Modular metal wall framing system

A wall frame is constructed with a pair of horizontally disposed metal channel members and a series of vertical studs spaced at predetermined intervals along the channel members. The studs are accurately located within the channel members by vertically upstanding tab stops which are struck out from the channel members. Pronged retainers are also struck outwardly from the channel members to fit through alignment slots formed in the studs. Weakened areas on the channel members can be crimped against the studs to lock the studs in place on the channel members. Horizontally disposed spacer bars are adapted to interconnect with a series of studs to strengthen and further align the studs and to provide a support surface against which dry wall or the like may be fastened.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates in general to metal wall frames, and in particular to such frames which include channels and studs having integrally formed connectors, locators and retainers.

2. Description of Prior Developments

Framing systems have been developed using metal channels and studs in place of more conventional wood frames. Such systems have been adapted to construct various structures including residential and commercial buildings, and particularly the partitions of such buildings. Although these systems function adequately, they may be difficult to use and can take longer to assemble than conventional wood frames.

Because of these drawbacks, many builders have been reluctant to adopt prior metal framing systems. Moreover, installers have experienced difficulty in correctly installing prior metal framing systems. Installers also dislike the snipping and cutting of the metal frame members required in such systems, as the sharp metal edges can result in cut hands and torn clothes. For these reasons, wood frames are still the most commonly used frames for residential construction.

Although wood frames have been widely accepted by builders and installers, wood frames are not fireproof and wood tends to buckle, warp, split, shrink, and bend out of shape. Moreover, a wood stud is heavier and more awkward to work with than a metal stud, and is currently about twice the price of a metal stud.

Even with the drawbacks associated with wood frames, wood is still the material of choice of most builders, particularly since carpenters are familiar with wood frame construction and can nail wood frames together with a nail gun faster than they can screw a nail into a metal frame with a screw gun.

The following comparison of existing standard wood and conventional metal study applications may be of value in fully appreciating the advantages of the present invention.

Installation of a wall partition constructed of wooden studs, after upper and lower plates have been installed, requires the following steps for each stud:1. Measure 16 inches on center or 24 inches on center from the previously installed stud and appropriately mark the measured distance on the upper and lower plate.2. Measure the distance between upper and lower plates.3. Measure the length of the stud to be installed to be equal to the measurement in the previous step and mark the stud where it is to be cut.4. Cut the stud. The cut must be square, using a miter box, skill saw guide, etc.5. Place the stud into position between the plates. Adjust the position of the stud by applying a level to assure that it is plumb, top to bottom, side to side and front to back.6. Nail the bottom portion of the stud to the lower plate using two nails which can be nailed manually or with an automatic nailing gun.7. Climb a ladder or scaffold and nail the top portion of the stud to the upper plate, again using two nails.8. Usually framers will also install horizontal wood members to serve as braces and spacers between the studs. In such case there are the following additional steps:A. Measure and mark a piece of stud lumber to fit between the studs.B. Cut the piece of lumber square to form a brace.C. Nail two nails to one end of the brace and into one stud.D. Nail two nails into the other end of the brace and into the other stud.9. When electricians run electrical cable through the studs, it is necessary for them to first bore a hole through each stud individually, i.e. those studs which will have cable going through them.

It can be seen that wood fame construction requires many individual time-consuming steps. Moreover, problems associated with wood studs include:1. Wood is not fireproof.2. Wood buckles, splits, shrinks and bends out of shape.3. A wood stud is heavier and clumsier to work with than a corresponding metal stud.4. A wood stud is currently about double the price of a metal stud, and with continuing depletion of natural reserves, prices for lumber will likely continue to rise.

Installation of a partition constructed of metal studs, after the upper and lower channels have been installed, requires the following steps for each stud:1. Measure 16 inches on center or 24 inches on center from a previously installed stud and appropriately mark the measured distance on the upper and lower channels.2. Measure the distance between upper and lower channels.3. Measure the length of the stud to be installed to be equal to the measurement in the previous step and mark the stud where it is to be cut.4. Cut the two side flanges of the stud with a pair of snippers, then bend the central backbone of the stud back and forth until it breaks off.5. Place the stud into position between the channels where previously marked. Adjust the position of the stud by applying a level to assure that it is plumb, top to bottom and side to side.6. Take two screw and individually mount each screw onto a screw gun and screw the bottom portion of the stud into the lower channel.7. Climb a ladder, and again, take two screws and individually mount each onto a screw gun and screw the upper portion of the stud into the upper channel.8. Many installers also place a horizontal brace and spacing member which runs through the apertures of several studs. In such case, there are the following additional steps:A. Run the bracing member through the apertures of several studs.B. Cut little tabs to connect and fasten each stud to its section of bracing member.C. Line up each stud to be properly aligned and plumb with each corresponding section of bracing member.D. Screw into a precut tab to connect the stud to the bracing member.

It can be seen that conventional metal frame construction requires many individual time consuming steps. Moreover, problems associated with conventional metal studs include:1. There does not seem to be any installation time savings of metal over wood. In fact, one can argue that a wooden frame will go up faster than a metal frame because of the extra time required with metal in the process of cutting the stud to size and the fumbling required with screws as opposed to automatic nailing with a nailing gun and nail cartridges.2. Since there do not appear to be real economies in time in the conventional installation of metal frames, many framing contractors prefer to use wood, the “old-fashioned” way.3. When snipping and breaking off a piece of a metal stud, hands and clothing tend to get cut very easily.4. Fumbling with the individual placement of a screw onto a screw gun and screwing into a conventional metal stud is cumbersome, annoying and more time-consuming than simply applying a cartridge-loaded nailing gun to wood.5. Tunneling spacing members through holes in a series of studs and then dealing with the connection of the tabs between the studs and the spacing members is cumbersome, awkward and annoying.

However, metal stud installation does include the following benefits:1. Metal is virtually fireproof.2. Metal is lightweight and easier to work with than wood.3. Metal studs remain intact and square and do not warp.4. Metal studs are currently about half the price of wooden studs.5. Metal studs have precut holes for electrical and other cable running.

Accordingly, a need exists for a framing system which is easy to understand, quick to assemble, which does not require extensive cutting or snipping and which is cost-effective as compared to current alternative methods.

A further need exists for such a system which is more economical to use than wood frame systems and which is readily accepted by architects, builders, installers and end users.

A further need exists for a framing system which provides accurate spacing between studs and which is available with modular interchangeable components.

Still a further need exists for a framing system which offers a complete and simple solution rather than a partial solution to the entire installation process.

SUMMARY OF THE INVENTION

The present invention has been developed to fulfill the needs noted above and therefore has as an object the provision of a metal framing system for supporting the walls, floors and ceilings of various building structures including residential and commercial buildings.

This invention provides a comprehensive and cost-effective solution to the construction industry in the creation and installation of wall/partition frames by facilitating a much simpler and speedier installation resulting in greatly reduced labor costs while at the same time maintaining quality control in the integrity and accuracy of the installation.

The construction industry whose workers are tradition and trade-oriented has been very slow to adopt any innovative methodologies or technologies. On the other hand, there is always a desire on the part of builders and consumers to reduce costs in building.

The only way to satisfy both ends of the spectrum is to present a solution which creates significant cost-savings while at the same time having certain key ingredients: simple, easy to learn, practical (makes life easier for the worker) and also provides a complete solution, rather than dribs and drabs.

This invention has the key ingredients to satisfy the worker and take away the worker's opposition to innovation. Those same ingredients have the effect of cutting costs for the builder. Time is money, and a speedy operation becomes a less expensive one.

Previous patents and innovations have in most instances offered a solution to only a small part of the process—rather than to the whole thing. This invention provides a complete solution. Importantly, the invention does not seek to “replace” steps in stud-wall building with a “better mouse trap”. Instead it just eliminates some of the steps entirely for the tradesperson.

While saving money and streamlining operations, the invention maintains the integrity and accuracy of the installation. Studs must be perfectly square-plumb and on center for drywall installation.

Another object of the invention is the provision of a metal framing system which is easy to use, quick to assemble and does not require metal cutting during frame assembly.

Another object of the invention is the provision of a complete modular framing system which is simple in form, easy to learn and easy to use.

A further object of the invention is the provision of a metal wall framing system which eliminates some of the steps required to construct a conventional metal or wood frame, while providing a square, plumb and on-center metal frame for supporting drywall or other wall materials.

Yet another object of the invention is the provision of a metal framing system which is significantly faster and more economical to assemble than other wood and metal framing systems.

Still another object of the invention is the provision of a modular metal framing system which is easily used by an unskilled, lower-cost worker. The system is also intended for use by inexperienced do-it-yourself homeowners lacking the tools, knowledge and experience of a skilled professional framer.

A further object of the invention is the provision of a metal wall framing system which does not require supplemental hardware, requires no supplemental fasteners, nails, electric tools or other power tools, nor any measuring devices or cutting devices.

Still a further object of the invention is the provision of a modular metal framing system which includes a side spacer or bracer which optionally provides spacing and alignment of studs and serves as a larger surface for supporting drywall and into which metal screws can be more conveniently secured to hold the drywall to the frame.

These and other objects are met by the present invention which is directed to a modular metal framing system for constructing wall frames in virtually any type of building construction. The system is complete insofar as it requires virtually no additional hardware and can be readily used by unskilled labor. Metal wall frames constructed in accordance with the invention can be completed in a fraction of the time and at much lower cost than wood frames as well as other conventional metal frame systems.

In accordance with the invention, upper and lower metal channels are formed with a series of evenly spaced locators or stops which accurately locate a series of metal studs along the channels. The channels also include retainers or prongs located adjacent to the locators or stops for fitting within slots formed in the studs. The channels further include scored or notched areas located adjacent to the stops and prongs for allowing a portion of each channel side wall to be crimped inwardly to hold a stud in place on the channel.

In order to interconnect and mount a stud on a channel, the stud is simply moved along the channel with a sliding movement until the stud engages a stop. Just before the stud engages a stop, one or more locators or prongs slide into mating slots formed in the stud to hold and guide the stud into alignment with the stop. Notched or perforated portions in the channel sidewalls are then crimped inwardly to hold the stud in place within the channel. This provides a bracing system for spacing and leveling.

The aforementioned objects, features and advantages of the invention will, in part, be pointed out with particularity, and will, in part, become obvious from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which form an integral part thereof.

In the various figures of the drawings, like reference characters designate like or similar parts.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be described in conjunction with the drawings, beginning withFIG. 1which shows a channel member10constructed in accordance with the invention. Channel member10is adapted to be installed in a known manner on a lower support surface such as a floor. An identical second or upper channel member10is typically installed in a known manner on an overhead support surface such as a ceiling. The upper and lower channel members are aligned parallel with one another and typically aligned within a common vertical plane.

Channel member10includes a flat, longitudinally-extending central floor12and a pair of upstanding parallel side walls14which are bent upwardly at right angles from each side of floor12. Channel member10is formed of a sheet metal material such as steel. A stud locator or stop member in the form of a tab16is struck or punched upwardly from the channel floor12leaving behind an open aperture18in floor12.

Tab16may take virtually any shape such as the rectangular tab show inFIG. 1. Preferably, tab16is aligned vertically perpendicular to floor12and laterally or transversely perpendicular to each side wall14. In this manner, tab16is “square” with both the floor and side walls of the channel member. A series of longitudinally-spaced tabs16is formed in channel member10with each tab located at regular intervals. Tabs16can be located at predetermined longitudinal spacings of, for example, 16 and/or 24 inches.

One or more retaining members20are also struck out or punched up from channel floor12, leaving behind an open aperture22in floor12. As shown inFIG. 1, a pair of tapered, pointed retainer members is laterally spaced on each side of tab16. The retainer members may be ramped upwardly from floor12as seen inFIG. 1aor formed in an “L” shape as seen inFIG. 1b.

InFIG. 1b,the base24of retainer20is aligned perpendicularly upwardly from the floor12of channel member10and is located at the same longitudinal position on floor12as is tab16. A leg26extends from base24on retainer20and is bent back over floor12and aligned parallel with floor12.

As further seen inFIG. 1, a cut, notched, perforated or otherwise weakened crimp portion28is formed along one or both sidewalls14. As shown, a pair of rectangular crimp portions28is formed along the top edge29of each side wall14. Each crimp portion28is longitudinally spaced a predetermined distance away from each tab16to allow the crimp portions28to be squeezed or crimped inwardly toward each other in order to crimp a stud in place within channel member10, as described more fully below.

As seen inFIG. 2, a stud30is formed of a metal material, such as steel, in accordance with the invention. Stud30includes a central column portion32and a pair of parallel side walls34projecting perpendicularly from the column portion. An inturned lip36is formed on the outer end portion of each side wall34. One or more alignment slots38are formed through the end portion40of stud30for receiving and interconnecting with one or more of the retainer members20on channel member10.

As can be appreciated from a review ofFIG. 2(a), the stud30is fitted between the side walls14of the channel member10with the bottom edge of the stud making sliding contact against the channel floor12and with the side walls34of the stud making sliding contact against the side walls14of the channel member. As the stud30approaches the tab16on the channel member10, the tips of the retainer members20enter the alignment slots38in the stud30.

When the stud is fully and properly butted flat against the tab16, it is also fully seated against the retainer members20. In the example of the retainer member20ofFIG. 3, the rear face of column portion32abuts the tab16as well as the base24of each retainer member20. Once this three position contact has been achieved, the stud30is properly and fully aligned and seated within the channel member10.

At this point, the crimp portions28are bent inwardly from the side walls14of channel member10to form locking members44. An open notch46is thus formed in the top edge29of each side wall14. The locking members44can be closely spaced from the lips36on stud30or in contact with lips36.

The general spacing of the interconnected channel member10and stud30is shown inFIG. 3wherein the stud is held in position vertically by the retainer members20, held laterally by contact with side walls14and locked longitudinally by abutment in one direction with tab16and in the other by abutment with locking members44.

A variation of this positioning, locating, aligning and locking stud and channel framing system is shown inFIG. 4wherein the retainer members20are struck out from the side walls14of the channel member10and extend inwardly over the floor12of the channel member. The stud30is modified to locate the elongated alignment slots38in a vertical orientation in order to receive and mate with the retainer members20. The tab16is arranged as in the prior example, and crimp portions28are formed in side walls14as in the prior example.

A further variation of the invention is shown inFIGS. 4(a) and4(b) wherein the retainer members20enter vertical slots38through the inside surface50of channel member10rather than through the outside or back side52as shown inFIG. 4. In the example ofFIG. 4, the back side52is slid into and against the retainer members20in the direction of arrow54. In the example ofFIGS. 4(a) and4(b), the inside surface50is slid into and against the retainer members20in the direction of arrow56.

In the example ofFIG. 4(a), a cut-out portion58can be formed in each lip36for providing clearance for the passage of retainer members20through the lips36. Alternatively, as shown inFIG. 4(b), the base24of the retainer members can be dimensioned to extend into the channel member to provide clearance of leg26over lip36. Crimp portions28are formed adjacent to lips36inFIG. 4and adjacent to back surface52and to slots38inFIGS. 4(a) and4(b).

In each of the prior examples, a pair of identical channel members10is aligned with one channel member directly above another. One channel member may be attached by fasteners to a floor and the other similarly attached to a ceiling. The tabs16on each channel member are vertically aligned one directly over the other and the channel members are carefully plumbed longitudinally parallel with one another as well.

The aligned channel members provide for the accurate vertically plumbed alignment of the studs when the studs are pushed against a pair of aligned tabs16; one tab being on the upper channel member and one on the lower channel member. In this case, the alignment slots38on each opposite end of the stud30are identical so that both ends of the studs are aligned by sliding the studs against a pair of stops or tabs16and interengaging the slots38with retainer members20on each channel member10. Crimp portions28are then bent inwardly as described above.

A further embodiment of the invention is shown inFIG. 5wherein the lower end of the stud30is the same as shown in any of the prior examples and in this case, as shown inFIG. 2. The channel member10is shown as inFIG. 1to match the slot pattern on the stud. What is different about the stud30inFIG. 5is the addition of an extender member60which is telescopically held within and between the side walls34of the top portion62of stud30.

Rather than secure the upper or top portion62of stud30directly to an overhead channel member10, the extender60is vertically adjusted by sliding within the top portion62to engage the tabs16and retainer members20on the channel member10. The side walls64on extender60may be slightly inwardly tapered toward one another to form a snug sliding friction fit against the side walls34of top portion62. This prevents the extender from having a loose slack fit within the stud30.

The upper portion66of the extender60may be transversely or laterally enlarged along outwardly tapered portions68to prevent the extender60from sliding completely into the stud30by interfering with or abutting against the top edge70of stud30. As further seen inFIG. 5, the extender60is formed with a pair of upper alignment slots72and a pair of lower alignment slots74.

Normally, the lower alignment slits74are engaged with retainer members20on an upper channel member10attached to a ceiling. The retainer members20are thus spaced below the ceiling on which the upper channel member is fastened and spaced below the floor12of the upper channel member10. With this arrangement, the top edge78of the extender60fits snugly against the floor12of the upper channel member. When the upper slots72are engaged with the retainer members20, the top edge78of the extender60is spaced a small distance below the floor12of the upper channel member. This spacing accommodates settling of the ceiling and floors of the building structure and/or allows for additional loading which can compress and lower a ceiling.

When a stud30is attached directly to an upper channel member without an extender60, it is suitable for use in load bearing walls, providing the gauge of the metal stud meets the strength requirements for a load bearing partition. However, when the extender60is used, it is loosely telescopically positioned within the stud and as such is not suitable for use in load bearing walls.

As seen inFIG. 5(a), the pairs of upper and lower alignment slits72,74ofFIG. 5may each be replaced with a single elongated slot72,74. This single slot concept can also be used in place of the alignment slots38formed on the stud30. In these cases, the retainer members20can be replaced with a single wider retainer which extends across substantially the entire width of each single elongated alignment slot.

The extender60ofFIG. 5(a) is shown inFIG. 6mounted to an upper channel member10having a large single retainer member struck out from the floor12of the channel member and inserted through the upper alignment slot72on extender60. The extender60is formed with a push hole80to allow an installer to push the extender60upwardly with a rod or the like engaged within hole80while pushing the lower end of stud30against a tab16as shown inFIG. 5and inserting the retainer members20through the stud slots38. This can be done without the use of a ladder, with an installer standing on the floor.

A variation of the horizontally or transversely elongated alignment slots72,74ofFIG. 5is shown inFIG. 7wherein the alignment slots72,74are elongated vertically and the mating retainer members20are formed as inFIG. 4. Push holes80can be alternatively formed in the side walls64of extender60.

In each of the embodiments discussed above, the upper and lower portions of each stud30are secured in place between the upper and lower channels10and held in place by stops such as tabs16which are accurately positioned on, for example, 16 inch or 24 inch spacings. An alternative embodiment of this arrangement is to secure the bottom portion of each stud30as described in any of the examples above, but to allow the upper portion of each stud to slide longitudinally within the upper channel member without being locked in place.

This can be achieved by eliminating the tabs16from the upper channel member10. One or more “L” shaped retainer members20as shown inFIG. 1(b) serve as the stop against which the stud is positioned. The base24of retainer member20acts as a stop like tab16, and the leg26of retainer member20acts as a longitudinally-extending guide over which the top portion of the stud30or extender60freely slides.

In this embodiment, the upper channel member10need not be accurately aligned horizontally from wall to wall with the lower channel member10. The lower channel member10is spaced and positioned where desired and the upper channel member10is simply approximately located above the lower channel member. Although the upper and lower channel members are aligned vertically in a common plane, they are not necessarily spaced and aligned accurately on 16 inch or 24 inch centers with one another. This allows for wall variations which may be wider on top than at the bottom or vice versa.

In this case, the lower ends of the studs30are secured within a channel member10as discussed in connection with the previous embodiments. The upper ends of the studs30(or extenders60) are simply slid onto the retainer members20and left to freely slide or “float” along the length of retainer legs26. Accurate spacing of the studs30can still be achieved, however, by the use of one or more central spacer or bracer bars84as shown inFIG. 8.

InFIG. 8, the upper ends of the studs30are provided with extenders60which are free to slide longitudinally or “float” along retainer members20as noted above. The lower end of each stud30is positioned and locked in place as inFIG. 2(a). After two or three of the studs30are so arranged and placed in the upper and lower channel members10, one or more spacer bars84are connected to the central or middle portion86of each stud30.

As seen inFIGS. 8 and 8(a), each spacer bar84has a series of accurately spaced tongue members88struck out of the sheet metal spacer material leaving behind an opening90. The tongue members are spaced apart, for example, on 16 inch and/or 24 inch centers, and are dimensioned to fit or snap within receiving members of sockets formed on the studs30.

One example of such receiving members is shown inFIG. 9wherein a vertically, elongated receiving slot92is punched through the side wall34of stud30directly and immediately adjacent to the inner surface50of channel member10. Arched shaped bands or loops94are punched through the central column portion32of stud30from the outer surface or back side52toward the inner surface50to form a socket96which receives the free end98of tongue members88.

Socket96is dimensioned to receive each tongue member88with a tight locking fit or a snap fit. While the tongue members inFIGS. 8 and 8(a) are shown with a rectangular shape, they can also be formed with a triangular shape similar to the retainer members20shown inFIG. 1. Although only one spacer bar84is required, two can be used as shown inFIG. 8attached to opposite side walls34of each stud30.

A further variation of the spacer bar assembly is shown inFIG. 10wherein a rectangular indented or recessed portion100is formed in the side wall34of stud30adjacent to a pair of sockets96. The recessed portion100receives the flat spacer bar84with a flush fit so that the spacer bar does not extend outwardly from the plane of side wall34, or extends only slightly outwardly. In either case, the spacer bar84will not interfere with the placement of drywall.

A variation of the socket96ofFIG. 9is shown inFIG. 11wherein one or more loops or bands94are stuck out from the central column portion32from the inner face50of stud30toward its outer face52. In this manner, the bands94project from outer face52and therefore the receiving slot92ofFIG. 9is not required.

InFIG. 12, a pair of spacers84is shown aligned for insertion within two pairs of sockets96formed on the outer or backside52of column portion32. InFIGS. 13 and 14the spacer bar84is formed with an L-shaped tongue member88and the stud30is formed with a single elongated slot102for receiving the tongue member88.

As seen inFIG. 15, two triangular tongue members88are struck out perpendicularly from spacer bar84to enter a pair of receiving slots formed in sidewalls34in the same manner as receiving slots92shown inFIG. 9.

There has been disclosed heretofore the best embodiment of the invention presently contemplated. However, it is to be understood that the various changes and modifications may be made thereto without departing from the spirit of the invention.