Footer track with moisture vent

Description

RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 60/668,661, filed Apr. 6, 2005, U.S. Provisional Application No. 60/629,566, filed Nov. 19, 2004 and U.S. Provisional Application No. 60/628,880, filed Nov. 18, 2004, the entireties of which are incorporated by reference herein and made a part of this specification.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to building construction and, more specifically, relates to a wall footer track configured to permit drainage or venting of moisture within the stud space of a wall.

2. Description of the Related Art

In general, prior art wall footer tracks have failed to accommodated drainage or venting of moisture that has become trapped within the interior of the footer track, either during the construction process or within the space between the studs of the wall after completion of the building structure. Without a sufficient drainage or ventilation mechanism, the prior art walls are susceptible to moisture buildup within the stud space, which may cause a variety of problems, such as damage to the wall covering elements (e.g., drywall) or facilitating mold growth, among others.

In one attempt to provide for moisture drainage, a prior art footer track includes a drain hole located substantially in the center of the footer track web. A felt-like material is placed between the web of the footer track and the structure on which the footer track is supported. The felt-like material is intended to wick moisture from the interior of the footer track through the drain hole. However, in practice, this arrangement has not proven effective at removing a sufficient amount of moisture from the track.

SUMMARY OF THE INVENTION

Accordingly, a need exists for a footer track structure that effectively permits the evacuation of moisture from the interior of the footer track. Preferred embodiments of the present wall footer track are provided with a plurality of moisture vents, or drain openings configured to permit moisture within the stud space of an associated wall to readily escape. Desirably, a boundary of each drain opening is defined by both of a web of the footer track and one of the legs of the footer track. Advantageously, with such an arrangement, moisture within the stud space may be substantially or completely evacuated from the interior of the footer track. The drain openings may be of any shape and may be oriented in a parallel or alternating fashion along opposing sides of the footer track.

A preferred embodiment is a footer track for supporting a plurality of wall studs. The footer track includes a web and a pair of legs extending in an upward direction from opposing sides of the web. The pair of legs are spaced from one another a distance sufficient to accommodate a wall stud therebetween. The footer track defines a plurality of drain openings spaced along a length of the footer track. Each of the plurality of drain openings has a boundary defined by both of the web and one of the pairs of legs.

A preferred embodiment is a footer track for supporting a plurality of wall studs. The footer track includes a web and a pair of legs extending in an upward direction from opposing sides of the web. The pair of legs are spaced from one another a distance sufficient to accommodate a wall stud therebetween. The footer track defines a plurality of drain openings spaced along a length of the footer track. Each of the drain openings is at least partially defined by one of the pairs of legs and each of the drain openings extends at least to a juncture between the one of the legs and the web.

A preferred method of making a footer track includes creating a plurality of openings spaced along a length of a relatively flat, elongate workpiece. The method also includes bending edge portions of the workpiece to create a pair of legs extending from opposing sides of a web of the workpiece. The bending is configured such that a boundary of each of the openings is at least partially defined by both the web and one of the pairs of legs.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects and advantages of the present invention are described in greater detail below with reference to drawings of preferred embodiments, which are intended to illustrate, but not to limit, the present invention. The drawings contain seven (7) figures.

FIG. 1 is a partial perspective view of a stud wall assembly having certain features, aspects and advantages of the present invention. The wall assembly includes a bottom footer track and a plurality of studs (two shown).

FIG. 2 is a partial perspective view of a footer track including drain openings having certain features, aspects and advantages of the present invention.

FIG. 3 is a partial perspective view of a modification of the footer track of FIG. 2.

FIG. 4 is a partial perspective view of a modification of the stud wall assembly of FIG. 1. The footer track of FIG. 4 includes elongated drain openings in a staggered, or alternating, orientation.

FIGS. 5a, 5b and 5c are top, side and end views, respectively of the footer track of FIG. 4.

FIG. 6 is a partial perspective view of another modification of the stud wall assembly of FIG. 1. The footer track of FIG. 4 includes elongated drain openings in a parallel orientation.

FIGS. 7a, 7b and 7c are top, side and end views, respectively of the footer track of FIG. 6.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates a wall assembly including a footer track 10 having certain features, aspects and advantages of the present invention. Preferably, the footer track 10 includes a web 12 and a pair of legs 14 extending from opposing sides of the web 12. In the illustrated arrangement, the footer track 10 is generally C-shaped in cross-section. However, the footer track 10 may also be of other configurations as well. For example, in certain arrangements, the legs 14 may not extend from the web 12 in a generally perpendicular orientation, but may be oriented at other angles relative to the web 12. Further, in certain arrangements, the footer track 10 may include a portion defining a plurality of slots configured to locate and space studs 16 from one another. In such an arrangement, the footer track 10 may be generally M-shaped and include a central portion that defines the plurality of slots.

Preferably, the footer track 10 is configured to be placed with the web 12 resting on a support surface, such as a floor for example (not shown). Desirably, the legs 14 are spaced apart a distance sufficient to accommodate the stud 16 therebetween. A plurality of studs typically are supported by the footer track 10 in a spaced arrangement along the length of the footer track 10. For example, in one arrangement, the studs 16 may be spaced sixteen (16) inches from one another. The width of the track 10 (i.e., a perpendicular distance between legs 14) may vary according to the stud width and/or the needs of an individual job. Furthermore, the height of the legs 14 may be varied depending on the individual application of the footer track 10. For example, the legs 14 may be 3⅝ inches, 5⅝ inches or 6⅛ inches, or any other suitable dimension, in height from the web 12.

Preferably, the footer track 10 is constructed from a relatively light gauge steel material, such as 16, 18, 20 or 22 gauge, for example. In addition, the material may be galvanized, if desired. For example, preferred galvanization includes G40, G60, G90 or greater. However, other levels of galvanization may also be used. Furthermore, other suitable materials may be used to construct the footer track 10, as will be appreciated by one of skill in the art. For example, other types of metals, polymer/plastic or composite materials may be used.

Desirably, the footer track 10 includes a plurality of vents, or drain openings 20 along its length. As described in greater detail below, preferably the drain openings 20 are at least partially located within one of the legs 14 and extend at least to a juncture between the leg 14 and the web 12. Thus, with such an arrangement, the drain opening 20 is not spaced above the inner surface of the web 12, but extends at least to the inner surface of the web 12. Accordingly, the opening 20 facilitates complete drainage of water, or other liquids, from within the footer track 10 (the space between the legs 14). In some arrangements, however, the openings 20 may be spaced slightly or substantially above the inner surface of the web 12. Such arrangements may be suitable for use in environments where large amounts of water, or other fluids, are not likely to become trapped within the interior of the footer track 10 or, for example, where another component is placed within the bottom interior of the footer track 10. In another alternative arrangement, the drain openings 20 may be located within the web 12 and extend at least to the juncture between the leg 14 and the web 12.

In one preferred arrangement, the drain openings 20 are spaced along the footer track 10 at an interval other than the planned interval of the studs 16. Preferably, the spacing interval for the drain openings 20 is a value other than common stud spacing intervals, e.g., 12, 16 and 24 inches. In one presently preferred arrangement, the spacing interval for the drain openings 20 is approximately 9 inches. Advantageously, with such an arrangement, the likelihood of the studs 16 blocking a significant number of drain openings 20 is reduced, therefore permitting sufficient drainage despite the specific stud layout or how close the first drain opening 20 is relative to an end of the footer track 10. Other suitable spacing of the drain openings 20 may also be used. For example, the drain openings 20 may be spaced 9, 10, 12, 14, 16, 18, 20, 22 or 24 inches from one another, as well as other suitable dimensions, along a length of the footer track 10. Furthermore, spacing of the drain openings 20 may be less than 9 inches, such as 4 or 5 inches, for example, or greater than 24 inches. As will be appreciated, the distance of the initial drain opening 20 relative to an end of the footer track 10 may vary due to the footer track 10 being cut to a desired length prior to installation.

With reference to FIG. 2, one preferred arrangement of the drain openings 20 is illustrated. As described above, preferably, the drain openings 20 are sized, shaped or located such that a boundary 22 of each drain opening 20 is defined by each of the web 12 and one of the legs 14 of the footer track 10. In the arrangement of FIG. 2, the drain opening 20 extends upwardly within the leg 14 from the intersection between the web 12 and leg 14 such that the majority, and preferably the entirety, of the opening 20 is defined within the leg 14. In such an arrangement, the drain opening 20 extends all the way to the inner surface of the web 12 to facilitate complete drainage of moisture or fluid from the footer track 10. In a preferred arrangement, the drain opening 20 is generally semi-circular in shape. However, as noted previously, in some arrangements, the drain opening 20 may be spaced either slightly or substantially above the inner surface of the web 12, such that the entire drain opening 20 is located within the leg 14.

With reference to FIG. 3, a modification of the drain opening 20 of FIG. 2 is illustrated, and is indicated by the reference numeral 20a. However, general discussion of a drain opening 20 includes drain openings 20 and 20a, as well as other disclosed openings, unless otherwise noted.

The drain opening 20a of FIG. 3 preferably extends away from the intersection of the web 12 and leg 14 such that a portion of the opening 20a is located within each of the web 12 and leg 14. Accordingly, a portion of the boundary 22 of the drain opening 20a is defined by the web 12 and the remainder of the boundary is defined by the leg 14. In a preferred arrangement, approximately one-half of the opening 20a is located within the web 12 and the other approximately one-half of the opening 20a is located within the leg 14. Such an arrangement enhances the drainage function of the openings 20a. However, the drain opening 20a may be arranged to divide other relative proportions of the opening 20a between the web 12 and leg 14, as desired. Preferably, the drain opening 20a is generally circular in shape (when viewed with the web 12 and leg 14 lying in a single plane). However, other suitable shapes may also be used.

Desirably, the footer tracks 10 of FIGS. 2 and 3 are formed from an elongate workpiece by a roll forming process. In one arrangement, the openings 20 are created by a die punching process. However, other suitable manufacturing techniques may be used in addition or in the alternative. Preferably, the openings 20 are created in the workpiece and, subsequent to the creation of the openings 20, the workpiece is manipulated to attain the desired cross-sectional shape. In one arrangement, edge portions of the workpiece are bent relative to a central portion of the workpiece to create the generally C-shaped cross-section having a web 12 and legs 14, as shown in FIGS. 1-3. Desirably, the edge portions are bent such that the openings 20 are located relative to a juncture between the web 12 and legs 14, as described above with reference to either FIG. 2 or FIG. 3. In the alternative, however, the workpiece may be manipulated to partially or completely create the desired cross-sectional shape prior to the creation of the openings 20.

FIGS. 4 and 5 illustrate a modification of the footer track 10 of FIGS. 1-3. The footer track of FIGS. 4 and 5 is substantially similar to the footer track 10 of FIGS. 1-3 and, accordingly, like reference numerals are used to denote like components, except that a prime (′) is added. Features of the footer track 10′ that are not specifically discussed herein may be assumed to be the same or similar to the corresponding features of the footer track 10 of FIGS. 1-3.

FIG. 4 is a perspective view of a stud wall assembly incorporating the footer track 10′. A pair of studs 16′ are shown positioned within an interior of the footer track 10′. Preferably, the studs 16′ rest on an upper surface of a web 12′ of the footer track 10′ between a pair of legs 14′. Desirably, the spacing of the legs 14′ is configured to receive the studs 16′ between the legs 14′ with a relatively snug fit.

The openings 20′ of the footer track 10′ are elongate, rather than being generally circular. Preferably, the openings 20′ have substantially straight, opposing sides and rounded ends. The elongate openings 20′ provide a greater area for moisture to escape from the interior of the footer track 10′. In addition, preferably, the openings 20′ are provided in an alternating, or staggered, orientation. That is, preferably, each of the openings 20′ is located on an opposite side of the web 12′ from each adjacent opening 20′.

With reference to FIGS. 5a, 5b and 5c, each opening 20′ defines a length L and a width W. The illustrated width W is indicated as the perpendicular dimension of the portion of the opening 20′ disposed on either of the web 12′ or leg 14′ Accordingly, for openings 20′ disposed within both of the web 12′ and leg 14′, the actual width dimension of the opening 20′ is twice the indicated width W.

As discussed above, the openings 20′ are spaced from one another by a spaced dimension S along a length of the footer track 10′. The spaced dimension S may vary to accommodate an individual application of the footer track 10′, but preferably is configured such that the studs 16′ (FIG. 4) do not block a substantial number of the openings 20′ when the wall is assembled. Accordingly, the ventilation or drainage ability of the openings 20′ preferably are not compromised in the finished wall construction.

Another feature of the footer track 10′ of FIGS. 4 and 5 is the provision of an advantageous surface feature 30 associated with one or more of the openings 20′. Preferably, the surface feature 30 is configured to guide liquid toward the openings 20′ and, in some arrangements, may also improve the strength or rigidity characteristics of the track 10′. For example, in the illustrated arrangement, the surface feature comprises a rib, or crease 30, formed in the web 12′ and associated with each of the openings 20′. The crease 30 preferably protrudes upwardly from the upper surface of the web 12′ and may be formed by any suitable process before, during or after the formation of the opening 20′. In alternative arrangements, the crease 30 may be indented to protrude downwardly from the upper surface of the web 12′. Furthermore, other suitable liquid directing arrangements may be utilized, such as a ramp-like structure leading to the opening 20′, for example.

Advantageously, the crease 30 increases the resistance to bending of the web 12′ and, therefore, the resistance to bending of the footer track 10′. Thus, the crease 30 increases the rigidity of the footer track 10′ to partially or fully offset the loss in rigidity resulting from the removal of material to create the opening 20′. Thus, the crease 30 may be of any suitable height or arrangement to provide the desired degree of reinforcement. In addition, the crease 30 may assist in channeling liquid to the opening 20′.

In some arrangements, the crease 30 includes multiple segments. For example, the illustrated crease 30 includes three linear segments that originate at a common end point adjacent the opening 20′ and extend away from the opening 20′ toward the centerline of the web 12′. In the illustrated arrangement, the common end point of the segments of the crease 30 is located substantially at the edge of its corresponding opening 20′. A center segment of the crease 30 extends generally perpendicular to the leg 14′ of the footer track 10′. The two additional segments of the crease 30 extend at an angle to the center segment. The angle may be varied as desired, but in the illustrated arrangement is approximately at 45 degrees to both the center segment and associated leg 14′. The length of each segment of the crease 30′ may also be varied as desired, but preferably is less that about one-half the width of the web 12′. Furthermore, each segment of the crease may linear or non-linear and may be continuous or interrupted.

FIGS. 6 and 7a, 7b and 7c illustrate a modification of the footer track 10′ of FIGS. 4 and 5, which is referred to by the reference numeral 10″. The footer track 10″ is substantially similar to the footer track 10′ of FIGS. 4 and 5 and, accordingly, like reference numerals are used to denote like components. Features of the footer track 10″ not specifically described may be assumed to be similar to the footer track 10 or 10′ described above, or to be of a conventional construction.

The footer track 10″ includes elongate openings 20″, which may be defined by a leg 14″ of the footer track 10″ or by a combination of the legs 14″ and web 12″ of the footer track 10″, as described above. However, in the illustrated arrangement, the openings 20″ are oriented in a parallel fashion. That is, the openings 20″ of each leg 14″ are disposed substantially across from the openings 20″ of the opposing leg 14″.

As illustrated in FIG. 7a, a crease 30″ may be associated with one or more of the openings 20″ and, preferably, with each of the openings 20″. FIG. 7a illustrates two preferred embodiments of a crease 30″. Crease 30a″ is substantially similar to the crease 30 described above with respect to FIGS. 4 and 5.

Crease 30b″ is well-suited for use with a footer track 10″ wherein the openings 20″ are arranged in a parallel configuration. Crease 30b″ comprises a segment that extends from the opening 20″ on one side of the web 12″ to an opening 20″ on an opposite side of the web 12″. In the illustrated arrangement, the crease 30″ is a straight line segment that extends between directly opposed openings 20″. However, in other arrangements, the line segment may not be linear and/or may extend between openings 20″ that are not directly across from one another. Furthermore, preferably, the crease 30″ extends to an edge of each opening 20″, however, in alternative arrangements it may end short of the edge of the opening 20″. Additionally, although the crease 30″ includes a single line segment in the illustrated arrangement, additional line segments may also be provided.

Several preferred examples of a vented footer track have been disclosed herein. However, it is to be understood that the invention is not to be limited to the disclosed examples. For instance, although circular and elongate openings (generally, 20) have been shown, the openings may be of any other suitable shape, for example, but without limitation, square, rectangular, trapezoidal, triangular or octagonal. Furthermore, although the vented track structure is described specifically in the context of a footer track herein, it is contemplated that the inventive features, aspects and advantages may be applied to other structural track members, such as rim tracks or floor joists, for example, but without limitation.

Furthermore, the size of the openings 20 may be varied according to the desired application. For example, the width W preferably is between about one-quarter to about one inch and the length L preferably is between about one inch and about four inches. One consideration in determining the minimum size of the opening 20 is to size the opening 20 large enough to ensure that the opening 20 will not become clogged with dust or debris and that surface tension of water will not operate to effectively close off the opening 20. With respect to the maximum size, it is preferred that the opening 20 be small enough to inhibit or prevent the passage of pests, such as rodents, for example, through the opening 20. Although such sizing is preferred to accommodate these considerations, other suitable dimensions may also be used. For example, the width W may be less than one-quarter inch or greater than one inch. Furthermore, the length L may be less than one inch or greater than four inches. Preferably, if the openings 20 are less than about one and three-quarters inches, the spacing dimension S is an odd number in inches. Preferably, if the openings are greater than about one and three-quarters in length, the spacing dimension S is an odd or even number in inches. Such an arrangement assists in avoiding repetitive obstruction of the openings 20 by the studs 16.

In addition, the relationship of the position of the openings 20 on one side of the web 12 relative to the position of the openings 20 on the opposite side of the web 12 may be varied as desired. For example, the alternating orientation disclosed herein advantageously reduces that likelihood that the track 10 will bend, due to the absence of material at the openings 20, when the track 10 is handled. However, parallel orientations may be desired to increase available venting or drainage when a concern with bending of the track 10 during handling is either reduced or not present. Furthermore, other relative positioning may be desirable, such as a partial overlap of the openings 20 on opposite sides of the web 12, for example.

Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In particular, while the present footer track has been described in the context of particularly preferred embodiments, the skilled artisan will appreciate, in view of the present disclosure, that certain advantages, features and aspects of the footer track may be realized in a variety of other applications, many of which have been noted above. Additionally, it is contemplated that various aspects and features of the invention described can be practiced separately, combined together, or substituted for one another, and that a variety of combination and subcombinations of the features and aspects can be made and still fall within the scope of the invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims.