Modular Metal Wall Framing System

Abstract

A metal stud assembly includes a stud used in constructing a metal wall frame between two channel members, and an extender longitudinally slidably mounted within the stud. The stud includes a central column portion, two side walls formed on opposite sides of the central column portion, a retainer, at least one alignment slot formed in the stud for receiving the retainer formed on one of the channel members, and an indented portion formed in at least one of the side walls for receiving a spacer bar. The alignment slot is formed in at least one end portion of the central column portion. The extender includes an upper portion having side walls parallel to the side walls of the stud, and a lower portion having side walls that join the upper portion side walls at a top end and which taper at a bottom end to fit within the stud.

Description

CROSS-REFERENCE TO RELATED APPLICATION

This is related to, and claims the benefit under 35 USC §119(e) of U.S. Provisional Application for Patent No. 60/824,652, which was filed on Sep. 6, 2006.

FIELD OF THE INVENTION

The present invention relates in general to metal wall frames, and in particular to such frames which include channels and studs having integrally formed connectors, locators, and retainers.

BACKGROUND OF THE INVENTION

Framing systems have been developed using metal channels and studs in place of more conventional wood frames. Such systems have been adapted to construct various structures including residential and commercial buildings, and particularly the partitions of such buildings. Although these systems function adequately, they are sometimes difficult to use and can take longer to assemble than can conventional wood frames.

Because of these drawbacks, many builders have been reluctant to adopt conventional metal framing systems. Moreover, installers have experienced difficulty in correctly installing some conventional metal framing systems. Installers also dislike the snipping and cutting of the metal frame members required in such systems, as the sharp metal edges can result in cut hands and torn clothes. For these reasons, wood frames are still commonly used for residential construction.

Although wood frames have been widely accepted by builders and installers, wood frames are not fireproof and wood tends to buckle, warp, split, shrink, and bend out of shape. Moreover, a wood stud is heavier and more awkward to work with than a metal stud, and is currently about twice the price of a metal stud.

Even with the drawbacks associated with wood frames, wood is still the material of choice of most builders, particularly since carpenters are familiar with wood frame construction and can nail wood frames together with a nail gun faster than they can screw a fastener into a metal frame with a screw gun.

The following comparison of existing standard wood and conventional metal stud applications might be of value in fully appreciating the advantages of the present invention.

Installation of a wall partition constructed of wooden studs, after upper and lower plates have been installed, requires the following steps for each stud:

• • 1. Measure 16 inches on center or 24 inches on center from the previously-installed stud and appropriately mark the measured distance on the upper and lower plate.
  • 2. Measure the distance between upper and lower plates.
  • 3. Measure the length of the stud to be installed to be equal to the measurement in the previous step and mark the stud where it is to be cut.
  • 4. Cut the stud. The cut must be cut square, using a miter box, skill saw guide, etc.
  • 5. Place the stud into position between the plates. Adjust the position of the stud by applying a level to assure that it is plumb, top to bottom, side to side and front to back.
  • 6. Nail the bottom portion of the stud to the lower plate using two nails, either manually or with a nailing gun.
  • 7. Climb a ladder or scaffold and nail the top portion of the stud to the upper plate, again using two nails.
  • 8. Usually framers will also install horizontal wood members to serve as braces and spacers between the studs. In such case there are the following additional steps:
    • A. Measure and mark a piece of stud lumber to fit between the studs.
    • B. Cut the piece of lumber square to form a brace.
    • C. Nail two nails to one end of the brace and into one stud.
    • D. Nail two nails into the other end of the brace and into the other stud.
  • 9. When electricians run electrical cable through the studs, it is necessary for them to first bore a hole through each stud individually, that is, through those studs that will have cable going through them.

It is apparent that wood fame construction requires many individual time-consuming steps. Moreover, problems associated with wood studs include:

• • 1. Wood is not fireproof.
  • 2. Wood can buckle, split, shrink, and bend out of shape.
  • 3. A wood stud is heavier and clumsier to work with than a corresponding metal stud.
  • 4. A wood stud is currently about double the price of a metal stud, and with continuing depletion of natural reserves, prices for lumber will likely continue to rise.

Installation of a partition constructed of conventional metal studs, after the upper and lower channels have been installed, requires the following steps for each stud:

• • 1. Measure 16 inches on center or 24 inches on center from a previously-installed stud and appropriately mark the measured distance on the upper and lower channels.
  • 2. Measure the distance between upper and lower channels.
  • 3. Measure the length of the stud to be installed to be equal to the measurement in the previous step and mark the stud where it is to be cut.
  • 4. Cut the two side flanges of the stud with a pair of snippers, and then bend the central backbone of the stud back and forth until it breaks off.
  • 5. Place the stud into position between the channels where previously marked. Adjust the position of the stud by applying a level to assure that it is plumb, top to bottom and side to side.
  • 6. Take two screws and individually mount each screw onto a screw gun and screw the bottom portion of the stud into the lower channel.
  • 7. Climb a ladder, and again, take two screws and individually mount each onto a screw gun and screw the upper portion of the stud into the upper channel.
  • 8. Many installers also place a horizontal brace and spacing member that runs through the apertures of several studs. In such case, there are the following additional steps:
    • A. Run the bracing member through the apertures of several studs.
    • B. Cut little tabs to connect and fasten each stud to its section of bracing member.
    • C. Line up each stud to be properly aligned and plumb with each corresponding section of bracing member.
    • D. Screw into a precut tab to connect the stud to the bracing member.

It can be seen that conventional metal frame construction requires many individual time-consuming steps. Moreover, problems associated with conventional metal studs include:

• • 1. There does not seem to be any installation time savings of metal over wood. In fact, one can argue that a wooden frame will go up faster than a metal frame because of the extra time required with metal in the process of cutting the stud to size and the fumbling required with screws as opposed to automatic nailing with a nailing gun and nail cartridges.
  • 2. Since the conventional installation of metal frames does not appear to provide real economies of time, many framing contractors prefer to use wood, the “old-fashioned” way.
  • 3. When snipping and breaking off a piece of a metal stud, hands and clothing tend to get cut very easily.
  • 4. Fumbling with the individual placement of a screw onto a screw gun and screwing into a conventional metal stud is cumbersome, annoying, and more time-consuming than simply applying a cartridge-loaded nailing gun to wood.
  • 5. Tunneling spacing members through holes in a series of studs and then dealing with the connection of the tabs between the studs and the spacing members is cumbersome, awkward, and annoying.

However, metal stud installation does provide the following benefits:

• • 1. Metal is virtually fireproof.
  • 2. Metal is lightweight and easier to work with than wood.
  • 3. Metal studs remain intact and square and do not warp.
  • 4. Metal studs are currently about half the price of wooden studs.
  • 5. Metal studs have precut holes for electrical and other cable running.

Accordingly, a need exists for a framing system that is easy to understand and quick to assemble, that does not require extensive cutting or snipping, and that is cost-effective as compared to current alternative methods.

A need also exists for a framing system that is more economical to use than wood frame systems and that is readily acceptable to architects, builders, installers, and end users.

A need also exists for a framing system that provides accurate spacing between studs and that is available with modular interchangeable components.

A need also exists for a framing system that offers a complete and simple solution rather than a partial solution to the entire installation process.

BRIEF SUMMARY OF THE INVENTION

The present invention is a metal framing system for supporting the walls, floors, and ceilings of various building structures including residential and commercial buildings. The invention is an apparatus that is useful, for example, in the construction industry, and is also useful to end users who are performing home construction projects.

This invention provides for much simpler and speedier installation of wall/partition frames, resulting in greatly reduced labor costs while at the same time maintaining quality control in the integrity and accuracy of the installation.

The construction industry, whose workers are tradition- and trade-oriented, has been very slow to adopt any innovative methodologies or technologies. On the other hand, there is always a desire on the part of builders and consumers to reduce costs in building. The only way to satisfy both ends of the spectrum is to present a solution that creates significant cost-savings while at the same time has certain key ingredients: simple, easy to learn, practical (makes life easier for the worker), and also provides a complete solution, rather than incremental benefits.

The present invention provides ingredients to satisfy the worker and take away the worker's opposition to innovation. Those same ingredients have the effect of cutting costs for the builder. Time is money, and a speedy operation becomes a less expensive one.

Previous innovations have in most instances offered a solution to only a small part of the process, rather than to the whole thing. The present invention provides a complete solution. Importantly, the invention does not seek to replace steps in stud-wall building with a better process. Instead, it just eliminates some of the steps entirely for the tradesperson.

While saving money and streamlining operations, the invention maintains the integrity and accuracy of the installation; studs are square-plumb and on center for drywall installation.

The invention also provides a metal framing system that is easy to use, quick to assemble, and does not require metal cutting during frame assembly.

The invention also provides a complete modular framing system that is simple in form, easy to learn, and easy to use.

The invention also provides a metal wall framing system that eliminates some of the steps required to construct a conventional metal or wood frame, while providing a square, plumb, and on-center metal frame for supporting drywall or other wall materials.

The invention also provides a metal framing system that is significantly faster and more economical to assemble than other wood and metal framing systems.

The invention also provides a modular metal framing system that is easily used by an unskilled, lower-cost worker. The system is also intended for use by inexperienced do-it-yourself homeowners lacking the tools, knowledge, and experience of a skilled professional framer.

The invention also provides a metal wall framing system that does not require supplemental hardware, requires no supplemental fasteners, nails, electric tools or other power tools, or any measuring devices or cutting devices.

The invention also provides a modular metal framing system that can include an optional side spacer or bracer that provides spacing and alignment of studs and serves as a larger surface for supporting drywall and into which metal screws can be more conveniently secured to hold the drywall to the frame.

The present invention is directed to a modular metal framing system for constructing wall frames in virtually any type of building construction. The system is complete insofar as it requires virtually no additional hardware and can be readily used by unskilled labor. Metal wall frames constructed in accordance with the invention can be completed in a fraction of the time and at much lower cost than wood frames as well as other conventional metal frame systems.

In accordance with the invention, upper and lower metal channels are formed with a series of evenly-spaced locators or stops that accurately locate a series of metal studs along the channels. The channels also include retainers or prongs located adjacent to the locators or stops for fitting within slots formed in the studs. The channels further include scored or notched areas located adjacent to the stops and prongs for allowing a portion of each channel side wall to be crimped inwardly to hold a stud in place on the channel, or flexible clips that hold the stud in place along the channel.

In order to interconnect and mount a stud on a channel, the stud is simply moved along the channel with a sliding movement until the stud engages a stop. Just before the stud engages a stop, one or more locators or prongs slide into mating slots formed in the stud to hold and guide the stud into alignment with the stop. Notched or perforated portions in the channel sidewalls are then crimped inwardly to hold the stud in place within the channel. Alternatively, flexible clips are bent inward to hold the stud in place. This provides a bracing system for spacing and leveling.

According to a particular aspect of the invention, a metal stud assembly includes a stud adapted for constructing a metal wall frame between a pair of channel members, and an extender longitudinally slidably mounted within the stud. The stud includes a longitudinally-extending central column portion having a pair of opposite end portions, a pair of side walls formed on opposite sides of the central column portion, a first retainer, and at least one elongated alignment slot formed in the stud that is adapted to receive the first retainer formed on one of the channel members. The alignment slot is formed in at least one of the end portions of the central column portion. The extender includes an upper portion having side walls that are substantially parallel to the side walls of the stud, and a lower portion having side walls that join the upper portion side walls at a top end and which taper to smaller dimensions at a bottom end, such that the bottom end fits within the stud.

The stud can also include an indented portion formed in at least one of the side walls that is adapted to receive a spacer bar. The metal stud assembly can include a plurality of studs, as well as at least one spacer bar interconnecting adjacent ones of the studs, coupled to respective the indented portions formed in the studs.

The lower portion side walls of the extender can taper linearly inward. In this case, the extender can be formed with a push hole for pushing and sliding the extender within the stud. The metal stud assembly can also include a second retainer formed on the channel member, and the first retainer can have at least one slot formed therein that receives the second retainer.

According to another aspect of the invention, a metal wall frame system includes a series of metal studs according to the metal stud assembly described above. The system also includes a metal channel member, a series of stops formed at predetermined intervals along the channel member, and a series of retainer members formed at predetermined intervals along the channel member. The metal channel member has a floor portion and a pair of side walls upstanding from the floor portion. The series of metal studs is interconnected to the channel member. Each stud is butted against a respective one of the stops, and each stud receives a respective one of the retainer members.

The system can also include a series of spacer bars. Each spacer bar interconnects adjacent studs.

The stops can be formed as upstanding tabs struck from the channel member. In this case, the system can also include a series of longitudinally spaced crimp portions crimped inwardly from the side walls and locking the studs on the channel member. Each of the studs can include a socket, and each spacer bar can include a series of projections respectively extending into each of the sockets.

The metal channel member described above can be a lower channel member, and the system can also include an upper channel member interconnected to the extender. The extender can include an elongated slot, and the upper channel member can include a retainer member that engages the elongated slot to interconnect the upper channel member to the extender.

According to another aspect of the invention, a metal stud assembly includes a stud adapted to be used in the construction of a metal wall frame between a pair of channel members, and an extender longitudinally slidably mounted over the stud. The stud includes a longitudinally-extending central column portion having a pair of opposite end portions, a pair of side walls formed on opposite sides of the central column portion, a first retainer, at least one elongated alignment slot formed in the stud adapted to receive the first retainer formed on one of the channel members, and an indented portion formed in at least one of the side walls adapted to receive a spacer bar. The alignment slot is formed in at least one of the end portions of the central column portion. The extender includes an upper portion having side walls that are substantially parallel to the side walls of the stud, and a lower portion having side walls that fit over the stud.

The lower portion side walls of the extender can taper linearly inward.

The lower portion of the extender can join the upper portion side walls at a top end and taper to larger dimensions at a bottom end, such that the bottom end fits over the stud.

The assembly can also include a tapered section. The lower portion of the extender can fit over the stud and join the upper portion side walls at the tapered section. The tapered section provides a transition in dimensions between the upper portion and the lower portion.

The extender can be formed with a push hole for pushing and sliding the extender within the stud.

The metal stud assembly can also include a second retainer formed on channel member, and the first retainer can have at least one slot formed therein that receives the second retainer.

According to another aspect of the invention, a metal wall frame system includes a series of metal studs as described above. The system also includes a metal channel member having a floor portion and a pair of side walls upstanding from the floor portion, a series of stops formed at predetermined intervals along the channel member, and a series of retainer members formed at predetermined intervals along the channel member. The series of metal studs is interconnected to the channel member. Each stud is butted against a respective one of the stops. Each said stud receives a respective one of the retainer members.

The metal wall frame system can also include a series of spacer bars. Each spacer bar is adapted to connect adjacent studs.

The stops can be formed as upstanding tabs struck from the channel member. In this case, the system can also include a series of longitudinally spaced crimp portions crimped inwardly from the side walls and locking the studs on the channel member. Each of the studs can include a socket and each spacer bar can include a series of projections respectively extending into each of the sockets.

The metal channel member described above can be a lower channel member, and the system can also include an upper channel member interconnected to the extender. In this case, the extender can include an elongated slot, and the upper channel member can include a retainer member that engages the elongated slot to interconnect the upper channel member to the extender.

The aforementioned features and advantages of the invention will, in part, be pointed out with particularity, and will, in part, become apparent from the following more detailed description of the invention, taken in conjunction with the accompanying drawings, which form an integral part thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a portion of a metal wall framing channel member constructed in accordance with the invention;

FIG. 1A is a partial central longitudinal sectional view taken through a first embodiment of a retainer member;

FIG. 1B is a view similar to FIG. 1A showing an alternative embodiment of a retainer member;

FIG. 2 is a perspective view of a bottom portion of a stud constructed in accordance with the invention;

FIG. 2A is a perspective view of the stud of FIG. 2 interconnected to the channel member of FIG. 1;

FIG. 3 is a top plan view of FIG. 2A;

FIG. 4 is a perspective view of an alternative embodiment of the stud of FIG. 2 connected to an alternative embodiment of the channel of FIG. 1;

FIG. 4A is a view similar to FIG. 4 showing another embodiment of the invention;

FIG. 4B is a top plan view of FIG. 4A;

FIG. 5 is a schematic perspective view of the stud and channel of FIG. 2A provided with a vertically sliding extender;

FIG. 5A is a perspective view of an alternative embodiment of the extender of FIG. 5;

FIG. 6 is a partial view of the extender of FIG. 5A interconnected to an alternative embodiment of an upper channel member;

FIG. 7 is a view similar to FIG. 6 showing another embodiment of an extender connected to an upper channel member similar to that shown in FIG. 4;

FIG. 8 is a partial perspective view of a wall frame constructed in accordance with the invention and showing the use of a pair of horizontally disposed space bars;

FIG. 8A is a top plan view of a portion of one of the spacer bars of FIG. 8;

FIG. 9 is a partial perspective view of another embodiment of a stud constructed in accordance with the invention and formed with a socket struck out from the central column of the stud;

FIG. 10 is a view similar to FIG. 9 showing another embodiment of socket construction and a stud having an indented portion formed along one or both side walls;

FIG. 11 is a schematic view similar to FIG. 9 showing a spacer bar interconnected to a stud constructed with an alternative embodiment of the socket of FIG. 9;

FIG. 12 is a partial schematic top plan view of a pair of spacer bars aligned with a channel member having sockets for receiving each spacer;

FIG. 13 is a partial perspective view of a spacer bar formed with an alternative embodiment of a socket;

FIG. 14 is a partial schematic top plan view of a spacer bar provided with an alternative tongue configuration for insertion within the socket of FIG. 13;

FIG. 15 is a partial perspective view of a series of studs spaced apart and mutually braced by an alternative embodiment of spacer bar and an alternative embodiment of sockets formed on the studs as shown in FIG. 10;

FIG. 16 is a perspective view of a portion of a metal wall framing channel member showing a rounded tab stop member constructed in accordance with the invention;

FIG. 17 is a perspective view of a portion of a metal wall framing channel member showing a rounded retainer member constructed in accordance with the invention;

FIG. 18 is a perspective view of a portion of a metal wall framing channel member showing flexible clips constructed in accordance with the invention;

FIG. 18A is a top plan view of FIG. 18;

FIG. 19 shows a tabbed retainer member in an upper channel member;

FIG. 20 shows an alternative embodiment of the extender of FIG. 5A;

FIG. 21 shows another alternative embodiment of the extender of FIG. 5A;

FIG. 22 shows another alternative embodiment of the extender of FIG. 5A;

FIG. 23 shows an alternative embodiment of the retaining member of FIG. 1B;

FIGS. 24-29 show details of an arrangement that can be used as an alternative to that shown in FIG. 8;

FIG. 30 is a perspective view of a portion of a metal wall framing channel member constructed in accordance with the invention as an alternative to that of FIG. 1; and

FIG. 31 provides side, front, and top views of the exemplary embodiment of FIG. 29.

In the various figures of the drawings, like reference characters designate like or similar parts.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described in conjunction with the drawings, beginning with FIG. 1, which shows a channel member 10 constructed in accordance with the invention. The channel member 10 is adapted to be installed in a known manner on a lower support surface such as a floor. An identical second or upper channel member 10 is typically installed in a known manner on an overhead support surface such as a ceiling. The upper and lower channel members are aligned parallel with one another and typically aligned within a common vertical plane.

The channel member 10 includes a flat, longitudinally-extending central floor 12 and a pair of upstanding parallel side walls 14 that are bent upwardly at right angles from each side of the floor 12. The channel member 10 is formed of a sheet metal material such as steel. A stud locator or stop member in the form of a tab 16 is struck or punched upwardly from the channel floor 12, leaving behind an open aperture 18 in the floor 12. As shown in FIG. 1, the tab is squared-off to provide a large surface area as a stop member for the stud. Alternatively, as shown in FIG. 16, the tab 16 can be rounded, so as to make it less likely that a worker will be cut by the tab or that clothing will be snagged during installation.

Preferably, the tab 16 is aligned vertically perpendicular to the floor 12 and laterally or transversely perpendicular to each side wall 14. In this manner, the tab 16 is square with both the floor and side walls of the channel member. A series of longitudinally-spaced tabs 16 is formed in the channel member 10, with each tab located at regular intervals. The tabs 16 can be located at predetermined longitudinal spacings of, for example, 16 and/or 24 inches.

One or more retaining members 20 are also struck out or punched up from the channel floor 12, leaving behind an open aperture 22 in the floor 12. As shown in FIG. 1, a pair of tapered, pointed retainer members is laterally spaced on each side of the tab 16. The retainer members can be ramped upwardly from the floor 12 as shown in FIG. 1A, or can be formed in an “L” shape as shown in FIG. 1B. As shown in FIG. 1, the retainer members are pointed to provide an easy insertion through slots in the stud. Alternatively, as shown in FIG. 17, the retainer members 20 can have rounded tips, so as to make it less likely that a worker will be cut by the retainer member or that clothing will be snagged during installation.

As shown in FIG. 1B, the base 24 of the retainer 20 is aligned perpendicularly upwardly from the floor 12 of the channel member 10 and is located at substantially the same longitudinal position on the floor 12 as is the tab 16. A leg 26 extends from the base 24 on the retainer 20 and is bent back over the floor 12 and is aligned substantially parallel with the floor 12. Alternatively, as shown in FIG. 23, the retaining members 20 can be formed directly above the aperture 22, for example by shearing and forming the retaining member in a direction straight up from the channel floor 12.

As also shown in FIG. 1, a cut, notched, perforated, or otherwise weakened crimp portion 28 is formed along one or both sidewalls 14. As shown, a pair of rectangular crimp portions 28 is formed along the top edge 29 of each side wall 14. Each crimp portion 28 is longitudinally spaced a predetermined distance away from each tab 16 to allow the crimp portions 28 to be squeezed or crimped inwardly toward each other in order to hold a stud in place within the channel member 10, as described more fully below. Alternatively, a flexible clip 104 can be used in place of the crimp portion 28, as shown in FIG. 18 and as described more completely below.

As shown in FIG. 2, a stud 30 is formed of a metal material, such as steel, in accordance with the invention. The stud 30 includes a central column portion 32 and a pair of parallel side walls 34 projecting perpendicularly from the column portion. An inturned lip 36 is formed on the outer end portion of each side wall 34. One or more alignment slots 38 are formed through the end portion 40 of the stud 30 for receiving and interconnecting with one or more of the retainer members 20 on the channel member 10.

As can be appreciated from a review of FIG. 2A, the stud 30 is fitted between the side walls 14 of the channel member 10 with the bottom edge of the stud making sliding contact against the channel floor 12 and with the side walls 34 of the stud making sliding contact against the side walls 14 of the channel member. As the stud 30 approaches the tab 16 on the channel member 10, the tips of the retainer members 20 enter the alignment slots 38 in the stud 30.

When the stud is fully and properly butted flat against the tab 16, it is also fully seated against the retainer members 20. In the example of the retainer member 20 of FIG. 3, the rear face of the column portion 32 abuts the tab 16 as well as the base 24 of each retainer member 20. Once this three-position contact has been achieved, the stud 30 is properly and fully aligned and seated within the channel member 10.

At this point, the crimp portions 28 are bent inwardly from the side walls 14 of channel member 10 to form locking members 44. An open notch 46 is thus formed in the top edge 29 of each side wall 14. The locking members 44 can be closely spaced from the lips 36 on the stud 30 or in contact with the lips 36.

Alternatively, flexible clips 104 can be used in place of the locking members 44 to hold the stud in place. As shown in FIG. 18, these clips 104 are substantially rectangular in shape, with one side of the clip defined by the upper edge of the sidewall 14. The lower side 106, parallel to the upper edge of the sidewall, and the transverse edge 108, closer to the stud 30, are both at least partially separated from the sidewall, and bend inward, hinged at the transverse edge 110 farther from the stud 30. The hinge functionality of the distal transverse edge 110 can be provided by the natural bend of the unbroken connection of that edge 110 to the channel sidewall 14. Alternatively, the distal edge 110 can be scored or perforated, or can be thinned along a line that is intended to function as a hinge, or can be modified in any known fashion to provide an easy bend to the clip 104.

The edge 108 of the clip 104 encroaching within the channel member 10 prevents movement of the stud 30 along the longitudinal direction of the channel in much the same manner as the locking members 44. FIG. 18A is a top plan view of a section of channel, clearly showing a bent clip 104, with a leading edge 108 jutting out within the channel member 10. The flexible clips 104 shown in FIG. 18 provide advantages over use of the locking members 44 in that more precise and uniform blocking means is provided, it is easier to bend the flexible clip than it is to crimp over the locking members, saving time and effort in assembling the stud system, and bending the flexible clips into position provides less opportunity for injury to a person assembling the stud system. It is intended that any description of the present invention including the locking members 44 or crimp portions 28 applies correspondingly to the alternative embodiment of FIG. 18, that is, an embodiment in which the flexible clips 104 replace the crimp portions 28 and locking members 44.

FIG. 29 shows an alternative placement of the clip 104. As shown, the clip 104a can be struck or otherwise formed from an intermediate portion of the sidewall, rather than at the upper edge of the sidewall as described above. Either arrangement of the clip 104, 104a can be used alone, or both can be used at the same area of the channel 12 if desired. FIG. 30 shows alternative views of the section of the channel member shown in FIG. 29.

The general spacing of the interconnected channel member 10 and the stud 30 is shown in FIG. 3 wherein the stud is held in position vertically by the retainer members 20, held laterally by contact with the side walls 14 and locked longitudinally by abutment in one direction with the tab 16 and in the other by abutment with the locking members 44 or the flexible clips 104.

A variation of this positioning, locating, aligning, and locking stud and channel framing system is shown in FIG. 4 wherein the retainer members 20 are struck out from the side walls 14 of the channel member 10 and extend inwardly over the floor 12 of the channel member. The stud 30 is modified to locate the elongated alignment slots 38 in a vertical orientation in order to receive and mate with the retainer members 20. The tab 16 is arranged as in the prior example, and crimp portions 28 or flexible clips 104 are formed in side walls 14 as in the prior example.

A further variation of the invention is shown in FIGS. 4A and 4B wherein the retainer members 20 enter the vertical slots 38 through the inside surface 50 of the channel member 10 rather than through the outside or back side 52 as shown in FIG. 4. In the example of FIG. 4, the back side 52 is slid into and against the retainer members 20 in the direction of the arrow 54. In the example of FIGS. 4A and 4B, the inside surface 50 is slid into and against the retainer members 20 in the direction of the arrow 56.

In the example of FIG. 4A, a cut-out portion 58 can be formed in each lip 36 for providing clearance for the passage of the retainer members 20 through the lips 36. Alternatively, as shown in FIG. 4B, the base 24 of the retainer members can be dimensioned to extend into the channel member to provide clearance of the leg 26 over the lip 36. The crimp portions 28 or flexible clips 104 are formed adjacent to the lips 36 in FIG. 4 and adjacent to the back surface 52 and to the slots 38 in FIGS. 4A and 4B.

In each of the prior examples, a pair of identical channel members 10 is aligned with one channel member directly above another. One channel member can be attached by fasteners to a floor and the other similarly attached to a ceiling. The tabs 16 on each channel member are vertically aligned one directly over the other and the channel members are carefully plumbed longitudinally parallel with one another as well.

The aligned channel members provide for the accurate vertically-plumbed alignment of the studs when the studs are pushed against a pair of aligned tabs 16, one tab being on the upper channel member and one on the lower channel member. In this case, the alignment slots 38 on each opposite end of the stud 30 are identical so that both ends of the studs are aligned by sliding the studs against a pair of stops or tabs 16 and interengaging the slots 38 with the retainer members 20 on each channel member 10. The crimp portions 28 or flexible clips 104 are then bent inwardly as described above.

A further embodiment of the invention is shown in FIG. 5, wherein the lower end of the stud 30 is the same as that shown in any of the prior examples and in this case, as shown in FIG. 2. The channel member 10 is shown as in FIG. 1 to match the slot pattern on the stud. What is different about the stud 30 in FIG. 5 is the addition of an extender member 60, which is telescopically held within and between the side walls 34 of the top portion 62 of the stud 30.

Rather than secure the upper or top portion 62 of the stud 30 directly to an overhead channel member 10, the extender 60 is adjusted vertically by sliding within the top portion 62 to engage the tabs 16 and the retainer members 20 on the channel member 10. The lower side walls 64 on the extender 60 have more compact dimensions than the upper portion 66, to form a snug sliding friction-fit against the side walls 34 of the top portion 62. The area between the lower side walls 64 and the upper portion 66 can be slightly tapered to provide a suitable transition in dimension. This prevents the extender from having a loose slack fit within the stud 30.

The upper portion 66 of the extender 60 can be transversely or laterally enlarged along the outwardly tapered portions 68 to prevent the extender 60 from sliding completely into the stud 30 by interfering with or abutting against the top edge 70 of the stud 30. As further seen in FIG. 5, the extender 60 is formed with a pair of upper alignment slots 72 and a pair of lower alignment slots 74.

Normally, the lower alignment slots 74 are engaged with the retainer members 20 on an upper channel member 10 attached to a ceiling. The retainer members 20 are thus spaced below the ceiling on which the upper channel member is fastened and spaced below the floor 12 of the upper channel member 10. With this arrangement, the top edge 78 of the extender 60 fits snugly against the floor 12 of the upper channel member. When the upper slots 72 are engaged with the retainer members 20, the top edge 78 of the extender 60 is spaced a small distance below the floor 12 of the upper channel member. This spacing accommodates settling of the ceiling and floors of the building structure and/or allows for additional loading which can compress and lower a ceiling.

When a stud 30 is attached directly to an upper channel member without an extender 60, it is suitable for use in load-bearing walls, providing the gauge of the metal stud meets the strength requirements for a load-bearing partition. However, when the extender 60 is used, it is loosely telescopically positioned within the stud and as such is not suitable for use in load-bearing walls.

As shown in FIG. 5A, the pairs of upper and lower alignment slots 72, 74 of FIG. 5 can each be replaced with a single elongated slot 72, 74. This single slot concept can also be used in place of the alignment slots 38 formed on the stud 30. In these cases, the retainer members 20 can be replaced with a single wider retainer that extends across substantially the entire width of each single elongated alignment slot. As shown in FIG. 19, a tab can be struck out of the upper channel member 10 and bent over, to be used as a retainer member 20. Alternatively, as shown in FIGS. 32 and 33, the tab can be struck up and out from the channel member 10.

The extender 60 of FIG. 5A is shown in FIG. 6 mounted to an upper channel member 10 having a large single retainer member struck out from the floor 12 of the channel member and inserted through the upper alignment slot 72 on the extender 60. The extender 60 is formed with a push hole 80 to allow an installer to push the extender 60 upwardly with a rod or the like engaged within the hole 80 while pushing the lower end of the stud 30 against a tab 16 as shown in FIG. 5 and inserting the retainer members 20 through the stud slots 38. This can be done without the use of a ladder, with an installer standing on the floor.

In an alternative embodiment, shown in FIG. 20, the extender 60 can fit over the stud 30 rather than into the stud. In this embodiment, the wall system may be able to bear heavier loads than the embodiment of FIG. 5A. Similar to the previous embodiment, the extender 60 is adjusted vertically by sliding over the top portion 62 to engage the retainer members 20 on the upper channel member 10. The upper portion 66 on the extender 60 has more compact dimensions than the lower side walls 64, to form a snug sliding friction-fit over the side walls 34 of the top portion 62. The section between the lower side walls 64 and the upper portion 66 can be slightly tapered to provide a suitable transition in dimension.

In another alternative embodiment, shown in FIG. 21, the extender 60 again fits into the stud 30. The extender 60 is adjusted vertically by sliding into the top portion 62 to engage the retainer members 20 on the upper channel member 10. The lower side walls 64 on the extender 60 can be slightly tapered, preferably in a regular transition over substantially the length of the lower side walls 64 to form a snug sliding friction-fit within the side walls 34 of the top portion 62. The tapering of the sidewalls 64 provides a small enough dimension at the bottom such that the extender 60 can be inserted within the stud 30. Preferably, the upper portion 66 is not tapered, and is substantially parallel to the side walls 34 of the top portion 62.

In another alternative embodiment, shown in FIG. 22, the extender 60 fits over the stud 30. In this embodiment, the wall system may be able to bear heavier loads than the embodiment of FIG. 5A. The extender 60 is adjusted vertically by sliding into the top portion 62 to engage the retainer members 20 on the upper channel member 10. The lower side walls 64 on the extender 60 can be slightly tapered, preferably in a regular transition over substantially the length of the lower side walls 64 to form a snug sliding friction-fit over the side walls 34 of the top portion 62. The tapering of the sidewalls 64 provides a large enough dimension at the bottom such that the extender 60 can fit over the stud 30. Preferably, the upper portion 66 is not tapered, and is substantially parallel to the side walls 34 of the top portion 62.

A variation of the horizontally- or transversely-elongated alignment slots 72, 74 of FIG. 5 is shown in FIG. 7 wherein the alignment slots 72, 74 are elongated vertically and the mating retainer members 20 are formed as in FIG. 4. Alternatively, push holes 80 can be formed in the side walls 64 of extender 60.

In each of the embodiments discussed above, the upper and lower portions of each stud 30 are secured in place between the upper and lower channels 10 and held in place by stops such as tabs 16 which are accurately positioned on, for example, 16-inch or 24-inch spacings. An alternative embodiment of this arrangement is to secure the bottom portion of each stud 30 as described in any of the examples above, but to allow the upper portion of each stud to slide longitudinally within the upper channel member without being locked in place.

This can be achieved by eliminating the tabs 16 from the upper channel member 10. One or more “L” shaped retainer members 20 as shown in FIG. 1B serve as the stop against which the stud is positioned. The base 24 of the retainer member 20 acts as a stop-like tab 16, and the leg 26 of the retainer member 20 acts as a longitudinally-extending guide over which the top portion of the stud 30 or the extender 60 freely slides.

In this embodiment, the upper channel member 10 need not be accurately aligned horizontally from wall to wall with the lower channel member 10. The lower channel member 10 is spaced and positioned where desired and the upper channel member 10 is simply approximately located above the lower channel member. Although the upper and lower channel members are aligned vertically in a common plane, they are not necessarily spaced and aligned accurately on 16-inch or 24-inch centers with one another. This allows for wall variations that may be wider on top than at the bottom or vice versa.

In this case, the lower ends of the studs 30 are secured within a channel member 10 as discussed in connection with the previous embodiments. The upper ends of the studs 30 (or the extenders 60) are simply slid onto the retainer members 20 and left to freely slide or “float” along the length of the retainer legs 26. Accurate spacing of the studs 30 can still be achieved, however, by the use of one or more central spacer or bracer bars 84 as shown in FIG. 8. It is important to note that the use of such spacer bars is advantageous when constructing load-bearing walls, or in commercial applications. However, for residential, non-load-bearing applications, these spacer bars are not necessary, although they can be optionally provided.

In FIG. 8, the upper ends of the studs 30 are provided with extenders 60 that are free to slide longitudinally or “float” along the retainer members 20 as noted above. The lower end of each stud 30 is positioned and locked in place as in FIG. 2A. After two or three of the studs 30 are so arranged and placed in the upper and lower channel members 10, one or more spacer bars 84 are connected to the central or middle portion 86 of each stud 30.

As shown in FIGS. 8 and 8A, each spacer bar 84 has a series of accurately-spaced tongue members 88 struck out of the sheet metal spacer material, leaving behind an opening 90. The tongue members are spaced apart, for example, on 16-inch and/or 24-inch centers, and are dimensioned to fit or snap within receiving members or sockets formed on the studs 30.

FIGS. 24-29 show details of arrangements that can be used as alternatives to the arrangement shown in FIG. 8. As shown, connections of the spacer bar 84 to the studs 30 and of the studs 30 to the upper and lower channel members 10 are made differently. For example, tabs struck out and over from the horizontal spacer bar at measured intervals can be inserted into vertical slots in the studs. Likewise, tabs struck down and back from the upper channel can be inserted into horizontal slots at the tops of the studs. It will be apparent to those of skill in the art that other alternative connections and coupling arrangements can be utilized without departing from the spirit and scope of the invention as described and claimed herein, and the exemplary embodiments shown in FIGS. 24-29 are non-limiting examples. Further, some exemplary dimensions are shown in these drawings, which are included to provide an exemplary idea of scale and are not intended to be limitations on the useful dimensions contemplated for these or other disclosed or undisclosed embodiments.

One example of such receiving members is shown in FIG. 9 wherein a vertically, elongated receiving slot 92 is punched through the side wall 34 of the stud 30 directly and immediately adjacent to the inner surface 50 of the channel member 10. Arched-shaped bands or loops 94 are punched through the central column portion 32 of the stud 30 from the outer surface or back side 52 toward the inner surface 50 to form a socket 96 that receives the free end 98 of the tongue members 88.

The socket 96 is dimensioned to receive each tongue member 88 with a tight locking fit or a snap fit. While the tongue members in FIGS. 8 and 8A are shown having a rectangular shape, they can also be formed having a triangular shape similar to the retainer members 20 shown in FIG. 1. Although only one spacer bar 84 is required, two can be used, as shown in FIG. 8, attached to opposite side walls 34 of each stud 30.

A further variation of the spacer bar assembly is shown in FIG. 10, wherein a rectangular indented or recessed portion 100 is formed in the side wall 34 of the stud 30 adjacent to a pair of sockets 96. The recessed portion 100 receives the flat spacer bar 84 with a flush fit so that the spacer bar does not extend outwardly from the plane of the side wall 34, or extends only slightly outwardly. In either case, the spacer bar 84 will not interfere with the placement of drywall.

A variation of the socket 96 of FIG. 9 is shown in FIG. 11, wherein one or more loops or bands 94 are struck out from the central column portion 32 from the inner face 50 of the stud 30 toward its outer face 52. In this manner, the bands 94 project from the outer face 52 and therefore the receiving slot 92 of FIG. 9 is not required.

In FIG. 12, a pair of spacers 84 is shown aligned for insertion within two pairs of sockets 96 formed on the outer side or backside 52 of the column portion 32. In FIGS. 13 and 14 the spacer bar 84 is formed with an L-shaped tongue member 88 and the stud 30 is formed with a single elongated slot 102 for receiving the tongue member 88.

As shown in FIG. 15, two triangular tongue members 88 are struck out perpendicularly from the spacer bar 84 to enter a pair of receiving slots formed in the sidewalls 34 in the same manner as the receiving slots 92 shown in FIG. 9.

There has been disclosed heretofore the best embodiment of the invention presently contemplated. However, it is to be understood that the various changes and modifications may be made thereto without departing from the spirit and scope of the invention as set forth in the appended claims.

Claims

1. A metal stud assembly, comprising:

a stud adapted to be used in a metal wall frame between a pair of channel members; and

an extender longitudinally adapted to be slidably mounted within said stud;

wherein the stud includes a longitudinally-extending central column portion having a pair of opposite end portions, a pair of side walls formed on opposite sides of said central column portion, a first retainer, and at least one elongated alignment slot formed in said stud that is adapted to receive the first retainer formed on one of said channel members, wherein said alignment slot is formed in at least one of said end portions of said central column portion; and

wherein the extender includes an upper portion having side walls that are substantially parallel to the side walls of the stud, and a lower portion having side walls that join the upper portion side walls at a top end and which taper to smaller dimensions at a bottom end, such that the bottom end fits within the stud.

2. The metal stud assembly of claim 1, wherein the stud further includes an indented portion formed in at least one of said side walls that is adapted to receive a spacer bar.

3. The metal stud assembly of claim 2, wherein the stud is a plurality of studs, and further comprising at least one spacer bar that is adapted to interconnect adjacent ones of said studs, and is adapted to couple to respective said indented portions formed in said studs.

4. The metal stud assembly of claim 1, wherein the lower portion side walls of the extender taper linearly inward.

5. The metal stud assembly of claim 4, wherein said extender is formed with a push hole that is adapted to push and slide said extender within said stud.

6. The metal stud assembly of claim 4, wherein the retainer is a first retainer, the metal stud assembly further comprising

a second retainer formed on said channel member,

wherein said first retainer has at least one slot formed therein that is adapted to receive the second retainer.

7. A metal wall frame system, comprising:

a series of metal studs according to the metal stud assembly of claim 1;

a metal channel member having a floor portion and a pair of side walls upstanding from said floor portion, wherein the series of metal studs is adapted to interconnect to said channel member;

a series of stops formed at predetermined intervals along said channel member, wherein each said stud is adapted to be butted against a respective one of said stops; and

a series of retainer members formed at predetermined intervals along said channel member, wherein each said stud is adapted to receive a respective one of said retainer members.

8. The metal wall frame system of claim 7, further comprising a series of spacer bars, wherein each said spacer bar is adapted to interconnect adjacent ones of said studs.

9. The metal wall frame system of claim 7, wherein said stops are formed as upstanding tabs struck from said channel member.

10. The metal wall frame system of claim 9, further comprising a series of longitudinally spaced crimp portions crimped inwardly from said side walls and adapted to lock said studs on said channel member.

11. The metal wall frame system of claim 9, wherein each of said studs comprises a socket and wherein each said spacer bar comprises a series of projections adapted to respectively extend into each of said sockets.

12. The metal wall frame system of claim 7, wherein the metal channel member is a lower channel member, and further comprising an upper channel member adapted to interconnect to the extender.

13. The metal wall frame system of claim 12, wherein

the extender includes an elongated slot, and

the upper channel member includes a retainer member that is adapted to engage the elongated slot to interconnect the upper channel member to the extender.

14. A metal stud assembly, comprising:

a stud adapted for constructing a metal wall frame between a pair of channel members; and

an extender adapted to be longitudinally slidably mounted over said stud;

wherein the stud includes a longitudinally-extending central column portion having a pair of opposite end portions, a pair of side walls formed on opposite sides of said central column portion, a first retainer, at least one elongated alignment slot formed in said stud that is adapted to receive the first retainer formed on one of said channel members, and an indented portion formed in at least one of said side walls that is adapted to receive a spacer bar, wherein said alignment slot is formed in at least one of said end portions of said central column portion; and

wherein the extender includes an upper portion having side walls that are substantially parallel to the side walls of the stud, and a lower portion having side walls that are adapted to fit over the stud.

15. The metal stud assembly of claim 14, wherein the lower portion side walls of the extender taper linearly inward.

16. The metal stud assembly of claim 15, wherein said extender is formed with a push hole that is adapted to push and slide said extender within said stud.

17. The metal stud assembly of claim 15, wherein the retainer is a first retainer, the metal stud assembly further comprising

a second retainer formed on said channel member,

wherein said first retainer has at least one slot formed therein that is adapted to receive the second retainer.

18. A metal wall frame system, comprising:

a series of metal studs according to the metal stud assembly of claim 14;

a metal channel member having a floor portion and a pair of side walls upstanding from said floor portion, wherein the series of metal studs is adapted to be interconnected to said channel member;

a series of stops formed at predetermined intervals along said channel member, wherein each said stud is adapted to be butted against a respective one of said stops; and

a series of retainer members formed at predetermined intervals along said channel member, wherein each said stud is adapted to receive a respective one of said retainer members.

19. The metal wall frame system of claim 18, further comprising a series of spacer bars, wherein each said spacer bar is adapted to interconnect adjacent ones of said studs.

20. The metal wall frame system of claim 18, wherein said stops are formed as upstanding tabs struck from said channel member.

21. The metal wall frame system of claim 20, further comprising a series of longitudinally spaced crimp portions crimped inwardly from said side walls and adapted to lock said studs on said channel member.

22. The metal wall frame system of claim 20, wherein each of said studs comprises a socket and wherein each said spacer bar comprises a series of projections adapted to respectively extend into each of said sockets.

23. The metal wall frame system of claim 18, wherein the metal channel member is a lower channel member, and further comprising an upper channel member adapted to be interconnected to the extender.

24. The metal wall frame system of claim 23, wherein

the extender includes an elongated slot, and

the upper channel member includes a retainer member that is adapted to engage the elongated slot to interconnect the upper channel member to the extender.

25. The metal stud assembly of claim 14, wherein the lower portion of the extender is adapted to join the upper portion side walls at a top end and tapers to larger dimensions at a bottom end, such that the bottom end is adapted to fit over the stud.

26. The metal stud assembly of claim 14, further comprising a tapered section, wherein the lower portion of the extender is adapted to fit over the stud and join the upper portion side walls at the tapered section, wherein the tapered section provides a transition in dimensions between the upper portion and the lower portion.