Patent Publication Number: US-6209282-B1

Title: Framing studs for the construction of building structures

Description:
TECHNICAL FIELD 
     The present invention relates to a composite wood stud structure for the construction of building structures and particularly, but not exclusively, for use in the construction of walls and interconnectable with bottom and top plate members. 
     BACKGROUND ART 
     Composite joist structures are known and examples thereof can be found in U.S. Pat. No. 2,166,096 which describes an H-shaped metal beam to which is secured adjacent one elongated web thereof a longitudinal wooden stud. Composite studs have also been constructed from a thin web sheet having opposed wood strips extending substantially parallel to each other and at opposed ends and sides of the web. Such a construction is described in U.S. Pat. No. 5,144,785. Other types of H-like studs are disclosed in U.S. Pat. No. 4,658,557. There is also known a multitude of metal formed studs which engage in lower and top horizontal channels at predetermined locations therealong. Examples of these can be found in U.S. Pat. Nos. 3,101,817, 5,274,973 and 5,394,665. 
     SUMMARY OF INVENTION 
     It is a feature of the present invention to provide a composite stud which is economical to produce, which has excellent load bearing capacity and which is incorporated into a construction system to facilitate the erection of building structures and result in considerable savings of time and money. 
     According to the above feature, from a broad aspect, the present invention provides a composite wood stud for the construction of building structures. The stud is comprised of an elongated straight main member of substantially rectangular cross-section and having opposed flat side faces and opposed narrow flat end faces. A transverse elongated web piece of rectangular cross-section is secured along one of the opposed narrow flat end faces. The web piece is dimensioned and disposed to extend beyond the opposed flat side faces to define opposed wing sections. The web piece also has a width which is narrower than the width of the main member. The web piece provides an arresting force against longitudinal distortion of the straight main member and improves the load bearing capacity thereof. 
     According to a further broad aspect of the present invention there is provided a composite wood stud as above described in the previous paragraph and wherein the main member and the web piece(s) form a T-shaped cross-section load bearing wood stud. 
     According to a further broad aspect of the present invention the web piece is dimensioned and disposed to extend from one of the opposed flat side faces of the main member and beyond the other opposed flat side faces thereof to constitute a wing and thus a wood stud of substantially L-shaped cross-section. 
    
    
     BRIEF DESCRIPTION OF DRAWINGS 
     A preferred embodiment of the present invention will now be described with reference to the accompanying drawings in which: 
     FIGS. 1A and 1B are cross-section views of a composite wood stud of the present invention showing variations of the size of the elements of the composition; 
     FIGS. 2A and 2B are cross-section views of the composite wood stud of FIGS. 1A and 1B showing a further variant thereof wherein two web pieces are secured along narrow flat end faces of the main member; 
     FIGS. 3A and 3B are perspective views of the composite wood stud shown in cross-section in FIGS. 1A and 2A respectively and illustrating the bottom and top projecting tongues formed by the web pieces; 
     FIG. 4A is a perspective view, partly exploded, illustrating the construction of a wall frame with the composite wood stud of the present invention and its connection to the bottom and top plates; 
     FIG. 4B is a section view showing the construction of a wall, as in FIG. 4A, and illustrating the construction of the top and bottom plates and the projection of the top and bottom tongue of the web and utilizing the composite wood stud of FIG. 1A; 
     FIGS. 5A and 5B are similar to FIGS. 4A and 4B but illustrating a wall constructed with the composite wood stud of FIG. 2A; 
     FIG. 6 is a perspective view illustrating modifications made to the bottom plate and the main member of the composite wood stud whereby to interconnect therewith and therebetween cat members and to accommodate for the passage of electrical wiring or piping; 
     FIG. 7 is a further perspective view illustrating a further modification to the main member of the composite wood stud whereby to interconnect with a horizontal wood bracing board; 
     FIG. 8 is a fragmented section view showing the framing boards being notched to interlock with the horizontal notches or grooves provided in the main members of the composite wood stud; 
     FIG. 9 is a fragmented section view showing how a composite wood stud is located at a predetermined location within the transverse slot formed in a bottom plate and how the web tongue overlaps with the front edge of the bottom plates; 
     FIG. 10 is a plan view showing a wall framed with the composite wood stud of the present invention; 
     FIG. 11 is a perspective view, partly exploded, showing variations in the construction of a wall frame using the composite wood studs of the present invention and their associated bottom and top plate assemblies; 
     FIGS. 12 and 13 are fragmented perspective views showing the transverse connection of further construction members with the top or bottom plates; 
     FIGS. 14 and 15 are fragmented perspective views showing a jamb receiving plate secured to the composite wood stud to provide a frame for a window or door opening and using T- or H-shaped composite wood stud; 
     FIGS. 16 to  20  are cross-section views showing a further modification of the construction of the composite wood stud of the present invention and wherein the webs may be provided with a groove along their central longitudinal axis to mate with the end faces of the main member and wherein two main members may be connected to the web or to a pair of webs or three webs to form composite load bearing stud. 
     FIGS. 21A to  21 C show the modification of the composite wood stud and wherein the web piece extends from one of the opposed flat side faces of the main member and extends beyond the other side face and wherein the wood stud is utilized in the construction of wall endings where the wing connects with further wall constructing elements to enhance the load bearing capacity thereof; 
     FIGS. 22A to  22 C are section views similar to FIGS. 21A to  21 C and wherein there are two web pieces associated with a respective one of opposed narrow end faces of the main member; 
     FIGS. 23A and 23B are cross section views similar to FIGS. 22A and 22B and wherein the web pieces are notched and have a longer extent in its wing section; 
     FIGS. 24A and 24B illustrate a further modification of FIGS. 23A and 23B; 
     FIG. 25 is a section-view of a corner of prefabricated panels in which the corner structures are utilized and intermesh to secure adjacent panels together, herein two corner panels; and 
     FIG. 26 is a further section view showing a construction of a sound-proof partition wall using composite wood studs of the type illustrated in FIGS  1   a  and  1 B. 
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring now to the drawings, and more particularly to FIGS. 1A to  3 B, there is shown generally at  10  the composite wood stud of the present invention for the construction of building structures, such as the walls as shown in FIGS. 4A and 10. The composite wood stud  10  consists of an elongated straight main member  11  of substantially rectangular cross-section and having opposed flat side faces  12  and  12 A and opposed narrow flat end faces  13  and  13 A. A transverse elongated web piece  14 , of rectangular cross-section, is secured along one of the opposed narrow flat end faces  13  or  13 A. 
     The web piece  14  is dimensioned and disposed to extend beyond the opposed flat side faces  13  or  13 A to define opposed wing sections  15  and  15 A. The web piece  14  has a width “X” which is narrower than the width “Y” of the main member. As shown in FIG. 1B, the web piece  14  may be of shorter length and the main member  10  has a greater cross section. For example, in FIG. 1A, the main member could be a 2×3 inch stud whereas in FIG. 1B it is a 2×4 inch stud. The stud main members may also be 2×6 inch studs. The web piece  14  is nailed on or otherwise fastened to the main member to provide a solid connection therewith whereby to provide an arresting force against longitudinal distortion of the straight main member  11 , particularly if the wood contains humidity, and to improve the load bearing capacity thereof. 
     As shown in FIGS. 2A and 2B, the composite wood stud  10 ′ as therein shown is H-shaped and comprised of a web piece  14 ′ secured to the other flat end face  13  of the main member  11  and this provides greater resistance to longitudinal distortion and further improves low bearing capacity. As shown in FIG. 2B, the configuration of the elements forming the composite wood stud have different dimensions. A multitude of other variants in cross-sectional dimensions is achievable, as is obvious. 
     With reference now to FIGS. 3A and 3B, it can be seen that the web piece  14  extends beyond a lower end  16  of the main member  11  to define a bottom projecting tongue  17  which is adapted to extend over a side face  18 , see FIG. 5A, of a wall bottom plate  19 . If opposed web pieces  14  and  14 ′ are secured to the main member or stud  11 , then a projecting tongue  17 ′ would also be provided on the opposed side of the main member  11 . 
     The web piece  14  also extends beyond a top end  20  of the main member  11  to define a top projecting tongue  21  and  21 ′. This projecting tongue is better seen with further reference to FIGS. 4A to  5 B. As can be seen in these additional Figures the top projecting tongue  21  extends onto a side face  22  of a top plate member  23  of a wall. Accordingly, the web pieces complete the connection between the bottom plate  19  and top plate  23  by nailing or otherwise fastening these tongues to the bottom and top plate members to retain the main member  11  captive therebetween. 
     As shown in FIGS. 5A and 5B, the composite stud is of the type as shown in FIG.  3 B and the main member  11  is captive between the web pieces  14  and  14 ′ and the top and bottom plates  23  and  19 . The top plate  23  is also provided with two construction pieces, therein 2×4&#39;s or 2×3&#39;s, namely elements  23  and  24  with a face board  25  connected to the top element  24  and bridging the top plate  23  whereby to interlock them together through the face. The face board is of the same thickness as the web piece so as to provide a flat plane surface to attach construction sheeting material thereto such as gypsum wall boards. As shown in FIG. 5B, there are two face boards  25  and  25 ′ or horizontal web pieces secured respectively to opposed sides of the upper elongated horizontal element  24  when using a composite stud as shown in FIG. 3B. A wall structure as shown in FIG. 5B could be an interior division wall or an exterior wall. 
     Referring now to FIGS. 6 to  8 , there will be described various other features of the composite wood stud structure as well as the bottom and top plates. As shown in these Figures, the bottom plate  19  is an elongated wood piece of rectangular cross-section defining opposed flat side faces  26  and  26 ′ and opposed narrow flat end faces  27  and  27 ′. A plurality of equidistantly spaced transverse grooves  28  of rectangular cross-section, are formed in the upper side face  26  and dimensioned to receive a lower end portion of the main member  11 , as illustrated in FIGS. 6,  7  and  9 . The main member is received in close fit within the grooves  28 . Accordingly, these grooves as well as providing a better connection with the bottom plate  9 , also automatically space the composite studs at predetermined intervals such as 12 inch, 16 inch, or 24 inch, etc., spacing. 
     As also shown in FIG. 10, the top plate  22  may also be provided with transverse rectangular grooves  28 ′ to receive the other end of the main member  11  therein. 
     As shown in FIG. 6, the main member  11  may also be provided with a transverse rectangular groove  29  and  29 ′ on opposed flat side faces  12  and  12 A thereof and disposed in alignment therewith at a predetermined location from the bottom plate  19 . These grooves  29  receive therebetween a cat member  30  which provides bracing between the studs and also provide a backing element to which surface sheeting can be secured. Usually, these cat members are located at a spacing of 4 feet from the floor surface or the bottom edge of the bottom plate  19  to provide edge nailing of 4×8 feet sheeting material. 
     Referring to FIG. 7, it can be seen that the main members  11  may also be provided with transverse rectangular grooves  31  on one or opposed ones of its flat end faces  13  and  13 ′ and again disposed at a predetermined distance from the bottom edge of the bottom plate  19  for the purpose as above-described. An elongated wood brace board or wood strip  32  is received in these aligned grooves  31  of adjacent studs  11  whereby to maintain the studs in perfect parallel relationship. To do this in a more expeditious manner, the wood strips  32  and  32 ′, if they are provided on each side of the studs, may also be notched with a rectangular groove  33  as illustrated in FIG.  8 . This interlocks the wood strip  32  with the studs  11  and the outer faces  34  of these strips are then aligned flush with the outer end faces  13  and  13 ′ of the studs so that the web pieces  14  can then be connected thereto. However, in such an application the composite wood studs are constructed on site as the wall is erected. With the embodiment shown in FIG. 6, the composite wood pieces  10  could be premanufactured as the cat element  30  may be positioned thereafter. 
     Referring again to FIG. 10, there is shown the construction of a wall  35  constructed using the composite wood stud  10  of the present invention. It can be seen for example that cross pieces such as cross pieces  36  are held captive between the wing sections  15  and  15 A providing for better bracing and providing additional nailing surfaces. 
     With reference again to FIGS. 6 and 7, it can be seen that the main members  11  may also be provided with through bores  37  extending across the opposed flat side faces  12  and  12 ′ of the main member to receive therethrough wiring or piping as illustrated at  38 . Through bores  39  may also be provided in the bottom plate  19  as well as in the cat members  30  and the top plate members  22  and  24 , as shown in FIG.  11 . As also shown in FIG. 11 the top horizontal top plate member  24  may also be provided with transverse notches  40  spaced at predetermined intervals whereby to receive therein rafters to construct an upper floor or trusses of a roof structure if a roof is to be constructed thereover. Rectangular plates  41  may also be interconnected between the wings  15  and  15 A of adjacent composite wood studs  10  by clips  42  or other means to provide a quick connection. It is to be noted that with the use of the composite wood studs of the present invention and the associated bottom and top plates  19  and  22 , the construction of walls is “substantially perfect” and this accommodates these plates  41  to which electrical junction boxes may be secured without having to provide additional cat members. Composite cats  43  may also be connected at an appropriate height to provide additional wider nailing surfaces or the connection of electrical boxes or other types of elements thereto. 
     As can be seen from FIGS. 12 and 13, the upper member  24  of the top plate may be notched to receive horizontally opposed transverse members  44  which may be notched or not to construct ceilings. Also the configuration of the through bores  39  may be slotted as shown at  39 ′ in FIG.  12 . Again, as previously described these grooves  40  may be equidistantly spaced closer to one another, such as 12 inches apart as shown in FIG. 13, to provide closer spacing of elements  44  connected thereacross. 
     With reference now to FIGS. 14,  15  and  10 , it can be seen from FIG. 10 that a window opening  45  is formed within the wall structure  35 . In order to provide a flush side wall surface  46  to nail a window frame thereto, there is further provided, as shown in FIGS. 14 and 15, a jamb receiving member  47  which is secured to the opposed flat side face  12 A of the main member  11  and it fits and overlaps the wing section  15  of the web piece  14 . Accordingly, this jamb receiving member  47  is formed from a wood piece having a rectangular cross-section with an elongated rectangular notch  48  formed along an edge portion of one of the opposed narrow end faces, herein end face  49  of the member  47  and dimensioned to receive the wing section  15  of the web piece  14  in close fit therein. The jamb receiving member  47  is nailed directly into the main member  11 . Accordingly, a side wall surface  46 , as shown in FIG. 10, is obtained and the combination of the jamb receiving member  47 , and the composite stud  10  provide good load bearing and resistance to distortion and this is extremely important about a window frame. 
     As shown in FIG. 15, the jamb receiving member  47 ′ is provided with opposed elongated rectangular notches  48  and  48 ′ when the composite wood stud  10 ′ is provided with opposed web pieces  14  and  14 ″ whereby to receive the wing sections  15  of each of the opposed web pieces. 
     FIGS. 16 to  20  show various other modifications to the construction of a composite wood stud  10 . As shown in FIG. 16, the web piece  14  is provided with a central longitudinal groove  50  of shallow rectangular cross-section whereby to receive therein an outer end section  51  of the narrow flat end face  13 A of the main member  11 . FIG. 17 shows structures similar to FIG. 16 but wherein there are opposed web pieces  14  and  14 A both provided with the central longitudinal groove  50 . This groove further assists in the resistance against longitudinal distortion of the longitudinal main member  11 . 
     FIGS. 18 and 19 show a different type of structural member which is comprised of a web piece which is provided with opposed longitudinal grooves  52  and  52 ′ each adapted to receive an end section of the flat end faces  53  of opposed studs  54  interconnected together through the web piece  14 . As shown in FIG. 19, end web pieces  14  may be connected over the other end faces  53 ′ of the studs  54 . Alternatively, a composite load bearing stud assembly may be interconnected together as shown in FIG. 20 to form a double H load bearing composite stud assembly generally illustrated by reference numeral  55 . 
     Referring now to FIGS. 21A to  24 B, there will be described a composite wood stud similar to that as described and illustrated in FIGS. 1A and 1B but wherein the wood stud is comprised of a main member  60 , as shown in FIG. 21A, having a web piece  61  dimensioned and disposed to extend from one of the opposed flat faces only, herein face  62  of the main member  60  and disposed on its end face  63  and extending beyond the other end face  62 ′ to constitute a single wing  65 . As shown in FIGS. 21B and 21C, the wing  65  of the web piece  61  is connectable to further wall constructing elements, herein a further stud element  66 . The wing has an extent which is at least equal or longer than the width of the end faces  63  of the main member  60 . These composite L-cross-section wood studs are for use in the construction of ends of walls such as corners or intersecting wall sections where there is a need to provide for improved load bearing and backing members for securing wall covering boards thereto, as is well known in the art. 
     As shown in FIGS. 22A to  22 C, the web pieces  61  and  61 ′ may be provided on opposed sides of the main member  60  and they may receive a pair of studs  66  and  66 ′ therebetween to provide a different wall end structure. Wood strips  67  are also secured to the studs  66  and  66 ′ to provide a nailing surface. 
     FIGS. 23A,  23 B,  24 A and  24 B show further variants wherein the web pieces  61  and  61 ′ are notched at  68 . With such structures that it is necessary to also notch the base or top plates  69 , as shown by reference numeral  70 . 
     FIG. 25 shows a pair of prefabricated wall panels  71  and  72  having composite wood stud corner structures  73  and  73 ′ which interfit and which may be easily connected together from the outside wall surface  74  by driving fasteners, herein long nails, therethrough whereby the mating surfaces of the wood pieces  75  and  75 ′ interconnect with one another. As shown in the prefabricated wall, a T-shaped composite wood stud  10  is utilized in its construction and as hereinshown it also provides an air barrier  76  between the inner wall gypsum panel  77  and the insulation  78 . A vapor barrier sheet  79  is secured to the end face  13  of the main member  11  and a spacer  80  is secured in line with the main member stud  11 . An outer finishing board  81  is secured to the spacer  80  with a further air barrier space  82  therebetween. This is only a typical example of how the composite wall panel may be constructed and there are, of course, various other structures depending on the use of the panels. For example, these pre-fabricated panels could be used to construct refrigerated housings and this would involve a different combination of materials. 
     FIG. 26 shows a typical example of the construction of a sound-proof partition wall that we normally find between row housings. As hereinshown the partition or division wall is constructed with a composite wood stud  10  a shown in FIG. 1A and a composite wood stud  60  for the corner structures, as shown in FIG.  21 A. The web pieces  14  provide a spacing on opposed sides of the wall to which is attached gypsum boards  83  and  83 ′. Insulation is provided on both sides as illustrated by reference numerals  84  and  84 ′ and an air space  85  is provided inbetween. The space  85  could be filled with sound damping materials and the inner boards  86  and  86 ′ may also be sound absorbing boards, as are known in the art. 
     It is within the ambit of the present invention to cover any obvious modifications of the preferred embodiment described herein, provided such modifications fall within the scope of the appended claims.