Length adjustable composite stud and method of assembly thereof

Abstract

A length adjustable composite stud combining the advantages associated with metal studs with the advantages associated with conventional wood studs. The composite stud also allows for customized adjustments of its length using a set of simple and ergonomic steps. The composite stud includes a generally elongated frame member defining a generally open base channel. The composite stud also includes a core component configured and sized for allowing insertion thereof in the base channel. A longitudinal movement limiting structure formed by a frictional force between the core component and the frame member releasably retains the core component within the base channel in a core first position wherein a core longitudinal end is generally in register with a frame longitudinal end. The longitudinal movement limiting structure selectively allows longitudinal movement of the core component. A method for assembling the composite stud is also disclosed.

1 . A length adjustable composite stud comprising: 
 a generally elongated frame member, said frame member defining a frame longitudinal axis, a frame first longitudinal end and a generally opposed frame second longitudinal end; said frame member defining a generally open base channel, said base channel having a longitudinal channel opening;    a core component, said core component defining a core longitudinal axis, a core first longitudinal end and an opposed core second longitudinal end; said core component being at least partially insertable in said base channel with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis to form said composite stud therewith, said core component being axially and slidably movable relative to said frame member when at least partially inserted within said base channel; 
 longitudinal movement limiting means positioned between said frame member and said core component for releasably retaining said core component within said base channel in a core first position wherein said core first longitudinal end is generally in register with said frame first longitudinal end, said longitudinal movement limiting means selectively allowing longitudinal movement of said core component in a core first direction towards a core second position upon a moving force being applied on said core component, wherein when said core component is in said core second position, said core first longitudinal end protrudes from said frame first longitudinal end so as to adjust a length of said composite stud, said longitudinal movement limiting means being a frictional force occurring between frame member and said core component.  
   
   
   
       2 . The composite stud of  claim 1  further including transversal movement limiting means positioned between said frame member and said core component for preventing relative movement between said core component and said frame member in a direction other then said frame longitudinal axis when said core component is at least partially inserted within said base channel.  
   
   
       3 . The composite stud of  claim 2  wherein said frame member has a generally U-shaped cross-sectional configuration defining a frame base wall and a pair of frame side walls, at least one of said frame side walls being incurved inwardly adjacent said frame first longitudinal end so as to locally deform said U-shaped cross-sectional configuration, said incurved frame side wall being biased outwardly away by said core component when in said core first position to resiliently induce said frictional force between frame member and said core component.  
   
   
       4 . The composite stud of  claim 3  wherein said at least one of said frame side walls is plastically deformed inwardly adjacent said frame first longitudinal end so as to locally deform said U-shaped cross-sectional configuration, said deformed frame side wall being biased outwardly away by said core component when in said core first position to resiliently induce said frictional force between frame member and said core component.  
   
   
       5 . The composite stud of  claim 3  wherein: 
 said frame member has a generally U-shaped cross-sectional configuration defining a frame base wall and a pair of frame side walls; said frame base wall defining a base wall inner surface, a base wall outer surface and a pair of opposed base wall main peripheral edges; each of said frame side walls defining a corresponding side wall inner surface, a side wall outer surface, a side wall first main edge and a generally opposed side wall second main edge; each of said side wall first main edges being attached to a corresponding one of said base wall main peripheral edges; said frame side walls extending from said frame base wall so that said side wall inner surfaces are in a generally facing relationship relative to each other, said frame base wall and said frame side walls together forming said base channel; each of said frame side walls including a retaining flange extending inwardly from said side wall inner surface adjacent said side wall second main edge;    said core component having a generally rectangular cross-sectional configuration defining a core first main wall, a core second main wall, a core first auxiliary wall and a core second auxiliary wall; said core component being configured and sized so as to be insertable into said base channel with said core first main wall positioned generally adjacent said base wall inner surface and said core first and second auxiliary walls positioned generally adjacent a corresponding one of said side wall inner surface; said core first auxiliary wall being provided with a first retaining slot extending longitudinally at least partially therealong, said first retaining slot being configured and sized for receiving at least a section of one of said retaining flanges when said core component is inserted into said base channel; said core second auxiliary wall being provided with a second retaining slot extending longitudinally at least partially therealong, said second retaining slot being configured and sized for receiving at least a section of the other one of said retaining flanges when said core component is inserted into said base channel;    each said retaining flanges acting as a guiding rail for corresponding said first and second retaining slots when said core component is being axially and slidably moved relative to said frame member.    
   
   
       6 . The composite stud of  claim 2  wherein said transversal movement limiting means includes at least one retaining flange extending from said frame member, said retaining flange being configured and sized for abutting against a section of said core component when said core component is inserted in said base channel.  
   
   
       7 . The composite stud of  claim 6  wherein said at least one retaining flange further includes an in-turned lip substantially extending toward said base channel so as to facilitate insertion of said core component into said frame member from an insertion direction generally perpendicular relative to said frame longitudinal axis in a snap-like manner.  
   
   
       8 . The composite stud of  claim 7  wherein said longitudinal movement limiting means releasably retains said core component within said base channel when in said core second position.  
   
   
       9 . The composite stud of  claim 1  wherein said longitudinal movement limiting means releasably retains said core component within said base channel when in said core second position.  
   
   
       10 . A method for assembling a length-adjustable composite stud, said composite stud including a generally elongated frame member and a core component, said frame member defining a frame longitudinal axis, a frame first longitudinal end and a generally opposed frame second longitudinal end; said frame member having a generally U-shaped cross-sectional configuration defining a frame base wall and a pair of frame side walls and defining a generally open base channel, said base channel having a longitudinal channel opening, said core component defining a core longitudinal axis, a core first longitudinal end and an opposed core second longitudinal end; said core component being at least partially insertable in said base channel with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis to form said composite stud therewith, said core component being axially and slidably movable relative to said frame member when at least partially inserted within said base channel, said method comprising the steps of: 
 a) incurving inwardly at least one of said frame side walls adjacent said frame first longitudinal end so as to locally deform said U-shaped cross-sectional configuration, thereby forming a longitudinal movement limiting means being a frictional force occurring between frame member and said core component; and    b) at least partially inserting said core component in said base channel with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis to bias said incurved frame side wall outwardly away when in said core first position to resiliently induce said frictional force between frame member and said core component and form said composite stud therewith; thereby forming a longitudinal movement limiting means positioned between said frame member and said core component for releasably retaining said core component within said base channel in a core first position wherein said core first longitudinal end is generally in register with said frame first longitudinal end, said longitudinal movement limiting means selectively allowing longitudinal movement of said core component in a core first direction towards a core second position upon a moving force being applied on said core component, wherein when said core component is in said core second position, said core first longitudinal end protrudes from said frame first longitudinal end so as to adjust a length of said composite stud, whereby said longitudinal movement limiting means being a frictional force occurring between frame member and said core component.    
   
   
       11 . The method of  claim 10 , wherein step b) includes: 
 b1) at least partially inserting said core component in said base channel with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis; and    b2) axially sliding said at least partially inserted core component into said base channel toward said frame first longitudinal end to bias said incurved frame side wall outwardly away when in said core first position to resiliently induce said frictional force between frame member and said core component and form said composite stud therewith.    
   
   
       12 . The method of  claim 11 , wherein step a) includes: 
 a) plastically deforming inwardly said at least one of said frame side walls adjacent said frame first longitudinal end so as to locally deform said U-shaped cross-sectional configuration, whereby said deformed frame side wall is biased outwardly away by said core component when in said core first position to resiliently induce said frictional force between frame member and said core component.    
   
   
       13 . The method of  claim 12 , wherein step b2) includes: 
 b2) axially sliding said at least partially inserted core component into said base channel toward said frame first longitudinal end to bias said deformed frame side wall outwardly away when in said core first position to resiliently induce said frictional force between frame member and said core component and form said composite stud therewith.    
   
   
       14 . The method of  claim 11 , wherein step b1) includes: 
 b1) axially and slidably inserting at least a section of said core component in said base channel from one of said frame first and second longitudinal ends with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis.    
   
   
       15 . The method of  claim 14 , wherein step b1) occurs before step a).  
   
   
       16 . The method of  claim 11 , wherein step b1) includes: 
 b1) inserting at least a portion of said core component in said base channel from an insertion direction generally perpendicular relative to said frame longitudinal axis in a snap-like manner with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis.    
   
   
       17 . A method for assembling a length-adjustable composite stud, said composite stud including a generally elongated frame member and a core component, said frame member defining a frame longitudinal axis, a frame first longitudinal end and a generally opposed frame second longitudinal end; said frame member having a frame peripheral wall defining a generally U-shaped cross-sectional configuration defining a generally open base channel, said core component defining a core longitudinal axis, a core first longitudinal end and an opposed core second longitudinal end; said core component being at least partially insertable in said base channel with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis to form said composite stud therewith, said core component being axially and slidably movable relative to said frame member when at least partially inserted within said base channel, said method comprising the steps of: 
 a) incurving inwardly at least a portion of said frame peripheral wall adjacent said frame first longitudinal end so as to locally deform said U-shaped cross-sectional configuration, thereby forming a longitudinal movement limiting means being a frictional force occurring between frame member and said core component; and    b) at least partially inserting said core component in said base channel with said core longitudinal axis in a generally parallel relationship relative to said frame longitudinal axis to bias said incurved frame peripheral wall outwardly away when in said core first position to resiliently induce said frictional force between frame member and said core component and form said composite stud therewith; thereby forming a longitudinal movement limiting means positioned between said frame member and said core component for releasably retaining said core component within said base channel in a core first position wherein said core first longitudinal end is generally in register with said frame first longitudinal end, whereby said longitudinal movement limiting means being a frictional force occurring between frame member and said core component.