touch the sidewalls 20 of top track 14 proximate to the free end 37. In this
case, additional slight bends (for example 45 ) of clip 30 may be optionally
placed at fold line 38, to allow for a gap between the free end 37 of side
tabs
34 on clip 30 and sidewalls 20 of top track 14.
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As shown in Figure 6, a plurality of clips 50 are laterally attached to the
base
42 or sidewall 44 of the bottom track 40 at regular intervals. Slots 51, as
shown in Figure 7, between opposed sidewalls 44 and clips 50 are preferably
aligned. In one embodiment of the invention, each slot 51 is defined between
a clip 50 and an adjacent portion of sidewall 44. Each clip 50 includes a
fixed
base portion 52 attachable to base 42 and a free side tab 54 extending distal
from base portion 52 (Figures 6-7). As described further below, in one
embodiment of the invention each clip 50 may consist of a bent metal piece
attached to base 42 or sidewall 44
Clips 50 are preferably attached to base 42 at regular, spaced-apart
longitudinal intervals, with clip spacing distance 46. For example, the clip
spacing distance 46 between clips 50 may be selected to correspond to the
desired wall stud spacing. At respective ends of bottom track 40, clips 50 are
attached at half of the clip spacing distance 46 from the end, as indicated at
half clip spacing distance 48. End clips placed at half clip spacing distance
48
form a full clip spacing distance 46 when end portions of two bottom tracks 40
are longitudinally aligned. Clips 50 may be attached to base 42 or sidewall 44
by any known method.
Referring to Figure 8, clips 50 may be made from any gauge sheet metal or
any other suitable material. The clip material is bent at fold line 56,
forming a
base portion 52, and a pair of side tabs 54. Base portion 52 is sized to have
a
length between fold lines 56 less than the width of bottom trough 41, to allow
for a slot 51 between the side tabs 54 and the sidewall 44, as shown on
Figure 7. The width of base portion 52 may be of any size to be received
within the opening of the selected wall studs. Side tabs 54 may be bent along
the fold lines 56 to form tab angle 55 equal to or greater than 900. When tab
angle 55 is greater than 900, a portion of the side tabs 54 on clip 50 may
touch the sidewalls 44 of bottom track 40 proximate to the free end 57. In
this
case, additional slight bends (for example 450) of clip 50 may be optionally
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placed at fold line 58, to allow for a gap between the free end 37 of side
tabs
54 on clip 50 and sidewalls 44 of bottom track 40.
In one embodiment of the invention, each clip 30, 50 may be generally
rectangular in shape. As will be appreciated by a person skilled in the art,
clips 30, 50 may be formed in other configurations to define slots 31, 51 of
other shapes and sizes. In the illustrated embodiment, the length of side tab
34 of clips 30 may be longer in top track 14 than the length of side tab 54 of
clips 50 in bottom track 40. The ,difference between the length of the tabs
permits the studs to be inserted into the longer slot and thereafter displaced
therein to permit insertion into the shorter slot, as described in greater
detail
below.
In use, top track 14 is secured to a ceiling framework of a structure and
bottom track 40 is secured to the floor of the structure (Figure 1). Top and
bottom tracks 14, 40 are preferably installed so that slots 31, 51 formed
between top and bottom tracks 14, 40 and clips 30, 50 are vertically aligned.
End portions of some top and bottom tracks 14, 40 may abut a wall or may be
longitudinally aligned as described above to define top and bottom troughs 22,
41 of any desired length.
Referring to Figures 10-12, standard studs 9 are cut to the desired length to
extend between tracks 14, 40. ,PNferably studs 9 are cut to a length which is
slightly less than the installed distance between bases 18, 42 of aligned top
and bottom tracks 14, 40. By way of non-limiting example, studs 9 may be cut
to a length which is shorter than the distance between bases 18, 42 of top and
bottom tracks 14, 40. As shown in Figure 10, stud 9 may be secured to track
assembly 10 by first lifting stud 9 upwards as shown generally in direction
100
inserting upper end 6 of stud 9 into top trough 22 of top track 14 so that
sidewalls 7 at upper end 6 are received into opposed slots 31. The opposite
lower end 5 of stud 9 is then pivoted, in general direction 102, into position
(Figures 10-11) and dropped, in general direction 104, into aligned slots 51
of
bottom track 40 (Figure 12). Once installed as aforesaid, the lowermost edge
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of stud 9 is supported on the base 42 of bottom track 40 as shown in Figure
12.
Since the length of stud 9 is slightly less than the distance between bases
18,
42 of top and bottom tracks 14, 40, some relative movement of track
assembly 10 and studs 9 is permitted. Such a "slip track" system permits the
top track 14 to shift vertically relative to studs 9 and bottom track 40 if
the
ceiling height of the structure shifts or deflects. As will be appreciated by
a
person skilled in the art, changes in the relative spacing between the ceiling
and floor of a structure causing deflection of top track 14 may result from
loads applied to the structure and/or temperature fluctuations causing
expansion or contraction of structural components.
One significant advantage of the applicant's track assembly 10 is that stud 9
may be securely coupled to track assembly 10 without the use of special tools
or fasteners. That is, one upper end 6 of each stud 9 may be coupled to top
track 14 as described above (Figure 10) by an installer standing on the floor
of
the structure and extending stud 9 upwardly toward the ceiling. Accordingly,
ladders or additional braces or fasteners are not required. The opposite lower
end 5 of each stud 9 may also be secured to bottom track 40 as described
above without the use of fasteners or special tools. Thus studs 9 may be
easily installed at the correct locations and intervals and installation
errors by
unskilled tradesmen are avoided.
Another advantage of track assembly 10 is that stud 9 may be connected to
track assembly 10 in any desired orientation (i.e. with sidewalls 7 of stud 9
extending either toward or away from an end wall of the structure). This
allows
studs 9 to be placed in the optimum orientation to suit the particular
requirements of the wall in question.
A further advantage of track assembly 10 is that one or more selected studs 9
may be easily removed from track assembly 10 without the use of ladders or
other special tools or equipment by reversing the installation procedure
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illustrated in Figure 10, (i.e. by lifting stud 9 upwardly, pivoting one lower
end
out of bottom track 40 and then lowering stud 9 out of top track 14 to de-
couple it from track assembly 10). It is often convenient to remove a stud 9
from a track assembly 10 after initial installation to make room for
electrical
5 panels, plumbing or other building materials installed by sub-trades as
construction of a structure progresses.
An additional advantage of track assembly 10 in the presented embodiment is
that there are no cuts or notches forming holes in the sidewalls 20, 44 to
diminish the strength of the top and bottom tracks 14, 40.
While specific embodiments of the invention have been described and
illustrated, such embodiments should be considered illustrative of the
invention only and not as limiting the invention as construed in accordance
1 5 with the accompanying claims.
