WO2008024144A9 - Foldable metal wall frame assemblies for residential and commercial structures - Google Patents

Abstract

A foldable wall frame is disclosed and includes first and second track members spaced from each other, each track member having a center web and a pair of opposite side flanges. A plurality of spaced stud elements are positioned between and substantially perpendicular to the track members with each stud element having a first and a second end portion. A first attachment element is provided for pivotally securing the first end portion of each said stud element to the first track member. A second attachment element is also provided for pivotally securing the second end portion of each stud element to the second track member. The first and second pivotal attachment elements enable the first track member to be folded down proximate the second track member for storage and transportation, and to be unfolded at a construction site for installation into a building structure.

Description

Foldable Metal Wall Frame Assemblies for Residential and Commercial Structures

Related U.S. Applications

This application is a continuation-in-part of co-pending U.S. Patent Application Serial No. 11/446,317, filed June 2, 2006, to William C. Heirich entitled, "Apparartus for the Fabrication of Metal Wall Frame Members and Assembly of Wall Frames Therefrom, and Foldable Wall Frame Structures", the contents of which are hereby expressly incorporated herein by reference.

Technical Field

The present invention relates generally to the fabrication and assembling of building frame components and, more particularly, to devices and structures relating to frame components and assemblies made of metal. Specifically, the present invention relates to prefabricated foldable metal wall frame members which enable easy transportation and on-site assembly of the same for both commercial and residential structures.

Background Art

In general, wall structures for both residential and commercial construction have been made over the years using the so-called stick framing method and construction. In such stick frame construction, the structural walls are made from wood studs, and the top and bottom wood framing members are called plates. Typically, the studs and plates are made from two-by-four lumber members which are generally 2" in thickness and 4" in width cut to the desired length. Stick framing generally involves the technique of nailing the studs to the top and bottom plates and are normally spaced 16" on center to form a building structural wall. Systems for arranging these components into wall structures are illustrated in U.S. Patents No. 3,986,247, No. 4,876,787 and No. 5,646,860.

In recent years, high-rise and other commercial building structures have replaced standard stick frame construction with steel structures. High-rise buildings typically employ straight column members subjected to high axial compression forces. The use of solid or rectangular rolled-steel sections typically in the form of steel studs supported between steel tracks has now become the standard construction format for commercial wall construction. Such steel members can be produced economically in a wide range of sizes and are readily assembled on site into wall and window sections. Examples of such devices are illustrated in U.S. Patents No. 3,877,129 and No. 4,078,288.

Light gauge steel framing has been available to the construction market for well over forty years now. In fact, it has become the dominant, i.e. greater than 90 percent, construction technique in the commercial building industry. However, wood is still the dominant framing material for use in the residential construction field, still amounting to about 85-92 percent of new residential frame structures. Considerable time and money has been expended by numerous trade and industry organizations, particularly during the past ten or twelve years, in study and research to determine why there is this vast difference in usage between these two related construction fields, which at first glance would appear to have equal need and use for this material in their respective construction fields. As a result of the above studies, it has been determined that there has been noticeable progress made by light gauge steel framing in gaining a larger portion of the residential building market. Nonetheless, this progress has been a slow, moderate increase as opposed to the extreme dominance of steel framing vs. wood stick framing which has occurred in the commercial construction field.

There are a number of reasons for this disparity of usage of steel framing between these two fields of construction. Among the obstacles faced are entrenched traditional residential construction approaches as well as production methods for steel framing components. The production method of choice for producing light gauge steel framing has been, and will most likely continue to be, cold roll forming. This is due to its inherent low production cost with almost no material scrap loss factors. During the last 50 years, cold roll forming of steel has gone from substantially a "black art" with machines and materials which required considerable operator experience and skill, to a production technology which today is performed by higher precision machines and with fewer operator skills while using materials that are much more uniform in quality.

There are two main components used in light gauge metal framing. These components include studs (similar to wood framing) which in walls are the vertical members, and tracks, which are the top and bottom horizontal frame members to which the studs are attached. Both components are basically a U- shape component with the studs having inwardly turned stiffened lips or ledges on the outer distal edge of each leg while the tracks do not have such stiffening ledges. The tracks are dimensioned widthwise to fit over the ends of the studs, and the stud and track members are used to frame wall sections. The same basic shapes in wider and heavier gauge sizes are also used for floor framing sections. Both shapes are also used to assemble roof and other truss members of considerable spanning and load carrying capabilities.

Traditional cold roll forming devices consist of sets of two driven shafts positioned one above and one below a metal sheet passing through the device. Mounted on these shafts are roll elements whose profile has been machined to bend or form a strip of flat metal as it passes between the tightly spaced roll contours. This set of shafts, rolls and the mechanism that drives them is referred to as a roll pass. A roll former generally consists of a number of such roll passes mounted on a flat steel base with all passes being mounted in a straight line, and with all shafts in parallel with each other. The profile of each set of rolls in each succeeding pass is designed to gradually change the cross section of the initially flat metal strip fed into the machine, into the final desired shape as it passes through the sets of rolls. The number of passes required will vary with the complexity of the shape being formed as well as the type of material, its thickness and its physical properties.

To successfully roll form a finished shape, the metal's yield strength must not be exceeded as the metal is formed by the rolls. Assuming that the roll tooling has been properly designed to avoid this particular problem, there are a number of other factors which still cause problems in existing roll forming technology. The above referenced co-pending patent application focuses on significantly improved techniques and devices for accomplishing the formation of such roll formed metal studs and tracks as well as the assembling of metal studs and tracks into wall frame sections.

While the formation of metal wall frame studs and tracks as well as the preassembly of wall frame sections from such studs and tracks has been enhanced by the inventions of the above-referenced patent application, there still exists a number of problems relating to the acceptance and use of metal wall frame structures in the residential building market. One such problem involves teaching new assembly and construction techniques for on site formation of metal wall frames from the stud and track components to individuals who are used to using wood framing members. While one approach to lessen this problem involves the preassembly of basic metal wall frame structures at a location remote to the residential construction site, this solution creates a yet another set of new problems including the costs and complexities of transporting, unloading and then connecting the large and cumbersome preassembled metal wall frame structures. Thus, there remains a need in the art for metal wall frame structures as well as assembly techniques which overcome the aforementioned problems inherent in the existing technology. The present invention addresses and solves these particular problems in the art.

Summary of the Invention

Accordingly, it is one object of the present invention to provide pre-formed metal wall frame components and wall structures therefrom.

It is another object of the present invention to provide a wall frame structure from metal studs and tracks.

Yet another object of the present invention is to provide pre-fabricated metal wall frame units capable of being selectively attached to each other at the site of residential or commercial building construction to form a residential or commercial building structure.

Still another object of the present invention is to provide a pre-fabricated, foldable metal wall frame unit which is capable of easy transportation and selective erection on the site of residential or commercial building construction.

A further object of the invention is to provide a pre-fabricated, foldable metal wall frame unit which is adapted for ensuring good load transfer in load- bearing wall applications. To achieve the foregoing and other objects and in accordance with the purpose of the present invention, as embodied and broadly described herein, a foldable wall frame is disclosed. The wall frame includes first and second track members spaced from each other, each track member having a center web and a pair of opposite side flanges. A plurality of spaced stud elements are positioned between and substantially perpendicular to the track members with each stud element having a first and a second end portion. A first attachment element is provided for pivotally securing the first end portion of each said stud element to the first track member. A second attachment element is also provided for pivotally securing the second end portion of each stud element to the second track member. The first and second pivotal attachment elements enable the first track member to be folded down proximate the second track member for storage and transportation, and to be unfolded at a construction site for installation into a building structure.

In one modification of the invention, the first and second attachment elements are each in the form of a clip member having a pair of apertures and include a fastener attaching one aperture to an adjacent track member. In another modification, the frame includes removable retention members to selectively engage and hold the end portions of a stud element in the track members when the frame is in an unfolded position. In still another modification, the frame is selected from the group consisting of metal and wood.

In another aspect of the invention, the stud end portions are adapted for engagement with the track web portion upon unfolding of said frame to create a load-bearing wall.

In another modification, the wall frame further includes collapsible spacer members adapted for engaging the end portions of the stud elements to position the stud elements relative to the track members during formation and adapted for collapsible removal upon folding and transport of the wall frame, each spacer member including two interacting wedge elements and a mechanism for releasably attaching the wedge elements together to expand the spacer member for supporting load transfer through the stud element from the upper track member to the lower track member. In one form of this modification, the spacer members are adapted to engage the stud end portions upon unfolding of the frame to create load-bearing walls.

In still another modification of the invention, the wall frame further includes a pair of substantially parallel, transversely oriented notches disposed in the lower track web along the inside edges of adjacent studs to mark door frame positions.

Another aspect of the invention is wherein the stud member includes a center web portion having at least one elongated opening therein defined by a substantially elliptical edge. Each opening has a pair of side slots disposed opposite each other in the elliptical edge. The wall frame further includes an elongated brace member having a pair of opposite elongated side portions and at least two pairs of opposing notches disposed in the edges of the elongated side portions at their axial ends, the notches interengaging the elliptical edge slots to firmly hold the brace member between adjoining studs of the wall frame.

In still another modification, the track member center web includes a pair of raised transfer pads defining a depression cavity therebetween at the junction of the stud element end portions and the track member web to enhance the transfer of structural loads from the first track member to the second track member through the stud elements when the wall frame is in a fully unfolded and erect position. An additional modification of the invention is in the form of a foldable wall frame having upper and lower track members. Each track member has a center web and a pair of opposite side flanges, the track members being spaced from each other with their respective side flanges projecting toward each other. A plurality of spaced stud elements are also provided with each having a center web, a pair of opposite side flanges and a pair ledge portions projecting inwardly from the edges of the flanges. Each stud element has first and second, end portions and is arranged substantially parallel between the track members. A first attachment element pivotally secures the first end portion of each stud element to the upper track member. A second attachment element pivotally secures the second end portion of each stud element to the lower track member. The first and second pivotal attachment elements enable the upper track member to be folded down proximate the second track member for storage and transportation. Finally, a load transferring mechanism is disposed at the junctions of the first and second stud end portions and the upper and lower track members for enhancing and creating reliable load transference between the upper and lower track members when the wall frame is in a fully unfolded and erect position.

Yet another aspect of the invention is in the form of an elongated brace member for laterally supporting adjoining studs of a wall frame. The wall frame includes a plurality of studs interconnected at their ends between a pair of tracks, with each stud having a central web portion and side flanges. The brace member includes an elongated support element having first and second end portions, a pair of elongated side edges extending between the support element end portions, and a channel defined along the center of the support element and extending between the support element end portions. A first pair of opposing notches are defined in the side edges proximate the support element first end portion. A second pair of opposing notches are also defined in the side edges proximate the support element second end portion. The pairs of notches are sized and shaped for removable engagement with adjoining studs to provide lateral support thereof.

Brief Description of the Drawings

The accompanying drawings which are incorporated in and form a part of the specification illustrate preferred embodiments of the present invention and, together with a description, serve to explain the principles of the invention. In the drawings:

Fig. 1 is a front perspective view of a metal track member utilized with the present invention;

Fig. 2 is a front perspective view of a metal stud element utilized with the present invention;

Fig. 3 is a side view of a building wall section built using metal track member and stud element components in accordance with the present invention;

Fig. 4 is a front view of the wall section of Fig. 3;

Fig. 5 is a front view of a roof truss built utilizing metal components constructed in accordance with the present invention;

Fig. 6 is a side schematic of a standard stud element joint;

Fig. 7 is a side schematic of a stud element joint modified in accordance with one embodiment of the present invention;

Fig. 8 is a perspective view of a foldable wall frame constructed in accordance with the present invention and in an erected position;

Fig. 9 is a perspective view of the wall frame of Fig. 8 but in a folded condition for storage or shipping; Fig. 10 is a perspective view of the erected foldable wall frame of Fig. 8 but illustrating one embodiment for attaching two such wall frame sections together to form a building wall portion;

Fig. 11 is a side elevation view of a collapsible wall section constructed in accordance with the present invention and in full upright position;

Fig. 12 is a view similar to that of Fig. 11 but illustrating the wall section in a full collapsed state;

Fig. 13 is an end view of yet another embodiment of a collapsible wall section constructed in accordance with the present invention and in full upright position;

Fig. 14 is a side elevation of the device of Fig. 13;

Fig. 15 is an enlarged front perspective of a clip for securing a stud element for use in the embodiment illustrated in Fig. 13; and

Fig. 16 is an enlarged view of another embodiment of the collapsible wall section constructed in accordance with the present invention.

Fig. 17 is a side perspective of a foldable wall frame embodiment as constructed in accordance with the present invention;

Fig. 18 is a side view of a load bearing foldable wall frame embodiment in an erected position;

Fig. 19 is an enlarged, partial sectional view illustrating the junction of the stud and track of the embodiment illustrated in Fig. 18;

Fig. 20 is an enlarged perspective view of a track flange and a hole pattern therein;

Fig. 21 is an enlarged section of the embodiment illustrated in Fig. 19 and illustrating an attachment screw therein;

Fig. 22 is a perspective view of yet another modified embodiment of a stud member constructed in accordance with the present invention. Fig. 23 is a perspective view of a collapsible spacer element for use with non-load bearing foldable wall frame members.

Fig. 24 is a side perspective view of a foldable track and stud frame arrangement modified for use as a door frame;

Fig. 25 is a top perspective view of a saw device for creating the embodiment illustrated in Fig. 24;

Fig. 26 is a side perspective view of a snap-on brace member for use between stud elements of a metal frame panel for support purposes;

Fig. 27 is a side perspective view of a snap-on brace member in position between a pair of spaced stud elements of a metal frame panel;

Fig. 28 is a front elevation view of the snap-on brace member in position in a metal frame panel as taken substantially along line 67-67 of Fig. 27;

Fig. 29 is a front elevation view similar to Fig. 28 but illustrating two such snap-on brace members in position in a metal frame panel forming a conduit for wire;

Fig. 30 is an expanded side view illustrating two snap-on brace members nested together to illustrate continuous connection;

Fig. 31 is a side schematic illustrating a plurality of snap-on brace members in position in a metal frame panel forming a conduit for wire;

Fig. 32 is a side schematic view of a foldable wall frame illustrating yet another embodiment for providing pivotal loading support between stud elements and track members of the metal frame panel;

Fig. 33 is a sectional end view taken substantially along line 33-33 of Fig. 32;

π Fig. 34 is a side schematic view of a foldable wall frame illustrating still another embodiment for providing pivotal loading support between stud elements and track members of the metal frame panel utilizing a spring mechanism; and

Fig. 35 is an enlarged perspective view of the spring mechanism and transfer pad arrangement of the embodiment illustrated in Fig. 34.

Disclosure of the Invention

The present invention is a multifaceted foldable metal wall frame arrangement for residential and commercial building frames and the assembling of building structures therefrom. Referring first to Figs. 1-5, metal sheets may be formed using any desired process into metal frame components, but preferably using the process and apparatus of the above-referenced related pending patent application. In the present invention, substantially U-shaped metal frame components are utilized and interconnected for use in residential and commercial building frame structures. One of the primary components formed using the present invention is a metal track member 22 having a center web portion 24 and a pair of upright flanges 26, 28 that are preferably angled at approximately 90° relative to the web portion 24. The other primary component in a metal wall frame is a stud element 30. The stud element 30 includes a center web portion 24 having upright flanges 26, 28 as in the track member 22. In addition, the stud element 30 includes a pair of stiffened lip or ledge elements 32, 34 projecting inwardly toward each other substantially orthogonal from the distal edge of the flanges 26, 28. The web side 24 of the stud element 30 is typically termed the "hard side" while the stiffened lip edge side is typically termed the "soft side".

The metal components 22, 30 are preferably formed for assembly together into a wall frame unit 36. The frame unit 36 includes a plurality of stud members 30 spaced at about 16" centers and attached at each end to a track element 22. In another form, the metal components may be assembled to form a roof truss unit 38. In this form and by way of example only, the eaves and base support are formed from several track elements 22 and are interconnected with stud members 30.

Once the metal components are cut, formed into stud elements 30 and track members 22, and then punched, they must be assembled into building wall frame units 36. To accomplish this with more expediency and efficiency, the frame units may be pre-assembled. Despite the costs of steel framing leaning more and more in steel's favor as compared to wood framing, the cost for assembling the steel framing units in situ on the job site compared to comparable costs for wood framing has remained significantly higher, especially for residential construction projects. The lack of readily available experienced and skilled metal framing crews in most areas further increases this cost difference. One approach to this problem has been the in-house plant panelized framing where frame sections are produced in-plant under controlled conditions by less skilled labor and then trucked to the job site. Referring to the above-referenced related patent application, one such assembler embodiment is illustrated therein. In this embodiment, a device provides pre-cut stud elements and track members with pre-punched holes in the flanges. This device essentially produces an "erector set" of metal wall frame components which are taken by an assembler device and assembled into finished framed sections complete with door and window openings as designed by a computer software program. While generally more cost effective compared to prior typical job-site assembly, this approach has its own set of problems and limitations, in particular the cost of shipping large pre-assembled units and then handling such large and heavy units at a construction site without specialized equipment.

When assembling metal wall frame units, whether foldable or not, it is always preferred to obtain the tightest fit possible between the end portion of a stud element 30 and the web surface of a track member 22. To assist in accomplishing this in one form of the invention, the end portions of the stud elements may be modified by deformation. Referring to Fig. 6, a typical joint 289 between an end portion of a stud element and its associated track member is illustrated. Fig. 7 illustrates one form of a modified joint 290. In this modified embodiment, the end portion 292 of the stud 30 is compressed on all sides to form a reduced cross-sectional portion 294 as compared to the standard size cross-section 296. In this manner, the terminal edge 298 of the stud end portion 292 can readily abut the web surface 20 of the track 22 when the studs 30 are pressed against the tracks 22. Otherwise, a gap 299 may occur at the junction as in a typical prior art joint 289.

The deformation of the stud end portion 292 to create the reduced portion 294 may be performed as part of a final stud formation process, or it may be performed on an as needed basis at the site of assembly into wall units 36. This election is most preferred since a non-load bearing wall section will function quite well with a typical joint 289. However, a load bearing wall application will preferably benefit substantially from a modified joint 290 arrangement.

Referring now to Figs. 8-10, the completed frame units can be assembled as described above, or they can be assembled into the preferred folding frames as described below. The advantage of the folding frame arrangement is that the wall frame units 300 can be transported in a very compact manner as illustrated in Fig. 9 and then easily erected on site without any particular requirement for metal framing skills as illustrated in Fig. 8. Fig. 10 illustrates one embodiment for attaching adjacent erected wall panels by utilizing a pair of U-shaped attachment braces 302 and 304 having a cross-section just slightly less than that of the adjacently located tracks 22 and 22'. The braces 302 and 304 are positioned within the adjacent tracks 22 and 22' overlapping the abutment joint 306 between the two tracks 22 and 22". The flanges 24 of the tracks 22 and 22' are then attached, preferably by screws, to the flanges 308 of the braces 302 and 304 to secure the two wall panels together.

The embodiments of an automated assembler device, as described in the above referenced related patent application, require only about one fourth of the man-hours that manual assembly of frame panels requires. This is a savings of about 75-80 percent of the typical on-site manual assembly time of wood or metal frames. When the metal frame panels are preassembled in folding frame arrangements, the frame panels typically require only approximately 20-23% of the on-truck trailer space required for the unfolded frames. Typically, a tractor- trailer can haul approximately 50,000 lbs. of the folded frames while only being able to load approximately 8-12,000 pounds of non-folded frames. In addition, trucks may very well need to obtain an over-width permit at extra cost to haul non-folded metal frames if such frames project over the trailer bed width.

At the job site, a light crane is normally required for unloading the non- folded frames, while folded frames can usually be unloaded by hand. In addition, the folded frames can be stacked in less space at the job site and can pass through openings between studs when folded. This provides substantially easier on-site handling of the frames. In addition, there is a significant shortage of steel framers, while there are plenty of wood framers in the market. It would be relatively easy to train existing at wood framers to work with steel frames when they are preassembled and folded.

Referring more particularly to Figs. 11-24, a variety of folding frame arrangements or embodiments are illustrated herein. The folding frame embodiments require that two web sides of a stud 30, that is the hard side 336 and the soft side 338 as illustrated in Fig 17 for example, form hinges points with the upper and lower track flanges as illustrated below. In all of the folding embodiments illustrated herein, the same general hinge concept is incorporated. In frames that form outer walls, these frames must be load bearing, while interior walls are not.

In non-load bearing wall sections, which are primarily interior wall sections, the stud ends are left cut square with the studs cut short as illustrated below. In the embodiment illustrated in Figs. 11 and 12, the tracks 22 are attached partially to the studs 30, and this arrangement is particularly useful for non-load bearing interior wall frames. In one form, the ends of the studs 30 are attached by one screw 340 at one end and a second screw 342 at the opposite end. Preferably, the screw 340 is offset at opposite edges from the screw 342. While the remaining holes 344, 346 are preformed, there are no screws secured through these holes. In this manner, the tracks 22 can be swiveled around the screws 340, 342 and thereby fold the upper track 22 down against the lower track 22. During the assembly operation, collapsible spacers, as further described below, are used between the ends of the studs and the inner surface of the track webs. The spacers are then collapsed and removed after the primary screws 340, 342 are in place. No preparation of the stud ends is required as with load bearing walls described below. Alternatively, the studs 30 may be attached to the tracks 22 using metal clips 348 as illustrated in Figs. 13-15. In this embodiment, the stud elements 30 are attached to the metal clips 348 at each end thereof. The clips 348 each have two spaced apertures 350, 352, and a screw secures the aperture 350 at one end to a track member 22 and the opposite aperture 352 at the other end. In this manner, the upper track member 22 may be folded down onto the lower track member 22 as in the prior embodiment. Since such folded wall structures are much more compact than the fully assembled wall structures discussed in great detail above, they become much more transportable since they do not take up nearly the space in their folded form.

A folded frame section typically only occupies about 20-30% of the space of the unfolded frame. This compactness of the folded frame is a factor of the size of the stud leg and the stud center spacing. The folded frame section can be handled more easily in most job site situations. The smaller size allows the folded section to pass through standard door openings or between studs in already erected wall sections for instance, and a simple two wheel dolly can carry the weight and allow easy turning of the section. In situations where the foldable wall section is to be load bearing, certain modifications can be made. It should be understood that this folding concept is also applicable to wood frames as well.

Referring in particular to Figs. 13-16, the end portions of the studs are preferably mounted to the clips 348. To secure the studs in place after unfolding the wall section, an interlocking retainer mechanism 354 may be utilized for load bearing situations. In this embodiment, a first member 356 is provided with a recessed portion 358 in its upper surface adapted to receive an end portion 360 of a stud element 30. The first member 356 preferably has a flat lower surface 362 with teeth 364 and a pivot point 366. A second member 367 is provided having a flat lower surface 368 and a flat upper surface 370 with teeth 372. To utilize the retainer mechanism 354, the stud element end portion 360 is inserted into the recess 358 of the first member 356, and the second member 367 is then wedged beneath the first member 356 so that the teeth 364 interlock with the teeth 372. This assists the retainer mechanism 354 from slipping while providing a firm load-bearing surface to transfer loads from the track 22 through the studs 30.

Because of the radius that must always be present at the band junction between the web and flange portions of the track 22, it is not possible for the web of the stud to rest tightly and flush against the inner face of the track web. Without accounting for this issue, downward load transfer between the track and stud would place a sheer strain on the fasteners which join the two members as described below. These fasteners are primarily intended to hold the track and studs in position laterally with each other and to permit the relative folding action between them. Therefore, in load bearing walls the extreme lower edge of the trackway is preferably bent inwardly to transfer the downward load directly between the tracks and studs. This basically relieves the fastener of the shear load and improves the structural qualities of the panel frame.

To illustrate the above and referring now to Figs. 17-22, load bearing wall frames are illustrated. In this particular embodiment, the lower end portions 374 and upper end portions 375 of the studs 30 are modified by a steel cutting saw to create the notch pattern illustrated therein. This allows the studs 30 to fold in relationship with the tracks 22. In this particular embodiment, angular cuts 376 are made in each corner of both the upper and lower portions 375, 374 of the flanges 26, 28, in the soft side web 338. In addition, the web 24 is cut across between the cuts 376 to form a cut edge 378. In addition, the upper end portion 375 of the stud forming the hard side 336 is also cut in a manner similar to both the upper and lower portions 375, 374 of the stud carrying the soft side web 338. In the case of the lower end portion 374 of the hard side web 336, a crosscut 378 is not made to insure firm contact between it and the web 24 of the track 22 when in a fully erect position. As a result, these angular cuts 376 in the lower portion 374 create V-shaped notches 380 and leaves the bulk of the web hard side 336 in tact at its lower portion 374. The purpose of this arrangement is to allow the stud's web end members 381 to firmly contact and engage the web 24 of the track 22 when the studs and tracks are at 90° to each other as illustrated in Figs. 59 and 60.

It should be noted that the punch unit that creates the four hole pattern as illustrated in Fig. 20, also creates annular dimples 382 in the metal surrounding the circumferential edges of the screw holes 372, 374. This arrangement relieves most of the friction between the interface of the legs of the stud and track members and in turn enables a smoother folding action, which allows the screw head 340 to remain stationary in relationship to the track. In other words, it acts somewhat like a lock nut between the interface of the track leg and the underside of the screw head 340. In addition, the distance "d" between adjoining smaller holes 374 and 375 may be varied to accommodate different widths of stud legs in the various foldable embodiments illustrated herein. However, as previously indicated, only one of the two adjoining holes 374, 375 will be utilized to create a hinge to permit the folding of a stud relative to the tracks to which it is attached.

Referring now to Fig. 22, the ends 384, 386 of the stud 30 are modified in this particular embodiment. In this embodiment, each end 384, 386 is stamped using a blanking and forming die which pushes out a portion of the web and stiffened edges to form attachment elements 388 as illustrated. With this stud arrangement, the hard and soft sides can be positioned however desired as compared to the embodiment illustrated above. This stud then functions and performs similar to the embodiment illustrated in Figs 13-15 without requiring an additional component 348. In this embodiment, the attachment elements are integral with the stud itself.

As previously discussed, collapsible spacers may be utilized to center the studs evenly between the inside track web surfaces of the upper and lower tracks for non-load and load bearing wall sections. Referring now to Fig. 23, one embodiment of a spacer 388 includes a pair of spacer wedges 390, 392, preferably made of extruded aluminum. The upper wedge 390 includes a horizontal upper surface 394, a beveled surface 396, an end surface 398 and a wedge end surface 400. The lower wedge 392 preferably includes a horizontal bottom surface 402, a beveled surface 404 which terminates in a shoulder surface 406, an upper section surface 410, an end surface 408 and a wedge end surface 412. Each of the horizontal surfaces 394 and 402 include a transversely aligned notch 414, 416, respectively. The beveled surfaces 396, 404 are designed to slidingly fit against each other with the wedge end surface 400 of the upper wedge 390 abutting the shoulder surface 406 of the lower wedge 392. Each end surface 398, 408 includes an aperture therein which are coaxial with each other to receive a screw 418 for attaching the upper and lower wedges 390, 392 together, or for collapsing them by backing out the screw 418. When the screw 418 is backed out, the two spacer wedges 390, 392 slide apart and downwardly to allow their removal. The edges of the end portions of a stud 30 are designed to fit within the notches 414 or 416 to hold the studs in position and center them evenly until attached to the tracks 22. The spacers 388 may also be used to convert non-load bearing frame members to load bearing. In this instance, the studs 30 in a load bearing position need to be a proper gauge thickness for supporting the desired load, and may either be used with the extruded aluminum spacers 388 or changed out for the load bearing stud retainer mechanism 354 previously described. When the spacers 388 are utilized for such a conversion, the screw 418 is driven into place. The spacer 388 is then placed under the stud web, and the screw 418 is tightened to vertically expand the spacer 388 to support load transfer from the stud web to the track web. Since only a portion of a wall frame may need to be load bearing, the spacers 388 may be utilized only in the necessary and appropriate positions within the frame.

In certain instances, the foldable frame units of the present invention need to incorporate doorways therein. In order to accomplish this and as illustrated in Fig. 24, the web 24' of the bottom track 22' is cut to form a pair of substantially parallel, transversely oriented notches 420, 422 along the inside edges of adjacent studs 30'. The notches 420, 422 are preferably approximately 1/8 inch deep. This arrangement leaves the track 22' basically intact during shipping and framing erection on site. Once the frame is in place and before a door and frame are installed, the side flanges 26' and 28' of the track 22' are cut with a hacksaw or snips at the notches 420, 422. This enables easy removal of the portion of the track 22' between the studs 30' across a door threshold after erection on-site of a wall frame. Fig 25 illustrates a device and method of notching the lower track web 24' at a doorway site. The track 22' is positioned on a table saw 424, and a jig 426 includes a pin 428 sized to engage a hole 274 in the track flange 26' to position the table saw. The notches of 420, 422 are then created at the appropriate and desired locations. Referring now to Figs. 26-31 , a lateral bracing member 430 is illustrated and is particularly useful in providing lateral stability between studs attached to tracks, especially in the various foldable frame embodiments of the present invention. The brace member 430 preferably includes an elongated metal strip 432 having a flat center portion 434 and a pair of side wing portions 436, 438. Each wing portion 436, 438 includes, respectively, a substantially flat end element 440, 442 which are substantially parallel to the center portion 434, and an angularly inclined element 444, 446 (Fig. 28) which interconnects each of the flat end elements 440, 442, respectively, to the center portion 434. This arrangement creates a channel 448 defined between the center portion 434 and the inclined elements 444, 446.

One axial end portion includes a pair of opposing end notches 450, 452 in the flat end elements 440, 442, respectively. A similar pair of end notches 454, 456 are disposed in the flat end elements 440, 442, respectively, of the opposite axial end portion of the brace member 430. In addition, a third pair of opposing notches 458, 460 is defined in the flat end elements 440, 442, respectively, spaced laterally inwardly from the end notches 454, 456. The distance between the notches 458, 460 and the end notches 454, 456 is defined as distance "A", while the distance between the end notches 450, 452 and the end notches 454, 456 is defined as distance "B. In preferred form, the distance "A" is approximately equal to the width of a stud flange 26, while the distance "B" is approximately equal to the stud center-to-center distance in a wall frame structure.

In the illustrated embodiment of Figs. 26-31 , the webs 24 of spaced adjacent studs 462, 464 each includes an vertically elongated opening 466 defined by side edges 468. These openings are typically stamped into the web 24. The openings 466 also include opposing notches or slots 470, 472. The brace member 430 is twisted so that one axial end 474 is inserted through an opening 466, and the end notches 450, 452 interengage snugly with the notches 470, 472 defined in the side edges 468 of the opening 466 as illustrated in Fig. 28. The inwardly disposed set of notches 458, 460 of the opposite axial end 476 are similarly engaged with the notches 470, 472 of the next adjoining stud 464 so as to firmly snap fit the brace member 430 into place between the studs 462, 464 as illustrated in Fig. 27. This arrangement provides significant lateral support and strength to a wall frame. The second set of end notches 454, 456 in the axial end portion 476 are provided for use in the event that the hard and soft sides of two adjoining studs are reversed from that illustrated in Figs. 26 and 27.

Fig. 30 illustrates how the overlapping ends 474, 476 of two separate brace members 430 can internest and snap into the same retaining slots or notches 470, 472 in a web opening 466 to provide a continuing brace support between several adjoining studs in a wall frame. Moreover, it should be clear that the brace members 430 can not only be hand fastened in place without the use of tools or fasteners, but they will also readily fold along with the foldable frame embodiments previously described. Finally, and with reference to Figs. 29 and 31 , a pair of brace members 430 and 478 can be snapped into place with the brace member 478 being inverted relative to the brace member 430. In this manner, the channels 448 of each of the brace members 430, 478 create a conduit opening 480 in the wall frames and through which wires 482, piping and the like may be threaded and run once the wall frame is erected.

As previously discussed, the stud elements of the foldable metal frames must form hinge points with the upper and lower track flanges. In essence, hinge points must be created between the track members and the stud elements which are offset from each other, one on either side of the centerline of the stud elements as illustrated herein. The farther away these points are located from the centerline, the easier the frame will fold. In addition, the stud elements must be able to transfer the structural load from the upper track member to the lower track member, and there are several different embodiment illustrated above that accomplish this using expandable clips or stud end deformation arrangements. The key to forming the foldable track members lies in the fact that there must be some radius where the web of the track member and the leg of the stud element meet. This radius prevents the distal ends of the stud elements from sitting directly in contact with the webs of the track members for good load transference from and to the track members.

As a result of this recognition, Figs. 32-35 illustrate still other preferred embodiments for providing a foldable metal wall frame that permits good load transference between the upper and lower track members thereof. Rather than modifying the ends of the stud elements as in the previous embodiments, the webs 24 of the track members 22 are stamped and compressed to deform them and in so doing form transfer pads therein. As illustrated in the embodiment of Figs. 32-33, the web 24' of each track member 22 is stamped proximate the centerline 490 of the stud flange 26 of stud element 30. The stamping process creates a depression cavity 492 which in turn also creates a pair of raised transfer pads 494, 496 defining each side of the cavity 492. In this manner, when the frame unit 498 is in its erect position as illustrated in the Figs. 32-33, the upper and lower end portions of the stud web 24, the stud flanges 26, 28 and the stud stiffened edges or lips 32, 34 are firmly engaged with the pads 494, 496 to provide good load transference between the upper track 22 and lower track 22'.

When the tracks 22, 22' are rotated at their attachment screws 500, 502 in the direction indicated by the arrow 504, the upper and lower end portions of the stud web 24, the stud flanges 26, 28 and the stud stiffened edges or lips 32, 34 all slide off the pads 494, 496 into the adjacent cavity 492 to permit such folding action. When the frame unit 498 is then erected on site, the tracks 22, 22' are rotated at their attachment respective screws 500, 502 in the opposite direction of the arrow 504 so that the various end portions of the stud 30 reengage the transfer pads 494, 496 for firm stability and load transference. The depth of the cavity 492 along with the height of the pads 494, 496 is preferably equal to or slightly greater than the radius R between the web 24' and the legs or flanges 26', 28' of the track 22 or 22'. This arrangement effectively raises the web 24' for load transfer purposes, thus eliminating the effect of the radius R.

As illustrated in this and the various prior embodiments, punched or pre- drilled holes 506 are preferably provided in the legs 26', 28' of the tracks 22, 22' for the attachment screws 500, 502. This pre-drilled hole arrangement saves the time involved with the screws 500, 502 having to drill holes in both the legs of the tracks as well as the flanges of the stud when assembling the foldable frame unit. While this time saving is not much per screw, it does add up when one considers the thousands of holes drilled per day at the pre-assembly location for the foldable wall frame sections. In addition, the pre-punch or drilled holes 506 in the track legs 26', 28' may be oversized as illustrated in Fig. 32 to allow for some vertical movement when erecting or folding the wall frame unit 498. This permits the hinge arrangement created between the tracks 22, 22' and stud 30 to have some "give" to compensate for either minor physical variations or thermal expansion or contraction while still allowing good structural load transfer between the end portions of the stud 30 and the webs 24' of the tracks 22, 22'.

Referring now to Figs. 34 and 35, some additional alternate features are illustrated that can be stamped into or secured to the load transfer pads to assist both in load transference as well as in frame folding operations. In Fig. 34, a spring hinge 510 may be attached to opposite end portions of the stud 30 in lieu of using the attachment screws 500, 502. Each hinge 510 includes attachment plates 512, 514 mechanically fastened or spot welded in place to the tracks 22. 22' and the stud 30, and a spring mechanism 516. In this manner, the spring hinge 510 allows the tracks 22, 22' to be folded against each other for storage and transportation, and then assists in snapping the frame unit back into an erect position for installation and load transference. In Fig. 35, a raised stop element 520 is stamped into the web 24' at the time of creating the transfer pads 494, 496, against which the stud web 24 can abut and rest when the frame unit is in a folded position. In addition, a leaf spring member 522 may also be stamped into the web 24' which allows the stud web 24 to depress to its the folded position and rest against stop element 520, and then snap up to assist in holding the stud 30 in a vertical position when the frame unit is erected.

As can be seen from the above, a new and unique system is provided for rapidly and effectively securing the metal stud and track components into wall frames without requiring any particular metal assembly skills. Moreover, the invention includes a unique and new approach to prefabricated wall frames by providing various foldable wall frame structures that can be simply and easily erected on site without requiring metal working experience and training, thereby reducing the expense of erecting building structures as well as increasing the available work force for performing such tasks. The foldable wall frame units of the present invention also assist in the folding and erection operations as well as provide various alternatives to insure that good load transference is accomplished between the upper and lower tracks of the frame units once they are unfolded and installed into a housing structure. The present invention finally aids significantly in reducing the costs of manufacturing, transporting and installing metal wall framing as well as assists greatly in the ease of actual installation of the units into a complete structure for both commercial and residential uses.

The foregoing description and the illustrative embodiments of the present invention have been described in detail in varying modifications and alternate embodiments. It should be understood, however, that the foregoing description of the present invention is exemplary only, and that the scope of the present invention is to be limited to the claims as interpreted in view of the prior art. Moreover, the invention illustratively disclosed herein suitably may be practiced in the absence of any element which is not specifically disclosed herein.

Claims

I claim:

1. A foldable wall frame comprising: first and second track members spaced from each other with each said track member having a center web and a pair of opposite side flanges; a plurality of spaced stud elements, each having a first and a second end portion, and positioned between and substantially perpendicular to said track members; a first attachment element for pivotally securing said first end portion of each said stud element to said first track member; and a second attachment element for pivotally securing said second end portion of each said stud element to said second track member, said first and second pivotal attachment elements enabling the first track member to be folded down proximate said second track member for storage and transportation.

2. The foldable wall frame of claim 1 , wherein said first and second attachment elements each comprise a clip member having a pair of apertures, and a fastener attaching one said aperture to an adjacent track member.

3. The foldable wall frame of claim 1 , wherein said frame includes removable retention members to selectively engage and hold the end portions of a stud element in said track members when said frame is in an unfolded position.

4. The foldable wall frame of claim 1 , wherein said frame is selected from the group consisting of metal and wood.

5. The foldable wall frame of claim 1 , wherein said stud end portions are adapted for engagement with said track web portion upon unfolding of said frame to create a load-bearing wall.

6. The foldable wall frame of claim 1 , wherein said wall frame further comprises collapsible spacer members adapted for engaging the end portions of said stud elements to position said stud elements relative to said track members during formation and adapted for collapsible removal upon folding and transport of said wall frame, each said spacer member including two interacting wedge elements and means for releasably attaching said wedge elements together to expand said spacer member for supporting load transfer through said stud element from said upper track member to said lower track member.

7. The foldable wall frame of claim 2, wherein said spacer members are adapted to engage said stud end portions upon unfolding of said frame to create load-bearing walls.

8. The foldable wall frame of claim 1 , wherein said wall frame further includes a pair of substantially parallel, transversely oriented notches disposed in the lower track web along the inside edges of adjacent studs to mark door frame positions.

9. The foldable wall frame of claim 1 , wherein each said stud member includes a center web portion having at least one elongated opening therein defined by a substantially elliptical edge, each opening having a pair of side slots disposed opposite each other in said elliptical edge, and wherein said wall frame further comprises an elongated brace member having a pair of opposite elongated side portions and at least two pairs of opposing notches disposed in the edges of said elongated side portions at the axial ends, said notches interengaging said elliptical edge slots to firmly hold said brace member between adjoining studs of said wall frame.

10. The foldable wall frame of claim 1, wherein said track member center web includes a pair of raised transfer pads defining a depression cavity therebetween at the junction of said stud element end portions and track member web to enhance the transfer of structural loads from said first track member to said second track member through said stud elements when said wall frame is in a fully unfolded and erect position.

11. A foldable wall frame comprising: upper and lower track members each having a center web and a pair of opposite side flanges, said track members being spaced from each other with their respective side flanges projecting toward each other; a plurality of spaced stud elements each having a center web, a pair of opposite side flanges and a pair ledge portions projecting inwardly from the edges of said flanges, each stud element having first and second end portions and being arranged substantially parallel between said track members; a first attachment element for pivotally securing the first end portion of each said stud element to said upper track member; a second attachment element for pivotally securing the second end portion of each said stud element to said lower track member, said first and second pivotal attachment elements enabling said upper track member to be folded down proximate said second track member for storage and transportation; and a load transferring mechanism disposed at the junctions of said first and second stud end portions and said upper and lower track members for enhancing and creating reliable load transference between said upper and lower track members when said wall frame is in a fully unfolded and erect position.

12. The foldable wall frame of claim 11 , wherein each said load transferring mechanism comprises removable members to convert non-load bearing stud elements in said wall frame to load bearing elements to create reliable load transference in said wall frame when in an unfolded and erect position.

13. The foldable wall frame of claim 12, wherein each said load transferring mechanism comprises removable retention members to selectively engage and maintain the first and second end portions of a stud element against the center web of said track members when said frame is in an unfolded position.

14. The foldable wall frame of claim 12, wherein each said load transferring mechanism comprises collapsible spacer members adapted for engaging the end portions of said stud elements to position said stud elements relative to said track members during formation and adapted for collapsible removal upon folding and transport of said wall frame, each said spacer member including two interacting wedge elements and means for releasably attaching said wedge elements together to expand said spacer member for supporting load transfer through said stud element from said upper track member to said lower track member.

15. The foldable wall frame of claim 11 , wherein each said load transferring mechanism comprises a pair of raised transfer pads defining a depression cavity therebetween disposed in each said track member center web at the junction of said stud element end portions and track member web, said transfer pads enhancing the transfer of structural loads from said upper track member to said lower track member through said stud elements when said wall frame in a fully unfolded and erect position by substantially reducing the effect of the curvature radius between the center web and side flanges of each track member.

16. The foldable wall frame of claim 11 , wherein each said load transferring mechanism further includes a spring mechanism adapted for assisting in the relative movement between said upper and lower track members during the folding and the unfolding of said wall frame.

17. An elongated brace member for laterally supporting adjoining studs of a wall frame, said frame including a pair of tracks and a plurality of studs interconnected at their ends between said pair of tracks, each said stud having a central web portion and side flanges, said brace member comprising: an elongated support element having first and second end portions, a pair of elongated side edges extending between said support element end portions, and a channel defined along the center of said support element and extending between said end portions; a first pair of opposing notches defined in said side edges proximate said support element first end portion; and a second pair of opposing notches defined in said side edges proximate said support element second end portion, said first and second pairs of notches being sized and shaped for removable engagement with adjoining studs to provide lateral support thereof.

18. The brace member of claim 17, wherein said support element second end portion includes a third pair of opposing notches defined in said side edges and spaced a distance inwardly from said second pair of notches approximately equal to the width measurement of a stud side flange.

19. The brace member of claim 18, wherein said support element channel is sized to carry electrical and fluid conduit members.

20. The brace member of claim 17, wherein each said adjoining stud includes at least one elliptically-shaped opening defined by an elliptical edge in the center web portion thereof, said opening including a pair of opposed slots disposed in the elliptical edge thereof, and wherein said notches of said brace member support element are sized and shaped for snug engagement with the slots of said stud elliptical opening to maintain said brace member in firm support position between said adjoining studs.