Patent Publication Number: US-6701689-B2

Title: Stud spacer

Description:
FIELD OF THE INVENTION 
     The present invention relates to steel framing and particularly to steel wall construction and particularly to space bars used to extend between and connect studs. 
     BACKGROUND OF THE INVENTION 
     Generally, no metal walls are formed by automatically spacing and interconnecting a series of metal studs between upper and lower metal tracks. Typically the lower track is secured to a floor structure while the upper track is generally connected to an overhead structure. Wallboards or other types of interior wall materials are secured to the studs. 
     Loads placed on the studs from both the structure overhead (load-bearing) and wind or seismic (non-load-bearing) conditions will generally act as vertical and horizontal loads on the wall studs. These loads in most cases can result in damage to the studs and finishes if not properly braced. 
     The problem has been addressed in the past by providing lateral structural bracing elements to support studs in the weak direction. However, these bracing elements are relatively expensive and require significant labor to install. 
     In some cases, it is known to include spacer bars extending between the studs. However, many spacer bar designs require that the spacer bars be mechanically fastened by screws or weldment to the studs themselves. That, again, is labor intensive, time-consuming and in the end expensive. There have been attempts at providing a stud spacer bar that does not require mechanical fastening in the form of screws, fasteners or weldment. For example, see the disclosure found in U.S. Pat. No. 5,784,850. 
     SUMMARY OF THE INVENTION 
     The present invention entails a stud spacer for connecting to and extending between studs within a stud wall. The stud spacer includes an elongated member having a series of curved shaped notches formed in the member with each notch being adapted to receive a portion of a stud such that the stud spacer connects to and extends between respective studs. 
     In one exemplary embodiment, the elongated member includes a series of spaced apart generally S-shaped notches where the S-shaped notches receive portions of a respective stud. Further, in an exemplary embodiment, each S-shaped notch includes a pair of spaced apart edges with each edge including a curved node and wherein the curved nodes are offset with respect to each other. 
     Further, in another exemplary embodiment, the stud spacer of the present invention is incorporated into a wall structure including a series of spaced apart studs. In this embodiment, the stud spacer extends through a series of openings formed in the respective studs that form a part of the wall structure. The stud spacer engages, effectively connects, and spaces the respective studs. This is achieved by a series of curved shaped notches formed in the stud spacer. Particularly, the curved shaped notches are pressed into engagement with the studs such that a portion of the web of each stud projects into the curved shaped notches. 
     Other objects and advantages of the present invention will become apparent and obvious from a study of the following description and the accompanying drawings which are merely illustrative of such invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a portion of a wall structure showing the stud spacer of the present invention extending through a series of studs. 
     FIG. 2 is a side elevational view of the stud spacer of the present invention. 
     FIG. 2A is an enlarged fragmentary side elevational view of a portion of the stud spacer particularly illustrating the construction of a notch formed in the stud spacer. 
     FIG. 3 is an end elevational view of the stud spacer. 
     FIG. 4 is a fragmentary perspective view illustrating a web portion of a stud being projected into a curved shaped notch formed in the stud spacer. 
     FIG. 5 is a fragmentary perspective view showing an alternative design wherein the stud spacer of the present invention is secured to a stud via a connecting clip. 
    
    
     DESCRIPTION OF AN EXEMPLARY EMBODIMENT 
     With further reference to the drawings, particularly FIG. 1, the stud spacer of the present invention is shown therein and indicated generally by the numeral  10 . Stud spacer  10  basically comprises an elongated member that forms a part of a wall structure indicated generally in FIG. 1 by the numeral  12 . Before discussing the stud spacer  10  in detail, a brief review of the wall structure  12  will follow. In that regard, wall structure  12  includes a lower track  14 , an upper track (not shown), a series of spaced apart studs  16  and the stud spacer  10  engaged with the respective studs  16 . Lower track  14  is adapted to receive and underlie the studs  16  and is typically secured to a floor structure. The upper track, on the other hand, overlies the studs  16  and connects thereto. Typically the upper track will be supported by one or more overhead joists or other type of overhead support structure. 
     Each stud  16  that form a part of the wall structure  12  includes a pair of flanges  16   a  and  16   b  and a central web  16   c . As seen in the drawings, web  16   c  includes an opening  16   d . As will be appreciated from subsequent portions of this disclosure, the stud spacer  10  in the exemplary embodiment disclosed herein extends through the openings  16   d  formed in the respective studs  16 . In conventional fashion, wall boards in the form of dry wall or paneling are typically secured to the outside of the respective studs  16 . 
     Turning to the stud spacer  10 , it is seen that the same comprises an elongated member  20  that includes a central portion (web)  20   a  and a pair of sides (flanges)  20   b . As seen in the drawings, the central portion  20   a  of the elongated member  20  includes a series of aligned openings and a pair of spaced apart reinforcing ribs. Further, the pair of sides  20   b  are angled slightly outwardly with respect to the central portion  20   a.    
     Formed in each side  20   b  of the elongated member  20  is a series of curved shaped notches  30 . See FIGS. 2 and 2A. Each curved shaped notch includes a pair of opposed edges  32  and  34 . Formed on each curved shape edge  32  and  34  is a curved node or convex segment  36 . As seen in the drawings, the curved nodes or convex segments  36  are offset such that in one orientation of the elongated member  20 , one curved node  36  will be spaced above and offset with respect to the other curved node or convex segment. Also, formed on each edge  32  and  34  is a concave segment  38 . Like the curved nodes  36 , the concave segments  38  of each notch  30  are offset with respect to each other. 
     In use, the stud spacer  10  is extended through the openings  16   d  formed in a series of studs  16 . As illustrated in the drawings, the elongated member  20  is pressed into engagement with the respective studs  16 . More particularly, the curved shaped notches  30  formed in the sides  20   b  are aligned with the web  16   c  of the respective studs  16  and by pressing the elongated member  20  downwardly or towards the web, a portion of the web  16   c  is pushed or inserted into a respective curved shaped notch  30 . It will be appreciated that the notches  30  are uniformly spaced along the sides  20   b  of the elongated member  20 . Further, the notches  30  are disposed in corresponding pairs. That is, a notch formed in one side of the elongated member  20  is aligned with a notch formed in the other side. Thus, when the elongated member  20  is pressed downwardly on the web  16   c , it follows that a portion of the web of a respective stud extends upwardly into the pair of corresponding notches  30 . 
     The engagement of a portion of the web  16   c  with notches  30  is generally sufficient to secure the elongated member  20  to a respective stud  16 . As will be understood by those skilled in the art, there is no requirement that the elongated member  20  be fastened to the respective studs  16  by screws, weldment or other fastener means. However, in some applications, it may be desirable to utilize a clip as an interface connector between the elongated member  20  and the respective studs  16 . In this regard, reference is made to FIG. 5 that illustrates such an exemplary embodiment. Therein a clip  40  is shown connected by fasteners to both the stud  16  and the underlying elongated member  20 . In this particular case, the clip  40  includes a pair of opposed flanges that extend down adjacent the sides  20   b  of the elongated member  20 . However, it should be appreciated again that no clips are required in the case and even if a clip is optionally used, that various clip designs can be employed. 
     The stud spacer  10  may be constructed of various types of materials such as, for example, galvanized steel complying with ASTM A653. Typically, studs are spaced on 16 inch and 24 inch centers in metal wall construction. It is contemplated that in one exemplary embodiment of the present invention that the notches  30  would be spaced on 4 inch centers. Various lenghts of stud spacers can be provided. However, in one exemplary design the stud spacer  10  will extend 4 feet plus an appropriate amount for overlapment. In some situations a 3 inch overlapment is sufficient and therefore, in that case, the stud spacer would be approximately 51 inches long. 
     There are many advantages to the stud spacer  10  of the present invention. Among the advantages is that the stud spacer  10  tends to automatically adjust for various web thicknesses found in studs. While the dimensions of the curved shaped notch  30  can certainly vary and will vary depending on applications, it is contemplated that in one exemplary design that the width of the notch, that is the distance between edges  32  and  34  would be approximately 0.1180 inches. As viewed in FIG. 2A, the horizontal distance between the two curved nodes  36  of a respective notch would be approximately 0.020 inches. Therefore, it is appreciated that the notch  30  will tend to automatically adjust for various web thicknesses. That is, the height that the web extends into or projects into the notch  30  will vary depending upon the thickness of the web  16   c  of the stud  16 . In some cases, the web  16   c  of the stud will project through substantially the entire height of the notch  30 , while in other cases the web  16   c  may only project a relatively short distance into the notch  30 . In any event, the elongated member  20  and the notches  30  formed thereon tend to easily seat about the web  16   c  of the respective studs  16 . In most cases, one would not need a hammer or the like to pound the stud spacer  10  into engagement with the web  16   c.    
     The stud spacer  10  of the present invention also automatically spaces the studs  16  during the construction of the wall structure  12 . Thus, a great deal of time is not wasted laying out the studs in the wall structure. Further, the stud spacer  10  when engaged with the respective studs tends to prevent the studs from bowing and therefore improves wall hanging operations and the appearance of the completed wall. Further, the stud spacer  10  when connected between successive or adjacent studs causes the studs to resist rotation and displacement. In the end, the stud spacer of the present invention reduces labor costs and provides an economical and sturdy wall construction. 
     The present invention may, of course, be carried out in other specific ways than those herein set forth without departing from the scope and the essential characteristics of the invention. The present embodiments are therefore to be construed in all aspects as illustrative and not restrictive and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.