Slotted track with double-ply sidewalls

A slotted upper track (10) has double-thick sidewalls (34, 36 and 40, 42) through which the slots (54, 50 and 52, 56) extend. The sidewalls (34, 36 and 40, 42) and an interconnecting web (38) form a central channel in which upper end portions of the studs (12) are received. The upper track or header (10) includes secondary channels outwardly of the central channel that are formed by the flanges of the central channel (34, 36 and 40, 42) and auxiliary flanges (30, 46) and auxiliary webs (32, 44). The header or upper track (10) is of a one-piece construction, making it relatively economically to construct. Upper end portions of wallboard panels (WP) are positioned outwardly of the sidewalls (34, 36 and 40, 42) of the central channel. Trim panels (TP) of wallboard are connected to the auxiliary flanges (30, 46) and are positioned laterally outwardly of the upper end portions of the main wallboard panels (WP). The trim panels (TP) will move with the header or upper track (10) and the main wallboard panels (WP) will move with the studs (12).

TECHNICAL FIELD

This invention relates to framing walls composed of horizontal tracks and vertical studs. More particularly, it relates to an upper track construction that both permits vertical deflection and enables the wall to withstand larger wind loads or other side loads.

BACKGROUND OF THE INVENTION

It is known to provide a framing wall construction which permits relative movement between the lower track and stud assembly and the upper track so that vertical movement of the upper track relative to the studs and the lower track can occur during earthquakes, settlement, and other conditions which want to cause vertical movement between components of the framing wall.

U.S. Pat. No. 5,127,760, granted Jul. 7, 1992, to Todd A. Brady, shows a framing wall that includes vertically slotted tracks that are connected to the upper ends of studs by screws which extend through the slots and screw into upper end portions of the studs. A vertical space is provided between the upper ends of the studs and the web of the upper track. The upper track is free to move vertically relative to the studs while remaining connected to the studs by the screws.

U.S. Pat. No. 5,471,805, granted Dec. 5, 1995, to Dwayne W. Becker, shows a construction which allows vertical movement of the upper track relative to the studs without there being any screw connection of the studs to the upper track. Upper end portions of the studs extend into the upper track and merely slide up and down within a space defined by the track sidewalls.

Neither the construction disclosed by U.S. Pat. No. 5,127,760 nor the construction disclosed by U.S. Pat. No. 5,471,805 will permit the wall to withstand substantial side loads, such as gusting wind loads. There is a need for a framing wall construction that utilizes some of the features disclosed by U.S. Pat. Nos. 5,127,760 and 5,471,805 while at the same time providing the wall with the ability to withstand substantial side loads. It is the principal object of the present invention to fill this need.

BRIEF SUMMARY OF THE INVENTION

The building construction assembly of the present invention includes a horizontal header and vertical studs wherein the header is capable of vertical movement relative to the studs. The assembly of the invention includes an upper track or header that has a web and flanges connecting to the web. The flanges each comprise an inside part and an outside part that are connected together at lower edges. At least one of the flanges has at least one vertical slot in both the inside part and the outside part. The assembly includes a stud having a width less than the distance between the inside parts of the flanges. The stud is positioned between the inside parts of the two flanges. A screw extends through the slots in the inside and outside parts of the flange. The screw has a head that contacts the outside flange on opposite sides of the slot. The screw connects to the flanges of the header to the stud and permits the header to move vertically with respect to the stud.

Preferably, vertical slots are formed in both of the flanges. Each vertical slot extends through both the inner and outer part of the flanges. The screw fastener extends through each slot and into the stud. The screw fastener has a head that is contiguous the sheet metal on opposite sides of the slot.

Preferably, the flanges of the header and a web that interconnects the flanges of the header form a central channel and the header includes a side channel on at least one side of the central channel. The side channel has a web that is connected to the top of the outside part of the flange on its side of the header. This outside flange extends downwardly from the header in a spaced relationship from the outer part of the sidewall of the central channel, so as to form the secondary channel outwardly of the central channel. According to the invention, the secondary channel has a width substantially equal to a wallboard member that is attached to the studs.

This construction permits vertical movement of the upper track or header relative to the remaining portion of the wall, and at the same time adapts the wall to withstand substantial wind loads or other side loads.

Other objects, advantages and features of the invention will become apparent from the description set forth below, from the structure illustrated in the drawing, and from the principles that are embedded in the specific structures that are illustrated and described.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT

The various concepts are principles which make up the invention can be best understood by considering the following description of an example embodiment of the invention.

Referring toFIGS. 1,2and4, the upper track is designated10and the stud is designated12. As best shown byFIG. 4, the track10is constructed from a single sheet of sheet metal that is bent along eight fold lines14,16,18,20,22,24,26,28. These fold lines divide the track10into nine panels or sections30,32,34,36,38,40,42,44,48. Panels34,36and40,42are all substantially equal in width. Panels30,48are narrower than the panels34,36,40,42. In the finished product, panel30is perpendicular to panel32. Panel32is perpendicular to panel34. Panel34is parallel to panel36. Panel38is perpendicular to both panel36and panel40. Panel40is parallel to and adjacent panel42. Panel42is perpendicular to panel44. Panel44is perpendicular to panel48. Right angle corners are formed at each of the folds14,16,20,22,26,28. Panels34,36are moved together and panels40,42are moved together. Panels34,36and40,42are perpendicular to panel38. Panels34,36and40,42form the sidewalls of a channel. The panel38forms a web for the channel. Together, panels34,36,38,40,42form a channel having a channel space below the web38and inwardly of the sides34,36and40,42of the channel. As shown byFIG. 2, web10is connected to an overhead structure OS, e.g. a roof or upper floor.

Panels30,48are parallel to each other and to the walls34,36and40,42.

The structure formed by the panels36,38,40is like the track disclosed by the aforementioned U.S. Pat. No. 5,127,760. The addition of panels34,42connected at their bottoms to the bottoms of the panels36,40give the track a sidewall thickness that is double the sidewall thickness of the track disclosed by U.S. Pat. No. 5,127,760. In the track disclosed by the patent, the two sidewalls of the track are provided with a plurality of longitudinally spaced apart slots that extend perpendicular to the track. In the track10, similar slots are placed in all four of the panels34,36,40,42. When panels34,36are together and panels40,42are together, the slots50,52are in substantial alignment with the slots54,56. In effect, slots54,50form a single slot in a double-thick sidewall and slots52,54form a slot in a double-thick second sidewall for the track10.

In similar fashion to the stud and track assembly disclosed by U.S. Pat. No. 5,127,760, screw fasteners S extend through the slots54,50and56,52and screw into the flanges60,62of the stud12. In addition to flanges60,62, the stud12has a web64and lips66,68. The flanges60,62extend perpendicular from the web64on the same side of the stud12. Lips66,68extend laterally inwardly from their points of connection with the flanges60,62, in co-planar parallelism with each other. Lips66,68are also parallel to the web64and are perpendicular to the flanges60,62.

The screws S have heads H that are wider than the slots50,54and52,56. As a result, the heads H bear against the sheet metal that closely borders the sides of the slots50,54,52,56. Screws S have threaded shanks60(FIG. 3) which form openings62in the stud flanges60,62. Preferably also, each head H includes a cylindrical spacer64between the head H and the threaded section60. Cylindrical portion64is narrower than the slots50,54and52,56. Portions64includes end surfaces66which contact the stud flanges60,62in the manner shown byFIG. 3. Sections64are preferably slightly longer than the combined thickness of the panels34,36and40,42. As a result, when the end surface66is against the stud flange60,62, there is a slight axial space68between the header of the screw H and the confronting side of the stud flange60,62. As a result, the screws S can be tightened and the sections64will act as spacers to keep the screwhead SH from clamping against the panels34,42. As a result, the screws S can be tightened and still will be able to freely move up and down in the slots50,54and52,56. This feature is disclosed and claimed in my co-pending application Ser. No. 11/108,311, filed Apr. 18, 2005, and entitled Wall Construction.

As illustrated in U.S. Pat. No. 5,127,760, a framing wall is composed of a plurality of vertical studs and upper and lower horizontal track. The upper and lower ends of the studs fit within the channel spaces of the tracks with the flanges of the studs being closely adjacent the sidewalls of the tracks. Each track is separately installed in a vertical position between the upper and lower tracks. At the lower end, the tracks do not include slots. Screws are inserted through the sidewalls of the tracks and screwed into the flanges of the studs. At the upper end, the screws S are inserted through slots that are outwardly adjacent the flanges of the studs. As the screws S are self-tapping and when turned they form openings in the flanges and then the threaded portions60move into the openings and engage the sheet metal surrounding the openings, as shown byFIG. 3.

The sidewalls of the upper track10are twice as thick as the sidewalls of the upper track disclosed by U.S. Pat. No. 5,127,760. This makes the wall stronger and capable of withstanding larger side loads, e.g. wind loads, than the wall disclosed in U.S. Pat. No. 5,127,760.

When the studs12are connected to the upper and lower tracks, wallboard panels WP are connected to the studs12, by screws70that extend through the wallboard panels WP and screw into the studs flanges60,62. The upper edge portions72of the wallboard panels WP have outer sides which are substantially flush with the outer surfaces of the panels30,48. After the panels WP are installed to the studs12, narrow strips of wallboard WP are secured to the panels38,48by the use or screws70. Thus, panels WP are secured to the studs12. Trim panels TP are secured to the upper side portions of the track10. The track slots50,54and52,56permit vertical deflection or movement between the upper track10and the upper ends of the studs. Trim panels TP can move with the upper track10. As they move, the upper track10and the trim panels TP move relative to the studs12and the panels WP.

A particularly important feature of the present invention is the one-piece construction of the track10. Another important feature is the double thickness of the sidewalls of the upper track10, formed by the panels34,36and40,42. The use of the screws S that are illustrated completes an advantageous combination that is superior to the prior art assemblies that include only some of these features. InFIG. 3, the head H of screw S is shown having a screwdriver tip receiving socket SS.

The track10can be constructed by providing a long strip of sheet metal that is as wide as the combined widths of the panels30,32,34,36,38,40,42,44,46. This strip is then conveniently bent along the hinge lines14,16,18,20,22,24,26,28to form the upper track shape that is illustrated. The tracks are made into convenient lengths, e.g. 8 ft., 10 ft., 12 ft., etc. These sections and/or cut portions of the sections may be used to form the upper tracks for the framing walls of a building.

The illustrated embodiments are only examples of the present inventions and, therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments illustrated and described herein.