Abstract:
A system is provided for constructing a wall frame having a PVC stud, a PVC channel member, a groove formed in the PVC stud and a tongue formed in the PVC channel, wherein the tongue and groove are adapted to detachably couple the PVC stud and the PVC channel. The invention includes snap-on features that allow the components to be removably secured. The invention provides components that are constructed to eliminate insect infestation, rotting, shrinkage, warping and splintering.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is related to and claims priority to U.S. Provisional Patent Application Ser. No. 61/049,102, filed Apr. 30, 2008, entitled PVC WALL FRAMING SYSTEM, the entirety of which is incorporated herein by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    n/a 
       FIELD OF THE INVENTION 
       [0003]    The present invention relates to plastic wall framing systems. More particularly, the invention relates to PVC framing systems having snap-on components. 
       BACKGROUND OF THE INVENTION 
       [0004]    Known framing systems include wood framing systems and metal framing systems. These known framing systems are used to construct various residential and commercial building structures, including partitions. 
         [0005]    Wood framing systems are widely accepted by the construction industry. Carpenters are familiar with wood frame construction and can nail wood frames together quickly with nail guns. In spite of the ease of construction, wood framing systems have several drawbacks, including absorbing moisture; increasing fire risk; and increasing susceptibility to insect infestation, rotting, shrinking, warping, and splintering; among other drawbacks. Additionally, the cost of purchasing lumber continues to increase. 
         [0006]    Metal framing systems are less widely adopted than wood framing systems, but have found popularity in the commercial construction industry. The construction industry is trade-oriented, so workers are less inclined to embrace the special training required to properly snip and cut the metal frame members. Additionally, metal screws are needed to construct the metal frames. Metal framing systems have several drawbacks, including poor thermal performance, poor sound performance and tendency to oxidize (e.g. rust), among other drawbacks. 
       SUMMARY OF THE INVENTION 
       [0007]    The invention overcomes these drawbacks and other drawbacks of known systems by providing PVC framing systems having snap-on components. The PVC framing systems may be used to construct various residential and commercial building structures, including partitions. The PVC framing components may include studs and tracks, angles, furring channels, and other PVC framing components. 
         [0008]    According to one embodiment, the snap-on components may employ a tongue and groove configuration. For example, the tracks may include tongues, or protrusions, that engage grooves that are formed in the studs. Alternatively, the studs may include tongues, or protrusions, that engage grooves that are formed in the tracks. As a result, no additional hardware, such as nails, screws, or other hardware may be needed to construct the PVC frames. The snap-on feature reduces the amount of time needed to assemble PVC frames. The snap-on feature also reduces construction costs that otherwise would be associated with fastening the PVC frames, including the cost of the additional hardware (e.g., nails, screws, etc.) and the corresponding power tools (e.g., nail gun, screw gun, etc.). 
         [0009]    According to one embodiment, the PVC framing components may be extruded or injection molded into desired shapes. This allows the PVC framing components to be formed as one piece components with features such as crevices, holes, protrusions and other features. Additionally, the appearance of the PVC framing components may be modified using stains or pigments. 
         [0010]    The PVC framing components provide several benefits over wood and/or metal framing components. For example, the PVC components absorb little moisture; do not oxidize; may be manufactured to reduce fire risk and to eliminate insect infestation, rotting, shrinking, warping, and splintering; among providing other benefits. 
         [0011]    Furthermore, the PVC framing components are workable similar to wood framing components. Thus, end users may continue to use traditional wood working techniques, tools, fasteners, etc., to construct the PVC framing systems. 
         [0012]    These and other features and advantages of the invention will be apparent through the detailed description of the embodiments and drawings attached hereto. It is also to be understood that both the foregoing general description and the following detailed description are exemplary and not restrictive of the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]    A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, wherein like designations refer to like elements, and wherein: 
           [0014]      FIG. 1  illustrates a perspective view of a stud and track assembly for a non-load bearing application according to one embodiment of the invention; 
           [0015]      FIG. 2A  is a cross-sectional view of a stud for a non-load bearing application according to one embodiment of the invention; 
           [0016]      FIG. 2B  is a cross-sectional view of a track for a non-load bearing application according to one embodiment of the invention; 
           [0017]      FIG. 3  illustrates a snap-on feature for a stud and track assembly according to one embodiment of the invention; 
           [0018]      FIG. 4  illustrates a perspective view of a stud and track assembly for a load bearing application according to one embodiment of the invention; 
           [0019]      FIG. 5A  is a cross-sectional view of a stud for a load bearing application according to one embodiment of the invention; 
           [0020]      FIG. 5B  is a cross-sectional view of a track for a load bearing application according to one embodiment of the invention; 
           [0021]      FIG. 6  illustrates a snap-on feature for a stud and track assembly according to one embodiment of the invention; 
           [0022]      FIG. 7A  illustrates a bridging strip in a non-engaged position for securing adjacent studs according to one embodiment of the invention; 
           [0023]      FIG. 7B  illustrates adjacent studs having openings for receiving a bridging component according to one embodiment of the invention; 
           [0024]      FIG. 8  illustrates a bridging strip in an engaged position for securing adjacent studs according to one embodiment of the invention; 
           [0025]      FIG. 9  illustrates PVC hat channels that may be secured to trusses in a ceiling or to a wall structure for anchoring a partition material according to one embodiment of the invention; 
           [0026]      FIG. 10  illustrates PVC furring strip that may be secured to masonry walls for anchoring a partition material according to one embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0027]    While specific embodiments of the invention are discussed herein and are illustrated in the drawings appended hereto, the invention encompasses a broader spectrum than the specific subject matter described and illustrated. As would be appreciated by those skilled in the art, the embodiments described herein provide but a few examples of the broad scope of the invention. There is no intention to limit the scope of the invention only to the embodiments described herein. Like reference numbers will be used herein to identify like elements. 
         [0028]      FIG. 1  illustrates an embodiment of the PVC framing system  10  having studs  12  and a track  14 . According to one embodiment, the studs  12  and the track  14  may be constructed of a PVC material or other synthetic material. The track  14  may be formed in a U-shaped geometry to include projections  15  that extend into cavity  16  from opposing inner side surfaces  13  of the track  14 . While the projections  15  are illustrated to be generally rectangular in shape, the projections  15  may be any shape, including wedge shape, circular shape, triangular shape, or any other shape. According to one embodiment, the projections  15  may be positioned along a longitudinal direction “L” at spaced intervals along the track  14 . For example, the projections  15  may be positioned along the longitudinal direction “L” at regular intervals of four inches center-to-center, six inches center-to-center, eight inches center-to-center, twelve inches center-to-center, etc. 
         [0029]      FIG. 2A  illustrates a cross-sectional view of the stud  12 . The stud  12  may include a C-shaped geometry and may include an opening  22  that runs along one side of the stud  12  in a lengthwise direction. The opening  22  may be provided to expose a hollow central portion  20  of the stud  12 . According to one embodiment, the studs  12  may be designed having geometrical shapes that minimize the use of material to provide lightweight studs. These lightweight studs may be used for non-load bearing applications, such as providing a framing structure to hang drywall or other partition forming material. According to one embodiment, ribs may be formed on the stud  12  to increase load bearing capacity. For example, ribs may be formed in an interior portion of the stud  12  to increase load bearing capacity. According to one embodiment, opposing grooves  24  may be formed on external surfaces of the stud  12  to receive corresponding projections  15  from the track  14 . According to one embodiment, the stud  12  may include passages that enable objects, such as electrical wires, plumbing pipes, and/or other objects, to pass through the stud  12 . One skilled in the art will readily appreciate that the studs  12  may be formed of different geometrical shapes without departing from the spirit of the invention. 
         [0030]      FIG. 2B  illustrates a cross-sectional view of the track  14 . The track  14  may include a U-shaped geometry and may include an opening that runs along one side of the track  14  in a lengthwise direction. The opening may be provided to expose a hollow central portion  26  of the track  14 . According to one embodiment, ribs may be formed in the track  14  to increase retention strength. Opposing projections  15  may be formed on internal surfaces of the track  14  to engage corresponding grooves  24  that are provided on the studs  12 . Alternatively, projections may be formed along a bottom surface  27  of the track  14  to engage a bottom portion of the stud  12  in order to provide an enhanced structure to resist lateral movement of the stud  12 . One skilled in the art will readily appreciate that the track  14  may be formed of different geometrical shapes to receive the studs  12  without departing from the scope of the invention. 
         [0031]      FIG. 3  illustrates an embodiment of the PVC framing system  10  wherein the grooves  24  on the stud  12  are aligned with the projections  15  on the track  14 . The stud  12  and the track  14  may be fastened together with a snapping mechanism. For example, a downward force may be applied to the stud  12  to securely snap the stud  12  onto the track  14 . Once engaged, the stud  12  and track  14  may be mechanically coupled together. According to one embodiment, the stud  12  and track  14  may be unlocked by applying an upward force to the stud  12  in a direction away from the track  14 . Other fastening mechanisms will be appreciated by those skilled in the art and are intended to be encompassed by the invention. 
         [0032]      FIG. 4  illustrates a second embodiment of the PVC framing system  40  having studs  42  and a track  14 . According to one embodiment, the studs  42  and the track  14  may be constructed of a PVC material or other synthetic material. The track  14  may be formed in a U-shaped geometry to include projections  15  that extend into cavity  16  from opposing inner side surfaces  13  of the track  14 . While the projections  15  are illustrated to be generally rectangular in shape, the projections  15  may be any shape, including wedge shape, circular shape, triangular shape, or any other shape. According to one embodiment, the projections  15  may be positioned along a longitudinal direction “L” at spaced intervals along the track  14 . For example, the projections  15  may be positioned along the longitudinal direction “L” at regular intervals of four inches center-to-center, six inches center-to-center, eight inches center-to-center, twelve inches center-to-center, etc. 
         [0033]      FIG. 5A  illustrates a cross-sectional view of the stud  42 . The stud  12  may include a rectangular shaped geometry. The center portion  50  of the stud  42  may be hollow. Alternatively, the center portion  50  of the stud  42  may include reinforcing ribs to increase load bearing capacity of the stud  42 . For example, the reinforcing ribs may be formed in an interior portion of the stud  42  to increase load bearing capacity. According to one embodiment, the studs  42  may be designed having geometrical shapes that minimize the use of material to provide lightweight studs. These reinforced lightweight rectangular studs  42  may be used for load bearing applications, such as supporting weighted structures. According to one embodiment, the studs  42  may include passages that enable objects, such as electrical wires, plumbing pipes, and/or other objects, to pass therethrough. According to one embodiment, opposing grooves  24  may be formed on external surfaces of the stud  42  to receive corresponding projections  15  from the track  14 . One skilled in the art will readily appreciate that the studs  42  may be formed of different geometrical shapes without departing from the spirit of the invention. 
         [0034]      FIG. 5B  illustrates a cross-sectional view of the track  14 . The track  14  may include a U-shaped geometry and may include an opening that runs along one side of the track  14  in a lengthwise direction. The opening may be provided to expose a hollow central portion  26  of the track  14 . According to one embodiment, ribs may be formed in the track  14  to increase retention strength. Opposing projections  15  may be formed on internal surfaces of the track  14  to engage corresponding grooves  24  that are provided on the studs  42 . Alternatively, projections may be formed along a bottom surface  27  of the track  14  to engage a bottom portion of the stud  42  in order to provide an enhanced structure to resist lateral movement of the stud  42 . One skilled in the art will readily appreciate that the track  14  may be formed of different geometrical shapes to receive the studs  42  without departing from the scope of the invention. 
         [0035]      FIG. 6  illustrates an embodiment of the PVC framing system  40  wherein the grooves  24  on the stud  42  are aligned with the projections  15  on the track  14 . The stud  42  and the track  14  may be fastened together with a snapping mechanism. For example, a downward force may be applied to the stud  42  to securely snap the stud  42  onto the track  14 . Once engaged, the stud  42  and track  14  may be mechanically coupled together. According to one embodiment, the stud  42  and track  14  may be unlocked by applying an upward force to the stud  42  in a direction away from the track  14 . Other fastening mechanisms will be appreciated by those skilled in the art and are intended to be encompassed by the invention. 
         [0036]      FIG. 7A  illustrates a bridging strip  70  having strip openings  72 .  FIG. 7B  illustrates studs  42  having stud openings  75  with stud projections  76 . The bridging strip  70  is designed to pass through the stud openings  75  so that the stud projections  76  engage the strip openings  72 . 
         [0037]      FIG. 8  illustrates the bridging strip  70  in an engaged position for securing adjacent studs  42  according to one embodiment of the invention. The bridging strip  70  may be provided through the stud openings  75  so that the strip openings  72  are mechanically coupled to the stud projections  76 . The bridging strip  70  provides enhanced support to the PVC framing structure  40  by interlocking the studs  42 . While the stud projections  76  are illustrated to be generally rectangular in shape, the stud projections  76  may be any shape, including wedge shape, circular shape, triangular shape, or any other shape. The stud projections  76  and the bridging strip  70  may be fastened together with a snapping mechanism. For example, a downward force may be applied to the bridging strip  70  to securely snap the stud projections  76  into the strip openings  72 . Once engaged, the stud  42  and bridging strip  70  may be mechanically coupled together. According to one embodiment, the stud  42  and the bridging strip  70  may be unlocked by applying an upward force to the bridging strip  70 . Other fastening mechanisms will be appreciated by those skilled in the art and are intended to be encompassed by the invention. 
         [0038]      FIG. 9  illustrates a PVC hat channel  90  that may be secured to trusses in a ceiling or to a wall structure.  FIG. 10  illustrates PVC furring strip  100  that may be secured to masonry walls. The PVC hat channel  90  and the PVC furring strip  100  may be provided to anchor a partition material, such as drywall or other partition material. 
         [0039]    Once in place, the PVC framing system  10 , 40  may be used to mount a partition material, such as drywall or other partition material. The partition material may be mounted to the PVC framing structure using traditional wood screws. In this regard, the PVC material is workable like wood. If needed, the PVC components may be cut using wood working power tools. Therefore, the invention provides a new technology that will be readily adopted by end users that are traditionally slow to adopt new technologies. 
         [0040]    According to one embodiment, the invention provides improved sound transmission, improved thermal efficiency and enhances environmental performance, as measured by Leeds guidelines for “green” construction. The invention enhances environmental performance by providing recyclable, reclaimable and/or reusable products. 
         [0041]    It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention.