Mold resistant structural drywall track

Abstract

A mold resistant structural drywall track system is disclosed. In one embodiment, the track system comprises a base section, lower side wall, lateral support, and upper side wall. The lateral support supports wall material, such as gypsum board, above the floor to prevent moisture from wicking into the gypsum board. Additionally, ventilation and drainage means are included to allow for ventilation and drainage of moisture that may collect behind a wall. The base section, lower side wall, and lateral support generally form a cavity with the lower side wall substantially perpendicular to the base section. Preferably, the lower side wall is in the same plane as the finished wall surface above, thereby preventing damage to gypsum board, including any rubber base or resilient material installed over the gypsum board. The drywall track system may be employed with metal stud structures as well as wood frame structures.

Description

BACKGROUND

The present invention relates generally to systems for attaching drywall also referred to as gypsum board and like wall materials to metal stud and wood framing, and in particular to a structural drywall track that is mold resistant.

Steel stud framing is well known and commonly used in both commercial and residential construction. Such framing is typically utilized to construct interior and exterior partitions and generally consists of sill plates, runners, tracks, or channels located at the top and bottom of a wall, with studs extending between the channels, much like more traditional wood sill plates and wood studs. Both the sill plates and the studs are typically C-shaped or U-shaped. The studs are typically attached to the channels by mechanical fastening means, such as self-tapping screws. Once all of the electrical and mechanical appurtenances have been installed between the studs, gypsum drywall boards may then be attached to the studs, again typically with mechanical fastening means, to complete the wall. Wood stud framing is also commonly used today, particularly in residential construction, and employs similar tracks and studs structure.

In a majority of construction projects, the lower-most sheet of gypsum board is installed first, with the subsequent sheets being placed on top of the lower sheets for temporary support during construction. When installed in this manner, installers will typically place the lower-most sheet of gypsum board directly on the floor surface adjacent to the lower sill plate. Because the floor surfaces of construction sites, particularly commercial sites and residential basements, tend to be formed from concrete, moisture may wick through the concrete and into the gypsum board through capillary action. This promotes the formation of mold in the gypsum board.

According to some sources, the issue of mold contamination in residential and commercial buildings is quickly surpassing lead-based paint and asbestos as one of the real-estate industry's most vexing and potentially costly problems. Mold, particularly black mold (stachybotrys chartarum), is believed to cause flu-like and allergy-like symptoms, including skin rashes, inflammation of the respiratory tract, bloody noses, fever, headaches, neurological problems, and suppression of the immune system. While legal claims for toxic mold contamination were virtually unheard of five to ten years ago, litigation concerning such contamination is dramatically on the rise.

To grow and reproduce, mold requires food, air, a surface to grow on, suitable temperature, and moisture. In an occupied building, little can be done to eliminate the first four conditions. Therefore, minimizing the moisture is an effective approach to eliminate mold growth and to prevent it from growing. One limitation to the use of gypsum board in building construction is that this material is particularly susceptible to absorb moisture in a damp environment and hence, foster mold growth. Moisture in construction environments and finished buildings can be due to seepage, leaky roofs or pipes, flooding, condensation, and the like.

A number of approaches have been adopted to avoid subjecting gypsum boards to moisture during the installation process. First, to prevent such contact, installers may employ shims or wedges between the floor and the gypsum board during construction. Once the gypsum board is attached to the studs, the shims or wedges should then be removed to prevent moisture from wicking from the floor to the gypsum board through the shims or wedges. Often, installers simply leave the shims or wedges in place despite this concern. This approach can also lead to an uneven installation of the gypsum boards unless the installer is careful to ensure that all shims or wedges are uniform.

Another approach is to use a bent steel wedge. In this method, an installer places one end of a long and slender piece of steel, which is curved beneath the gypsum board such that the curved ends face up. The installer then steps on the free end to lower the free end and elevate the end beneath the gypsum board. Once the gypsum board is elevated, the installer may affix the gypsum board to the studs and then remove the bent steel wedge. This method is problematic as it is often difficult to coordinate the use of a bent steel wedge with one's foot while simultaneously holding and attempting to affix a piece of gypsum board to the studs. Additional helpers may be useful, but their use affects overall project efficiency by requiring additional man-hours of labor.

Even where gypsum board is placed above the surface of a floor, it is often placed with too little of a gap to avoid becoming moist. Gypsum board should be placed a minimum of ⅜-inch and preferably approximately ½-inch above the floor surface to prevent moisture from the floor surface from wicking into the gypsum board. These heights also help to keep the gypsum board dry in the case of unintended spills, floods, plumbing leaks, or the like, or routine cleaning efforts. Even a diligent installer may only place the gypsum board approximately ¼-inch or less above the floor when using the prior art methods of temporarily elevating the gypsum board discussed above. Often, this may still lead to mold growth.

Where the gypsum board is raised above the floor as described above, it creates an open space between the floor and the gypsum board that is not covered. Often, a layer of finishing material such as a rubber or resilient base is installed over the finished gypsum board as trim between the board and the floor. The rubber base will cover the gap between the floor and the gypsum board. While this configuration is aesthetically pleasing, it is susceptible to damage. It is fairly common in a commercial environment for cleaning crews to vacuum, mop, wax, or buff flooring, which can lead to contact between the cleaning equipment and the rubber base. Because there typically is no gypsum board or other supporting material behind a portion of the base, the base can become deformed by contact with cleaning equipment leading to damage to or deformation of it. This can also occur by the base being struck by moving furniture or human feet and the like.

Another approach to addressing the above concerns is illustrated in U.S. Patent Application US 2005/0183361 A1 to Frezza. This patent application proposes the use of a sill plate, which supports the gypsum board above the floor structure. This is accomplished by the use of a track that has a shelf generally parallel to and positioned above the floor structure that is used to support the gypsum board. The shelf forms a “T” shape with the wall of the plate, which is fastened to the metal studs. One significant disadvantage of this structure is that the space between the shelf and the floor is generally concave, so that after installation if any lateral forces are applied below the shelf it likely will result in deformation of the gypsum board or other exposed material as discussed above.

Another significant disadvantage of Frezza is that it lacks provisions for ventilation and drainage in the event water or moisture builds up behind the wall. The U-or C shape of the sill plate proposed by Frezza will act as a cup to pool moisture built up behind the wall. Without adequate drainage from the sill plate, it could actually promote mold growth in the event of a flood or similar water-related catastrophe. U.S. Patent Application No. US 2005/0155317A1 also to Frezza suffers from many of these defects as well.

Thus, it would be beneficial to provide an improved drywall track, which incorporates features that prevent the gypsum board from contacting a floor surface while at the same time preventing structural damage to the wall, drainage to reduce any moisture retained by the wall and allow early detection of the presence water and ventilation to reduce the amount of moist warm air within the wall cavity.

All references cited herein are incorporated by reference to the maximum extent allowable by law. To the extent a reference may not be fully incorporated herein, it is incorporated by reference for background purposes and indicative of the knowledge of one of ordinary skill in the art.

SUMMARY

The above problems are solved by the apparatus and systems of the present invention. In accordance with one embodiment of the present invention, a mold resistant structural drywall track is provided. Throughout this patent, gypsum board and drywall are used generically to describe gypsum board, drywall, and similar wall material.

The drywall track includes a base section in communication with a floor structure. The base section is fastened to the floor structure through a mechanical floor attachment such as power-actuated fasteners, expansion anchors, or anchor bolts. A lower side wall is connected to the base section and substantially perpendicular thereto. A lateral support is connected to the lower side wall and substantially parallel to the base section. The lateral support supports wall material, such as gypsum board, above the lateral support and floor structure. An upper side wall is connected to the lateral support and substantially perpendicular thereto. The upper side wall is fastened to the metal stud framing or other structural members.

Additional optional features include ventilation slots located in the lower side wall and drains located in the base section to facilitate ventilation and drainage of water and other liquids from the track. Thermal, acoustical, or fire-rated insulation material may be disposed in the cavity formed by the base section, lower side wall, and lateral support. The lower side wall may also include a layer of finished material disposed on its outer surface. A stop, connected to the base section and generally parallel to the lower side wall, may be used to laterally support the stud. The drywall track may also be configured to be double-sided for installation with an interior partition so that drywall is supported on both sides of the partition by the track.

In another embodiment of the invention, a drywall track adapted for renovating an existing wall track is provided. The drywall track includes a base section in communication with existing wall structure, including a metal track. A lower side wall is connected to the base section and substantially perpendicular thereto. A lateral support is connected to the lower side wall and substantially parallel to the base section. The lateral support supports wall material above the lateral support and floor structure. An upper side wall is connected to the lateral support and substantially perpendicular thereto. The upper side wall is fastened to the metal stud framing or other structural members.

Additional optional features include ventilation slots located in the lower side wall and drains located in the base section to facilitate ventilation and drainage of water and other liquids from the track. Thermal, acoustical, or fire-rated insulation material may be disposed in the cavity formed by the base section, lower side wall, and lateral support. The lower side wall may also include a layer of finished material disposed on its outer surface. A stop, connected to the base section and generally parallel to the lower side wall, may be used to keep the lower side wall flush upon an existing metal track or wood sill.

In another embodiment of the invention, a system for supporting gypsum board above a floor structure is provided. The system is comprised of a head track and a floor track. The head track includes a head plate in communication with a wall structure. First and second side walls are attached to the head plate and are oriented perpendicular to the head plate, which is fastened at the top of the wall structure. The floor track includes a base section fastened to the floor structure through a mechanical floor attachment such as power-actuated fasteners, expansion anchors, or anchor bolts. A lower side wall is connected to the base section and substantially perpendicular thereto. A lateral support is connected to the lower side wall and substantially parallel to the base section. The lateral support supports wall material above the lateral support and floor structure. An upper side wall is connected to the lateral support and substantially perpendicular thereto. The upper side wall is fastened to the metal stud framing or other structural members.

Additional optional features include ventilation slots located in the lower side wall and the head plate and drains located in the base section to facilitate ventilation and drainage of water and other liquids from the track. Notches formed in the interface of the lower side wall and the lateral support and the interface of the base section and lower side wall are also provided to facilitate installation of finish materials. Thermal, acoustical, or fire-rated insulation material may be disposed in the cavity formed by the base section, lower side wall, and lateral support. The lower side wall may also include a layer of finished material disposed on its outer surface. A stop, connected to the base section and generally parallel to the lower side wall, may be used to laterally support the stud. The drywall track may also be configured to be double-sided for installation with an interior partition so that gypsum board is supported on both sides of the partition by the track.

In another embodiment of the present invention, the lateral support is adapted to accommodate a plurality of gypsum boards.

In yet another embodiment of the invention, the drywall track system is employed with wood framing. The structures of the above-described tracks are similar. Instead of being attached to metal stud framing, the drywall tracks are employed with traditional wood stud framing, commonly used in residential construction.

Other objects, features, and advantages of the present invention will become apparent with reference to the drawings and detailed description that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a current solution for interior walls illustrating the track 202 and gypsum boards 212 and 214 attached to the track 202.

FIG. 2 is a side view of a current solution for exterior walls illustrating the track 222 and gypsum boards 230 and 232 attached to the track 222 and metal strap 238.

FIG. 3 is a perspective view of a sill plate 250, which includes a second shelf 266 that supports the gypsum board (not shown) above the floor 252.

FIG. 4 is a side view of one embodiment of the present invention used in connection with an interior wall partition.

FIG. 5 is a perspective view of an embodiment of the present invention including optional slots 24 in the lower side wall 14 and optional insulation material 44.

FIG. 6 is a side view of another embodiment of the present invention used in connection with an exterior wall partition.

FIG. 7 is a perspective view of another embodiment of the present invention used in connection with after-market installations illustrating slots 24 in the track system 10 and base 12 with stop 22.

FIG. 8 is perspective view of another embodiment of the present invention illustrating base 12 of the floor track 80 with drains 28, slots 24 in the lower side wall 14, and the head track 50.

FIG. 9 is a side view of another embodiment of the present invention illustrating a track system 10 adapted to accommodate a plurality of gypsum boards 32.

FIG. 10 is a side view of another embodiment of the present invention illustrating a plurality of the after-market embodiment of the invention installed in series.

FIG. 11 is a perspective view of another embodiment of the present invention adapted for installation with wood stud framing.

FIG. 12 is a perspective view of another embodiment of the present invention adapted for installation with wood stud framing.

DESCRIPTION

In the following detailed description of the preferred embodiments, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific preferred embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is understood that other embodiments may be utilized and that logical changes may be made without departing from the spirit or scope of the invention. To avoid detail not necessary to enable those skilled in the art to practice the invention, the description may omit certain information known to those skilled in the art. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims.

Referring to FIG. 1, a conventional sill plate 200 employed in an interior partition is illustrated. The sill plate 200 is comprised of a metal track 202 and gypsum boards 212 and 214. The metal track 202 is fastened to the floor structure (not shown) and to metal stud 216 usually by self-tapping metal screws. The metal track 202 is generally comprised of a U-shaped structure having a base 204, first wall 206, and second wall 208. The first wall 206 is taller than standard track walls to allow the attachment of both gypsum boards 212 and 214. The walls are generally perpendicular to the base 204. Commonly, gypsum board 212 is a paperless gypsum board with fiberglass facings, such as Georgia Pacific DensGlass Gold™, and is set directly on the concrete or other floor structure. The gypsum boards 212 and 214 are fastened to the metal track 202 using drywall screws. Commonly, a rubber base 210 or some other finish such as carpet is used to improve the aesthetic appearance of the wall by covering the interface between the gypsum board and the floor. While FIG. 1 illustrates a sill plate employing two gypsum boards, installations with a single gypsum board are also common.

An alternative to the sill plate 200 of FIG. 1 is shown in FIG. 2, which illustrates application to an exterior partition. Like its interior partition counterpart, this sill plate 220 is comprised of a metal track 222 and gypsum boards 230 and 232. The metal track 222 is fastened to the floor structure (not shown) and to a metal stud 240 usually by self-tapping metal screws. The metal track 222 is generally comprised of a U-shaped structure having a base 224, first wall 226, and second wall 228. The walls are generally perpendicular to the base 224. A metal strap 238 is also included for the attachment of both Gypsum Boards 230 and 232. The gypsum boards 230, typically a paperless gypsum board product, and 232 are fastened to the metal strap 238 using drywall screws. The exterior sheathing 234 is attached to the metal stud 240.

Conventional sill plates 200, such as the sill plate shown in FIG. 1, are common throughout the industry. Typically, such sill plates are manufactured in lengths of 8, 10, 12, or 16 feet. Overall heights are typically 1-inch to 1¼-inch. In each case, the dimensions may be varied depending on the circumstances. For example, each of the walls may be shorter than 1-inch, or higher than 1¼-inch. In addition, the walls need not be identical in height. Rather, the walls may be formed to different heights, if the application so provides. Typically, however, the walls will be of the same height, which is approximately between 1-inch and 1¼-inch.

Studs 216 and 240 are generally C-shaped, and may comprise a first side and a second side spanning between a central portion. As shown in FIG. 1, the metal track 202 and gypsum boards 212 and 214 are fastened to both sides of the stud 216. Non-C-shaped studs may also be used. In addition, conventional wood studs may be utilized. Preferably, the studs are C-shaped.

As previously discussed, because floor surfaces (shown in FIG. 3 and marked as 252) may be formed from concrete, moisture may wick from the floor into the gypsum boards 212 or 230. Even if the floor is relatively free of moisture, moisture may reach the gypsum boards 212 and 230 through other means if the boards 212 and 230 are installed close to the floor. For example, spills, either accidental or from routine cleaning, may moisten the portions of the gypsum boards 212 and 230 closest to the floor. Alternatively, moisture can accumulate in the wall either through humidity conditions, plumbing failures or through flood or other water-related catastrophes. These situations promote the formation of mold in the gypsum boards comprising the wall.

FIG. 3 illustrates an alternative sill plate 250. The sill plate 250 is comprised a horizontal base 254 with a first wall 256 and second wall 258 extending vertically therefrom. The sill plate 250 also includes a first flap 260 and a second flap 262 bent toward the outside of the sill plate 250. Thus, flaps 260, 262 are substantially parallel to walls 256, 258, respectively. The first flap 260 forms a first shelf 264 and the second flap 262 forms a second shelf 266. Shelves 264, 266 extend outward from the first and second walls 256, 258 and are generally parallel to the horizontal base 254. The sill plate 250 is attached to the metal stud 268 through a fastener. Metal stud 268 has first and second walls 270 and 272. The gypsum board (not shown) is supported on either the first or second shelves 264, 266 or both and fastened to the respective wall 256, 258.

As shown in FIG. 3, “W” denotes the width of the first shelf 264. “H” denotes the height of the second wall 258, and “h” denotes the height of the second shelf 266 relative to the base 254. Like the sill plates 200 and 220 of FIGS. 1 and 2, sill plate 250 provides a generally C or U-shaped structure that will retain water and other liquids resulting in pooling of these liquids behind the wall structure. This retention of liquid will facilitate mold growth in the gypsum board. Moreover, sill plate 250 generally has an open cavity below the shelves 264, 266. Thus, if an object strikes the gypsum board or a decorative covering like a rubber base, it will likely damage the gypsum board or decorative covering due to the absence of lateral support below the shelves 264, 266. The present invention overcomes these shortcomings.

Turning to FIGS. 4 and 5, one embodiment of the present invention, adapted for installation with interior partitions is illustrated. The track system 10 includes a base section 12 that is secured to the floor structure 30 through a floor attachment 66 or other suitable attachment means. The floor attachment 66 is preferably fastened by power-actuated fasteners, expansion anchors, anchor bolts, and the like. A lower side wall 14 is connected to the base section 12 and generally perpendicular thereto. Lateral support 16 is connected to the lower side wall 14 and forms a horizontal plane generally parallel to that formed by the base section 12. Upper side wall 18 is connected to the lateral support 16 and is generally perpendicular thereto. The upper side wall 18 is secured to the stud 36 through the use of a fastener 20A (not shown in FIG. 4, shown in FIG. 5), which is preferably a self-tapping metal screw. Other suitable fasteners include rivets, welded connections, and the like may be used. As shown in FIGS. 4 and 5, gypsum board 32 is supported on the lateral support 16 and fastened to the upper side wall 18 and stud 36 by fastener 20B, which is preferably a bugle head drywall screw. Other suitable fastening means include flathead nails in wood framing and construction adhesives.

“Gypsum board” is used herein to refer generically to a variety of wall materials that may be used in conjunction with the track system. This is not intended to be limiting and includes tile backer board, cement board, ceramic tile, stone, metal lath, plaster, stucco, wood siding, wood panels, metal panels, acoustical panels, and the like. Optional resilient base material 34 is shown in FIG. 4. This may include rubber or other resilient material used to enhance the aesthetic appearance of the track system after installation.

As shown in FIGS. 4 through 12, it is preferred that the lower side wall 14 be substantially coplanar with the gypsum board 32 supported by the lateral support 16. While this is not required by the invention, it provides significant advantages, including eliminating an open cavity below the lateral support. As shown in FIG. 3, certain other sill plates leave an open cavity below the gypsum board, which allows the material below it to become damage or deformed due to routine cleaning, accidentally striking, and other occurrences. In the preferred embodiment of the invention, the base section 12, lower side wall 14, and lateral support 16 form a generally closed cavity with the lower side wall substantially coplanar with the gypsum board 32. In other embodiments of the invention, a layer of finished material is disposed on the outward-facing surface (opposite the stud 36) of the lower side wall 14 so that it may form a part of the finished wall after the gypsum board 32 is textured and painted or covered. This eliminates the need for a rubber base 34 or other decorative object to be included with the installation of the gypsum board 32 and track 10.

As shown in FIGS. 4 and 5, this embodiment of the track system is double sided so that each side is comprised of a base section 12, lower side wall 14, lateral support 16, and upper side wall 18. FIG. 4 illustrates the height “H” between the floor structure 30 and the lateral support 16. Although FIGS. 4 and 5 show the track system with each side having a height “H” that are equal, that is not required by the invention. One skilled in the art will appreciate that the height “H” may be varied depending upon the intended application of the track system 10.

Because height “H” can be precisely controlled, the gypsum board 32 installed may be attached to the studs at controlled heights above the floor structure 30. While a height “H” of 1-inch is preferred, heights ranging from ¼-inch to 4-inches may be employed depending upon the application of the track system 10. For example, where the minimum gypsum board protection is required, then “H” would be ¼. In more severe, high-risk installations where the maximum gypsum board protection is required, then “H” would be 4′.

Similarly, the width “W”, of the lateral supports 16 (as shown in FIG. 5) may also be precisely controlled. A width equal to the thickness of the gypsum board 32 is generally preferred, which would typically be ½-inch for residential wood framing and ⅝-inch in commercial metal framing. Widths ranging from ¼-inch to 2½-inch may be employed depending upon the application of the track system 10. A larger width, such as 2½-inches, may be desirable for an application requiring multiple layers of gypsum boards 32 of ⅝ inch width.

FIG. 9 is an example of such an application. This would be used where a four-hour fire rated wall construction is required and four layers of ⅝ inch gypsum board would be installed. As shown in FIG. 9, multiple gypsum boards 32 may be employed with this and other embodiments of the present invention. The track 10 illustrated in this figure includes a horizontal base 12, optional stop 22, lower side wall 14, lateral support 16, and upper side wall 18. The upper side wall 18 is connected to the stud 36 through fastener 20A. This embodiment includes a dual-sided configuration of the track 10 with four gypsum boards 32 installed on each side. The track may include additional optional features (not shown) such as ventilation slots 24, drains 28, and other features discussed with respect to the other embodiments of the invention.

The inclusion of lateral supports 16 results in a uniform installation of the gypsum board 32 across a given wall structure. This is because it would be difficult for even a careless installer to attach the gypsum board 32 while part of it rests on the floor 30 or at an uneven height. Accordingly, even an unaware contractor will be forced to utilize the track 10 of the present invention in the correct manner, as the track 10 itself facilitates proper installation of gypsum board 32 regardless of the knowledge base of the installer.

Turning to FIG. 5, additional enhancements to the track 10 include ventilation or drainage slots 24 to facilitate drainage of water and other liquids that have built up in the cavity of the wall and allow the early detection of a moisture catastrophe. A drain 28 may also be included. As shown in FIG. 5, the drain 28 is preferably located in the base section 12 and the slots 24 are located in the lower side wall 14. The drain 28 and slots 24 may be located anywhere so long as they facilitate drainage of fluids. A stop 22 can also be employed to enhance the fit of the base section 12 against the stud 36. The stop 22 prevents the base section 12 from shifting under the stud 36 after the upper side wall 18 is secured.

Optional insulation material 44 may be disposed in the cavity formed by the base section 12, lower side wall 14, and lateral support 16. The insulation material 44 may be thermal insulation, fiberglass, acoustical insulation, flame or fire retardant insulation, and the like. The exterior surface of the lower side wall 14, that is the surface facing opposite the stud 36, may also include a finished surface (not shown). The finishing may be galvanized, painted, or coated steel; anodized, painted, or coated aluminum; or a colored composite, vinyl, or plastic; or the natural unfinished surface of the material used. Any material suitable for exposure in a commercial or residential building environment may be employed. The addition of the finished surface eliminates the need for a resilient or rubber base 34 (FIG. 4), wood trim, tile, stone or carpet base that are commonly used to enhance the aesthetic appearance of the interface between the wall and floor.

In another embodiment of the present invention, shown in FIG. 6, the track system 10 is adapted for an exterior partition. This track 10 includes a base section 12, lower side wall 14, lateral support 16, and upper side wall 18. Additionally, the track 10 includes a second lower side wall or back wall 64 that is fastened by fastener 20C to the side of the stud 36 opposite the first lower wall 14. Wall material 42 (exterior sheathing) is typically present with this application. This embodiment optionally may include a slot 24, drain 28, insulation material 44, and finished surface. The back wall 64 enhances the attachment of the track 10 to the stud 36 and floor structure 30. Fastener 20B is used to fasten the gypsum board 32 to the upper side wall 18 and the stud 36.

Another embodiment of the present invention adapted for installation with existing wall structure is illustrated in FIG. 7. While this system will work with new construction, it is designed to be a retrofit application for existing wall structure for example where remodeling or repair is needed. Turning to FIG. 7, the stud 36 is shown attached to a standard track 38 and floor structure 30. The track system 10 includes a base section 12, lower side wall 14, lateral support 16, and upper side wall 18. A stop 22 is included to enhance securing the lower side wall 14 to the stud 36. As shown in the figure, the base section 12 does not extend all the way across the bottom of the standard track 38. The width between the stop 22 and the lower side wall 14 is approximately equal to the width between the upper side wall 18 and the lower side wall 14. This assists with maintaining the lower portion of the lower side wall 14 flush against the standard track 38 after the upper side wall 18 is attached to the stud 36. The gypsum board 32 is secured in the same manner using a fastener 20B. Fastener 20A secures the upper side wall 18 to the stud 36. The stop 22 prevents the base section 12 from shifting under the stud 36 after the upper side wall 18 is secured.

This embodiment optionally may include a slot 24, drain 28, insulation material 44 (not shown), resilient base 34, and finished surface (not shown). One or more of these retrofit track systems may be installed in series. FIG. 10 illustrates a side view of four such tracks installed together. One skilled in the art will appreciate the advantages of this configuration where a certain enhanced fire rating may be desired or where additional gypsum boards 32 are desired. As shown in the figure, for this embodiment, each track 10 is comprised of a horizontal base 12, optional stop 22, lower side wall 14, lateral support 16, and upper side wall 18. For the inner-most track 10, the upper side wall 18 is attached to the stud 36 by fastener 20A. The outer tracks 10 are attached to the inner tracks 10 by means of one or more fasteners.

Yet another embodiment of the present invention is shown in FIG. 8. This track system 10 includes a head track 50 and a floor track 80. The head track 50 is comprised of a head plate 52 and a first side wall 54, a second side wall 56, and optional slots 58. The head track 50 is attached at the top of the wall to the stud 36 through the use of fasteners 60, which are preferably self-tapping screws. Preferably, the head track 50 includes slots 58 to facilitate ventilation of the wall. Inclusion of ventilation or drainage slots 24 and drains 28 in the floor track 80 in conjunction with slots 58 in the head track 50 will allow air to circulate through the wall, thereby allowing it to drain or dry in the event moisture is introduced into the wall.

Floor track 80 includes a base section 12, lower side wall 14, lateral support 16, and upper side wall 18. It is preferred that the floor track 80 include a flange 26 to support the gypsum board 32 on the lateral support 16. Fastener 20A is used to attach the upper side wall 18 to the stud 36. Fastener 20B goes through flange 26 and the gypsum board 32 to attach to upper side wall 18. Optional drywall tape and joint compound 46 may be used to enhance the installation of the gypsum board 32. Other means such as epoxy, glue, construction adhesive, nails in wood framing, and the like may also be used to secure the gypsum board 32.

This embodiment optionally may include a slot 24, drain 28, insulation material 44 (not shown), resilient base 34, floor structure 30, and floor finish material 76. It is preferred that a notch 72, formed at the interface between the base section 12 and the lower side wall 14, is included to enhance installation of the track system 10 with the floor finish material 76. As shown in FIG. 8, the floor finish 76 may be layered upon the floor structure 30. Notch 72 allows the lower side wall 14 to be elevated to a desired level to accept a portion of the floor finish material 76. Additionally, a notch 74, formed at the interface between the lower side wall 14 and lateral support 16, is also preferred. Notch 74 allows for the enhanced performance of the drywall tape and joint compound 46 and to be terminated at a consistent horizontal line between flange 26 and the lower sidewall 14.

The exterior surface of the lower side wall 14, that is the surface facing opposite the stud 36, may also include a finished surface (not shown). The finishing may be galvanized, painted, or coated steel; anodized, painted, or coated aluminum; or a colored composite, vinyl, or plastic; or the natural unfinished surface of the material used. Any material suitable for exposure in a commercial or residential building environment may be employed. The addition of the finished surface eliminates the need for a resilient or rubber base, wood trim, tile, stone or carpet base that are commonly used to enhance the aesthetic appearance of the interface between the wall and floor.

The track system of the present invention is also adapted to be used in wood frame installations. FIGS. 11 and 12 illustrate such embodiments. In FIG. 11, an embodiment for retrofit application is illustrated. This particular track system 300 includes a base section 312, stop 322, lower side wall 314, lateral support 316, upper side wall 318, resilient or wood base 334, and slots 324. The upper side wall 318 is fastened to the wood stud framing 368 by fastener 320A, which is preferably a wood screw. Other fasteners including nails or bolts may also be used. Gypsum board 332 is fastened to the upper side wall 318 by fastener 20B, preferably a bugle head drywall screw. Gypsum Board 332 may also be attached to studs 368 with flathead nails. The base section 312 is in contact with floor structure 330.

FIG. 12 illustrates an interior wall partition embodiment similar to that shown in FIG. 5. The track system 300 of this embodiment is shown as a dual-wall track system and includes a base section 312, lower side wall 314, lateral support 316, upper side wall 318, resilient or wood base 334, and slots 324. The base section 312 is attached to floor structure 330 through the floor attachment 366. Preferably, a mechanical structural attachment means, such as power actuated fasteners, expansion anchors or anchor bolts and the like, is used to attach the base section 312 to the floor structure 330. This provides the advantage of additional structural strength to withstand forces imposed by earthquakes, high winds, snow loads, live loads, dead loads, impacts, etc. The gypsum board 332 is fastened to the upper side wall 318 by fastener 320B, preferably a bugle head drywall screw. Upper side wall 318 is fastened to the stud 368 by fastener 320A.

Optional insulation material may be disposed in the cavity formed by the base section 312, lower side wall 314, and lateral support 316. The insulation material may be thermal insulation, fiberglass, acoustical insulation, flame or fire retardant insulation, and the like. The exterior surface of the lower side wall 314, that is the surface facing opposite the stud 368, may also include a finished surface (not shown). The finishing may be galvanized, painted, or coated steel; anodized, painted, or coated aluminum; or a colored composite, vinyl, or plastic; or the natural unfinished surface of the material used. Any material suitable for exposure in a commercial or residential building environment may be employed. The addition of the finished surface eliminates the need for a resilient or rubber base, wood trim, tile, stone or carpet base that are commonly used to enhance the aesthetic appearance of the interface between the wall and floor.

The floor tracks and head tracks shown and described in accordance with the present invention may be formed from metals such as steel or aluminum, plastics, composites, or any other suitable material. Depending on the material, the tracks may be bent, roll formed, extruded, molded, or formed in other suitable manners. The preferred manner of forming the tracks is through roll forming of coiled stock steel. By using the roll forming process, a continuous length of coiled stock may be bent or otherwise formed into shape by feeding the stock between successive pairs of rolls that increasingly shape the material into the desired cross-section. As the continuous length of track exits the roll forming machine, a cutoff machine may cut the continuous roll into predetermined lengths, typically in the range of 8 feet to 16 feet. This method is desirable for mass-produced, quality controlled tracks.

The structural aspects of the track allow it to be engineered to accommodate the required deflection and end reactions of the associated studs. The track is also configured to resist the axial forces in load-bearing stud conditions. In conjunction with engineered studs, the track will be an integral component of both load bearing and non-load bearing wall assemblies.

Accordingly, the present invention provides for the proper installation of gypsum board in steel or wood stud framing systems without slowing the efficiency of construction. The use of lateral supports in the track system eliminates the need for, and hence the errors caused by, shims, bent steel wedges, or similar means commonly employed during construction to keep the gypsum board at a uniform level about the floor structure. Because these mechanisms are no longer needed, the installer of the gypsum board has a convenient place to rest the board during installation. This results in shortened construction time.

The primary advantage of the present invention is that it prevents mold from forming in gypsum board and other portions of interior and exterior walls while at the same time providing improved structural support. Other advantages of the present invention include a drainage means to relieve water or other liquids, which have formed or pooled within the cavity of wall. The present invention also allows for the wall cavity to be ventilated and air to circulate within the cavity. This allows moist, warm air to escape the cavity and reduces the possibility of mold growth. With traditional sill plates, such as that disclosed in Frezza, the sill plate is U- or C-shaped, thereby creating a cup to collect liquids. This will result in increased humidity in a wall and will increase the likelihood of mold formation and growth. Another advantage of the present invention is that it provides a structural member below the lateral support that is substantially flush with the wall after installation. This helps to prevent damage to that portion of the wall, which is frequently covered by a rubber base, carpet, or other aesthetic covering.

It should be apparent from the foregoing that an invention having significant advantages has been provided. While the invention is shown in only a few of its forms, it is not just limited but is susceptible to various changes and modifications without departing from the spirit thereof.

Claims

1. A drywall floor track comprising:

a base section in communication with a floor structure;

a lower side wall connected to the base section, wherein the lower side wall is substantially coplanar with the wall material;

a lateral support connected to the lower side wall and adapted to support wall material above the floor structure; and

an upper side wall connected to the lateral support.

2. The apparatus of claim 1 further including at least one ventilation slot.

3. The apparatus of claim 1 further including at least one drain.

4. The apparatus of claim 1, wherein the lower side wall is substantially perpendicular to the base section and the lateral support.

5. The apparatus of claim 1 further including insulation material disposed in a cavity formed by the base section, lower side wall, and lateral support.

6. The apparatus of claim 1 further including a stop connected to the base section.

7. The apparatus of claim 1, wherein the lower side wall includes a layer of finished material.

8. The apparatus of claim 1 further including a second lower side wall connected to the base section and opposed to the first lower side wall.

9. The apparatus of claim 1, wherein the lateral support is selected from a plurality of lateral supports having widths ranging between ½ inch and 2½ inches.

10. The apparatus of claim 1, wherein the lateral support is ½ inch above the base section.

11. The apparatus of claim 1 further including:

a second lower side wall connected to the base section and opposed to the first lower side wall;

a second lateral support connected to the second lower side wall and adapted to support wall material above the floor structure; and

a second upper side wall connected to the second lateral support.

12. The apparatus of claim 11 further including insulation material disposed in a cavity formed by the base section, the first and second lower side walls, and the first and second lateral supports.

13. The apparatus of claim 11, wherein at least one of the lower side walls includes a layer of finished material.

14. A renovation drywall floor track for installation with existing wall structure, the track comprising:

a base section in communication with an existing wall structure;

a lower side wall connected to the base section, wherein the lower side wall is substantially coplanar with the wall material;

a lateral support connected to the lower side wall and adapted to support the wall material above a floor structure; and

an upper side wall connected to the lateral support and adapted to be secured to the existing wall structure.

15. The apparatus of claim 14 further including at least one ventilation slot.

16. The apparatus of claim 14 further including at least one drain.

17. The apparatus of claim 14, wherein the lower side wall is substantially perpendicular to the base section and the lateral support.

18. The apparatus of claim 14 further including insulation material disposed in a cavity formed by the base section, lower side wall, and lateral support.

19. The apparatus of claim 14 further including a stop connected to the base section.

20. The apparatus of claim 14, wherein the lower side wall includes a layer of finished material facing opposite from the existing wall structure.

21. A system for supporting wall material above a floor structure, the system comprising:

a head track having a head plate in communication with a wall structure, a first side wall connected to the head plate, and a second side wall connected to the head plate and opposed to the first side wall;

and

a floor track having a base section in communication with the floor structure, a lower side wall connected to the base section, wherein the lower side wall is substantially coplanar with the wall material, a lateral support connected to the lower side wall and adapted to support wall material above the floor structure, and an upper side wall connected to the lateral support.

22. The system of claim 21 further including a flange connected to the lateral support and opposed to the upper side wall.

23. The system of claim 21 further including a notch in an interface formed by the lower side wall and the lateral support.

24. The system of claim 21 further including a notch in an interface formed by the base section and the lower side wall of the floor track.

25. The system of claim 21, wherein the lower side wall includes one ventilation slot.

26. The system of claim 21, wherein the head track includes at least one ventilation slot.

27. The system of claim 21, wherein the lower side wall includes a layer of finished material facing opposite from the wall structure.

28. The system of claim 21, wherein the base section includes a drain.

29. The system of claim 21, wherein insulation material is disposed in a cavity formed by the base section, the lower side wall, and the lateral support.

30. The system of claim 21, wherein the lower side wall is generally perpendicular to the base section and the lateral support.

31. The system of claim 21, wherein the base section includes a stop.

32. The system of claim 21, wherein the lateral support is selected from a plurality of lateral supports having widths ranging between ½ inch and 2½ inches.

33. They system of claim 21, wherein the lateral support is ½ inch above the base section.