FRAMING MEMBERS TO ENHANCE THERMAL CHARACTERISTICS OF WALLS

Abstract

Various metal framing members enhance thermally insulative characteristics of a wall. Framing members include a metal stud with a web portion having through-holes that include at least one piece of retained material. Each of the through-holes lengthens or disrupts thermally conductive paths across the framing member, forming convoluted or serpentine thermal paths. The through-holes are arranged in a pattern that defines a truss structure that includes a number of straight-line web sections that extend uninterruptedly diagonally across a width of the web portion. Framing members include tracks, to hold metal studs, each with a web portion with through-holes that lengthen or disrupt thermally conductive paths. The framing members may be the result of a continuous manufacturing processing, formed of a unitary singular piece of material (e.g., galvanized metal). Thermally insulative gaskets or membranes may insulate the tracks from adjacent structure or surfaces. Structures may be provided as a kit.

Description

BACKGROUND

1. Technical Field

The present disclosure relates to structural members, for example metal framing members.

2. Description of the Related Art

Metal studs and framing members have been used in the areas of commercial and residential construction for many years. Metal studs offer a number of advantages over traditional building materials, such as wood. For instance, metal studs can be manufactured to have strict dimensional tolerances, which increase consistency and accuracy during construction of a structure. Moreover, metal studs provide dramatically improved design flexibility due to the variety of available sizes and thicknesses and variations of metal materials that can be used. Moreover, metal studs have inherent strength-to-weight ratio which allows them to span longer distances and better resist forces such as bending moments.

Although metal studs exhibit these and numerous other qualities, there are some challenges associated with their manufacture and use in construction. For instance, existing designs typically sacrifice strength over weight of the stud. Conventional metal studs are often formed from one piece of metal and weigh about 0.77 pounds per foot, or 6.2 pounds per eight foot stud having dimensions of 3⅝ inch deep by 1¼ inch flange of 22 gauge.

Furthermore, manufacturing efficiency considerations can play a large role in the design of a metal stud because additional manufacturing operations can quickly increase the cost of each stud, which results in an unmarketable metal stud. Thus, the uniform design of existing metal studs often employs more material than is necessary for a given strength.

Additionally, thermal performance is becoming increasingly important. Various regulatory agencies and/or standards setting organizations are tightening thermal performance characteristics or requirements for buildings in order to reduce energy consumption related to heating and/or cooling of interior spaces. Increases in thermal performance are becoming increasingly more difficult to achieve.

BRIEF SUMMARY

Various structural or framing members are disclosed which may enhance thermally insulative characteristics of a wall or other structure incorporating the structural or framing members. Structural or framing members include metal studs having web portions with patterns of discontinuities that lengthen or disrupt thermally conductive paths. Structural or framing members include metal tracks to hold metal studs, the tracks having web portions with patterns of discontinuities that lengthen or disrupt thermally conductive paths. The structural or framing members may be used with thermally insulative gaskets or membranes which may insulate the tracks from adjacent structure or surfaces.

The patterns of discontinuities lengthen, interfere or otherwise interrupt thermal conduction laterally across a width of various structural or framing members (e.g., metal stud, metal track). This has been found to significantly increase thermal performance, reducing heat transfer across the structural or framing members, and hence across a thickness of a wall built using the structural or framing members.

Further, because of the configurations of discontinuities discussed in the present disclosure, the structural or framing members have improved structural characteristics such as improved compression and tension resistance as compared to other metal structural or framing members that contain discontinuities. In particular, in some implementations of the present disclosure, the patterns of discontinuities can form or define a truss structure in a web portion of the structural or framing member. The truss structure can include a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of discontinuities. These configurations and others discussed herein provide enhanced strength without increasing the weight of the structural or framing member.

A metal framing member may be summarized as including: an elongated channel member, the elongated channel member made of a metal and having a web portion, a first end, a second end, a major length between the first and the second ends, a first edge along the major length, a second edge along the major length, a first flange that extends along the first edge at a non-zero angle to the web portion of the elongated channel member, and a second flange that extends along the second edge at a non-zero angle to the web portion of the elongated channel member, the web portion having a pattern of elongated through-holes which are elongated along the major length of the elongated channel member, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along at least a portion of a width of the web portion of the elongated channel member, each row extending along at least one intermediate portion of the major length of the elongated channel member, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, the elongated through-holes which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the elongated channel member the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.

The number of straight-line web sections may include at least a first plurality of straight-line web sections and a second plurality of straight-line web sections that respectively extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes, and wherein the first plurality of straight-line web sections may respectively intersect the second plurality of straight-line web sections. The truss structure may include the number of straight-line web sections that respectively extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes in at least two different diagonal directions. The at least two different diagonal directions may include a first diagonal direction offset from the major length of the elongated channel member by an offset angle in a first rotational direction and a second diagonal direction offset from the major length of the elongated channel member by the offset angle in a second rotational direction, the second rotational direction opposite the first rotational direction, the offset angle greater than zero degrees and less than ninety degrees. The offset angle may include a forty-five degree angle. A width of each of the number of straight-line web sections may be at least three fourths of an inch. A width of each of the number of straight-line web sections may be at least three thirty-seconds of an inch.

The metal framing member may further include: for at least a majority of the elongated through-holes, a respective piece of retained material that extends from the respective elongated through-hole out of a plane of the web portion, the piece of retained material which overlies the respective elongated through-hole, attached to the web portion at each of a pair of opposed ends across a major axis of the respective elongated through-hole and attached to the web portion along a first lateral edge of the respective elongated through-hole and spaced from a second lateral edge of the respective elongated through-hole to form a slot therewith that provides fluid communications between the first major face of the web portion and the second major face of the web portion via the respective elongated through-hole.

The elongated through-holes may be arranged in three or four rows. A largest lateral dimension of the elongated channel member may be no greater than four inches. The width of the web portion of the elongated channel member may be three and five eighths inches. The elongated through-holes may be arranged in at least three rows, the elongated through-holes of each row may be shifted longitudinally along the major length with respect to the elongated through-holes of a nearest neighboring row, and two of the number of straight-line web sections may pass between each elongated through-hole and at least one nearest neighboring elongated through-hole within the same row. At least a majority of the number of straight-line web sections may pass between two neighboring elongated through-holes of each of the plurality of rows. The pattern of elongated through-holes may extend continuously between a first location and a second location, the first and the second locations may be spaced inwardly from respective ones of the first and the second ends by not more than 6 inches from the first and the second ends, respectively. The major length of the elongated channel member may have at least two intermediate portions, the web portion may have the pattern of elongated through-holes that defines the truss structure at each of the at least two intermediate portions, and a knock out portion may be positioned between each of one or more pairs of the at least two intermediate portions. Every direct shortest line path laterally across the width of the web portion over at least a majority of the major length of the elongated channel member may encounter at least one of the elongated through-holes. Each of the plurality of rows may include at least three elongated through-holes. Each of the plurality of rows may include at least five elongated through-holes. The truss structure may include a pattern of straight-line web sections, the pattern of straight-line web sections complementary at least in part to the pattern of elongated through-holes. Each of the respective pieces of retained material may include a first portion and a second portion, the first portion of the retained material may form a first angle measured with respect to a plane formed by the web portion, and the second portion of the retained material may form a second angle measured with respect to the plane formed by the web portion. The elongated through-holes may be respectively elongated in a direction substantially parallel to the major length of the elongated channel member.

A wall kit may be summarized as including: a plurality of metal studs, the metal studs each including a respective elongated stud channel member having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the metal stud, the web portions of each of the metal studs having a respective major length and a minor width, the minor width perpendicular to the major length; and at least a first track, the first track including a first elongated track channel member, the first elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the first track having a respective major length and a minor width, the minor width perpendicular to the major length, wherein the web portion of at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member has a pattern of elongated through-holes which are elongated along a direction parallel to the major length, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, the elongated through-holes which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.

The elongated through-holes may be arranged in at least three rows, every direct shortest line path laterally across the width over the at least one intermediate portion of the web portion of the first elongated stud channel member may encounter a plurality of the elongated through-holes, and two of the number of straight-line web sections may pass between each elongated through-hole and at least one nearest neighboring elongated through-hole within the same row. The truss structure may include the number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes in at least two different diagonal directions, the at least two different diagonal directions comprising a first diagonal direction offset from a longitudinal axis of the at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member by an offset angle in a first rotational direction and a second diagonal direction offset from the longitudinal axis by the offset angle in a second rotational direction, the second rotational direction opposite the first rotational direction, the offset angle greater than zero degrees and less than ninety degrees. The web portions of both: i) the elongated stud channel members and ii) the first track channel member may each respectively have the pattern of elongated through-holes and the truss structure. Each of the plurality of rows may include at least three elongated through-holes. The web portion of the at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member may further have, for at least a majority of the elongated through-holes, at least one piece of retained material that extends from the respective elongated through-hole out of a plane of the web portion, the piece of retained material which overlies the respective elongated through-hole, attached to the web portion at each of a pair of opposed ends across a major axis of the respective elongated through-hole and attached to the web portion along a first lateral edge of the respective elongated through-hole and spaced from a second lateral edge of the respective elongated through-hole to form a slot therewith that provides fluid communications between the first major face of the web portion and the second major face of the web portion via the respective elongated through-hole.

The wall kit may further include: at least a second track that includes a second elongated track channel member, the second elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the second track having a major length and a minor width, the minor width perpendicular to the major length; wherein the web portion of the second elongated track channel member has a pattern of elongated through-holes which are elongated along a direction parallel to the major length of the second elongated channel member, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.

A wall may be summarized as including: at least a first track; and a plurality of metal studs extending perpendicularly from the first track and spaced apart from each other by a defined distance, wherein: the metal studs each include a respective elongated stud channel member having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the metal stud, the web portions of each of the metal studs having a respective major length a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length; the first track includes a first elongated track channel member, the first elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the first track having a respective major length, a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length, and the web portion of at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member has at least one set of a pattern of elongated discontinuities which are elongated along a direction parallel to the major length, the elongated discontinuities arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated discontinuities of each row shifted longitudinally along the major length with respect to the elongated discontinuities of at least one other row, the elongated discontinuities which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated discontinuities define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated discontinuities, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated discontinuities.

The web portions of both: i) the elongated stud channel members and ii) the first track channel member may each respectively have the pattern of elongated discontinuities and the truss structure. The discontinuities may be arranged in at least three rows, every direct shortest line path laterally across the width at least over the one or more intermediate portions of the web portion of the first elongated stud channel member encounters at least one of the discontinuities, and two of the number of straight-line web sections pass between each discontinuity and at least one nearest neighboring discontinuity within the same row. Each of the plurality of rows may include at least three discontinuities.

The wall may further include: at least a second track that includes a second elongated track channel member, the second elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portions of the second track having a respective major length, a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length; and wherein the web portion of the second elongated track channel member may have a pattern of elongated discontinuities which are elongated along a direction parallel to the major length, the elongated discontinuities arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated discontinuities of each row shifted longitudinally along the major length with respect to the elongated discontinuities of at least one other row, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated discontinuities define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated discontinuities, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated discontinuities.

A metal framing member may be summarized as including: an elongated channel member, the elongated channel member made of a metal and having a web portion, a first end, a second end, a major length between the first and the second ends, one or more intermediate portions located at least between a first location and a second location, the first and the second locations which are spaced inwardly from respective ones of the first and the second ends, respectively, a first edge along the major length and a second edge along the major length, a first flange that extends from the first edge, and a second flange that extends from the second edge, the web portion having a pattern of through-holes, the through-holes arranged in a plurality of rows, the rows arranged laterally along at least a portion of a width of the web portion of the elongated channel member, each row extending along at least the one or more intermediate portions of the major length of the elongated channel member, the through-holes of each row shifted longitudinally along the major length with respect to the through-holes of at least one other row to provide serpentine thermally conductive paths laterally across the width of at least the one or more intermediate portions of the web portion of the elongated channel member, each through-hole which provides fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, at least one of the one or more intermediate portions which has a truss structure comprising a plurality of truss elements that respectively extend directly and uninterruptedly through at least a portion of the pattern of through-holes in at least two different diagonal directions, each of the plurality of truss elements passing between two neighboring through-holes in at least one of the plurality of rows.

Each of the plurality of rows may include at least three through-holes. At least a majority of the plurality of truss elements may pass between two neighboring through-holes of each of the plurality of rows. The first and second locations may be spaced inwardly from respective ones of the first and the second ends by more than 4 inches but not more than 6 inches from the first and the second ends, respectively. The through-holes may be arranged in three or four rows. A width of each of the plurality of truss elements may be at least three thirty-seconds of an inch. A largest lateral dimension of the elongated channel member may be no greater than four inches.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the drawings, identical reference numbers identify similar elements. For clarity of illustration, similar elements within a figure may only be called out for a representative element of similar elements. Of course, any number of similar elements may be included in a metal stud, and the number of similar elements shown in a drawing is intended to be illustrative, not limiting. The sizes and relative positions of elements in the drawings are not necessarily drawn to scale. For example, the shapes of various elements and angles are not necessarily drawn to scale, and some of these elements may be arbitrarily enlarged and positioned to improve drawing legibility. Further, the particular shapes of the elements as drawn, are not necessarily intended to convey any information regarding the actual shape of the particular elements, and may have been solely selected for ease of recognition in the drawings.

FIG. 1A is an isometric view of a structural or framing member in the form of a metal stud with sets of a pattern of discontinuities and a number of punches or knock outs spaced therealong, according to one illustrated embodiment.

FIG. 1B is an outside plan view of the metal stud of FIG. 1A.

FIG. 1C is a side elevational view of the metal stud of FIG. 1A.

FIG. 1D is an inside plan view of the metal stud of FIG. 1A.

FIG. 1E is an enlarged isometric view of a portion of the metal stud of FIG. 1A, showing a punch-out or knock out.

FIG. 1F is an enlarged isometric view of a portion of the metal stud of FIG. 1A, showing another punch or knock out.

FIG. 1G is an enlarged isometric view of a web stiffener or reinforcement plate, according to one illustrated embodiment, which can be used with the metal stud of FIG. 1A.

FIG. 2A is a partial inner side isometric view of a metal stud with a pattern of discontinuities that extend completely along a length thereof, according to another illustrated embodiment.

FIG. 2B is a partial end isometric view of the metal stud of FIG. 2A.

FIG. 2C is an enlarged partial end isometric view of a portion of a major face of the metal stud of FIG. 2A.

FIG. 3A is a partial inner side isometric view of an elongated stud channel member with a pattern of discontinuities in the form of through-holes with a single piece of material remains attached along at least one lateral edge of the through-hole and at each end of the through-hole, according to one illustrated embodiment.

FIG. 3B is a partial inner side isometric view of an elongated stud channel member with a pattern of discontinuities in the form of through-holes with a single piece of material remains attached along at least one lateral edge of the through-hole and at each end of the through-hole, according to one illustrated embodiment.

FIG. 3C is an enlarged cross-sectional view showing the configuration of the single piece of material at each through-hole in the elongated stud channel member depicted in FIG. 3B, according to one illustrated embodiment.

FIG. 3D is a partial inner side isometric view of an elongated stud channel member with a pattern of discontinuities in the form of through-holes with a single piece of material remains attached along at least one lateral edge of the through-hole and at each end of the through-hole, according to one illustrated embodiment.

FIG. 3E is an enlarged cross-sectional view showing the configuration of the single piece of material at each through-hole in the elongated stud channel member depicted in FIG. 3D, according to one illustrated embodiment.

FIG. 4A is a top plan view of a structural or framing member for use with metal studs in the form of a metal track having a pattern of discontinuities, according to one illustrated embodiment.

FIG. 4B is a partial isometric view of the metal track of FIG. 4A, separated from a structure or surface by a thermal barrier according to one aspect of the disclosure.

FIG. 4C is a partial top plan view of the metal track of FIG. 4A.

FIG. 5A is an outer side end isometric view of a metal track having a pattern of discontinuities for use with metal studs and a number of stand-off elements or feet, according to another illustrated embodiment.

FIG. 5B is an outer side plan view of the metal track of FIG. 5A.

FIG. 6 is an isometric environmental view showing two metal studs adjacent a wall according to some aspects of the disclosure.

FIG. 7A is an inner side isometric view of a metal structural or framing member having a pattern of discontinuities, according to one illustrated embodiment.

FIG. 7B is an inside plan view of the metal structural or framing member of FIG. 7A.

FIG. 7C is a cross-sectional view of the metal structural or framing member of FIG. 7A.

FIG. 8 is an inside plan view of a metal structural or framing member having a pattern of discontinuities arranged into four rows, according to one illustrated embodiment.

FIG. 9 is an inside plan view of a metal structural or framing member having a pattern of discontinuities arranged into five rows, according to one illustrated embodiment.

DETAILED DESCRIPTION

FIGS. 1A-1Eshow a structural or framing member in the form of a metal stud 10, according to one illustrated embodiment.

The metal stud 10 includes an elongated stud channel member 12 having a web or web portion 14 that includes a first (e.g. inner) major face 28a and a second (e.g., outer) major face 28b, and a pair of flanges 16a, 16b that along with the web portion 14 form a channel. As discussed below, the web portion 14 includes one or more sets of patterns of discontinuities 18, which contribute to the enhanced thermal performance of the metal stud 10.

The metal stud 10 has a first end 20a, a second end 20b opposed to the first end 20a across a length 22 (e.g., major length or major dimension illustrated in FIG. 1B) of the metal stud 10. The metal stud 10 has a width 24 that extends laterally across or perpendicularly to the length 22 of the metal stud 10.

The pair of flanges 16a, 16b extends from respective edges 26a, 26b of the web portion 14 at non-zero angles. For example, the flanges 16a, 16b may extend at a right angle or perpendicular to the first major face 28a of the web portion 14. The elongated stud channel member 12 may include a first lip 30a that extends perpendicularly from the first flange 16a to overlie a portion of the web portion 14, and a second lip 30b that extends perpendicularly from the second flange 16b to overlie a portion of the web portion 14. The flanges 16a, 16b may be formed by bending a single, unitary sheet of material. Likewise, the lips 30a, 30b may be formed by bending the single, unitary sheet of material.

The first major face 28a extends between the inner faces of the flanges 16 on the “inside” portion of the metal stud 10. The second major face 28b opposes the first major face 28a and extends between the outer faces of the flanges 16 on the “outside” portion of the metal stud 10.

The metal stud 10 may have one or more intermediate portions located between a first location 34a and a second location 34b. The first location 34a and the second location 34b are spaced inwardly from respective ones of the first and the second ends 20a, 20b by a distance of not more than 6 inches, or not more than 4 inches, or not more than 2 inches or not more than 1½ inches.

The pattern of discontinuities 18 or through-holes may cause the web portion 14 to be weaker than a solid web. As such, according to an aspect of the present disclosure, the discontinuities 18 can be arranged in a pattern that defines a truss structure within the web portion 14. In particular, the truss structure can include a number of straight-line web sections that extend uninterrupted diagonally across the width 24 of the web portion 14 through at least a portion of the pattern of discontinuities 18. Such truss structure may advantageously provide substantial structural strength while permitting inclusion of the pattern of discontinuities 18 for enhanced thermal performance of the metal stud 10.

As one example, a structural and framing member according to at least one embodiment of the present disclosure may provide a 65% to 70% reduction in thermal conductivity while maintaining structural strength within 1% to 2% of structural members that have a solid web. Therefore, structural and framing members according to the present disclosure may be particularly suitable for use in load bearing walls, rather than curtain walls. However, the structural and framing members of the present disclosure may be used for any structural, framing, or construction context, including non-load-bearing walls.

Furthermore, additional strengthening, particularly proximate the critical end points, may be desirable. Thus, in at least some instances, one or more reinforcements that improve the structural performance of the metal stud 10 (e.g., improve the crippling resistance of the metal stud) may be optionally attached, physically joined, or otherwise coupled to the metal stud 10. For example, the metal stud 10 may optionally include a web stiffener 19 physically joined to the second major face 28b of the web portion 14 proximate the one or both ends of the metal stud 10 as depicted in FIGS. 1B and 1C. Alternatively or additionally, the metal stud 10 may optionally include a web stiffener 19 physically joined to the first major face 28a of the web portion 14 proximate the one or both ends of the metal stud 10. The web stiffeners 19 may extend partially or completely across the width 24 of the metal stud 10.

In particular, FIG. 1G shows a web stiffener 19, according to one illustrated embodiment. The web stiffener 19 may take the form of a reinforcement plate, for example a rectangular plate of metal (e.g., steel, galvanized steel). Such web stiffeners 19 may include metallic stiffeners of a gauge at least equal to the gauge of metal used to fabricate all or a portion of the metal stud 10, and preferably of a heavier gauge that that of the metal stud 10. To increase the structural rigidity of the web stiffeners 19 additional structural stiffening elements such as corrugations 21a, 21b (two shown, collectively 21), ridges, bends, convolutions, or similar structural stiffening elements can be included in at least some of the web stiffeners 19 to increase the structural strength of the metal stud 10. In some instances, such web stiffeners 19 may be attached or otherwise bonded to the metal stud 10 using a plurality of fasteners such as screws, bolts, clips, or similar. In some instances, such web stiffeners 19 are attached or otherwise bonded to the metal stud 10 using one or more adhesives or by weldment (e.g., electric resistance welding).

The web portion 14 of the metal stud 10 may include one or more punch-out or knock out portions 35a-35n (collectively 35, only two called out). The punch-out or knock out portions 35 are sized to accommodate the passage of utilities (e.g., cables, wires, pipes, tubing, conduit), structural reinforcing members, and/or structural support members and extend through a thickness of the web portion 14. The punch-out or knock out portions 35 are generally distributed along the length 22 of the metal stud 12, for example at periodic positions (e.g., every 24 inches). A stamping, punching, or cutting process may form the punch-out or knock out portions 35.

As best illustrated in FIG. 1E, the punch-out or knock out portions 35 may include a plurality of penetrations through the web portion 14. In the example depicted in FIG. 1E, each of the punch-out or knock out portions 35 includes a generally circular first penetration 37 and a “key shaped” second penetration 38. In such instances, the second penetration 38 includes an oblate oval penetration 39a coupled to a generally rectangular keyway portion 39b. In the implementation depicted in FIG. 1E, the first penetration 37 is laterally centered on the web portion 14 and has a diameter that ranges from about one-half inch (½″) to about two inches (2″), for example 11/16″. The second penetration 38 is laterally centered on the web portion 14 and has a width of from about one inch (1″) to about two inches (2″), for example one and one-half inches (1½″). The second penetration 38 can have an overall height of from about one inch (1″) to about four inches (4″), for example 2⅞″. The keyway portion 39b can have a width of from about one-half inch (½″) to about one inch (1″), for example three-quarters of an inch (¾″). The keyway portion 39b can have a height of from about one-half inch (½″) to about one inch (1″), for example three-quarters of an inch (¾″). The distance between the center of the first penetration 37 and the top of the keyway portion 39b of the second penetration 38 can range from about one-quarter inch (¼″) to about one inch (1″), for example 11/32″. In some implementations, the metal stud 10 may be provided from the manufacturer or to the end user with the punch-out or knock out portions 35 partially closed (e.g., scored, creased, or perforated tabs, shelves or roll edges for the end user to punch-out or knock out as needed or desired).

FIG. 1F depicts an optional or alternate type of punch-out or knock out that retains some of the material from the web portion 14 to form tabs, shelves or roll edges 137, to eliminate exposure of utilities to sharp edges. As depicted in FIG. 1F, the optional punch-out or knock out portion 35 may include a first section 139a with a one and one-half inch (1½″) by one and three-quarters inch (1¾″) opening and a second section 139b with a three-quarters inch (¾″) inch by three-quarters inch (¾″) opening. One or more tabs, shelves or roll edges 137 may be bent or rolled out of plan (e.g., perpendicular or at a right angle or greater than a right angle) with respect to the first major face 28a of the web portion 14. In some implementations, the metal stud 10 may be provided from the manufacturer or to the end user with the punch-out or knock out portions 35 completely open (e.g., tabs, shelves or roll edges bent back). In other implementations, the metal stud 10 may be provided from the manufacturer or to the end user with the punch-out or knock out portions 35 partially closed (e.g., scored, creased, or perforated tabs, shelves or roll edges for the end user to bend back as desired). For instance, the first section 139a may be selectively openable by the end user, and the second section 139b may be open to provide the end user access to more easily bend the tabs, shelves or roll edges.

As illustrated in the embodiment of FIGS. 1A-1F, the punch-out or knock out portions 35 may identify divisions between various intermediate portions of the metal stud 10. Thus, punch-out or knock out portions 35 may be positioned between respective pairs of the intermediate portions. Notably, a solid web portion separates the punch-out or knock out portions 35 such that the none of the discontinuities 18 extend into or intersect the punch-out or knock out portions 35, thereby eliminating a potential source of weakness that might otherwise reduce the structural rigidity of the web portion 14 and hence the metal stud 10. Thus, any number of individual discontinuities 18 may be grouped into distinct sets having one or more patterns, each of which includes any number of individual discontinuities 18.

As described in detail herein, the discontinuities 18 may take a large variety of forms. Typically, the discontinuities 18 will take the form of through-holes which extend completely through a thickness of the web portion 14 of the elongated stud channel member 12. The through-holes 18 may be formed in a variety of manners, for example stamped, pressed, punched, etched, cut, laser cut, hydro-cut, machined, etc. At least a portion of the material removed from the web portion 14 to provide the through-hole 18 remains attached to the web portion along at least one lateral edge of the through-hole 18 and at each end of the through-hole 18. The at least partial longitudinal bridging of the through-hole 18 using at least a portion of the material removed from the through-hole 18 enhances the strength of the web portion 14 when compared to complete separation and removal of the material from the through-hole 18. One or more punching operations, punching and bending operations, or punching and twisting operations may be used to provide a through-hole 18 in which at least some of the displaced web portion 14 resulting from the formation of the through-hole 18 is permitted or otherwise caused to remain attached along at least one lateral edge and at both ends of the through-hole 18.

The metal stud 10 may be comprised of any of a variety of metals (e.g., steel, iron, aluminum). The metal stud 10 may optionally include one or more surface treatments or coatings, such as galvanizing, that is applied over the base metal forming the stud 10. The metal stud 10 may be formed via a continuous manufacturing process (e.g., bending, punching, turning, polishing, galvanizing) from a single, unitary piece of material. The process may produce metal stud stock with a web portion 16, opposed flanges 16a, 16b, lips 30a, 30b, and discontinuities 18, which may be cut laterally to produce pieces or segments of desired size.

FIGS. 2A-2C show a structural or framing member in the form of a metal stud 10′, according to one illustrated embodiment.

The metal stud 10′ of FIGS. 2A-2C is similar in many respects to the metal stud 10 of FIGS. 1A-1E, and similar or even identical structures identified by using common reference numbers in the figures. Only significant differences between the metal studs 10, 10′ are discussed below.

In contrast to the metal stud 10 of FIGS. 1A-1E, the metal stud 10′ of FIGS. 2A-2C has a continuous distribution of discontinuities (e.g., through-holes 18) along the entire length 22 of the web portion 14. That is, the pattern of discontinuities (e.g., through-holes 18) extend to, through, or between the first and second ends 20a, 20b of the metal stud 10′. Further, the metal stud 10′ of FIGS. 2A-2C omits punch-out or knock out portions 35. Some implementations may include punch-out or knock out portions 35, while retaining the pattern of discontinuities (e.g., through-holes 18) that extend to, through, or between the first and second ends 20a, 20b of the metal stud 10′.

As best illustrated in FIG. 2C, the through-holes 18 may be elongated. For example, the through-holes 18 may each have an oval, a rectangular, or a rounded rectangular profile. The oval, rectangular, or rounded rectangular profile may have a major axis 36 aligned with or parallel to a major axis 38 of the first major face 28a and/or the major length 22 (FIG. 1B) of the elongated stud channel member 12. The oval, rectangular, or rounded rectangular profiles may have a minor axis 42 parallel to a minor axis 40 of the major face 28a and/or the width 24 (FIG. 1B) of the elongated stud channel member 12, and hence lateral or perpendicular to or major axis 38 of the major face 28 and/or the major length 22 (FIG. 1B) elongated stud channel member 12.

As illustrated in FIGS. 2B and 2C, the through-holes 18 may be elongated through-holes 18. For example, each of the through-holes 18 may have an oval, a rectangular, or a rounded rectangular profile having a major axis 36 aligned with or parallel to a major axis 38 of the web portion 14 and/or major length 22 of the metal stud 10, 10′. Each of the through-holes 18 may have a minor axis 42 parallel to a minor axis 40 of the web portion 14 and/or width 40 of the metal stud 10, 10′, hence lateral or perpendicular to the major axis 38 of the web portion 14 and/or length 22 of the metal stud 10, 10′.

According to one example embodiment, the through-holes 18 may, for example have a length of approximately two inches (2″) to five inches (5″), and a width of about one-eighth inch (⅛″) to about one-half inch (½″), for example three-eighths of an inch (⅜″). The through-holes 18 in each row 44 may be spaced apart from one another by approximately one-half inch (½″). The rows 44 may be spaced apart from each other by approximately three-quarters inch (¾″) (e.g., centerline-to-centerline of rows), resulting in approximately seven-sixteenths inch ( 7/18″) of material between corresponding or overlapping through-holes in nearest neighbor rows 44. Other sizes, dimensions and/or spacing may be employed.

As best illustrated in FIG. 2B, the discontinuities (e.g., through-holes 18) are arranged in a plurality of rows 44a, 44n (seven shown, only two called out in Figure, collectively 44), the rows 44 are arranged laterally along the minor axis 40 or width 41 of the first major face 28a or the width 24 (FIG. 1B) of the elongated stud channel member 12 and extend through the web portion 14 to the second major face 28b. The discontinuities (e.g., through-holes 18) of each row 44 extend along the major axis 38 of the major face 28 and/or the major length 22 (FIG. 1B) of the elongated stud channel member 12. The discontinuities (e.g., through-holes 18) of each row 44 are shifted longitudinally along the major axis 38 of the web portion 14 or major length 22 (FIG. 1B) of the metal stud 10, 10′ with respect to the discontinuities of at least one other row 44. For example, the discontinuities (e.g., through-holes 18) of each row 44 may be shifted longitudinally along the major axis 38 of the web portion 14 or major length 22 (FIG. 1B) of the metal stud 10′ with respect to the discontinuities of at least one nearest neighboring row 44. The pattern of discontinuities 18 ensures that every direct shortest line path laterally across the width 41 on a portion of the major face 28 of the elongated stud channel member 12 encounters at least one of the discontinuities (e.g., through-holes 18), and preferably multiple ones of the discontinuities (e.g., through-holes 18), providing an interrupted or convoluted or serpentine thermally conductive path across the width 41 of the web portion 14 of the metal stud 10, 10′.

In some implementations, the pattern of discontinuities (e.g., through-holes 18) can define a truss structure within the web portion 14. In particular, the truss structure can include a number of straight-line web sections that extend uninterrupted diagonally across the width 24 of the web portion 14 through at least a portion of the pattern of discontinuities 18. Such truss structure may advantageously provide substantial structural strength while permitting inclusion of the pattern of discontinuities 18 for enhanced thermal performance of the metal stud 10′.

The rows 44 may be aligned as illustrated, each of the through-holes 18 of all even numbered rows 44 aligned laterally with the corresponding thorough-holes 18 in the other even numbered rows 44, and each of the through-holes 18 of all odd numbered rows 44 aligned laterally with the corresponding thorough-holes 18 in the other odd numbered rows 44. Alternatively, the through-holes 18 may be staggered differently than illustrated. For example, there may be three different row alignments, where each of the through-holes 18 of every third row 44 is aligned laterally with the corresponding through-holes 18 in the other ones of every third row 44. Thus, the through-holes 18 of the first, fourth, seventh and tenth rows 44 align, the through-holes 18 of the second, fifth, eighth, and eleventh rows 44 align, and the through-holes 18 of the third, sixth and ninth rows 44 align. Likewise, other numbers of row alignment repeat patterns (e.g., four, five, six) may be employed to provide tortious thermally conductive path laterally across the width 24 of the elongated stud channel member 12.

FIGS. 3A-3E show an elongated stud channel member 12 with a pattern of discontinuities in the form of through-holes 18 where a single piece of material 300a-300c (collectively 300) remains attached along at least one lateral edge of the through-hole 18 and at each end of the through-hole 18, according to various illustrated embodiments. Although the single pieces of material 300 depicted in each of FIGS. 3A-3E are shown extending from the second major face 28b of the web portion 14 for clarity and ease of discussion, it should be appreciated that some or all of the single pieces of material 300 may alternatively or additionally extend from the first major face 28a of the web portion 14.

In particular, FIG. 3A shows a single piece of material 300a that extends out of a plane formed by the second major surface 28b of the web portion 14. The single piece of material 300a attaches to the web portion 14 along one lateral edge 304 of each through-hole 18. The single piece of material 300a also attaches to the web portion at each end 306a, 306b of each through-hole 18. The through-hole 18 and single piece of material 300a may be formed, for example by a punching or pressing operation. The single piece of material 300a has a substantially planar portion 302a that extends at an angle 308 from a plane formed by the of the second major surface 28b. For example, the angle 308 can equal 63 degrees or other dimensions. As another example, in some implementations, the angle 308 can be such that a largest distance between the planar portion 302a and the second major surface 28b is about 0.1185 inches. The single piece of material 300a can have a width of about 0.236 inches or other dimensions.

At each end, the substantially planar portion 302a transitions back, on a continuous or variable radius curve, an angle, or combination thereof, to the web portion 14. The retention of the single piece of material 300a and the attachment of the single piece of material along a lateral edge 304 and at both ends 306a, 306b adds structural strength to the web portion 14, and hence the elongated stud channel member 12.

FIG. 3B shows a single piece of material 300b that extends out of a plane of the plane formed by the second major surface 28b of the web portion 14. The single piece of material 300b attaches to the web portion 14 along one lateral edge 304 of each through-hole 18. The single piece of material 300b also attaches to the web portion at each end 306a, 306b of each through-hole 18. As shown in the enlarged view provided in FIG. 3C, at least a first portion 350b of the single piece of material 300b may form a first angle 354 with respect to the plane formed by the second the major surface 28b of the web portion 14. In at least some instances, the first angle 354 may be 45 degrees, although other first angles 354 that fall in a range of from about 10 degrees to about 80 degrees may be used. As shown in the enlarged view provided in FIG. 3C, at least a second portion 352b of the single piece of material 300b may lie in a plane parallel to the plane formed by the second major surface 28b of the web portion 14.

The through-hole 18 and single piece of material 300e may be formed using one or more forming and/or cutting operations. For example, slits corresponding to the location of each of the discontinuities 18 may be made on the web portion 14. A punching or pressing operation may form the first portion 350b and the second portion 352b of the single piece of material 300b. The single piece of material 300b has a bend or creased portions 302b in the corners that physically couple or connect both the first portion 350b and the second portion 352b to the web portion 14. The retention of the single piece of material 300b and the attachment of the single piece of material along a lateral edge 304 and at both ends 306a, 306b adds structural strength to the web portion 14, and hence the elongated stud channel member 12.

FIG. 3D shows a single piece of material 300d that extends out of a plane formed by the second major surface 28b of the web portion 14. The single piece of material 300d attaches to the web portion 14 along one lateral edge 304 of each through-hole 18. The single piece of material 300d also attaches to the web portion at each end 306a, 306b of each through-hole 18. As shown in the enlarged view provided in FIG. 3E, at least a first portion 350d of the single piece of material 300d may form a first angle 354 with respect to the plane formed by the second major surface 28b of the web portion 14. In at least some instances, the first angle 354 may be 45 degrees, although other first angles 354 from 10 degrees to 80 degrees may be used. As shown in the enlarged view provided in FIG. 3H, at least a second portion 352d of the single piece of material 300d may form a second angle 356 with respect to the plane formed by the second major surface 28b of the web portion 14. In at least some instances, the second angle 356 may be 30 degrees, although other second angles 356 that fall in a range of from about 1 degrees to about 90 degrees may be used.

The through-hole 18 and single piece of material 300d may be formed using one or more forming and/or cutting operations. For example, slits corresponding to the location of each of the discontinuities 18 may be made on the web portion 14. A punching or pressing operation may form the first portion 350d and the second portion 352d of the single piece of material 300d. Notably, the single piece of material 300d has a bend or creased portions 302d in the corners that connect both the first portion 350d and the second portion 352d to the web portion 14. The retention of the single piece of material 300d and the attachment of the single piece of material along a lateral edge 304 and at both ends 306a, 306b adds structural strength to the web portion 14, and hence the elongated stud channel member 12.

FIGS. 4A, 4B, and 4C show a structural or framing member in the form of a metal track 400 for use with metal studs 10 (FIGS. 1A-1E, 2A-2C), according to one illustrated embodiment.

The track 400 includes an elongated track member 402, which has a web portion 404 and a pair of flange portions 406a, 406b, which from a channel along with the web portion 404. As discussed below, the web portion 404 includes one or more sets of patterns of discontinuities 418, which contribute to the enhanced thermal performance of the metal track 400.

The metal track 400 has a first end 420a, a second end 420b opposed to the first end 420a across a length 422 (e.g., major length or major dimension illustrated in FIG. 4A) of the metal track 400. The metal track 400 has a width 424 that extends in a direction laterally across or perpendicularly to a major axis 438 of the web portion 404 and/or the length 422 of the metal track 400.

The web portion 404 has a first major face 404a (visible in FIG. 4A) and a second major face 404b opposed from the first major face 404a across a thickness of the web portion 404. The first major face 404a extends between the inner faces of the flange portions 406 on the “inside” portion of the metal track 400. The second major face 404b extends between the outer faces of the flange portions 406 on the “outside” portion of the metal track 400.

The web portion 404 has a first edge 408a and a second edge 408b along the major length 422 of the elongated track member 402. A first one of the flange portions 406a extends along the first edge 408a perpendicularly to the first major face 404a of the elongated track member 402. A second one of the flange portions 406b extends along the second edge 408b perpendicularly to the first major face 404a of the elongated track member 402. The first and the second flange portions 406a, 406b are spaced apart from one another to closely receive the width 24 of the metal studs 10, 10′ therebetween. The metal track 400 may have a width 440 of about three inches (3″) to about six inches (6″) and a thickness of approximately one and one-half inches (1½″), and may have any suitable length (e.g., 8 feet, 10 feet, 12 feet).

As noted above, the web portion 404 has a pattern of discontinuities 418 (only two called out in FIG. 4A), which lengthen a thermally conductive path or otherwise interrupt thermal conduction laterally across a width 440 of the web portion 404 and hence laterally across the metal track 400.

The discontinuities 418 may take the form of through-holes 418 that extend completely through the web portion 404 of the track 400. The through-holes 418 may be formed in a variety of manners, for example stamped, pressed, punched, etched, cut, laser cut, hydro-cut, machined, etc.

As illustrated in FIGS. 4B and 4C, the through-holes 418 may be elongated through-holes 418. For example, each of the through-holes 418 may have an oval, a rectangular, or a rounded rectangular profile having a major axis 436 aligned with or parallel to a major axis 438 of the web portion 404 and/or major length 422 of the elongated track member 402. Each of the through-holes 418 may have a minor axis 442 parallel to a minor axis 440 of the web portion 404 and/or width 424 of the elongated track member 402, hence lateral or perpendicular to the major axis 438 of the web portion 404 and/or length 422 of the elongated track member 402.

The through-holes 418 may, for example have a length of approximately two inches (2″), and a width of about one-eighth inch (⅛″) to about one-half inch (½″), for example three-eighths of an inch (⅜″). The through-holes 418 in each row 444 may be spaced apart from one another by approximately one-half inch (½″). The rows 444 may be spaced apart from each other by approximately three-quarters inch (¾″) (e.g., centerline-to-centerline of rows), resulting in approximately seven-sixteenths inch ( 7/16″) of material between corresponding or overlapping through-holes in nearest neighbor rows 444. Other sizes, dimensions and/or spacing may be employed.

As illustrated, the discontinuities (e.g., through-holes 418) are arranged in a plurality of rows 444a-444n (seven shown, only two called out, collectively 444), the rows 444 arranged laterally along the width 424 of the web portion 404 of the elongated track member 402, with the discontinuities (i.e., through-holes 418) of each row 444 extending along the major axis 438 of the web portion 404 or major length 422 of the elongated track member 402. The discontinuities (i.e., through-holes 418) of each row 444 are shifted longitudinally along the major length or major axis 438 with respect to the discontinuities (i.e., through-holes 418) of at least one other row 444. For example, the discontinuities (i.e., through-holes 418) of each row 444 are shifted longitudinally along the major length or major axis 438 with respect to a nearest neighboring row 444. The pattern of discontinuities (i.e., through-holes 418) ensures that every direct shortest line path laterally across the width 424 of a longitudinal section of the web portion 404 of the elongated track member 402 encounters at least one of the discontinuities (i.e., through-holes 418), and preferably multiple discontinuities, providing an interrupted or convoluted or serpentine thermally conductive path 423 (FIG. 4C) across the width 424 of the elongated track member 402.

The rows 444 may be aligned as illustrated, each of the through-holes 418 of all even numbered rows 444 aligned laterally with the corresponding thorough-holes 418 in the other even numbered rows 444, and each of the through-holes 418 of all odd numbered rows 444 aligned laterally with the corresponding thorough-holes 418 in the other odd numbered rows 444. Alternatively, the through-holes 418 may be staggered differently than illustrated. For example, there may be three different row alignments, where each of the through-holes 418 of every third row 444 is aligned laterally with the corresponding thorough-holes 418 in the other ones of every third row 444. Thus, the through-holes 418 of the first, fourth, seventh and tenth rows 444 align, the through-holes 418 of the second, fifth, eighth, and eleventh rows 444 align, and the through-holes 418 of the third, sixth and ninth rows 444 align. Likewise, other numbers of row 444 alignments (e.g., four, five, six) may be employed to provide tortious thermally conductive path laterally across the width 424 of the elongated track member 402.

In some implementations, the pattern of discontinuities (e.g., through-holes 418) can define a truss structure within the web portion 404. In particular, the truss structure can include a number of straight-line web sections that extend uninterrupted diagonally across the width 424 of the metal track 400 through at least a portion of the pattern of discontinuities 418. Such truss structure may advantageously provide substantial structural strength while permitting inclusion of the pattern of discontinuities 418 for enhanced thermal performance of the metal track 400.

The track 400 may be comprised of any of a variety of metals (e.g., steel, iron, aluminum). The track 400 may optionally include one or more surface treatments or coatings, such as galvanizing, applied over the base metal forming the stud 10. The track 400 may be formed via a continuous manufacturing process (e.g., bending, punching, turning, polishing, galvanizing) from a single, unitary piece of material. The process may produce metal track stock with a web portion 404, opposed flanges 406a, 406b, and discontinuities 418, which may be cut laterally to produce pieces or segments of desired size.

The discontinuities 418 may take a large variety of forms. Typically, the discontinuities 418 will take the form of through-holes 418 extending completely through a thickness of the web portion 404 that include one or more pieces of retained material, to strengthen the web portion 404 of the elongated track member 402. At least a portion of the material displaced in forming the through-hole 418 remains attached to the web portion 404 along at least one lateral edge of the through-hole 418 and at each end of the through-hole 418. The at least partial longitudinal bridging of the through-hole 418 using at least a portion of the material displaced in forming through-hole 418 enhances the strength of the web portion 404 when compared to complete separation and removal of the material from the through-hole 418. One or more punching operation or punching and bending or twisting operations may be used to provide a through-hole 418 in which at least some of the material displaced in forming the through-hole 418 is permitted or otherwise caused to remain attached along at least one lateral edge and at both ends of each respective through-hole 418. For example, the metal track may employ any of the through-hole structures with retained material illustrated and described with reference to FIGS. 3A-3C.

As best illustrated in FIG. 4B, the track 400 may be thermally insulatively separated from a structure or surface 450 by one or more thermal barriers 452. The thermal barrier 452 may, for example, take the form of a sill gasket or other membrane (e.g., bubble foam gasket). The thermal barrier 452 may have the same or similar dimensions to the web 404. The thermal barrier 452 may, for example have a thickness of approximately three-sixteenths of an inch ( 3/16″).

FIGS. 5A and 5B show a metal track 400′ according to another illustrated embodiment.

The track 400′ of FIGS. 5A and 5B is similar in many respects to the track 400 of FIGS. 4A-4C. Similar or identical structures are indicated by the same reference numbers as used in FIG. 4A-4C. In the interest of brevity, only significant differences are discussed below.

The web portion 404′ may include a plurality of stand-off elements 429a-429n (collectively 429, only two called out in FIG. 5A and one in FIG. 5B) which extend outwardly from the outer major face 404b of the web portion 404′. The stand-off elements 429 may take the form of a plurality of conical or hemispherical dimples or similar structures which provide feet that minimize an area of contact between the web portion 404′ and any structure or surface onto which the web portion 404′ is placed immediately or proximally adjacent. For instance, in some installations, the track 400′ may be placed adjacent, carried by or physically coupled either directly to concrete or a metal beam (e.g., steel I-beam), or indirectly via a thermal barrier 452 (FIG. 4B). Minimizing the area of contact may advantageously reduce conductive heat transfer between the track 400′ and the other structure or surface. The web portion 404′ may have the pattern of discontinuities 418. In some implementations, a piece of retained material 415 overlies each discontinuity (e.g., as illustrated in FIG. 5B) and may serve as a louver.

The various components described herein may be packaged or supplied as a kit or wall kit, with or without other components.

For example, a kit or wall kit may include a plurality of metal studs 10. The metal studs 10 may, for instance, take the form of the metal studs 10 described herein, including the patterns of discontinuities 18.

Also for example, a kit or wall kit may include one or more tracks 400, 400′. For example, the kit may include two tracks 400, 400′ (e.g., lower track, upper track) for each wall. The tracks 400 may be integral or provided in separate sections, for example three sections of lower track 400 and three sections of upper track 400, to create a given wall. Such may be determined based on the length of the track segments, which should accommodate shipping, and the length of the wall to be constructed or assembled. The track(s) 400 may, for instance, take the form of the tracks 400 described herein including the patterns of discontinuities 418.

Also for example, a kit or wall kit may include one or more thermal barriers 452, for use as thermal insulation between a respective track and an adjacent structure or surface (e.g., concrete, steel beam). Each thermal barrier 452 has a length that is at least as long as a major length of the respective elongated track member 402 and has a width that is at least as wide as the width of the web portion of the respective elongated track member 402 of the track that the thermal barrier will insulate. The thermal barrier may, for example, take the form of a sill gasket, for instance a thin (e.g., 3/16″ thick) bubble foam gasket or thermally insulative membrane. The thermal barrier may be used with tracks that include the set off elements or that omit the set off elements.

FIG. 6 shows a wall kit 600 assembled as a wall 648, according to one aspect of the present disclosure.

The assembled wall kit 600 includes a plurality of metal studs, for instance a first stud 610a and a second stud 610b (only two shown for ease of illustration, collectively 610), and one or more metal tracks, for instance a lower track 660a and upper track 660b (collectively 660). The metal studs 610 may, for example, be mounted in the track(s) 660, with the metal studs 610a, 610b positioned spatially apart from each other at a defined distance or spacing to create the wall 648.

As previously described, the metal studs 610 may each include a respective web portion 604a, 604b (collectively 604) with a respective plurality of discontinuities 618a, 618b (collectively 618) to lengthen, interfere or disrupt a thermally conductive path across the metal stud 610. For example, rows of discontinuities 618 may be staggered or offset with respect to one another along a longitudinal axis, such that there is not direct laterally path across a width of the web portion 604. The metal studs 610 may each respectively include a pair of flanges 612, 614, opposed to one another across the minor axis or width of the web portion 604a, 604b.

As previously described, the tracks 660 may each include a respective web portion 604a, 604b (collectively 604) with a respective plurality of discontinuities 618 to lengthen, interfere or disrupt a thermally conductive path across the track 660. For example, rows of discontinuities 618 may be staggered or offset with respect to one another along a longitudinal axis, such that there is not direct laterally path across a width of the web portion 604. The tracks 660 may each respectively include a pair of flanges (not called out in FIG. 6), opposed to one another across the minor axis or width of the web portion 604a, 604b. Alternatively, in some implementations the tracks 660 may omit the discontinuities 618 from the respective web portions 604.

The assembled wall kit 600 or wall 648 may also include one or more insulative barriers (e.g., sill gaskets), for instance a lower insulative barrier 670a and an upper insulative barrier 670b, positioned to thermally insulate the tracks 660a, 660b, from adjacent structures or surfaces 650. Notably, a portion of the upper insulative barrier 670b is shown removed to expose a portion of the web portion 604b of the upper track 660b and associated discontinuities 618.

The metal studs 610 are positioned parallel to and spatially separated from each other. The metal studs 610 are secured in the track(s) 660, for example via rivets, bolts and nuts, screws, or other fasteners, with or without adhesive, and/or via welding. In particular, the first and second metal studs 610a, 610b are spaced apart from one another at a defined distance, spacing or interval (e.g., 16 inches).

Each stud 610 may optionally include one or more punch-out or knock out portions 635 in the web portion 604, positioned at various locations along the lengths of the metal studs 610, such as described previously herein. The punch-out or knock out portions 635 define a plurality of longitudinal passages for positioning utility lines through the metal studs 610. In this aspect, smaller utility lines, such as an electrical wire 652, can be positioned through the longitudinal passage or numerous longitudinal passages to physically separate utility lines from each other and away from sharp edges of the first and second elongated stud channel members 612, 614 of the metal studs 610. The longitudinal passages may partially or completely structurally support utility lines, such as the electrical wire 652 and a pipe 654. Additionally, the longitudinal passages allow egress of utility lines to physically separate the utility lines from each other and away from sharp edges of the first and second elongated stud channel members 612, 614 to reduce or prevent damage to the lines and to increase safety.

FIGS. 7A-7C show a structural or framing member 700 that has a pattern of discontinuities 718, according to one illustrated embodiment.

The framing member 700 includes an elongated channel member 712 having a web or web portion 714 that includes a first (e.g., inner) major face 728a and a second (e.g., outer) major face 728b opposed across a thickness of the web portion 714 from the first major face 728a, and a pair of flanges 716a, 716b that along with the web portion 714 form a channel. As discussed below, the web portion 714 includes one or more sets of patterns of discontinuities 718, which contribute to the enhanced thermal performance of the framing member 700. The discontinuities 718 may have a structure the same as or similar to any of the discontinuity structures previously discussed herein, optionally including any of the various shapes and types of retained material discussed above. Thus, although the discontinuities 718 illustrated in FIG. 7C respectively have retained material with only a first bend, the discontinuities 718 may have retained material with more than one bend or face, such as those shown, for example, in FIG. 2C, FIG. 3A, FIG. 3C, or FIG. 3E.

As best shown in FIG. 7A, the framing member 700 has a first end 720a and a second end 720b opposed to the first end 720a across a length 722 of the framing member 700. The framing member 700 has a width 724 that extends laterally across or perpendicularly to the length 722 of the framing member 700. As examples, the length 722 of the framing member can be eight feet, ten feet, twelve feet, or other dimensions. As examples, the width 724 of the framing member can be six inches or other dimensions.

The pair of flanges 716a, 716b extend from respective first and second edges 726a, 726b of the web portion 714 at non-zero angles. For example, the flanges 716a, 716b may extend at a right angle or perpendicular to the first major face 728a of the web portion 714. As illustrated best in FIG. 7C, each of flanges 716a and 716b may have a depth 762. For example, the depth 762 can equal about 1.625 inches or other dimensions.

The elongated channel member 712 may further include a first lip 730a that extends perpendicularly from the first flange 716a to overlie a portion of the web portion 714, and a second lip 730b that extends perpendicularly from the second flange 716b to overlie a portion of the web portion 714. The flanges 716a, 716b may be formed by bending a single, unitary sheet of material. Likewise, the lips 730a, 730b may be formed by bending the single, unitary sheet of material. As illustrated best in FIG. 7C, each lip 730a and 730b may have a lip width 760. For example, the lip width 760 can equal about 0.5 inches (½ of an inch) or other dimensions. A lip thickness 764 can equal about 0.054 inches, 0.150 inches, 0.1875 inches, or other dimensions.

The first major face 728a extends between the inner faces of the flanges 716 on the “inside” portion of the framing member 700. The second major face 728b opposes the first major face 728a and extends between the outer faces of the flanges 716 on the “outside” portion of the framing member 700.

The framing member 700 may have one or more intermediate portions located between a first location 734a and a second location 734b. The first location 734a and the second location 734b may be spaced inwardly from respective ones of the first and the second ends 720a, 720b by a distance of not more than 6 inches, or not more than 4.375 inches, or not more than 4 inches, or not more than 2 inches, or not more than 1½ inches, or not more than other dimensions.

The pattern of discontinuities 718 can extend through each of the one or more intermediate portions of the length 722 of the web portion 714. As shown in FIGS. 7A and 7B, in some implementations, a single intermediate portion and associated pattern of discontinuities 718 can extend uninterrupted from the first location 734a to the second location 734b.

However, in other implementations, as shown in FIGS. 1A, 1B, 1D, and 6, the web portion 714 can include at least two intermediate portions that are spaced from each other and that each feature the pattern of discontinuities 718. For example, a punch-out or knock out portion may be positioned between each pair of neighboring intermediate portions of the at least two intermediate portions.

The discontinuities 718 may take a large variety of forms. Typically, the discontinuities 718 will take the form of through-holes which extend completely through a thickness of the web portion 714 of the elongated channel member 712. The thickness of the web portion 714 can be about 0.054 inches, 0.150 inches, 0.1875 inches, or other dimensions. The through-holes 718 may be formed in a variety of manners, for example stamped, pressed, punched, etched, cut, laser cut, hydro-cut, machined, etc.

At least a portion of the material removed from the web portion 714 to provide the through-hole 718 may remain attached to the web portion 714 along at least one lateral edge of the through-hole 718 and at each end of the through-hole 718. The at least partial longitudinal bridging of the through-hole 718 using at least a portion of the material removed from the through-hole 718 enhances the strength of the web portion 714 when compared to complete separation and removal of the material from the through-hole 718. One or more perforating operations, punching operations, punching and bending operations, or punching and twisting operations may be used to provide a through-hole 718 in which at least some of the displaced web portion 714 resulting from the formation of the through-hole 718 is permitted or otherwise caused to remain attached along at least one lateral edge and at both ends of the through-hole 718. For example, the retained material may be shaped as shown in detail in FIG. 2C, FIG. 3A, FIG. 3C, FIG. 3E, or other shapes.

As illustrated best in FIG. 7B, the through-holes 718 may be elongated through-holes 718. For example, each of the through-holes 718 may have an oval, a rectangular, or a rounded rectangular profile having a major axis 736 aligned with or parallel to the major length 722 of the framing member 700. Each of the through-holes 718 may have a minor axis that is aligned with or parallel to the width 724 of the web portion 714 and perpendicular to the major axis 736. In other implementations, the through-holes 718 may be offset from parallel to the major length 722 of the framing member by some amount (e.g., a relatively minor amount such as five degrees). Further, as used herein, the term “parallel” should not be interpreted to require exact mathematical precision, but instead to convey a general relationship.

Each of the through-holes 718 has a length 738 along its major axis 736 and a width 740 along the minor axis. As examples, the length 738 of each through-hole 718 can be between 2 and 5 inches. For example, the length 738 of each through-hole 718 can be about 2.938 inches or other dimensions. As examples, the width 740 of each through-hole 718 can be between 0.125 and 0.25 inches. For example, the width 740 of each through-hole 718 can be about 0.150 inches or other dimensions. In some implementations, the through-holes 718 do not have uniform lengths 738 and/or widths 740. For example, in some implementations, the through-holes 718 have staggered lengths.

As shown in FIGS. 7A-C, the through-holes 718 are arranged into three rows which may be denominated, for example, as two outer rows 780a and 780c and an inner row 780b. The through-holes 718 of each row 780 are shifted longitudinally along the major length 722 with respect to the through-holes 718 of each nearest neighboring row. In other implementations, the through-holes 718 are not arranged in straight lines.

The two outer rows 780a and 780c are respectively laterally spaced from the first edge 726a and the second edge 726b by a row-edge spacing distance 744. For example, the row-edge spacing distance 744 can be one inch or other dimensions. The inner row 780b is respectively laterally spaced from each outer row 780a and 780c by a row-row spacing distance 746. For example, the row-row spacing distance 746 can be two inches or other dimensions. Thus, the inner row 780b can be respectively laterally spaced from the first edge 726a and the second edge 726b by one-half the width 724 of the web portion 714. The through-holes 718 of each row 780 may be respectively spaced longitudinally such that a discontinuity repetition distance 742 from the first end of one through-hole 718 to the first end of the next neighboring through-hole 718 in the same row is equal to about 4 inches or other dimensions.

In some implementations, each of the through-holes 718 of every alternating row are aligned laterally. In particular, as illustrated in FIGS. 7A and 7B, the respective through-holes 718 of the first and second outer rows 780a and 780c are respectively aligned laterally. Alternately, the rows 780 may be staggered differently than illustrated. For example, the rows 780 may be staggered according to three different alignments, such that none of the rows 780 have every respective through-hole thereof laterally aligned with the respective through-holes of another row.

In some implementations, as shown in FIG. 7A, the outer rows 780a and 780c of discontinuities 718 extend closer to first and second locations 734a and 734b than the inner row 780b of discontinuities 718 so extends. In other implementations, as shown in FIG. 7B, the inner row 780b of discontinuities 718 extends closer to first and second locations 734a and 734b than the outer rows 780a and 780c of discontinuities 718 so extend.

The pattern of discontinuities 718 ensures that every direct shortest line path laterally across the width 724 at each of the intermediate portions of the web portion 714 encounters at least one of the discontinuities (e.g., through-holes 718), and preferably multiple ones of the discontinuities (e.g., through-holes 718), providing an interrupted or convoluted or serpentine thermally conductive path across the width 724 of the web portion 714 of the framing member 700 at each of the one or more intermediate portions. In some implementations, the intermediate portions and corresponding respective patterns of discontinuities 718 aggregately correspond to a majority of the length 722 of the web portion 714 such that every direct shortest line path laterally across the width 724 of at least a majority of the web portion 714 encounters at least one of the discontinuities (e.g., through-holes 718). The intermediate portions may aggregately correspond to other amounts or portions of the length 722 of the web portion 714, as well (e.g., three-fourths of the length 722).

According to an aspect of the present disclosure, the pattern of discontinuities 718 defines a truss structure 750 within the web portion 714. A portion of the truss structure 750 is visually highlighted in FIG. 7B for ease of illustration and description. However, it should be understood that the truss structure 750 is not limited to the portion that is visually highlighted.

The truss structure 750 includes a number of straight-line web sections 752 (only two called out as straight-line web sections 752a and 752b). Each straight-line web section 752 extends uninterrupted diagonally across the width 724 of the web portion 714 through at least a portion of the pattern of discontinuities 718. Each straight-line web section 752 has a width 754. For example, the width 754 can be a minimum width experienced by the straight-line web section 752 as it extends through at least a portion of the pattern of discontinuities 718. As examples, the width 754 of each straight-line web section 752 can range from three thirty-seconds of an inch to 1.5 inches. In some implementations, the width 754 of each straight-line web section 752 is at least three thirty-seconds of an inch. In other implementations, the width 754 of each straight-line web section 752 is at least 0.25 inches. In other implementations, the width 754 of each straight-line web section 752 is at least 0.75 inches.

In some implementations, each of the straight-line web sections 752 extends in a respective one of a first diagonal direction and a second diagonal direction that is different than the first diagonal direction. In some implementations, the first diagonal direction is offset from a longitudinal axis of the elongated channel member 712 by an offset angle 756 in a first rotational direction. The longitudinal axis of the elongated channel member 712 is parallel to the length 722 of the elongated channel member 712. The second diagonal direction is offset from the longitudinal axis of the elongated channel member 712 by the offset angle 756 in a second rotational direction that is opposite the first rotational direction. The offset angle 756 is greater than zero degrees and less than ninety degrees. In some implementations, as shown in FIG. 7B, the offset angle 756 equals forty-five degrees. In other implementations, the offset angles by which the first and second diagonal directions are respectively offset from the longitudinal axis of the elongated channel member 712 are not of equal magnitude.

The truss structure 750 advantageously provides substantial structural strength to the framing member 700 while permitting inclusion of the pattern of discontinuities 718 for enhanced thermal performance of the framing member 700.

The framing member 700 may be comprised of any of a variety of metals (e.g., steel, iron, aluminum). The framing member 700 may optionally include one or more surface treatments or coatings, such as galvanizing, that is applied over the base metal forming the elongated channel member 712. The framing member 700 may be formed via a continuous manufacturing process (e.g., bending, punching, turning, polishing, galvanizing) from a single, unitary piece of material. The process may produce metal stud stock with a web portion 714, opposed flanges 716a, 716b, lips 730a, 730b, and discontinuities 718, which may be cut laterally to produce pieces or segments of desired size.

FIG. 8 is an inside plan view of a metal structural or framing member 800 having a pattern of discontinuities 818 arranged into four rows 880a-880d, according to one illustrated embodiment. The framing member 800 of FIG. 8 is similar in many respects to the framing member 700 of FIGS. 7A-C, and similar or even identical structures may be identified by using common reference numbers in the figures. Only significant differences between the framing members 700 and 800 are discussed below.

The discontinuities 818 are arranged into four rows 880 which may be denominated, for example, as a first outer row 880a, a second outer row 880d, a first inner row 880b, and a second inner row 880c. The rows 880 are laterally spaced along a width 824 of a web portion 814 of the framing member 800. The discontinuities 818 of each row 880 are shifted longitudinally along a major length 822 of the web portion 814 with respect to the discontinuities 818 of each nearest neighboring row.

The rows 880 extend longitudinally in one or more intermediate portions of the length 822 of the web portion 814. The one or more intermediate portions may are located between a first location 834a and a second location 834b on the web portion 814 of the framing member 800. The one or more intermediate portions may be continuous, as shown in FIG. 8, or may be discontinuous (e.g., interrupted by one or more knock-out portions).

In some implementations, each of the discontinuities 818 of every alternating row are aligned laterally. In particular, as illustrated in FIG. 8, the respective discontinuities 818 of the first outer row 880a and the second inner row 880c are respectively aligned laterally while the respective discontinuities 818 of the first inner row 880b and the second outer row 880d are respectively aligned laterally. Alternately, the rows 880 may be staggered differently than illustrated. For example, the rows 880 may be staggered according to three different alignments, four different alignments, etc.

In some implementations, as shown in FIG. 8, the first outer row 880a and second inner row 880c of discontinuities 818 extend closer to first and second locations 834a and 834b than the first inner row 880b and second outer row 880d of discontinuities 818 so extend. In other implementations, the second outer row 880d and first inner row 880b of discontinuities 818 extend closer to first and second locations 834a and 834b than the second inner row 880c and first outer row 880a of discontinuities 818 so extend.

According to an aspect of the present disclosure, the pattern of discontinuities 818 defines a truss structure 850 within the web portion 814. A portion of the truss structure 850 is visually highlighted in FIG. 8 for ease of illustration and description. However, it should be understood that the truss structure 850 is not limited to the portion that is visually highlighted.

The truss structure 850 includes a number of straight-line web sections 852 (only two called out as straight-line web sections 852a and 852b). Each straight-line web section 852 extends uninterrupted diagonally across the width 824 of the web portion 814 through at least a portion of the pattern of discontinuities 818.

Each straight-line web section 852 has a width 854. For example, the width 854 can be a minimum width experienced by the straight-line web section 852 as it extends through at least a portion of the pattern of discontinuities 818. As examples, the width 854 of each straight-line web section can range from three thirty-seconds of an inch to 1.5 inches. In some implementations, the width 854 of each straight-line web section 852 is at least three thirty-seconds of an inch. In other implementations, the width 854 of each straight-line web section 852 is at least 0.25 inches. In other implementations, the width 854 of each straight-line web section 852 is at least 0.75 inches.

In some implementations, each of the straight-line web sections 852 extends in a respective one of a first diagonal direction and a second diagonal direction that is different than the first diagonal direction. In some implementations, the first diagonal direction is offset from a longitudinal axis of framing member 800 by an offset angle 856 in a first rotational direction. The longitudinal axis of the framing member 800 is parallel to the length 822 of the web portion 814. The second diagonal direction is offset from the longitudinal axis of the framing member 800 by the offset angle 856 in a second rotational direction that is opposite the first rotational direction. The offset angle 856 is greater than zero degrees and less than ninety degrees. In some implementations, as shown in FIG. 8, the offset angle 856 equals forty-five degrees. In other implementations, the offset angles by which the first and second diagonal directions are respectively offset from the longitudinal axis of the framing member 800 are not of equal magnitude.

The truss structure 850 advantageously provides substantial structural strength to the framing member 800 while permitting inclusion of the pattern of discontinuities 818 for enhanced thermal performance of the framing member 800.

FIG. 9 is an inside plan view of a metal structural or framing member 900 having a pattern of discontinuities 918 arranged into five rows 980a-980e, according to one illustrated embodiment. The framing member 900 of FIG. 9 is similar in many respects to the framing member 700 of FIGS. 7A-C, and similar or even identical structures may be identified by using common reference numbers in the figures. Only significant differences between the framing members 700 and 900 are discussed below.

The discontinuities 918 are arranged into five rows 980 which may be denominated, for example, as a first outer row 980a, a second outer row 980e, a first inner row 980b, a second inner row 980c, and a third inner row 980d. The rows 980 are laterally spaced along a width 924 of a web portion 914 of the framing member 900. The discontinuities 918 of each row 980 are shifted longitudinally along a major length 922 of the web portion 914 with respect to the discontinuities 918 of each nearest neighboring row.

The rows 980 extend longitudinally in one or more intermediate portions of the length 922 of the web portion 914. The one or more intermediate portions may are located between a first location 934a and a second location 934b on the web portion 914 of the framing member 900. The one or more intermediate portions may be continuous, as shown in FIG. 9, or may be discontinuous (e.g., interrupted by one or more knock-out portions).

In some implementations, each of the discontinuities 918 of every alternating row are aligned laterally. In particular, as illustrated in FIG. 9, the respective discontinuities 918 of the first outer row 980a, the second inner row 980c, and the second outer row 980e are respectively aligned laterally while the respective discontinuities 918 of the first inner row 980b and the third inner row 980d are respectively aligned laterally. Alternately, the rows 980 may be staggered differently than illustrated. For example, the rows 980 may be staggered according to three different alignments, four different alignments, five different alignments, etc.

In some implementations, as shown in FIG. 9, the first inner row 980b and third inner row 980d of discontinuities 918 extend closer to first and second locations 934a and 934b than the first outer row 980a, the second outer row 980e, and the second inner row 980c of discontinuities 918 so extend. In other implementations, the first outer row 980a, the second outer row 980e, and the second inner row 980c of discontinuities 918 extend closer to first and second locations 934a and 934b than the first inner row 980b and third inner row 980d of discontinuities 918 so extend.

According to an aspect of the present disclosure, the pattern of discontinuities 918 defines a truss structure 950 within the web portion 914. A portion of the truss structure 950 is visually highlighted in FIG. 9 for ease of illustration and description. However, it should be understood that the truss structure 950 is not limited to the portion that is visually highlighted.

The truss structure 950 includes a number of straight-line web sections 952 (only two called out as straight-line web sections 952a and 952b). Each straight-line web section 952 extends uninterrupted diagonally across the width 924 of the web portion 914 through at least a portion of the pattern of discontinuities 918.

Each straight-line web section 952 has a width 954. For example, the width 954 can be a minimum width experienced by the straight-line web section 952 as it extends through at least a portion of the pattern of discontinuities 918. As examples, the width 954 of each straight-line web section 952 can range from three thirty-seconds of an inch to 1.5 inches. In some implementations, the width 954 of each straight-line web section 952 is at least three thirty-seconds of an inch. In other implementations, the width 954 of each straight-line web section 952 is at least 0.25 inches. In other implementations, the width 954 of each straight-line web section 952 is at least 0.75 inches.

In some implementations, each of the straight-line web sections 952 extends in a respective one of a first diagonal direction and a second diagonal direction that is different than the first diagonal direction. In some implementations, the first diagonal direction is offset from a longitudinal axis of framing member 900 by an offset angle 956 in a first rotational direction. The longitudinal axis of the framing member 900 is parallel to the length 922 of the web portion 914. The second diagonal direction is offset from the longitudinal axis of the framing member 900 by the offset angle 956 in a second rotational direction that is opposite the first rotational direction. The offset angle 956 is greater than zero degrees and less than ninety degrees. In some implementations, as shown in FIG. 9, the offset angle 956 equals forty-five degrees. In other implementations, the offset angles by which the first and second diagonal directions are respectively offset from the longitudinal axis of the framing member 900 are not of equal magnitude.

The truss structure 950 advantageously provides substantial structural strength to the framing member 900 while permitting inclusion of the pattern of discontinuities 918 for enhanced thermal performance of the framing member 900.

As one example, a structural and framing member according to at least one embodiment of the present disclosure may provide a 65% to 70% reduction in thermal conductivity while maintaining structural strength within 1% to 2% of structural members that have a solid web. Therefore, structural and framing members according to the present disclosure may be particularly suitable for use in load bearing walls, rather than curtain walls. However, the structural and framing members of the present disclosure may be used for any structural, framing, or construction context, including non-load-bearing walls.

The various embodiments may provide a stud with enhance thermal efficiency over more conventional studs. While metals are typically classed as good thermal conductors, the studs described herein employ various structures and techniques to reduce conductive thermal transfer across the web portion of the stud. For instance, the discontinuities may contribute to the energy efficiency of the stud. The retained material, and configurations in which at least a portion of the retained material is attached to at least one lateral edge of each of the plurality of discontinuities and to the longitudinal ends of each of the plurality of discontinuities may reinforce or structurally strengthen the areas of the web surrounding the plurality of discontinuities.

The teachings of commonly assigned U.S. patent application Ser. No. 14/189,548 filed Feb. 25, 2014, U.S. patent application Ser. No. 13/767,764 filed Feb. 14, 2013 and U.S. provisional patent application Ser. No. 61/903,513 filed Nov. 13, 2013 are incorporated herein by reference in their entireties.

While various specific examples of metal studs and metal tracks are disclosed, other implementations may employ other structures or configurations. The various embodiments described above can be combined to provide further embodiments. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.

These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.

Claims

1. A metal framing member, comprising:

an elongated channel member, the elongated channel member made of a metal and having a web portion, a first end, a second end, a major length between the first and the second ends, a first edge along the major length, a second edge along the major length, a first flange that extends along the first edge at a non-zero angle to the web portion of the elongated channel member, and a second flange that extends along the second edge at a non-zero angle to the web portion of the elongated channel member, the web portion having a pattern of elongated through-holes which are elongated along the major length of the elongated channel member, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along at least a portion of a width of the web portion of the elongated channel member, each row extending along at least one intermediate portion of the major length of the elongated channel member, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, the elongated through-holes which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the elongated channel member the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.

2. The metal framing member of claim 1 wherein the number of straight-line web sections comprise at least a first plurality of straight-line web sections and a second plurality of straight-line web sections that respectively extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes, and wherein the first plurality of straight-line web sections respectively intersect the second plurality of straight-line web sections.

3. The metal framing member of claim 1 wherein the truss structure comprises the number of straight-line web sections that respectively extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes in at least two different diagonal directions.

4. The metal framing member of claim 3 wherein the at least two different diagonal directions comprise a first diagonal direction offset from the major length of the elongated channel member by an offset angle in a first rotational direction and a second diagonal direction offset from the major length of the elongated channel member by the offset angle in a second rotational direction, the second rotational direction opposite the first rotational direction, the offset angle greater than zero degrees and less than ninety degrees.

5. The metal framing member of claim 4 wherein the offset angle comprises a forty-five degree angle.

6. The metal framing member of claim 1 wherein a width of each of the number of straight-line web sections is at least three fourths of an inch.

7. The metal framing member of claim 1 wherein a width of each of the number of straight-line web sections is at least three thirty-seconds of an inch.

8. The metal framing member of claim 1, further comprising:

for at least a majority of the elongated through-holes, a respective piece of retained material that extends from the respective elongated through-hole out of a plane of the web portion, the piece of retained material which overlies the respective elongated through-hole, attached to the web portion at each of a pair of opposed ends across a major axis of the respective elongated through-hole and attached to the web portion along a first lateral edge of the respective elongated through-hole and spaced from a second lateral edge of the respective elongated through-hole to form a slot therewith that provides fluid communications between the first major face of the web portion and the second major face of the web portion via the respective elongated through-hole.

9. The metal framing member of claim 1 wherein the elongated through-holes are arranged in three or four rows.

10. The metal framing member of claim 1 wherein a largest lateral dimension of the elongated channel member is no greater than four inches.

11. The metal framing member of claim 1 wherein the width of the web portion of the elongated channel member is three and five eighths inches.

12. The metal framing member of claim 1 wherein the elongated through-holes are arranged in at least three rows, the elongated through-holes of each row are shifted longitudinally along the major length with respect to the elongated through-holes of a nearest neighboring row, and two of the number of straight-line web sections pass between each elongated through-hole and at least one nearest neighboring elongated through-hole within the same row.

13. The metal framing member of claim 1 wherein at least a majority of the number of straight-line web sections pass between two neighboring elongated through-holes of each of the plurality of rows.

14. The metal framing member of claim 1 wherein the pattern of elongated through-holes extend continuously between a first location and a second location, the first and the second locations spaced inwardly from respective ones of the first and the second ends by not more than 6 inches from the first and the second ends, respectively.

15. The metal framing member of claim 1 wherein the major length of the elongated channel member has at least two intermediate portions, the web portion has the pattern of elongated through-holes that defines the truss structure at each of the at least two intermediate portions, and a knock out portion is positioned between each of one or more pairs of the at least two intermediate portions.

16. The metal framing member of claim 1 wherein every direct shortest line path laterally across the width of the web portion over at least a majority of the major length of the elongated channel member encounters at least one of the elongated through-holes.

17. The metal framing member of claim 1 wherein each of the plurality of rows comprises at least three elongated through-holes.

18. The metal framing member of claim 1 wherein each of the plurality of rows comprises at least five elongated through-holes.

19. The metal framing member of claim 1 wherein the truss structure comprises a pattern of straight-line web sections, the pattern of straight-line web sections complementary at least in part to the pattern of elongated through-holes.

20. The metal framing member of claim 8 wherein each of the respective pieces of retained material comprise a first portion and a second portion, the first portion of the retained material forms a first angle measured with respect to a plane formed by the web portion, and the second portion of the retained material forms a second angle measured with respect to the plane formed by the web portion.

21. The metal framing member of claim 1 wherein the elongated through-holes are respectively elongated in a direction substantially parallel to the major length of the elongated channel member.

22. A wall kit, comprising:

a plurality of metal studs, the metal studs each including a respective elongated stud channel member having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the metal stud, the web portions of each of the metal studs having a respective major length and a minor width, the minor width perpendicular to the major length; and

at least a first track, the first track including a first elongated track channel member, the first elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the first track having a respective major length and a minor width, the minor width perpendicular to the major length,

wherein the web portion of at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member has a pattern of elongated through-holes which are elongated along a direction parallel to the major length, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, the elongated through-holes which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.

23. The wall kit of claim 22 wherein the elongated through-holes are arranged in at least three rows, every direct shortest line path laterally across the width over the at least one intermediate portion of the web portion of the first elongated stud channel member encounters a plurality of the elongated through-holes, and two of the number of straight-line web sections pass between each elongated through-hole and at least one nearest neighboring elongated through-hole within the same row.

24. The wall kit of claim 22 wherein the truss structure comprises the number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes in at least two different diagonal directions, the at least two different diagonal directions comprising a first diagonal direction offset from a longitudinal axis of the at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member by an offset angle in a first rotational direction and a second diagonal direction offset from the longitudinal axis by the offset angle in a second rotational direction, the second rotational direction opposite the first rotational direction, the offset angle greater than zero degrees and less than ninety degrees.

25. The wall kit of claim 22 wherein the web portions of both: i) the elongated stud channel members and ii) the first track channel member each respectively have the pattern of elongated through-holes and the truss structure.

26. The wall kit of claim 22 wherein each of the plurality of rows comprises at least three elongated through-holes.

27. The wall kit of claim 22 wherein the web portion of the at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member further has, for at least a majority of the elongated through-holes, at least one piece of retained material that extends from the respective elongated through-hole out of a plane of the web portion, the piece of retained material which overlies the respective elongated through-hole, attached to the web portion at each of a pair of opposed ends across a major axis of the respective elongated through-hole and attached to the web portion along a first lateral edge of the respective elongated through-hole and spaced from a second lateral edge of the respective elongated through-hole to form a slot therewith that provides fluid communications between the first major face of the web portion and the second major face of the web portion via the respective elongated through-hole.

28. The wall kit of claim 22, further comprising:

at least a second track that includes a second elongated track channel member, the second elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the second track having a major length and a minor width, the minor width perpendicular to the major length;

wherein the web portion of the second elongated track channel member has a pattern of elongated through-holes which are elongated along a direction parallel to the major length of the second elongated channel member, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.

29. A wall, comprising:

at least a first track; and

a plurality of metal studs extending perpendicularly from the first track and spaced apart from each other by a defined distance, wherein:

the metal studs each include a respective elongated stud channel member having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the metal stud, the web portions of each of the metal studs having a respective major length a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length;

the first track includes a first elongated track channel member, the first elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the first track having a respective major length, a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length, and

the web portion of at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member has at least one set of a pattern of elongated discontinuities which are elongated along a direction parallel to the major length, the elongated discontinuities arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated discontinuities of each row shifted longitudinally along the major length with respect to the elongated discontinuities of at least one other row, the elongated discontinuities which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated discontinuities define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated discontinuities, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated discontinuities.

30. The wall of claim 29 wherein the web portions of both: i) the elongated stud channel members and ii) the first track channel member each respectively have the pattern of elongated discontinuities and the truss structure.

31. The wall of claim 29 wherein the discontinuities are arranged in at least three rows, every direct shortest line path laterally across the width at least over the one or more intermediate portions of the web portion of the first elongated stud channel member encounters at least one of the discontinuities, and two of the number of straight-line web sections pass between each discontinuity and at least one nearest neighboring discontinuity within the same row.

32. The wall of claim 29 wherein each of the plurality of rows comprises at least three discontinuities.

33. The wall of claim 29, further comprising:

at least a second track that includes a second elongated track channel member, the second elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portions of the second track having a respective major length, a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length; and

wherein the web portion of the second elongated track channel member has a pattern of elongated discontinuities which are elongated along a direction parallel to the major length, the elongated discontinuities arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated discontinuities of each row shifted longitudinally along the major length with respect to the elongated discontinuities of at least one other row, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated discontinuities define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated discontinuities, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated discontinuities.

34. A metal framing member, comprising:

an elongated channel member, the elongated channel member made of a metal and having a web portion, a first end, a second end, a major length between the first and the second ends, one or more intermediate portions located at least between a first location and a second location, the first and the second locations which are spaced inwardly from respective ones of the first and the second ends, respectively, a first edge along the major length and a second edge along the major length, a first flange that extends from the first edge, and a second flange that extends from the second edge, the web portion having a pattern of through-holes, the through-holes arranged in a plurality of rows, the rows arranged laterally along at least a portion of a width of the web portion of the elongated channel member, each row extending along at least the one or more intermediate portions of the major length of the elongated channel member, the through-holes of each row shifted longitudinally along the major length with respect to the through-holes of at least one other row to provide serpentine thermally conductive paths laterally across the width of at least the one or more intermediate portions of the web portion of the elongated channel member, each through-hole which provides fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, at least one of the one or more intermediate portions which has a truss structure comprising a plurality of truss elements that respectively extend directly and uninterruptedly through at least a portion of the pattern of through-holes in at least two different diagonal directions, each of the plurality of truss elements passing between two neighboring through-holes in at least one of the plurality of rows.

35. The metal framing member of claim 34 wherein each of the plurality of rows comprises at least three through-holes.

36. The metal framing member of claim 34 wherein at least a majority of the plurality of truss elements pass between two neighboring through-holes of each of the plurality of rows.

37. The metal framing member of claim 34 wherein the first and second locations are spaced inwardly from respective ones of the first and the second ends by more than 4 inches but not more than 6 inches from the first and the second ends, respectively.

38. The metal framing member of claim 34 wherein the through-holes are arranged in three or four rows.

39. The metal framing member of claim 34 wherein a width of each of the plurality of truss elements is at least three thirty-seconds of an inch.

40. The metal framing member of claim 34 wherein a largest lateral dimension of the elongated channel member is no greater than four inches.