Corner studs and manufacturing method

Abstract

A corner stud ( 50 ) has intersecting first and second walls ( 52, 54 ) that back up corner edge portions of wallboard panels ( 40, 42 ) that meet at the inside corner. The walls ( 52, 54 ) are braced by walls ( 64, 70 ) and flanges ( 76, 78 ). Wall ( 52 ) and wall ( 70 ) may be parallel to each other and to flange ( 76 ). Wall ( 54 ) and wall ( 64 ) may be parallel to each other and flange ( 78 ). The stud ( 50, 52, 200, 202 ) may have a web bent about a longitudinal axis to form web parts separated by an inside angle (a). The angle a may be an obtuse angle below one hundred eighty degrees (180°) to about two hundred seventy degrees (270°).

1 . An elongated corner stud comprising:
 a web having opposite side edges;   sidewalls connected to the opposite side edges and extending outwardly from the web;   said web and sidewall forming a channel;   a flange extending laterally inwardly from each sidewall; and   said web being bent along a longitudinal axis, dividing the web into two parts separated by a channel side angle that is between about ninety degrees (90°) and about two hundred and seventy degrees (270°).   
   
   
       2 . The stud of  claim 1 , wherein the inside angle between the two web parts is substantially about ninety degrees (90°). 
   
   
       3 . The stud of  claim 1 , wherein the channel side angle between the two web parts is substantially about one hundred and fifty degrees (150°). 
   
   
       4 . The stud of  claim 1 , wherein the channel side angle between the two web parts is substantially about two hundred and ten degrees (210°). 
   
   
       5 . The stud of  claim 1 , wherein the channel side angle between the two web parts is an obtuse angle less than one hundred and eighty degrees (180°). 
   
   
       6 . The stud of  claim 1 , wherein the channel side angle between the two web parts is greater than one hundred and eighty degrees (180°) but less than about two hundred and seventy degrees (270°). 
   
   
       7 . An elongated sheet metal inside corner stud, comprising:
 a first wall;   a second wall;   a third wall;   a fourth wall;   said first wall having a first edge and a second edge;   said second wall having a first edge and a second edge;   said third wall having a first edge and a second edge;   said fourth wall having a first edge and a second edge;   said second edge of said first wall being connected to the first edge of the second wall;   said second edge of the third wall being connected to the first edge of the first wall;   said second edge of the third wall being connected to the first edge of the first wall;   said second edge of the second wall being connected to the first edge of the fourth wall;   said first wall being perpendicular to the second wall and the third wall, and parallel to the fourth wall;   said second wall being perpendicular to the first wall and the fourth wall, and parallel to the third wall; and   said first and second walls forming an inside corner that is adapted to be positioned to provide a backing for wallboard edges that meet at the inside corner.   
   
   
       8 . The inside corner stud of  claim 7 , further comprising a first flange connected to the first edge of the third wall and a second flange connected to second edge of the fourth wall. 
   
   
       9 . The inside corner stud of  claim 8 , wherein the first flange is substantially perpendicular to the third wall and the second flange is substantially perpendicular to the fourth wall. 
   
   
       10 . A corner stud assembly in a framing wall, comprising:
 an upper track forming an inside corner;   a lower track forming an inside corner below the inside corner formed by the upper track;   said upper track having perpendicular flanges at the upper inside corner;   said lower track having perpendicular flanges at the lower inside corner formed by the lower track;   an elongated sheet metal, inside corner stud, comprising:   a first wall;   a second wall;   a third wall;   a fourth wall;   said first wall having a first edge and a second edge;   said second wall having a first edge and a second edge;   said third wall having a first edge and a second edge;   said fourth wall having a first edge and a second edge;   said second edge of said first wall being connected to the first edge of the second wall;   said second edge of the third wall being connected to the first edge of the first wall;   said second edge of the third wall being connected to the first edge of the first wall;   said second edge of the second wall being connected to the first edge of the fourth wall;   said first wall being perpendicular to the second wall and the third wall, and parallel to the fourth wall;   said second wall being perpendicular to the first wall and the fourth wall, and parallel to the third wall; and   said first and second walls forming an inside corner that is inwardly adjacent to the flanges at the inside corners of the upper and lower tracks, and is adapted to provide a backing for wallboard edges that meet at the inside corner.   
   
   
       11 . The corner stud assembly of  claim 10 , wherein the inside corner stud comprises a first flange connected to the first edge of the third wall; and
 a second flange connected to the second edge of the fourth wall.   
   
   
       12 . The corner stud assembly of  claim 10 , wherein the first flange is perpendicular to the third wall and the second flange is perpendicular to the fourth wall. 
   
   
       13 . The corner stud assembly of  claim 10 , wherein the upper track forms an outside corner, the lower track forms an outside corner below the outside corner formed by the upper track, an elongated stud extending between the outside corner of the upper track and the outside corner of the lower track, said outside stud contacting intersecting upper and lower track flanges at the outside corner. 
   
   
       14 . The corner stud assembly of  claim 13 , wherein the outside corner stud has a web in contact with upper and lower outside track flanges and a flange in contact with upper and lower outside track flanges. 
   
   
       15 . The method of manufacturing a corner stud, comprising:
 providing an elongated sheet metal member;   roll forming the sheet metal member to give it a channel shape formed by a web, opposite sidewalls extending substantially perpendicular to the web, and flanges on the sidewalls opposite the web which are bent inwardly towards each other in co-planar parallelism; and   bending the web about a longitudinal axis to divide it into two web parts that are separated by an angle giving the web a dihedral shape.   
   
   
       16 . The method of  claim 15 , comprising bending the web to create a dihedral angle on the channel side of the stud that is larger than one hundred and eighty degrees (180°). 
   
   
       17 . The method of  claim 15 , comprising bending the web to create a dihedral angle on the channel side of the stud that is substantially about two hundred and seventy degrees (270°). 
   
   
       18 . The method of  claim 15 , comprising bending the web so that the dihedral angle is substantially about two hundred and ten degrees (210°). 
   
   
       19 . The method of  claim 15 , comprising bending the web to create a dihedral angle on the channel side of the stud that is substantially about one hundred and fifty degrees (150°). 
   
   
       20 . The method of  claim 15 , comprising bending the web by use of a sheet metal bending break.