Inverted bridging connector

A connection between a wall stud, channel-shaped bridging member and connector that resists torsional forces, the connector being suited to interlock with the interior of the bridging member channel and to be fastened to the bridging member outside the channel, depending on the orientation of the bridging member.

BACKGROUND OF THE INVENTION

The present invention relates to steel stud building wall systems and especially to apparatuses for stabilizing steed studs to prevent lateral movement and torsion in such systems.

Many industrial, and a growing number of residential, buildings are constructed with steel stud wall framing for a variety of reasons. Steel framing is fireproof, does not warp, cannot be infested, and does not rot. When a wall is built with any kind of stud, wood or steel, it is generally desirable to fix sequential studs relative to each other and each against lateral movement and torsion. In wood-stud walls, a short piece of wood blocking is typically nailed to adjacent stud pairs to stabilize them. In steel-stud walls, an elongated steel bridging member is typically inserted horizontally through pre-punched openings in a series of vertical studs to keep them aligned. Steel studs have excellent columnar strength when they are straight, but a significant portion of that strength is lost if the studs are twisted. Because steel studs are particularly vulnerable to torsion, the bridging member, which is typically channel-shaped, having a horizontal web and two vertical side flanges, is made to closely fit the openings in the vertical studs in order to maximize torque resistance. In additional to mechanical torque, metal studs can twist or bend in response to the heat of a fire when the drywall sheathing, which acts as a firebreak, is destroyed. When metal studs twist or bend, they lose their weight-bearing capacity, multiplying the damage caused directly by fire.

While channel-shaped bridging members closely received in the openings can help restrain the studs from twisting, some twisting can still occur and the studs can still shift or bend parallel to the wall. A variety of sheet metal brackets, beginning with a simple right angle, have been designed to prevent this shifting or bending. The prior art brackets are all relatively labor intensive to install and their connections are all relatively weak. Fore example, with the simple right angle bracket, the installer places the horizontal leg of the bracket on the bridging member and the vertical leg of the bracket against the web of the wall stud. Screws are inserted through both legs to attach the bracket to the bridging member and the stud. The bracket relies on the screw connections to function, and the installer must ensure that the bracket is placed correctly. Later prior art brackets have improved on this basic connection.

The prior art also includes short bridging members that, like the wood blocking members mentioned above, span only adjacent studs and have ends tailored for fastening the wall studs, but these bridging members are relatively expensive because they use additional material to form the ends, they require a large number of fasteners, and they are necessarily of fixed length, which makes them useless if the spacing between any two studs has to be varied from the norm.

The prior art also includes elongated bridging members with a series of slots that are designed for mating with the opening in the wall stud webs, but these make relatively weak connections and also have the disadvantage that they cannot accommodate any variation in the spacing between studs.

It is an object of the present invention to provide a bracket that uses less material than prior art brackets, installs faster and more easily using fewer fasteners, and forms a connection that is stronger, resisting both lateral and torsional loads better than the prior art. It is a particular object of the present invention to provide a bracket that can be installed both outside and within the channel shape of the typical bridging member. The ability to install within the channel shape is especially advantageous because bridging members are frequently installed upside down, as a u-channel instead of the more correct n-channel.

SUMMARY OF THE INVENTION

The present invention provides a connector for firmly connecting and stabilizing a building wall steel stud in concert with a bridging member. The bridging member passes through an opening in each of several studs in a section of a wall. The bridging member is designed to keep the studs in alignment along the length of the wall when it is installed through the studs.

The present invention provides a connector with edges that interlock with the web of a wall stud to provide exceptional torsional rigidity. The edges are braced by the body parts of the connector, allowing them to resist substantially higher loads than flanges adjacent to the web of the wall stud.

The present invention provides a connector with edges or similarly narrow lines that interface with the sides of the bridging members that connect wall studs, also providing exceptional torsional rigidity. These narrow interfaces are braced by flanges that intersect with the sides of the bridging members instead of being positioned alongside and parallel to the sides of the bridging members.

The interfaces with the sides of the bridging members are further reinforced by bracing the opposite ends of the flanges against the web of the wall stud, so that the diagonal flanges are trapped between the sides of the bridging members and the web of the wall stud.

The exceptional strength of the interlocking connections between the bridging connector, the bridging member and the wall stud allow the bridging connector to be firmly connected with a single fastener that attaches the body of the bridging connector to the bridging member.

For added strength, additional fasteners can be used to attach the bridging connector to the wall stud.

The present connector is shaped to conform to the inner surfaces of the bridging member, but can be attached either within or outside the channel shape of the bridging member.

The present connector is mechanically interlocked with the boundary flanges of the bridging member and is restrained between the boundary flanges of the bridging member and the web of the stud.

The present connector can interface with the planar boundary flanges of the typically bridging member, providing an improved interlock between the two.

The present connector can interface with all three internal surfaces of the typical bridging member, providing a further improved interlock between the two.

The present connector provides a central portion with a channel shape similar to that of the typical bridging member, providing a further improved interlock between the two.

The present connector provides a central portion with a right-angled channel shape, providing a further improved interlock between the two.

The present connector can extend laterally beyond the bridging member to provide improved connection between the bridging member and the web of the stud.

The present connector provides side flanges that brace the boundary flanges of the bridging member against the web of the stud.

The present connector provides a fastener embossment that stiffens the connector around the fastener opening and can provide contact with the bridging member when the connector is installed outside the bridging member channel.

The present connector can fastened with a single fastener, easing and speeding installation.

The present connector provides slots that with edges that face and can interface with the web of the stud on either side of the stud web opening.

The present connector provides a connection that reinforces the stud against torsional rotation on a vertical axis. The same connection reinforces the bridging member against rotation on a horizontal axis.

DETAILED DESCRIPTION OF THE INVENTION

As shown inFIGS. 1, 4-7 and 10-12, the present invention is a building connector1that comprises a substantially vertical wall stud2, a substantially horizontal bridging member11, and a bridging connector19. The structural members are typically made from cold-formed sheet steel, and the bridging connector19is preferably made from cold-formed steel, but any or all can be made from other sufficiently strong materials, formed by any appropriate method of manufacture.

As shown inFIGS. 1-4 and 7-10, the substantially vertical wall stud2preferably has a central web3with an opening8, a first side flange9integrally attached to the central web3, and a second side flange9integrally attached to the central web3. The central web3is typically bounded by four sides4, and the central web3has an inner surface6and an outer surface7. The opening8in the central web is typically elongated vertically, with an edge65that has two elongated vertical portions66to either side and two concave portions68joining the vertical portions66. The side flanges9have inner surfaces53and outer surfaces54. In addition, the wall stud2typically has first and second stiffening flanges57attached to the first and second side flanges9, respectively. The stiffening flanges57have inner edges59that face each other, inner surfaces61and outer surfaces62.

As shown inFIGS. 1-4 and 7-10, preferably the substantially horizontal bridging member11has an at least partially planar middle web12, an at least partially planar first boundary flange17, and an at least partially planar second boundary flange17. The at least partially planar middle web12preferably has a first boundary13and a second boundary13, an internal surface15and an external surface16. Preferably, the at least partially planar first boundary flange17is angularly joined to and extends from the middle web12at the first boundary13. The first boundary flange17preferably has an internal surface71and an external surface72. Preferably, the at least partially planar second boundary flange17is angularly joined to and extends from the middle web12at the second boundary13. The second boundary flange17preferably has an internal surface71facing toward the internal surface71of the first boundary flange17and an external surface72facing away from the external surface72of the first boundary flange17. Preferably, the first and second boundary flanges17of the bridging member11have first and second outer edges75, respectively, that are mutually parallel.

As shown inFIGS. 1, 5-7, 11 and 12, the bridging connector19preferably contacts the central web3of the wall stud2and is fastened to the bridging member11. Preferably, the bridging connector19has a first body part20, a first interior surface21and a first exterior surface22. The first body part20preferably has a first inner edge23and a first outer edge101. Preferably, a rigid central portion11of the first body part20is dimensioned to conform to substantially planar portions of the internal surface71of the first boundary flange17and the internal surface71of the second boundary flange17of the horizontal bridging member11. Thus, the first body part20preferably makes at least two points of contact with the internal surface71of one of the first and second boundary flanges17and at least one point contact with the internal surface71of the other of the first and second boundary flanges17.

As shown inFIGS. 14-19, preferably the first exterior surface22is opposite the first interior surface21. One of the first interior surface21and the first exterior surface22preferably faces the bridging member11. Preferably, the first body part20has a first side boundary33and a second side boundary33. The central portion111of the bridging connector19is preferably bounded by a first straight borderline130and a second straight borderline130. Preferably, the first and second outer edges75of the first and second boundary flanges17, respectively, of the bridging member11.

As shown inFIGS. 1, 5-7, 11 and 12, the central portion111of the first body part20is preferably dimensioned so that the central portion111of the first body part20can interface with the internal surfaces71of the first and second boundary flanges17of the bridging member11such that the bridging connector19is restrained from rotational movement on a vertical axis131relative the bridging member11by the mechanical interlock between central portion111of the bridging connector19and the first and second boundary flanges17of the bridging member11.

As shown inFIGS. 1, 5-7, 11 and 12, preferably a first substantially planar part117of the central portion111of the first body part20is dimensioned to conform to a substantially planar portion of the internal surface71of the first boundary flange17of the horizontal bridging member11. A second substantially planar part117of the central portion111of the first body part20is preferably dimensioned to conform to a substantially planar portion of the internal surface71of the second boundary flange17of the horizontal bridging member11.

As shown inFIGS. 1, 5-7, 11 and 12, the central portion111of the first body part20is preferably dimensioned to conform to adjacent portions of the internal surfaces15of the middle web12, the internal surface71of the first boundary flange17and the internal surface71of the second boundary flange17of the horizontal bridging member11.

As shown inFIGS. 14-19, preferably the central portion111of the first body part20has a central web portion112, a first border extension117, and a second border extension117. The central web portion112preferably has a first border113and a second border113, an inside surface115and an outside surface116. Preferably, the first border extension117is joined to the first border113. The first border extension117preferably has an inside surface118and an outside surface119. The second border extension117is preferably joined to the second border113. Preferably, the second border extension120has an inside surface118and an outside surface119. The central web portion112of the first body part20preferably is angularly related to the first border extension117and the second border extension120.

As shown inFIGS. 14-19, preferably the angle between the inside surface115of the central web portion112and the inside surface118of the first border extension117is orthogonal. The angle between the inside surface115of the central web portion112and the inside surface118of the second border extension120preferably is orthogonal as well.

As shown inFIGS. 14-19, preferably the first border extension117extends from the first border113to a first juncture123. The second border extension117preferably extends from the second border113to a second juncture123. Preferably, the first body part20includes a first lateral extension124that is joined to the first juncture123and extends past the first boundary flange17of the bridging member11to the first side boundary33of the first body part20of the bridging connector19. The first body part20preferably includes a second lateral extension124that is joined to the second juncture124and extends past the second boundary flange17of the bridging member11to the second side boundary33of the first body part20of the bridging connector19. Preferably, the first border extension117is angularly related to the first lateral extension124. The second border extension117preferably is angularly related to the second lateral extension124.

As shown inFIGS. 14-19, preferably the first lateral extension124has a first interior surface125and a first exterior surface126. The second lateral extension126preferably has a second interior surface125and a second exterior surface126. Preferably, the angle between the outside surface119of the first border extension117and the exterior surface126of the first lateral extension124is orthogonal. The angle between the outside surface119of the second border extension117and the exterior surface126of the second lateral extension124also is preferably orthogonal.

As shown inFIGS. 1, 5-7, 11 and 12, preferably, a first side flange35is attached to the first side boundary33and a second side flange35is attached to the second side boundary33. The first side flange35preferably has an inner surface37and an outer surface38opposite the inner surface37. Preferably, the second side flange35has an inner surface37and an outer surface38opposite the inner surface37. The first side flange35of the bridging connector2preferably interfaces with the first boundary flange17of the bridging member11. Preferably, the second side flange35of the bridging connector2interfaces with the second boundary flange17of the bridging member11. The first side flange35of the bridging connector2and the first boundary flange17of the bridging member11preferably are at least partially nonparallel. Preferably, the second side flange35of the bridging connector2and the second boundary flange17of the bridging member11are at least partially nonparallel. The sides flanges35preferably have outer end edges91, lower edges95, and inner end edges103.

As shown inFIGS. 7, 11 and 12, the outside surface116of the central web portion112preferably is adjacent the internal surface15of the middle web12of the bridging member11. Preferably, the outside surface119of the first border extension117is adjacent the internal surface171of the first boundary flange17of the bridging member11. The outside surface119of the second border extension120preferably is adjacent the internal surface181of the second boundary flange17of the bridging member11.

As shown inFIGS. 7, 11 and 12, preferably the central web portion112of the bridging connector19includes a first fastening embossment127centered on a first fastener opening82. The first fastener embossment127preferably does not contact the middle web12of the bridging member11. The fastener embossment127is preferably the same height as the boundary flanges17of the bridging member11, and it is preferably round, but its height and circumference can take other dimensions and forms.

As shown inFIGS. 1, 5-7, 11 and 12, preferably, only a single fastener81fastens the bridging connector19to the bridging member11, and the single fastener81is inserted through the fastener opening82in the first fastening embossment127. Additional fasteners81can be used if additional strength is needed. There can also be additional fastener embossments127. When the bridging connector19is installed outside the bridging member11channel, there is a force couple between the fastener81and the geometric features of the bridging connector19that abut the central web3of the wall stud2. The same force couple exists when the bridging connector19is installed in the bridging member11channel, but the preferred form of the bridging connector19has a geometry that itself resists rotation around a vertical axis131so that the fastener81prevents the bridging connector19from escaping the bridging member11channel. In the preferred embodiment, the fastener81is a sheet metal screw81, other fasteners81can be used.

Alternatively, as shown inFIGS. 1, 5 and 6, the inside surface115of the central web portion112preferably faces the external surface16of the middle web12of the bridging member11. Preferably, the first juncture123between the first border extension117and the first lateral extension124of the bridging connector19is adjacent the first boundary13of the middle web12of the bridging member11. The second juncture123between the second border extension117and the second lateral extension124of the bridging connector19preferably is adjacent the second boundary13of the middle web12of the bridging member11.

As shown inFIGS. 1, 5 and 6, preferably the central web portion112of the bridging connector19includes a first fastening embossment127that contacts the external surface16of the middle web12of the bridging member11.

As shown inFIGS. 1, 5 and 6, only a single fastener81preferably fastens the bridging connector19to the bridging member11, and the single fastener81is inserted through the fastener opening82in the first fastening embossment127, where the fastening embossment127of the bridging connector19contacts the external surface16of the middle web12of the bridging member.

As shown inFIGS. 1, 5-7, 11 and 12, preferably the first inner edge23has a first web interface portion24and a second web interface portion24The bridging connector19preferably has a second body part20and a neck32joining the first body part20to the second body part20. Preferably, the second body part20has a second interior surface21, a second exterior surface22opposite the second interior surface11, a second inner edge29with a third web interface portion24and a fourth web interface portion24. One of the second interior surface21and the second exterior surface22preferably faces the bridging member11. Preferably, the neck32joins the first body part20to the second body part20between the first web interface portion24and the second web interface portion24of the first inner edge23and between the third web interface portion24and the fourth web interface portion24of the second inner edge29. The neck32preferably passes through the opening8in the central web3of the wall stud2. Preferably the first web interface portion24and a second web interface portion24of the first inner edge23interface with the central web3of the wall stud2. The third web interface portion24and the fourth web interface portion24of the second inner edge29preferably interface with the central web3of the wall stud2.

As shown inFIGS. 7, 11 and 12, preferably a rigid central portion111of the second body part20is dimensioned to conform to adjacent portions of at least two of the internal surfaces15,71of the middle web12, the first boundary flange17and the second boundary flange17of the horizontal bridging member11. The second body part20preferably makes at least two point of contact with the internal surface71of one of the first and second boundary flanges17and at least one point of contact with the internal surface71of the other of the first and second boundary flanges17.

As shown inFIGS. 7, 11 and 12, referably the central portion111of the second body part20is dimensioned so that the central portion111of the second body part20can interface with the internal surfaces71of the first and second boundary flanges17of the bridging member11such that the bridging connector19is restrained from rotational movement on a vertical axis relative the bridging member11by the mechanical interlock between central portion111of the bridging connector19and the first and second boundary flanges17of the bridging member11.

As shown inFIGS. 7, 11 and 12, a first substantially planar part117of the central portion111of the second body part20is preferably dimensioned to conform to a substantially planar portion of the internal surface71of the first boundary flange17of the horizontal bridging member11. Preferably, a second substantially planar part117of the central portion111of the second body part20is dimensioned to conform to a substantially planar portion of the internal surface71of the second boundary flange17of the horizontal bridging member11.

As shown inFIGS. 7, 11 and 12, the central portion111of the second body part20is preferably dimensioned to conform to adjacent portions of the internal surfaces15of the middle web12, the internal surface71of the first boundary flange17and the internal surface71of the second boundary flange17of the horizontal bridging member11.

Preferably, the central portion111of the second body part20has a central web portion112, a first border extension117, and a second border extension117joined to the second border113. The central web portion112preferably has a first border113and a second border113, an inside surface115and an outside surface116. Preferably, the first border extension117is joined to the first border113, the first border extension117having an inside surface118and an outside surface119. The second border extension117is preferably joined to the second border113, the second border extension120having an inside surface118and an outside surface119. Preferably, the central web portion112of the second body part20is angularly related to the first border extension117and the second border extension120.

The angle between the inside surface115of the central web portion112of the second body part20and the inside surface118of the first border extension117of the second body part20is preferably orthogonal. Preferably, the angle between the inside surface115of the central web portion112of the second body part20and the inside surface118of the second border extension120of the second body part20is also orthogonal.

The first border extension117of the second body part20preferably extends from the first border113to a first juncture123. Preferably, the second border extension117of the second body part20extends from the second border113to a second juncture123. The second body part20preferably includes a first lateral extension124that is joined to the first juncture123and extends past the first boundary flange17of the bridging member11to the first side boundary33of the first body part20of the bridging connector19. Preferably, the second body part20includes a second lateral extension124that is joined to the second juncture124and extends past the second boundary flange17of the bridging member11to the second side boundary33of the first body part20of the bridging connector19. The first border extension117of the second body part20preferably is angularly related to the first lateral extension124of the second body part20. Preferably, the second border extension117of the second body part20is angularly related to the second lateral extension124of the second body part20.

The first lateral extension124of the second body part20preferably has a first interior surface125and a first exterior surface126. Preferably, the second lateral extension126of the second body part20has a second interior surface125and a second exterior surface126. The angle between the outside surface119of the first border extension117of the second body part20and the exterior surface126of the first lateral extension124of the second body part20is preferably orthogonal. Preferably, the angle between the outside surface119of the second border extension117of the second body part20and the exterior surface126of the second lateral extension124of the second body part20is also orthogonal.

As shown inFIGS. 1 and 4, a first side flange35is preferably attached to the first side boundary33of the second body part20and a second side flange35is attached to the second side boundary33of the second body part20. Preferably, the first side flange35of the second body part20has an inner surface37and an outer surface38opposite the inner surface37. The second side flange35of the second body part20preferably has an inner surface37and an outer surface38opposite the inner surface37. Preferably, the first side flange35of the second body part20of the bridging connector2interfaces with the first boundary flange17of the bridging member11. The second side flange35of the second body part20of the bridging connector2preferably interfaces with the second boundary flange17of the bridging member11. Preferably, the first side flange35of the second body part20of the bridging connector2and the first boundary flange17of the bridging member11are at least partially nonparallel. The second side flange35of the second body part20of the bridging connector2and the second boundary flange17of the bridging member11preferably are at least partially nonparallel as well.

As shown inFIGS. 7, 11 and 12, preferably the outside surface116of the central web portion112of the second body part20is adjacent the internal surface15of the middle web12of the bridging member11. The outside surface119of the first border extension117of the second body part20preferably is adjacent the internal surface171of the first boundary flange17of the bridging member11. Preferably, the outside surface119of the second border extension120of the second body part20is adjacent the internal surface181of the second boundary flange17of the bridging member11.

As shown inFIGS. 7, 11 and 12, the central web portion112of the first body part20of the bridging connector19preferably includes a first fastening embossment127centered on a first fastener opening82. Preferably, the first fastener opening82does not contact the middle web12of the bridging member11.

As shown inFIGS. 7, 11 and 12, only a single fastener81preferably fastens the bridging connector19to the bridging member11, and the single fastener81is inserted through the fastener opening82in the first fastening embossment127.

Alternatively, as shown inFIGS. 1, 5 and 6, preferably the inside surface115of the central web portion112of the second body part20faces the external surface16of the middle web12of the bridging member11. The first juncture123between the first border extension117of the second body part20and the first lateral extension124of the second body part20of the bridging connector19preferably is adjacent the first boundary13of the middle web12of the bridging member11. Preferably, the second juncture123between the second border extension117of the second body part20and the second lateral extension124of the second body part20of the bridging connector19is adjacent the second boundary13of the middle web12of the bridging member11.

As shown inFIGS. 1, 5 and 6, the central web portion112of the first body part20of the bridging connector19preferably includes a first fastening embossment127that contacts the external surface16of the middle web12of the bridging member11.

As shown inFIGS. 1, 5 and 6, preferably only a single fastener81fastens the bridging connector19to the bridging member11, and the single fastener81is inserted through the fastener opening82in the first fastening embossment127. The fastening embossment127of the bridging connector19preferably contacts the external surface16of the middle web12of the bridging member.