Abstract:
An apparatus for supporting and retaining a plurality of parallel spaced apart wall studs 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.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 62/341,858 filed May 26, 2016 entitled Track System for Supporting Wall Studs. 
     
    
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
       [0002]    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 
       [0003]    Metal wall studs are commonly used 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. 
         [0004]    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 systems an outer track and a movable inner track are provided to achieve the slip track functionality. 
         [0005]    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 cases it is time-consuming and labour-intensive to remove the fasteners from the tracks and reinstall the wall studs in the correct orientation. 
         [0006]    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. 
         [0007]    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. 
         [0008]    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. 
         [0009]    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 code specifies that cuts or notches through the flanges of the tracks are not permitted. 
       SUMMARY OF THE INVENTION 
       [0010]    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. 
         [0011]    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. 
         [0012]    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. 
         [0013]    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 to permit vertical movement of the stud located therein between engaged and disengaged positions by sliding the stud vertically. 
         [0014]    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 
         [0015]    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 bottom track to define corresponding larger slots in the top track. 
         [0016]    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 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 studs into engagement with the bottom slots of the bottom track. 
         [0017]    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 
         [0018]    In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view, 
           [0019]      FIG. 1  is a perspective view of an assembly for forming a wall according to a first embodiment of the present invention. 
           [0020]      FIG. 2  is a perspective view of a top track of the assembly of  FIG. 1 . 
           [0021]      FIG. 3  is a cross-sectional view of the top track of  FIG. 2  as taken along section lines  3 - 3 . 
           [0022]      FIG. 4  is a plan view of a cut sheet for forming a clip for use in the top track of  FIG. 2 . 
           [0023]      FIG. 5  is a front view of the bent top track clip of  FIG. 4 . 
           [0024]      FIG. 6  is a perspective view of a bottom track of the assembly of  FIG. 1 . 
           [0025]      FIG. 7  is a cross-sectional view of the bottom track of  FIG. 6  taken along section  7 - 7 . 
           [0026]      FIG. 8  is a plan view of a cut sheet for forming a clip for use in the bottom track of  FIG. 6 . 
           [0027]      FIG. 9  is a front view of the bent bottom track clip of  FIG. 8 . 
           [0028]      FIG. 10  is a fragmented, perspective view of the track assembly showing steps for releasably coupling a wall stud to the top and bottom tracks. 
           [0029]      FIG. 11  is a detailed, cross-sectional view showing a lower end of a wall stud disposed above a track slot. 
           [0030]      FIG. 12  is a detailed, cross-sectional view showing a lower end of a wall stud seated within a track slot. 
       
    
    
     DETAILED DESCRIPTION 
       [0031]    Referring to  FIG. 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 ). 
         [0032]    As shown best in  FIG. 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. 
         [0033]    As shown in  FIG. 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  FIG. 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  ( FIGS. 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 . 
         [0034]    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. 
         [0035]    Referring to  FIG. 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  FIG. 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 90°. 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 . 
         [0036]    As shown in  FIG. 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  FIG. 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  ( FIGS. 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 . 
         [0037]    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. 
         [0038]    Referring to  FIG. 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  FIG. 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 90°. When tab angle  55  is greater than 90°, 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 45°) of clip  50  may be optionally 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 . 
         [0039]    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. 
         [0040]    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 ( FIG. 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. 
         [0041]    Referring to  FIGS. 10-12 , standard studs  9  are cut to the desired length to extend between tracks  14 ,  40 . Preferably 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  FIG. 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 ( FIGS. 10-11 ) and dropped, in general direction  104 , into aligned slots  51  of bottom track  40  ( FIG. 12 ). Once installed as aforesaid, the lowermost edge of stud  9  is supported on the base  42  of bottom track  40  as shown in  FIG. 12 . 
         [0042]    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. 
         [0043]    One significant advantage of the applicant&#39;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 ( FIG. 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. 
         [0044]    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. 
         [0045]    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 illustrated in  FIG. 10 , (i.e. by lifting stud  9  upwardly, pivoting one lower end  5  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 panels, plumbing or other building materials installed by sub-trades as construction of a structure progresses. 
         [0046]    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 . 
         [0047]    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 with the accompanying claims.