Polymer construction stud and seaming

Abstract

The building construction stud and the sheathing panel are fastened together by at least one fastener. A stud end cap terminates the stud. The stud has an outer wall defining a pair of plastic sheathing surfaces and first and second side walls, and at least one longitudinally extending void space. At least one fastener anchor and structural reinforcement is substantially contained within the interior of the stud outer wall. In some embodiments, the fastener anchor and structural reinforcement includes a plurality of longitudinally extending stud wall ribs projecting inwardly from the first sheathing surface. In other embodiments, a cell divider is provided that is parallel to and slightly spaced from the first and second sheathing surfaces. In still other embodiments, the internal reinforcement defines an "X" geometry within the cell. These fastener anchors and structural reinforcements are configured to increase rigidity and strength and also to enhance fastener engagement.

Description

Technical Field

[0001] The present invention generally relates to static structures such as buildings for illustrative purposes, but is not limited thereto. More specifically, improved high-cost-effective building components are used for constructing buildings. These building components desirably facilitate construction while also providing enhanced beneficial properties.

Background Art

[0002] Wood has long been a preferred material for building construction. Wood can be easily cut to specified dimensions by construction workers on site using a low-cost and very hard carbon steel saw, can be easily and securely fixed by using low-cost fasteners, is extremely strong for a given weight, resists sagging, and is generally low in cost. When wood is used to construct a building, future renovation projects can be easily achieved due to the easy cutting and fixing on site again.

[0003] Unfortunately, wood is limited in terms of the length of the undamaged part of the tree and the basic shapes that can be easily cut by a sawmill. Even when properly cut, wood can warp or twist during drying or in response to subsequent changes in environmental humidity. Wood is also easily damaged by water, fungi, and insects such as termites. Furthermore, wood is not always available at a low cost (especially in the drier regions of the world and during periods of high demand). Competing natural products such as steel, stone, cement, bricks, and ceramic tiles have much greater resistance to the environment and pests, but these are expensive to obtain and are much more difficult to cut, shape, fix, and then renovate.

[0004] One popular product that has been developed to enhance or replace lumber, particularly for exterior decks apart from many other projects, is polymer wood composite (PWC). Exemplary U.S. patents whose teachings are incorporated herein by reference include U.S. Patent No. 6,153,293 to Dahl et al., titled "Extruded wood polymer composite and method of manufacture"; U.S. Patent No. 6,651,398 to Gregori, titled "Decking assembly and decking kit with hold-down clip"; and U.S. Patent No. 6,958,185 to Zehner, titled "Multilayer synthetic wood component".

[0005] PWC products combine the inherent strength of wood cellulose with the water, fungus, and pest resistance of plastic by extruding the polymer with reduced-size wood fibers such as wood chips or shredded wood. Most commonly, PWC is extruded into standard dimensional lumber sizes and is a solid product. The resulting boards are very heavy, undesirably expensive, and remain susceptible to distortion and degradation over time when in contact with moisture or in a very high humidity environment.

[0006] Other artisans have similarly designed plastic products that are intended, in at least some embodiments, to augment or replace lumber without using wood at all. Exemplary U.S. patents whose teachings are incorporated herein by reference include U.S. Patent No. 5,783,286 to DiNicola, entitled "Hollow-core plastic structural lumber alternative"; U.S. Patents Nos. 6,881,367 and 6,890,637 to Baker, entitled "Composite materials, articles of manufacture produced therefrom, and methods for their manufacture", and U.S. Patent No. 8,065,848 to Carlson et al., entitled "Structural member".

[0007] There are a number of problems associated with using plastic instead of wood. Among these, but not limited to, the main ones are as follows: the higher cost of plastic materials; the difficulty of fabricating and cooling a material without slack or distortion; maintaining a geometric shape without slack or distortion after installation within a building; recycling plastic at the end of a building's life; and providing suitable fastener attachment to plastic lumber. One common technique for improving the structural integrity of plastic is to incorporate a filler, usually a fibrous material. One widely used filler is glass fiber, which can be useful for strength, slack, and distortion, and in some cases can also improve fastener attachment. However, glass fiber is very abrasive and thus greatly accelerates the wear of manufacturing and building construction equipment. During cutting and drilling, glass fiber dust can be annoying and dangerous, and in some cases exposes workers' health to risk, thus forcing the use of special masks or respirators. Further, at the end of life, fibrous fillers are also extremely difficult or impossible to reasonably separate from plastics of different compositions, making recycling much more difficult, if not impossible. As a result, currently available and known plastic lumber products that do not use wood address some of the problems, but none adequately address all of them.

[0008] In addition to standard dimensional lumber applications, there are other applications where the plastic composition desirably provides an alternative to wood and other building materials. Panels are one such area. Exemplary U.S. patents whose teachings are incorporated herein by reference include the following: U.S. Patent No. 3,886,705 to Cornland, titled "Hollow structural panel of extruded plastics material and a composite panel structure formed thereof"; U.S. Patent No. 5,294,472 to Arnold et al., titled "Oblique web multiple surface panels fabricated of aromatic polycarbonates"; U.S. Patent No. 5,706,620 to De Zen, titled "Thermoplastic structural system and components therefor and method of making same"; U.S. Patent No. 8,590,271 to Thiagarajan et al., titled "Multi-wall structural components having enhanced radiatransmission capability"; Des 405,545 to Forbis, titled "Fence plank"; Des 490,544 to Givoni, titled "Structural panel"; Des 500,370 to Givoni, titled "Structural panel"; Des 503,000 to Forbis, titled "Fence panel"; and Des 564,106 to Amato, titled "Deck panel". These architectural panels provide the same opportunities and problems as those described above herein with reference to standard dimensional lumber.

[0009] The various related additional patents, the relevant teachings and content of which are incorporated herein by reference, include the following: U.S. Patent Application No. 3,364,638 by Santangelo, titled "Composite plastic and corrugated panel"; U.S. Patent Application No. 3,435,575 by Pottiez, titled "Process and extruded elements for industrial manufacturing of furniture, furniture components and similar constructions"; U.S. Patent Application No. 3,450,593 by Fossier et al., titled "Panel having rims bonded with glass fibers and polyester resin"; U.S. Patent Application No. 3,662,507 by Espeland, titled "Preformed building wall construction"; U.S. Patent Application No. 3,732,138 by Almog; U.S. Patent Application No. 3,783,563 by Moore, titled "Prefabricated building components"; U.S. Patent Application No. 3,819,466 by Winfield et al., titled "Reinforced and insulating building panel"; U.S. Patent Application No. 3,948,347 by Rutledge, titled "Acoustical panel"; U.S. Patent Application No. 3,974,612 by Kamer, titled "Structural element"; U.S. Patent Application No. 4,035,536 by Morrison, titled "Sandwich panel core"; U.S. Patent Application No. 4,441,291 by Sokoler et al., titled "Panel, in particular for self-supporting roof structures and self-supporting roof structures assembled of such panels"; U.S. Patent Application No. 4,606,959 by Hillinger, titled "Honeycomb panel";U.S. Patent Application No. 4,718,213 by Butterfield, titled "Decorative beam assembly"; U.S. Patent Application No. 4,749,601 by Hillinger, titled "Composite structure"; U.S. Patent Application No. 5,030,662 by Banerjie, titled "Construction material obtained from recycled polyolefins containing other polymers"; U.S. Patent Application No. 5,052,164 by Sandow, titled "Method for manufacturing a panel assembly and structure resulting therefrom"; U.S. Patent Application No. 5,471,809 by Frankel, titled "Composite building materials from recyclable waste"; U.S. Patent Application No. 5,789,477 by Nosker et al., titled "Composite building materials from recyclable waste"; U.S. Patent Application No. 6,497,956 by Phillips et al., titled "Structural recycled plastic lumber"; U.S. Patent Application No. 6,986,934, U.S. Patent Application No. 7,169,460, U.S. Patent Application No. 7,211,310, U.S. Patent Application No. 7,419,717, U.S. Patent Application No. 7,763,345, U.S. Patent Application No. 8,021,741, U.S. Patent Application No. 8,658,274, and U.S. Patent Application No. 8,834,992 by Chen et al., titled "Thermoplastic planks and methods for making the same"; U.S. Patent Application No. 7,795,329 by Nosker et al., titled "Use of recycled plastics for structural building forms"; U.S. Patent Application No. 8,629,221 by Nosker et al., titled "Compositions and methods of making plastic articles";U.S. Patent Application No. 8,752,348 by Bowman, titled "Composite pre-formed construction articles"; Des 211,517 by Pettier, titled "Extruded cellular panel for furniture"; Des 423,116 by Gregori, titled "Decking"; Des 431,658 by Gregori, titled "Decking"; Des 451,612 by Thibault et al., titled "Top of a deck member"; Des 453,045 by Ohanesian, titled "Post for a storage shed"; Des 473,955 by Gregori, titled "Structural member"; Des 474,286 by Gregori, titled "Structural member"; Des 485,373 by Morton et al., titled "Deck plank extrusion"; Des 531,324 by Takagi, titled "Deck plank extrusion"; Des 564,678 by Simko, titled "Construction member"; and Des 585,568 by Kikuchi, titled "Synthetic board for building purposes".;

[0010] Presumably, as may be apparent, despite the enormous progress and extensive research and development that have been made, there remains a need for a cost-effective alternative to wood lumber that overcomes both the geometric limitations and vulnerabilities to the environment, pests, and warping while retaining the advantages of easy cutting and fastening of wood, is reusable, and can be easily cleaned.

[0011] In addition to the foregoing patents, Webster's New Universal Unabridged Dictionary, Second Edition copyright 1983 is hereby incorporated by reference in its entirety for definitions of words and terms used herein. SUMMARY OF THE INVENTION

[0012] In a first statement, the invention is a building construction stud including the following: a generally adjacent outer wall of plastic defining a length, width, depth, a cross-section transverse to the length, and an interior, the interior being substantially contained within the generally adjacent outer wall of plastic; at least one empty space generally parallel to the generally adjacent outer wall of plastic and substantially contained within the interior; and at least one fastener fixing and structural reinforcement substantially contained within the interior.

[0013] In a second aspect, the invention is a combination of a building construction stud, a building construction sheathing panel, and at least one fastener for attaching the building construction sheathing panel to the building construction stud. The building construction stud includes a stud length, a stud width, a stud depth, a stud cross-section transverse to the stud length, and generally adjacent plastic stud outer walls defining the stud interior. The stud interior is substantially contained within the generally adjacent plastic stud outer walls. The plastic stud outer walls include a generally flat first sheathing surface parallel to the stud outer wall longitudinal and width axes, a generally flat second sheathing surface distal to and generally parallel to the first sheathing surface, a generally flat first stud side wall parallel to the stud outer wall longitudinal and width axes, a generally flat second stud side wall distal to and generally parallel to the first stud side wall, and at least one void space generally adjacent to and longitudinally parallel with the plastic stud and substantially contained within the stud interior. The plastic stud outer wall length is greater than the plastic stud outer wall depth, the generally adjacent plastic stud outer wall cross-section defines a rectangle, and the generally adjacent plastic stud outer wall depth is greater than the generally adjacent plastic stud outer wall width. A plurality of longitudinally extending stud wall ribs project inwardly from the generally flat first sheathing surface. The stud wall ribs are configured to increase rigidity and strength and to enhance fastener engagement. At least one fastener passes through the building construction sheathing panel, the generally flat first sheathing surface, and each of the plurality of longitudinally extending stud wall ribs, thereby attaching the building construction sheathing panel to the building construction stud.

[0014] In a third statement, the invention is a combination of a building construction stud and a building construction stud end cap. The building construction stud includes a stud length, a stud width, a stud depth, a stud cross-section transverse to the stud length, and a generally adjacent stud outer wall of plastic that defines the interior of the stud, as well as a stud interior substantially contained within the generally adjacent stud outer wall of plastic. At least one empty space is longitudinally parallel to the generally adjacent stud of plastic and is substantially contained within the stud interior. A generally flat first sealing surface is parallel to the longitudinal and width axes of the stud outer wall. A generally flat second sealing surface is distal to and generally parallel to the generally flat first sealing surface. A generally flat first stud side wall is parallel to the longitudinal and width axes of the stud outer wall. A generally flat second stud side wall is distal to and generally parallel to the generally flat first stud side wall. The building construction stud end cap includes a terminal cap that is orthogonal to and abuts each of the generally flat first sealing surface, the generally flat second sealing surface, the generally flat first stud side wall, and the generally flat second stud side wall. At least one cap side wall rises from the terminal cap and is inserted into the stud interior. The cap top surface is surrounded by at least one cap side wall and is distal to the terminal cap.

Brief Description of the Drawings

[0015] The foregoing objects and other objects, advantages and novel features of the invention can be understood and recognized by reference to the following detailed description taken in conjunction with the accompanying drawings.

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Figure 16

Figure 17

Figure 18

Figure 19

Figure 20

Figure 21

Figure 22

Figure 23

Figure 24

Figure 25

Figure 25a

Figure 25b

Figure 26

Figure 27

DETAILED DESCRIPTION OF THE INVENTION

[0016] As set forth in the preferred embodiment, the present invention generally provides a polymeric building component having adjacent outer walls, at least one, preferably a plurality of, longitudinally extending hollow portions or void spaces within the outer walls, and, in some embodiments, structural reinforcement and fastener securing internal webs that divide and define the hollow portions.

[0017] In the preferred embodiment of the present invention shown in FIGS. 1 and 3, the construction stud 10 is composed of an outer wall 11, at least one secondary fastener securing and internal reinforcement 12, and a void space 14. In this preferred embodiment, at least two secondary fastener securing and internal reinforcements 12 are provided and arranged to define an X-shaped cross-section therebetween, creating a semi-open profile with an excellent strength-to-weight ratio.

[0018] Although shown as having a somewhat uniform thickness, the outer wall 11 is slightly thicker on the narrower vertically extending surfaces than on the wider surfaces in some embodiments. In those embodiments, an additional wall thickness is selected to assist in the attachment of nails and screws. Again for illustrative and non-limiting purposes, a 2×4 standard dimensional stud has actual dimensions of 1.5×3.5 inches. The 1.5-inch face is typically in contact with a wall, sheathing, etc. As a result, fasteners for attaching drywall or other panels or sheathing penetrate the 1.5-inch face. At this time, the additional thickness on the 1.5-inch face provides a somewhat more secure attachment. As shown in FIG. 1, the outer wall 11 includes a generally flat first sheathing surface 11a that is parallel to the outer wall longitudinal axis and the width axis. The generally flat second sheathing surface 11b is distal to and generally parallel to the generally flat first sheathing surface 11a. The side walls 11c and 11d include generally flat surfaces that are perpendicular to the first and second sheathing surfaces 11a and 11b and parallel to the outer wall longitudinal axis and the width axis of the outer wall 11.

[0019] These foregoing definitions of the width axis and the depth axis are provided solely for convenience in referring to the various faces of the outer wall 11 and are selected herein to correspond to the building outer wall when the stud 10 is used as a vertical wall stud. In such a case, the building outer wall height axis is parallel to the outer wall 11 longitudinal axis, the building outer wall width axis is parallel to the outer wall 11 width axis, and the building outer wall depth axis or thickness axis is parallel to the outer wall 11 depth axis. Nevertheless, such designations are for convenience and understanding only and are understood not to limit the invention in any way.

[0020] The interior of the preferred embodiment construction stud 10 includes two secondary fastener fixings and internal reinforcing members 12 arranged in an X pattern, creating four empty spaces 14 each having a triangular prism geometry. In the preferred embodiment construction stud 10, the space 14 between the internal reinforcing members 12 is open to the atmosphere. Although not preferred for many reasons including more difficult initial fabrication, more difficult installation by construction workers, and much more difficult reuse at the end of the building's life, in some alternative embodiments, these spaces are filled with a suitable solid or foamed material including, for illustrative and non-limiting purposes, wood, resin and plastic, metal, ceramic or cement materials, or combinations or composites of the foregoing. In yet another alternative embodiment, for example, only some of these spaces at both ends or at periodic locations or at predetermined intermediate locations are filled with additional material.

[0021] The internal reinforcing members 12 help reduce heat and sound transmission while also improving the strength-to-weight ratio. Further, these internal reinforcing members 12 provide a second fixing point for fasteners installed within the preferred embodiment construction stud 10. This helps ensure that the fasteners are securely fixed by providing additional grip to prevent the fasteners from backing out, which is extremely beneficial. While in some embodiments a single pair of internal reinforcing members 12 arranged in an X pattern may be sufficient, the preferred embodiment construction stud 10 instead comprises three pairs of internal reinforcing members 12 with each pair arranged in an X pattern. Each pair of internal reinforcing members 12 is separated from adjacent pairs by cell dividers and internal reinforcing members 13 so that both add reinforcing strength to the preferred embodiment construction stud 10 and divide the interior of the preferred embodiment construction stud 10 into several smaller sections.

[0022] One particularly notable benefit of subdividing the internal space within the preferred embodiment construction stud 10 is that fasteners of reasonable length are much more likely to penetrate not only the outer wall 11, but also at least one of the internal reinforcing members 12 and 13, and possibly several. As already noted above, achieving this is highly beneficial to ensure that the fastener is firmly fixed or remains firmly fixed.

[0023] The preferred embodiment construction stud 10 is preferably made entirely and solely from plastic containing any suitable combination of unused or recycled inclusions and is particularly suitable for internal non-load-bearing applications. In the most preferred embodiments, the plastic composition forming the bulk of the stud 10 is homogeneous and uniform, which greatly facilitates recycling. Nevertheless, it is also understood that in some of the most preferred embodiments where the bulk of the stud 10 is homogeneous and uniform, various compositional or nominally surface coatings, treatments or finishes lacking in homogeneity or uniformity may be applied with respect to the bulk of the stud 10.

[0024] The benefits of plastic are that plastic is not necessarily subject to the same degree and timing of price fluctuations as wood and other natural materials. In addition, plastic can be completely recyclable if not exposed to significant amounts of ultraviolet light, especially when used indoors. Preferred materials can be ground and reused, reused for alternative products, or filled for concrete when recovering construction waste or during either the demolition or renovation of a building several years later. As a result, in some life cycles, plastic can present potential carbon offsets. Plastic is not a food source for pests and fungi and has no problems associated with flooding, or warping associated with moisture content or humidity changes. Plastic can also be easily washed and cleaned on site. This is particularly desirable in areas where there is a large amount of rainfall, a high water table, moisture, water penetration, or other risks of exposure, insect activity, or a lack of available wood.

[0025] Nevertheless, in some alternative embodiments, there are requirements or purposes that result in such alternative embodiments that include plastics mixed with other materials. For purposes of illustration and not limitation, some load-bearing applications may benefit from the incorporation of glass or other reinforcing fibers.

[0026] In some embodiments, caps are provided that encompass and reinforce the ends and adjacent structures to which the studs are attached to facilitate the attachment of the preferred embodiment construction studs 10 adjacent to both ends. Preferred caps are shown in FIGS. 26 and 27 described herein below. In other embodiments, where a predetermined length that is not further cut is known and required, the ends are filled or reinforced with additional material. In yet other embodiments, where a predetermined length including a cut to an intermediate length is known and required, the intermediate portion of the void space 14 is selectively filled or otherwise reinforced to accommodate a plurality of predetermined potential lengths that are used or required in the field.

[0027] Various embodiments of the devices designed in accordance with the present invention are shown in various figures. Some embodiments are identified by three-digit numbers, and the various parts within each embodiment are designated by single-digit numbers. However, since many of the parts are similar or the same between embodiments, the single-digit numbering is maintained where possible, such that the same, similar, or like functions can be more readily identified between some embodiments. Unless otherwise indicated, one of ordinary skill in the art will readily recognize these similarities and understand that, in many cases, similarly numbered single-digit parts can be substituted from one embodiment to another in accordance with this teaching, except where such substitution would impair the operation of some embodiments. As a result, one of ordinary skill in the art can readily determine the functions and operations of many of the parts shown herein without unnecessary additional explanation. Additionally, the various alternative embodiments exhibit features that are understood to be applicable to other embodiments whose significance and desirability will be readily determined by one of ordinary skill in the art upon examination of this disclosure.

[0028] FIG. 1 shows a profile or open view of a preferred embodiment construction stud 10 that could be made in a familiar 2×4 standard dimensional lumber geometry. FIG. 2 shows a similar profile or open view of an alternative embodiment construction stud 20 that could be made in a familiar 2×6 standard dimensional lumber geometry. The two embodiments are otherwise very similar, but the alternative embodiment construction stud 20 with a larger 5.5 - inch dimension has a total of four cells, each having a pair of internal reinforcements 22 arranged in an X - pattern. Each pair is separated from adjacent pairs by cell dividers and internal reinforcements 23 (a total of three of these are depicted).

[0029] FIG. 3 shows a simple rectangular side view of the preferred embodiment construction stud 10, showing a generally flat first sheathing surface 11a, with the stud 10 shown horizontally on the page in this view. As shown, the length of the preferred embodiment construction stud 10 is indefinite, but typical standard lengths for illustrative and non - limiting purposes could be 96 inches, 120 inches, and 144 inches. A side view of the alternative embodiment construction stud 20 is consistent with this.

[0030] FIGS. 4 and 6 show a second alternative embodiment construction stud 30. Most of these components are similar or the same as those of the preferred embodiment construction stud 10, but the second alternative embodiment construction stud 30 additionally includes tabs 36 that can be used to eliminate the need for studs at corners. The second alternative embodiment construction stud 30, and the third alternative embodiment construction stud 40 shown in FIG. 5, each have such tabs 36, 46 that extend within a 1.5 - inch plane. These tabs 36 and 46 eliminate the need for studs at corners by creating proper spacing and contact for drywall, etc. at the corners.

[0031] FIG. 7 shows a fourth alternative embodiment construction stud 30' that is similar to that of FIG. 4 and is not separately numbered, but still has tabs 36' extending from the corner between the 1.5-inch face and the 3.5-inch face. However, in this fourth alternative embodiment construction stud 30', the tabs run parallel to the face of the 3.5-inch face. Again, this tab 36' is configured to eliminate the stud at the corner by creating proper spacing and contact for drywall and the like at the corner.

[0032] FIGS. 8 and 10 show a fifth alternative embodiment construction stud 50. Most of these components are again similar to or the same as those of the preferred embodiment construction stud 10, but the fifth alternative embodiment construction stud 50 is described as a top stud and thus includes a pair of tabs 56. The tabs 56 are provided to extend within the planes of the side walls 51c and 51d, allowing drywall to impact into the stud and providing space for the truss or ceiling beam to expand and contract. The fifth alternative embodiment construction stud 50 and the sixth alternative embodiment construction stud 60 shown in FIGS. 8 and 9 respectively have tabs 56, 66 that extend within the planes of this side wall.

[0033] Figures 11 and 13 show the seventh alternative embodiment construction stud 70. In this embodiment, the second fastener fixing structure and internal reinforcement 12 and the cell divider and internal reinforcement 13 of the preferred embodiment construction stud 10 are each replaced by an "I" geometry internal structure that is generally parallel to and near the substantially flat first and second seaming surfaces 71a, 71b and includes two internal reinforcements 75 that extend in a plane close thereto. The long central internal reinforcement 77 is placed substantially centrally between the two side walls 71c, 71d and extends in a plane parallel thereto. In this seventh alternative embodiment construction stud 70, the fastener driven into the stud 70 from the generally flat first seaming surface 71a first penetrates the outer wall 71, then penetrates a small void 74, and then penetrates the adjacent internal reinforcement 75. As already explained in the foregoing specification, this significantly helps to ensure that nails, screws and other fasteners have a permanent holding force. The eighth alternative embodiment construction stud 80 has internal reinforcements that are of a very similar "I" geometry but are rather of an exemplary 2×6 format than the exemplary 2×4 format of FIG. 11.

[0034] The ninth alternative embodiment construction stud 90 shown in FIGS. 14 and 16 and the tenth alternative embodiment construction stud 100 shown in FIG. 15 each have a geometry similar to that of the seventh alternative embodiment construction stud 70. However, instead of having a single long central disposed internal reinforcement 77, the ninth alternative embodiment construction stud 90 has a pair of long internal reinforcements 97 that are each spaced a proportionally small distance from the nearest adjacent side walls 91c, 91d. These construction studs 90 and 100 provide greatly improved fastener holding force regardless of whether the fastener is driven from the seaming surfaces 91a, 91b, 101a, 101b or from the side walls 91c, 91d, 101c, 101d.

[0035] Figures 17, 18, and 21 show the preferred embodiment construction sheathing panel 200. As depicted, the panel 200 has a basic sheet-like geometric shape with a relatively large length and width and a relatively small thickness or depth. For illustrative and non-limiting purposes, exemplary dimensions of the preferred embodiment construction sheathing 200 include the following: 4’×8’×1 / 2” or 5 / 8” for walls and floors; or 2’×12’×1 / 2” for ceilings. As best seen in FIG. 18, the preferred embodiment construction sheathing panel 200 preferably includes a tongue 206 and a mating groove 208 provided along both edges, most commonly the longitudinal edges. The tongue 206 and the groove 208 function in a known manner, enabling the installer to abut the sheets against each other in a better-fixed and sealed interlocking manner. Although not shown, in some embodiments, the construction sheathing panel designed in accordance with the teachings of the present invention has a grooving to assist with structural requirements.

[0036] Figures 19 and 20 show a first alternative embodiment construction sheathing panel 210 having similar or like tongues 216 and mating grooves 218. However, in this first alternative embodiment construction sheathing panel 210, an internal geometry similar to that of the preferred embodiment construction stud 10 is preferably provided. The outer wall 211 forms an outer enclosure centered on a plurality of cells defined by cell dividers and internal reinforcements 213, and provided within each cell are a pair of second fastener attachment structures and internal reinforcements 212, each of which functions in a manner similar to similar components found within the preferred embodiment construction stud 10. In some embodiments including the first alternative embodiment construction sheathing panel 210, a thicker outer face 219 may be provided depending on the needs or desires of a particular application. In other embodiments, the outer wall 211 is instead of a consistent thickness.

[0037] While the preferred or alternative embodiment studs can be of any suitable opacity, the construction sheathing panels 200 and 210 are preferably transparent or translucent. This allows a carpenter or other person constructing the structure to save time by being able to see studs such as the preferred embodiment construction studs 10 through the sheathing, thereby being able to measure and estimate the stud locations and subsequently attach to the studs without having to blindly fix them. In addition to the transparency or translucency of the panels, the sheathing in most embodiments is also paintable to allow for opacity, custom coloring or decoration, and to reduce or prevent ultraviolet damage to the plastic. This also provides potential labor savings by reducing the need for taping or covering the sheetrock with paint and texture.

[0038] An eleventh alternative embodiment construction stud 110 is shown in FIGS. 22, 24, and 25. Instead of having spreading internal reinforcement, this eleventh alternative embodiment construction stud 110 provides internal projecting wall ribs 118 that increase rigidity and strength without increasing the overall wall thickness, thereby keeping the overall weight and material consumption to a minimum. The wall ribs 118 are shown in FIGS. 22, 24, and 25 and are provided only on the sheathing surfaces 111a, 111b where the drywall or panel is to be attached. Nevertheless, in some alternative embodiments, more or fewer inner surfaces of the stud 110 are provided with the wall ribs 118.

[0039] As shown in the greatly exaggerated Figure 25a for communicating what would otherwise be difficult to convey visually, a fastener such as screw 2, or in an alternative embodiment a nail or other through-type fastener, is driven into the sealing surface 111a, and both the sealing surface 111a and the wall rib 118 are pushed, thereby bending or deforming in the direction of the opposing sealing surface 111b. This bending causes the sealing surface 111a to be more likely to arc such that a portion of the wall rib 118 that projects most into the interior of the stud 110 spreads away from an adjacent similar portion of the wall rib 118. This net effect of the spreading-apart adjacent wall ribs 118 enables the fastener 2 to penetrate the stud 110 (more easily than if there were no bending within the first sealing surface 111a) with a minimum additional interference from the wall rib 118.

[0040] However, for communicating what would otherwise be difficult to convey visually, and as shown in the greatly exaggerated Figure 25b, when a fastener such as screw 2 is pulled away from the stud 110 (e.g., when a force is applied that tends to pull out a drywall, the sealing 200, or other object secured to the stud 110), the resulting force tends to cause the sealing surface 111a to arc away from the opposing sealing surface 111b. This movement causes each of the portions of the wall rib 118 that project most into the center of the stud 110 to be drawn closer together and out towards an adjacent similar portion of the wall rib 118. This net effect of drawing the adjacent wall ribs 118 together increases the force required to pull the fastener out of the stud 110, thereby creating additional interference from the wall rib 118. As a result, the addition of the wall rib 118 increases the force required to insert the fastener, and these same wall ribs increase the force required to pull or extract the fastener from the stud 110, with the former force being less than the latter force. Additionally, these wall ribs require both less material and less total weight than if the outer wall of the stud 110 were simply made thicker.

[0041] As will be appreciated, in some embodiments, each of the material, dimensions, and overall geometric shape of the wall rib 118, the first sealing surface 111a, and the fastener 2 can be varied to meet the needs of a particular application. For illustrative and non-limiting purposes, the width of the valleys between the protruding teeth and the width of the protruding teeth can each be increased or decreased to be appropriate for optimal functioning with a particular size or type of fastener.

[0042] The twelfth alternative embodiment construction stud 120 shown in FIG. 23 incorporates a wall rib 128 having a similar geometric shape and function into the wall rib 118. These wall ribs 121 are further combined with a pair of internal reinforcements 125, each spaced a relatively small distance from the adjacent ribbed wall 121. Since the internal reinforcements 125 have a similar geometric shape and function to the internal reinforcements 75 of the seventh alternative embodiment construction stud 70, the stud 120 provides even greater holding power and structural rigidity. As will likely be apparent, these construction studs 110 and 120 provide improved fastener holding power.

[0043] FIGS. 26 and 27 show preferred or alternative embodiment stud caps 300 and 310. In these embodiments, both stud caps 300 and 310 have a solid that caps the terminal end of the stud. For illustrative purposes, the stud cap 300 is configured to terminate the stud 120, while the stud cap 310 is configured to terminate the stud 110. When properly placed within the end of the stud, as described hereinbelow, the fastener is driven into the solid core of the stud cap, allowing the carpenter to install the fastener from substantially any direction or angle (as is the convention with wood studs).

[0044] Both have similar features including top surfaces 302 and 312; side walls 306 and 316; ribs 308 and 318; and end caps 304 and 314. As described above, in the preferred embodiments of the stud end caps 300, 310, the volume within the space defined by the top surfaces 302 and 312; side walls 306 and 316; and end caps 304 and 314 is solid. Nevertheless, in some alternative embodiments, there will be a limited airspace, and in still other alternative embodiments, there will be a predetermined web similar to internal reinforcements (such as 12, 13, 75, and 77).

[0045] As is apparent from the inspection of FIGS. 26 and 27, the side wall 316 defines a volume that extends substantially over the entire end cap 314, exposing only a small tongue or overhang of the end cap 314 in FIG. 27. This small tongue or overhang is configured to engage the outer wall 111 when the stud cap 310 is fully and properly inserted into the end of the stud 110, thereby preventing the stud cap 310 from dropping into the stud 110 beyond the end cap 314. The stud 120 has an additional internal reinforcement 125 that makes the open void space 124 of a smaller cross-section than that of the cavity 114, so the side wall 306 leaves a much larger tongue or overhang exposed on the end cap 304.

[0046] In addition, the side wall 316 forms a plane orthogonal to the top surface 312 and the end cap 314. In contrast, the side wall 306 is not flat, and as a result the top surface 302 is slightly smaller. The rib 318 is configured to engage the inside of the outer wall 111, creating a slight plastic deformation therebetween in the manner of a bottle stopper to ensure a good and robust fit therebetween. However, like the stopper, the slightly smaller top surface 302 allows this surface to be inserted with a less precise alignment more easily before the rib 308 engages the outer wall 121, making the installation not overly difficult.

[0047] The features distinguishing stud end caps 300 and 310 from each other are provided for illustrative purposes and are not mutually exclusive. In other words, for purely illustrative and non-limiting purposes, in some alternative embodiments, the larger tongue defined by end cap 304 is used in combination with sidewall 316 that is flat and disposed orthogonally. Further, each of stud end caps 300 and 310 is shown having top surfaces 302 and 312 that are generally flat and parallel to end caps 304, 314, but in some alternative embodiments, top surfaces 302 and 312 comprise notches or cutouts corresponding to internal webs created by the following features: second fastener securing structures and internal reinforcements 12, 22, 32, 42, 52, 62, 72, 82, 92, 102; cell dividers and internal reinforcements 13, 23, 33, 43, 53, 63; internal reinforcements 75, 85, 95, 105, 125; long central internal reinforcements 77, 87, 97, 107; and wall ribs 118, 128.

[0048] As may be apparent from the foregoing, various embodiments of the present invention utilize only plastic building components. There are two main components corresponding to plastic building materials: the first is a structural stud and the second is a sheathing. Both of these structures include an outer wall and are hollow, serve as structural reinforcements, and have additional internal reinforcements that improve fastener holding power. The combination of the outer wall, the internal reinforcements, and the cavities therein delays heat and sound transmission while also providing a good strength-to-weight ratio and less material usage. Further, the materials used are only plastics whose advantages are fully described hereinabove.

[0049] The specific plastic used has many requirements. The first requirement is that the type of plastic used preferably has low creep. Creep is the low-temperature flow of the plastic that causes permanent distortion of the plastic. Further, the plastic is such that the structure interacts favorably with the selected fasteners in a way that prevents the fasteners, screws, and nails (for illustrative and non-limiting purposes) from loosening or withdrawing while being loaded by events such as opening and closing doors and windows; normal impacts and blows into the wall; and wind, rain, and snow in the case of load-bearing installations.

[0050] Industrial Applicability Exemplary embodiments of the present invention solve the inadequacies of the prior art by providing a homogeneous and single-plastic building construction stud having a generally adjacent outer wall of plastic; at least one longitudinal space substantially contained therein and parallel to the generally adjacent outer wall of plastic; and at least one fastener fixing and structural reinforcement substantially contained therein.

[0051] The present invention and preferred and alternative embodiments have been developed for many purposes. Not all of these purposes are found in every embodiment, but these purposes nevertheless provide a sense of general intent and many possible advantages available from the embodiments of the present invention.

[0052] A first object of the present invention is to provide an improved high-cost efficiency building component used for constructing a building. As a result, an object of the present invention is to require less material for a given length and strength requirement, and less material generally cools more rapidly, which is beneficial both in terms of the cost of the material and during manufacturing. A second object of the present invention is to facilitate on-site building construction and renovation by the building components being easily and safely cut or otherwise processed by construction workers and being easily cleaned as required. As a result, an object of the present invention is to use materials that are not dangerous to construction workers during building construction. Another object of the present invention is to reduce vulnerability to the environment and pests. Another object of the present invention is that the building components are easily reused at the end of the building's life. Yet another object of the present invention is to provide suitable fastener fixability.

[0053] The foregoing describes what is believed to be the preferred embodiments of the present invention, but no material limitations are intended with respect to the scope of the claimed invention. Further, features and design alternatives that will be apparent to those skilled in the art are considered to be incorporated herein. The scope of the present invention is set forth and specifically described in the following claims.

Claims

1. A building construction stud (120), A continuous plastic outer wall (121) defining the length, width, depth, a cross section perpendicular to the length, longitudinal axis, width axis, depth axis, and interior, wherein the interior is substantially housed within the outer wall. A first covering surface (121a) parallel to the longitudinal axis and width axis of the outer wall, A second coating surface (121b) spaced apart from and parallel to the first coating surface, A first side wall (121c) parallel to the longitudinal axis and depth axis of the outer wall, and A second side wall (121d) spaced apart from and parallel to the first side wall. An exterior wall (121) equipped with, A plurality of longitudinally extending wall ribs (128) that are substantially housed within the exterior wall and extending longitudinally parallel to the longitudinal axis of the exterior wall, and a plurality of longitudinally extending wall ribs (128) that each extend from the exterior wall and project from the exterior wall into the interior of the at least one of the open spaces, wherein the wall ribs are configured to increase rigidity and strength and to enhance engagement with fasteners, The above includes at least one fastener fixing and structural reinforcing member (125) substantially contained within it, Building construction studs including

2. The building construction stud according to claim 1, wherein the exterior wall and the at least one fastener fixing and structural reinforcement material have the same composition. A building construction stud according to claim 1, including the building construction stud according to claim 1.

3. The building construction stud according to claim 1, wherein the length of the exterior wall is greater than the depth of the exterior wall, the cross-section of the exterior wall is defined as a rectangle, and the depth of the exterior wall is greater than the width of the exterior wall.

4. The building construction stud according to claim 1, wherein the at least one fastener fixing and structural reinforcing member is integral with the exterior wall.

5. The building construction stud according to claim 4, wherein the at least one fastener fixing and structural reinforcement member is substantially contained within the interior, dividing the interior into a plurality of open spaces.

6. The at least one fastener fixing and structural reinforcing member is A first fastener fixing and structural reinforcement member, which is planar, parallel to the first and second covering surfaces, positioned between the first and second covering surfaces, more adjacent to the first covering surface than to the second covering surface, extending completely between the first and second side walls, and dividing the interior into a second and third empty space, A second fastener fixing and structural reinforcement member is planar, parallel to the first fastener fixing and structural reinforcement member, positioned between the second covering surface, extending completely between the first side wall and the second side wall, and dividing the interior into a second and a third open space. The building construction stud according to claim 5, further comprising:

7. The building construction stud according to claim 3, wherein at least a first subset of the plurality of longitudinally extending wall ribs protrudes inward from the first covering surface, and the first subset of the plurality of longitudinally extending wall ribs is configured to increase rigidity and strength and to enhance engagement with fasteners.

8. The building construction stud according to claim 6, further comprising a planar third fastener fixing and structural reinforcing member extending between the first fastener fixing and structural reinforcing member and the second fastener fixing and structural reinforcing member, the planar third fastener fixing and structural reinforcing member being parallel to the first side wall.

9. A planar fourth fastener fixing and structural reinforcing member extending between the first fastener fixing and structural reinforcing member and the second fastener fixing and structural reinforcing member, the planar fourth fastener fixing and structural reinforcing member being parallel to the second side wall It further includes, The planar third fastener fixing and structural reinforcement member is adjacent to the first side wall and distal to the planar fourth fastener fixing and structural reinforcement member. The planar fourth fastener fixing and structural reinforcement member is adjacent to the second side wall and distal to the planar third fastener fixing and structural reinforcement member. The building construction stud according to claim 8.

10. Further equipped with building construction stud end caps (300), The aforementioned building construction stud end caps are: End caps (304) perpendicular to and in contact with each of the first covering surface, the second covering surface, the first side wall, and the second side wall; At least one end cap side wall (306) rising from the end cap and inserted into the stud; and The end cap top surface (302) is surrounded by the at least one end cap side wall and is distal to the end cap. including, The building construction stud according to claim 3.

11. The aforementioned at least one end cap sidewall further: It includes four end cap sidewalls, each of which rises from the end cap, defining a volume enclosed by the four end cap sidewalls, the end cap, and the top surface of the end cap; The volume has a volumetric cross-section that traverses the longitudinal axis of the stud outer wall; The volumetric cross-section has a larger area adjacent to the end cap than the top surface of the end cap. The building construction stud according to claim 10.

Images