WO1996003557A1

WO1996003557A1 - Metal construction stud

Info

Publication number: WO1996003557A1
Application number: PCT/CA1995/000440
Authority: WO
Inventors: Mark Kolenc
Original assignee: Mark Kolenc
Priority date: 1994-07-21
Filing date: 1995-07-21
Publication date: 1996-02-08
Also published as: AU3338295A; EP0774031A1; CA2154402C; JPH10502982A; CA2154402A1

Abstract

A metal construction stud (10) has an elongate channel-form metal member (12) with opposed ends (14 and 16) and a central cavity (22) which extends between the opposed ends (14 and 16). Filler blocks (24 and 26) are secured in the central cavity (22) at each of the opposed ends (24 and 26) with the balance of the central cavity (22) remaining empty. The filler blocks (14 and 16) are of a material having properties similar to wood. The metal construction stud (10) is characterized by the opposed ends (14 and 16) being both planar and at right angles to the elongate channel-form metal member (12). When the elongate channel-form metal member (12) is positioned horizontally on a ground surface wooden plates (34 and 36) can be positioned flush with the opposed ends (14 and 16) and secured in place by driving nails through the wooden plates (34 and 36) and into the filler blocks (24 and 26).

Description

TITLE OF THE INVENTIONt

Metal Construction Stud

FIELD OF THE INVENTION

The present invention relates to a metal construction stud.

BACKGROUND OF THE INVENTION

Metal construction studs have numerous advantages. As construction grade wood products become increasingly scarce, metal studs are providing a cost effective alternative. They can be manufactured to uniform quality specifications, that are becoming increasingly difficult to maintain with wood. They do not warp if improperly stored. They are light weight making them easier to handle. They can be made of whatever gauge of metal is required to suit load specifications of an the intended application.

The reason metal construction studs have not completely replaced wood construction studs is that metal construction studs require a departure from conventional construction methods. With conventional construction methods a wood frame wall is constructed laying horizontally along the ground, and then is raised to a vertical position. With metal construction studs a bottom track and a top track are secured into position. The metal studs are then cut to length and secured to the top track and the bottom track.

The closest prior art to the present invention is United States Patent 4,001,993 entitled "Steel Wall Stud and the Wall Frame Employing the Same" invented by Daniels and issued to Kaiser Steel Corporation, as assignee, in 1977. This reference discloses a metal stud that has tabs that extend beyond the end of the stud. These tabs are intended to be placed in face to face contact with the vertical faces of wooden top plates and bottom plates. Each of the tabs have holes through which nails are driven into the wooden plates. To prevent the walls of the metal stud from digging into the wooden plates, transverse particle board strips are positioned at each end of the metal stud. In order to secure the particle board strips to the metal stud filler blocks are positioned at either end of the metal stud to which the transverse particle board strips may be nailed or glued.

The Kaiser Steel Corporation stud described cannot be used in constructing a wall laying horizontally along the ground in accordance with conventional wood construction methods. When laying horizontally along the ground, it is impossible to gain access to all of the tabs in order to place nails through the holes in the tabs and into the wooden plates. A further problem is encountered in placing drywall sheeting onto a wall constructed using the Kaiser Steel Corporation stud, as in order to fit tabs one either side of the wooden plates, as described, the Kaiser Steel Construction stud must of necessity extend beyond the width of the wooden plates. SUMMARY OF THE INVENTION

What is required is a metal construction stud that can be used without departing from conventional construction techniques.

According to the present invention there is provided a metal construction stud which includes an elongate channel-form metal member having opposed ends and a central cavity which extends between the opposed ends. At least one filler block is secured in the central cavity. The filler block is of a material having properties similar to wood.

With the metal construction stud, as described, the presence of filler blocks made of wood or a suitable wood substitute within the central cavity enables the metal construction stud to be used in the same manner as wooden construction studs. Metal construction studs manufactured in accordance with the teachings of the invention that are intended to be nailed to a wooden top plate and bottom plate to make an interior wall will have filler blocks positioned at each of the opposed ends. The construction framer drives nails through the top plate and bottom plate into the filler blocks at opposed ends of the metal construction studs to build the interior wall. Where an opening for a door or window is to be positioned the filler blocks are positioned at spaced intervals along the central cavity. This enables the opening to be reinforced. It will be appreciated that the metal construction stud, as described, can be manufactured in a number of standard lengths and standard widths. It is preferred that the channel-form metal member be in the form of a "C" channel. The "C" channel imitates a rectangular profile of a wooden construction stud while economizing on the use of material. The "C" channel has a primary wall and two generally "L" shaped secondary walls extending perpendicularly from the primary wall thereby defining a generally rectangular central cavity.

Although beneficial results may be obtained through the use of the metal construction stud, as described above, it is not always possible to exactly predict the length of metal construction stud that will be required. Even more beneficial results may, therefore be obtained when the filler blocks protrude from the opposed ends. This enables the length of the metal construction stud to be trimmed using the same types of saws used for cutting wood.

Although beneficial results may be obtained through the use of the metal construction stud, as described above, it is important to be able to run plumbing pipes and electrical wire through the wall being constructed. Even more beneficial results may, therefore, be obtained when the primary wall has an opening. The opening serves as a utility corridor through which wires and pipes can be extended.

Although beneficial results may be obtained through the use of the metal construction stud, as described above, it is important that the means by which the filler blocks are secured within the central cavity be cost effective. Even more beneficial results may, therefore, be obtained when the filler blocks are secured in position by indenting portions of the primary walls and the secondary walls into the central cavity such that the indented portions of the primary walls and secondary walls extend into the filler block.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent from the following description in which reference is made to the appended drawings, wherein:

FIGURE 1 is a perspective view of a metal construction stud fabricated in accordance with the teachings of the present invention.

FIGURE 2 is a front elevation view of the metal construction stud illustrated in FIGURE 1.

FIGURE 3 is a side elevation view of the metal construction stud illustrated in FIGURE 1.

FIGURE 4 is an end elevation view in section of the metal construction stud illustrated in FIGURE 1. FIGURE 5 is a side elevation view of an interior wall constructed with the metal construction stud illustrated in FIGURE 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment, a metal construction stud generally identified by reference numeral 10, will now be described with reference to FIGURES 1 through 5.

Referring to FIGURE 1, metal construction stud 10 includes an elongate "C" channel-form metal member 12 having opposed ends 14 and 16. Referring to FIGURE 4, "C" channel-form metal member 12 has a primary wall 18 and two generally "L" shaped secondary walls 20 extending perpendicularly from primary wall 18, thereby defining a generally rectangular central cavity 22 which extends between opposed ends 14 and 16. Referring to FIGURE 5, filler blocks 24 and 26 are secured in central cavity 22. Filler blocks 24 are secured adjacent to opposed ends 14 and 16, as illustrated in FIGURES 2 and 3. In some applications it is advantageous to actually have filler blocks protrude from one of opposed ends 14 or 16. Secondary filler blocks 26 may be positioned at spaced intervals along central cavity 22. As will be apparent from a review of FIGURE 5, not every one of metal construction studs 10 need have filler blocks 26. Filler blocks 24 and 26 are made of a material having properties of wood. Suitable material may include wood, wood composite, polymers with suitable properties or the like. The properties that are desirable include the ability to hold and maintain a nail or screw, and the ability to cut with saws used in wood construction. Referring to FIGURE

4, filler blocks 24 and 26 are secured in position by indenting portions 28 of primary walls 18 and secondary walls 20 into central cavity 22, such that indented portions 28 of primary walls 18 and secondary walls 20 extend into filler block 24 or 26. Referring to FIGURE 2 primary wall 18 has an opening 30. Opening 30 provides a utility corridor through which wires and pipes can be extended.

The use and operation of metal construction stud 10 will now be described with reference to FIGURES 1 through

5. Metal construction stud 10 is intended to be used in accordance with wood frame construction techniques. Referring to FIGURE 5, it is intended that a wooden top plate 34 and a wooden bottom plate 36 be used. Metal construction studs are fastened in place by nailing through wooden top plate 34 and wooden bottom plate 36 into filler blocks 24 positioned at each of opposed ends 14 and 16. In the areas adjacent door and window openings metal construction studs 10 also have secondary filler blocks 26. As will be apparent from a review of FIGURES 2 and 3, filler blocks 24 can be trimmed with a saw to adjust the length of metal construction stud 10, as required. The interior wall is constructed laying down horizontally and then is raised to a vertical position. Once in a vertical position it is nailed in place. Wires or pipes can then be extended along the wall through openings 30.

It will be apparent to one skilled in the art that modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention as defined by the Claims.

Claims

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE PROPERTY OR PRIVILEGE IS CLAIMED ARE AS FOLLOWS:

1. A metal construction stud (10) having an elongate channel-form metal member (12) having opposed ends (14 and 16) and a central cavity (22) which extends between the opposed ends (14 and 16), filler blocks (24) secured in the central cavity (22) at each of the opposed ends (24) with the balance of the central cavity (22) remaining empty, the filler blocks (14 and 16) being of a material having properties similar to wood, characterized by: the opposed ends (14 and 16) being both planar and at right angles to the elongate channel-form metal member (12), such that when the elongate channel-form metal member (12) is positioned horizontally on a ground surface wooden plates (34 and 36) can be positioned flush with the opposed ends (14 and 16) and secured in place by driving nails through the wooden plates (34 and 36) and into the filler blocks (24).

2. The metal construction stud (10) as defined in Claim 1, wherein the channel-form metal member (12) is a "C" channel having a primary wall (18) and two generally "L" shaped secondary walls (20) extending perpendicularly from the primary wall (18) thereby defining a generally rectangular central cavity (22).

3. The metal construction stud (10) as defined in Claim 1, wherein one of the filler blocks (24) protrudes from one of the opposed ends ( 16) , thereby leaving a portion of that filler block (24) exposed for the purpose to trimming to a desired length at a construction site.

4. The metal construction stud (10) as defined in Claim 1, wherein the filler blocks (24) are secured in position by indenting portions (28) of the primary walls (18) and the secondary walls (20) into the central cavity (22) such that the indented portions (28) of the primary walls (18) and secondary walls (20) extend into the filler blocks (24).