TRACK SYSTEM FOR SUPPORTING WALL STUDS

Abstract

An apparatus for supporting and retaining a plurality of parallel spaced apart wall studs comprises a longitudinally extending base having first and second side edges and first and second opposed sidewalls extending generally perpendicular to the base from the first and second side edges, wherein the base and sidewalls together define a trough for receiving and retaining an end portion of the plurality of wall studs. The apparatus further comprises a plurality of clips sized to fit within and extend transversely across the trough, each of the plurality of clips having first and second tabs extending from the base wherein the first and second tabs each define a slot with a corresponding of the first and second sidewalls sized to receive a portion of the wall studs therein.

Description

BACKGROUND OF THE INVENTION

1. Field of Invention

The present invention relates generally to construction and in particular to a method and apparatus for supporting a plurality of parallel spaced apart wall studs.

2. Description of Related Art

Metal wall studs are commonly used in the construction trade for framing walls and other structures. The studs are installed at spaced intervals to provide a framework for installation of drywall panels and the like.

Various track systems are known in the prior art for supporting wall studs at the desired location. Such systems typically comprise a top track secured to the ceiling and a bottom track secured to the floor in alignment with the top track. Each wall stud is positioned between the top and bottom tracks and secured in place with screws or crimping. In the case of “slip track” systems, the wall studs may be cut to a length less than the overall vertical distance between the top and bottom tracks. This permits some movement of the top track relative to the bottom track after installation of the wall studs. Slip track systems can thus accommodate deflection in the ceiling position relative to the wall and floor, for example due to changes in applied loads or temperature fluctuations. In some prior art systems an outer track and a movable inner track are provided to achieve the slip track functionality.

In conventional wall construction systems each stud is secured to the top and bottom tracks with fasteners, such as metal screws. This typically requires installers to use a ladder and a screw gun to secure the top end of each stud to the top track and building frame. The bottom end of each stud is secured to the bottom track in a similar manner. In some cases, inexperienced tradesmen may install the studs at incorrect track locations, resulting in inconsistent spacing between the studs or off-vertical positioning. In such cases it is time-consuming and labour-intensive to remove the fasteners from the tracks and reinstall the wall studs in the correct orientation.

Some fastener-less stud alignment systems are known in the prior art where wall studs are held in place with clips or tabs formed in the tracks rather than by separate fasteners. Such systems avoid the need for screw guns or other tools for driving fasteners. However, in some cases the track clips are not designed to receive standard wall studs and custom studs must be used. In other cases, studs cannot be easily extracted from the clips after installation, particularly in the case of heavier gauge studs.

U.S. Pat. No. 6,647,691, Becker et al., exemplifies the prior art in this field. Becker describes a track arrangement for supporting wall studs where the studs are held in place in the tracks with opposed clips. Each clip consists of a portion of track sidewall bent inwardly to form a cam surface and a stud ridge receiver. The studs may or may not be bottomed-out in the tracks depending on whether or not the wall is load bearing.

One drawback of the Becker et al. track arrangement is that, once installed, the wall studs cannot be easily decoupled from the tracks. Rather, significant force would be required to extract the stud side flanges from the track clips. Also, the Becker et al. arrangement requires that each stud be inserted within the top and bottom tracks in the same orientation, i.e. with stud side flanges projecting in one direction only. Furthermore, the Becker et al. system requires punching the tabs from the track itself which disadvantageously compromises the continuity of the track and may be prohibited by some building codes.

U.S. Pat. No. 8,615,959 B2, Ferguson et al. also describes a track arrangement for supporting wall studs where the studs are held in place with tabs and slots formed in the tracks by use of a metal press. Similar to Becker et al., a drawback of this arrangement is that in some jurisdictions building code specifies that cuts or notches through the flanges of the tracks are not permitted.

SUMMARY OF THE INVENTION

According to a first embodiment of the present invention there is disclosed an apparatus for supporting and retaining a plurality of parallel spaced apart wall studs. The apparatus comprises a longitudinally extending base having first and second side edges and first and second opposed sidewalls extending generally perpendicular to the base from the first and second side edges, wherein the base and sidewalls together define a trough for receiving and retaining an end portion of the plurality of wall studs. The apparatus further comprises a plurality of clips sized to fit within and extend transversely across the trough, each of the plurality of clips having first and second tabs extending from the base wherein the first and second tabs each define a slot with a corresponding of the first and second sidewalls sized to receive a portion of the wall studs therein.

The clip may include a bottom portion extending between the first and second tabs. The bottom portion of the clip may be substantially planar. The bottom portion of the clip may be secured to the base. The first and second tabs may extend substantially parallel to the first and second side walls.

Each of the first and second tabs may include a bottom portion proximate to the base portion and a top portion distal from the base portion of the clip. The bottom and top portions may have a bend angle therebetween. The bottom portion may be angled towards the first or second side wall and wherein the top portion is angled away from the first or second side wall.

Each of the plurality of clips may be formed from a substantially planar unitary sheet of material. The plurality of clips may be spaced along the trough at regular intervals. The slots may be adapted to restrain horizontal movement of the stud located therein in the engaged position. The slots may be adapted to permit vertical movement of the stud located therein between engaged and disengaged positions by sliding the stud vertically.

According to a first embodiment of the present invention there is disclosed a kit for forming a wall comprising at least one top track, at least one bottom track and a plurality of metal wall studs having sidewalls sized to be received within the slots of the top and bottom tracks. Each of the top and bottom tracks comprises a longitudinally extending base having first and second side edges and first and second opposed sidewalls extending generally perpendicular to the base from the first and second side edges, wherein the base and sidewalls together define a trough for receiving and retaining an end portion of the plurality of wall studs. Each of the top and bottom tracks further comprises a plurality of clips sized to fit within and extend transversely across the trough, each of the plurality of clips having first and second tabs extending from the base wherein the first and second tabs each define a slot with a corresponding of the first and second sidewalls sized to receive a portion of the wall studs therein. The kit further comprises

The base of the top track may extend along a plane parallel to the base of the bottom track at a distance greater than a length of the plurality of metal studs to permit the relative sliding movement of the plurality of metal studs. The trough of the top track may have a depth exceeding a depth of the trough of the bottom track. The tabs of the top track may have a length exceeding a length of the tabs of the bottom track to define corresponding larger slots in the top track.

According to a first embodiment of the present invention there is disclosed a method for forming a wall comprising securing a bottom track to a floor surface and securing a top track to a ceiling surface. Each of the bottom top tracks comprises a longitudinally extending base having first and second side edges and first and second opposed sidewalls extending generally perpendicular to the base from the first and second side edges, wherein the base and sidewalls together define a trough for receiving and retaining an end portion of the plurality of wall studs. Each of the bottom and top tracks further comprise a plurality of clips sized to fit within and extend transversely across the trough, each of the plurality of clips having first and second tabs extending from the base wherein the first and second tabs each define a slot with a corresponding of the first and second sidewalls sized to receive a portion of the wall studs therein. The method further comprises providing a plurality of metal wall studs, engaging a top end of each of the plurality of metal wall studs within the slots of the top track, rotating each of the plurality of metal studs into alignment with the slots of the bottom track and vertically moving each of the plurality of metal studs into engagement with the bottom slots of the bottom track.

Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,

FIG. 1 is a perspective view of an assembly for forming a wall according to a first embodiment of the present invention.

FIG. 2 is a perspective view of a top track of the assembly of FIG. 1.

FIG. 3 is a cross-sectional view of the top track of FIG. 2 as taken along section lines 3-3.

FIG. 4 is a plan view of a cut sheet for forming a clip for use in the top track of FIG. 2.

FIG. 5 is a front view of the bent top track clip of FIG. 4.

FIG. 6 is a perspective view of a bottom track of the assembly of FIG. 1.

FIG. 7 is a cross-sectional view of the bottom track of FIG. 6 taken along section 7-7.

FIG. 8 is a plan view of a cut sheet for forming a clip for use in the bottom track of FIG. 6.

FIG. 9 is a front view of the bent bottom track clip of FIG. 8.

FIG. 10 is a fragmented, perspective view of the track assembly showing steps for releasably coupling a wall stud to the top and bottom tracks.

FIG. 11 is a detailed, cross-sectional view showing a lower end of a wall stud disposed above a track slot.

FIG. 12 is a detailed, cross-sectional view showing a lower end of a wall stud seated within a track slot.

DETAILED DESCRIPTION

Referring to FIG. 1, a track assembly 10 for supporting wall studs 9 is generally illustrated at 10. Track assembly 10 includes a top track 14 attached to the ceiling framework of a building and a bottom track 40 attached to the floor of a building. The top track 14 includes a horizontal base 18 and a pair of opposed vertical sidewalls 20 extending generally perpendicular to base 18. The bottom track 40 includes a horizontal base 42 and a pair of opposed vertical sidewalls 44 extending generally perpendicular to the base 42. Base 18 with sidewalls 20 and base 42 with sidewalls 44 together define generally U-shaped top and bottom troughs 22 and 41. As described further below, each top and bottom trough 22 and 41 is sized to receive an end 6, 5 of a stud 9 therein. The height of sidewall 20 and hence the depth of top trough 22 may be larger in the top track 14 (FIGS. 2-3) than the height of sidewall 44 and hence the depth of bottom trough 41 of the bottom track 40 (FIGS. 6-7).

As shown best in FIG. 10, each stud 9 includes a base 8 and opposed flanges or sidewalls 7 extending in parallel planes perpendicular to base 8. Studs 9 are conventional in structure and are typically constructed of 12-25-gauge steel. Studs 9 can be cut to the desired length by any commonly known means or selected to have the desired length.

As shown in FIG. 2, a plurality of clips 30 are laterally attached to the base 18 or sidewall 20 of the top track 14 at regular intervals. Slots 31, as shown in FIG. 3, between opposed sidewalls 20 and clips 30 are preferably aligned. In one embodiment of the invention, each slot 31 is defined between a clip 30 and an adjacent portion of sidewall 20. Each clip 30 includes a fixed base portion 32 attachable to base 18 and a free side tab 34 extending distal from base portion 32 (FIGS. 2-3). As described further below, in one embodiment of the invention each clip 30 may consist of a bent metal piece attached to base 18 or sidewall 20.

Clips 30 are preferably attached to base 18 at regular, spaced-apart longitudinal intervals, with clip spacing distance 24. For example, the clip spacing distance 24 between clips 30 may be selected to correspond to the desired wall stud spacing. At respective ends of top track 14, clips 30 are attached at half of the clip spacing distance 24 from the end, as indicated at half clip spacing distance 26. End clips placed at half clip spacing distance 26 form a full clip spacing distance 24 when end portions of two top tracks 14 are longitudinally aligned. Clips 30 may be attached to base by any known method.

Referring to FIG. 4, clips 30 may be made from any gauge sheet metal or any other suitable material. The clip material is bent at fold line 36, forming a base portion 32, and a pair of side tabs 34. Base portion 32 is sized to have a length between fold lines 36 less than the width of top trough 22, to allow for a slot 31 between the side tabs 34 and the sidewall 20, as shown on FIG. 3. The width of base portion 32 may be of any size to be received within the opening of the selected wall studs. Side tabs 34 may be bent along the fold line 36 to form the at tab angle 35 equal to or greater than 90°. When tab angle 35 is greater than 90°, a portion of the side tabs 34 on clip 30 may touch the sidewalls 20 of top track 14 proximate to the free end 37. In this case, additional slight bends (for example 45°) of clip 30 may be optionally placed at fold line 38, to allow for a gap between the free end 37 of side tabs 34 on clip 30 and sidewalls 20 of top track 14.

As shown in FIG. 6, a plurality of clips 50 are laterally attached to the base 42 or sidewall 44 of the bottom track 40 at regular intervals. Slots 51, as shown in FIG. 7, between opposed sidewalls 44 and clips 50 are preferably aligned. In one embodiment of the invention, each slot 51 is defined between a clip 50 and an adjacent portion of sidewall 44. Each clip 50 includes a fixed base portion 52 attachable to base 42 and a free side tab 54 extending distal from base portion 52 (FIGS. 6-7). As described further below, in one embodiment of the invention each clip 50 may consist of a bent metal piece attached to base 42 or sidewall 44.

Clips 50 are preferably attached to base 42 at regular, spaced-apart longitudinal intervals, with clip spacing distance 46. For example, the clip spacing distance 46 between clips 50 may be selected to correspond to the desired wall stud spacing. At respective ends of bottom track 40, clips 50 are attached at half of the clip spacing distance 46 from the end, as indicated at half clip spacing distance 48. End clips placed at half clip spacing distance 48 form a full clip spacing distance 46 when end portions of two bottom tracks 40 are longitudinally aligned. Clips 50 may be attached to base 42 or sidewall 44 by any known method.

Referring to FIG. 8, clips 50 may be made from any gauge sheet metal or any other suitable material. The clip material is bent at fold line 56, forming a base portion 52, and a pair of side tabs 54. Base portion 52 is sized to have a length between fold lines 56 less than the width of bottom trough 41, to allow for a slot 51 between the side tabs 54 and the sidewall 44, as shown on FIG. 7. The width of base portion 52 may be of any size to be received within the opening of the selected wall studs. Side tabs 54 may be bent along the fold lines 56 to form tab angle 55 equal to or greater than 90°. When tab angle 55 is greater than 90°, a portion of the side tabs 54 on clip 50 may touch the sidewalls 44 of bottom track 40 proximate to the free end 57. In this case, additional slight bends (for example 45°) of clip 50 may be optionally placed at fold line 58, to allow for a gap between the free end 37 of side tabs 54 on clip 50 and sidewalls 44 of bottom track 40.

In one embodiment of the invention, each clip 30, 50 may be generally rectangular in shape. As will be appreciated by a person skilled in the art, clips 30, 50 may be formed in other configurations to define slots 31, 51 of other shapes and sizes. In the illustrated embodiment, the length of side tab 34 of clips 30 may be longer in top track 14 than the length of side tab 54 of clips 50 in bottom track 40. The difference between the length of the tabs permits the studs to be inserted into the longer slot and thereafter displaced therein to permit insertion into the shorter slot, as described in greater detail below.

In use, top track 14 is secured to a ceiling framework of a structure and bottom track 40 is secured to the floor of the structure (FIG. 1). Top and bottom tracks 14, 40 are preferably installed so that slots 31, 51 formed between top and bottom tracks 14, 40 and clips 30, 50 are vertically aligned. End portions of some top and bottom tracks 14, 40 may abut a wall or may be longitudinally aligned as described above to define top and bottom troughs 22, 41 of any desired length.

Referring to FIGS. 10-12, standard studs 9 are cut to the desired length to extend between tracks 14, 40. Preferably studs 9 are cut to a length which is slightly less than the installed distance between bases 18, 42 of aligned top and bottom tracks 14, 40. By way of non-limiting example, studs 9 may be cut to a length which is shorter than the distance between bases 18, 42 of top and bottom tracks 14, 40. As shown in FIG. 10, stud 9 may be secured to track assembly 10 by first lifting stud 9 upwards as shown generally in direction 100 inserting upper end 6 of stud 9 into top trough 22 of top track 14 so that sidewalls 7 at upper end 6 are received into opposed slots 31. The opposite lower end 5 of stud 9 is then pivoted, in general direction 102, into position (FIGS. 10-11) and dropped, in general direction 104, into aligned slots 51 of bottom track 40 (FIG. 12). Once installed as aforesaid, the lowermost edge of stud 9 is supported on the base 42 of bottom track 40 as shown in FIG. 12.

Since the length of stud 9 is slightly less than the distance between bases 18, 42 of top and bottom tracks 14, 40, some relative movement of track assembly 10 and studs 9 is permitted. Such a “slip track” system permits the top track 14 to shift vertically relative to studs 9 and bottom track 40 if the ceiling height of the structure shifts or deflects. As will be appreciated by a person skilled in the art, changes in the relative spacing between the ceiling and floor of a structure causing deflection of top track 14 may result from loads applied to the structure and/or temperature fluctuations causing expansion or contraction of structural components.

One significant advantage of the applicant's track assembly 10 is that stud 9 may be securely coupled to track assembly 10 without the use of special tools or fasteners. That is, one upper end 6 of each stud 9 may be coupled to top track 14 as described above (FIG. 10) by an installer standing on the floor of the structure and extending stud 9 upwardly toward the ceiling. Accordingly, ladders or additional braces or fasteners are not required. The opposite lower end 5 of each stud 9 may also be secured to bottom track 40 as described above without the use of fasteners or special tools. Thus studs 9 may be easily installed at the correct locations and intervals and installation errors by unskilled tradesmen are avoided.

Another advantage of track assembly 10 is that stud 9 may be connected to track assembly 10 in any desired orientation (i.e. with sidewalls 7 of stud 9 extending either toward or away from an end wall of the structure). This allows studs 9 to be placed in the optimum orientation to suit the particular requirements of the wall in question.

A further advantage of track assembly 10 is that one or more selected studs 9 may be easily removed from track assembly 10 without the use of ladders or other special tools or equipment by reversing the installation procedure illustrated in FIG. 10, (i.e. by lifting stud 9 upwardly, pivoting one lower end 5 out of bottom track 40 and then lowering stud 9 out of top track 14 to de-couple it from track assembly 10). It is often convenient to remove a stud 9 from a track assembly 10 after initial installation to make room for electrical panels, plumbing or other building materials installed by sub-trades as construction of a structure progresses.

An additional advantage of track assembly 10 in the presented embodiment is that there are no cuts or notches forming holes in the sidewalls 20, 44 to diminish the strength of the top and bottom tracks 14, 40.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the invention only and not as limiting the invention as construed in accordance with the accompanying claims.

Claims

1. An apparatus for supporting and retaining a plurality of parallel spaced apart wall studs comprising: a longitudinally extending base having first and second side edges and first and second opposed sidewalls extending generally perpendicular to said base from said first and second side edges, wherein said base and sidewalls together define a trough for receiving and retaining an end portion of said plurality of wall studs;a plurality of clips sized to fit within and extend transversely across said trough, each of said plurality of clips having first and second tabs extending from said base,wherein said first and second tabs each define a slot with a corresponding of said first and second sidewalls sized to receive a portion of the wall studs therein.

2. The apparatus of claim 1 wherein said clip includes a bottom portion extending between said first and second tabs.

3. The apparatus of claim 2 wherein said bottom portion of said clip is substantially planar.

4. The apparatus of claim 2 wherein said bottom portion of said clip is secured to said base.

5. The apparatus of claim 1 wherein said first and second tabs extends substantially parallel to said first and second side walls.

6. The apparatus of claim 1 wherein each of said first and second tabs include a bottom portion proximate to said base portion and a top portion distal from said base portion of said clip.

7. The apparatus of claim 6 wherein said bottom and top portions have a bend angle therebetween.

8. The apparatus of claim 7 wherein said bottom portion is angled towards said first or second side wall and wherein said top portion is angled away from said first or second side wall.

9. The kit of claim 1 wherein each of said plurality of clips is formed from a substantially planar unitary sheet of material.

10. The kit of claim 1 wherein said plurality of clips are spaced along said trough at regular intervals.

11. The kit of claim 1 wherein said slots are adapted to restrain horizontal movement of the stud located therein in the engaged position.

12. The kit of claim 1 wherein said slots are adapted to permit vertical movement of the stud located therein between engaged and disengaged positions by sliding the stud vertically.

13. A kit for forming a wall comprising: at least one top track formed in accordance with claim 1;at least one bottom track formed in accordance with claim 1; anda plurality of metal wall studs having sidewalls sized to be received within said slots of said top and bottom tracks.

14. The kit of claim 14 wherein said base of said top track extends along a plane parallel to said base of said bottom track at a distance greater than a length of said plurality of metal studs to permit the relative sliding movement of said plurality of metal studs.

15. The kit of claim 13 wherein said trough of said top track has a depth exceeding a depth of said trough of said bottom track.

16. The kit of claim 13 wherein said tabs of said top track have a length exceeding a length of said tabs of said bottom track to define corresponding larger slots in said top track.

17. A method for forming a wall comprising: securing a bottom track to a floor surface;securing a top track to a ceiling surface,wherein each of said bottom top tracks comprises: a longitudinally extending base having first and second side edges and first and second opposed sidewalls extending generally perpendicular to said base from said first and second side edges, wherein said base and sidewalls together define a trough for receiving and retaining an end portion of said plurality of wall studs;a plurality of clips sized to fit within and extend transversely across said trough, each of said plurality of clips having first and second tabs extending from said base,wherein said first and second tabs each define a slot with a corresponding of said first and second sidewalls sized to receive a portion of the wall studs therein.providing a plurality of metal wall studsengaging a top end of each of said plurality of metal wall studs within said slots of said top track;rotating each of said plurality of metal studs into alignment with said slots of said bottom track; andvertically moving each of said plurality of metal studs into engagement with said bottom slots of said bottom track.