Not Applicable.
Not Applicable.
Not Applicable.
Exemplary embodiment(s) of the present disclosure relate to stick-built construction frame systems and, more particularly, to a support wall frame system including at least one end track and a frame member connected thereto, wherein the frame member has a series of ribs and stiffeners to increase its shear strength so that the frame member resists twisting thereby preventing racking of the support wall.
Stick frame construction or simply stick construction is used for a large portion of the frame of a building, is used in a large percentage of smaller scale building construction projects. Stick construction utilizes studs, lightweight materials, typically either wood or metal, to construct the frame, including walls, floor joists and roof trusses of the building under construction, wood studs being typical in residential construction and metal studs being typical in commercial construction. Stick frame construction produces a building frame that has a relatively high strength to weight ratio.
While a strong frame can be produced using standard stick frame construction, there is room for improvement. One issue building design engineers grapple with is trying to increase the shear strength of the frame built, especially, the vertical or wall components of the frame. A stick frame constructed building is subject to in plane lateral forces, caused by wind and earthquakes. If such in plane force is sufficiently strong, the building can be subject to racking, wherein the walls of the building come out of square. Racking causes damage to carious components of the building, including the walls, both interior and exterior, cabinets, doors and windows, flooring, especially upper story flooring, and in extreme cases, structural failure.
In wood stick frame construction, engineers focus on the strength of the wood used to produce the stud as well as bracing the frame and the walls via sheathing and other methods, in order to increase the shear strength of the structure built in order to thereby reduce the potential for racking. In addition to these considerations, in metal stick construction, engineers also focus on the geometry of the frame, particularly the stud, to increase the overall shear strength of the stud and thereby increase overall shear strength of the frame produced.
Accordingly, a need remains for a frame system in order to overcome at least one aforementioned shortcoming. The exemplary embodiment(s) satisfy such a need by providing a support wall frame system including a frame member having a series of ribs and stiffeners and at least one end track connected to the frame member, that is convenient and easy to use, lightweight yet durable in design, versatile in its applications, and designed for increasing the frame members shear strength so that the frame member resists twisting and prevents racking of the support wall. The present disclosure provides non-obvious improvements to the subject matter disclosed in U.S. Pat. No. 5,315,804 and U.S. Published Patent Application Nos. US20040074200A1, US20050166524A1, and US20060144009A1, which were filed by the applicant of the present application.
In view of the foregoing background, it is therefore an object of the non-limiting exemplary embodiment(s) to provide a metal stud to be used in stick frame construction wherein the geometry of the stud, as well as the receiving portion of the end track that receives the stud, are designed to increase the shear strength of the stud and thus the overall support wall produced, for a given material used to produce the stud. These and other objects, features, and advantages of the non-limiting exemplary embodiment(s) are provided by a support wall frame system for providing increased shear strength thereby preventing twisting and racking of a support wall. Such a support wall frame system advantageously includes a metal frame member that is of relatively simple design and construction, being produced using standard manufacturing techniques, so that the metal frame stud is economically attractive to potential consumers for this type of product. Use of the metal frame member is relatively straightforward requiring only the standard skills application to metal stick frame. Special tools to produce the frame using the metal frame member of the present invention are not required.
In a non-limiting exemplary embodiment, the support wall frame system includes at least one end track, and a frame member received within the at least one end track. The frame member includes a plurality of ribs and a plurality of stiffeners spaced therefrom, respectively. The plurality of ribs are statically affixed to the at least one end track, and the plurality of stiffeners are abutted against the at least one end track.
In a non-limiting exemplary embodiment, the frame member has a single and unitary metal body.
In a non-limiting exemplary embodiment, the metal frame member includes an elongate stud that has a stud base with a first stud side wall extending upwardly from a first end of the stud base and a second stud side wall extending upwardly from an opposing second end of the base. The first stud side wall and the second stud side wall are coextensive and parallel with each other and each is oriented in perpendicular fashion with respect to the stud base. At least one inwardly directed first rib is located along a first length of the first stud side wall while at least one inwardly directed second rib is located along a second length of the second stud side wall. An end of the stud is received within an end track.
In a non-limiting exemplary embodiment, the at least one end track includes a bottom end track and a top end track, each including a track base that has a first track side wall extending upwardly from a first side of the track base and a second track side wall extending upwardly from a second side of the track base. The first track side wall has an inwardly directed first detent and the second track side wall has a second inwardly directed detent. The stud is disposed between the first track side wall and the second track side wall such that the first detent is received within the first rib and the second detent is received within the second rib. A first return leg extends inwardly from a first distal end of the first stud side wall while a second return leg extends inwardly from a second distal end of the second stud side wall. The first return leg and the second return leg are substantially similar in length to one another, are each oriented in perpendicular fashion with respect to the first stud side wall and the second stud side wall and are each oriented in parallel fashion with respect to the stud base.
In a non-limiting exemplary embodiment, a first flange extends downwardly from a third distal end of the first return leg while a second flange extends downwardly from a fourth distal end of the second return leg. The first flange and the second flange are substantially similar in length to one another, are each oriented in perpendicular fashion with respect to the first return leg and the second return leg and are each oriented in parallel fashion with respect to the first stud side wall and the second stud side wall. At least one inwardly directed stiffener is located along a third length of the base.
In a non-limiting exemplary embodiment, the stiffener is generally V-shaped. The first rib and the second rib are each generally U-shaped. The stud base, the first stud side wall, and the second stud side wall are each integral with one another, being formed from a single and continuous sheet or section of material. At least one first fastener passes through the first detent and the first rib while a second fastener passes through the second detent and the second rib. The stud has a width with a first dimension and the end track has an inside diameter with a second dimension that is substantially similar to the first dimension.
There has thus been outlined, rather broadly, the more important features of non-limiting exemplary embodiment(s) of the present disclosure so that the following detailed description may be better understood, and that the present contribution to the relevant art(s) may be better appreciated. There are additional features of the non-limiting exemplary embodiment(s) of the present disclosure that will be described hereinafter and which will form the subject matter of the claims appended hereto.
The novel features believed to be characteristic of non-limiting exemplary embodiment(s) of the present disclosure are set forth with particularity in the appended claims. The non-limiting exemplary embodiment(s) of the present disclosure itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
Those skilled in the art will appreciate that the figures are not intended to be drawn to any particular scale; nor are the figures intended to illustrate every non-limiting exemplary embodiment(s) of the present disclosure. The present disclosure is not limited to any particular non-limiting exemplary embodiment(s) depicted in the figures nor the shapes, relative sizes or proportions shown in the figures.
The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which non-limiting exemplary embodiment(s) of the present disclosure is shown. The present disclosure may, however, be embodied in many different forms and should not be construed as limited to the non-limiting exemplary embodiment(s) set forth herein. Rather, such non-limiting exemplary embodiment(s) are provided so that this application will be thorough and complete, and will fully convey the true spirit and scope of the present disclosure to those skilled in the relevant art(s). Like numbers refer to like elements throughout the figures.
The illustrations of the non-limiting exemplary embodiment(s) described herein are intended to provide a general understanding of the structure of the present disclosure. The illustrations are not intended to serve as a complete description of all of the elements and features of the structures, systems and/or methods described herein. Other non-limiting exemplary embodiment(s) may be apparent to those of ordinary skill in the relevant art(s) upon reviewing the disclosure. Other non-limiting exemplary embodiment(s) may be utilized and derived from the disclosure such that structural, logical substitutions and changes may be made without departing from the true spirit and scope of the present disclosure. Additionally, the illustrations are merely representational are to be regarded as illustrative rather than restrictive.
One or more embodiment(s) of the disclosure may be referred to herein, individually and/or collectively, by the term “non-limiting exemplary embodiment(s)” merely for convenience and without intending to voluntarily limit the true spirit and scope of this application to any particular non-limiting exemplary embodiment(s) or inventive concept. Moreover, although specific embodiment(s) have been illustrated and described herein, it should be appreciated that any subsequent arrangement designed to achieve the same or similar purpose may be substituted for the specific embodiment(s) shown. This disclosure is intended to cover any and all subsequent adaptations or variations of other embodiment(s). Combinations of the above embodiment(s), and other embodiment(s) not specifically described herein, will be apparent to those of skill in the relevant art(s) upon reviewing the description.
References in the specification to “one embodiment(s)”, “an embodiment(s)”, “a preferred embodiment(s)”, “an alternative embodiment(s)” and similar phrases mean that a particular feature, structure, or characteristic described in connection with the embodiment(s) is included in at least an embodiment(s) of the non-limiting exemplary embodiment(s). The appearances of the phrase “non-limiting exemplary embodiment” in various places in the specification are not necessarily all meant to refer to the same embodiment(s).
Directional and/or relationary terms such as, but not limited to, left, right, nadir, apex, top, bottom, vertical, horizontal, back, front and lateral are relative to each other and are dependent on the specific orientation of an applicable element or article, and are used accordingly to aid in the description of the various embodiment(s) and are not necessarily intended to be construed as limiting.
If used herein, “about” means approximately or nearly and in the context of a numerical value or range set forth means±15% of the numerical.
If used herein, “substantially” means largely if not wholly that which is specified but so close that the difference is insignificant.
The non-limiting exemplary embodiment(s) is/are referred to generally in
In a non-limiting exemplary embodiment, the at least one end track 34 can be matched with the ribs 30, 32 for providing a predetermined layout configuration so the user knows which frame member 11 should be attached to each section of the at least one end track 34. This will simplify the framing installation process. Use of the ribs 30, 32 increases the axial load capacity. Such ribs 30, 32 are specially designed to accommodate fasteners to fit flush metal to metal without undesirable separation.
In a non-limiting exemplary embodiment, the frame member 11 may also have the fold down knockout for bracing while permitting electrical and plumbing components to pass therethrough. As perhaps best shown in
In a non-limiting exemplary embodiment, the present disclosure overcomes the need to provide reinforcement straps while providing higher shear resistance values. However, if desired, the reinforcement straps may be employed if desired.
In a non-limiting exemplary embodiment, as perhaps best shown in
In a non-limiting exemplary embodiment, the frame member 11 has a single and unitary metal body.
With reference to
In a non-limiting exemplary embodiment, an optional first flange 24 extends downwardly from the end of the first return leg 20 while an optional second flange 26 extends downwardly from the end of the second return leg 22. The first flange 24 and the second flange 26 are each substantially similar in length are perpendicularly oriented with respect to their respective return leg 20 and 22, and are substantially parallel with the first stud side wall 16 and the second stud side wall 18.
In a non-limiting exemplary embodiment, a pair of stiffeners 28 is located along the stud base 14 in spaced apart fashion, each stiffener being a generally V-shaped member that protrudes inwardly into the metal frame member 10 toward the first return leg 20 and the second return leg 22. Although two stiffeners 28 are illustrated, the use of a single stiffener or more than two stiffeners is also possible.
In a non-limiting exemplary embodiment, a first pair of inwardly directed, generally U-shaped ribs 30 is located along the first stud side wall 16 while a second pair of inwardly directed, generally U-shaped ribs 32 is located along the second stud side wall 18.
In a non-limiting exemplary embodiment, the metal frame member 10 is substantially symmetrical about a vertical axis that passes in perpendicular fashion, through the midpoint of the stud base 14.
Advantageously, the entire metal frame member 10 is formed from a single, integral, and continuous sheet of metal, such aluminum, steel, and the like, and is formed into the particular geometry using an appropriate manufacturing technique (stamping, extrusion, roll forming, etc.,). The size of a particular metal frame member 10, including the length, width, depth and gauge of metal used is dependent on the job at hand is engineered accordingly. For example,
Ideally, each corner of the stud 12 is radiused to help prevent cutting injuries to workers handling the stud 12 while the end of each flange 24 and 26, if used, and if not, the end of each return leg 20 an 22 is appropriately finished, again to help prevent cutting injuries to workers handling the stud 12.
In a non-limiting exemplary embodiment, as seen in
In a non-limiting exemplary embodiment, a series of first inwardly directed detent pairs 42 is located along the first track side wall 38 while a series of second inwardly directed detent pairs 44 is located along the second track side wall 40. Each first detent pair 42 is located directly across from a respective one of the second detent pairs 44. The spacing between each first detent pair 42, and thus the second detent pair 44, is based on the particular frame being built such as 18 inches spacing for 18 inches on center stud construction as is known in the art.
With reference to
In order to install a stud 12 within the end track 34, an end of the stud 12 is placed into the end track 34 to that each first rib 30 receives a respective one of the first detents 42 of the end track 34 and each second rib 32 receives a respective one of the second detents 44 of the end track 34. As the width of the stud 12 (distance between outer surface of first side wall 16 and the outer surface of the second side wall 18) is substantially similar to the inside diameter (distance between the inner surface of the first track side wall 38 and the inner surface of the second track side wall 40), the stud 12 is generally friction held in place. The first detents 42 received within the first ribs 30 and the second detents 44 received within the second ribs 32 help lock the stud 12 in place within the end track 34.
Appropriate fasteners 46 are passed through each first rib-first detent pair and through each second rib-second detent pair to firmly attach the stud 12 to the end track 34. The fasteners 46 can be self-tapping or openings 48 can be pre-punched within each first rib 30 and each second rib as well as within each first detent 42 and each second detent 44. The rib-detent combination is dimensioned so that the installed fastener 46 is at best flush with the outer surface of the end track 34 (or countersunk as illustrated) for each of attaching appropriate sheathing to either side of the frame built. The detent-rib locking helps prevent stud 12 twisting within the end track 34, which tends to occur in conventional systems, especially after one side of the stud 12 is fastened to the end track 34. Each stud 12 is fastened to an end track 34 on either end of the stud 12.
While non-limiting exemplary embodiment(s) has/have been described with respect to certain specific embodiment(s), it will be appreciated that many modifications and changes may be made by those of ordinary skill in the relevant art(s) without departing from the true spirit and scope of the present disclosure. It is intended, therefore, by the appended claims to cover all such modifications and changes that fall within the true spirit and scope of the present disclosure. In particular, with respect to the above description, it is to be realized that the optimum dimensional relationships for the parts of the non-limiting exemplary embodiment(s) may include variations in size, materials, shape, form, function and manner of operation.
The Abstract of the Disclosure is provided to comply with 37 C.F.R. § 1.72(b) and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the above Detailed Description, various features may have been grouped together or described in a single embodiment for the purpose of streamlining the disclosure. This disclosure is not to be interpreted as reflecting an intention that the claimed embodiment(s) require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter may be directed to less than all of the features of any of the disclosed non-limiting exemplary embodiment(s). Thus, the following claims are incorporated into the Detailed Description, with each claim standing on its own as defining separately claimed subject matter.
The above disclosed subject matter is to be considered illustrative, and not restrictive, and the appended claims are intended to cover all such modifications, enhancements, and other embodiment(s) which fall within the true spirit and scope of the present disclosure. Thus, to the maximum extent allowed by law, the scope of the present disclosure is to be determined by the broadest permissible interpretation of the following claims and their equivalents, and shall not be restricted or limited by the above detailed description.
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