Sheet metal intersection studs

Abstract

A corner stud (40) has a four-sided post portion (42) that sits into a corner region of a framing wall. The post portion includes a pair of flanges (92, 96) which form a right angle inside corner at the inside corner of the framing wall. Edge portions of wallboard panels (108, 110) connect to the flanges (92, 96). A post portion 112 of an intersection stud (110) fits within the tracks at a location between the corners. Inside corners are formed by flanges (148, 160) and (154, 166) against which edge portions (180, 182) of wallboard panels (184, 186) and (188, 190) are connected. The edge portions (180, 182, 188, 190) of the wallboard are connected to and backed up by the flanges (148, 160, 154, 166).

Description

TECHNICAL FIELD

This invention relates to sheet metal framing walls. More particularly, it relates to the provision of studs usable where two walls intersect, for facilitating the connection together of the two walls.

BACKGROUND OF THE INVENTION

Building walls intersect each other at corners and at locations between the corners. U.S. Pat. No. 4,689,930, granted Sep. 1, 1987, to Robert J. Menchetti, discloses a corner stud to which two standard studs are connected. U.S. Pat. No. 3,363,377, granted Jan. 16, 1968, to Melvin H. Beckman, and U.S. Pat. No. 4,283,892, granted Aug. 18, 1981, to Larry B. Brown disclose studs constructed to be usable at an intersection of a first wall with a second wall between its corners. FIG. 1 of the drawing herein shows a prior art use of two standard studs where two walls intersect at a corner. FIG. 3 of the drawing herein shows the use of two standard prior art studs at an intersection of two walls between the corners.

There is a need for intersection studs for use at the corners and between the corners that facilitates construction of the walls while reducing both material and labor. It is the primary object of the present invention to fill this need.

BRIEF SUMMARY OF THE INVENTION

According to the invention, a corner stud is provided that has generally tubular post portion which fits into the corner regions of the upper and lower tracks where they meet at the corners and which includes flanges forming a right angle inside corner to which edge portions of wallboard panels are secured.

It is also an object of the invention to provide an intersection stud which fits into the upper and lower tracks between the corners of a wall and which includes a pair of flanges that project into the upper and lower tracks of an intersecting wall, and to which edge portions of wallboard panels are secured.

In preferred form, a sheet metal corner stud incorporating the invention comprises a first wall, a second wall, a third wall and a fourth wall. The first wall has a first edge and a second edge. The second wall had a first edge and a second edge. The third wall has first edge and a second edge. The fourth wall has a first edge and a second edge. The second edge of the first wall is connected to the first edge of the second wall. The second edge of the second wall is connected to the first edge of the fourth wall. The second edge of the third wall is connected to the first edge of the fourth wall. A first flange is provided that has a first edge that is connected to the first edge of the first wall. The first flange extends from the first wall in a direction opposite from the direction that the second wall extends from the first wall. A second flange is provided that has a first edge that is connected to the second edge of a fourth wall. The second flange extends from the fourth wall in a direction opposite from the direction that the third wall extends from the fourth wall. The first flange has an outer surface and the second flange has an outer surface. The first flange extends substantially perpendicular to the second flange.

The between-the-corners intersection stud preferably comprises a first wall having a first edge and a second edge, a second wall having a first edge and a second edge, and a third wall having a first edge and a second edge. The second edge of the first wall is connected to the first edge of the second wall. The second wall extends perpendicular from the first wall. The second edge of the second wall is connected to the first edge of the third wall. The third wall extends perpendicular from the second wall and in spaced apart parallelism with the first wall. The stud includes a first flange having a first edge and a second edge. The first edge is connected to the first edge of the first wall. The first flange extends perpendicular from the first wall. The stud includes a second flange having a first edge and a second edge. The first edge is connected to the second edge of the third wall. The second flange extends perpendicular from the third wall towards and in co-planar parallelism with the first flange. A third flange has a first edge and a second edge. The first edge is connected to the second edge of the first flange. The third flange extends perpendicular from the first flange in a direction opposite the direction that the first wall extends from the first flange. A fourth flange has a first edge and a second edge. The first edge is connected to the second edge of the second flange. The fourth flange extends perpendicular from the second flange in a direction opposite from the direction that the third sidewall extends from the second flange. The third flange and the fourth flange extend in spaced apart parallelism with each other. The intersection stud has a width dimension extending between the outside surface of the second wall and the outside surfaces of the first and second flanges which is substantially equal to the width dimension between the outside surface of the third flange and the outside surface of the fourth flange.

Another object of the present invention is to provide an intersection stud positionable at a corner where two walls meet which has a first sided post portion that fits inside end portions of upper and lower tracks, and flanges which project from the post portion perpendicular to each other inside the upper and lower tracks adjacent the corner post.

Another object of the invention is to provide an intersection stud between the corners which has a post portion that fits into upper and lower tracks at a location between corners and includes a pair of flanges which project from the post into end portions of upper and lower tracks that intersect the tracks in which the post portion is situated.

Other objects, advantages and features of the invention will become apparent from the description of the best mode set forth below, from the drawings, from the claims and from the principals that are embodied in the specific structures that are illustrated and described.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Like reference numerals are used to designate like parts throughout the several views of drawing, and:

FIG. 1 is a cross sectional view taken at a corner formed where two walls meet, showing a prior art arrangement of conventional studs at such corner;

FIG. 2 is a cross sectional view of a corner stud embodying the present invention;

FIG. 3 is a cross sectional view of a prior art intersection construction between corners;

FIG. 4 is a cross sectional view of an inner section stud of the present invention that is utilized at an intersection between corners;

FIG. 5 is an exploded pictorial view of the corner stud shown by FIG. 2, showing the lower portion of the stud within the intersecting lower tracks and showing the intersecting upper tracks spaced above the corner stud;

FIG. 6 is a fragmentary pictorial view of the between-the-corner intersection stud shown by FIG. 4, showing its lower portion within the intersecting tracks of the two walls which intersect between corners;

FIG. 7 is an exploded pictorial view of two corner components for the upper and lower tracks, performed for installation at a corner between two perpendicular sections of the track;

FIG. 8 is an exploded pictorial view of track components usable at an intersection between the corners, such components being adapted to be used with three straight sections of track that meet the three ends of the components that is illustrated; and

FIG. 9 shows the use of miter cuts at the ends of two lengths of track for making a right angle at a corner where the lengths of tracks meet.

DETAILED DESCRIPTION OF THE ILLUSTRATED INVENTION

For background purposes, FIGS. 1 and 3 show prior art assemblies where one wall intersects another wall. FIG. 1 shows an intersection at a corner. FIG. 3 shows an intersection between corners. Referring to FIG. 1, a first stud 10 is provided at the end of a first wall 12. A second stud 10 is shown at the end of a second wall 14. Stud 10 includes a flange 16. A wall board panel 18 is attached to the wall 12 in the manner shown. End portion 20 of the panel 18 is connected to the stud flange 16. Then, the web 22 is positioned against wall board panel 18, in the manner illustrated. Web 22 is suitably secure to the stud 10. Then, wall board panel 24 is connected to stud flange 26, in the manner illustrated.

Referring to FIG. 3, a first framing wall 28 is constructed from upper and lower tracks and a plurality of studs 30, in known-fashion. Then, a wallboard wall panel 32 is connected to one side of the framing wall. Then, a stud 34 at one end of an intersecting wall 36 is connected to stud flange 38. Wall 36 comprises upper and lower tracks and a plurality of studs interconnecting the tracks.

In the prior art arrangements shown by FIGS. 1 and 3, the metal framing members of the two walls are separated by wall board 12, 32.

Referring to FIGS. 2 and 5, the corner intersection stud 40, exemplifying an aspect of the invention, comprises a four-sided corner post 42 having upper and lower ends that fit within upper and lower tracks 44, 46, between the webs 48, 50 and 52, 54, as illustrated. The post portion 42 of corner stud 40 has a first wall 56 having a first edge 58 and a second edge 60. A second wall 62 has a first edge 64 and a second edge 66. A third wall 68 has a first edge 70 and a second edge 72. A fourth wall 74 has a first edge 76 and a second edge 78. The second edge of the wall 56 is connected to the first edge of wall 62. The second edge 66 of wall 62 is connected to the first edge 70 of wall 68. The second edge 72 of wall 68 is connected to the first edge 76 of wall 74. As best illustrated by FIG. 2, the post portion 42 of wall 40 is positioned between the opposite flanges 80, 82 of lower track 84 for wall 86. In a perpendicular direction, the post portion has a dimension substantially equal to the distance between flanges 52, 54 of track 56. In the same direction, the post portion 42 fits between flanges 48, 50 of track 44. The width of wall 56 allows wall 56 to fit between flanges 88, 90 of track 92.

Corner stud 40 includes a first flange 92 having a first edge 94 connected to the first edge 58 of first wall 56. Flange 62 and wall 56 form a right angle corner with each other. A second flange 96 has a first edge 98 connected to the second edge 78 of fourth wall 42. Flange 96 and wall 74 together form a right angle corner, as shown in FIG. 2. Flange 92 may be provided with an end flange 100 and a return flange 102. In similar fashion, flange 98 may be provided with an end flange 104 and a return flange 106. End flange 100 is perpendicular to flange 92 and is perpendicular to return flange 102. End flange 104 is perpendicular to flange 96 and is perpendicular to end flange 106. Flanges 92, 102 are parallel and flanges 96, 106 are parallel.

As best shown by FIG. 5, the post portion 42 of corner stud 40 is positioned at the corner of the wall, with its lower end portion within the intersecting tracks 46, 84. Flange 96 is positioned inwardly adjacent flange 52. Flange 92 is positioned inwardly adjacent flange 80. At the top of the stud wall 40, flange 96 is inwardly adjacent flange 48 and flange 92 is inwardly adjacent flange 86. As shown by FIG. 2, wallboard panel 108 is connected to flange 92 and wallboard panel 110 is connected to flange 96. Accordingly, there is solid backing for the wallboard panels 108, 110 at the corner where they meet.

The between-the-corner intersection stud 110 comprises a post portion 112 that fits at its bottom into a lower track and at its top into an upper track. FIG. 6 shows a lower track 114 having a web 116 and a pair of flanges 118, 120 that project upwardly from the opposite edges of the web 116. An intersecting track 122 has a web 124 and a pair of flanges 126, 128 that project upwardly from the side edges of the web 124. A portion of the flange 116 is cut away at the end of the track 124. If FIG. 6 is inverted, it would show intersecting upper tracks and the upper end portion of the stud 110. The post portion 112 of stud 110 comprises a first wall 130 having a first edge 132 and a second edge 134. A second wall 136 has a first edge 138 and a second edge 140. A fourth wall 142 has a first edge 144 and second edge 146. The second edge 134 of the first wall 130 is connected to the first edge 138 of the second wall 136. The second edge 140 of the second wall 136 is connected to the first edge 144 of the third wall 142. A first flange 148 has a first edge 150 and a second edge 152. A second flange 154 has a first edge 156 and a second edge 158. The first edge 150 of flange 148 is connected to the first edge 132 of wall 130. Flange 148 extends perpendicular to wall 130 and is in co-planar parallelism with flange 154. The second edge 146 of wall 142 is connected to the first edge 158 of flange 154. Flange 154 is perpendicular to the third wall 132. A third flange 160 has a first edge 162 and a second edge 164. Edge 162 of flange 160 is connected to edge 152 of flange 148. A fourth flange 166 has a first edge 168 that is connected to the second edge 156 of flange 154. Flange 166 includes a second edge 168. Flanges 160, 166 are parallel to each other and are perpendicular to the flanges 148, 154. End flanges 170, 172 may be connected to the edges 164, 168 of the flanges 160, 166. Return flanges 174, 176 may be connected to the end flanges 170, 172.

The outside dimension measured from the outer surfaces of flanges 148, 154 and the outer surface of second wall 36 is substantially equal to the inside dimension between the flanges 118, 120 of the track 114. The distance between the outside surfaces of the flanges 160, 166 is substantially equal to the distance between the inside surfaces of flanges 126, 128. The post portion 112 of the stud 110 is wider than the distance between the inside surfaces of the flanges 126, 128.

FIG. 4 is a sectional view in a mid portion of the stud 110. It shows edge portions 180, 182 of wallboard panels 184, 186 being outwardly adjacent the flanges 148, 154. Preferably the wallboard is connected to the flanges 148, 154. Wall board edge portions 186, 188 are outwardly adjacent the flanges 160, 166. Preferably, these wallboard edges 186, 188 are connected to the flanges 160, 166, such as by use of screws. As shown by FIG. 4, the wallboard edges 180, 186 and 182, 188 are backed up where they meet by the flanges 148, 160 and 154, 166.

Both forms of intersection studs 40, 110 can be easily and quickly installed in the upper and lower tracks and then the wallboard can be applied to the framing members.

FIG. 7 shows a pair of corner members 200, 200′ usable at a corner between two perpendicular tracks. Corner member 200, 200′ comprises an

L-shaped web 202 and flanges 204, 206, 208, 210. All four flanges 204, 206, 208, 210 extend perpendicular to the web 202. Flanges 204 and 208 meet and form a right angle corner and flanges 206 and 210 meet and form a right angle corner. The corner member 200 is positioned at a corner between two perpendicular straight sections of track that are leading into the corner. The ends of the straight sections of the track may butt up against the ends of the corner member 200. Corner member 200′ is a mirror image of corner member 200.

FIG. 8 shows members 212, 212′ that are each usable at an intersection of two walls between corners. It comprises a T-shaped web 214 and flanges 216, 218, 220, 222, 224. All of the flanges 216, 218, 220, 222, 224 extend perpendicular to the T-shaped web 214. Flanges 216, 218 extend perpendicular to each other and meet at a right angle corner. Flanges 222, 224 extend perpendicular to each other and meet at a right angle corner. Flange 220 extends along the outside of a straight section of the member 212 which is positioned between the ends of two collinear straight sections of track. The stem portion of the member 212 includes the flanges 218, 224 adapted to be collinear with an intersecting perpendicular section of track. Member 212′ is a mirror image of member 212.

In place of using the corner member shown by FIG. 7, the ends of the two straight section of track may be cut at a 45 degree angle as shown by FIG. 9. Then the cut ends 230, 230′, 232, 232′ of the two sections 234, 234′, 236, 236′ can be brought together so that the two sections will meet and form a right angle.

The construction shown by FIGS. 7-9 can all be used with both the top tracks and the bottom tracks.

The illustrated embodiments are only examples of the present invention and, therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments that are illustrated and described herein, but rather are to be determined by the following claims, interpreted according to accepted doctrines of patent claim interpretation, including use of the doctrine of equivalents and reversal of parts.

Claims

1. An intersection stud for a framing wall, comprising:

a post portion having an upper end adapted to be fitable between the flanges of an upper track and a lower portion adapted to be fitable between the flanges of a lower track; and

a pair of flanges on said post portion forming an inside corner that is adapted to be positioned to provide a backing for wallboard edges that meet at the corner.

2. The intersection stud of claim 1, wherein the post portion of the stud has four sides and four corners and the two flanges extend perpendicular to each other from a common corner.

3. The intersection stud of claim 1, wherein the post portion of the stud has three sides, a pair of co-planar flanges projecting inwardly from two of the sides, and a pair of parallel second flanges projecting perpendicularly from the first two flanges and forming two inside corners for backing up edge portions of wallboard members that meet at the corners.

4. A sheet metal corner stud, comprising:

a first wall;

a second wall;

a third wall;

a fourth wall;

said first wall having a first edge and a second edge;

said second wall having a first edge and a second edge;

said third wall having a first edge and a second edge;

said fourth wall having a first edge and a second edge;

said second edge of said first wall being connected to the first edge of the second wall and forming a right angle corner with the second wall;

said second edge of the second wall being connected to the first edge of the fourth wall and forming a right angle corner with the third wall;

said second edge of the third wall being connected to and forming a right angle corner with the fourth wall;

a first flange having a first edge connected to the first edge of the first wall and forming a right angle corner with the first wall;

said first flange extending away from the first wall in a direction opposite from the direction that the second wall extends from the first wall;

a second flange having a first edge connected to the second edge of the fourth wall and forming a right angle corner with the fourth wall;

said second flange extending from the fourth wall in a direction opposite from the direction that the third wall extends from the fourth wall;

said first flange having an outer surface;

said second flange having an outer surface; and

said outer surface of said first flange extending substantially perpendicular to the outer surface of the second flange.

5. The sheet metal corner stud of claim 4, wherein the first flange has a second edge and said corner stud further includes a web having a first edge connected to the second edge of the first flange and forming a right angle corner with the first flange, and having a second edge; and

said corner stud also including a third flange having a first edge connected to the second edge of the web, and forming a right angle corner with said web and extending in spaced parallelism with the first flange, from said web towards the fourth wall of the stud.

6. The sheet metal corner stud of claim 4, wherein the second flange has a second edge and said corner stud further includes a web having a first edge connected to the second edge of the second flange and forming a right angle with the second flange, and having a second edge; and

said corner stud also including a third flange having a first edge connected to the second edge of the web, and forming a right angle corner with said web and extending in spaced parallelism with the first flange, from said web towards the first wall of the stud.

7. The sheet metal corner stud of claim 5, wherein the second flange has a second edge and said corner stud further includes a web having a first edge connected to the second edge of the second flange and forming a right angle with the second flange, and having a second edge; and

said corner stud also including a third flange having a first edge connected to the second edge of the web, and forming a right angle corner with said web and extending in space parallelism with the first flange, from said web towards the first wall of the stud.

8. A sheet metal framing assembly, comprising first and second lower channels meeting at a corner, each said channel having a bottom web including first and second edges and a pair of laterally spaced apart connected to and extending upwardly from said edges, said channels having a first pair of flanges coming together and defining an inner corner and a second pair of flanges coming together and forming an outer corner;

a sheet metal corner stud at the corner, comprising:

a first wall;

a second wall;

a third wall;

a fourth wall;

said first wall having a first edge and a second edge;

said second wall having a first edge and a second edge;

said third wall having a first edge and a second edge;

said fourth wall having a first edge and a second edge;

said second edge of said first wall being connected to the first edge of the second wall and forming a right angle corner with the second wall;

said second edge of said second wall being connected to the first edge of the third wall and forming a right angle corner with the third wall;

said second edge of said third wall being connected to the first edge of the fourth wall and forming a right angle corner with the fourth wall;

a first flange having a first edge connected to the first edge of the first wall and forming a right angle corner with the first wall;

said first flange extending away from the first wall and in a direction opposite from the direction that the second wall extends from the first wall;

a second flange having a first edge connected to the second edge of and forming a right angle corner with the fourth wall;

said second flange extending from the fourth wall in a direction generally opposite from the direction that the third wall extends from the fourth wall;

said first flange having an outer surface;

said second flange having an outer surface;

said outer surface of said first flange extending substantially perpendicular to the outer surface of the second flange;

said sheet metal corner stud including a lower end portion that sets down into the corner region formed by the lower channel members;

wherein the second and third walls of the corner stud are inside bottom track flanges that meet and form an outside corner; and

wherein the first and second flanges of the corner stud are contiguous bottom track flanges that meet and form an inside corner.

9. A sheet metal intersection stud, comprising:

a first wall having a first edge and a second edge;

a second wall having a first edge and a second edge;

a third wall having a first edge and a second edge;

said second edge of the first wall being connected to the first edge of the second wall, said second wall extending perpendicular from the first wall;

said second edge of the second wall being connected to the first edge of the third wall, said third wall extending perpendicular from the second wall and in spaced apart parallelism with the first wall;

a first flange having a first edge and a second edge, said first edge being connected to the first edge of the first wall, said first flange extending perpendicular from the first wall;

a second flange having a first edge and a second edge, said first edge being connected to the second edge of the third wall, said second flange extending perpendicular from the third wall towards and in co-planar parallelism with the first flange;

a third flange having a first edge and a second edge, said first edge being connected to the second edge of the first flange, said third flange extending perpendicular from the first flange in a direction opposite the direction that the first wall extends from the first flange;

a fourth flange having a first edge and a second edge, said first edge being connected to the second edge of the second flange, said fourth flange extending perpendicular from the second flange in a direction opposite from the direction that the third side wall extends from the second flange;

said third flange and said fourth flange extending in spaced apart parallelism with each other;

said intersection stud having a width dimension extending between the outside surface of the second wall and the outside surfaces of the first and second flanges which is substantially equal to the width dimension between the outside surface of the third flange and the outside surface of the fourth flange.

10. For use with a corner stud that fits into L-shaped corner portions of upper and lower tracks, a corner comprising:

an L-shaped web having perpendicular first and second legs having intersecting first and second inner edges and intersecting third and fourth outer edges;

first and second flanges extending from the inner edges of the web perpendicular to the web and to each other;

third and fourth flanges extending from the third and fourth edges of the web, in the same direction as the first and second flanges, and extending perpendicular to the web and to each other; and

said first leg of the web and said first and third flanges forming one end of the corner fitting and said second leg of the web and said second and fourth flanges forming a second and fourth corner fitting.

11. For use with an intersection stud that intersects upper and lower tracks at a location between two corners, a T fitting comprising:

a T-shaped web having an elongated first portion and a second stem portion intersecting the first portion between the ends of the first portion, said web having first and second edges that are perpendicular to each other, a third and fourth edges that are perpendicular to each other and a fifth edge that is parallel to the first and fourth edges and perpendicular to the second and third edges;

first and second flanges connected to the first and second edges of the web and extending perpendicular to the web and to each other;

third and fourth flanges connected to the third and fourth edges of the web and extending perpendicular to the web and to each other;

a fifth flange connected to the fifth edge of the web and extending perpendicular to the web and the second and third flanges and extending parallel with the first and fourth flanges;

said first and fifth flanges and the web forming a first end of the member;

said second and third flanges and the web region between them forming a second end of the member; and

said fourth and fifth flanges and the web region between them forming a third end of the member;

whereby straight sections of track may be positioned in line with the first and third ends of the member and a perpendicular section of track may be positioned in line with the second end of the member.