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Description  |
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BACKGROUND
1. Field of the Invention
The present invention relates to structures for incorporation into wall
structures of the type that include one or more panels of drywall material
supported by a metal framed structure including a plurality of
spaced-apart vertically arranged wall studs. More particularly, this
invention pertains to a new wall stud structure that is advantageously
configured for rapid and simplified wall frame assembly.
2. Description of the Prior Art
The wall unit formed of panels or sections of drywall, such as gypsum
board, supported by a (preferably metallic) frame is a commonly employed
and favored construction for retail business establishments and offices. A
plurality of such units can be employed to define a semi-permanent
arrangement of office or other space suitable to the retail or other
business tenant's needs. Representative wall unit arrangements of this
type are disclosed in the following U.S. Patent Ser. Nos.: 3,394,507 of
Doke for "Metallic Structure for Interior Walls to Carry Shelf Brackets
and Wallboard"; 3,407,547 of Doke et al. for "Metallic Wall Stud Structure
for Supporting Shelf Brackets"; 3,492,766 of Andrews for "Adjustable
Stud"; 3,509,669 of Plemens for "Support Structure for Shelving";
3,714,748 of Costruba for "Support Structure for Shelving"; and 3,730,477
of Wavrunek for "Bracket Support Unit for Integral Wall Construction".
The vertically arranged wall studs not only provide a frame for supporting
the wallboard panels but also must accommodate means for supporting one or
more shelf brackets in many wall units. The brackets, in turn, may be used
to support one or more shelves for merchandise, storage, books or the
like--an extremely advantageous and often necessary feature that
complicates both the design and installation of the wall studs.
The bracket support structure itself generally includes a wall standard
comprising an elongated bar with a series of longitudinal slots for
accommodating the inner tongue of the shelf bracket(s). An elongated
housing must be provided for retaining and supporting the wall standard
both with and without the additional weight of the bracket and shelves.
A number of arrangements have been adopted to engage the bracket support
structure to the frame of the wall unit. Certain of these have included
the incorporation of an elongated housing within the wall stud for
directly receiving the slotted wall standard while others have employed a
stud or stud arrangement adapted to receive a bracket support unit. In the
latter instance the wall studs only secure the position of the wall
standard indirectly.
The Doke, Doke et al., Plemens and Costruba patents generally disclose
symmetrical arrangements of pairs of studs for supporting wall standards
on either side of a wall unit. The opposed ends of the studs define
laterally directed channels for accepting and supporting the wall
standards. The vertical position of the wall standard within each
laterally directed channel may be secured by means of screws, clips or the
like.
In each of the aforesaid arrangements, the channels formed within the stud
substantially enclose the wall standard. Thus, when fabricating a wall
unit incorporating such studs, the assembler must either handle a
cumbersome unit including a pair of studs, wall standards and associated
apparatus or work with a somewhat disassembled unit. In the former
instance, the heavy and awkward unit demands considerable effort in
attempting to attain proper plumbed location. Even then, some misalignment
may occur with respect to the wall standard as some "play" is inevitable
within the retaining channels. In the latter instance, a nearly impossible
task awaits the assembler after aligning the stud. The wall standard is
generally of sufficient length to render the sliding of the standard into
the channel a most difficult task.
The Wavrunek patent discloses a wall construction in which the wall
standard is secured within an elongated extruded housing. The housing is
independent of the wall studs which are simply U-shaped channels arranged
back to back on either side of the housing. While offering certain
advantages in terms of simplicity, the fabrication of a wall unit
including such arrangements is complex and exacting. The studs are
individually positioned, doubling the opportunity for error in placement.
Even a small error or misalignment may prove to be both structurally and
aesthetically disastrous. Thus, any economies due to its overall
simplicity of design are more than overcome by the increased cost of
proper installation of such an unit. An improved bracket support structure
is disclosed in the pending U.S. patent application of the inventors
herein Ser. No. 621,255, entitled "Integral Bracket Support Structure".
The structure disclosed therein presents an economical roll formed
structure that, like Wavrunek, is separate from the supporting wall studs.
While the various arrangements discussed above possess certain desirable
features, they disclose that the prior art has failed to provide a wall
stud construction, compatible with the needs of contemporary wall unit
design, that offers economy of manufacture and ease, and hence economy, in
wall unit fabrication.
SUMMARY OF THE INVENTION
The present invention addresses the foregoing and additional disadvantages
of the prior art by providing an improved stud for use in framing a wall
unit. The stud includes a pair of unitary stud portions. Each of the stud
portions is a mirror image of the other and these portions are arranged
back to back to form a common web.
Each stud portion includes at least one inner flange and an adjacent
interior edge orthogonal thereto. Such arrangement defines a shoulder for
forming an open surface channel.
In another aspect, the invention provides a wall unit construction member.
The member includes means for retaining a wall standard. There is further
provided means adapted to receive the last-named means that includes an
open surface channel.
The preceding, and other, advantages and features of the invention will
become further apparent from the detailed description that follows. The
description is accompanied by a set of drawing figures. Numerals of the
figures and the description refer to features of the invention, like
numerals referring to like features of the invention throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an overall partially broken perspective view of a wall unit, such
as a partition, incorporating a stud in accordance with the invention;
FIG. 2 is an exploded perspective view of the cooperative arrangement of
wall standard, bracket support and stud in accordance with the invention;
FIG. 3 is a sectional view taken at section line 3--3 of FIG. 1 indicating
the cross-sectional geometry of the stud of the invention both with and
without bracket support; and
FIG. 4 is an enlarged sectional view taken at the line 4--4 of FIG. 2 that
illustrates in detail the structure of the roll formed stitches that
secure the common web of the stud.
DETAILED DESCRIPTION
Referring now to the drawings, FIG. 1 is an overall partially broken
perspective view of a wall unit 10, such as a common partition, which
incorporates a stud 12 in accordance with the invention. As mentioned
supra, units or partitions of such nature are often found in offices,
retail and other business environments.
The wall unit 10 includes a frame comprising a plurality of studs 12 in
accordance with the invention. The wall stud of the invention will be
described in greater detail infra. However, as can be seen in FIG. 1, the
stud 12, formed preferably of either sheet metal or sheet steel, is of a
generally back-to-back T-shape with common stem and transverse members
arranged to coincide with opposed wallboard surface panels.
The stem of the T-shaped configuration extends from the top to the bottom
of the stud 12 forming a double strength web 14. Polygonal and round
apertures 16 and 17 respectively are provided within the extent of the web
14. Such apertures act as orifices which permit the passage of electrical
conduit, reinforcing bars, such as the illustrated bar 18, and associated
material for securing the reinforcing bar 18 to the frame of the wall unit
10. In the event a bar 18 were to pass through the polygonal aperture 16,
the round aperture 17 is a useful location for passage of wire for
securing the bar tightly to the bottom of the aperture 16, a preferred
construction arrangement when a reinforcing bar 18 is employed in
conjunction with a wall unit featuring the arrangement shown generally in
FIG. 1.
Referring to the top of the T-shape that faces out of FIG. 1, this
transverse member of the stud 12 is seen to include a pair of outer
flanges 20 and 22 which are secured to and provide a base for mounting
flanges 24 and 26 of an elongated bracket support 28. The support 28
secures a wall standard including a plurality of longitudinal slots for
engaging the inner end of at least one wall bracket 30 that, in turn,
protrudes from the wall unit to support a shelf perpendicular thereto. The
bracket support 28 shown in FIG. 1 and, in somewhat greater detail in the
following figure, is generally of the type shown and claimed in pending
U.S. Patent Application Ser. No. 621,255.
The plurality of vertically-arranged studs that define the frame of the
wall unit 10 run from and are secured to a U-shaped cap 34 and U-shaped
track 36 at their upper and lower ends, respectively. Drywall panels 38,
40 and 42 enclose the metallic frame and provide facings for the wall
unit.
Prior to constructing an office from partitions of the type shown in FIG.
1, markings, including the lines 44 and 46 are made on the floor 47 of the
"shell" structure. Such markings are very carefully drawn and located from
the detailed floor plan to be implemented. An essential to proper
construction of the partition arrangement and realization of the
customer's desired office plan is the careful and exacting adherence of
the placement of the sections of the partitions to the customer's
architectural plans. The actual implementation of the plan, of course,
relies upon a combination of the skill of the installer and the difficulty
of the task presented to him. An essential feature and advantage of the
present invention, to be shown and discussed below, is the manner in which
installation of a wall unit is enhanced and the resulting product rendered
reliably exacting and to the customer's specifications by means of
incorporation of wall studs in accordance with the invention. Further, by
simplifying the ease of installation with which the workman may exactly
adhere to the floor markings, such as the markings 44 and 46 that are
conventionally provided for locating the wall brackets 30, 30', 32 and 32'
and their supports, the use of the studs can dramatically lower
installation costs and minimize costs incurred through revision of
unsatisfactory work. Less skilled labor is required to install a partition
arrangement including wall units that are framed with wall studs in
accordance with the invention. Alternatively, skilled labor can install
such partitions with greatly increased speed.
FIG. 2 presents an exploded perspective view of the cooperative arrangement
of a wall standard, bracket support and stud in accordance with the
invention. As mentioned, supra, the bracket support 28 is as shown in
Applicants' invention entitled "Integral Bracket Support". Briefly, that
bracket support arrangement is adapted to hold an elongated wall standard
50 upright whereby it may receive, within an interior slot 52, a mating,
inwardly protruding tongue portion of a wall bracket (not shown).
Edge notches are provided in the sides of the wall standard 50 that act as
regions for accepting inwardly-projecting keys (not shown) which interlock
the vertical position of the wall standard within a roll formed elongated
housing which defines the bracket support 28. The support 28, formed of a
single roll formed piece of sheet metal or sheet steel, includes a lateral
channel 48 for accepting the wall standard 50, an interiorly projecting
portion 56 for accommodating the interior tongue that interlocks with the
slotted wall standard 50, an outwardly projecting passageway 58 formed
between the outwardly projecting roll formed blade members 60 and 62 and
the aforementioned mounting flanges 24 and 26. A lengthwise covering 64 of
elastomeric material may be employed for aesthetic purposes. While the
invention is illustrated with reference to this particular bracket
support, it is nonetheless compatible with other particular structures of
like nature and not limited either in utility or otherwise thereto.
The wall stud 12 of the invention is preferably formed of two identical
cold rolled portions arranged back-to-back as in a mirror image. The
separate roll formed portions are "stitched" together along the length of
the double strength common web 14 by means of interlocking tongue and slot
arrangements shown more clearly in FIG. 4.
FIG. 3 is a horizontal section of the wall unit 10 taken at line 3--3 of
FIG. 1 that, in conjunction with the perspective view of FIG. 2, gives a
ready understanding and illustration of the stud 12 and its function with
regard to the remainder of the partition structures. Viewing corresponding
portions of these two figures, it can be seen that each of the two mirror
image paired portions that comprise the stud 12 includes a series of roll
formed bends that project outwardly from the common double strength web 14
to form, when assembled (i.e. stitched together) a structure that includes
an easily accessible surface cavity for simplified mounting of the bracket
support 28. Further, the stud, an economically manufactured roll formed
structure, as a consequence of the numerous folds, possesses significant
rigidity and stiffness regardless of the presence or absence of a bracket
support 28 and therefore is a meritorious structural element standing
alone.
Viewing the sectional geometry of the stud 12, angle bends 66, 66' adjacent
the web 14 join inwardly projecting segments 68 and 68' respectively to
form a rear channel for accepting the interiorly projecting portion 56 of
the bracket support 28.
Outwardly directed shoulders are formed adjacent the rear channel by the
orthogonally-folded inner flanges 72, 72' and interior edges 74 nd 74'
respectively. The outwardly projecting shoulders define an open surface
channel therebetween. The surface channel is adapted to accommodate the
lateral channel 48 of the bracket support 28. As opposed to prior art
means for retaining a shelf bracket supporting apparatus, the open surface
channel of the stud 12 demands neither the awkward and tricky sliding of
the wall standard 50 into place within a substantially fully enclosed
channel nor the aligning of a bulky unit including both wall standard and
stud. Further, the surface channel is easily plumbed to assure correct
placement throughout its elongated length. The use of a 25 double portion
stud is, of course, superior in terms of ease of installation to that of
independent, paired studs that require much attention to the tasks of
alignment and maintenance of proper separation distance throughout their
lengths for both accuracy of construction and proper appearance.
At the opposite end of the common web 14, there exists a corresponding
construction for receiving a bracket support. Unlike that described supra,
the surface and rear channels defined, in part, by the opposed inwardly
projecting segments 96 and 98 and the orthogonally-folded inner flanges
100 and 102, do not house a bracket support. This permits one to observe
that the stud portions have been rolled so that the angles created between
the adjacent inwardly-projecting segments and orthogonally-folded inner
flanges are slightly less than ninety (90.degree.) degrees. Thus, absent a
bracket support, the rear channel presents a somewhat narrowing,
pincer-like appearance between the inwardly-projecting segments 96 and 98.
This feature of the geometry of the stud further simplifies the wall unit
assembly process. The pincer action is sufficient to hold the bracket
support, thereby freeing both of the installer's hands for the other
required construction tasks, such as drilling screw holes, checking
alignment and the like. Further, Applicants have found that the bracket
support unit can be adequately secured to the stud for construction
purposes by a combination of the above-described pincer action and the
taping together of the outer flanges of the stud and the mounting flanges
of the bracket support by means of suitable industrial adhesive tape.
Outer flanges 20 and 22 are roll formed adjacent and orthogonal to the
interior edges 74 and 74' respectively. As mentioned supra, the outer
flanges of the stud match and provide elongated surfaces for engaging the
mounting flanges 24 and 26 of the bracket support 28. Interiorly folded
outer edges 78 and 78' add further stability and stiffness to the roll
formed stud.
The means for attaching the stud 12 to the bracket support 28 and to the
drywall panels of the wall unit 10 may be seen in FIG. 3. As is shown,
self tapping sheet metal screws, such as the screw 92 secure the matching
flanges of the stud 12 and the bracket support 28 throughout their common
lengths. Wall screws, such as the screw 94 fix wallboard, stud 12 and
bracket support 28 in a three ply sandwich arrangement. Thus, the vertical
relationship of the bracket support 28 and wall standard 50 to the stud is
additionally secured by the means for attaching the drywall panels 38 and
40. The particular arrangement of means for mounting these elements
relative to each other provides substantially greater assurance that the
wall standard 50 will maintain its preferred position while bearing the
weight and moments transferred to it by the cantilevered shelf and
associated loading than is the case in the instance of various prior art
arrangements which rely, for example, upon combinations of clips and spot
welds.
While spot welds may be seen to be employed liberally in the prior art,
their use has been avoided in recognition of the metallurgical degradation
and consequent structural weakening that may result from that process. As
mentioned above, the two portions of the stud are stitched together as a
part of the roll forming process wherein a roll punch, for example, may be
utilized.
FIG. 4 is an enlarged sectional view taken at line 4--4 of FIG. 2 which
illustrates in detail the structure of the roll formed stitches that
secure the common, double strength web 14 of the stud. The separate sheet
metal portions forming the stud are indicated at 84 and 86. As is seen in
FIG. 2, each stitch represents a tongue-and-slot arrangement. Referring
particularly to FIG. 4 it can be seen that these stitch arrangements are
provided by first punching through the two portions 84 and 86 of the web
14 (from left to right in the instance shown in FIG. 4) then rolling down
the threads from the punching process into a common tongue 88. A common
slot 90 remains in the wake of the restructuring of the double strength
web 14.
The two portions 84 and 86 forming the double strength web 14 are securely
stitched together. As is seen, at the point of attachment or stitch there
exists a four-ply structure that is tightly rolled down. This secure
arrangement is accomplished without the application of the severe heat
gradients that characterize welding and may cause significant
metallurgical degradation of the structure.
Thus it is seen that there has been provided by the invention an improved
wall stud for use in the framing of conventionally utilized wall units.
The stud is both economical to manufacture as a consequence of its
simplified structure that is easily amenable to economical roll formation
processing without sacrifice of strength or stiffness and economical in
terms of installation. By providing an easily accessible surface channel
and double stud structure, the stud and bracket support are easily and
quickly positioned and fixed in accordance with the architects plans.
While the present invention has been illustrated and discussed with regard
to its presently preferred embodiment, its scope is in no wise limited
thereto. Rather, it is limited only insofar as defined in the following
set of claims and equivalents thereof.
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