STAGGERED STUD WALL BRACING SYSTEM

Abstract

A staggered stud wall system includes a top track having a main top web and depending inner and outer flanges, a bottom track having a main bottom web and vertically projecting inner and outer flanges, a first plurality of studs having a main stud web and at least one stud flange secured to inner top and bottom track flanges, a second plurality of studs having a main stud web and at least one stud flange secured to the outer top and bottom track flanges, the main top web and the main bottom web having a width greater than a width of the main stud web of the first and second plurality of studs, and stud bracing being installed to prevent movement of inner edges of the first and second plurality of studs relative to the top track and the bottom track.

Description

BACKGROUND

The present invention relates generally to building construction techniques, and more specifically to a system used to enhance existing staggered stud wall systems to enable such walls to be employed in load-bearing applications.

Conventional building walls are assembled using horizontal steel top and bottom tracks, vertical steel “C” configuration studs secured to the top and bottom tracks, wallboard panels secured at seams to the vertical studs, and in many cases, insulation applied between opposing wallboard panels and between vertical studs. Interior walls use gypsum wallboard panels, and exterior walls usually employ more robust Glassmat™ board or cement board panels, optionally having strength enhancing fibers.

While the insulation creates a thermal barrier between the wallboard panels, there is no insulation at the attachment point of the wallboard panels to the vertical studs. As such, the entire intra-panel space is occupied by the stud, without any insulation. These points have been noted as breaks in the thermal barrier. Many municipalities have taken steps to revise the respective local building codes to require higher thermal insulation standards, especially for exterior walls.

Efforts to increase the thermal efficiency of such walls often involve the relatively costly and time consuming wrapping of the walls with insulating foam panels, especially when such walls are for the exterior of a building. Another approach to increasing the thermal efficiency of a wall is to assemble a so-called “party wall.” Relatively wider top and bottom tracks are employed, with the width increased from approximately 3⅝ or 4 inches (the width of a conventional steel “C”-stud), to approximately six inches. As is known in the art, the top and bottom tracks have an inner and outer vertical flange. Vertical studs are staggered so that every other stud is secured to the inner flange, and the other alternate studs are secured to the outer flange. The vertical studs are spaced at 24-inch spacing, and the wallboard panels are secured to these studs. However, the total stud spacing, including the alternating studs attached to both the inner and outer flanges is 12 inches.

Thus, an inner space is defined by the space between the inner edges of the studs and the remaining space of the top and bottom tracks. In this space, insulation is inserted to create a more continuous thermal barrier which enhances the thermal retention of the walls and is superior to that of conventional wall construction. The fact that the studs no longer act as an interruption to the thermal barrier over the cross-section of the wall significantly increases the thermal rating of the wall.

However, a drawback of conventional “party walls” is that since each stud is only secured to the top and bottom tracks on one side, the studs are prone to twisting or other misalignment when subject to heavy loads. Accordingly, “party walls” have not been considered suitable for exterior or load-bearing applications.

Accordingly, there is a need for an improved “party wall” that provides the benefits of enhanced thermal ratings for a load-bearing or external wall application.

SUMMARY

The above-listed need is met or exceeded by the present staggered stud wall bracing system in which the vertical studs of a “party wall” are more positively secured to the top and bottom tracks so that twisting or other unwanted movement under load is prevented and the wall is sufficiently stable to be used in load bearing or external applications. As such, the exterior panel is glass mat or cement board panel, and the interior panel is conventional gypsum wallboard.

The additional support for the vertical studs is provided in one embodiment by bracing taking the form of horizontally-positioned struts which pass through openings in a main web or panel of the struts and connect each of the staggered struts together. Thus, using the struts, the studs attached to the inner flange are attached to each other and also to the studs attached to the outer flange. Such connection is achieved by locating the opening in the main stud web in an off-center position so that the openings are in registry as the studs are assembled, and the opening is located in an overlapping portion of the stud.

In a preferred embodiment, the openings are keyed or otherwise noncircular, and the struts are provided with complementary clips or collars to matingly engage the openings and thus hold the studs in position against loads. Also it is preferred that the openings in the main stud webs are off-center on each stud, so that upon assembly, openings of the first and second plurality of studs are in registry with each other.

In an embodiment, the struts are “u”-shaped, and are connected to each other in a telescoping arrangement, using set screws or the like to secure the adjacent strut segments in position.

In another embodiment, the studs are held in position by providing the top and bottom tracks with inwardly projecting tabs or ribs. Upper and lower edges of the studs are provided with recesses or grooves that matingly accommodate the tabs. It is contemplated that one embodiment of the present system employs both the horizontal struts and the tabs and recesses for more securely retaining the studs in position.

More specifically, a staggered stud wall system is provided, including a top track having a main top web and depending inner and outer top flanges, a bottom track having a main bottom web and vertically projecting inner and outer bottom flanges, a first plurality of studs having a main stud web and at least one stud flange secured to the inner flanges of the top and bottom tracks, a second plurality of studs having a main stud web and at least one stud flange secured to the outer flanges of the top and bottom tracks, the main top web and the main bottom web having a width greater than a width of the main stud web of the first and second plurality of studs, a first plurality of wallboard panels secured to the first plurality of studs, forming an interior wall surface, a second plurality of wallboard panels secured to the second plurality of studs, forming an exterior wall surface, insulation being inserted in an interior space defined between inner edges of the first and second plurality of studs and the corresponding inner and outer flanges of the top and bottom tracks, and stud bracing being installed to prevent movement of inner edges of the first and second plurality of studs relative to the top track and the bottom track.

In an embodiment, the stud bracing includes openings in the main stud web of the first and second plurality of studs, and at least one strut generally horizontally positioned to connect openings of adjacent studs. In one embodiment, the openings are non-circular and each strut is provided with complementary clips or collars configured for matingly engaging the openings. Preferably, complementary collars are securable to the at least one strut, or clips are provided on each side of a strut web.

In an embodiment, the at least one strut is a plurality of struts configured for telescopingly engaging each other. Preferably, fasteners are included for securing adjacent struts together in a determined telescoping arrangement. In a preferred embodiment, each strut is “u”-shaped in vertical cross-section.

In an embodiment, the stud bracing includes providing the top and bottom tracks with inwardly projecting tabs, and upper and lower edges of the main stud webs of the first and second pluralities of studs are provided with recesses that matingly accommodate the tabs.

In an embodiment, the first plurality of wallboard panels is conventional paper-faced gypsum wallboard, and the second plurality of wallboard panels is one of Glassmat™ board or cement board.

In another embodiment, a staggered stud wall system is provided, including a top track having a main top web and depending inner and outer top flanges, a bottom track having a main bottom web and vertically projecting inner and outer bottom flanges, a first plurality of studs having a main stud web and at least one stud flange secured to the inner flanges of the top and bottom tracks, a second plurality of studs having a main stud web and at least one stud flange secured to the outer flanges of the top and bottom tracks, the main top web and the main bottom web having a width greater than a width of the main stud web of the first and second plurality of studs, a first plurality of wallboard panels secured to the first plurality of studs, forming an interior wall surface, a second plurality of wallboard panels secured to the second plurality of studs, forming an exterior wall surface, insulation being inserted in an interior space defined between inner edges of the first and second plurality of studs and the corresponding inner and outer flanges of the top and bottom tracks, and stud bracing being installed to prevent movement of inner edges of the first and second plurality of studs relative to the top track and the bottom track, the stud bracing taking the form of at least one of horizontal struts engaging openings in the main stud webs of the first and second pluralities of studs, and tabs projecting inwardly from the main top web and the main bottom web for engaging complementary recesses that matingly accommodate the tabs.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a PRIOR ART party wall using wooden framing;

FIG. 2 is a side view of the present bracing system, including top and bottom tracks with fastening formations and a web of the stud with a strut keyway;

FIG. 3 is an overhead plan view of the present system as shown in FIG. 2; and

FIG. 4 is a fragmentary perspective view of a strut engaging an opening in a stud and being secured in place by clips.

DETAILED DESCRIPTION

Referring now to FIG. 1, a known, prior art “party wall” system using wooden framing is fragmentarily depicted and generally designated 10, including a wooden footer 12, and a wooden header (not shown), as well as a plurality of vertically-projecting wooden studs 14. The party wall 10 is distinguishable from conventional walls in that both the header and the footer 12 are wider than the traditional “2×4” lumber, having a width “W” of at least about 4 to 6 inches, based on the understanding that conventional 2×4 lumber is actually 1.5×3.5 inches. Each of the footer 12 and the header have an inside edge 16 and an opposite outside edge 18. A first plurality of inside studs 14a is placed flush with the inside edge 16, and a second plurality of outside studs 14b is placed flush with the outside edge 18. The distance between studs 14a and 14b on each side along the length of the footer 12 may vary to suit the application, however in one embodiment, the spacing is 24 inches. Thus, the spacing between an inside and an outside stud is 12 inches, which of course may vary to suit the application, provided the studs 14 are placed at regular intervals per the local code.

At least one inside wallboard panel 20 is secured to the inside studs 14a and at least one outside wallboard panel 22 is secured to the outside studs 14b using fasteners (not shown) such as screws or nails as are well known in the art. A space 24 is defined between inner edges 26 of each of the studs 14a and 14b. At least one bat of insulation 28 is inserted in a serpentine arrangement into the space 24 to enhance the thermal properties of the wall 10. It is contemplated that the insulation 28 extends the full height of the wall 10. Unlike traditional wall construction, the party wall 10 lacks the thermal blocks created by the wallboard panels being directly connected to the studs on each side, where the framing is only as wide as a typical stud, approximately 3.5 inches. Instead, the party wall 10 features insulation all along the space 24, which is unbroken by studs 14a, 14b. As indicated above, such construction has been considered unsuitable for exterior walls, due to the possibility of the studs 14a, 14b becoming axially twisted by environmental shear forces, mostly wind-induced.

Referring now to FIGS. 2-4, the present staggered stud wall system is generally designated 40 and includes a “C”-profile top track 42, analogous to the header of FIG. 1, having a main top web 44 and depending inner and outer top flanges 46, 48. A similar “C”-profile bottom track 50 analogous to the footer 12, has a main bottom web 52 and vertically projecting inner and outer bottom flanges 54, 56. A first plurality of studs 58 each has a main stud web 60 and at least one stud fastening flange 62, secured to the inner flanges 54 of the top and bottom tracks 42, 50. A second plurality of studs 64 has a main stud web 66 and at least one stud fastening flange 68 secured to the outer flanges 48, 56 of the top and bottom tracks 42, 50.

Preferably, the main top web 44 and the main bottom web 52 each have a width “W” (FIG. 3) greater than a width of the main stud web 60, 66 of the first and second plurality of studs 58, 64. In an embodiment, the width “W” of the top and bottom webs 44, 52 is six inches, however other widths are contemplated depending on the application and the local building code. Once the wall frame is constructed using the top track 42, the bottom track 50 and the studs 58, 64, a bat of insulation 70 (FIG. 3) is inserted into an interior space 72 defined between inner edges of the first and second plurality of studs and the corresponding inner and outer flanges of the top and bottom tracks between the studs 58, 64, in similar fashion to the conventional party wall 10.

Next, a first plurality of wallboard panels 74 is secured to the first plurality of studs 58, forming an interior wall surface, and a second plurality of wallboard panels 76 is secured to the second plurality of studs, forming an exterior wall surface. As seen, the wallboard panels 74, 76 are contemplated as having at least a single panel thickness, or multiple panel thicknesses, depending on the application and local building codes. As such, in general, as described above, the present wall system 40 resembles the prior art party wall 10. It is also contemplated that the first plurality of wallboard panels 74 is conventional paper-faced gypsum wallboard, forming an interior wall, and the second plurality of wallboard panels 76 is one of Glassmat™, cement board or other known construction panels suitable for exterior use.

Referring now to FIGS. 2-4, an important feature of the present wall system 40 is the inclusion of stud bracing 80 for preventing unwanted movement of inner edges 78 of the first and second plurality of studs 58, 64 relative to the top track 42 and the bottom track 50. In the preferred embodiment, the stud bracing 80 takes the form of at least one rigid strut 82 that is preferably horizontally oriented and as such is parallel to the top track 42 and the bottom track 50. Various configurations are contemplated for the struts 82, including tubular or “C” or “U”-shaped cross-section, or polygonal cross-sections. Also, as seen in FIG. 4, telescoping struts 82 are envisioned with a first strut segment 82a axially slidingly engaging another strut segment 82b to achieve a desired length.

Openings 84 in the main stud webs 60, 66 are constructed and arranged to accommodate passage of the struts 82. As seen in FIG. 2, the openings 84 are irregular or non-circular for accommodating a complementary cross-section of the strut to achieve a more secure assembly. It will be seen that the openings 84 are off-center on each of the studs 58, 64 and more specifically off-center on the stud webs 60, 66 so that upon assembly, the openings 84 of both pluralities of studs 58, 64 are in registry with each other. As the wall system 40 is assembled, the struts 82 are inserted into the aligned openings 84 once the studs 58, 64 are secured in place.

Referring now to FIGS. 2-4, in some embodiments, clips 86 are provided at the junction of the strut 82 and the opening 84 to secure the strut to the studs 58, 64. As seen in FIG. 2, the clip 86 takes the form of a non-circular piece 88 (shown hidden) that is placed transversely on the strut 82 and clamps against each side of the main stud web 60, 66, so that the main stud web is sandwiched between the clips.

Referring now to FIG. 4, it is contemplated that the opening 84 is vertically enlarged to form a slot, and the clip 86 includes a main flange 90 having a horizontally enlarged portion 92 provided with a slit 94 complementary in dimension to a thickness of the main stud web 60, 66. The clip 86 is then fastened to the strut 82 using fasteners 96 such as screws, chemical adhesive or the like. In some embodiments, it is contemplated that the clips 86 are rotatable about the struts 82, provided that they are securable against the main stud webs 60, 66. Also, in some cases, fasteners 98 are provided for securing telescoping strut portions 82a, 82b together.

Referring again to FIG. 2, the stud bracing 80 is also envisioned as including providing at least one of the top and bottom tracks 42, 50 with inwardly (vertically) projecting tabs 100. Also, upper and lower edges 102, 104 of the main stud webs 60, 66 of the first and second pluralities of studs 58, 64 are provided with recesses 106 that matingly accommodate the tabs 100 and as such prevent rotation of the studs relative to the top and bottom tracks 42, 50. As seen in FIG. 2, the tabs 100 are preferably wedge-shaped, having points 108 formed at the intersection of angled walls 110. However, other shapes are contemplated.

While a particular embodiment of the present staggered stud wall bracing system has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.

Claims

1. A staggered stud wall system, comprising: a top track having a main top web and depending inner and outer flanges;a bottom track having a main bottom web and vertically projecting inner and outer flanges;a first plurality of studs having a main stud web and at least one stud flange secured to the inner flanges of said top and bottom tracks;a second plurality of studs having a main stud web and at least one stud flange secured to said outer flanges of said top and bottom tracks;said main top web and said main bottom web having a width greater than a width of said main stud web of said first and second plurality of studs;a first plurality of wallboard panels secured to said first plurality of studs, forming an interior wall surface;a second plurality of wallboard panels secured to said second plurality of studs, forming an exterior wall surface;insulation being inserted in an interior space defined between inner edges of said first and second plurality of studs and said corresponding inner and outer flanges of said top and bottom tracks; andstud bracing being installed to prevent movement of inner edges of said first and said second plurality of studs relative to said top track and said bottom track.

2. The wall system of claim 1, wherein said bracing includes openings in said main stud web of said first and second plurality of studs, and at least one strut generally horizontally positioned to connect openings of adjacent studs.

3. The wall system of claim 2, wherein said openings in said main stud webs are off-center on each said stud, so that upon assembly, openings of the first and second plurality of studs are in registry with each other.

4. The wall system of claim 2, wherein said openings are non-circular and said at least one strut is provided with complementary clips or collars configured for matingly engaging said openings.

5. The wall system of claim 4, wherein said clips are rotatable relative to said at least one strut, and are rotatable between an unlocked and locked position.

6. The wall system of claim 2, wherein said at least one strut is a plurality of struts configured for telescopingly engaging each other.

7. The wall system of claim 6, further including fasteners for securing adjacent struts together in a determined telescoping arrangement.

8. The wall system of claim 6, wherein each said at least one strut is “u”-“shaped.

9. The wall system of claim 1 wherein said stud bracing includes providing the top and bottom tracks with inwardly projecting tabs, and upper and lower edges of said main stud webs of said first and second pluralities of studs are provided with recesses that matingly accommodate the tabs.

10. The wall system of claim 4 wherein said stud bracing includes providing the top and bottom tracks with inwardly projecting tabs, and upper and lower edges of said main stud webs of said first and second pluralities of studs are provided with recesses that matingly accommodate the tabs.

11. The wall system of claim 1 wherein said first plurality of wallboard panels is conventional paper-faced gypsum wallboard, and said second plurality of wallboard panels is one of Glassmat™ or cement board.

12. A staggered stud wall system, comprising: a top track having a main top web and depending inner and outer flanges;a bottom track having a main bottom web and vertically projecting inner and outer flanges;a first plurality of studs having a main stud web and at least one stud flange secured to the inner flanges of said top and bottom tracks;a second plurality of studs having a main stud web and at least one stud flange secured to said outer flanges of said top and bottom tracks;said main top web and said main bottom web having a width greater than a width of said main stud web of said first and second plurality of studs;a first plurality of wallboard panels secured to said first plurality of studs, forming an interior wall surface;a second plurality of wallboard panels secured to said second plurality of studs, forming an exterior wall surface;insulation being inserted in an interior space defined between inner edges of said first and second plurality of studs and said corresponding inner and outer flanges of said top and bottom tracks; andstud bracing being installed to prevent movement of inner edges of said first and said second plurality of studs relative to said top track and said bottom track, said stud bracing taking the form of at least one of horizontal struts engaging openings in said main stud webs of said first and second pluralities of studs, and tabs projecting inwardly from said main top web and said main bottom web for engaging complementary recesses that matingly accommodate said tabs.