Patent Abstract:
In embodiments of the present invention improved capabilities are described for a protective device for use with a metal stud. This invention protects in-wall piping, conduit and wiring from inadvertent puncturing by drywall screws during the installation of wall boarding.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of the following U.S. patent application, which is incorporated by reference in its entirety: U.S. patent application Ser. No. 11/445,905, filed Jun. 2, 2006. 
     
    
     BACKGROUND 
       [0002]    1. Field 
         [0003]    The present invention relates to conduit protection devices and more particularly, relates to conduit protective devices for use with metal studs and the like. 
         [0004]    2. Description of the Related Art 
         [0005]    The use of metal studs has recently become increasing popular in both commercial and residential construction projects. A typical metal stud  1 ,  FIG. 1 , features a central region  2  from which two legs  3 ,  4  generally, outwardly, and perpendicularly extend. The legs  3 ,  4  generally have a distance D 1  that is less than the distance D 2  of the central region  2  (typically about ⅓ the distance) and often include regions  5 ,  6  that extend perpendicularly inwards and towards each other which substantially increase the overall strength of the metal stud  1 . Together, the central region  2  and the legs  3 ,  4  define a central cavity or channel  7 . 
         [0006]    In practice, the metal stud  1  is generally placed longitudinally upright with a wall structure and the face of the wall (for example sheet rock, plywood, planks, or the like) are secured against one of the outer faces  8  of the legs  3 ,  4  using screws  9  (typically self-piercing metal “speed screws” or the secured against one of the outer faces  8  of the legs  3 ,  4  using screws  9  (typically self-piercing metal “speed screws” or the like) as is well known in the construction industry. These screws  9  generally extend into the cavity  7 . 
         [0007]    During construction, it is often necessary to run conduits such as, but not limited to, plumbing and electrical pipes as well as wires (not shown) through apertures  10  disposed within the central region  2  of the metal stud  1 . For ease of installation, the apertures  10  and conduits are often placed within the metal studs  1  prior to securing the facing of the wall to the metal stud  1 . Unfortunately, if the screws  9  used to secure the facing of the wall to the metal stud  1  are inserted near a conduit or wire, the screw  9  can easily pierce and damage the conduit or wire. Often times, the damage is not detectable until after the wall has been fully constructed. During the installation of drywall, it is not uncommon for a drywall screw to penetrate a water or sanitary waste pipe located within the studwork. When this occurs, a leak forms which may not be readily apparent. Usually, the damage may only be detected after the system is charged for the first time. In other cases, the damage is not discovered until the screw corrodes and becomes dislodged from the piping (which could take up to several years to occur). Locating the source of the leak can be difficult and time consuming, resulting in extensive water damage and repair work. In the event of a gas line puncture, there is considerably more potential for greater damage to occur. 
         [0008]    It is known to protect conduits and wires from damage. However, most of the known devices are either intended for wood (and therefore not applicable to metal studs  1 ) or are expensive, complex and require the user to assemble several different parts using bolts or the like. 
         [0009]    Accordingly, what is needed is a protective device that is particularly suited for use with metal studs. The protective device should be inexpensive and easy to use. The protective device should not require specialized tools or require complex assembly. 
         [0010]    It is important to note that the present invention is not intended to be limited to a system or method which must satisfy one or more of any stated objects or features of the invention. It is also important to note that the present invention is not limited to the preferred, exemplary, or primary embodiment(s) described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present invention, which is not to be limited except by the following claims. 
       SUMMARY 
       [0011]    The puncture solution may include two parts: 1. a non-metallic sleeve; and 2. a metallic ring covered by the non-metallic sleeve. When the two parts are assembled together and installed over a pipe, conduit or wire, a protective shield is formed. During the subsequent installation of drywall, screws (or nails) are deflected by the shield around the pipe or wire, thusly preventing damage yet still allowing the screw to join the sheetrock to the stud and fulfilling its intended purpose. 
         [0012]    In an aspect of the invention, a protective device for use with a metal stud may include a non-metallic sleeve with an opening disposed along a longitudinal axis of the non-metallic sleeve, wherein the non-metallic sleeve comprises flexible members disposed along the opening, wherein the flexible members have a length that is at least equal to the thickness of the metal stud; a hinge displaced along the opening of the metallic sleeve, wherein the non-metallic sleeve can flex along the hinge to widen a gap in the non-metallic sleeve by pinching two first protrusions of the non-metallic sleeve on either side of the hinge in order to install the non-metallic sleeve on a pipe, conduit, or wire, and a metallic sleeve having an opening that is adapted to fit over the non-metallic sleeve, wherein when a fastener encounters the metallic sleeve, it is deflected by the metallic sleeve. The device may include a snap on the non-metallic sleeve for securing the non-metallic sleeve to the stud. The first protrusions may press against a surface of the stud and prevent rotation of the protective device within the stud. The hinge may be a living hinge. The device may include second protrusions of the non-metallic sleeve that press against a surface of the stud and prevent rotation of the protective device within the stud. The device may further include a stop displaced between the first protrusions that prevents over-stressing the non-metallic sleeve during installation by limiting the range of motion of the non-metallic sleeve when the first protrusions are pinched. The non-metallic sleeve opening may be generally cylindrical. The metallic sleeve may be generally cylindrical. The flexible members may isolate the pipe, conduit, or wire from the metal stud. The non-metallic sleeve may support the pipe, conduit, or wire. The non-metallic sleeve may isolate the pipe, conduit, or wire from the metallic sleeve. 
         [0013]    In an aspect of the invention, a metal stud may include at least one hole punched longitudinally through the metal stud, and a protective device displaced in the punched hole, wherein the protective device includes a non-metallic sleeve with an opening disposed along a longitudinal axis of the non-metallic sleeve, wherein the non-metallic sleeve comprises flexible members disposed along the opening, wherein the flexible members have a length that is at least equal to the thickness of the metal stud, a hinge displaced along the opening of the metallic sleeve, wherein the non-metallic sleeve can flex along the hinge to widen a gap in the non-metallic sleeve by pinching two first protrusions of the non-metallic sleeve on either side of the hinge in order to install the non-metallic sleeve into the punched hole, and a metallic sleeve having an opening that is adapted to fit over the non-metallic sleeve, wherein when a fastener encounters the metallic sleeve, it is deflected by the metallic sleeve. The metal stud may further include a snap on the non-metallic sleeve for securing the non-metallic sleeve to the stud. The first protrusions may press against a surface of the metal stud and prevent rotation of the protective device within the metal stud. The hinge may be a living hinge. The metal stud may further include second protrusions of the non-metallic sleeve that press against a surface of the metal stud and prevent rotation of the protective device within the metal stud. The metal stud may further include a stop displaced between the first protrusions that prevents over-stressing the non-metallic sleeve during installation by limiting the range of motion of the non-metallic sleeve when the first protrusions are pinched. The non-metallic sleeve opening and the metallic sleeve opening may be generally cylindrical. The flexible members may isolate a pipe, conduit, or wire from the metal stud. The non-metallic sleeve may isolate a pipe, conduit, or wire from the metallic sleeve. 
         [0014]    According to one embodiment, the present invention features a protective device for use with a metal stud having a length, a width and a thickness. The protective device includes a body and a reduced region. The body defines a first passage disposed along a longitudinal axis of the body and has a length that is at least equal to the thickness of the metal stud. The reduced region is disposed proximate a first end of the body and defines a second passageway fluidly coupled to the first passageway. The outer cross-section of the reduced region is smaller than an outer cross-section of the body. 
         [0015]    The body preferably includes a shoulder region proximate an interface between the body and the reduced region and has a length that is greater than a length of the reduced region. The outer cross-section of the reduced region is preferably substantially circular. The reduced region may include a tapered and/or threaded outer surface. 
         [0016]    The first and the second passageways preferably include a first and a second opening disposed about generally opposite ends of the protective device and are preferably generally cylindrical. The body and the reduced region also preferably substantially enclose the first and the second passageways. 
         [0017]    According to another embodiment, the present invention features a protective device for use with an aperture in a metal stud having a length, a width and a thickness. The protective device includes a body, a reduced region, and a passageway disposed along a longitudinal axis of the protective device. The body has a length that is at least equal to the thickness of the metal stud and the reduced region is disposed proximate a first end of the body and includes an outer cross-section that is smaller than an outer cross-section of the body. The passageway includes a first and a second opening disposed about generally opposite ends of the protective device. 
         [0018]    According to yet a further embodiment, the present invention features a protective device including means for securing to the protective device within an aperture disposed in a central region of a metal stud, means for extending through the thickness of the metal stud, the means having an outer cross-section that is larger than the aperture in the metal stud, and a passageway disposed along a longitudinal axis of the protective device, the passageway having a first and a second opening disposed about generally opposite ends of the protective device. 
         [0019]    These and other systems, methods, objects, features, and advantages of the present invention will be apparent to those skilled in the art from the following detailed description of the preferred embodiment and the drawings. All documents mentioned herein are hereby incorporated in their entirety by reference. 
         [0020]    All documents mentioned herein are hereby incorporated in their entirety by reference. References to items in the singular should be understood to include items in the plural, and vice versa, unless explicitly stated otherwise or clear from the text. Grammatical conjunctions are intended to express any and all disjunctive and conjunctive combinations of conjoined clauses, sentences, words, and the like, unless otherwise stated or clear from the context. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0021]    The invention and the following detailed description of certain embodiments thereof may be understood by reference to the following figures. 
           [0022]      FIG. 1  is an end perspective view of one embodiment of a typical prior art metal stud. 
           [0023]      FIG. 2  is a top end perspective view of one embodiment of the protective device according to the present invention in combination with a metal stud. 
           [0024]      FIG. 3  is a side perspective view of one embodiment of the protective device according to the present invention. 
           [0025]      FIG. 4  is a side plan view of another embodiment of the protective device having a tapered reduced region according to the present invention. 
           [0026]      FIG. 5  is a side plan view of another embodiment of the protective device wherein the reduced region includes a threaded outer surface according to the present invention. 
           [0027]      FIG. 6  is a side plan view of another embodiment of the protective device wherein the reduced region includes at least one protrusion or rib according to the present invention. 
           [0028]      FIG. 7  depicts a typical metal stud wall construction with water and electrical wiring. 
           [0029]      FIG. 8A  shows a wall with the puncture solution installed. 
           [0030]      FIG. 8B  shows the puncture solution installed into a metal stud. 
           [0031]      FIG. 9  shows the puncture solution installation. 
           [0032]      FIG. 10A  depicts an exploded view of the puncture solution assembly. 
           [0033]      FIG. 10B  depicts features of the puncture solution. 
           [0034]      FIG. 10C  depicts a spring sleeve of the puncture solution. 
           [0035]      FIG. 11A  depicts the puncture solution in use and, in  FIG. 11B , a screw deflection. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    A protective device  20 ,  FIG. 2 , is particularly suited for protecting a conduit (such as, but not limited to, an electrical or fluid conduit) or wire  22  disposed through an aperture  10  in a metal stud  1  (as described above) from damage from a screw  9 . In the preferred embodiment, the aperture  10  is disposed in the central region  2 , though this is not a limitation of the present invention and the aperture  10  may be disposed through the legs  3 ,  4 . The protective device  20  preferably features a body  24  that includes a reduced region  26  and a passageway  28  the extends through the body  24 . 
         [0037]    As used wherein, the thickness of the metal stud is intended to be the length of the metal stud  1  which the protective device  20  passes through. More specifically, in the embodiment wherein the protective device  20  is disposed within an aperture  10  in the central region  2 , the thickness is defined to be the length D 1  of the legs  3 ,  4 . 
         [0038]    Referring specifically to  FIG. 3 , the passageway  28  preferably extends along a longitudinal axis L of the protective device  20  and includes a first and at least a second opening  30 ,  32  disposed about generally opposite ends  31 ,  33  of the protective device  20 . The body  24  of the protective device  20  preferably features a length L 1  that is equal to or greater than the thickness of the metal stud  1  and is preferably constructed from a very hard material such a metal or the like. Because the body  24  extends at least through the thickness of the metal stud  1 , any screws  9  that are accidentally inserted proximate the protective device  20  will contact the body  24  which has sufficient hardness to prevent the screw  9  from penetrating the passageway  28 . The body  24  preferably has a generally tubular outer cross-section, though the body  24  may include any other shape known to those skilled in the art. 
         [0039]    The reduced region  26  preferably has a length L 2  that is equal to or greater than the thickness of the aperture  10 . In the preferred embodiment, the reduced region  26  has a length L 2  that large enough such that the reduced region  26  extends just past the outer surface of the metal stud  1 . The length L 2  is preferably less than the length L 1  of the body  24 . A benefit of this arrangement is that less force is required to insert or secure the protective device  20  within the aperture  10  of the metal stud  1 . The reduced region  26  also features an outer cross-section D 3  that substantially the same as the cross-section of the aperture  10  and is preferably smaller than the outer cross-section D 4  of the body  24 . The outer cross-section D 3  is preferably large enough to generate enough friction with the aperture  10  to hold the protective device  20  within the aperture  10 . Optionally, an adhesive, bonding agent, solder, or the like may be used to secure the reduced region  26  within the aperture  10 . 
         [0040]    The reduced region  26  preferably has a generally cylindrical or tubular outer shape. Alternatively, the reduced region  26 ,  FIG. 4 , may feature a tapered or conical shape and/or may include a threaded outer surface  40 ,  FIG. 5 . In the embodiment wherein the protective device  20  includes a threaded outer surface  40 , at least a portion of the body  24  preferably includes a non-cylindrical region  42 . The non-cylindrical region  42  preferably features a multi-faceted surface adapted to engage a wrench or the like, and is preferably used to rotate the protective device  20  and thread the reduced region  26  into the aperture  10 . According to yet another embodiment, the reduced region  26  may include one or more ribs or protrusions  46  that frictionally engage the aperture  10  when the protective device  20  is inserted within the aperture  10 . 
         [0041]    The interface  36  between the body  24  and the reduced region  26  preferably forms a rim, shoulder, or flanged region  38 . Referring to  FIG. 2 , the reduced region  26  is inserted into the aperture  10  in the metal stud  1  until the rim  38  is substantially against the inner surface  11  of the metal stud  1 , preferably the inner surface  11  of the central region  2 . Because the reduced region  26  is disposed within the aperture  10 , the body  24  extends through the cavity  7  of the metal stud  1  and through the thickness of the metal stud  1 . As discussed above, because the length L 2  of the reduced region  26  is approximately the same as the thickness of the aperture  10 , the force required to insert/secure the protective device  20  within the metal stud  1  is reduced. 
         [0042]    The protective device  20 ,  FIGS. 2 and 3 , may optionally include a bushing  50  or the like. The bushing  50  is preferably sized and shaped to fit within the second opening of the passageway  28 , though it could also be sized and shaped to fit within the first opening  30 . Alternatively, the bushing  50  may be sized and shaped to fit over the ends  31 ,  33  of the protective device  20 . In any event, the bushing  50  preferably positively locates the conduit or wires  22  within the passageway  28  and prevents damage to the conduit/wires  22  and may include any bushing design known to those skilled in the art. 
         [0043]    In another embodiment, a protective device  802  may comprise at least two parts: 1. a non-metallic sleeve  1002 ; and 2. a metallic ring  1004  covered by the non-metallic sleeve. When the two parts are assembled together and installed over a pipe, conduit or wire, a protective shield is formed. During the subsequent installation of drywall, fasteners, such as screws or nails, are deflected by the shield around the pipe or wire, thusly preventing damage yet still allowing the screw to join the sheetrock to the stud and fulfilling its intended purpose. The protective device  802  may comprise a non-metallic isolator  1002 , or sleeve, between the pipe and the metal stud with adjustable, centering fingers that may support the pipe. The protective device  802  may snap into the stud to ensure that it stays in place after installation over the pipe or wires. A hardened spring steel sleeve  1004  may deflect a fastener, such as a screw, on contact. The non-metallic sleeve  1002  may have two ears  1010  to help install the protective device  802  around the pipe. The ears  1010  may also ensure that the protective device  802  is installed correctly within the stud and may prevent the rotation of the protective device  802  in such a way as to not expose the opening  1024  in the spring sleeve  1004  to the potential path of a fastener, such as a drywall screw. The protective device  802  may snap over the pipe in a one-handed operation. Stops  1015  on the ears  1010  may prevent over stressing the non-metallic sleeve  1002  during installation. The non-metallic sleeve  1002  may also have two legs  1012  that ensure that the protective device  802  is installed correctly within the stud by preventing the rotation of the unit in such a way as to expose the opening  1024  in the spring sleeve  1004  to the potential path of a fastener. 
         [0044]    Referring to  FIG. 7 , a standard metal stud  702  with a copper water pipe  704  may be installed through punched-out holes  708  in the stud  702 . The wall may be finished with sheetrock  710 . Referring to  FIG. 8A , the wall system is shown with the protective device  802  installed into each of the studs.  FIG. 8B  shows a close-up view of the protective device  802  snapped into the open “c” section of the metal stud  702  through the punched hole  708 . 
         [0045]    Referring to  FIG. 9 , to install the protective device  802 , the two ears  1010  may be squeezed together to spread the opening in the non-metallic sleeve. Once the opening is spread, the non-metallic sleeve  1002  may then be placed over the pipe or wire  704 . 
         [0046]    Referring to  FIG. 10A , an exploded view shows the two components that make up the protective device  802 : the non-metallic sleeve  1002  and the hardened spring sleeve  1004 . The non-metallic sleeve  1004  may have the following features: anti-rotation ears  1010 , anti-rotation legs  1012  and two flexible snaps  1014  to secure the protective device  802  to the metal stud  702 . The ears  1010  may have two stop features  1015  that meet during installation and prevent the non-metallic sleeve  1004  from being over stressed during installation. 
         [0047]    Referring to  FIG. 10B , a front view of the non-metallic sleeve  1004  shows additional features: a living hinge  1018  and flexible fingers  1020  which are used to support the pipe or wire and isolate the pipe and wire from the metal stud  702 . Referring to  FIG. 10C , a spring sleeve  1004  may be assembled over the non-metallic sleeve  1002  and prevent the drywall mounting fastener from penetrating the pipe or wires. An opening  1022  in the non-metallic sleeve  1004  enables its placement over a pipe, conduit or wiring. 
         [0048]    When the non-metallic sleeve  1002  is placed over the pipe, wire, or conduit, it may be snapped into a punched-out hole  708  in the stud  702 . Ears  1010  of the non-metallic sleeve  1002  may be pinched together along the living hinge  1018  until the stops  1015  meet, then the opening  1022  of the non-metallic sleeve  1002  is placed over the pipe, wire, or conduits. When the ears  1010  are released, the non-metallic sleeve  1002  closes around the pipe, wire, or conduit. The ears  1010  and legs  1012  of the sleeve  1002  may prevent rotation of the non-metallic sleeve by pressing against a surface of the stud  702 . In embodiments, a snap  1014  may secure the non-metallic sleeve to the stud  702 . In embodiments, flexible fingers  1020  may surround the pipe, wire, or conduit opening in the sleeve  1002  and may extend into the punched-out hole  708  in the stud  702 , thus providing isolation of the pipe, conduit, or wire from the stud  702 . A metallic sleeve  1004  may be placed over the non-metallic sleeve  1002 . The non-metallic sleeve  1002  may serve as an isolator between the metallic sleeve  1004  and the pipe, wire, or conduit. The metallic sleeve may provide protection from puncture or penetration by a fastener. 
         [0049]    Referring to  FIGS. 11A and 11B , the two states that could occur during driving the wall fastener  1102  are shown. In  FIG. 11 , the screw  1102  is in the direct path to penetrate the pipe  704 . The screw hits the protective device  802  and is deflected by the spring sleeve  1004 .  FIG. 11B  shows the fully driven screw being flush with the drywall  710  and deflected past the pipe, conduit, or wire. 
         [0050]    In an embodiment, a protective device for use with a metal stud may include a non-metallic sleeve with an opening disposed along a longitudinal axis of the non-metallic sleeve, wherein the non-metallic sleeve comprises flexible members disposed along the opening, wherein the flexible members have a length that is at least equal to the thickness of the metal stud, a hinge displaced along the opening of the metallic sleeve, wherein the non-metallic sleeve can flex along the hinge to widen a gap in the non-metallic sleeve by pinching two first protrusions of the non-metallic sleeve on either side of the hinge in order to install the non-metallic sleeve on a pipe, conduit, or wire; and a metallic sleeve having an opening that is adapted to fit over the non-metallic sleeve, wherein when a fastener encounters the metallic sleeve, it is deflected by the metallic sleeve. The device may include a snap on the non-metallic sleeve for securing the non-metallic sleeve to the stud. The first protrusions may press against a surface of the stud and prevent rotation of the protective device within the stud. The hinge may be a living hinge. The device may include second protrusions of the non-metallic sleeve that press against a surface of the stud and prevent rotation of the protective device within the stud. The device may further include a stop displaced between the first protrusions that prevents over-stressing the non-metallic sleeve during installation by limiting the range of motion of the non-metallic sleeve when the first protrusions are pinched. The non-metallic sleeve opening may be generally cylindrical. The metallic sleeve may be generally cylindrical. The flexible members may isolate the pipe, conduit, or wire from the metal stud. The non-metallic sleeve may support the pipe, conduit, or wire. The non-metallic sleeve may isolate the pipe, conduit, or wire from the metallic sleeve. 
         [0051]    In an embodiment, a metal stud may include at least one hole punched longitudinally through the metal stud, and a protective device displaced in the punched hole, wherein the protective device includes a non-metallic sleeve with an opening disposed along a longitudinal axis of the non-metallic sleeve, wherein the non-metallic sleeve comprises flexible members disposed along the opening, wherein the flexible members have a length that is at least equal to the thickness of the metal stud, a hinge displaced along the opening of the metallic sleeve, wherein the non-metallic sleeve can flex along the hinge to widen a gap in the non-metallic sleeve by pinching two first protrusions of the non-metallic sleeve on either side of the hinge in order to install the non-metallic sleeve into the punched hole, and a metallic sleeve having an opening that is adapted to fit over the non-metallic sleeve, wherein when a fastener encounters the metallic sleeve, it is deflected by the metallic sleeve. The metal stud may further include a snap on the non-metallic sleeve for securing the non-metallic sleeve to the stud. The first protrusions may press against a surface of the metal stud and prevent rotation of the protective device within the metal stud. The hinge may be a living hinge. The metal stud may further include second protrusions of the non-metallic sleeve that press against a surface of the metal stud and prevent rotation of the protective device within the metal stud. The metal stud may further include a stop displaced between the first protrusions that prevents over-stressing the non-metallic sleeve during installation by limiting the range of motion of the non-metallic sleeve when the first protrusions are pinched. The non-metallic sleeve opening and the metallic sleeve opening may be generally cylindrical. The flexible members may isolate a pipe, conduit, or wire from the metal stud. The non-metallic sleeve may isolate a pipe, conduit, or wire from the metallic sleeve. 
         [0052]    Accordingly, the present invention features a protective device that is particularly suited for use with metal studs. The protective device is inexpensive and easy to use and does not require specialized tools or require complex assembly. 
         [0053]    While the invention has been disclosed in connection with the preferred embodiments shown and described in detail, various modifications and improvements thereon will become readily apparent to those skilled in the art. Accordingly, the spirit and scope of the present invention is not to be limited by the foregoing examples, but is to be understood in the broadest sense allowable by law. 
         [0054]    All documents referenced herein are hereby incorporated by reference.

Technology Classification (CPC): 7