CONSTRUCTION FRAMING SYSTEM INCLUDING A LAYOUT TRACK

BACKGROUND

Framing systems may include a plurality of studs positioned between an upper track member and a lower track member. Ensuring the studs are appropriately spaced is time consuming and may require repeated measurements to obtain the desired spacing. An example of a structural framing member is shown and described in U.S. Pat. No. 9,010,070, entitled “Structural Framing Member,” issued on Apr. 21, 2015, the entire disclosure of which is incorporated by reference herein. Additionally, inserting a fastener into materials having different thicknesses may be difficult.

While various kinds of framing systems, and other associated components have been made and used, it is believed that no one prior to the inventors have made or used the invention described in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the principles of the present invention.

FIG. 1 depicts a schematic perspective view of a construction framing system including a plurality of studs, a plurality of fasteners, and a first example of upper and lower layout tracks;

FIG. 2 depicts an enlarged schematic perspective view of a portion of the lower layout track of FIG. 1;

FIG. 3A depicts a schematic sectional view of a stud of FIG. 1 being inserted into the lower layout track of FIG. 1;

FIG. 3B depicts a schematic sectional view of fasteners of FIG. 1 being inserted into the stud and lower layout track of FIG. 3A;

FIG. 3C depicts a schematic sectional view of fasteners, stud, and lower layout track of FIG. 1, after the fasteners have been inserted into the stud and lower layout track;

FIG. 4 depicts a schematic perspective view of a portion of a second example of a lower layout track configured for use with the construction framing system of FIG. 1; and

FIG. 5 depicts a flow chart describing an exemplary method of manufacturing the layout track of FIGS. 1 and 4.

The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

To the extent that spatial terms such as “upper,” “lower,” “vertical,” “horizontal,” or the like are used herein with reference to the drawings, it will be appreciated that such terms are used for exemplary description purposes only and are not intended to be limiting or absolute. In that regard, it will be understood that devices such as those disclosed herein may be used in a variety of orientations and positions not limited to those shown and described herein.

I. Example of a Construction Framing System

FIG. 1 shows an example of a construction framing system (10) that includes a plurality of studs (shown as studs (12a-e)), an upper layout track (14), a lower layout track (16), and a plurality of fasteners (shown as fasteners (18a-e)). As shown, upper and lower layout tracks (14, 16) sandwich therebetween opposing terminal ends of studs (12a-e). While five studs (12a-e) and five fasteners (18a-e) are shown in FIG. 1, construction framing system (10) may include more or fewer studs and/or fasteners.

Construction framing system (10) may also include additional upper layout tracks (14) and/or lower layout tracks (16). Studs (12a-e) may be separated (or spaced apart) by a regular or repeating distance, such as 12 inches on center, 16 inches on center, or 24 inches on center. When studs are spaced at a regular or repeating distance, that is typically referred to as on module spacing. Other spacings of studs (12a-e) are also envisioned. For example, in some embodiments, some studs may be spaced apart a first distance, while other studs are spaced apart a second distance and the first and second distances may be different. When studs are spaced at a distance that is different than the typical regular or repeating distance, that is typically referred to as off module spacing. Upper layout track (14) is shown rotated 180 degrees relative to lower layout track (16). While upper and lower layout tracks (14, 16) are shown as being identical, upper layout track (14) may be different than lower layout track (16), if desired. Upper and lower layout tracks (14, 16) are each shown as having a generally U-shaped profile (see FIGS. 3A-3C). In other embodiments, one or both of upper and lower layout tracks (14, 16) may comprise something other than a U-shaped profile.

A. First Example of a Layout Track

FIG. 2 shows a first example of lower layout track (16). However, this description of lower layout track (16) also applies to upper layout track (14). As shown, lower layout track (16) includes a web (20) and first and second flanges (22, 24). Layout track (16) is sized and configured to receive and end of studs (12a-e) between first and second flanges (22, 24). First flange (22) extends perpendicular to web (20), and second flange (24) extends perpendicular to web (20). However, it is envisioned that first flange (22) and/or second flange (24) may extend at a variety of non-zero angles relative to web (20). Second flange (24) is separated from first flange (22) by web (20). In other words, web (20) connects first and second flanges (22, 24) that are positioned opposite one another. As shown, first and second flanges (22, 24) are substantially equal in height. In other embodiments, one of first and second flanges (22, 24) may have a height that is greater than the other. As shown, flanges (22, 24) are substantially planar. In other embodiments one or both flanges (22, 24) may comprise one or more bends such that one or both flanges (22, 24) are nonplanar. By way of example only, in some embodiments, upper layout track (14) may comprise flanges that are nonplanar that form an offset profile. One example of a track with an offset profile is manufactured by Clarkwestern Dietrich Building Systems LLC and marketed with the designation of an “Offset Deep Leg” track or “ODL” track. Further, in the illustrated embodiment, web (20) is substantially flat. In other embodiments, web (20) may comprise one or more offsets and/or ridges, such that the web (20) is not substantially flat.

First flange (22) includes a first array (26) of apertures (28a-v). Similarly, second flange (24) includes a second array (30) of apertures (28a-v). Apertures (28a-v) of first and second arrays (26, 30) are configured to provide pilot holes to assist with the insertion of fasteners (18a-e). Each aperture (28a-v) of first and second arrays (26, 30) of apertures (28a-v) extend completely through respective first and second flanges (22, 24). First array (26) is arranged along a first longitudinal axis (LA1). Similarly, second array (30) is arranged along a second longitudinal axis (LA2), which is spaced apart from and parallel to first longitudinal axis (LA1). First and second arrays (26, 30) are shown as being identical; however, first and second arrays (26, 30) may be different. While first flange (22) is shown as including first array (26) and second flange (24) is shown as including second array (30), it is envisioned that one of first or second flanges (22, 24) may optionally omit the apertures altogether and instead be solid. As shown, apertures (28a-v) of first array (26) are longitudinally and vertically aligned with a corresponding aperture of apertures (28a-v) of second array (30). For example, aperture 28a of first array (26) is longitudinally and vertically aligned with aperture (28a) of second array (30), aperture (28b) of first array (26) is longitudinally and vertically aligned with aperture (28b) of second array (30), and so on. Lower layout track (16) includes opposing first and second terminal ends (32, 34) (see FIG. 1). First flange (22) has a terminal end (36), and second flange (24) has a terminal end (38).

With continued reference to FIG. 2, first and second arrays (26, 30) of apertures (28a-v) are arranged in a predetermined longitudinal pattern corresponding to predetermined lengths of lower layout track (16). This pattern may repeat at a predetermined interval along the length of lower layout track (16). As shown, three consecutive apertures (28a-c) have the same shape, and the next consecutive aperture (28d) has a shape that is different than the prior apertures (28a-c). As shown, the repeating longitudinal pattern is circular aperture, circular aperture, circular aperture, diamond aperture. Particularly, the pattern for adjacent apertures is circular aperture (28a), circular aperture (28b), circular aperture (28c), and diamond aperture (28d). This pattern repeats as circular aperture (28e), circular aperture (28f), circular aperture (28g), and diamond aperture (28h). This pattern again repeats as circular aperture (28i), circular aperture (28j), circular aperture (28k), and diamond aperture (28l). This pattern again repeats as circular aperture (28m), circular aperture (28n), circular aperture (28o), and diamond aperture (28p). This pattern again repeats as circular aperture (28q), circular aperture (28r), circular aperture (28s), and diamond aperture (28t). This pattern repeats as circular aperture (28u), circular aperture (28v), and so on. As shown, apertures (28d, 28h, 28l, 28p, 28t) comprise a diamond shaped aperture. Apertures (28a-c, 28e-g, 28i-k, 28m-o, 28q-s, 28u-v) comprise a circle shaped aperture. In some versions, apertures (28a-c, 28e-g, 28i-k, 28m-o, 28q-s, 28u-v) may have an inner dimension of 3/32 inches; however, other dimensions are also envisioned.

According to a specific example, first on module aperture (28d) has a first shape. As shown, the first shape is a diamond. However, the first shape may alternatively be a variety of suitable shapes including a circle, square, star, triangle, pentagon, hexagon, or clover. The first shape may be any other suitable shape as would be apparent to one skilled in the art in view of the teachings herein. As used herein, an on module aperture refers to an aperture located at a location along layout track (16) to facilitate identification and installation of a stud utilizing on module spacing relative to an adjacent stud (e.g., a distance of 12 inches on center, 16 inches on center, or 24 inches on center relative to an adjacent stud). Off module aperture (28e) has a second shape that is different than the first shape. As shown, the second shape is a circle. Similar to the first shape, the second shape may be a variety of suitable shapes including a circle, square, star, triangle, pentagon, hexagon, or clover, provided the second shape is different than the first shape. The second shape may be any other suitable shape as would be apparent to one skilled in the art in view of the teachings herein. As used herein, an off module aperture refers to an aperture located at a location along layout track (16) to facilitate identification and installation of a stud utilizing off module spacing relative to an adjacent stud (e.g., a distance other than 12 inches on center, 16 inches on center, or 24 inches on center relative to an adjacent stud). Second on module aperture (28h) may have the first shape or a third shape that is different than the first or second shapes. Similar to the first and second shapes, the third shape may be a variety of suitable shapes including a circle, square, star, triangle, pentagon, hexagon, or clover, provided the third shape is different than the second shape and could be different than the first shape as well. For example, with the first shape being a diamond and the second shape being a circle, the third shape may be a square, star, triangle, pentagon, hexagon, or clover. The third shape may be any other suitable shape as would be apparent to one skilled in the art in view of the teachings herein As shown, second on module aperture (28h) has the same shape as first on module aperture (28d). Off module aperture (28e) is positioned between first on module aperture (28d) and second on module aperture (28h). First on module aperture (28d) is separated from second on module aperture (28h) by a predetermined on module length (L3). Similarly, second on module aperture (28h) is separated from third on module aperture (28l) by predetermined on module length (L3), third on module aperture (28l) is separated from fourth on module aperture (28p)by predetermined on module length (L3), and fourth on module aperture (28p)is separated from fifth on module aperture (28t) by predetermined on module length (L3). Off module aperture (28i) has the second shape. Off module apertures (28e, 28i) are also separated by the predetermined on module length (L3). Adjacent apertures of the first and second arrays (26, 30) define a spacing comprising a predetermined off module length (L2), which can be one inch on center. Off module aperture 28i)is positioned further from off module aperture (28e) than second on module aperture (28h). As shown, off module apertures (28e-g) are positioned between first and second on module apertures (28d, 28h). Off module apertures (28f-g) have the second shape (i.e., the same shape as off module aperture (28e)). As shown, the second shape is a circle extending completely through first and second flanges (22, 24).

With continued reference to FIG. 2, first terminal end aperture (28a) is positioned a predetermined terminal end length (L1) away from terminal end (32). For example, in one embodiment aperture (28a) is located a distance of 1 inch away from terminal end (32). Terminal end length (L1) is shown as equal to off module length (L2) (i.e., the distance between adjacent apertures (28b-v). In one embodiment, the length (which may also be referred to as a distance) between adjacent apertures (28b-c) is 1 inch on center. Similarly, the length between adjacent apertures (28c-d) is 1 inch on center. Particularly, first and second arrays (26, 30) may utilize circular apertures with a diameter of 3/32 inches starting 1 inch from terminal end (32), and continue at 1 inch on center for the remainder of the length of lower layout track (16). In embodiments where the overall length of layout track (16) is a multiple of on module length (L3) (i.e., the overall length of layout track (16) is the product of on module length (L3) and an integer), then the final aperture (i.e., the second terminal aperture (28v)) of the first and second arrays (26, 30) is an off module aperture located terminal end length (L1) from the opposing terminal end (34). For example, if terminal end length (L1) is 1 inch, off module length (L2) is 1 inch, on module length (L3) is 4 inches, and the overall length of layout track (16) is a multiple of 4 inches (e.g., 10 feet, 12 feet, etc.), then the final aperture (i.e., second terminal end aperture (28v)) of first and second arrays (26, 30) is located 1 inch away from opposing terminal end (34). By having first terminal end aperture (28a) at a terminal end length (L1), which is equal to off module length (L2), from first terminal end (32) and by having second terminal end aperture (28v) at a terminal end length (L1) from second terminal end (34), a first terminal end (32) of a second lower layout track (not shown but similar to lower layout track (16)) may by butted against second terminal end (34) of first lower layout track (16) without affecting the off module length (L2) between adjacent apertures. In other words, if two layout tracks (16) with this type of spacing are butted against each other (i.e., second terminal end (34) of a first lower layout track (16) is butted against first terminal end (32) of a second lower layout track (16)), then the length between the second terminal end aperture (28v) of the first layout track (16) and the first terminal end aperture (28a) of the second layout track (16) will be twice off module length (L2) and the distance between the final on module aperture of the first layout track (16) and the first on module aperture of the second layout track (16) will be twice on module length (L3). As a result, installers can continue to use on module apertures to install studs at on module spacing spanning across adjacent layout tracks (16) that are butted against each other.

In some instances, terminating ends of first flange (22) and second flange (24) may include a complementary cutout. Such complementary cutouts of a first layout track (16) and a second layout track (16) that are butted against each other in accordance with the description herein may cooperatively define a complete on module aperture. Such a cooperatively formed on module aperture may have any suitable shape as would be apparent to one skilled in the art in view of the teachings herein. In some instances, the cooperatively formed aperture may be unique from other on module apertures in order to visually indicate that such an aperture is associated with a juncture between first and second layout tracks (16) that abut against each other at respective terminal ends (32, 34). However, after cooperatively formed aperture is suitably formed via two layout tracks (16) abutting against each other, cooperatively formed aperture may function in substantially similar manner as other on module apertures in accordance with the description herein.

It is envisioned that lower layout track (16) may be manufactured to have a predetermined length, which may be for example, 8 feet, 10 feet, 12 feet, and so on. Additional predetermined lengths are also envisioned. The overall length may be adjusted on-site by cutting lower layout track (16) to a desired length on-site prior to installation. If lower layout track (16) is cut on-site at an on module aperture, then that track may still be used together with another layout track (16) to provide on module stud spacing across both of those layout tracks via on module apertures located in both layout tracks. Upper and lower layout tracks (14, 16) may each be integrally formed together as a single unitary piece. In some versions, upper and lower layout tracks (14, 16) may be formed from metal (e.g., steel).

Having first array (26) preformed into first flange (22) and/or second array (30) preformed into second flange (24) may aid in the layout of studs (12a-e). As used herein, “preformed” means that the features are formed in the part prior to installation, and preferably in the factory as opposed to in the field (i.e., at the location of installation). For example, studs (12a-e) used in wall framing system (10) may have a respective spacing of 12 inches on center, 16 inches on center, 24 inches on center, or any other suitable distance. Studs (12a-e) separated by a predetermined distance on center means the center of adjacent studs are spaced apart by 12 inches, 16 inches, 24 inches, or any other suitable distance. Having first array (26) preformed into first flange (22) and/or second array (30) preformed into second flange (24) at the predetermined spacing may accelerate the framing process by allowing the installer to easily identify the correct location for the studs (12a-12e), thereby saving time and money.

For example, in the illustrated lower layout track (16), the unique shape of on module apertures (28d, 28h, 28l, 28p, 28t) signifies a predetermined distance, such as 4 inches, from the last adjacent unique shape. Having the on module length (L3) be 4 inches may be particularly beneficial, because the most common stud spacing is 12 inches on center, 16 inches on center and 24 inches on center. Accordingly, having on module length (L3) be 4 inches would allow the installer (e.g., the contractor) to count three patterns (i.e., three on module lengths (L3)) for a 12 inch on center stud spacing, four patterns (i.e., four on module lengths (L3)) for a 16 inch on center stud spacing, six patterns (i.e., six on module lengths (L3)) for a 24 inch on center stud spacing, and so on. In other words, it may be beneficial to have the on module length (L3) be such that common on center stud spacing is a multiple of the on module length (L3). If a condition arises where off module spacing (i.e., spacing that is different than the standard on center spacing of 12 inches, 16 inches, or 24 inches) is desired, the contractor may utilize an off module aperture (28a-c, 28c-g, 28i-k, 28m-o, 28q-s, 28u-v), then return to the on module spacing. The installer can still use off module apertures to locate the desired location for installation of the stud. For example, if an installer comes to a termination point, such as a door jamb or window jamb, where on module spacing is no longer desired, then the installer can utilize off module apertures to find the appropriate location for the off module stud. Off module spacing is still likely to be an increment of 1 inch, therefore it may be particularly beneficial to configure layout track (16) such that off module length (L2) between adjacent apertures, regardless of if they are on module apertures or off module apertures, is 1 inch. Off module apertures (28a-c, 28c-g, 28i-k, 28m-o, 28q-s, 28u-v) may be used to accommodate double studs or off module stud layout. For example, in the off module stud layout, the contractor may continue to use off module apertures (28a-c, 28e-g, 28i-k, 28m-o, 28q-s, 28u-v) instead of returning to using on module apertures (28d, 28h, 28l, 28p, 28t) when inserting fasteners to secure studs in the desired location. In the specific example shown, the 4 inch on center repeating longitudinal pattern allows for suitability of studs having a 12 inch on center spacing, a 16 inch on center spacing, or a 24 inch on center spacing using the same lower layout track (16). Having first array (26) preformed into first flange (22) and/or second array (30) preformed into second flange (24) may aid in the construction of multi-piece assembled jamb studs and box beam headers. The arrangement of apertures described herein can be utilized on tracks having a variety of web sizes, gauges, and flange heights.

B. Example of Method of Securing

A method of securing lower layout track (16) with studs (12a-e) is now described with reference to FIGS. 3A-3C. Fasteners (18a-e) are configured to be inserted through apertures (28a-v) and into studs (12a-e). As shown in FIGS. 3A-3C, fasteners (18a) are configured to be inserted through one of on module apertures (28d) and into stud (12a). Use of additional apertures (28a-c, e-v) and studs (12b-e) is also envisioned and would be substantially identical to the description regarding stud (12a) and on module aperture (28d) herein. FIG. 3A shows a schematic sectional view of stud (12a) of FIG. 1 being inserted in direction (46) into lower layout track (16). As shown, lower layout track (16) has a width (w1) and a thickness (t1). Width (w1) of lower layout track (16) may vary to accommodate different widths of studs. Thickness (t1) of lower layout track (16) may be greater to provide greater rigidity or smaller to provide greater flexibility. Similarly, stud (12a) has a width (w2) and a thickness (t2).

FIG. 3B shows a schematic sectional view of fasteners (18a) being inserted into stud (12a) and lower layout track (16). By way of example only, fasteners (18a-e) may be self-tapping screws. As shown, fasteners (18a) are being inserted in an inward direction (48, 50) through on module apertures (28d) in both first flange (22) and second flange (24) and into the flanges of stud (12a). Fasteners (12a) include a tip (40), threaded portion (42), and a head (44). As shown, fasteners (18a) have a generally circular cross-sectional area that is different than the shape of on module apertures (28d). For example, the shape of on module apertures (28d) may be a square, diamond, or star extending completely through first and second flanges (22, 24). Fastener (18a) has a first cross-sectional shape (shown as circular). Fastener (18a) is configured to be inserted into on module aperture (28d) having the shape that is different than the first cross-sectional shape of fasteners (18a). Threaded portion (42) has a maximum diameter (d2). In some embodiments, maximum diameter (d2) of threaded portion (42) is greater than a maximum diameter (d1) defined by on module apertures (28d) of the arrays (26, 30). Similarly, as shown, maximum diameter (d2) of threaded portion (42) is greater than a maximum diameter (d1) defined by on module apertures (28h, 28l, 28p, 28t) of the arrays (36, 40). As generally shown in FIG. 1, if adjacent studs (12a, 12b) are intended to be installed such that they are spaced apart 16 inches on center and on module apertures (28d, 28h, 28l, 28p, 28t) are each spaced apart 4 inches from the adjacent on module apertures (28d, 28h, 28l, 28p, 28t), another fastener (18b) can be inserted through another on module aperture (28t) and into the flanges of stud (12b) based on the predetermined pattern formed by first array (26) and/or second array (30).

FIG. 3C shows a schematic sectional view of fasteners (18a), stud (12a), and lower layout track (16) of FIG. 1 after fasteners (18a) have been inserted into stud (12a) and lower layout track (16). Upper and lower layout tracks (14, 16) aid in attaching or fixing studs (12a-e) (e.g., light gauge steel metal studs) and layout track (14, 16) together. In conventional light gauge steel tracks and studs, tips (40) of fasteners (18a-e) penetrate through the different layers of metal and then the threaded portion (42) of fasteners (18a-e) “grab” the different layers (thickness of stud (12a-e) and thickness of first and second flanges (22, 24)) and tighten stud (12a) and lower layout track (16) together. As shown, first and second flanges (22, 24) have a thickness (t1) that is less than a thickness (t2) of studs (12a-e). Studs (12a-e) may have a certain thickness to provide the desired amount of structural support for a predetermined loading. In some instances, where upper and lower layout tracks (14, 16) are used for light gauge steel framing, first and second flanges (22, 24) may have a thickness (t1) from about 0.015 inches (25 gauge) to about 0.117 inches (10 gauge); this thickness may also be referred to as decimal thickness. In other embodiments the thickness (t1) of flanges (22, 24) may be greater than the thickness (t2) of studs (12a-e), while in other embodiments the thickness (t1) of flanges (22, 24) may be the same as the thickness (t2) of studs (12a-e).

The lighter in decimal thickness the material is of upper and lower layout tracks (14, 16), the easier tip (40) of fastener (18a-e) bites into and drives through the material of upper and lower layout tracks (14, 16). Once fastener (18a-e) hits the midpoint range screwing the different thickness of materials together may become more challenging. Having first array (26) preformed into first flange (22) and/or second array (30) preformed into second flange (24) eliminates screwing together two thickness (t1, t2) of material (e.g., steel material). Having first array (26) preformed into first flange (22) and/or second array (30) preformed into second flange (24) also provides “guide holes” and keeps fasteners (18a-e) from wandering before fasteners (18a-e) sufficiently bite into the material. Without first and second arrays (26, 30) of apertures (28a-v), if tip (40) of fastener (18a-e) does not immediately “bite” into first and second flanges (22, 24), tip (40) dulls making it more difficult to insert fastener (18a-e). Having first array (26) preformed into first flange (22) and/or second array (30) preformed into second flange (24) eliminates this.

C. Second Example of a Layout Track

FIG. 4 shows a second example of a lower layout track (116). Lower layout track (116) may be used instead of lower layout track (16) in construction framing system (10) shown in FIG. 1. Therefore, lower layout tack (116) may be substantially similar to lower layout track (16) described above, with differences elaborated below. FIG. 4 shows a first example of lower layout track (116). However, this description of lower layout track (116) also applies to a second example of an upper layout track. As shown, lower layout track (116) includes a web (120) and first and second flanges (122, 124). Layout track (116) is sized and configured to receive anend of studs (12a-e) between first and second flanges (122, 124). First flange (122) extends perpendicular to web (120), and second flange (124) extends perpendicular to web (120). However, it is envisioned that first flange (120) and/or second flange (122) may extend at a variety of non-zero angles relative to web (120). Second flange (124) is separated from first flange (122) by web (120). In other words, web (120) connects first and second flanges (122, 124) that are positioned opposite one another. Similar to flanges (122, 124) discussed above and shown in FIG. 2, as shown in FIG. 4, first and second flanges (122, 124) are substantially equal in height. In other embodiments, one of first and second flanges (122, 124) may have a height that is greater than the other. Further, in the illustrated embodiment, web (120) is substantially flat. In other embodiments, web (120) may comprise one or more offsets and/or ridges, such that the web (120) is not substantially flat.

First flange (122) includes a first array (126) of apertures (128a-v). Similarly, second flange (124) includes a second array (130) of apertures ((128a-v). First array (126) of apertures (128a-v) and second array (130) of apertures (128a-v)may be substantially similar to first array (26) of apertures (128a-v) and second array (30) of apertures (28a-v) described above, with differences elaborated below. Therefore, apertures ((128a-v) of first and second arrays (126, 130) may provide similar functionality and benefits of aperture (128a-v) described above. Apertures ((128a-v) of first and second arrays (126, 130) are configured to provide pilot holes to assist with the insertion of fasteners (118a-e). First and second arrays (126, 130) of apertures ((128a-v) extend completely through respective first and second flanges (122, 124). First array (126) is arranged along a third longitudinal axis (LA3). Similarly, second array (130) is arranged along a fourth longitudinal axis (LA4), which is spaced apart from and parallel to third longitudinal axis (LA3). First and second arrays (126, 130) are shown as being identical; however, first and second arrays (126, 130) may be different. While first flange (122) is shown as including an array (126) and second flange (124) is shown as including second array (130), it is envisioned that one of first or second flanges (122, 124) may optionally omit the apertures altogether and instead be solid. As shown, apertures ((128a-v) of first array (126) are longitudinally and vertically aligned with a corresponding aperture of apertures ((128a-v) of second array (130). For example, aperture (128a) of first array (126) is longitudinally and vertically aligned with aperture (128a) of second array (130), aperture (128b) of first array (126) is longitudinally and vertically aligned with aperture (128b) of second array (130), and so on. Lower layout track (116) includes opposing first and second terminal ends similar to first and second terminal ends 32, 34 of FIG. 1. First flange (122) has a terminal end (136), and second flange (124) has a terminal end (138).

With continued reference to FIG. 4, first and second arrays (126, 130) of apertures ((128a-v) are arranged in a predetermined pattern corresponding to predetermined lengths of lower layout track (116). This pattern may repeat at a predetermined interval. As shown, the repeating longitudinal pattern is circular aperture, circular aperture, circular aperture, diamond aperture, circular aperture, circular aperture, circular aperture, triangular aperture, circular aperture, circular aperture, circular aperture, square aperture, circular aperture, circular aperture, circular aperture, and star aperture. As shown, off module apertures (128a-c, 128c-g, 128i-k, 128m-o, 128q-s, 128u-v) comprise a circle shaped aperture. In some versions, off module apertures (128a-c, 128c-g, 128i-k, 128m-o, 128q-s, 128u-v) may have an inner dimension of 3/32 inches; however, other dimensions are also envisioned. On module apertures (128d, 128t) comprise a diamond shaped aperture. On module aperture (128h) comprises a triangle shaped aperture. On module aperture (128l) comprises a square aperture. On module aperture (128p)comprises a star shaped aperture. As a result, the predetermined pattern repeats every 16 apertures. However, the predetermined pattern may alternatively repeat every 8, 12, or 20 apertures. It should be understood that the predetermined pattern may repeat with any suitable number of apertures as would be apparent to one skilled in the art in view of the teachings herein.

According to a specific example, on module aperture (128d) has a first shape. As shown, the first shape is a diamond. However, the first shape may alternatively be a variety of suitable shapes including a circle, square, star, triangle, pentagon, hexagon, or clover. The first shape may be any other suitable shape as would be apparent to one skilled in the art in view of the teachings herein. Off module aperture (128e) has a second shape that is different than the first shape. As shown, the second shape is a circle. Similar to the first shape, the second shape may be a variety of suitable shapes including a circle, square, star, triangle, pentagon, hexagon, or clover, provided the second shape is different than the first shape. The second shape may be any other suitable shape as would be apparent to one skilled in the art in view of the teachings herein. Second on module aperture (128h) may have the first shape or a third shape that is different than the first or second shapes. For example, with the first shape being a diamond and the second shape being a circle, the third shape may be a square, star, triangle, pentagon, hexagon, or clover. Unlike FIG. 2 where second on module aperture (28h) has the same shape as first on module aperture (28d), second on module aperture (128h) has a third shape (shown as a triangle). The third shape may be any suitable shape as would be apparent to one skilled in the art in view of the teachings herein. Off module aperture (128e) is positioned between first on module aperture (128d) and second on module aperture (128h). First on module aperture (128d) is separated from second on module aperture (128h) by a predetermined on module length (L6). Similarly, second on module aperture (128h) is separated from third on module aperture (128l) by predetermined on module length (L6), third on module aperture (128l) is separated from fourth on module aperture (128p)by predetermined on module length (L6), and fourth on module aperture (128p)is separated from fifth on module aperture (128t) by predetermined on module length (L6). Off module aperture (128i) has the second shape. Off module apertures (128e, 128i) are also separated by predetermined on module length (L6). Adjacent apertures of the first and second arrays (126, 130) define a spacing comprising a predetermined off module length (L5), which can be one inch on center. Off module aperture (128i) is positioned further from off module aperture (128e) than second on module aperture (128h). As shown, off module apertures (128e-g) are positioned between first and second on module apertures (128d, 128h). Off module apertures (128f-g) have the second shape (i.e., the same shape as off module aperture (128e). As shown, the second shape is a circle extending completely through first and second flanges (122, 124).

With continued reference to FIG. 4, first terminal end aperture (126a) is positioned a predetermined terminal end length (L4) away from terminal end (132). For example, in one embodiment aperture (128a) is located a distance of 1 inch away for the terminal end (132). Terminal end length (L4) is shown as equal to off module length (L5) (i.e., the distance between adjacent apertures (128b-v). In one embodiment, the length (which may also be referred to as a distance) between adjacent apertures (128b-c) is 1 inch on center. Similarly, off module length (L5) between adjacent apertures (128c-d) is 1 inch on center. Particularly, first and second arrays (126, 130) may utilize apertures with a diameter of 3/32 inches starting 1 inch from terminal end (132), and continue at 1 inch on center for remainder of lower layout track (116). In embodiments where the overall length of layout track (116) is a multiple of on module length (L6) (i.e., the overall length of layout track (16) is the product of on module length (L6) and an integer), then the final aperture (i.e., the second terminal aperture (128v)) of the first and second arrays (126, 130) is an off module aperture located terminal end length (L4) from the opposing terminal end (134). For example, if terminal end length (L4) is 1 inch, off module length (L5) is 1 inch, on module length (L6) is 4 inches, and the overall length of layout track (16) is a multiple of 4 inches (e.g., 10 feet, 12 feet, etc.), then the final aperture (i.e., second terminal end aperture (128v)) of first and second arrays (126, 130) is located 1 inch away from the opposing terminal end (134). By having first terminal end aperture (128a) at a terminal end length (L4), which is equal to off module length (L5), from first terminal end (132) and by having a second terminal end aperture (128v) at a terminal end length (L4) from the second terminal end, a first terminal end (132) of a second lower layout track (116) may by butted against second terminal end (134) of first lower layout track (116) without affecting the off module length (L5) between adjacent apertures. In other words, if two layout tracks are butted against each other (i.e., the second terminal end of a first lower layout track (116) is butted against first terminal end of a second lower layout track (116)), then the length between the second terminal end aperture (128v) of the first layout track (16) and the first terminal end aperture (128a) of the second layout track (116) will be twice off module length (L5) and the distance between the final on module aperture of the first layout track (116) and the first on module aperture of the second layout track (116) will be twice on module length (L6). As a result, installers can continue to use on module apertures to install studs at on module spacing spanning across adjacent layout tracks (116) that are butted against each other.

In some instances, terminating ends of first flange (122) and second flange (124) may include a complementary partial cutout. Such complementary cutouts of a first layout track (116) and a second layout track (116) that are butted against each other in accordance with the description herein may cooperatively define a complete on module aperture. Such a cooperatively formed on module aperture may have any suitable shape as would be apparent to one skilled in the art in view of the teachings herein. In some instances, the cooperatively formed aperture may be unique from other on module apertures in order to visually indicate that such an aperture is associated with a juncture between first and second layout tracks (116) that abut against each other at respective terminal ends (132, 134). However, after cooperatively formed aperture is suitably formed via two layout tracks (116) abutting against each other, cooperatively formed aperture may function in substantially similar manner as other on module apertures in accordance with the description herein.

Having first array (126) preformed into first flange (122) and/or second array (130) preformed into second flange (124) may aid in the layout of studs (112a-e). Having array (126) preformed into first flange (122) and/or second array (130) preformed into second flange (124) at the predetermined spacing may accelerate the framing process by allowing the installer to easily identify the correct location for the studs (12a-12e), thereby saving time and money. Having first array (126) preformed into first flange (122) and/or second array (130) preformed into second flange (124) may aid in the construction of multi-piece assembled jamb studs and box beam headers.

Lower layout track (116) may have different “shaped” punchouts to further signify different on center spacings. Instead of the 4 inch on center spacing for traditional layouts, lower layout track (116) may be punched with specific shapes (squares for 12 inch on center, triangles for 16 inch on center and stars for 24 inch on center), to simplify the layout spacing. Off module apertures (128a-c, 128e-g, 128i-k, 128m-o, 128q-s, 128u-v) may still be used for off module stud spacing. As a result, if the construction requires different on center spacing in certain areas, the proper location for the studs within lower layout track (116) is easily identifiable for each condition.

D. Example of Manufacturing a Layout Track

A method (210) of manufacturing layout track (14, 16, 116) from a suitable sheet of material is shown in FIG. 5. Sheet may be formed of any suitable material and include any suitable dimensions as would be apparent to one skilled in the art in view of the teachings herein. In some instances, the sheet on which method (210) is performed is pre-cut a suitable length for a layout track (16, 116) prior to the method (210) of manufacture. In other instances, such a sheet may be cut into a suitable length after method (210) of manufacturing is completed or during any suitable time, as would be apparent to one skilled in the art in view of the teachings herein, while method (210) of manufacturing is being performed.

At step (212), method (210) includes punch forming on module apertures (28d, 128d) having a first shape through layout track (14, 16, 116) using a punch press. At step (214), method (210) includes punch forming off module apertures (28e, 128e), having a second shape, different than the first shape, through layout track (14, 16, 116). While the current method (210) includes punch forming on module apertures (28d, 128d) and subsequently punch forming off module apertures (28e, 128e), it should be understood that on module apertures and off module apertures may be punch formed in any suitable order as would be apparent to one skilled in the art in view of the teachings herein. It is envisioned that adjacent apertures may be punch formed simultaneously or consecutively. For example, as layout track (14, 16, 116) is moved longitudinally relative to a punch press, additional apertures may be formed singularly or in groups.

Therefore, in some instances, a single on module aperture of a first shape may be formed simultaneously while three off module apertures of a second shape are formed. Subsequently, the sheet on which apertures are formed may be moved a suitable longitudinal distance relative to punch press in order to repeat the process of forming a single on module aperture with three off module apertures that are offset from adjacent apertures a suitable offset distance (such as length (L2) or length (L5)). In other instances, a single on module aperture of a first shape may be formed, and subsequently three off module operators of a second shape may be formed, either simultaneously or subsequently.

At step (216), method (210) includes bending the layout track (14, 16, 116) to form a U-shape with at least one on module aperture (28d, 28h, 28l, 28p, 28t, 128d, 128h, 128l, 128p, 128t) and at least one off module aperture (28a-c, 28e-g, 28i-k, 28m-o, 28q-s, 28u, 28v, 128a-c, 128e-g, 128i-k, 128m-o, 128q-s, 128u, 128v) positioned on a first flange (22, 122) and at least on module aperture (28d, 28h, 28l, 28p, 28t, 128d, 128h, 128l, 128p, 128t) and at least one off module aperture (28a-c, 28e-g, 28i-k, 28m-o, 28q-s, 28u, 28v, 128a-c, 128e-g, 128i-k, 128m-o, 128q-s, 128u, 128v,) positioned on second flange (24, 124). First flange (22, 122) and second flange (24, 124) are separated by web (20, 120). in other embodiments, the act of bending may be performed before the punch forming of on module apertures 28d, 28h, 28l, 28p, 28t, 128d, 128h, 128l, 128p, 128t) and off module apertures (28a-c, 28e-g, 28i-k, 28m-o, 28q-s, 28u, 28v, 128a-c, 128e-g, 128i-k, 128m-o, 128q-s, 128u, 128v).

III Exemplary Combinations

The following examples relate to various non-exhaustive ways in which the teachings herein may be combined or applied. It should be understood that the following examples are not intended to restrict the coverage of any claims that may be presented at any time in this application or in subsequent filings of this application. No disclaimer is intended. The following examples are being provided for nothing more than merely illustrative purposes. It is contemplated that the various teachings herein may be arranged and applied in numerous other ways. It is also contemplated that some variations may omit certain features referred to in the below examples. Therefore, none of the aspects or features referred to below should be deemed critical unless otherwise explicitly indicated as such at a later date by the inventors or by a successor in interest to the inventors. If any claims are presented in this application or in subsequent filings related to this application that include additional features beyond those referred to below, those additional features shall not be presumed to have been added for any reason relating to patentability.

EXAMPLE 1

A construction framing system comprising: (a) first and second studs; (b) a first layout track, wherein a first end of the first stud is received within the first layout track and a first end of the second stud is received within the first layout track comprising: (i) a web, (ii) a first flange extending perpendicular to the web, and (iii) a second flange extending perpendicular to the web, wherein the second flange is separated from the first flange by the web, and (iv) a first array of preformed apertures extending completely through the first flange, wherein the first array of preformed apertures is arranged along a first longitudinal axis, the first array of preformed apertures comprising: (A) a first off module aperture having a first shape, (B) a first on module aperture having a second shape that is different from the first shape, (C) a second on module aperture having a shape that is selected from the group consisting of the second shape and a third shape that is different than the first shape and the second shape, wherein the first off module aperture is positioned between the first on module aperture and the second on module aperture, wherein the first on module aperture and the second on module aperture are separated by a predetermined distance; (c) a first fastener inserted through the first on module aperture and into the first stud; and (d) a second fastener inserted through the second on module aperture and into the second stud.

EXAMPLE 2

The construction framing system of Example 1, wherein the predetermined distance is selected from the group consisting of 12 inches on center, 16 inches on center, and 24 inches on center.

EXAMPLE 3

The construction framing system of any preceding Example, wherein adjacent preformed apertures of the first array of preformed apertures are spaced apart an off module length of one inch on center.

EXAMPLE 4

The construction framing system of any preceding Example, wherein the first shape is a circle and the second shape is a diamond.

EXAMPLE 5

The construction framing system of any preceding Example, further comprising a second off module aperture having the first shape, wherein the first off module aperture and the second off module aperture are separated by the predetermined distance.

EXAMPLE 6

The construction framing system of Example 5, further comprising a third off module aperture and a fourth off module aperture positioned between the first on module aperture and the second on module aperture, wherein the third off module aperture and the fourth off module aperture each have the first shape.

EXAMPLE 7

The construction framing system of any preceding Example, wherein the second on module aperture has the second shape.

EXAMPLE 8

The construction framing system of any preceding Example, wherein the first shape is selected from the group consisting of a circle, diamond square, star, triangle, pentagon, hexagon, and clover.

EXAMPLE 9

The construction framing system of any preceding Example, wherein the first fastener has a generally circular cross-sectional area that is different than the first shape.

EXAMPLE 10

The construction framing system of any preceding Example, wherein the second shape is selected from the group consisting of a circle, diamond square, star, triangle, pentagon, hexagon, and clover.

EXAMPLE 11

The construction framing system of any preceding Example, wherein the first shape is a circle.

EXAMPLE 12

The construction framing system of any preceding Example, further comprising a second array of preformed apertures extending completely through the second flange, wherein the second array of preformed apertures is arranged along a second longitudinal axis that is parallel to the first longitudinal axis.

EXAMPLE 13

The construction framing system of Example 12, the second array of preformed apertures comprising: (a) a third off module aperture having the first shape, (b) a third on module aperture having the second shape, (c) a fourth on module aperture having a shape that is selected from the group consisting of the second shape and the third shape, wherein the third off module aperture of the second array of preformed apertures is positioned between the third on module aperture and the fourth on module aperture of the second array of preformed apertures, wherein the third on module aperture and the fourth on module aperture of the second array of preformed apertures are separated by the predetermined distance, and (d) a fourth off module aperture having the first shape.

EXAMPLE 14

The construction framing system of any preceding Example, wherein the first fastener includes a threaded portion having a maximum cross-sectional area, wherein the maximum cross-sectional area of the threaded portion is greater than a maximum cross-sectional area defined by the first on module aperture.

EXAMPLE 15

The construction framing system of any preceding Example, wherein the layout track comprises a first terminal end and a second terminal end opposite the first terminal end and the first array of preformed apertures further comprises a first terminal end aperture located between the first terminal end and the first on module aperture, wherein the distance between the first terminal end and the first terminal end aperture is equal to the distance between the first terminal end aperture and the adjacent preformed aperture in the first array of preformed apertures.

EXAMPLE 16

The construction framing system of Example 15, wherein the first array of preformed apertures further comprises a second terminal end aperture located between the second on module aperture and the second terminal end, wherein the distance between the second terminal end aperture and the second terminal end is equal to the distance between the second terminal end aperture and the adjacent preformed aperture in the first array of preformed apertures.

EXAMPLE 17

The construction framing system of any preceding Example, wherein the first layout track is integrally formed together as a single unitary piece of metal.

EXAMPLE 18

A layout track comprising: (a) a web; (b) a first flange extending perpendicular to the web; (c) a second flange extending perpendicular to the web and separated from the first flange by the web; and (d) a first array of preformed apertures, wherein the first array of preformed apertures extends completely through the first flange, wherein the first array of preformed apertures comprises apertures that define a repeating longitudinal pattern, the repeating longitudinal pattern comprising: (i) a first off module aperture having a first shape, (ii) a second off module aperture having the first shape, (iii) a third off module aperture having the first shape, and (iv) a first on module aperture having a second shape that is different from the first shape, wherein the first off module aperture is adjacent to the second off module aperture, the second off module aperture is adjacent to both the first off module aperture and the third off module aperture, the third off module aperture is adjacent to both the second off module aperture and the first on module aperture, and the first on module aperture is adjacent to the third off module aperture.

EXAMPLE 19

The layout track of Example 18, wherein adjacent preformed apertures of the first array of preformed apertures are spaced apart from each other a distance of one inch on center.

EXAMPLE 20

The layout track of any of Examples 18 through 19, wherein the first array of preformed apertures is arranged along a first longitudinal axis, wherein the wherein the second array of preformed apertures is arranged along a second longitudinal axis that is parallel to the first longitudinal axis.

EXAMPLE 21

A layout track comprising: (a) a web; (b) a first flange extending perpendicular to the web, wherein the first flange extends an overall length from a first terminal end to a second terminal end; (c) a second flange extending along the overall length and perpendicular to the web and separated from the first flange by the web; and (d) a first array of preformed apertures, wherein the first array of preformed apertures extends completely through the first flange, wherein the first array of preformed apertures comprises (i) a first off module aperture having a first shape, wherein the first off module aperture is located a terminal end length from the first terminal end, (ii) a second off module aperture adjacent to the first off module aperture and located an off module length from the first off module aperture, (iii) a first on module aperture having a second shape that is different from the first shape, wherein the first on module aperture is located such that the second off module aperture is located between the first off module aperture and the first on module aperture, (iv) a second on module aperture having a shape that is selected from the group consisting of the second shape and a third shape that is different than the first shape and the second shape, wherein the second on module aperture is located an on module length from the first on module aperture, wherein the on module length is a multiple of the off module length.

EXAMPLE 22

The layout track of Example 21, wherein the overall length of the web is a multiple of the on module length.

EXAMPLE 23

The layout track of any of Example 20 through Example 22, further comprising a third off module aperture located the terminal end length from the second terminal end.

EXAMPLE 24

The layout track of any of Example 20 through Example 23, wherein the terminal end length is equal to the off module length.

EXAMPLE 25

The layout track of any of Example 20 through Example 24, wherein the terminal end length is one inch and the off module length is one inch.

EXAMPLE 26

The layout track of any of Example 20 through Example 25, wherein the on module length is four inches.

EXAMPLE 27

The layout track of any of Example 20 through Example 26, wherein the overall length is selected from the group consisting of 10 feet and 12 feet.

EXAMPLE 28

The layout track of any of Example 20 through Example 27, wherein the terminal end length is one inch.

EXAMPLE 29

The layout track of any of Example 20 through Example 28, wherein the off module length is one inch.

EXAMPLE 30

The layout track of any of Example 20 through Example 29, wherein the on module length is four inches.

EXAMPLE 31

A method of manufacturing a layout track for construction framing, the method comprising: punch forming a first off module aperture and a second off module aperture through the layout track, wherein the first off module aperture and the second off module aperture each comprise a first shape; punch forming a first on module aperture and a second on module aperture through the layout track, wherein the first on module aperture and the second on module aperture have a second shape that is different than the first shape; and bending the layout track to form a first flange, a second flange and a web, wherein the first off module aperture and the first on module aperture are positioned on the first flange and the second off module aperture and the second on module aperture are positioned on the second flange, wherein the first and second flanges are separated by the web.

EXAMPLE 32

The method of Example 31, wherein the act of bending is performed after the punch forming of the first off module aperture, the second off module aperture, the first on module aperture, and the second on module aperture.

IV. Miscellaneous

It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein may be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. that are described herein. The above-described teachings, expressions, embodiments, examples, etc. should therefore not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined will be readily apparent to those of ordinary skill in the art in view of the teachings herein. Such modifications and variations are intended to be included within the scope of the claims.

Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.

CONSTRUCTION FRAMING SYSTEM INCLUDING A LAYOUT TRACK

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Provisional Applications (1)