Patent Publication Number: US-2007119843-A1

Title: Wall framing system

Description:
BACKGROUND OF THE INVENTION  
      The development of erected-on-site and prefabricated framing systems for various types of buildings including, in particular, residential dwellings, has increasingly favored the use of formed metal framing components, such as column or so-called stud members, horizontal upper and lower track members and other members needed for strength and rigidity of a wall frame. Several developments have taken place with respect to providing metal framing members which may be formed with means for attaching the column members to the track members. For example, U.S. Pat. No. 5,394,665 issued Mar. 7, 1995 to Johnson, and assigned to an affiliate of the assignee of the present invention, is directed to a framing system with column and track members formed with cooperating protrusions or projections of different geometries which are adapted to interlock the framing components. However, the geometries of the protrusions or projections somewhat limit the ability to engage one member with the other regardless of the direction of movement of the members relative to each other during assembly. Still further, it has been deemed desirable and necessary to reinforce the structural integrity of a framing system for building walls of various types whereby the framing members should also be secured to each other with mechanical fasteners, including self-drilling metal penetrating screws, for example.  
      There has also been a realization of the need for improvements in formed metal framing systems whereby framing members, such as column or stud members and track members, may be formed of sheet metal, including steel, of different thicknesses, and wherein there are provided cooperating projections and recesses in the members at points of connection therebetween. These features and the desirability of connecting the members with mechanical fasteners has resulted in the development of the present invention.  
     SUMMARY OF THE INVENTION  
      The present invention provides an improved wall framing system, useful in the fabrication of various types of buildings, including residential dwelling units, in particular.  
      In accordance with one aspect of the present invention, a wall framing system is provided with cooperating vertical column and generally horizontal track or beam type framing members which are adapted to be interconnected and located precisely relative to each other by cooperating projections and recesses formed in such members, respectively. In particular, the projections of one member are formed to substantially nest in recesses formed in the cooperating member whereby the members may be quickly precisely located relative to each other and connected to each other.  
      Further in accordance with the invention, the interconnections between column and track members or between column and so-called blocking members may be reinforced by securing the members to each other with mechanical fasteners, including self-drilling type screws, for example. The screws have shallow or low height heads which are conveniently disposed in the dual purpose recess and projection portions of the track and blocking members to maintain a substantially planar surface for placement of paneling and other structures adjacent to or contiguous with the framing system.  
      In accordance with yet a further aspect of the present invention, a wall framing system is provided which includes cooperating column and horizontal beam or track members, as well as reinforcing or blocking members, wherein cooperating projections and recesses are formed which are substantially circular whereby the members may be more conveniently moved relative to each other into positions whereby the recesses and projections fully engage to at least temporarily lock the members together. In this way, cooperating frame members, such as column and track members, may be more quickly interconnected since the members may be moved relative to each other in different directions or in different ways and do not require precise alignment, initially, in order to obtain engagement between the projections on one member and the cooperating recesses on the other member.  
      Still further, the present invention contemplates the provision of a wall framing system which lends itself well to fabrication using continuous forming machinery for roll forming metal shapes, such as channel-shaped members which may or may not have reentrant distal flange portions. The framing system is dimensionally tolerant whereby framing members of different metal gauges may be interconnected while maintaining the integrity of connections between members at the locations of the cooperating projections and recesses formed in the respective members.  
      Accordingly, the present invention provides a metal wall framing system wherein the cooperating studs or column members and track members include built-in securing or connection means that allow the members to be snapped together at predetermined intervals or positions relative to each other and the connections may be reinforced with the use of mechanical fasteners, if desired. Accordingly, a system is provided which is easy to assemble and relatively inexpensive to manufacture and still further provides a framing system which is of superior strength.  
      Those skilled in the art will further appreciate the above-mentioned advantages and superior features of the invention, together with other important aspects thereof, upon reading the detailed description which follows in conjunction with the drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a perspective view of a portion of a building which includes a wall framing system in accordance with the invention;  
       FIG. 2  is a detail perspective view showing a typical connection between a track member and a column or stud member for the framing system of the invention;  
       FIG. 3  is a side elevation of a column or stud member for the framing system of the invention;  
       FIG. 4  is a front elevation of the column member shown in  FIG. 3 ;  
       FIG. 5  is a section view taken generally along the line  5 - 5  of  FIG. 3 ;  
       FIG. 6  is a perspective view of a typical horizontal beam or track section for the framing system of the invention;  
       FIG. 7  is a perspective view of a track section showing a partial cut in the web portion of the track section for ease of removing unneeded portions of a track or beam member, such as at a doorway or window sill;  
       FIG. 8  is a section view taken generally along the line  8 - 8  of  FIG. 6 ;  
       FIG. 9  is a section view showing the connections between a column member and upper and lower track members and taken in an orientation corresponding to the line  9 - 9  of  FIG. 2 ;  
       FIG. 10  is a perspective view of a brace or blocking member for the wall framing system of the present invention; and  
       FIG. 11  is a table of certain dimensions for exemplary ones of track, column and blocking members in accordance with the invention. 
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT  
      In the description which follows like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale and certain features may be shown exaggerated in scale or in somewhat generalized or schematic form in the interest of clarity and conciseness.  
      Referring to  FIG. 1  there is shown a portion of a building, such as a residential dwelling unit, generally designated by the numeral  20  and including a wall framing system in accordance with the invention and generally designated by the numeral  22 . Various types of building construction may utilize a wall framing system, such as the framing system  22 . By way of example, the building  20  is characterized by a foundation  24 , which may be of a perimeter or slab type, and a roof truss system  26 .  
      Disposed between the foundation  24  and the truss system  26  is framing system  22 , including elongated lower horizontal track members  28 , which may be continuous or provided in predetermined segments for ease of transport and handling. Track members  28  are characterized as upturned channel shaped members, as will be described in further detail herein. Wall framing system  22  is also provided with spaced apart vertically extending column members  30  which are engaged with track members  28 , extend vertically at predetermined spaced apart intervals and are engaged at their opposite ends with downwardly facing channel shaped upper track members  32 , constructed substantially like the track members  28 .  
      Various predetermined lengths of bracing or blocking members  34 ,  36 ,  38 , and  40 , for example, may be utilized to interconnect and reinforce adjacent column members  30  and to form framing members at doorways and windows, for example. In other words, bracing or blocking members may form at least portions of window framing for a window  39 , for example, such as contiguous, back to back members  40  shown in  FIG. 1 . Similar bracing or blocking members may be used in outlining a doorway  37 , such as indicated for the contiguous back to back framing or blocking members  38 . Such bracing or blocking members may also be used to reinforce the framing system at various locations, such as indicated for the members  34 . Each of brace or blocking members  34 ,  36 ,  38  and  40  are characterized by the same general configuration as will be described further herein, but may be formed of various lengths, as needed, to provide the requisite reinforcement or to outline the perimeter of a window or door, for example. In like manner, the column members  30  may be of various lengths, such as indicated for members  42 ,  44  and  45 , for example,  FIG. 1 . Doorways and window frames may be reinforced by plural, generally contiguous back to back column members  30  and bracing members  38  and  40 , as shown in  FIG. 1 .  
      The track members, such as members  28 , may be cut away at various locations, including, for example, at the threshold of a doorway, as indicated by numeral  50  in  FIG. 1 . In this way at least one or more portions of a channel shaped track member may be eliminated when desired. Still further, the framing system  22  may be reinforced at particular locations, such as at doorways and windows, as mentioned above and shown in  FIG. 1 , by providing requisite strength of the framing system utilizing back to back arranged plural framing members.  
      Referring now to  FIGS. 3, 4 , and  5 , further details of a typical one of the column or stud members  30  are illustrated. Column or stud member  30  may be formed of sixteen gauge to twenty-two gauge galvanized steel and having the respective dimensions indicated in drawing  FIGS. 3 through 5  and as set forth in the table of  FIG. 11 . The dimensions a through n, a 1  and b 1  given in the table of  FIG. 11  are exemplary and are typical for the material thicknesses specified. Column members  30  are characterized as channel shaped members having a transverse web part  54  and opposed flanges  56  and  58 ,  FIGS. 3 through 5 . Flanges  56  and  58  are provided with reentrant distal edge portions or lips  57  and  59 , respectively, and substantially parallel to web  54 . The web  54  and the flanges  56  and  58  may be notched at their opposite ends, as indicated by numerals  60  and  62 , whereby the longitudinal extent of a major portion of web  54  and of portions of the reentrant edges or lips  57  and  59 , if provided for a column member  30 , is greater than the flanges  56  and  58  at opposite ends  54   a  and  54   b , respectively. Such configuration of the web and flanges of column members  30  provide clearance at the radii formed at the juncture of the flanges and webs of the cooperating track members  28  and  32  when the members  30  are inserted within the confines of the channel shaped track members, as illustrated in  FIG. 9 . As shown in  FIG. 4 , each column member  30  may have one or more utility conductor holes  64  formed therein, one shown in  FIG. 4 , to allow for training of utility conductors, not shown, along the wall framing system  22 , as needed.  
      As shown in  FIGS. 3 and 5 , the column members  30  each include at least four spaced apart circular recesses  66  formed in the flanges  56  and  58 , as illustrated. Recesses  66  are formed in opposed pairs in alignment with each other on flanges  56  and  58 . Recesses  66  preferably are formed with the dimensions e, f, g and h for receiving cooperating projections formed on track members  28  as will be further described. Recesses  66  are advantageously circular in configuration and relatively shallow, that is, having a depth not substantially exceeding the wall thickness of the flanges  56  or  58 , for example. Recesses  66  are also defined by a substantially planar and circular flat bottom wall part  68  integral with a curved, annular, transition part  68   a ,  FIG. 5 , for transition to flange  56  or  58 . Recesses  66  may be formed by a suitable coining, punch or similar metal displacement operation. Recesses  66  are each also provided with fastener receiving and locating or “pilot” holes centered in the recesses and identified by the dimension g in  FIG. 5 , for example. The location of the center of each of the recesses  66  is indicated by dimension i in  FIG. 5 . Hole diameter g is suitable for a fastener receiving pilot hole and for allowing a self-drilling or self-tapping screw, such as a panhead self-drilling screw  69 , see  FIG. 9 , to be used for fastening members  28  and  32  to members  30 , for example.  
      Other mechanical fasteners, such as rivets, may be used, however, fasteners  69  are preferred for the embodiments described in detail herein. Screws  69  may be of a type commercially available under the trademark GRABBER from Grabber Construction Products Division of John Wagner Associates, Inc. Screws  69  are operable to be threadedly engaged with the wall  68  upon assembly of a column member  30  to a track member  28  or  32  or to a blocking or brace member  34 ,  36 ,  38  or  40 . For the exemplary sizes and dimensions of members  28 ,  30 ,  32  and  34  given herein a preferred screw size is a no. 10 panhead self-drilling screw of about 0.75 inches overall length and including a no. 2 Phillips drive. Other drive configurations may be provided. Screws  69 , as shown in  FIG. 9 , include circular pan heads  69   a  and self-drilling threaded shanks  69   b.    
      Referring now to  FIGS. 6 through 8 , track members  28  and  32  are characterized by a configuration, as shown for track member  28 , which is defined by a base or web portion  70 , opposed parallel flanges  72  and  74  and spaced apart pairs of inwardly facing opposed projections  76  which may be located on the flanges  72  and  74  at predetermined positions. Projections  76  are also formed by a coining, punch or similar operation for displacing material of the flanges  72  and  74 , as illustrated, and to the dimensions p through u, as indicated in  FIG. 8 . Exemplary values for dimensions p through w are shown in  FIG. 11 . Projections  76  are located on flanges  72  and  74  in such a way as to engage the flanges of column members  30  at the recesses  66 , respectively, to forcibly register or connect the members with each other. Projections  76  are also circular and dimensioned to conform to and register with the recesses  66  in the manner illustrated in  FIG. 9 . Projections  76  are also defined by circular and planar or flat walls  77  substantially parallel to flanges  72  and  74 . Walls  77  are integral with curved annular transition parts  77   a  which are integral with flanges  72  or  74 , respectively.  
      Screw fastener pilot holes of dimension u are preferably formed centered in walls  77 . The diameters q of circular walls  77  are at least as great as the diameters of screw heads  69   a  and any washer or the like, not shown, larger than the screw head and placed thereunder. Accordingly, the flanges  72  and  74 , as well as the flanges  56  and  58  may be elastically deflected to allow the projections  76  to register in the recesses  66  of a column member and connections between members  28  and  30  and between members  30  and  32  are then reinforced by securing the members to each other with the mechanical fasteners  69 , as illustrated in  FIG. 9 . As shown in  FIG. 9  also, the heights of fastener heads  69   a  do not cause the heads to project substantially above the surfaces of flanges  72  and  74 , thanks to the recesses formed by the projections  76 , respectively.  
      As shown in  FIG. 6 , additional projections  76  may be located along the flanges  72  and  74 , as needed, and disposed relatively close to each other in situations wherein column members are placed directly adjacent to each other at high stress locations in the framing system  22 . As shown in  FIG. 7 , any one of the track members may be modified to provide a member  28   a , for example, as needed, by providing a slot or relief cut  80  transversely between the flanges  72  and  74 , to provide ease of cutting away unneeded portions of respective track members. For example, at the doorway  37  shown in  FIG. 1 , track members  28  may be dimensioned such that the transverse slot  80  is cut completely through web  70  and through the radius portions of respective track member between web  70  and flanges  72  and  74 , respectively, to facilitate ease of cutting away unneeded parts of the track member. Utility openings  81 ,  FIGS. 6 and 7 , may also be provided in track members  28  or  28   a , as illustrated.  
      Referring briefly to  FIG. 10 , there is illustrated one of the brace or blocking members  34  which is characterized by a channel shaped member having a web portion  90  and opposed parallel flanges  92  and  94 . Inwardly facing opposed projections  96 , corresponding substantially to the projections  76 , may be formed in the flanges  92  and  94 , as illustrated, for registering in selectively positioned recesses  66  of column members  30  and the like for locating and securing the brace or blocking members  34  in the framing system  22 . For the dimensions given herein in the table of  FIG. 11 , the flanges  92  and  94  extend beyond the transverse ends  90   a  and  90   b  of the web  90  by a dimension x to allow these members to engage column members  30 , for example, as illustrated in  FIG. 1 . Bracing, or brace or blocking members  37 ,  38  and  40  are essentially constructed the same as members  34 , but are of various predetermined lengths, as needed.  
      Track member  32  is defined by a web  71  and opposed flanges  73  and  75  in which opposed pairs of projections  76  are formed for engaging recesses of the opposite end of column members  30 , as shown in  FIG. 9 . The distances between the inside or facing surfaces of the flanges of members  28 ,  28   a ,  30  and  34 , for example, should remain constant regardless of the gauge or thickness of material being used to form these members. However, the distances between the outwardly facing surfaces of the flanges  56  and  58  of column members  30  will vary with the gauge or material thickness of the column members  30 . Accordingly, the members  28 ,  30  and  32  are dimensioned to fit together, as illustrated in  FIG. 9 , such that the recesses  66  are engaged by the projections  76  or  96  (projections  76  are shown in  FIG. 9 ) regardless of variations in material thickness or gauge. However, when the screw fasteners  69  are inserted through the pilot holes or openings in the projection walls  77  to forcibly engage the recess walls  68  and then tightened, any gap between the walls  77  and  68  will be closed. Still further, the locations of the recesses  66  on column members  30  and projections  76  on the track members  28  and  32  are such that the opposite ends  54   a  and  54   b  of webs  54  substantially fully engage the track webs  71  and  70 , respectively, as shown in  FIG. 9 . The relieved edges  90   a  and  90   b  of brace members  34 ,  FIG. 10 , are also adapted to engage webs  54  of cooperating column members  30  when these members are assembled to each other. Accordingly greater surface area of contact for load bearing is accomplished with the framing system  22  of the invention.  
      Framing component forming systems for fabricating the components described hereinabove are commercially available, such as from Knudson Mfg., Inc. of Broomfield, Colo. Such forming systems are operable to form the shapes of the components, the component lengths, and the recesses and projections on the respective components including the requisite locations of such projections and recesses. Accordingly, by predetermining the locations of the projections and recesses on the track components and the brace or blocking members, as well as on the column members, all of these members may be located relative to each other and locked together in their correct positions without any further measurements being required by persons fabricating a structure utilizing a wall framing system, such as the framing system  22 . In this way, the speed with which a framing system may be erected is substantially improved. Still further, preplacement of the recesses and projections on the respective components of the framing system, together with use of mechanical fasteners which are located by use of the pilot or clearance holes in the recesses and projections also facilitates the ease with which the framing system may be constructed and secured. Fabrication of the framing system components and erection or assembly of wall framing system  22  is believed to be within the purview of one skilled in the art based on the foregoing description.  
      A preferred embodiment of a wall framing system in accordance with the invention has been described in detail hereinabove. Wall framing systems such as the system  22  may be erected on site or substantially prefabricated in many particular versions or configurations utilizing the components  28 ,  30 ,  32 ,  34 ,  36 ,  38 ,  40 ,  42 ,  44  and  45 , for example, in accordance with the invention. Components  32  and  28  are of identical construction, typically, and the components  28 ,  30 ,  32 ,  34 ,  36 ,  38 ,  40 ,  42 ,  44  and  45  may be of various lengths as will be appreciated by those skilled in the art. However, thanks to the configurations of these members and the improved configuration of the projections and cooperating recesses formed in the respective members, together with the fasteners used to reinforce the connections between members, an improved wall framing system is realized. Although a preferred embodiment of the invention has been described in detail, those skilled the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.