Techniques to Assemble, Design, Fabricate, Install, Specify, and Use Structures Combining Different Member Types for Building Construction Framing and Comparable Applications

FIELD OF THE INVENTION

The present application relates to different support member types in combination; and more particularly (but not exclusively) pertains to the architecture, assembly, bracing, componentry, configuration, construction, design, fabrication, implementation, installation, interconnection, kitting, operation, performance, planning, processing, reinforcement, and use of structures including building studs of different materials for wall framing and comparable applications.

BACKGROUND OF THE INVENTION

On an annual basis, the construction industry ordinarily generates more than five-hundred billion dollars ($500,000,000) of the United States (U.S.) Gross Domestic Product (GDP), and it is generally expected that this amount will increase in the future based on current predictions—perhaps reaching or even exceeding one trillion dollars ($1,000,000,000) in a few years. Concomitant with such lofty expectations, competitive pressure routinely challenges construction businesses to improve efficiency without compromising performance unacceptably. For instance, high-efficiency “light frame” construction practices have been widely adopted to fabricate a variety of residential buildings (e.g. single-family homes/houses, townhouses, duplexes, triplexes, fourplexes, and higher density multifamily, MultiDwelling Units (MDUs) like apartment/condominium complexes, etc.). Such practices are more specifically described hereafter, but first certain underlying terminology and related aspects are described as follows.

In general, a “frame” refers to a structure that at least partly supports and/or shapes a building feature such as a wall, roof, floor platform, ceiling (usually defined by the underside of a roof and/or floor platform), or the like. Consistent with this understanding and context, “framework” and “framing” each refer to a single frame, multiple frames, and/or a frame system. Also, “framing” further refers to the act of providing any frame(s), framework(s), and frame system(s). Designation of such terms specific to a building feature type like the “wall” type often takes the form “wall frame,” “wall framework,” and “wall framing,” respectively. Further, the verb “to frame” includes to assemble, build, construct, design, fabricate, form, install, make, prepare, provide, and/or supply a frame(s), framework(s), or framing often for a particular building feature type as in “frame a wall” or the like. A typical frame includes rigidly fixed mechanical members (“frame members” or just “members”) provided as a single unitary piece of material with the frame members each being a different portion thereof, a construct of rigidly fixed frame members formed by assembling/fitting together originally separate, independent components, or any combination of the foregoing. A building feature is usually finished by applying material to the structure defined by a frame.

“Light frame” construction practices (“light framing”) utilize frame members that are lighter and thinner than those of certain alternative frame construction practices—usually seeking to minimize the overall amount of frame member material consumed. For light framing, solid wood frame members tend to be used to a greater extent than those of alternative material such as metal, engineered wood, or any of various other materials—although a preference for each of these tends to arise specific to certain circumstances. As used herein, “wood material” and “wooden material” each refers to any composition that includes one or more of solid wood, engineered wood, and a substance derived from wood

For light framing, construction lumber of certain sizes and grades is used to provide solid wood frame members. Usually, the bulk of light framing members are noticeably elongated with a length much greater than any other dimension (often well-more than ten times greater) including horizontally extending plates to secure various framing structures, ceiling/floor joists, angularly framed roof rafters, and vertically extending building “studs” routinely used for wall framing. Consequently, light frame construction sometimes is described as “stick building,” “stick construction,” and the like.

Efforts to establish specific standardized sizes and grades of construction lumber (for framing or the like) hope to make lumber production/manufacture more cost-effective and commensurately increase widespread availability of standardized construction lumber from local suppliers. For instance, the National Institute of Standards and Technology (NIST) Voluntary Product Standard PS 20-15 entitled: “American Softwood Lumber Standard” (April 2015) (hereafter “PS 20-15”) resulted from such efforts. PS 20-15 defines a category of size-standardized “dimension” lumber (also called “dimensional” lumber) by reference to a set/range of different standard lumber sizes subject to an acceptable degree of variation/tolerance. Dimension lumber requirements are largely orchestrated to be suitable for use as frame members. Also, dimension lumber grading generally aligns with the various structural/performance-based needs of light frame construction—delineating different grades based on certain target lumber design values indicative of suitability for a particular purpose (usually in terms of certain material properties like strength, stiffness, etc.). In fact, PS 20-15 explicitly recognizes that various dimension lumber sizes/grades may be called framing, joists, planks, rafters, or studs.

Dimension lumber pieces generally have the same shape that resembles a form of rectangular hexahedron in solid geometry terms (also a cuboid, right or rectangular cuboid, rectangular parallelepiped, or right rectangular prism). For a given lumber piece, this shape has six (6) ideally flat, rectangular faces each extending parallel to one other face set-apart opposite therefrom and meeting the remaining four (4) faces perpendicularly to define the four (4) sides/edges of its rectangular perimeter. Correspondingly, each side/edge of a given rectangular face is shared where two faces meet perpendicularly. While a face with four (4) equal sides defines a square, it should be understood that a square is a form of rectangle in planar geometry terms. Otherwise, two opposed sides of a rectangular face are sized differently than the other two opposed sides. In correspondence to such shaping, each dimension lumber piece has three (3) actual linear dimensions extending in three (3) mutually perpendicular directions. Each dimension represents the true/real quantified straight line distance over which such dimension extends, being specifically designated as actual/true thickness (AT), width (AW), and length (AL)—where thickness AT and width AW are often much less than length AL as expressed in the inequality AT≤AW<<AL. The actual as-applied three-dimensional (3-D) characterization of a dimension lumber piece routinely is expressed “AT by AW by AL” (AT×AW×AL) and in the U.S. it is widely understood that thickness AT and width AW values are in units of the inch (″) and length AL values are in units of the foot (′).

In correspondence to such a shape in the ideal, a dimension lumber piece has two end faces generally separated by length AL that each approximate a rectangle with dimensions of “AT by AW” (equivalent to AT×AW). Further, a cross-section taken transverse to the longitudinal direction of the lumber piece approximates a rectangular profile with roughly constant/uniform (AT by AW or AT×AW) dimensions from one of the two opposed end faces to the other. The remaining four faces longitudinally extend between to span two opposed end faces. Two of these longitudinal faces are oppositely disposed edge faces with rectangular dimensions AT by AL (AT×AL) with an approximate separation distance of width AW. The other two longitudinal faces are opposed side faces with rectangular dimensions AW by AL (AW×AL) with an approximate separation distance of thickness AT.

Per PS 20-15 lumber is a manufactured product derived from a log by sawing or planing (generally includes solid wood and engineered wood). The initial separation of lumber from a log of a suitable tree species or otherwise deriving lumber therefrom often involves lengthwise (longitudinal) sawing along the wood grain (or proximately so)—commonly referred to as ripping, rip-sawing, rip-cutting, or the like. Ordinarily, the saw equipment best-suited to perform ripping operations (and to a lesser extent various other equipment-aided procedures e.g. handling, transport, etc.) imparts a relatively rough and uneven surface texture to the longitudinal faces with evident tool marks on occasion—commonly identified as “rough-sawn,” “rough-cut,” or just “rough lumber” in the industry. Also, rough lumber tends to have an unacceptable degree of dimensional variation and/or otherwise lacks sufficient uniformity to be desirable. As a result, the vast majority of rough-cut dimension lumber is supplied after its longitudinal faces have been processed by wood milling, jointer, and/or planarizing equipment that removes material to define four smoother and more planar longitudinal faces (edge faces and side faces) sometimes referred to as “dressed” and/or “surfaced” faces/lumber. Also, machine milling sometimes rounds each of the four corners where the side faces and edge faces meet instead of leaving sharper, more rectilinear corners. Such rounding efforts aim to reduce the likelihood of damage caused or sustained by severely angular/sharper corners. The rounded corners may each corresponds to an arcuate curve subtending approximately ninety degrees (90°) with a constant or modestly varying radius (R) that is much less than thickness AT (R<<AT≤AW<<AL). It should be appreciated that before surfacing the four longitudinal (edge and side) faces, corner rounding (if any), and like operations; the transverse cross-sectional dimensions of thickness and width for rough lumber substantively exceed the dressed lumber thickness AT and width AW (e.g. AT by AW, AT×AW, etc.) because of the material removed by surfacing.

Despite the pervasive supply of dimension lumber with dressed longitudinal faces, PS 20-15 designates standard sizes by reference to constant values for undressed/rough lumber thickness and width cross-sectional dimensions. To confuse matters further, under some circumstances technical advancements have reduced the amount of rough-cut excess needed to adequately dress the edge and side faces. As a result, the rough-cut cross-sectional dimensions used to reference size under PS 20-15 may not be consistent depending on the particular tree species involved, quality of the lumber source log, the processing equipment and/or procedures used, the specific lumber size/grade targeted, the particular lumber manufacturer/producer, etc.—and potentially the PS 20-15 thickness and width size values may not even exist at all. Accordingly, the rough-lumber cross-sectional dimensions at most are titular applying “in name only” befitting designation in PS 20-15 and herein as merely “nominal”—being specifically identified as thickness NT and width NW, such that AT≤NT and AW<NW. Fortunately, the particular pair of actual cross-sectional dimension values (AT×AW) referenced by a particular pair of (potentially nonexistent) nominal values (NT×NW) have all remained constant. Thus, while rooted in tradition, the rough-cut dimensions used to reference a standardized lumber size per PS 20-15 may be nothing more than an index value applied to look-up the actual, as-applied cross-sectional dimensions of AT by AW (AT×AW).

PS 20-15 specifies three distinct nominal size categories as follows: (a) “boards” for which nominal thickness NT is less than two inches (NT<2″) and nominal width NW is greater than or equal to two inches (NW≥2″), (b) “dimension lumber” for which nominal thickness NT is greater than or equal to two inches and less than five inches (2″≤NT<5″) and nominal width NW is greater than or equal to two inches (NW≥2″), and (c) “timbers” for which the least dimension (equivalent to nominal thickness NT as used herein) is greater than or equal to five inches (NT≥5″). Typically, within each category standardized sizes only take on certain values that usually differ incrementally from one to that next. For instance, dimensional lumber is not only subject to the above-indicated range of nominal thickness rNT from two to less than five inches (2″≤rNT<5″), but also only six (6) standardized nominal thickness NT sizes/values are recognized that include two inches (NT=2″) and each different half inch (½″) multiple from NT=2″ (2″=4×½″) up through four and one-half inches (NT=4½″=9×½″) (namely 2, 2½, 3, 3½, 4, and 4½ all in inches. The nominal width NW of dimension lumber also start at two inches (NW=2″) increasing in half-inch increments up through five inches (NW=5″), then increasing by a one inch increment to six inches (NW=6″) and then by two inch increments up to sixteen inches (NW=16″).

By way of example, “2 by 4” designates a typical dimension lumber framing stud by referring to nominal values for thickness (NT=2″) and width (NW=4″) potentially corresponding to rough-cut thickness/width dimensions to some degree. Unless specified by special order or the like, dimension lumber surfacing to smooth/planarize the longitudinal edge and side faces ordinarily occurs well before reaching the construction site. The removal of material attendant to surfacing results in actual values for thickness of one and one half inches (AT=1½″) and width of three and one-half inches (AW=3½″) subject to an acceptable degree of variation (e.g. tolerance or the like). In practice, each different standardized size of dimension lumber has unique nominal thickness NT and width NW values and unique actual thickness AT and width AW values—typically standards documentation includes a table or similar format that lists the nominal thickness NT and width NW values commonly used to designate a particular standardized size and the companion pair of actual thickness AT and width AW values uniquely corresponding to such nominal values. Consequently, nominal NT×NW values can serve as an index to look-up the actual values. Designation of a particular precut dimension lumber length AL is by reference to an actual value ordinarily in feet (′) without involvement of a nominal value or the like. Generally, standardized precut length values are multiples of either one foot (1′) or two feet (2′) subject to any applicable requirements specified in certified grading rules. Considering the commonly available dimension lumber AT×AW sizes collectively (e.g. from 2×2 to 4.5×16 inches nominally), length AL ranges from six feet I-(AL=6′) to as long as twenty-four feet (AL=24′) usually in multiples of two feet (2′). However, smaller nominal thickness NT and width NW values like 2×4 studs ordinarily do not have a length AL value at the upper end of the range. Indeed, standardized values of length AL for a nominal 2×4 stud usually are multiples of two feet (2′) ranging from six feet (AL=6′) to sixteen feet (AL=16′) and sometimes as longer (e.g. AL=18′ and/or AL=20′). In contrast much larger AT×AW sizes on the order of 2×10 and 2×12 operable as joists often are readily available up to twenty-four feet (AL=24′).

Although often the medium of choice, solid wood is not without certain limits. For instance, wood poses a greater fire hazard than other materials. While flame retardant treatment can curtail this hazard to some extent, it poses a potential risk to the environment and health of those exposed to treated wood. Wood is susceptible to damage by termite, carpenter ant, carpenter bee, teredo, and other insect infestation and decay by fungal (mold) colonization (e.g. blue stain, brown rot, dry rot, heart rot, sap stain, wet rot, white rot, and the like) that can be exacerbated by bacterial colonization. Such biologically caused wood damage and/or decay can range from superficial cosmetic damage to major remediation efforts to address fundamental structural failure or widespread mold growth inside walls, ceilings, etc. Like flame retardant treatments, treatments to reduce or prevent biologic susceptibility may trade one problem for another by posing potential health and/or environmental hazards—countervailing at least some of the advantage being sought in the first place.

Perhaps overshadowing such concerns, is the ever-present potential of solid wood members to warp. Indeed, it is not unusual for wood warping to infamously dominate most if not all of the foregoing—given the breadth and depth accompanying its potential to result in noticeable cost overruns, schedule delays, inferior materials and/or craftsmanship, labor and/or material availability, unpredictability, and other uncertainties. In a broad sense, warping refers to any deviation of lumber from a desired shape (planarity, smoothness, evenness, desired dimension, shape, or the like. More specific warp categories include: a “bow” along timber length l so that one of the two opposed side faces is concave and the other is convex; a “crook/wain” forms along length l such that the two opposed edge faces are concave and convex, respectively; a “kink” is a localized crook (e.g. knot-caused); a “cup” causes such edges to be higher/lower than the wood face part therebetween, a “twist/wind” roughly resembles a helix making the ends nonplanar, and the like. Other common wood defects (sometimes suspected warp causes) include: “check” cracking in annual growth rings part way through the lumber in contrast to a “split” that passes all the way through (sometimes even end-to-end), a “dead knot” is a knothole (often surrounded by a dark hole) with a loose knot piece if any is still present at all. In contrast, a “tight knot” retains all its content that is immobile, “shake” is a grain separation between growth rings that extends along the face and sometimes below it.

While one modestly warped stud in a wall frame may pose an only slightly greater risk of irregular appearance that likely would go unnoticed by the casual observer, a small minority of warped studs close to one another tend to be cumulative in effect as to a finished wall prepared therefrom—posing a greater risk that the appearance would be noticeably irregular. Further, while wood studs with undue warping can be screened-out before installation in a wall frame structure, warping can occur after such screening as a function of changing moisture content of the wood and a myriad of other variables. Indeed, as presently understood, wood warping is a complex function of many variables with varying degrees of interdependence. Generally, it is believed that uneven, unduly fast, or unduly slow variation in the uptake or release of wood moisture content is frequently of primary significance. Secondarily, other potentially influences include: the tree species harvested for the wood; weather exposure, nutrient availability, and other environmental factors likely to impact tree development prior to harvest; moisture content of the tree at harvest; orientation, anisotropy, patterning, evenness/irregularity of wood grain, constituent fibers, and any stress or shrinkage thereof; moisture uptake capacity of the wood; wood cut type, (e.g. flat-sawn, quarter-sawn, radially-sawn, rift-sawn, etc. . . . ); exposure to certain environmental conditions like certain minimum and/or maximum temperature extremes the frequency/duration certain temperature extreme exposure, temperature cycling exposure including relative magnitude of cycle excursions, frequency, rate of change, and variability of any of the foregoing); airflow and sunlight exposure of the wood; and the like. Although a consensus is building as to the major factors contributing to warp formation, it remains uncertain whether a given piece of lumber will warp and, if so, when, and to what extent. Indeed, some details relating to warp causation and the degree certain factors contribute to warping appear to remain in dispute—while still others seem to defy complete understanding (if any at all).

As used herein, “metal material,” and “metallic material” each refers to any composition that is at least fifty percent (50%) by weight comprised of one or more metal elements (where metal elements include all elements except Hydrogen (H), Deuterium (D), Tritium (T), Nitrogen (N), Oxygen (O), Phosphorus (P), Sulfur (S), Selenium (Se), any Halogen, and any Noble gas). In contrast to wood (especially solid wood lumber), metal frame members are not subject to warping, check cracking, splitting, shake and like deformities plaguing solid wood—and also are inflammable unlike solid and engineered wood. Also, biologic entities that threaten wood are generally inconsequential to metal. However, unlike wood metal frame member compositions can be susceptible to corrosion/rusting that sometimes results in the added expense of an anticorrosion coating, and frequently have mechanical properties inferior to those of wood (e.g. low buckling resistance). Moreover, thermal conductivity of an ordinary metal frame member exceeds that of wood to such extent it can inadvertently become a thermal bridge that effectively bypasses thermal insulation. More particularly, thermal bridging from the exterior wall surface to the interior wall surface can undermine the ability to cost-effectively maintain an indoor temperature that is pleasant or sometimes just tolerable even if regulated by Heating, Venting, and Air Conditioning (HVAC) equipment or other means. Accordingly, wood studs and metal studs are both far from ideal.

Even so, occasionally loadbearing wall framing utilizes structural metal members (e.g. cold-formed steel) a substitute for wood, but such utilization tends to be infrequent when solid wood framing would do because of cost and/or other factors. More frequently, a predominantly wood-framed structure may utilize structural steel to reinforce/support long-span wood-framed floors/ceilings and the like. Additionally or alternatively, loadbearing wall framing with solid wood studs sometimes is used in combination with non-loadbearing wall framing with nonstructural metal studs and/or framing fire barrier walls, which have become fairly established metal framing niches.

As used herein, “engineered wood” broadly includes: (a) chemically and/or mechanically densified wood; (b) a composite with a wood-based substance (e.g. wood chips, fibers, flakes, particles, sawdust, strands, and/or veneers) in combination with one or more coupling agents (e.g. one or more glues, adhesives, binders, resins, cements, thermoplastic polymers, and/or thermoset polymers that include: composite panels (e.g. chipboard, fiberboard, particleboard, and Oriented Strand Board (OSB) or flakeboard), and structural composite lumber (e.g. laminated veneer, parallel strand, laminated strand, and oriented strand lumber); (c) wood-plastic composite mixtures of wood fibers and/or wood flour, a binder, and a thermoplastic polymer (e.g. polypropylene, polyvinylchloride polyethylene, aliphatic polyester, etc.); (d) a wood construct of smaller wood pieces rigidly joined together by one or more coupling agents (e.g. finger-joint, comb-joint, I-beams, I-joists, etc.); and (e) wood laminae/plies/veneer bonded to provide plywood, cross-laminated lumber, laminated timber, etc. Engineered wood like I-joists and structural composite lumber are used in floor, ceiling, and roof framing to some extent—particularly when superior strength is required as compared to solid wood. Also, it should be appreciated that plywood, OSB, and similar engineered wood panels commonly provide sheathing for subflooring and exterior walls.

Other potential alternatives to solid wood, metal, and engineered wood include high-strength synthetic polymer compositions; and still other alternatives are fiber-reinforced composites including one or more polymer constituents strengthened by fibers of glass, carbon, aramid, basalt, and/or another type. Fiber orientation can be random, unidirectional, a mixture of differently directed fibers (e.g. certain fiber fabric weaves), or vary otherwise. Additionally or alternatively, composite fibers can include one or more fiber fabric layers and/or fiber fabric weaves, fiber tows, twisted and/or braided fiber bundles, and/or another single-layer or multilayer arrangement. To augment or replace fiber reinforcement, other composites include carbon nanotubes, inorganic particulates, and/or glass microspheres to provide a degree of reinforcement. While perhaps cost-effective under limited circumstances, such composites ordinarily fail to be competitive with other frame members of a wood material or metal material.

At present, solid wood framing tends to remain the favored choice, and tends to be more readily available and cost-effective than other materials such as metal, engineered wood, and composites when required to bear a significant mechanical load. Despite significant advances in the development of new materials, a cost-effective dimensional lumber replacement remains unlikely—even considering warping potential. Consequently, there remains an ongoing demand for further contributions in this area of technology.

By way of transition to the remainder of the present application, the present application may provide information to clarify, supplement, define, exemplify, or otherwise advance understanding of certain “terminology” with a “defining description” that may appear in in any order, association by placement adjacent one another to the extent suitable contextually, technically, and otherwise. Such terminology could be: any word (e.g. compound, blend, portmanteau, acronym, abbreviation, initial word forms), or other symbology (e.g. one or more alphanumeric characters, punctuation marks, mathematical expressions, and/or other marking), alone or in any phrase, character string, concatenation, mixture, multiple, or combination of the foregoing. The terminology and defining description can be associated in any manner such as: linking/referral language (e.g. a verb with any other word optional); close proximity or adjacency; delineated with paired punctuation (e.g. (parentheses), ‘single’ or “double” quotes, «guillemets», [brackets], {braces}, -dashes-, etc.); a single marking in between e.g. a colon:, dash-, equal sign=, etc.; and/or character contrast in pitch, emboldening, letter case, and the like. A defining description can specify terminology meaning in any manner, including: direct statement/explanation, delineation of meaning scope/limits, recitation of one or more examples (e.g. a positive/inclusive example type, a negative/exclusive example type, or both), by comparison and/or contrast to other terminology/meanings, etc.); originate new terminology in exercise of a patentee's lexicographic option (e.g. one or more new words, symbols, markings, signs, operators, or combinations of any of the foregoing) with the meaning specified by the defining description; specify an abridgement representative of a longer/fuller form per the defining description (e.g. an abbreviation, acronym, initialization, blend or compound word, etc.); specify/identify/represent a value that may be constant or subject to a tolerance or other degree of uncertainty; a mathematical variable with potential to vary as to at least two values either of a numerically quantifiable variety (e.g. either a continuously or a discretely varying numeric value) or a qualitative variety with potential to vary in value non-numerically as to two or more discrete categories (qualitative discrete non-numeric value variation); and any combination or multiple of the foregoing.

Any meaning of terminology defined herein applies in addition to any other meaning of the associated terminology including any ordinary and customary meaning and any meaning as understood by those of ordinary skill in the art pertaining to the patent application to the extent consistent to do so with the meaning defined herein applying as an alternative to any inconsistency. Further, a definition applies to a given occurrence of the terminology without regard to format, any accompanying punctuation, or any difference relative to another occurrence (including occurrence with the defining description) unless explicitly stated to the contrary. In addition, a terminology definition shall apply to each occurrence of the terminology unless: the defining description of such terminology expressly specifies otherwise or a subsequent defining description differs in one or more respect to redefine the same terminology (a “redefinition”) in which case such redefinition shall apply to any further occurrence of the terminology for the remainder of the present application unless specified otherwise by its defining description or the terminology is subject to further redefinition.

The present application is not all-inclusive or exhaustive—being merely representative and non-exclusively exemplary. From the perspective of those of ordinary skill in the art pertaining to the present application, any patent claim that follows or innovation otherwise described herein can be practiced without one or more details included in the description and/or with one or more additional features, elements, aspects, or the like not recited therein. Any obvious addition, modification, deletion, combination, or other variation of the present application teachings is also within the scope of any properly construed patent claim appended hereto or innovation otherwise described herein. Accordingly, the information provided herewith (including any drawing figure) is not intended to narrow the scope of any patent claim that follows—as compared to the scope of such patent claim defined by the language recited therein when properly construe.

SUMMARY

Certain forms of the present application relate to unique architecture, assemblies, apparatus, applications, bracing, building frames, componentry, configurations, devices, fabrication, implementation, installation, interconnectors, kitting, methodologies, operations, processing, structures, and systems. Further forms include unique techniques involving building studs of distinct types applied in combination. Other forms of the present application are directed to unique construction framing that includes building studs of different materials.

Another form of the present application includes a finishing stud with a face wall and two members each extending away from the face wall and a stud interconnector. The interconnector comprises a first end portion defining a finishing stud receiver, a second end portion defining a structural stud receiver opposite the finishing stud receiver, and an intermediate portion fixed to the first end portion and the second end portion to extend therebetween. The finishing stud receiver includes two tabs structured to each engage a different one of the two members in bearing contact if the finishing stud is correspondingly aligned with the finishing stud receiver and brought together therewith. The structural stud receiver includes two arms structured to receive a structural stud therebetween. In certain variations of this form, the finishing stud is comprised of a metallic material and/or the structural stud is comprised of a wood material; the finishing stud includes the two members each as a different one of two opposed walls set apart to define a recess therebetween and the finishing stud receiver includes a tongue member spaced apart from each of the two tabs to correspondingly define two slots—being structured to intermesh with the finishing stud if the two slots each receive a different one of the two members between the tongue member and a different one of the two tabs and the recess receives the tongue member; the finishing stud receiver includes spring biasing to define a stud clip with the two tabs opposite each other and pressing against a different one of two opposite sides of the finishing stud if the two tabs receive the finishing stud therebetween; the two arms oppose one another and a structural stud is fastened therebetween; and/or the two tabs oppose each other and finishing stud is fastened therebetween; a loadbearing capacity of the finishing stud is less than or equal to 50% of the structural stud with respect to longitudinal compression loading; and/or the stud interconnector is comprised of metal and includes two elongate rails each terminating in a respective one of the two tabs opposite a respective one of the two arms and a cross-connection fixed between the two rails to space-apart the two rails opposite one another.

Still another form is directed to a system that comprises: a finishing stud including a first end portion, a second end portion longitudinally opposing the first end portion, an interface wall, two opposed sidewalls each extending away from the interface wall, and the finishing stud being comprised of a metallic material; and a stud interconnection brace including a finishing stud receiver, a structural stud receiver spaced-apart opposite the finishing stud receiver, and a stiffness to resist relative motion between the finishing stud receiver and the structural stud receiver during intended use. The finishing stud receiver includes two opposed side tabs to each contact a different one of the two opposed sidewalls, defines a first fastener opening, and is structured to inhibit movement of either one of the two opposed side tabs past the face wall if the finishing stud receiver engages the finishing stud to connect therewith. The structural stud receiver includes two opposed side arms and defines a second fastener opening.

Alternatively or additionally, a further form is directed to a stud interconnector that comprises: a first end portion defining a first stud receiver, a second end portion defining a second stud receiver opposite the first stud receiver, a stud support bridge portion fixed between the first end portion and the second end portion, and a stiffness to resist relative motion between the first stud receiver and the second stud receiver while used as intended. The first stud receiver includes: a stud clip with two opposed clip members resiliently biased to provide compressive stud contact by firmly pressing thereagainst, a tongue member, two slots each defined between the tongue member and a different one of the two clip members, and a first fastener opening defined through the first stud receiver. The second stud receiver includes: two arms disposed opposite one another, the two arms defining a relative positioning range, and a second fastener opening defined through the second stud receiver. The stud interconnector extends a first distance projected along a reference axis centered between the two clip members and the two arms. A second distance separates the two clip members transverse to the reference axis and a third distance separates the two arms transverse to the reference axis. The second distance is less than 50% of the first distance and the second distance is greater than the third distance.

Yet a further form of the present application includes a stud interconnector in the form of a unitary piece of sheet metal structured to define a cross-connection and two elongate side rails each meeting the cross-connection along a different one of two bend regions, and the two bend regions approximate bend radii turning about 90 degrees from the cross-connection to each of the two elongate rails. The interconnector includes a first stud receiver opposite a second stud receiver, and two elongate side rails each define a respective one of two jaws of the first stud receiver and a respective one of two stud receiver arms of the second stud receiver. The cross-connection defines an outthrust tongue member of the first stud receiver. The first stud receiver further includes two slots each defined between the outthrust tongue member and a respective one of the two jaws. Optionally, this form includes: a metal stud with a face wall and two opposed walls extending away from the face wall and set apart to interpose a recess, a first fastener extending through the first stud receiver and into the metal stud to attach the interconnector and the metal stud while the two slots receive the two opposed walls and the recess receives the outthrust tongue member to fit together the first stud receiver and the metal stud with the metal stud clipped between the two jaws, a wood stud and a second fastener extending through the second stud receiver and into the wood stud while received between the two stud receiver arms to attach the interconnector and the wood stud.

One other form of the present application includes: providing a finishing stud including two opposed walls and an interconnector including a first stud receiver with two ears and a second stud receiver with two arms opposite the first stud receiver; attaching the interconnector and the finishing stud in a subassembly while fit together to engage the two opposed walls with the two ears; receiving a structural stud at least partly between the two arms while opposed by the finishing stud of the subassembly; determining alignment status of the finishing stud after receiving of the structural stud; selecting a position of the second stud receiver relative to the structural stud in response to the alignment status by adjustment of the second stud receiver; and fastening the second stud and the subassembly in the position to form an interconnected stud assembly. Optionally forming several like interconnected subassemblies to form a wall finishing assembly and applying material to the wall finishing assembly to provide a finished wall.

Another form comprises: a finishing stud with a face wall and two side portions extending from the face wall, and a stud interconnection brace including a finishing stud receiver and a structural stud receiver spaced-apart opposite one another. Stiffness of the interconnection brace imparts an extent of resistance to relative motion between the finishing stud receiver and the structural stud receiver. The finishing stud receiver includes two side tabs engaging the two side portions and is structured so the finishing stud receiver and the finishing stud bear against one another to inhibit extension of any part of the two side tabs past the face wall when fit together. The structural stud receiver includes two structural stud receiving rails. Optionally, this form, includes a structural stud incorporated in a structural stud frame assembly, the finishing stud receiver defines a first fastener opening and the structural stud receiver defines a second fastener opening, a first fastener extends through the first fastener opening and into the finishing stud to form a subassembly, and a second fastener extends through the second fastener opening and into the structural stud to attach the subassembly in an interconnected stud assembly with the structural stud received between the two structural stud receiving rails. In further options for this form: the two side portions are two opposed side walls spaced apart to interpose a recess, the stud receiver includes a tongue member and two slots each defined between the tongue member and a different one of the two side tabs, and the two opposed side wall are interest between the two side tabs and about the tongue member while received in the two slots with the tongue member received in the recess. In yet another variation, the finishing stud receiver defines a stud clip with the two side tabs spring biased to close against the finishing stud when disposed there between.

The preceding information of the present application is merely an introduction to certain representative forms, features, objects, embodiments, innovations, and/or aspects thereof, and should not to be considered exhaustive, restrictive, limiting, or exclusive as to the rest of the present application subject matter—especially regarding the scope, breadth, meaning, interpretation, coverage, or construction of any patent claim provided herewith. Indeed, the preceding text merely serves as a modest forward to the rest of the present application. Regarding the drawing figures provided herewith and briefly described hereafter, several considerations follow. The recurrence of like reference numerals in different drawing figures designate like features. A recurring like feature may be shown or otherwise represented in a different manner from one drawing to the next to enhance understanding, check obfuscation, preserve clarity, prevent undue crowding, or the like. Once a detailed written description of this like feature is set forth with reference to one or more of drawing figures setting forth such feature, it may not be subject to further description to curb redundancy. Alternatively, the detailed description of this like feature may be set forth in two or more separate descriptive passages that each correspond to a different drawing figure reference—often depending on the pertinent characteristics of the like feature. The drawing figures are not necessarily shown to scale except to the extent expressly described to be so. The present application specification includes any accompanying drawing figures. Such figures illustrate various aspects of the specification text and together therewith explain certain principles thereof. The following descriptions briefly introduce the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

FIG. 1 depicts a partly diagrammatic, partial interior view of a finished wall embodiment of the present application with two cutaways to compare the finished wall to a finishing framework and a wall support frame of a wall understructure and twice-broken partly sectional view line 2-2 for FIG. 2.

FIG. 2 shows three partially diagrammatic, right-side views of the finished wall of FIG. 1 vertically set apart per the twice-broken, partly sectional view line 2-2 of FIG. 1 to depict an upper, middle, and lower finishing stud attachment to a sectioned wall plate, a structural stud, and a sectioned sill plate of a wall support frame, respectively, with a stud interconnector fastened to both the finishing and structural studs and sectioned finishing material applied to a finishing stud face opposite the wall support frame. Also, FIG. 2 depicts the partly sectional view line 3-3 for FIG. 3.

FIG. 3 depicts a partially diagrammatic, top view of the finished wall of FIG. 2 along partly sectional view line 3-3 of FIG. 2 that includes stud interconnector fixed to the finishing stud and the structural stud both in section with the sectioned finishing material applied to the finishing stud—and further shows section line 4-4 for FIG. 4.

FIG. 4 is a cross-sectional view of the stud interconnector of FIGS. 1-3 per the 4-4 section line of FIG. 3.

FIG. 5 is a perspective view of a further stud interconnector embodiment.

FIG. 6 is a perspective view of the stud interconnector of FIG. 5 clipped to the finishing stud of FIGS. 1-4 to form a clipped stud subassembly.

FIGS. 7A & 7B (“FIG. 7” collectively) depict a wall assembly process of a further embodiment of the present application in flowchart form.

DETAILED DESCRIPTION

The following description sets forth various details in writing to provide a thorough understanding of the principles and subject matter of the present application including any patent claim that follows and any innovation otherwise described herein. To promote this understanding, the description refers to certain aspects—using specific language to explain the same accompanied by any drawing figures to the extent the subject matter of the present application admits to illustration. If a given aspect of the present application subject matter is well-known, less detail about such given aspect may be presented by way of illustration, writing, or both as compared to any aspect that is unknown (or at least not as well-known) to sharpen clarity of this description. This description and any attendant drawing figures present the subject matter of the present application by way of one or more examples, forms, instances, or the like; and sometimes includes one or more alternatives, modifications, or variants of the same—but the description is not intended to be all-inclusive. Instead, it is merely representative and exemplary. Accordingly, the description sets forth representative examples only and does not constrict, limit, restrict, reduce, restrain, or otherwise narrow the coverage/scope of any patent claim that follows nor that of any innovation otherwise described herein.

In one embodiment of the present application, a finished building wall includes wall finishing material applied to a wall understructure comprised of a support frame and several wall finishing subassemblies each attached thereto. The support frame includes several structural studs each vertically extending between horizontally extending sill and wall plates. The subassemblies each include a finishing stud attached to the sill and wall plate and a stud brace extending therebetween to form a multistud interconnection with the finishing stud and one of the structural stud at opposite ends thereof. Collectively, the subassemblies define an interior framework to interface with the finishing material. This framework can be better-suited to provide such interface than some configurations of the support frame.

FIG. 1 depicts finished wall 22 of building 20 of a further embodiment in a partly diagrammatic, partial interior view with two cutaways. Finished wall 22 includes wall understructure 24 and interior wall covering material 26 applied thereto that defines interior finished surface 28 adapted to provide a desired appearance and/or elicit an effect. In FIG. 1, horizontal axis H and vertical axis V indicate corresponding directions as represented by like-labeled, perpendicularly intersecting rays of common origin. As partly shown in FIG. 1, finished wall 22 is generally continuous without any window, doorway, gap, or other discontinuity; and vertically extends a generally constant height h from a generally level, horizontal floor (not shown)—without variation as can result if a stairway, floor ramp, vaulted or otherwise variously shaped ceiling, or the like is present—in order to preserve clarity. Furthermore, interior finished surface 28 is generally planar and smooth being parallel/coplanar with the FIG. 1 view plane and generally perpendicular to a plane that is parallel/coplanar with the floor (not shown). Interior wall covering material 26 defines forms finished wall cover to define interior finished surface of finished wall 22—being cutaway left of material cutaway margin 32 to reveal wall understructure 24. Correspondingly, finished wall 22 extends to the right of material cutaway margin 32.

FIG. 1 briefly introduces certain constituents of wall understructure 24, including wall frame 40 including lower plate 41, upper plate 45, and structural studs 50 rigidly fixed together; wall mounting interface framework 60 formed interior to wall frame 40 with structural studs 50 each connected to one of finishing stud 80 via one of stud interconnectors 100 extending therebetween. Structural studs 50 and finishing studs 80 each longitudinally extend approximately parallel to one another along longitudinal axis S and longitudinal axis F, respectively (only a few are depicted in FIG. 1 to preserve clarity). Further, axes S and F each extend vertically along vertical axis V about parallel thereto and are coincident or parallel with the FIG. 1 view plane or nearly so. The assembly of wall frame 40 and wall mounting interface framework 60 includes several stud frame extensions 65 each including one of structural studs 50 and one of finishing studs 80 rigidly joined to one of stud interconnectors 100. Stud frame extensions 65 each project finishing studs 80 interior to structural studs 50 of wall frame 40. Cutaway margin 32 removes interior wall covering material 26 left thereof to partly uncover wall interface framework 60. Cutaway margin 34 removes wall interface framework 60 left thereof to partly reveal wall frame 40.

The unique architecture of wall understructure 24 not only can offer an inner wall core structure suitable for loadbearing wall applications, but also an ability to counteract a certain degree of warping and/or other nonconformity and even potentially elevate performance otherwise relative to other schemes. Wall understructure includes wall frame 40 and wall mounting interface framework 60 rigidly fixed together. Wall frame 40 utilizes solid wood studs 50 of suitably sized and graded dimension lumber that each extend longitudinally in a vertical direction with state-of-the-art structural loadbearing capacity for vertical loading in compression. In contrast, wall mounting interface framework 60 has metallic finishing studs 80 that each extend longitudinally in a vertical direction without a comparable structural loadbearing capacity. Instead, as constructed, arranged, and utilized in wall understructure 24, finishing studs 80 tend to have favorable attributes where structural studs 50 are weak and vice versa—such that material properties of one type complement those of the other type.

Wall frame 40 interspaces structural studs 50 horizontally with separation distance being a function of various structural/performance properties thereof; however, sixteen inches (16″) center-to-center is common in the U.S. for structural studs 50 of dimension lumber with nominal 2×4 or 2×6 size and a grade of “stud” or better. So arranged, horizontal separation between structural studs 50 is usually occupied by thermal insulation 59 that is blown-in loose or installed in batts—just to name a couple of possibilities. Wall understructure 24 has the ability to offset some degree of irregularity of wood frame 40 in general and structural studs 50 in particular with wall mounting interface framework 60. For instance, structural studs 50 often bearing a share of the load imposed by building structures resting on wall frame 40—like that imposed by the weight of roof and any higher building levels/floors, and the like (not shown). Such requirements routinely limit cost-effective options with respect to various properties of structural studs 50, such as size, grade, treatment, shape, size, frame configuration, cost, durability, susceptibilities, and/or composition—just to name a few. As a result, structural stud 50 constraints often include a significant structural loadbearing capacity for vertically applied loading in compression.

In contrast, finishing studs 80 of wall mounting interface framework 60 outperform structural studs 50 in other ways such as retaining shape without warping and lacking susceptibility to various biologic agents. Further, interface wall 83 defines a flat wall finishing face 87 to more uniformly back wall finishing material 26 that tends to be more uniform than solid wood studs. Because structural studs 50 provide structural/mechanical support to any major degree, finishing studs 80 can be made of metal in an amount that is less than for structural metal studs because of the non-loadbearing role of finishing studs 80. Further, metal material poses no meaningful risk of warpage or significant fire hazard—and further is not susceptible to biologic agents like wood-damaging insect species and certain funguses. This relatively reduced amount of metal for finishing studs 80 results in correspondingly light-weight members that are accordingly easier to handle and can be placed/positioned/moved with greater resolution compared to cost-effectively handling heavier structural metal studs of a loadbearing type. Moreover, metallic composition also readily facilitates definition of a highly uniform surface of interior interface wall 83 for attachment of interior wall covering material 26. Certain nonlimiting embodiments of finishing stud 80 are formed from one or more pieces of sheet metal, are extruded, or otherwise include a metallic composition and so is designated metal stud 80a in the alternative.

FIGS. 1-3, each correspond to a different one of three mutually perpendicular view planes. The FIGS. 1&2 view planes are both vertical and intersect perpendicularly along a vertical line common to both, while the FIG. 3 view plane is horizontal. In addition to the multiple cutaway interior view of finished wall 22 in FIG. 1, FIG. 2 depicts three broken side views in partial section as taken along view line 2-2 of FIG. 1 that each show a different finishing stud 80 and wall frame 40 attachment region. As taken along view line 3-3 of FIG. 2, FIG. 3 shows a top view of one multistud interconnection 63 in partial section as provide by a respective stud interconnector 100.

FIGS. 2 & 3 supplement the details of wall frame 40 already described in connection with FIG. 1. In contrast to wall mounting interface framework 60, wall frame 40 is the dominant support structure of wall understructure 24. Wall frame 40 includes lower plate 41 positioned along the base of exterior wall 36 and upper plate 45 positioned above lower plate 41 along the top of exterior wall 36. Lower plate 41 and upper plate 45 each longitudinally extend along longitudinal axis P1 and P2, respectively (see FIG. 1). Axes P1 and P2 are approximately parallel to each other and horizontal axis H. Accordingly, a constant or nearly constant vertical distance separates lower plate 41 and upper plate 45. Given the perpendicular orientation of the FIG. 2 view plane relative to the FIG. 1 view plane, longitudinal axes P1 and P2 are likewise perpendicular to the view plane of FIG. 2. In the depicted embodiment, lower plate 41 and upper plate 45 are identical or almost identical as to shape, dimensioning, composition, and salient mechanical/physical properties. Additionally, lower plate 41 and upper plate 45 both have about the same approximately rectangular shape defined by two respective cross-sections each taken along different respective wall plate sectional planes transverse to different longitudinal axes P1 and P2. Lower plate 41 and upper plate 45 each include upper side face 41a opposite lower side face 41b. Upper side face 41a and lower side face 41b are separated by plate thickness (pt) therebetween that is approximately the same for both lower plate 41 and upper plate 45. Lower plate 41 and upper plate 45 also each include exterior face 42a opposite interior face 42b that defines plate width (pw) therebetween. Plate width pw is approximately the same for both lower plate 41 and upper plate 45 and is greater than plate thickness pt (pw>pt).

Structural studs 50 each longitudinally extend along vertical axis V and approximate a rectangular cross-sectional shape along a sectional plane generally perpendicular to the respective longitudinal axis S thereof. Structural studs 50 each longitudinally terminate at lower stud end face 51a opposite stud end face 51b. For each structural stud 50, lower stud end face 51a engages upper side face 41a of lower plate 41 and is attached thereto by one or more framing fasteners (not shown); and upper stud end face 51b engages lower side face 41b of upper plate 45 and is attached thereto by one or more other framing fasteners (not shown). Structural studs 50 each define different side faces 52 oppositely disposed relative to one another. For each different one of structural studs 50, its two side faces 52 are each separated by approximately the same structural stud thickness (st) from one to the next. Structural studs 50 each define flush stud face 53a opposite offset face 53b that are separated by approximately the same structural stud width (sw) therebetween. It follows that, as referenced herein, structural studs 50 each have thickness (depth) and width dimensions of represented by st×sw with the understanding that thickness (depth) is less than width (st<sw).

Plate width pw is greater than the structural stud width sw (pw>sw). For the depicted embodiment, structural studs 50 each are a form of standardized solid wood dimensional lumber with the more specific alternative designation as wood studs 50a (without limitation thereto). For such form, wood studs 50a nominally are of 2×4 inch size (st×sw 2×4 inches) with actual dimensions of about 1.5×3.5 inches (st×sw≈1.5×3.5 inches). Without limitation, one common alternative is standardized dimensional wood lumber of a nominal 2×6 inch size (st×sw≈2×6 inches) corresponding to an actual 1.5×5.5 inch size (st×sw≈1.5×5.5 inches). In other embodiments a different compositions and/or size may be employed. Likewise, the depicted embodiment of lower plate 41 and upper plate 45 is a particular form of solid wood dimensional lumber with pt×pw nominal dimensions of about 2×6 inches (pt×pw≈2×6 inches) and actual dimensions of about 1.5×5.5 inches (pt×pw≈1.5×5.5 inches). In the depicted embodiment, wood studs 50a are each of nominal 2×4 inch form with pw being about 2 inches greater than sw (pw≈2 inches and pw>sw).

When structural studs 50 are assembled between lower plate 41 and upper plate 45, the flush stud face 53a of each one is positioned to be generally flush and even with exterior face 42a of both lower plate 41 and upper plate 45 so that flush stud face 53a of each structural stud 50 is approximately coplanar with exterior face 42a of both lower plate 41 and upper plate 45. Flush stud face 53a is exterior to offset stud face 53b for each structural stud 50 after assembly in wall frame 40. In contrast to the generally even/flush alignment of flush stud face 53a, offset stud face 53b of each structural stud 50 is positioned exterior to interior face 42b of both lower plate 41 and upper plate 45 by offset distance (sb). Setback distance sb is the difference between pw and sw (i.e. sb=pw−sw≈5.5−3.5≈2 inches). Correspondingly, lower plate 41 and upper plate 45 both interiorly extend offset distance sb from stud face 53b from each of structural studs 50 to the interior face 42b of both lower plate 41 and upper plate 45. As a result, lower plate 41 and upper plate 45 each include wall plate lip portion 43 protruding from offset stud face 53b to interior face 53b. Each wall plate lip portion 43 protrudes offset distance sb to the interior. Sill plate 42, upper plate 45, and structural studs 50 structurally assembled in the manner described herein define wall frame 40 of the depicted embodiment. In other embodiments, structural members (e.g. structural studs 50, lower plate 41, and upper plate 45 of the depicted embodiment) may differ as to composition, shape, size, or like and/or as to the architecture of the corresponding assembly.

In particular, wall frame 40 can be assembled from suitable dimension lumber to provide a robust a “loadbearing wall” as often required for outer/exterior walls that define the outer perimeter of building 20 and sometimes those to the interior even if also dividing interior space into rooms. At least in part, building 20 utilizes finished wall 22 to separate interior building space (inside or indoors) from that exterior to it (outdoors or outside), and correspondingly define at least a part of an outermost boundary or perimeter of building 20, provide a barrier to unauthorized impingement or intrusion into building 20, protect interior contents of building 20 from unpleasant weather, more readily regulate interior temperature of building 20, control/monitor ingress and/or egress with respect to building 20, and the like. Given such utilization and status, finished wall 22 is more specifically designated exterior wall 36. Relative to many climates, weather phenomena tend to dominate exterior environment varying significantly with the seasons (often with uncomfortable extremes on occasion) as compared to the indoor environment (particularly when regulated by HVAC equipment or the like). Exterior wall 36 is a specific type of finished wall 22 relative the interior walls (not shown) commonly utilized to partition a building into different rooms or the like within the bounds defined by exterior wall 36 and the like. Likewise, as used herein, “interior” and “exterior” references correspond the relative position of one to another and may be grounded with respect to exterior wall 36. For instance, as to the following sequence of four features of finished wall 22 (exterior wall 36): (a) the interior finished surface 28, (b) interior wall covering material 26, (c) finishing interface framework 60, and (d) wall frame 40; a given preceding entry is “interior” to any proceeding entry. Conversely, a given proceeding entry is “exterior” as to any preceding entry with respect to the four entries (a)-(d) listed in sequence. Similarly, interior wall covering material 26/wall understructure 24 is interior/exterior relative to wall understructure 24/interior wall covering material 26, respectively.

Additionally, exterior wall 36 includes mechanical, physical, composition, treatment/processing, etc. to satisfy mechanical support structure requirements, such as certain load-bearing capacity specifics (e.g. longitudinally applied compressive load capacity sufficient to contribute to load support resulting from weight of a structure above exterior wall 36 like a roof, floor/story, or other above-located structure). Concomitantly, exterior wall 36 is more specifically designated a form of load-bearing wall 38 in the alternative. Relative to a floor/platformed-based wall framing stick construction fabrication of wall frame 40, “load-bearing wall” broadly includes a wall or part thereof structured to bear a requisite share of the mechanical load posed by the weight of building structure thereover (e.g. roof, floor/story, etc.) or any other manner or way of imposing the same or nearly the same load in terms of magnitude and application direction. In one favored embodiment of wall understructure 24 with load-bearing structural studs 50 and non-loadbearing finishing studs 80, a finishing stud load-bearing capacity is less than sixty percent (<60%) of a structural stud load-bearing capacity with respect to a longitudinally applied load in compression. In a more favored wall understructure embodiment, the finishing stud load-bearing capacity is less than forty percent (<40%) of a structural stud load-bearing capacity with respect to the longitudinally applied load in compression. In an even more favored wall understructure embodiment, the finishing stud load-bearing capacity is less than twenty percent (<20%) of the structural stud load-bearing capacity with respect to the longitudinally applied load in compression. Any of these embodiments are further favored if the finishing studs are comprised of metallic material and the structural studs are comprised of wood material.

In addition to wall frame 40, wall understructure 24 also includes finishing studs 80 depicted more specifically as metal studs 80a. Finishing studs 80 each include upper end portion 81a longitudinally opposing lower end portion 81b and elongate intermediate portion 82 longitudinally extending therebetween. Along intermediate portion 82, each of finishing studs 80 interconnects to a respective one of structural studs 50 via a corresponding one of stud interconnectors 100 extending therebetween to form multistud interconnection 63. Further, upper end portion 81a and lower end portion 81b of each of finishing studs 80 are mounted to wall frame 40 above and below the respective one of structural studs 50. This multistud interconnection 63 defined with stud interconnector 100 and the upper and lower mounting of a different one of the finishing studs 80 each forms a different one of finishing stud frame extensions 65. The quantity of finishing stud frame extensions 65 desired to extend and buffer finished wall 22 of a desired size, collectively define wall mounting interface framework 60 of wall understructure 24. Through the corresponding multistud interconnection 63 with one of stud interconnectors 100, the attachment position of each of finishing stud frame extensions 65 to wall frame 40 relative to a corresponding one of the structural studs 50 is selectable over a continuously variable position adjustment range. Through attachment position selection, routinely the negative consequences of at least some warped or otherwise nonconforming structural studs 50 can be mitigated or even effectively counteracted. Finishing studs 80 so installed operate as an intermediary between interior wall covering material 26 and wall frame 40 to often providing noticeably better alignment and appearance of finished wall 22 than would result from direct attachment of interior wall covering material 26 directly to structural studs 50 of wall frame 40 without wall mounting interface framework 60 therebetween.

Finishing studs 80 each extend longitudinally along axis F from lower end portion 81a to upper end portion 81b with intermediate portion 82 therebetween. Finishing studs 80 each include interface wall 83 (alternatively designated face member 84) and two walls extending away from interface wall 83 opposite one another (as depicted, flanges 85 are in a more specific form of two opposed sidewalls 86). Interface wall 83 and opposed sidewalls 86 generally extend longitudinally along axis F in the depicted form. Interface wall 83 defines wall finishing face 87 and opposed sidewalls 86 each define a respective one of two side faces 89. As perhaps best shown in FIG. 3, opposed sidewalls 86 each depart interface wall 83 at a corresponding one of two interface junctures 88 to end at a respective one of two edges 86a. Edges 86a each define one of two wall termini 87a, respectively. In the depicted form, opposed sidewalls 88a and 88b are set apart to define recess 90 therebetween (depicted in a more specific form as longitudinal channel 91). Longitudinal channel 91 is bounded by inward interface wall surface 88a opposite wall finishing face 87 and two opposed inward sidewall surfaces 89a opposite side faces 89. A section plane perpendicular to axis F defines U-shaped cross-sectional shape 91a of interface wall 83, opposed sidewalls 86, and longitudinal channel 91, collectively.

Lower end portion 81a and upper end portion 81b of finishing stud 80 each define lower plate mounting termination 92a and upper plate mounting termination 92b, respectively, (as depicted, plate mounting tabs are more specifically designated as follows). Lower plate mounting termination 92a and upper plate mounting termination 92b each depict two oppositely disposed plate mounting tabs 92 each as two different plate side engagement ears 93a transversely opposite one another relative to axis F, Each of plate side engagement ears 93a is formed by outwardly ending a terminal part of each of sidewalls 86. These two plate side engagement ears flank plate interior engagement ear 93b that extends downward from interface wall 83 for lower plate mounting termination 92a and upward for upper plate mounting termination 92b. Accordingly, engagement ears 93a and 93b (collectively and each generically designated “ear 93”) total six for a given finishing stud 80 in the illustrated embodiment. In one implementation, plate fastener 98 is structured to extend through fastener opening 96 and extend into or through lower plate 41 or upper plate 45, respectively. A more specific form of plate fastener 98 includes nail 99 suitable to securely penetrate and remain anchored in wood or a similar material comprising lower plate 41 and upper plate 45. As shown, nail 99 is a flat head/smooth shank type that includes fastener head 99a with a flat head nail structure and fastener tip 99b longitudinally opposite fastener head 99a. Further, nail 99 includes nail shank 99c therebetween that interconnects fastener head 99a and fastener tip 99b. Nail shank 99 typically comprises the bulk of nail longitude with an approximately constant diameter therealong. Fastener tip 99b can be pointed to facilitate penetration of wood or the like. As potentially best shown in FIGS. 2 & 3, fastener tip extends through opening 96 to penetrate into or pass through one of the lower plate 41 and upper plate 45 in response to an adequate longitudinally applied compressive force.

As shank nail 99 bears against ear 92a or 92b where in the vicinity of a respective plate fastener opening 96 after receiving nail 99 therethrough so that tip 99b penetrates mounts finishing stud 80 to wall frame 40 opposite a respective structural stud 50 via lower end portion 81a and upper end portion 81b of finishing stud 80 to lower plate 41 and upper plate 45, respectively. In one implementation, wood nail 99 extends through opening 96 and into or through either lower plate 41 or upper plate 45 to securely be anchored thereto, respectively. More particularly, in one specific embodiment that includes lower plate 41 and upper plate 45 each as nominal 2×4 or 2×8 inch solid wood lumber, nail 99 extends an approximate length of about 1.5 inches (1&½″) with an approximate shank diameter of about 0.148 inch (0.148″) in correspondence to a gauge 9 nail—and is fabricated from an iron-containing metal (Fe-based composition) with any coating/treatment applied to provide sufficient resistance to nail oxidation/rust and the like.

One way of fabricating metal stud 80a utilizes a common, raw carbon steel sheet metal (an alloy comprised of Fe and carbon (C—a metalloid), and possibly a few other components. This raw sheet metal stock typically includes a level of galvanization (i.e. application of zinc (Zn)) and/or other treatment to an extent that cost-effectively resists oxidation/rust of and Fe-based steel as needed. In one form, galvanization takes place to the G40 standard (i.e. Zn is applied to a core of steel with about 0.40 ounces per square-foot (0.40 oz/ft²). The sheet metal stock is cut, stamped, etched, or otherwise shaped into a planar, rectangular form of unitary sheet metal piece 94, from which just one finishing stud 80 can be made subsequently. This shaping includes defining end notches to facilitate later separation of forming three openings 96 at first with two slots between the two opposed side engagement ears 93a and the mounting in a generally planar form to provide a single, unitary sheet metal piece 94 for each finishing stud 80. This process may include extra material in the vicinity of two junctures 95 where finishing stud 80 transitions between interface wall 83 and each of sidewalls 86. Formation of junctures 88 and sidewalls 86 is provided by shaping sheet metal piece 94. For instance, sidewalls 86 that merge/depart interface wall 83 can be formed by uniformly bending generally equally sized and shaped end portions of sheet metal piece 94 disposed transverse to its longitude. The vicinity of such junctures 88 and corresponding bends may include a slightly thicker material for mechanical reinforcement, or the depicted form of metal stud 80a, it can be formed from a single, unitary piece of sheet metal 1a. More particularly, stud fabrication includes stamping and bending the two flanges 85 to extend along two approximately parallel planes that are approximately perpendicular to a plane along with the interface wall. In one particular fabrication approach, the sheet metal is stamped so that the metal is thicker along the bend sites to offset any tendency to be thinned/weakened by bending. Alternatively or additionally, metal stud 80a is comprised of a suitable carbon steel with outer galvanization by zinc (ZN) to improve resistance to oxidation (rusting) among other things. With the distance spanned by interface wall 83 between sidewalls approximating 1.685 inches (1&⅝ths″) as perhaps best illustrated in FIGS. 3 and 4 as distance D1. More particularly, in one specific embodiment that length of wood nail 99 approximates 1.5 inches with a stem diameter of about 0.148 inch or nearly so—and is fabricated from an iron-based metal and galvanized with a zinc (Zn) containing coating to suitably resist undue oxidation (rusting) and the like.

Finishing stud fasteners 70 fasten finishing stud 80 along intermediate 82 portion. Interconnector 100 includes end portion 101a opposite end portion 101b—connected together by bridge portion 101c therebetween. As depicted, stud interconnector 100 is additionally a form of connection brace 102 that mechanically reinforces finishing stud 80 with the stability/support of wall frame 40 along intermediate portion 101c where potentially susceptible to flexure and undesired movement relative to the wall frame 40—particularly during installation as detailed further hereafter. Accordingly, in the depicted implementation of connection brace 102, bridge portion 101c inwardly defines strut 102b that resists relative motion in response to longitudinally applied force (particularly compressive longitudinal force) with stiffness sufficient to provide the same.

Stud interconnector 100 includes finishing stud receiver 110 opposite structural stud receiver 160. Finishing stud receiver 110 includes two ears 112 opposing one another in engagement with sidewalls 86 of finishing stud 80 along its intermediate portion 102. Ears 112 are each predrilled with one of two fastener openings 113 to receive finishing stud fastener 70. Ears 112 are alternatively designated side tabs 114 specific to the depicted embodiment. Finishing stud receiver 110 further includes receiver tab 116 disposed in recess 90 (channel 91) and is further designated tongue member 118. Between tongue member 118 and side tabs 114 are two slots 120. Sidewalls 86 are disposed in slots 120. Finishing stud receiver 110 is configured as a finishing stud clip 130 with each side tab 114 being one of two opposed clip members 132. Finishing stud clip 130 is structured with spring biasing 134 to firmly engage each side face 89 of sidewall 86. Spring biasing 134 is provide for each clip member 132 as biasing 136a and 136b, respectively; however, only one clip member 132 can include biasing 136a or 136b to resiliently urge each towards the other in a manner sufficient to clip to finishing stud 80 and provide a corresponding finishing stud subassembly 64. The sizing and structure of stud interconnector 100 defines a gap 223 between finishing stud 80 and structural stud 50 in each of the finishing stud extension constructs 63. Gap 223 provides a passage for electrical cabling or the like without the need for drilling through the structure. Finishing wall material 24 is mounted to wall finishing face 87.

As depicted in FIGS. 1-3, wall finishing material 24 is in the form of wallboard followed by deposition of wallboard mud to fill mounting screw dimples and form joint between different wallboard panels (e.g. fill-in tapered joints); alternatively apply and initial lath/plaster wall finishing material 24 instead of wallboard; after curing of wallboard mud or plaster sanding to provide desired degree of smooth and even finish; then coating the wallboard with primer followed by one or more coats of paint; as an alternative or addition—applying wallpaper or other wall covering; or the like paneling, smoothen wallboard by mudding/sanding, priming sanded wallboard, painting primed wall, apply wall covering, and the like (e.g. mounting several adjacent wallboard panels, mudding joints and depressions to fill-in discontinuities, sanding cured mud, priming after sanding, painting, etc.).

Finishing stud 80 is fastened to finishing stud receiver 110 with two finishing stud fasteners 140 engaged through one of openings 113. In the depicted form, finishing stud fastener 140 is a type of self-tapping metal screw 142. Screw 142 includes hex head 144a opposite self-tapping tip 144b with threaded stem 144c extending therebetween. Without limitation, one type of screw 142 is a number 8 9/16ths self-drilling framing screw.

Structural stud receiver 160 includes two arms 162 receiving structural stud 50 therebetween. Each structural stud receiver 160 defines fastener opening 164 therethrough and adjustment slot 166. Each adjustment slot includes structural stud fastener 168 therethrough. In the depicted form, structural stud fastener 168 is a nail 99 as previously described. Openings 164 are unoccupied in the depicted arrangement, but one or both may include a fastener in other embodiments.

In the illustrated embodiment, stud interconnector 100 is formed from a single, unitary sheet metal piece 200 that is stamped, etched or otherwise cut to make a single stud interconnector 100. After being so shaped, sheet metal piece 200 is bent to form two elongate side rails 210 each of a generally planar shape along a plane parallel to the other. A stud receiver end 212, each of elongate side rails 210 forms a different one of ears 112 (tabs 114 and clip members 132). At opposing stud receiver end 214, each of elongate side rails 210 forms one of arms 162. Elongate side rails 210 are shaped to change the distance D1 between ears 112 to distance D2 between arms 162, where D1 is greater than D2 (D1>D2). Cross-connection 220 (alternatively designated transverse connector 222) connects elongate side rails 210 and defines receiver tab 116 (tongue member 118). Cross-connection 220 meets elongate side rails 210 at corresponding junctures 220a and forms an approximate right angle A therewith as illustrated in FIG. 4. Centerline reference axis R is defined along stud interconnector 100 that is centered between ears 112 and arms 162 and bisects receiver tab 116. A plane containing axis R bisects stud interconnector 100 into two approximate mirror images of each other. The distance D3 occupied by stud interconnector 100 from stud receiver end 212 to stud receiver end 214 is greater than D1 and D2 (D3>D1>D2).

Referring to FIG. 5, stud interconnector 300 of another embodiment is illustrated; where like reference numerals refer to like features previously described. The following describes more details where stud interconnectors 100 and 300 differ with little or no description where alike. Stud interconnector 300 includes finishing stud receiver 310 opposite structural stud receiver 360. Finishing stud receiver 310 includes two oppositely disposed tabs 313 structured like side tabs 114 (ears 112) of finishing stud receiver 110 except that tabs 313 each include inwardly protruding stop member 320 and defines a corresponding notch 322. Like finishing stud receiver 110, finishing stud receiver 310 also includes receiver tab 116 (tongue member 117) defined by cross connection 220 to extend between tabs 310 with a different one of two slots 120 disposed in between.

Each of stop members 320 provides a different one of two abutment stops 324. One or both abutment stops 324 can potentially contact one or both edges 86a of sidewalls 86, respectively, to aid in the prevention/inhibition of movement of either of tabs 313 past mounting interface wall 82 of finishing stud 80 when finishing stud 80 and stud interconnector 300 intermesh to form provisional subassembly 380 as illustrated in FIG. 6. Either or both abutment stops 324 can operate in addition to or in lieu of one or both edges 86a of sidewalls 86 abutting one or both receiver slot termination margins 121, correspondingly; and/or tab edge 117 of receiver tab 116 (tongue member 118) defined by cross connection 220, abutting inward wall surface 88a of finishing stud 80. Also, it should be recognized that it is possible neither one of abutment stops 324 contacts finishing stud 80 before one of the foregoing alternatives takes place to halt movement of stud interconnector 300 and finishing stud 80 together each towards the other.

Also, stud interconnector 300 differs from stud interconnector 100 as to the configuration of two like fastener openings 312 through each of arms 362 for a total of four (4). In contrast to arms 162 of structural stud receiver 160, each of arms 362 defines two fastener openings 312 (one more than each of arms 162), but lacks adjustment slot 166. Fastener openings 312 each approximately resemble the others being structured to receive a respective structural stud fastener 168 in the form of nail 99, or alternatively a screw or other acceptable fastener type to rigidly fix structural stud receiver 360 and structural stud 50 when positioned between arms 362 (not shown). As illustrated in FIG. 6, finishing stud receiver 110 defines spring-biased stud clip 330 with two opposed clip members 332 each provided by a respective one of tabs 313. Stud clip 330 and stud clip 130 are ideally alike except for the aforementioned stop members 320 and notches 322 each defined by a respective tab 313 to provide the two abutment stops 324. The FIG. 6 depiction includes finishing stud 80 and finishing stud receiver 310 in an intermeshed state 80 with tongue member 118 received in recess 90 and sidewalls 86 each received in a corresponding one of the two slots 120 in between tongue member 118 and a different one of tabs 313 of finishing stud receiver 310. So Fit together in such manner, the spring-biasing of clip 330 urges clip members 332 to press against each a different one of sidewalls 86 of finishing stud 80 firmly enfolded therebetween to collectively form a provisionally adjustable subassembly 390. It should be appreciated that adjustable subassembly 390 facilitates selectively adjusting relative position between finishing stud 80 and stud interconnector in response to application of an opposing force sufficient to overcome the spring-biasing of stud clip 330 but not so great as to cause disassembly thereof. Absent disturbance by an opposing force, adjustable subassembly 390 remains firmly held together by clip 330. Once appropriately positioned relative to one another, finishing stud 80 and stud interconnector 300 can be more permanently joined through application of finishing stud fasteners 140 (e.g. self-tapping screws 142 or other appropriate fastener type) each with respect to a different one of fastener openings 113. Once appropriately adjusted and joined together, a construct like finishing stud subassembly 64 can be realized for use as one of several finishing stud frame extensions 65 that are each fastened to a different structural stud to form multistud interconnection 63 and build wall mounting interface framework 60 well-suited to application of interior wall covering material 26. As constituents of wall mounting interface framework 60, finishing studs 80 each include a respective interface wall 83 defining an interior wall finishing face 87 for application and attachment of interior wall covering material 26 therealong and correspondingly form finished wall cover 27 over understructure 24 hat presents finished surface 28 towards the interior and completes finished wall 22.

With general reference to the embodiments described in concert with FIGS. 1-6 and any alternatives or variants thereof, FIGS. 7A and 7B depict a flowchart bridging two connected, like-labeled sheets (both collectively FIG. 7)—to enhance understanding of certain aspects/features of description herein for any processes, methods, applications, and/or operations to assemble, construct, make, implement, install, specify, position, evaluate, adjust, utilize, or the like including fabrication process 400 described as follows. Fabrication process 400 begins at the top of FIG. 7A with start flag 410, then proceeds as directed by connecting arrow to operation 412. Operation 412 starts with selection of finishing stud 80 and stud interconnector 100 or 300 to form finishing stud subassembly 64 or provisional subassembly 390, respectively.

From operation 412, process 400 continues with operation 414 to align both selections with an imaginary reference axis (like axis R of FIGS. 2 and 3) midway between sidewalls 86 and tabs 114 bisecting tab 116 and stud 80 and so sidewall 86 faces a different slot 120 of stud receiver 110, 310 and tab 116 faces recess 90 of stud 80. Also, operation 414 includes placing stud receiver 110, 310 along intermediate portion 82 that extends along axial length of stud 80 between lower end portion 81a and upper and portion 81b thereof (see FIGS. 2 & 3). After alignment, operation 114 includes moving finishing stud 80 and stud interconnector 100, 300 together as slots 120 each receive a sidewall 86 and recess 90 receives tab 116 to interfit stud 80 and stud receiver 110, 310 by placing tab 116 between sidewalls 86 and each sidewall in a different slot 120 between tab 116 and a different clip member 132 (side tabs 114) and disposing finishing stud 80 in between clip members 132 of finishing stud receiver 110, 310. Movement of finishing stud 80 and stud receiver 110, 310 closer together continues until they abut halting further closure absent force that plastically deforms or fractures either or both. Consequently, a provisionally adjustable subassembly (such as subassembly 390 of stud interconnector 300 and finishing stud 80) results. Any gap along this reference axis separating finishing stud 80 and stud interconnector 100, 300 narrows as relative motion between them persists until they abut.

In certain embodiments, finishing stud 80 and stud receiver 110, 310 abut to halt further movement towards each other that has potential to cause plastic deformation, fracture, or other unacceptable result as to either or both. Alternatively or additionally, the two are structured to abut before either of tabs 116/clip members 132 extend past wall finishing face 87 defined by interior interface wall 83 of stud 80. For instance, with respect to stud receiver 310, relative position of stud 80 and one or both of abutment stops 324 of stud receiver 310 when they abut is specified to provide a particular degree closure and/or pressure between them without unacceptably risking an undesirable outcome. As an addition or alternative, the distance spanned by (a) one or both slots 120 between slot termination margin 121 and its termination with the closest tab 114 and/or tab 116, (b) the distance spanned by one or both sidewalls 86 between interface juncture 88 and its terminus 87a, and (c) the distance spanned from edge 117 of tab 116 and one or both of slot termination margins 121, or the like have the potential to change the relative distance traveled (e.g. along a reference axis) by stud 80 and stud receiver 110, 310 before they abut by adjusting the difference between certain distances. For instance, a difference of relative length of slots 120 and the distance sidewalls 86 extend away from wall 83 can be large enough to substantially change the relative distance traveled before stud 80 and interconnector 110, 310 abut.

After execution of operation 414, finishing stud 80 and stud receiver 110, 310 mesh together becoming interlocked to establish intermeshed configuration 289 that, among other things, refers to an interface between parts substantially limiting, restricting or constraining relative motion between such parts. More specifically, “interset elements” refer to parts or constituents positioned between or about one another. Intermeshed framing configuration 289 includes five (5) interset elements 290 comprised of two stud interset elements 290a in the form of two sidewalls 86 and three receiver interset elements 290b in the form of receiver tab 116 (tongue member 118) and two clip members 132, 332 (tabs 114, 313). It should be appreciated each of elements 290a is disposed between a unique pair of elements 290b (tab 116 and the closet of clip members 132, 332 that are both positioned about the two interset stud elements 290a, while sidewalls 86 receive tab 116 in between and are corresponding placed there about. Together, interset connector elements 290 are constituents that collectively define interset framing arrangement 290c.

Process 400 advances from operation 414 to operation 416 which includes attaching the finishing stud 80 and stud receiver 110, 310 while clipped and held together with one or more finishing stud fasteners 140. For instance, two fasteners each of the more specific form screw 142 can be inserted through fastener opening 113 for each of tabs 114, 313 and then appropriately torqued so the head of screw 142 engages a different one of tabs 114, 313 in bearing contact and into or through a respective one of sidewalls 86 to press then both together.

The execution of operation 416 results in the formation of a stud/interconnector subassembly (e.g. finishing stud subassembly 64) comprised of one finishing studs 80 and one stud interconnector 100, 300 rigidly fastened together with one or more finishing stud fasteners 140 or the like. Process 400 advances next to operation 418 that includes engaging such subassembly with a respective one of structural studs 50 of wall frame 40 positioned opposite therefrom. Such engagement includes positioning the finishing stud of the subassembly opposite a respective one of structural studs 50 initially set-apart therefrom by somewhat more than the maximum spanned by the two opposed stud receivers 110 and 160 for interconnector 100 or receiver 310 and 360 for interconnector 300. Next the structural stud receiver 160, 360 is moved closer to the respective one of the structural studs until disposed at least partially between arms 162, 362 with offset edge face 53b interior to oppositely disposed flush edge face 53a.

One embodiment of process 400 includes providing a complete, installed form of wall frame 40 including rigidly connected frame members, such as structural studs 50, lower plate 41, and upper plate 45 before beginning process 400 before beginning process 400 that depends the provision of such wall frame 400 to execute one or more operations thereof—e.g. the immediately foregoing operation 418. Another embodiment includes providing wall frame 40 in a sufficient state of completion (including installation thereof) to execute process 400 before or overlapping process 400, but before executing operation 418 to engage one of structural studs 50 of wall frame 40 in such state with a respective finishing stud subassembly 65. Alternatively or additionally, initial performance of operation 418 begins with the rightmost or leftmost structural stud of wall frame 40 and performance of the next iteration of operation 418 include engaging another stud subassembly 65 to another structural stud 50 adjacent to that most recently the subject of operation 418—being either to the immediate left for a rightmost start or to the immediate right for a leftmost start—progressing in the same direction from one to the next until execution of all iterations of operation 418 for process 400 or as otherwise specified.

Process 400 advances from operation 418 to operation 420 with subassembly 65 engaged, but not fastened to the respective one of structural studs 50. Before fastening, operation 420 includes determining alignment status of finishing stud 80 included in such engaged/unfastened subassembly 65 with the respective one of structural studs 50 adjustably positioned between its arms 162, 362. The alignment status determination of operation 420 includes assessing the degree of coplanarity of wall finishing face 87 (as defined by interior interface wall 83 of stud 80 included in subassembly 65) with a vertical plane such as the FIG. 1 view plane and the extent centered structural stud longitudinal axis S and centered finishing stud longitudinal axis F are vertical and parallel and able to define a vertical plane that is perpendicular to the FIGS. 1 and 3 view planes and coplanar or parallel with the FIG. 2 view plane. Also operation 420 alignment status determination includes evaluating the degree to which the vertical plane containing wall finishing face 83 is perpendicular to a horizontally planar floor and/or ceiling by application of a bubble level, plumb bob, or the like. Moreover, operation 420 includes measuring alignment of the wall finishing face 83 of the finishing stud subassembly relative the wall finishing face 83 of one or more other previously attached subassemblies 65 (if any) with a horizontal plumb line or other measurement procedure and/or instrumentation—particularly those closest to the subassembly 65 currently subject to operation 420. Furthermore, operation 420 includes inspection and measurement for any other nonconformity with potential to pose an unacceptable risk as to schedule, quality, cost, safety, and the like.

From operation 420, process 400 continues with conditional 430 that tests whether alignment is acceptable. If not (no or false), process 400 continues along negative branch 432 to operation 434 and also enters position adjustment loop 425. Operation 434 includes adjusting position of finishing stud subassembly 65 relative to the respective one of structural studs 50. While either may prove unacceptable as to alignment, installation of frame wall 40 including such stud 50 cannot be moved readily compared to engaged/unfastened subassembly 65. It should be appreciated that arms 162, 362 of stud receiver 160, 360 are positionally adjustable select to a modest range with the potential to reduce if not effectively eliminate misalignment or other deviation as might be caused by minor warping and/or other nonconformity. More specifically, position of either or both arms 162, 362 relative to relative to the engaged structural stud 50 and to a lesser extent (if any) possibly one or more studs 50 in close proximity hereto. Accordingly, position can be adjusted over such range to select one that is acceptable. After position selection in operation 434, loop 425 returns to operation 420 to re-evaluate alignment. After reevaluation, conditional 430 is again encountered to test if the alignment is appropriate. If so, the test is positive (yes/true), and process 400 moves per branch 438 to link 440 at the bottom of FIG. 7A to continue with link 442 at the top of FIG. 7B. From link 442, process 400 continues with operation 444. Operation 444 includes application of one or more structural stud fasteners 168 with respect to at least one arm 162, 362 of stud receiver 160, 360. Each arm 162 defines fastener opening 164 and arcuate slot 166 and each arm 362 defines two fastener openings 312. Structural stud fastener can be an appropriate type and size of wood engaging nail such as nail 99 previously describe, a suitable screw, or otherwise provide acceptable attachment of stud receiver 160, 360 and structural stud 50. In FIGS. 2 and 3, two structural stud fasteners 168 each extend through arcuate slot 166 defined a different one of the two arms 162 to penetrate and extend into or through structural stud 50 positioned therebetween. In FIGS. 5 and 6, no fasteners are shown with respect to openings 312 through each of arms 362.

From operation 444, process 400 continues with conditional 450 that tests if wall understructure 24 is complete. If not, process 400 returns to FIG. 7A along branch 452 in correspondence to link 454 of FIG. 7B and link 456 of FIG. 7A. From link 456, process 400 returns to operation 412 along path 458 of loop 480 to repeat operations 412, 414, 426, 418, 420, and conditional 430 from which a negative result directs process 400 along branch 432 to repeat operation 434, operation 420, and conditional 420 of loop 425 until the test of conditional 430 is affirmative in which case process 400 follows branch 438 to FIG. 7B to repeat operation 444 and conditional 450 to test if wall understructure 24 is yet complete. Notably, stud extension 64 includes rigid attachment of a finishing stud 80, interconnector 100, 300; and structural stud 50 together which occurs once for each execution of extension preparation loop 480. Several stud extensions 64, one for each different one of structural studs 50 collectively constitute wall mounting interface framework 62 to complete wall understructure 24.

Conversely, if conditional 450 tests positively, process 400 follows branch 460 to operation 462 to apply and attach interior wall covering material 26 to stud interface wall 83 along wall finishing face 87 defined thereby. Stud interface wall 83 is a part of each finishing stud 80 that in turn is part of wall understructure 24. Material may be applied in one or more layers, coatings, or the like; and may involve various procedures and operations to define finished surface 28 with a desired appearance. Collectively, the same forms finished wall cover 27 with finished surface 28 to the interior. With preparation of finished wall cover 27 that adequately defines finished surface 28, finished wall 22 is complete and process 400 halts at flag 470.

Any patent, patent application, or other document cited in the present application is hereby incorporated by reference in its entirety herein—except to the extent expressly stated to the contrary. Any conjecture, discovery, experiment, estimation, finding, guesswork, hypothesis, idealization, investigation, model, operating principle or mechanism, prophetic description, representation, speculation, theory, test, test or experimental results, or the like relating to any aspect of the present application is provided to enhance understanding of the subject matter thereof without restricting any patent claim that follows—except to the extent the foregoing is expressly and unambiguously recited in such patent claims. The organization of application content under one or more headings aims to enhance understanding of such content and promote application readability, but these headings are not intended to affect the scope, meaning, substance, or “prior art” status of such content, except to the extent (if any) unambiguously expressed to the contrary in connection with each specific instance thereof. No patent claim hereof or innovation otherwise described herein should be understood to include a clause with a “means for” or “step for” performing a function (e.g., means plus function clause or step plus function clause, respectively), unless expressly specified by reciting within such clause “means for . . . ” or “step for . . . ” followed in close proximity by a function in gerund (“-ing”) form. Except to the extent expressly indicated to the contrary, aspects recited in a process or method claim (such “aspects” collectively refer to any acts, actions, activities, clauses, conditions, conditionals, contingencies, elements, events, features, gerunds, limitations, operations, phases, phrases, stages, statements, steps, relationships, or the like) may be performed in any order or sequence irrespective of cardinality or otherwise. Furthermore, any two or more of such aspects may be performed simultaneously, concurrently, or overlapping in time. Indeed, no order, sequence, concurrence, simultaneity, or overlap of two or more of such aspects results just because the process or method claim: (a) recites one of these aspects before another within the claim language, (b) precedes the first occurrence of an aspect with an indefinite article (“a” or “an”) or no article (as is commonplace for a plural noun, a proper noun, a mass or uncountable noun, an abstract noun, a number, a noun followed by a number, an prepositions, any, all, some, many, several, another, each, and certain other types of terminology in the English language) followed by a one or more subsequent occurrences of such aspect preceded by a definite article (“the” or “said”), (c) ordinal numbers in word form (first, second, third, . . . ) each precede the same identifier, descriptor, item, or the like to distinguish between them (e.g., first device, second device, third device, . . . ; first one of the modules, second one of the modules, third one of the modules, . . . ; or the like), or (d) the process/method claim includes alphabetical or cardinal number labeling to improve readability, organization, or the like—except to the extent the content of such claim properly construed unambiguously imposes a particular order, sequence, concurrence, simultaneity, or overlap as to two or more of its aspects. To the extent a particular order, sequence, concurrence, simultaneity, or overlap is imposed as to certain aspects of a process/method claim, but not all aspects of such claim, the same does not impose any order, sequence, concurrence, simultaneity, or overlap as to any other aspect listed before, after, or between such certain aspects.

The subject matter of the foregoing description and any drawing figures of the present application is not all-inclusive or exhaustive—being merely representative and non-exclusively exemplary. With respect to any patent claim that follows or innovation otherwise described herein, those of ordinary skill in the art pertaining to the present application will recognize that the same can be practiced without one or more details included in the description; and will also recognize such innovation or patent claim can be practiced with one or more additional features, elements, aspects, or the like not recited therein. Further, any obvious alteration, modification, or variation that may result from the present application teachings is also within the scope of any properly construed patent claim appended hereto or innovation otherwise described. Accordingly, the information provided in the preceding writing and/or any accompanying drawing figure is not intended to constrict, limit, restrict, reduce, restrain, or otherwise narrow the scope of any patent claim that follows—as compared to the scope of such patent claim defined by the language recited therein when properly construed.

Techniques to Assemble, Design, Fabricate, Install, Specify, and Use Structures Combining Different Member Types for Building Construction Framing and Comparable Applications

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