FRAME ASSEMBLY FOR SUPPORTING A WALL PANEL

Abstract

A frame assembly for supporting a wall panel includes a stud configured to engage and support the wall panel, the stud having an end portion. The frame assembly also includes a track member having a generally U-shaped cross-section defined by a base and two sidewalls. The track member defines a longitudinal axis. The frame assembly further includes an engagement member coupled to the base of the track member and extending parallel to the longitudinal axis. The engagement member defines a slot that receives the end portion of the stud to support the stud.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional Patent Application No. 61/430,866, filed Jan. 7, 2011, the contents of which are herein incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to frame assemblies for supporting wall panels.

SUMMARY

In one embodiment, the invention provides a frame assembly for supporting a wall panel. The frame assembly includes a stud configured to engage and support the wall panel. The stud includes an end portion. A track member has a generally U-shaped cross-section defined by a base and two sidewalls. The track member defines a longitudinal axis. An engagement member is coupled to the base of the track member and extends parallel to the longitudinal axis. The engagement member defines a slot that receives the end portion of the stud to support the stud.

In another embodiment, the invention provides a frame assembly for supporting a wall panel. The frame assembly includes a plurality of studs. Each stud has a grooved surface and a first end portion and a second end portion opposite the first end portion. The plurality of studs are configured to engage and support the wall panel along the grooved surface. A first track member has a generally U-shaped cross-section defined by a base and two sidewalls. The first track member defines a first longitudinal axis. A first engagement member is coupled to the base of the first track member and extends parallel to the first longitudinal axis. The first engagement member defines a first plurality of slots spaced apart along the first longitudinal axis. The first plurality of slots receives the first end portions of the plurality of studs. A second track member has a generally U-shaped cross-section defined by a base and two sidewalls. The second track member defines a second longitudinal axis. A second engagement member is coupled to the base of the second track member and extends parallel to the second longitudinal axis. The second engagement member defines a second plurality of slots spaced apart along the second longitudinal axis. The second plurality of slots receives the second end portions of the plurality of studs to support the plurality of studs between the first track member and the second track member.

Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a frame assembly embodying the invention.

FIG. 2 is an exploded perspective view of the frame assembly shown in FIG. 1.

FIG. 3 is a plan view of a stud for use with the frame assembly shown in FIG. 1.

FIG. 4 is an enlarged end view of the stud shown in FIG. 3.

FIG. 5 is a plan view of a track member for use with the frame assembly shown in FIG. 1.

FIG. 6 is an enlarged view of a portion of the track member shown in FIG. 5.

FIG. 7 is an enlarged end view of the track member shown in FIG. 5.

FIG. 8 is a perspective view of a portion of another track member for use with a frame assembly.

FIG. 9 illustrates another frame assembly embodying the invention.

FIG. 10 is an enlarged view of a portion of the frame assembly shown in FIG. 9.

FIG. 11 is an enlarged view of another portion of the frame assembly shown in FIG. 9.

FIG. 12 is a perspective view of a portion of a stud for use with the frame assembly shown in FIG. 9.

FIG. 13 is an enlarged end view of a stud according to another embodiment of the invention.

FIG. 14 is a perspective view of a portion of the stud of FIG. 13.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

FIGS. 1-2 illustrate a frame assembly 20 embodying the invention. In the illustrated construction, the frame assembly 20 is configured to support one or more wall panels, such as, for example, drywall sheets, wood panels, glass panels, sheetrock, or other vertical wall panels. In other constructions, the frame assembly 20 may be configured to support other types of panels or may be configured to support other vertical or non-vertical members.

The illustrated frame assembly 20 includes a plurality of studs 24 and a track member 28. As shown in FIGS. 1-4, each stud 24 is an elongated member having a C-shaped cross-section defined by a web 32 and two sidewalls 36, 40. The sidewalls 36, 40 extend generally perpendicularly from the web 32 to define a channel 44 therebetween. Edge portions 48, 52 of the sidewalls 36, 40 are bent or rolled over to provide smooth edges and increase the stiffness of the sidewalls 36, 40. In the illustrated construction, the studs 24 may be composed of, for example, polyvinylchloride (PVC) or other plastic materials. In other constructions, the studs 24 may be composed of rolled steel or other metallic materials. In still other constructions, the studs 24 may be composed of wood. The studs 24 are configured to engage and support the wall panels. For example, a wall panel may extend over two or more successive studs 24 and be secured thereto. In some constructions, the wall panels may be nailed, screwed, adhesively bonded or otherwise secured to the sidewalls 36, 40 of the studs 24.

As shown in FIGS. 1-2 and 5-7, the track member 28 is an elongated member having a generally U-shaped cross-section defined by a base 56 and two sidewalls 60, 64. The sidewalls 60, 64 extend generally perpendicularly from the base 56 to define a channel 68 therebetween. The track member 28 defines a longitudinal axis 72 extending the length of the member 28. In the illustrated construction, the track member 28 is composed of PVC and may be extruded in a direction parallel to the longitudinal axis 72. In other constructions, the track member 28 may be composed of other suitable rolled or extruded materials such as, for example, steel or extrudable plastics. The track member 28 may be coupled (e.g., nailed, screwed, glued, or otherwise fixedly secured) to, for example, a floor or baseboard to support the studs 24 in a generally vertical manner.

The track member 28 also includes a pair of engagement members 76, 80. The illustrated engagement members 76, 80 includes projections or protrusions that are coupled to the base 56 of the track member 28 and extend into the channel 68 defined by the sidewalls 60, 64. In the illustrated construction, the engagement members 76, 80 are integrally formed as a single piece with the base 56 of the track member 28 such that the engagement members 76, 80 may be extruded as a single piece with the track member 28 in a direction parallel to the longitudinal axis 72. In other constructions, the engagement members 76, 80 and the track member 28 may be roll formed in the direction parallel to the longitudinal axis 72. Alternatively, the engagement members 76, 80 and the track member 28 may be machined or formed in a direction perpendicular to the longitudinal axis. In still other constructions, the engagement members 76, 80 may be integrally formed with the track member 28 using other suitable molding, machining, stamping, or forming techniques. In further constructions, the engagement members 76, 80 may be separate elements that are removably or permanently coupled to the track member 28.

The illustrated track member 28 includes two engagement members 76, 80 that are spaced apart from one another, spaced apart from the sidewalls 60, 64, and extend along the base 56 parallel to the longitudinal axis 72. In other constructions, the track member 28 may include a single engagement member that extends parallel to the longitudinal axis 72. In still other constructions, the track member 28 may include three or more engagement members that are spaced apart from one another and extend parallel to the longitudinal axis 72. In the illustrated construction, the engagement members 76, 80 extend along the entire length of the base 56 of the track member 28. In other constructions, such as the construction illustrated in FIG. 8, the engagement members 76, 80 may extend along only a portion of the base 56 of the track member 28.

As shown in FIGS. 5-7, each engagement member 76, 80 defines a plurality of slots 84, 88 that receive end portions 92 (FIGS. 1-2) of the studs 24 to support the studs 24. In the illustrated construction, the slots 84, 88 extend transversely, and more particularly perpendicularly, to the longitudinal axis 72 of the track member 28. Each slot 84, 88 of one engagement member 76, 80 is generally aligned with a corresponding slot 84, 88 of the other engagement member 76, 80. That is, an axis or straight line extending transversely to the longitudinal axis 72 extends parallel to and through one of the slots 84 of the first engagement member 76 and one of the slots 88 of the second engagement member 80. As such, each stud 24 is received in and engaged by both engagement members 76, 80 to support the stud 24 in the generally vertical manner.

In the illustrated construction, the slots 84, 88 are evenly spaced apart along the longitudinal axis 72 to support the studs 24 at predetermined distances from one another. For example, in one construction, the slots 84, 88 of each engagement member 76, 80 may be formed every 16″ or 24″ such that the studs 24 are spaced 16″ or 24″ apart when coupled to the track member 28. In other constructions, the slots 84, 88 may be formed relatively closer together (e.g., every 8″ or 4″) such that a user may adjust the spacing between adjacent studs 24 without having to use every slot.

Referring to FIGS. 1-2, the end portion 92 (e.g., bottom) of each stud 24 is received in a pair of corresponding slots 84, 88 of the engagement members 76, 80 such that the studs 24 extend generally perpendicularly from the base 56 of the track member 28. Although not shown, it should be readily understood that the frame assembly 20 can also include a second track member including similar engagement members. Slots in the engagement members of the second track member receive an opposite end portion (e.g., top) of each stud 24 to capture and support the studs 24 between the track members (i.e., between an upper track member and a lower track member). When the end portions 92 of the studs 24 are received in the slots 84, 88, the sidewalls 60, 64 of the track member 28 engage the sidewalls 36, 40 of the studs 24 to inhibit lateral movement of the studs 24 relative to the track member 28. Similarly, the engagement members 76, 80 engage the webs 32 of the studs 24 to inhibit longitudinal movement of the studs 24 relative to the track member 28. The studs 24 are thereby vertically supported by the track member 28 without using additional fasteners or securing elements, such as screws, nails, brackets, or clips.

FIG. 8 illustrates an alternative construction of a track member 96 for use with the frame assembly 20 shown in FIG. 1. Similar to the track member 28 shown in FIGS. 5-7, the illustrated track member 96 is an elongated member having a generally U-shaped cross-section defined by a base 100 and two sidewalls 104, 108. The sidewalls 104, 108 extend generally perpendicularly from the base 100 to define a channel 112 therebetween. The track member 96 defines a longitudinal axis 116 extending the length of the member 96.

The track member 96 also includes engagement members 120, 124 that are coupled to the base 100 and extend into the channel 112. The illustrated engagement members 120, 124 are integrally formed as a single piece with the track member 96, but only extend along a portion of the base 100. In other constructions, the engagement members 120, 124 may be separate elements that are removably or permanently coupled to the track member 96. Similar to the engagement members 76, 80 discussed above, each of the illustrated engagement members 120, 124 defines a slot 128, 132 configured to receive a stud (e.g., one of the studs 24 shown in FIGS. 1-2). However, since the engagement members 120, 124 only extend along a portion of the base 100, the track member 96 includes multiple sets or pairs of engagement members 120, 124 at evenly spaced intervals (e.g., every 4″, 8″, 16″, 24″, etc.) to support multiple studs.

FIGS. 9-11 illustrate another frame assembly 136 embodying the invention. Similar to the frame assembly 20 shown in FIGS. 1-2, the illustrated frame assembly 136 includes a plurality of studs 140, a first or upper track member 144, and a second or lower track member 148. Although not illustrated or described in detail, the track members 144, 148 may be similar to the track member 28 shown in FIGS. 5-7 or to the track member 96 shown in FIG. 8.

FIG. 12 illustrates one of the studs 140 of the frame assembly 136 in detail. The stud 140 is an elongated member having a C-shaped cross-section defined by a web 152 and two sidewalls 156, 160. The sidewalls 156, 160 extend generally perpendicularly from the web 152 to define a channel 164 therebetween. In the illustrated construction, two gaps or cutouts 168, 172 are formed at an end portion 176 of the stud 140. The first gap 168 is formed between the web 152 and the first sidewall 156 and the second gap 172 is formed between the web 152 and the second sidewall 160 such that the web 152 is disconnected from the sidewalls 156, 160 at the end portion 176. Such an arrangement allows movement of a portion 180 of the web 152 relative to the sidewalls 156, 160 to facilitate assembly of the studs 140 with the track members 144, 148. The disconnected portion 180 of the web 152 may bend or deflect relative to the sidewalls 156, 160 to provide clearance for engagement members (e.g., the engagement members 76, 80 shown in FIGS. 1-2 or the engagement members 120, 124 shown in FIG. 8) during assembly. In some constructions, a portion of the web 152 may also be similarly disconnected from the sidewalls 156, 160 at the opposite end of the stud 140.

Referring back to FIGS. 9-11, during installation and assembly, the upper track member 144 and the lower track member 148 are coupled (e.g., nailed, screwed, glued, or otherwise fixedly secured) to, for example, a ceiling and a floor, respectively. An end portion 184 (e.g., top) of each stud 140 is inserted into slots in the engagement members of the upper track member 144. Once coupled to the upper track member 144, the studs 140 are pivoted relative to the track members 144, 148 such that the other end portion 176 (e.g., bottom) of each stud 140 is received in slots in the engagement members on the lower track member 148. In some constructions, the studs 140 may be coupled to the lower track member 148 first and then pivoted to couple to the upper track member 144. As each stud 140 swings relative to the lower track member 148, the disconnected portion 180 (FIG. 12) of the web 152 contacts the engagement members of the lower track member 148 and is deflected. The stud 140 can thereby continue to pivot relative to the lower track member 148 until the disconnected portion 180 is aligned with the slots in the engagement members and snaps into place. The slots in the lower track member 148 are generally aligned with the slots in the upper track member 144 such that, when the disconnected portion 180 snaps into the slots, the stud 140 extends generally perpendicularly between the upper and lower track members 144, 148.

In constructions where the web 152 of the stud 140 is not disconnected from the sidewalls 156, 160, such as the stud 24 illustrated in FIGS. 3-4, the frame assembly 136 may be assembled in a similar manner. However, rather than only deflecting a portion of the web 152 relative to the sidewalls 156, 160, the entire end portion 176 of the stud 140 may bend or deflect slightly to clear the engagement members until the web 152 is aligned with the slots and snaps into place.

FIGS. 13 and 14 illustrate a stud 224 according to another embodiment of the invention. Although not illustrated or described in detail, the stud 224 can be used in place of stud 24 in any of the frame assemblies 20, 136 disclosed above, among others.

As described with respect to the embodiment of FIGS. 3 and 4, the stud 224 can be an elongated member having a generally C-shaped cross-section (taken transversely to the longitudinal dimension of the stud) which includes a web 232 and two sidewalls 236, 240. The sidewalls 236, 240 can extend generally perpendicularly from the web 232 to define a channel 244 therebetween. Edge portions 248, 252 of the sidewalls 236, 240 can be bent or rolled over to provide smooth edges and increase the stiffness of the sidewalls 236, 240. Stud 224 can be configured to engage and support wall panels or other loads, which can be nailed, screwed, or otherwise secured to the web 232 or sidewalls 236, 240 of one or more studs 224.

FIGS. 13 and 14 illustrate an embodiment in which sidewalls 236, 240 include grooves 260 on one or more surfaces. One or more grooves 260 can facilitate the securing of a wall panel to the stud 224 with a fastener (screw, nail, etc.) by providing a seat for the tip of the fastener as it is being installed, and can improve the stiffness, stability, and/or strength of the sidewall 236, 240 and the stud 224.

Alternatively, or in addition, dimples or similar notches in the surface of a sidewall 236, 240 and/or web can serve the same or similar purpose. In other embodiments, stud 224 can have a different number of webs 232 and/or sidewalls 236, 240 connected in various configurations and resulting in different cross-sectional shapes (L-shaped, I-shaped, T-shaped, triangular, quadrilateral, etc.). Alternative embodiments of stud 224 can be hollow, solid, or have both hollow and solid cross-sections (taken transversely to the longitudinal dimension of the stud), and can include grooved, dimpled, and/or smooth surfaces for securing a wall panel thereto.

Each groove 260 in the illustrated embodiment is V-shaped (in cross-section taken transversely to the longitudinal dimension of the stud), extends along the length, L of the sidewall 236, 240, and is positioned immediately adjacent another groove 260 such that a series of grooves 260 extends along the width, W of each sidewall 236, 240. As can be seen most clearly in FIG. 13, each groove 260 on one surface 236a of the sidewall is offset from a groove 260 on the opposite surface 236b of the sidewall such that the thickness, T of the sidewall 236 remains constant.

In some embodiments, one or more grooves 260 can extend along the entire length of the sidewalls 236, 240 or web 232 of a stud 224, or any portion thereof. Similarly, adjacent grooves 260 in a series can be spaced apart by various distances. The grooves 260 can be oriented to extend in any direction, can have any cross-sectional shape, and can vary in length, width, and height.

In the illustrated construction, the stud 224 can be composed of, for example, polyvinylchloride (PVC) or other plastic materials or wood composite or other composite materials, and can be formed by extrusion, injection molding, or and/or other processes. In other constructions, the studs 24 may be composed of steel or other metallic materials, and can be formed by extrusion, stamping, folding, and/or other processes. In still other constructions, the studs 224 can be composed of wood. The grooves can be formed during or after the manufacture of the stud.

Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described. Various features and advantages of the invention are set forth in the following claims.

Claims

1. A frame assembly for supporting a wall panel comprising:

a stud configured to engage and support the wall panel, the stud having an end portion;

a track member having a generally U-shaped cross-section defined by a base and two sidewalls, the track member defining a longitudinal axis; and

an engagement member coupled to the base of the track member and extending parallel to the longitudinal axis, the engagement member defining a slot that receives the end portion of the stud to support the stud.

2. The frame assembly of claim 1, wherein the engagement member is integrally formed as one piece with the base.

3. The frame assembly of claim 1, wherein the engagement member, base, and sidewalls are integrally formed as one piece.

4. The frame assembly of claim 1, wherein the engagement member is removably coupled with the base.

5. The frame assembly of claim 1, wherein the slot has an orientation substantially perpendicular to the longitudinal axis.

6. The frame assembly of claim 1, wherein the slot comprises a plurality of slots substantially, evenly spaced apart with respect to the longitudinal axis.

7. The frame assembly of claim 1, wherein the track member has a longitudinal length, and wherein the engagement member extends substantially the entire longitudinal length.

8. The frame assembly of claim 1, wherein the engagement member includes a first engagement member and a second engagement member.

9. The frame of claim 7, wherein the first engagement member and the second engagement member extend substantially parallel to the longitudinal axis.

10. The frame assembly of claim 8, where the first engagement member defines a first slot and the second engagement member defines a second slot, the first slot and the second slot being substantially aligned along an axis transverse to the longitudinal axis.

11. The frame assembly of claim 1, wherein the engagement member includes a plurality of discrete engagement members substantially, evenly spaced apart with respect to the longitudinal axis.

12. The frame assembly of claim 11, wherein each of the plurality of discrete engagement members defines a slot.

13. The frame assembly of claim 1, wherein the stud has a C-shaped cross section defined by a first sidewall, a second sidewall, and a web extending between the first sidewall and the second sidewall.

14. The frame assembly of claim 13, wherein at least one of the first sidewall and the second sidewall includes a grooved surface.

15. A frame assembly for supporting a wall panel, comprising:

a plurality of studs, each stud having a grooved surface and a first end portion and a second end portion opposite the first end portion, the plurality of studs configured to engage and support the wall panel along the grooved surface;

a first track member having a generally U-shaped cross-section defined by a base and two sidewalls, the first track member defining a first longitudinal axis;

a first engagement member coupled to the base of the first track member and extending parallel to the first longitudinal axis, the first engagement member defining a first plurality of slots spaced apart along the first longitudinal axis, the first plurality of slots receiving the first end portions of the plurality of studs;

a second track member having a generally U-shaped cross-section defined by a base and two sidewalls, the second track member defining a second longitudinal axis; and

a second engagement member coupled to the base of the second track member and extending parallel to the second longitudinal axis, the second engagement member defining a second plurality of slots spaced apart along the second longitudinal axis, the second plurality of slots receiving the second end portions of the plurality of studs to support the plurality of studs between the first track member and the second track member.

16. The frame assembly of claim 15, wherein each stud comprises a first side wall, a second sidewall, and a web extending between the first sidewall and the second sidewall.

17. The frame assembly of claim 16, wherein at least one of the first side wall and the second side wall includes the grooved surface.

18. The frame assembly of claim 15, wherein each slot of the first plurality of slots has an orientation substantially perpendicular to the first longitudinal axis.

19. The frame assembly of claim 18, where each slot of the second plurality of slots has an orientation substantially perpendicular to the second longitudinal axis.

20. The frame assembly of claim 15, wherein each slot of the first plurality of slots is substantially aligned with a slot of the second plurality of slots.