WALL FASTENER
A wall fastener that attaches a wallboard member to a mounting track in a manner that allows for relative movement between an overhead roof structure to which the mounting track is secured and a non-load bearing wall. The wall fastener holds the wallboard in a fixed position relative to the wall and the overhead structure to maintain a fire barrier.
The present application is a divisional of U.S. Utility patent application Ser. No. 10/750,998 entitled WALL FASTENER filed on Dec. 30, 2003.
BACKGROUND OF THE INVENTION1. Field of the Invention
The present invention is directed generally to the field of building construction and, more particularly, to connections between a non-load bearing stud wall and a mounting track that is secured to an overhead structure.
2. Related Art
A typical wall to overhead structure connection is an inverted U-shaped longitudinal mounting track or slip track that receives studs between the legs of the U-shaped track. A wall cladding member is attached to at least one side of the studs. One of the legs of the mounting track is received between the studs and the wall cladding material. A top surface of the studs and wall cladding member are spaced from the overhead structure in order to allow for settling or other movement of the overhead structure (sometimes referred to as the roof or floor deck) with respect to the wall.
Various structures and materials may be used to seal the space between the top surface of the studs and wall cladding member and the overhead structure for purposes of providing an appropriate fire rating. Known sealing structures and materials have several drawbacks. For example, the use of a sealant and filling material is typically useful for very small gaps in applications where small amounts of movement between the overhead structure and the wall are possible. A sealant and filling material is susceptible to deterioration and fatigue over repeated cycles of movement, which may result in loss of the necessary fire rating. Known sealing structures, such as the slip track assembly disclosed in U.S. Pat. Nos. 5,471,805 and 5,755,066, are complex systems that require large amounts of material at a relatively high cost. Thus, a simple, cost effecting sealing structure that provides an appropriate fire rating and provides a positive attachment between the studs and the mounting or slip track would be an important advance in the art.
SUMMARY OF THE INVENTIONThe present invention is directed to a wall fastener for use between a stud and a mounting or slip track. The wall fastener supports first and second wall cladding members and orients the wall cladding members relative to each other to provide a continuous wall cladding structure between the stud wall and the overhead structure to which the mounting track is secured. The wall fastener includes a first portion having first and second opposed primary surfaces and first and second sides. The first portion is secured to the mounting track with the first primary surface facing the mounting track and the second primary surface facing the first wall cladding member. The wall fastener also includes a second portion having a third primary surface that extends parallel to the first primary surface and is offset from the second primary surface a predetermined distance. The second portion is secured to the second wall cladding member with the third primary surface facing the second wall cladding member thereby positioning the second wall cladding member adjacent to the first wall cladding member. The wall fastener further includes a first fastening structure secured to the first side of the first portion. The first fastening structure slidingly engages the stud thereby retaining the wall fastener to the stud while providing for a sliding movement of the wall fastener relative to the stud.
Another aspect of the present invention is directed to a method of retaining a stud to a mounting track with a fastener such that the mounting track is vertically movable relative to the stud wall. The fastener includes a first portion having a first primary surface and first and second sides, and a fastening structure extending from the first side of the first portion. The method includes securing the first portion to the mounting track with the first primary surface facing the mounting track, and slidingly securing the fastening structure to the stud wall thereby retaining the stud wall to the mounting track so as to prevent lateral movement of the fastener relative to the stud wall while permitting vertical movement of the fastener relative to the stud wall.
A yet further aspect of the present invention is directed to a method of forming a wall fastener from a single piece of material. The wall fastener retains a stud wall to a mounting track and to support a secondary wall cladding member in engagement with a primary wall cladding member of the stud wall. The method includes forming a first portion that includes first and second opposed primary surfaces and first and second sides. The first portion is secured to the mounting track with the first primary surface facing the mounting track and the second primary surface facing the primary wall cladding member. The method further includes forming a second portion that includes a third primary surface that extends parallel to the first primary surface and is secured to the secondary wall cladding member, and positioning the secondary wall cladding member adjacent to the primary wall cladding member, forming a third portion that extends between the first and second portions, and forming a first fastener structure along the first side of the first portion. The first fastener structure is configured to engage a stud of the stud wall to retain the wall fastener to the stud wall while permitting vertical movement of the wall fastener relative to the wall.
Another aspect of the present invention relates to a wall fastener that is secured to a mounting track to support a secondary wall cladding member adjacent to a primary wall cladding member. The wall fastener includes a first portion having first and second opposed primary surfaces, the first primary surface defining a first portion plane, and the first portion being secured to the mounting track with the first primary surface facing the mounting track and the second primary surface facing the primary wall cladding member. A second portion of the wall fastener is spaced apart from the first portion a predetermined distance and includes third and fourth surfaces that extend parallel to the first surface. The second portion is secured to the secondary wall cladding member with the third primary surface facing the secondary wall cladding member and the fourth primary surface facing the first portion plane. A third portion of the wall fastener extends between the first and second portions to couple the first and second portions together, and a fourth portion of the wall fastener extends from the second portion in a direction toward the first portion plane and contacts the mounting track.
The present invention is also directed to a wall fastener configured to retain a stud wall to a mounting track, wherein the stud wall includes a plurality of studs and a primary wall cladding member secured to the plurality of studs. The wall fastener includes a first portion having first and second primary surfaces and first and second sides. The first portion is secured to the mounting track and is positioned between one of the plurality of studs and the primary wall cladding member with the first primary surface facing the mounting track and the one stud, and the second primary surface facing the primary wall cladding member. The wall fastener also includes a first fastening structure that extends from the first side of the first portion and retains the fastener to the one stud while providing sliding movement of the fastener relative to the one stud to provide vertical movement of the mounting track relative to the stud wall.
The present invention is also directed to a wall fastener configured to retain a stud wall to a mounting track, wherein the stud wall includes a plurality of studs and a primary wall cladding member secured to the plurality of studs. The wall fastener includes a first portion having first and second primary surfaces and first and second sides. The first portion is secured to the first side wall of mounting track with the first primary surface facing the outside surface of the first side wall and the second primary surface facing the first wall cladding member. The first portion also includes a first track retaining member that engages the inside surface of the first side wall.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein similar reference numerals designate similar or corresponding parts throughout the several views, and more particularly to
Slip track 50 is shown in
Stud 20 is shown in
The wall fastener 60, shown in
The second portion 64 of the wall fastener 60 is parallel but offset from the first portion 62 by a distance “D.” The second portion 64 defines third and fourth primary surfaces 72 and 74. The third portion 66 is horizontal and connects the top edge 75 of the first portion 62 to the bottom edge 73 of the second portion 64. The fourth portion 68 is horizontal and connects the top edge 71 of the second portion 64 with the top edge 69 of the contact member 70. The contact member 70 is in the same vertical plane as the first portion 60. The contact member 70 contacts the outside surface 55 of side wall 54 of the slip track 50 and provides extra support for the wall fastener 60 when the secondary wallboard member 40 is being secured to the third primary surface 72 of the wall fastener 60.
Primary wallboard member 32 is fastened to stud 20 with screws 94 or other conventional fastening means. Primary wall cladding member 32 is preferably gypsum board in large part due to its fire resistance properties. In that regard, it is understood that primary wall cladding member 32 may include multiple layers of wall material, for example, to create the required fire rating. The thickness of the primary wall cladding member 32 defines the distance “D” of the wall fastener 60. As stated above, stud 20 is spaced vertically lower than roof structure 10 a distance “S.” Likewise, primary wall cladding member 32 is spaced a distance “S1” from the overhead structure 10. Distance “S1” is typically several inches, but could be more or less depending on the application.
As mentioned above, the secondary wall cladding member 40 is attached to the third primary surface 72 of the fastener 60 with screws 92 or other conventional fastening means. Secondary wall cladding member 40 extends down from a top edge 42 that is adjacent to overhead structure 10 and overlaps in a sliding relationship with primary wall cladding member 32. Secondary wall cladding member has a vertical dimension “S2” which is greater than “S1” to provide overlap and ensure maintenance of the overlap for all expected relative movement between overhead structure 10 and the stud wall 30. The secondary wall cladding member 40 covers the space between the top end of primary wall cladding members 32 and the overhead structure 10. The secondary wall cladding member is preferably made of material similar to the material of the primary wall cladding member 32 and preferably has a similar thickness as primary wall cladding member 32 so as to provide a consistent fire rating.
A second example slip track assembly 100 is shown in
The wall fastener 160 as shown in
The present invention, as described, achieves a fire barrier connection that provides for vertical movement between the overhead structure and the stud wall. The slip track assembly generally functions in a telescoping fashion to provide for an appropriate fire rating even when relative movement occurs. The slip tracks of the present invention can also be used horizontally or in other orientations between two surfaces that may move relative to one another to provide a fire barrier.
The wall fasteners 60, 260, 360, 460, 560, and 1060 include fasteners 80, 82, 84 on both side edges that allow the respective wall fasteners to be slideably secured to the stud 20 on either side of the stud wall 30 (for example, see the arrangement of
Another aspect of the present invention is directed to a method of retaining a stud wall 20 to a mounting track 50 with a fastener such that the mounting track is vertically movable relative to the stud wall. The fastener of this method could be any of fasteners 60, 160, 260, 360, 460, 560, 660, 760, 860, 960, or 1060. The method includes securing a first portion of the fastener to the mounting track with a first primary surface facing the mounting track, and securing the fastening structure to the stud wall with a sliding attachment thereby retaining the stud wall to the mounting track so as to prevent lateral movement of the fastener relative to the stud wall while permitting vertical movement of the fastener relative to the stud wall.
A yet further aspect of the present invention is directed to a method of forming a wall fastener from a single piece of material. The fastener of this method could be any of fasteners 60, 160, 260, 360, 460, 560, 660, 760, 860, 960, or 1060. The method includes forming a first portion that includes a first opposed primary surface and a second opposed primary surface, and first side edge and second side edge. The first portion is secured to the mounting track with the first primary surface facing the mounting track and the second primary surface facing the first wallboard member. The method further includes forming a second portion that includes a third primary surface that extends parallel to the first primary surface and is secured to a second wallboard member, and positioning the second wallboard member adjacent to the first wallboard member, forming a third portion that extends between the first and second portions, and forming a first fastener structure along the first side edge of the first portion. The first fastener structure is configured to engage a stud to retain the wall fastener to the stud while permitting vertical movement of the wall fastener relative to the stud wall.
Numerous characteristics and advantages of the invention have been set forth, together with details of structure and function. It is to be understood, however, that the disclosure is illustrative only. Therefore, any changes made, especially in matters of shape, size, and arrangement, to the fullest extent by the general meaning of the terms in which the appended claims are expressed, are within the principle of the invention.
Claims
1. A wall fastener for use between a stud wall and a slip track, configured to support a first primary wallboard member and secondary wallboard member relative to each other to provide a continuous wall cladding material structure between the stud wall and the slip track, the slip track having side walls, the wall fastener comprising:
- a first portion having first and second opposed primary surfaces, the first portion secured to an outside surface of a sidewall of the slip track with the first primary surface facing the outside surface and the second primary surface facing the primary wallboard member;
- a second portion having a third primary surface that extends parallel to the plane of the first portion and is offset from the second primary surface a predetermined distance, the secondary wallboard member secured to the second portion with the third primary surface facing the secondary wallboard member, whereby the secondary wallboard member is in engagement with the primary wallboard member;
- a third portion extending between the top edge of the first portion and the bottom edge of the second portion to secure the first and second portions together;
- a fourth portion extending from the top edge of the second portion in a direction toward the plane of the first portion and in contact the with slip track; and
- a contact member extending from the fourth portion in a direction parallel to the first portion plane and in contact with the slip track.
2. The wall fastener of claim 1, wherein the primary wallboard member is secured to the stud wall and not secured to the wall fastener and the secondary wallboard member is secured only to the second portion.
3. The wall fastener of claim 2, wherein the primary wallboard member is secured to a plurality of studs and the first portion is movably positioned between the primary wallboard member and one of the studs.
4. The wall fastener of claim 1, wherein the secondary wallboard member is secured to the second portion, overlaps the primary wallboard member, and is movable relative to the primary wallboard member.
5. The wall fastener of claim 1, wherein the first portion includes an aperture formed therein, the aperture being sized to receive a fastener for securing the first portion to the slip track.
6. The wall fastener of claim 1, wherein the wall fastener comprises a single unitary piece of material.
7. The wall fastener of claim 1, wherein the predetermined distance is defined by a thickness of the primary wallboard member.
8. A method of forming a wall fastener, the wall fastener configured to retain a stud wall to a slip track and to support a secondary wallboard member in engagement with a primary wallboard member of the stud wall, the method comprising the steps of:
- forming a first portion having first and second opposed primary surfaces, the first portion secured to an outside surface of a side wall of the slip track with the first primary surface facing the outside surface and the second primary surface facing a primary wallboard member;
- forming a second portion having a third primary surface that extends parallel to the plane of the first portion and is offset from the second primary surface of the first portion a predetermined distance;
- securing the secondary wallboard member to the second portion with the third primary surface of the second portion facing the secondary wallboard member;
- positioning the secondary wallboard member in engagement with the primary wallboard member;
- forming a third portion that extends from the top edge of the first portion to the bottom edge of the second portion to secure the first and second portions together.
- forming a fourth portion extending from the top edge of the second portion in a direction toward the plane of the first portion and in contact the with slip track; and
- forming a contact member extending from the fourth portion in a direction parallel to the plane of the first portion and in contact with the slip track.
9. The method of claim 8, comprising the steps of securing the primary wallboard member to the stud wall and not to the wall fastener and securing the secondary wallboard member only to the third primary surface of the second portion.
10. The method of claim 9, comprising the steps of securing the primary wallboard member to a plurality of studs and positioning the first portion between the primary wallboard member and one of the studs so that the first portion can move therebetween.
11. The method of claim 8, comprising the steps of securing the secondary wallboard member to the third primary surface of the second portion, so that it overlaps with the primary wallboard member and is movable relative to the primary wallboard member.
12. The method of claim 8, comprising the step of forming an aperture in the first portion, the aperture sized to receive a fastener for securing the first portion to the slip track.
13. The method of claim 8, wherein the step of forming the third portion includes bending the third portion into an orientation substantially perpendicular to the top edge of the first portion and the bottom edge of the second portion.
Type: Application
Filed: Oct 19, 2007
Publication Date: Mar 27, 2008
Inventors: Brian Becker (St. Cloud, MN), Derek Becker (Watkins, MN), Robin Dockery (Kimball, MN)
Application Number: 11/875,762
International Classification: E04B 2/90 (20060101);