US20070130856A1

US20070130856A1 - Sheet metal intersection studs

Info

Publication number: US20070130856A1
Application number: US11/451,185
Authority: US
Inventors: Matt Surowiecki; Lawrence Gorham; Tadeusz (Ted) Wrobel
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-12-07
Filing date: 2006-06-12
Publication date: 2007-06-14
Also published as: WO2007067741A2; WO2007067741A3

Abstract

A corner stud (40) has a four-sided post portion (42) that sits into a corner region of a framing wall. The post portion includes a pair of flanges (92, 96) which form a right angle inside corner at the inside corner of the framing wall. Edge portions of wallboard panels (108, 110) connect to the flanges (92, 96). A post portion 112 of an intersection stud (110) fits within the tracks at a location between the corners. Inside corners are formed by flanges (148, 160) and (154, 166) against which edge portions (180, 182) of wallboard panels (184, 186) and (188, 190) are connected. The edge portions (180, 182, 188, 190) of the wallboard are connected to and backed up by the flanges (148, 160, 154, 166).

Description

RELATED APPLICATION

This application is a continuation-in-part application based on Ser. No. 11/296,115, filed Dec. 7, 2005, and entitled Sheet Metal Intersection Studs.

TECHNICAL FIELD

This invention relates to sheet metal framing walls. More particularly, it relates to the provision of studs usable where two walls intersect, for facilitating the connection together of the two walls.

BACKGROUND OF THE INVENTION

Building walls intersect each other at corners and at locations between the corners. U.S. Pat. No. 4,689,930, granted Sep. 1, 1987, to Robert J. Menchetti, discloses a corner stud to which two standard studs are connected. U.S. Pat. No. 3,363,377, granted Jan. 16, 1968, to Melvin H. Beckman, and U.S. Pat. No. 4,283,892, granted Aug. 18, 1981, to Larry B. Brown disclose studs constructed to be usable at an intersection of a first wall with a second wall between its corners. FIG. 1 of the drawing herein shows a prior art use of two standard studs where two walls intersect at a corner. FIG. 3 of the drawing herein shows the use of two standard prior art studs at an intersection of two walls between the corners.
There is a need for intersection studs for use at the corners and between the corners that facilitates construction of the walls while reducing both material and labor. It is the primary object of the present invention to fill this need.

BRIEF SUMMARY OF THE INVENTION

It is an object of the invention to provide an elongated sheet metal stud that includes a first corner portion including adjacent unitary walls set at an angle to each other, a second corner portion including adjacent unitary walls set an angle to each other, and a body portion interconnecting the first and second corner portions. The body portion and the first and second corner portions are parts of a unitary structure. The first corner portion is adapted to provide a backing for edge portions or wallboard panels that meet at the corner formed by said corner portion. The second corner portion is adapted to provide a backing for edge portions of wallboard panels that meet at the corner formed by said second corner portion. In some embodiments, the first corner portion forms an inside corner and the second corner portion forms an inside corner. In other embodiments, the first corner portion forms an inside corner and the second corner portion forms an outside corner.
It is another object of the invention to provide a corner stud that has a generally tubular post portion which fits into the corner regions of the upper and lower tracks where they meet at the corners and which includes flanges forming a right angle inside corner to which edge portions of wallboard panels are secured.
It is also an object of the invention to provide an intersection stud which fits into the upper and lower tracks between the corners of a wall and which includes a pair of flanges that project into the upper and lower tracks of an intersecting wall, and to which edge portions of wallboard panels are secured.
A sheet metal corner stud incorporating the invention comprises a first wall, a second wall, a third wall and a fourth wall. The first wall has a first edge and a second edge. The second wall had a first edge and a second edge. The third wall has first edge and a second edge. The fourth wall has a first edge and a second edge. The second edge of the first wall is connected to the first edge of the second wall. The second edge of the second wall is connected to the first edge of the fourth wall. The second edge of the third wall is connected to the first edge of the fourth wall. A first flange is provided that has a first edge that is connected to the first edge of the first wall. The first flange extends from the first wall in a direction opposite from the direction that the second wall extends from the first wall. A second flange is provided that has a first edge that is connected to the second edge of a fourth wall. The second flange extends from the fourth wall in a direction opposite from the direction that the third wall extends from the fourth wall. The first flange has an outer surface and the second flange has an outer surface. The first flange extends substantially perpendicular to the second flange.
The between-the-corners intersection stud preferably comprises a first wall having a first edge and a second edge, a second wall having a first edge and a second edge, and a third wall having a first edge and a second edge. The second edge of the first wall is connected to the first edge of the second wall. The second wall extends perpendicular from the first wall. The second edge of the second wall is connected to the first edge of the third wall. The third wall extends perpendicular from the second wall and in spaced apart parallelism with the first wall. The stud includes a first flange having a first edge and a second edge. The first edge is connected to the first edge of the first wall. The first flange extends perpendicular from the first wall. The stud includes a second flange having a first edge and a second edge. The first edge is connected to the second edge of the third wall. The second flange extends perpendicular from the third wall towards and in co-planar parallelism with the first flange. A third flange has a first edge and a second edge. The first edge is connected to the second edge of the first flange. The third flange extends perpendicular from the first flange in a direction opposite the direction that the first wall extends from the first flange. A fourth flange has a first edge and a second edge. The first edge is connected to the second edge of the second flange. The fourth flange extends perpendicular from the second flange in a direction opposite from the direction that the third sidewall extends from the second flange. The third flange and the fourth flange extend in spaced apart parallelism with each other. The intersection stud has a width dimension extending between the outside surface of the second wall and the outside surfaces of the first and second flanges which is substantially equal to the width dimension between the outside surface of the third flange and the outside surface of the fourth flange.
Another object of the present invention is to provide an intersection stud positionable at a corner where two walls meet which has a first sided post portion that fits inside end portions of upper and lower tracks, and flanges which project from the post portion perpendicular to each other inside the upper and lower tracks adjacent the corner post.
Another object of the invention is to provide an intersection stud between the corners which has a post portion that fits into upper and lower tracks at a location between corners and includes a pair of flanges which project from the post into end portions of upper and lower tracks that intersect the tracks in which the post portion is situated.
Other objects, advantages and features of the invention will become apparent from the description of the best mode set forth below, from the drawings, from the claims and from the principals that are embodied in the specific structures that are illustrated and described.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Like reference numerals are used to designate like parts throughout the several views of drawing, and:
FIG. 1 is a cross sectional view taken at a corner formed where two walls meet, showing a prior art arrangement of conventional studs at such corner;
FIG. 2 is a cross sectional view of a corner stud embodying the present invention;
FIG. 3 is a cross sectional view of a prior art intersection construction between corners;
FIG. 4 is a cross sectional view of an intersection stud of the present invention that is utilized at an intersection between corners;
FIG. 5 is an exploded pictorial view of the corner stud shown by FIG. 2, showing the lower portion of the stud within the intersecting lower tracks and showing the intersecting upper tracks spaced above the corner stud;
FIG. 6 is a fragmentary pictorial view of the between-the-corner intersection stud shown by FIG. 4, showing its lower portion within the intersecting tracks of the two walls which intersect between corners;
FIG. 7 is an exploded pictorial view of two corner components for the upper and lower tracks, performed for installation at a corner between two perpendicular sections of the track;
FIG. 8 is an exploded pictorial view of track components usable at an intersection between the corners, such components being adapted to be used with three straight sections of track that meet the three ends of the components that is illustrated;
FIG. 9 shows the use of miter cuts at the ends of two lengths of track for making a right angle at a corner where the lengths of tracks meet;
FIG. 10 is a view like FIG. 5 of another embodiment of the corner stud;
FIG. 11 is a view like FIGS. 5 and 10 of a further embodiment of the corner stud;
FIG. 12 is a view like FIGS. 5, 10 and 11 of another embodiment of the corner stud, such corner stud being adapted to back up a door jam;
FIG. 13 is a view like FIG. 4 of a second embodiment of a between-the-corners intersection stud;
FIG. 14 is a view like FIG. 13, showing the between-the-corners intersection stud backing up a door jam;
FIG. 15 is a view like FIGS. 5, 10 and 11 but of a corner stud adapted to be used at a corner where two walls intersect at an angle larger than 90 degrees;
FIG. 16 is a view like FIGS. 6 and 13 showing an intersection stud adapted to mate with an outwardly opening end stud at the end of a framing wall into which the plug portion of the between-the-corner stud projects;
FIG. 17 is a view like FIG. 1 showing a four-way intersection and a prior art arrangement of conventional studs at the intersection;
FIG. 18 is a view like FIG. 17, but showing a single stud embodiment of the invention at the intersection; and
FIG. 19 is a view like FIG. 18, but showing a two-stud embodiment of the invention at the intersection.

DETAILED DESCRIPTION OF THE ILLUSTRATED INVENTION

For background purposes, FIGS. I and 3 show prior art assemblies where one wall intersects another wall. FIG. 1 shows an intersection at a corner. FIG. 3 shows an intersection between corners. Referring to FIG. 1, a first stud 10 is provided at the end of a first wall 12. A second stud 10 is shown at the end of a second wall 14. Stud 10 includes a flange 16. A wall board panel 18 is attached to the wall 12 in the manner shown. End portion 20 of the panel 18 is connected to the stud flange 16. Then, the web 22 is positioned against wall board panel 18, in the manner illustrated. Web 22 is suitably secure to the stud 10. Then, wall board panel 24 is connected to stud flange 26, in the manner illustrated.
Referring to FIG. 3, a first framing wall 28 is constructed from upper and lower tracks and a plurality of studs 30, in known-fashion. Then, a wallboard wall panel 32 is connected to one side of the framing wall. Then, a stud 34 at one end of an intersecting wall 36 is connected to stud flange 38. Wall 36 comprises upper and lower tracks and a plurality of studs interconnecting the tracks.
In the prior art arrangements shown by FIGS. 1 and 3, the metal framing members of the two walls are separated by wall board 12, 32.
Referring to FIGS. 2 and 5, the corner intersection stud 40, exemplifying an aspect of the invention, comprises a four-sided corner post 42 having upper and lower ends that fit within upper and lower tracks 44, 46, between the webs 48, 50 and 52, 54, as illustrated. The post portion 42 of corner stud 40 has a first wall 56 having a first edge 58 and a second edge 60. A second wall 62 has a first edge 64 and a second edge 66. A third wall 68 has a first edge 70 and a second edge 72. A fourth wall 74 has a first edge 76 and a second edge 78. The second edge of the wall 56 is connected to the first edge of wall 62. The second edge 66 of wall 62 is connected to the first edge 70 of wall 68. The second edge 72 of wall 68 is connected to the first edge 76 of wall 74. As best illustrated by FIG. 2, the post portion 42 of wall 40 is positioned between the opposite flanges 80, 82 of lower track 84 for wall 86. In a perpendicular direction, the post portion has a dimension substantially equal to the distance between flanges 52, 54 of track 56. In the same direction, the post portion 42 fits between flanges 48, 50 of track 44. The width of wall 56 allows wall 56 to fit between flanges 88, 90 of track 92.
Corner stud 40 includes a first flange 92 having a first edge 94 connected to the first edge 58 of first wall 56. Flange 62 and wall 56 form a right angle corner with each other. A second flange 96 has a first edge 98 connected to the second edge 78 of fourth wall 42. Flange 96 and wall 74 together form a right angle corner, as shown in FIG. 2. Flange 92 may be provided with an end flange 100 and a return flange 102. In similar fashion, flange 98 may be provided with an end flange 104 and a return flange 106. End flange 100 is perpendicular to flange 92 and is perpendicular to return flange 102. End flange 104 is perpendicular to flange 96 and is perpendicular to end flange 106. Flanges 92, 102 are parallel and flanges 96, 106 are parallel.
As best shown by FIG. 5, the post portion 42 of corner stud 40 is positioned at the corner of the wall, with its lower end portion within the intersecting tracks 46, 84. Flange 96 is positioned inwardly adjacent flange 52. Flange 92 is positioned inwardly adjacent flange 80. At the top of the stud wall 40, flange 96 is inwardly adjacent flange 48 and flange 92 is inwardly adjacent flange 86. As shown by FIG. 2, wallboard panel 108 is connected to flange 92 and wallboard panel 110 is connected to flange 96. Accordingly, there is solid backing for the wallboard panels 108, 110 at the corner where they meet.
The between-the-corner intersection stud 110 comprises a post portion 112 that fits at its bottom into a lower track and at its top into an upper track. FIG. 6 shows a lower track 114 having a web 116 and a pair of flanges 118, 120 that project upwardly from the opposite edges of the web 116. An intersecting track 122 has a web 124 and a pair of flanges 126, 128 that project upwardly from the side edges of the web 124. A portion of the flange 116 is cut away at the end of the track 124. If FIG. 6 is inverted, it would show intersecting upper tracks and the upper end portion of the stud 110. The post portion 112 of stud 110 comprises a first wall 130 having a first edge 132 and a second edge 134. A second wall 136 has a first edge 138 and a second edge 140. A fourth wall 142 has a first edge 144 and second edge 146. The second edge 134 of the first wall 130 is connected to the first edge 138 of the second wall 136. The second edge 140 of the second wall 136 is connected to the first edge 144 of the third wall 142. A first flange 148 has a first edge 150 and a second edge 152. A second flange 154 has a first edge 156 and a second edge 158. The first edge 150 of flange 148 is connected to the first edge 132 of wall 130. Flange 148 extends perpendicular to wall 130 and is in co-planar parallelism with flange 154. The second edge 146 of wall 142 is connected to the first edge 158 of flange 154. Flange 154 is perpendicular to the third wall 132. A third flange 160 has a first edge 162 and a second edge 164. Edge 162 of flange 160 is connected to edge 152 of flange 148. A fourth flange 166 has a first edge 168 that is connected to the second edge 156 of flange 154. Flange 166 includes a second edge 168. Flanges 160, 166 are parallel to each other and are perpendicular to the flanges 148, 154. End flanges 170, 172 may be connected to the edges 164, 168 of the flanges 160, 166. Return flanges 174, 176 may be connected to the end flanges 170, 172.
The outside dimension measured from the outer surfaces of flanges 148, 154 and the outer surface of second wall 36 is substantially equal to the inside dimension between the flanges 118, 120 of the track 114. The distance between the outside surfaces of the flanges 160, 166 is substantially equal to the distance between the inside surfaces of flanges 126, 128. The post portion 112 of the stud 110 is wider than the distance between the inside surfaces of the flanges 126, 128.
FIG. 4 is a sectional view in a mid portion of the stud 110. It shows edge portions 180, 182 of wallboard panels 184, 186 being outwardly adjacent the flanges 148, 154. Preferably the wallboard is connected to the flanges 148, 154. Wall board edge portions 186, 188 are outwardly adjacent the flanges 160, 166. Preferably, these wallboard edges 186, 188 are connected to the flanges 160, 166, such as by use of screws. As shown by FIG. 4, the wallboard edges 180, 186 and 182, 188 are backed up where they meet by the flanges 148, 160 and 154, 166.
Both forms of intersection studs 40, 110 can be easily and quickly installed in the upper and lower tracks and then the wallboard can be applied to the framing members.
FIG. 7 shows a pair of corner members 200, 200′ usable at a corner between two perpendicular tracks. Corner member 200, 200′ comprises an
L-shaped web 202 and flanges 204, 206, 208, 210. All four flanges 204, 206, 208, 210 extend perpendicular to the web 202. Flanges 204 and 208 meet and form a right angle corner and flanges 206 and 210 meet and form a right angle corner. The corner member 200 is positioned at a corner between two perpendicular straight sections of track that are leading into the corner. The ends of the straight sections of the track may butt up against the ends of the corner member 200. Corner member 200′ is a mirror image of corner member 200.
FIG. 8 shows members 212, 212′ that are each usable at an intersection of two walls between corners. It comprises a T-shaped web 214 and flanges 216, 218, 220, 222, 224. All of the flanges 216, 218, 220, 222, 224 extend perpendicular to the T-shaped web 214. Flanges 216, 218 extend perpendicular to each other and meet at a right angle corner. Flanges 222, 224 extend perpendicular to each other and meet at a right angle corner. Flange 220 extends along the outside of a straight section of the member 212 which is positioned between the ends of two collinear straight sections of track. The stem portion of the member 212 includes the flanges 218, 224 adapted to be collinear with an intersecting perpendicular section of track. Member 212′ is a mirror image of member 212.
In place of using the corner member shown by FIG. 7, the ends of the two straight section of track may be cut at a 45 degree angle as shown by FIG. 9. Then the cut ends 230, 230′, 232, 232′ of the two sections 234, 234′, 236, 236′ can be brought together so that the two sections will meet and form a right angle.
The construction shown by FIGS. 7-9 can all be used with both the top tracks and the bottom tracks.
FIG. 10 shows upper and lower corner members 240, 242 which may be like corner members 200, 200′ shown in FIG. 7. FIG. 10 also shows a modified embodiment of the corner stud which is designated 244. It has upper and lower ends that fit within upper and lower track sections 240, 242. Stud 234 has a first wall 246 having a first edge 248 and a second edge 250. A second wall 252 has a first edge 254 and a second edge 256. A third wall 258 has a first edge 260 and a second edge 262. A fourth wall 264 has a first edge 266 and a second edge 268. First edge 248 of wall 246 is connected to first edge 266 of wall 264. Second edge 250 of wall 246 is connected to first edge 254 of second wall 252. The second edge 256 of wall 252 is connected to first edge 260 of wall 258. Second edge 262 of wall 258 is connected to a flange 270. Second edge 268 of wall 264 is connected to a second flange 272. The second edge of flange 262 is connected to a third flange 274. Upper track 242 has a first pair of opposite flanges 276, 278 and a second pair of opposite flanges 280, 282. The lower track section 242 has a first pair of opposite flanges 284, 286 and a second pair of opposite flanges 288, 290. When the upper and lower ends of the stud 246 are in the track sections 240, 242, wall 264 is inwardly adjacent flanges 280, 288 and wall 256 is inwardly adjacent flanges 276, 284. Wall 252 is inwardly adjacent flanges 282, 290. Flange 272 is inwardly adjacent the flanges 278, 286.
The wallboard members are not shown in FIG. 10. However, as shown in FIG. 2, one wallboard member will rest against flanges 280, 288 and wall 264. The second wallboard member rests against flanges 278, 286 and against the wall 272. Accordingly, at the inside corner, the intersecting wallboard members are each backed up by a sheet metal wall 264, 272.
The flanges 270, 272 may be in co-planar parallelism. They extend perpendicular to walls 258 and 272, providing them with stiffness.
The embodiment of FIG. 11 is similar to the embodiment of FIG. 10. The only difference is that wall 258′ is narrower. Also, flanges 274′ and 270′ have perpendicular lips 292, 294.
The corner structure shown by FIG. 12 is like the corner structure shown by FIG. 11 but shows shortened flanges 288′, 290′, the outer ends of which are substantially flush with the outer surface of wall 246. A door jam stile 300 is provided outwardly adjacent wall 246.
FIG. 13 should be compared to FIG. 6. A lower track 114 is illustrated. It has a bottom 116 and a pair of side flanges 118, 120. A second lower track 122 may intersect track 114 in the manner shown in FIG. 6. Or the two tracks may be joined together to form a member such as disclosed in FIG. 8. The upper track may be like track 114 or it may be constructed together with the intersecting track as shown in FIG. 8. In this embodiment, the stud 310 comprises a first wall 312, a second wall 314, a third wall 316, a fourth wall 318, a fifth wall 320, a sixth wall 322, a seventh wall 324, an eighth wall 326 and a ninth wall 328. Wall 312 is provided with a flange 330. In like fashion, wall 328 is provided with a flange 332. The flanges 330, 332 are spaced apart and are in co-planar parallelism with each other and with the walls 314, 318, 322, 326. Wall 314 is interconnected between and perpendicular to walls 312, 316. In similar fashion, wall 326 extends between and is perpendicular to the walls 324, 328. Walls 318, 322 are spaced apart and are perpendicular to walls 316, 324 and wall 320. The upper and lower ends of the stud 310 extend into the upper and lower tracks. The wall 318, 322 are inwardly adjacent the flanges on the track in which member 318, 320, 322 is placed. The relationship is like the relationship shown in FIG. 6 with respect to the member 160, 166, 170, 172, 174, 176. The upper and lower ends of the stud 310 also fit into the tracks 116 between the flanges 118, 120. This arrangement is shown by FIG. 6.
The relationship of the wallboard members to the stud 310 are as shown in FIG. 4. Wallboard panels 184, 186 that extend lengthwise of tracks 114 are outwardly adjacent the walls 316, 324. The perpendicular wallboard panels 188, 190 are outwardly adjacent the stud walls 318, 322. Accordingly, the edge portions of the wallboard panels 184, 186 and 188, 190 are backed up by the walls 316, 324 and 318, 322 of the stud 310.
FIG. 14 shows an assembly that is like the assembly of FIG. 13 except that a door jam stile 300 is positioned outwardly adjacent stud wall 320. Thus, in this embodiment, stud wall 320 forms one side boundary of a door opening in the wall that extends perpendicular to the wall that includes tracks 114.
FIG. 15 shows a corner stud 350 for a diagonal corner. This stud 350 includes a first wall 352 having a first edge 354 and a second edge 356. It includes a second wall 356 having a first edge 360 and a second edge 362. It also includes a third wall 364 having a first edge 366 and a second edge 368. It further has a fourth wall 370 having a first edge 372 and a second edge 374. It further has a fifth wall 376 having a first edge 378 and a second edge 380. Walls 352, 376 are spaced apart and are parallel to each other. Walls 358, 370 are spaced apart and are parallel to each other. Wall 364 is perpendicular to walls 358, 370. The first edge 354 of wall 352 is connected to a first edge 380 of a first flange 382. Flange 382 includes a second edge 384 that is connected to a flange 386. Flange 386 extends perpendicular to flange 282 and includes a lip 388. Edge 380 of wall 376 is connected to a flange 390. Flange 390 is perpendicular to wall 376 and is co-planar parallelism with flange 382. Flange 390 is connected to a flange 392 and flange 392 is connected to a lip 394. Flange 392 is perpendicular to flange 390 and is parallel to flange 386 and walls 352 and 376. Lip 394 is perpendicular to flange 392 and is in co-planar parallelism with lip 388. Both lips 388, 392 are in spaced parallelism with flanges 282, 390.
Corner stud 350 is basically like corner stud 349 shown by FIG. 10 except that in FIG. 10 the two portions of the stud 244 are perpendicular to each other and the stud 244 fits into tracks 240, 242 that are perpendicular to each other. In the embodiment of FIG. 15, the two portions of stud 350 are separated by an angle x that is larger than 90 degrees and smaller than 180 degrees. The corner is formed where true tracks meet at a line 400. Two straight track sections may be cut at an angle to form ends that meet at line 400. Or, a track fitting 420 may be used at the corner. Track fitting 420 has opposite ends 422, 424 which are adapted to a butt against the ends of straight sections of track (not shown) that extend away and opposite directions from corner fitting 420. The intersecting tracks or track fitting 420, whichever is used, includes flanges 426, 428, 430, 432 which extend perpendicular from a bottom web 434. The upper and lower ends of the stud 420 fit into the corner region of the upper and lower tracks. Wall 376 is closely adjacent flanges 426. Wall 370 is closely adjacent flanges 432. Wall 352 is closely adjacent flanges 428. Wall 358 is closely adjacent flanges 432. In this embodiment, the edges of the wallboard panels are preferably beveled and the wallboard panels meet each other at the corners. Specifically, one pair of wallboard members are positioned against walls 352, 358 are secured to them by sheet metal screws. Another pair of wall members are against walls 376, 370 and are secured to them by sheet metal screws.
FIG. 16 is a view like FIG. 4 with one modification. The walls 160′, 166′ are spaced closer together so that the flanges 500, 502 of a channel member 504 can be positioned outwardly adjacent the walls 160′, 166′ and the wallboard members 188, 190 will be positioned outwardly adjacent the flanges 500, 502. Channel 504 is a vertical member at the end of a framing wall that includes upper and lower tracks and horizontally spaced apart studs. Sheet metal screws are used to secure the flanges 500, 502 to the walls 160′, 166′.
FIG. 17 shows a four-way intersection of framing walls 550, 552, 554, 556 in which four conventional studs 558, 560, 562, 564 are used at the intersection. This is prior art. FIGS. 18 and 19 show intersection studs of the present invention that constitute a significant improvement over the prior art arrangement shown by FIG. 17.
FIG. 18 shows four bottom tracks meeting at the intersection. The bottom track for wall 550 includes a web 556 and a pair of flanges 568, 570. The bottom track for framing wall 554 includes a web 572 and a pair of flanges 574, 576. The bottom track for framing wall 554 includes a web 578 and a pair of flanges 580, 582. The bottom track for framing wall 556 includes a web 584 and a pair of flanges 586, 588. The intersection stud 590 has the cross sectional configuration that is shown in FIG. 18. It has four parts, each extending perpendicular to the parts on both sides of it. Part 1 comprises a first wall 592 and a first flange 594 that extends perpendicular to wall 592, towards the center of the track for framing wall 554. Part 1 also has a second wall 596 and a second flange 598. Flange 596 is spaced from and parallel with wall 592. Flange 598 is spaced from and in co-planar parallelism with flange 594. Stud wall 592 is inwardly adjacent the flanges 580 of the bottom track in which the first part is situated. Wall 596 is inwardly adjacent flange 582 of the same bottom track. Wall 592 makes a right angle or perpendicular corner with wall 600. Wall 600 makes a right angle or perpendicular corner with wall 502. Wall 502 makes a right angle or perpendicular corner with wall 604. Walls 600, 602, 604 form a second part of the stud 590 that fits in the upper and lower tracks of framing wall 556.
Stud wall 602 makes a right angle or perpendicular connection to stud wall 606. Stud wall 606 makes a right angle or perpendicular connection to stud wall 608. Stud wall 608 makes a right angle or perpendicular connection to stud wall 610. Walls 606, 610 are spaced apart and parallel to each other and perpendicular to wall 608. Walls 606, 608, 610 form the third part of the stud 590, the upper and lower ends of which are in the upper and lower tracks for framing wall 550.
Stud wall 610 makes a right angle or perpendicular corner with stud wall 612. Stud wall 612 makes a right angle or perpendicular corner with stud wall 614. Stud wall 614 makes a right angle or perpendicular corner with stud wall 616. Stud wall 612, 616 are spaced apart and parallel to each other and perpendicular to wall 614. Stud walls 612, 614, 616 form the fourth part of the stud 590. At its upper and lower ends, this four part sets into the upper and lower tracks for framing wall 552.
As illustrated in FIG. 18, edge portions of wallboard walls 620, 622, 624, 626, 628, 630, 632, 634. The intersecting edge portions of wallboard panels 620, 624 are screwed to the stud walls 604, 606 by the use of screws which are commonly used for securing wallboard to sheet metal framework. The edge portions of intersecting wallboard panels 622, 626 are in like fashion connected to the stud walls 612, 610 by the use of sheet metal screws. The edge portions of intersecting wallboard panels 630, 632 are secured to stud walls 616, 596 by the use sheet metal screws. The edge portions of intersecting wallboard panels 628, 632 are secured to stud walls 600, 592 by sheet metal screws. As can be seen, at the four inside corners formed at the intersection of the framing walls 550, 554 and 552, 556 are backed up by sheet metal walls which are connected together at the corners and to the rest of the stud 590 between the corners.
FIG. 19 shows the use of two identical studs 590′ at a four-way intersection. One of the studs 590′ can be used by itself at a T-intersection. For example, imagine that the upper and lower tracks each form a T as illustrated in FIG. 8. Let it also be assumed that there is no stud wall 554 and the track flanges 588, 574 constitute a single flange like flange 220 in FIG. 8. In this embodiment, the upper stud 590′ can be used at the intersection between framing wall 550 and the perpendicular framing wall which would exist in place of the framing walls 552, 556. Stud 590 includes a wall 602′ which connects at a right angle or perpendicular to stud wall 604. Also stud wall 612 makes a right angle or perpendicular connection to stud wall 614′. Flanges 603, 605 make right angle or perpendicular connections to the stud walls 602′, 614′. Sheet metal screws extend through the track flanges 568, 570 and 576, 586 and screw into the stud walls 610, 608 and screw into the stud walls 604, 612. Sheet metal screws extend through the track flanges 568, 570 and screw into the stud walls 610, 608. Then, when the wallboard panels 620, 622, 624, 626 are applied, sheet metal screws are used to screw the edge portions of panels 620, 622 to stud walls 608, 612 and to connect the edge portions of panels 624, 626 to stud walls 608, 610. This construction provides a solid sheet metal wall backing at the inside corners formed where the wallboard panels 620, 624 meet and the wallboard panels 622, 626 meet.
In the embodiment of FIGS. 4 and 6, walls 148, 160 form a first corner portion. Walls 154, 166 form a second corner portion. Walls 130, 136, 142 (FIG. 6) form a body portion that interconnects the first and second corner portions. In the embodiment of FIGS. 10, 11 and 12, walls 264, 272 form a first corner portion which is an inside corner. Walls 252, 258 form a second corner that is an outside corner. Walls 264, 246, 252 form a body portion that interconnects the two corner portions. In the embodiment of FIGS. 13 and 14, walls 316, 318 form a first corner portion. Walls 322, 324 form a second corner portion. Walls 318, 320, 322 form a body portion that interconnects the two corner portions. In these embodiments, both corner portions are inside corners. In the embodiment of FIG. 15, walls 370, 378 form a first corner portion. Walls 352, 358 form a second corner portion. Walls 358, 362, 370 form a body portion that interconnects the two corner portions. In this embodiment, the first corner portion forms an outside corner and the second corner portion forms an inside corner.
In the embodiment of FIG. 18, walls 592, 600 form a first wall portion. Walls 604, 606 form a second wall portion. Walls 600, 602, 604 form a body portion that interconnects the first and second corner portions. This embodiment includes two more corner portions 610, 612 and 596, 616. It includes a body portion 606, 608, 610 connecting corner portions 604, 606 and 610, 603. It also includes a body portion 612, 616, 6 - - - connecting corner portion 610, 612 and corner portion 596, 616.
The illustrated embodiments are only examples of the present invention and, therefore, are non-limitive. It is to be understood that many changes in the particular structure, materials and features of the invention may be made without departing from the spirit and scope of the invention. Therefore, it is my intention that my patent rights not be limited by the particular embodiments that are illustrated and described herein, but rather are to be determined by the following claims, interpreted according to accepted doctrines of patent claim interpretation, including use of the doctrine of equivalents and reversal of parts.

Claims

1. An intersection stud for a framing wall, comprising:

a post portion having an upper end adapted to be fitable between the flanges of an upper track and a lower portion adapted to be fitable between the flanges of a lower track; and

a pair of flanges on said post portion forming an inside corner that is adapted to be positioned to provide a backing for wallboard edges that meet at the corner.

2. The intersection stud of claim 1, wherein the post portion of the stud has four sides and four corners and the two flanges extend perpendicular to each other from a common corner.

3. The intersection stud of claim 1, wherein the post portion of the stud has three sides, a pair of co-planar flanges projecting inwardly from two of the sides, and a pair of parallel second flanges projecting perpendicularly from the first two flanges and forming two inside corners for backing up edge portions of wallboard members that meet at the corners.

4. A sheet metal corner stud, comprising:

a first wall;

a second wall;

a third wall;

a fourth wall;

said first wall having a first edge and a second edge;

said second wall having a first edge and a second edge;

said third wall having a first edge and a second edge;

said fourth wall having a first edge and a second edge;

said second edge of said first wall being connected to the first edge of the second wall and forming a right angle corner with the second wall;

said second edge of the second wall being connected to the first edge of the fourth wall and forming a right angle corner with the third wall;

said second edge of the third wall being connected to and forming a right angle corner with the fourth wall;

a first flange having a first edge connected to the first edge of the first wall and forming a right angle corner with the first wall;

said first flange extending away from the first wall in a direction opposite from the direction that the second wall extends from the first wall;

a second flange having a first edge connected to the second edge of the fourth wall and forming a right angle corner with the fourth wall;

said second flange extending from the fourth wall in a direction opposite from the direction that the third wall extends from the fourth wall;

said first flange having an outer surface;

said second flange having an outer surface; and

said outer surface of said first flange extending substantially perpendicular to the outer surface of the second flange.

5. The sheet metal corner stud of claim 4, wherein the first flange has a second edge and said corner stud further includes a web having a first edge connected to the second edge of the first flange and forming a right angle corner with the first flange, and having a second edge; and

said corner stud also including a third flange having a first edge connected to the second edge of the web, and forming a right angle corner with said web and extending in spaced parallelism with the first flange, from said web towards the fourth wall of the stud.

6. The sheet metal corner stud of claim 4, wherein the second flange has a second edge and said corner stud further includes a web having a first edge connected to the second edge of the second flange and forming a right angle with the second flange, and having a second edge; and

said corner stud also including a third flange having a first edge connected to the second edge of the web, and forming a right angle corner with said web and extending in spaced parallelism with the first flange, from said web towards the first wall of the stud.

7. The sheet metal corner stud of claim 5, wherein the second flange has a second edge and said corner stud further includes a web having a first edge connected to the second edge of the second flange and forming a right angle with the second flange, and having a second edge; and

said corner stud also including a third flange having a first edge connected to the second edge of the web, and forming a right angle corner with said web and extending in space parallelism with the first flange, from said web towards the first wall of the stud.

8. A sheet metal framing assembly, comprising first and second lower channels meeting at a corner, each said channel having a bottom web including first and second edges and a pair of laterally spaced apart connected to and extending upwardly from said edges, said channels having a first pair of flanges coming together and defining an inner corner and a second pair of flanges coming together and forming an outer corner;

a sheet metal corner stud at the corner, comprising:

a first wall;

a second wall;

a third wall;

a fourth wall;

said first wall having a first edge and a second edge;

said second wall having a first edge and a second edge;

said third wall having a first edge and a second edge;

said fourth wall having a first edge and a second edge;

said second edge of said second wall being connected to the first edge of the third wall and forming a right angle corner with the third wall;

said second edge of said third wall being connected to the first edge of the fourth wall and forming a right angle corner with the fourth wall;

said first flange extending away from the first wall and in a direction opposite from the direction that the second wall extends from the first wall;

a second flange having a first edge connected to the second edge of and forming a right angle corner with the fourth wall;

said second flange extending from the fourth wall in a direction generally opposite from the direction that the third wall extends from the fourth wall;

said first flange having an outer surface;

said second flange having an outer surface;

said outer surface of said first flange extending substantially perpendicular to the outer surface of the second flange;

said sheet metal corner stud including a lower end portion that sets down into the corner region formed by the lower channel members;

wherein the second and third walls of the corner stud are inside bottom track flanges that meet and form an outside corner; and

wherein the first and second flanges of the corner stud are contiguous bottom track flanges that meet and form an inside corner.

9. A sheet metal intersection stud, comprising:

a first wall having a first edge and a second edge;

a second wall having a first edge and a second edge;

a third wall having a first edge and a second edge;

said second edge of the first wall being connected to the first edge of the second wall, said second wall extending perpendicular from the first wall;

said second edge of the second wall being connected to the first edge of the third wall, said third wall extending perpendicular from the second wall and in spaced apart parallelism with the first wall;

a first flange having a first edge and a second edge, said first edge being connected to the first edge of the first wall, said first flange extending perpendicular from the first wall;

a second flange having a first edge and a second edge, said first edge being connected to the second edge of the third wall, said second flange extending perpendicular from the third wall towards and in co-planar parallelism with the first flange;

a third flange having a first edge and a second edge, said first edge being connected to the second edge of the first flange, said third flange extending perpendicular from the first flange in a direction opposite the direction that the first wall extends from the first flange;

a fourth flange having a first edge and a second edge, said first edge being connected to the second edge of the second flange, said fourth flange extending perpendicular from the second flange in a direction opposite from the direction that the third side wall extends from the second flange;

said third flange and said fourth flange extending in spaced apart parallelism with each other;

said intersection stud having a width dimension extending between the outside surface of the second wall and the outside surfaces of the first and second flanges which is substantially equal to the width dimension between the outside surface of the third flange and the outside surface of the fourth flange.

10. For use with a corner stud that fits into L-shaped corner portions of upper and lower tracks, a corner comprising:

an L-shaped web having perpendicular first and second legs having intersecting first and second inner edges and intersecting third and fourth outer edges;

first and second flanges extending from the inner edges of the web perpendicular to the web and to each other;

third and fourth flanges extending from the third and fourth edges of the web, in the same direction as the first and second flanges, and extending perpendicular to the web and to each other; and

said first leg of the web and said first and third flanges forming one end of the corner fitting and said second leg of the web and said second and fourth flanges forming a second and fourth corner fitting.

11. For use with an intersection stud that intersects upper and lower tracks at a location between two corners, a T fitting comprising:

a T-shaped web having an elongated first portion and a second stem portion intersecting the first portion between the ends of the first portion, said web having first and second edges that are perpendicular to each other, a third and fourth edges that are perpendicular to each other and a fifth edge that is parallel to the first and fourth edges and perpendicular to the second and third edges;

first and second flanges connected to the first and second edges of the web and extending perpendicular to the web and to each other;

third and fourth flanges connected to the third and fourth edges of the web and extending perpendicular to the web and to each other;

a fifth flange connected to the fifth edge of the web and extending perpendicular to the web and the second and third flanges and extending parallel with the first and fourth flanges;

said first and fifth flanges and the web forming a first end of the member;

said second and third flanges and the web region between them forming a second end of the member; and

said fourth and fifth flanges and the web region between them forming a third end of the member;

whereby straight sections of track may be positioned in line with the first and third ends of the member and a perpendicular section of track may be positioned in line with the second end of the member.

12. A sheet metal corner stud, comprising:

a first wall;

a second wall;

a third wall;

a fourth wall;

a fifth wall;

said first wall having a first edge and a second edge;

said second wall having a first edge and a second edge;

said third wall having a first edge and a second edge;

said fourth wall having a first edge and a second edge;

said fifth wall having a first edge and a second edge;

said second edge is said first wall being connected to the first edge of the second wall and forming a right angle corner with the second wall;

said second edge of the second wall being connected to the first edge of the third wall and forming a right angle corner with the third wall;

said first edge of the first wall being connected to the first edge of the fourth wall and forming a right angle corner with the fourth wall;

said second edge of the fourth wall being connected to the first edge of the fifth wall and forming a right angle corner with the fifth wall;

a first flange having a first edge connected to the second edge of the third wall and forming a right angle corner with the third wall;

a second flange having a first edge connected to the second edge of the fifth wall and forming a right angle corner with the fifth wall; and

said fourth and fifth walls forming an inside corner region at which edge portions of perpendicular wallboard members are received, each of which is backed up by one of said fourth and fifth walls.

13. The sheet metal corner stud of claim 12, comprising a first lip connected to the first flange and a second lip connected to the second flange.

14. A sheet metal intersection stud, comprising:

a first wall having a first edge and a second edge;

a second wall having a first edge and a second edge;

a third wall having a first edge and a second edge;

a fourth wall having a first edge and a second edge;

a fifth wall having a first edge and a second edge;

a sixth wall having a first edge and a second edge;

a seventh wall having a first edge and a second edge;

an eighth wall having a first edge and a second edge;

a ninth wall having a first edge and a second edge;

said first edge of first wall being connected to the first edge of the second wall, said second wall extending perpendicular to the first wall;

said first edge of the third wall having a first edge connected to the second edge of the second wall, said third wall extending perpendicular to the second wall and parallel with the first wall;

said second edge of the third wall being connected to the first edge of the fourth wall, said fourth wall extending perpendicular to the third wall;

said second edge of the fourth wall being connected to the first edge of the fifth wall, said fifth wall extending perpendicular to the fourth wall;

said fifth wall having a second edge connected to the first edge of the sixth wall, said sixth wall extending perpendicular to the fifth wall and parallel with the fourth wall;

said sixth wall having a second edge connected to the first edge of the seventh wall, said seventh wall extending perpendicular to the sixth wall and parallel to the first wall, the third wall and the fifth wall;

said seventh wall having a second edge connected to the first edge of the eighth wall, said eighth wall extending perpendicular to the seventh wall and parallel with the second wall, the fourth wall and the sixth wall;

said third and fourth walls forming an inside corner where edge portions of perpendicular wallboard panels meet; and

said sixth wall and said seventh wall forming an inside corner where edge portions of perpendicular wallboard panels meet and are backed up by said stud walls.

15. A sheet metal intersection stud, comprising a first wall having a first edge and a second edge;

a second wall having a first edge and a second edge;

a third wall having a first edge and a second edge;

a fourth wall having a first edge and a second edge;

a fifth wall having a first edge and a second edge;

a sixth wall having a first edge and a second edge;

a seventh wall having a first edge and a second edge;

first edge of first wall being connected to the first edge of the second wall, extending perpendicular to the first wall;

said second edge of the second wall being connected to the first edge of the third wall, said third wall extending perpendicular to the second wall;

said second wall of the third wall being connected to the first edge of the fourth wall, said fourth wall extending perpendicular to the third wall;

said second edge of the fourth wall being connected at the first edge of the fifth wall, said fifth wall extending perpendicular to the fourth wall;

said second edge of the fifth wall being connected to the first edge of the sixth wall, said sixth wall extending perpendicular to the fourth wall;

said second and third walls forming an inside corner where edge portions of perpendicular wallboard panel meet;

said fifth and sixth walls forming an inside corner where edge portions of perpendicular wallboard panels meet; and

said third, fourth and fifth walls forming a channel portion having opposite ends that fit into upper and lower tracks.

16. The sheet metal stud of claim 15, wherein the first edge of the first wall connects to a flange that extends perpendicular to the first wall, and the second edge of the sixth wall connects to a second flange that extends perpendicular to the sixth wall, and wherein the first and second flanges are parallel and extend towards each other.

17. An elongated sheet metal stud, comprising:

a first corner portion including adjacent unitary walls set at an angle to each other;

a second corner portion including adjacent unitary walls set at an angle to each other; and

a body portion interconnecting the first and second corner portions, said body portion and said first and second corner portions being parts of a unitary structure;

wherein the first corner portion is adapted to provide a backing for edge portions of wallboard panels that meet at the corner formed by said first corner portion; and

wherein the second corner portion is adapted to provide a backing for edge portions of wallboard panels that meet at the corner formed by said second corner portion.

18. The stud of claim 17, wherein the first corner portion forms an inside corner and said second corner portion forms an inside corner.

19. The stud of claim 17, wherein the first corner portion forms an inside corner and the second corner portion forms an outside corner.