Foldable metal wall frame assemblies for use in residential and commercial structures

Abstract

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

1 . A foldable wall frame comprising: 
 first and second track members spaced from each other with each said track member having a center web and a pair of opposite side flanges;    a plurality of spaced stud elements, each having a first and a second end portion, and positioned between and substantially perpendicular to said track members;    a first attachment element for pivotally securing said first end portion of each said stud element to said first track member; and    a second attachment element for pivotally securing said second end portion of each said stud element to said second track member, said first and second pivotal attachment elements enabling the first track member to be folded down proximate said second track member for storage and transportation.    
   
   
       2 . The foldable wall frame of  claim 1 , wherein said first and second attachment elements each comprise a clip member having a pair of apertures, and a fastener attaching one said aperture to an adjacent track member.  
   
   
       3 . The foldable wall frame of  claim 1 , wherein said frame includes removable retention members to selectively engage and hold the end portions of a stud element in said track members when said frame is in an unfolded position.  
   
   
       4 . The foldable wall frame of  claim 1 , wherein said frame is selected from the group consisting of metal and wood.  
   
   
       5 . The foldable wall frame of  claim 1 , wherein said stud end portions are adapted for engagement with said track web portion upon unfolding of said frame to create a load-bearing wall.  
   
   
       6 . The foldable wall frame of  claim 1 , wherein said wall frame further comprises collapsible spacer members adapted for engaging the end portions of said stud elements to position said stud elements relative to said track members during formation and adapted for collapsible removal upon folding and transport of said wall frame, each said spacer member including two interacting wedge elements and means for releasably attaching said wedge elements together to expand said spacer member for supporting load transfer through said stud element from said upper track member to said lower track member.  
   
   
       7 . The foldable wall frame of  claim 2 , wherein said spacer members are adapted to engage said stud end portions upon unfolding of said frame to create load-bearing walls.  
   
   
       8 . The foldable wall frame of  claim 1 , wherein said wall frame further includes a pair of substantially parallel, transversely oriented notches disposed in the lower track web along the inside edges of adjacent studs to mark door frame positions.  
   
   
       9 . The foldable wall frame of  claim 1 , wherein each said stud member includes a center web portion having at least one elongated opening therein defined by a substantially elliptical edge, each opening having a pair of side slots disposed opposite each other in said elliptical edge, and wherein said wall frame further comprises an elongated brace member having a pair of opposite elongated side portions and at least two pairs of opposing notches disposed in the edges of said elongated side portions at the axial ends, said notches interengaging said elliptical edge slots to firmly hold said brace member between adjoining studs of said wall frame.  
   
   
       10 . The foldable wall frame of  claim 1 , wherein said track member center web includes a pair of raised transfer pads defining a depression cavity therebetween at the junction of said stud element end portions and track member web to enhance the transfer of structural loads from said first track member to said second track member through said stud elements when said wall frame is in a fully unfolded and erect position.  
   
   
       11 . A foldable wall frame comprising: 
 upper and lower track members each having a center web and a pair of opposite side flanges, said track members being spaced from each other with their respective side flanges projecting toward each other;    a plurality of spaced stud elements each having a center web, a pair of opposite side flanges and a pair ledge portions projecting inwardly from the edges of said flanges, each stud element having first and second end portions and being arranged substantially parallel between said track members;    a first attachment element for pivotally securing the first end portion of each said stud element to said upper track member;    a second attachment element for pivotally securing the second end portion of each said stud element to said lower track member, said first and second pivotal attachment elements enabling said upper track member to be folded down proximate said second track member for storage and transportation; and    a load transferring mechanism disposed at the junctions of said first and second stud end portions and said upper and lower track members for enhancing and creating reliable load transference between said upper and lower track members when said wall frame is in a fully unfolded and erect position.    
   
   
       12 . The foldable wall frame of  claim 11 , wherein each said load transferring mechanism comprises removable members to convert non-load bearing stud elements in said wall frame to load bearing elements to create reliable load transference in said wall frame when in an unfolded and erect position.  
   
   
       13 . The foldable wall frame of  claim 12 , wherein each said load transferring mechanism comprises removable retention members to selectively engage and maintain the first and second end portions of a stud element against the center web of said track members when said frame is in an unfolded position.  
   
   
       14 . The foldable wall frame of  claim 12 , wherein each said load transferring mechanism comprises collapsible spacer members adapted for engaging the end portions of said stud elements to position said stud elements relative to said track members during formation and adapted for collapsible removal upon folding and transport of said wall frame, each said spacer member including two interacting wedge elements and means for releasably attaching said wedge elements together to expand said spacer member for supporting load transfer through said stud element from said upper track member to said lower track member.  
   
   
       15 . The foldable wall frame of  claim 11 , wherein each said load transferring mechanism comprises a pair of raised transfer pads defining a depression cavity therebetween disposed in each said track member center web at the junction of said stud element end portions and track member web, said transfer pads enhancing the transfer of structural loads from said upper track member to said lower track member through said stud elements when said wall frame in a fully unfolded and erect position by substantially reducing the effect of the curvature radius between the center web and side flanges of each track member.  
   
   
       16 . The foldable wall frame of  claim 11 , wherein each said load transferring mechanism further includes a spring mechanism adapted for assisting in the relative movement between said upper and lower track members during the folding and the unfolding of said wall frame.  
   
   
       17 . An elongated brace member for laterally supporting adjoining studs of a wall frame, said frame including a pair of tracks and a plurality of studs interconnected at their ends between said pair of tracks, each said stud having a central web portion and side flanges, said brace member comprising: 
 an elongated support element having first and second end portions, a pair of elongated side edges extending between said support element end portions, and a channel defined along the center of said support element and extending between said end portions;    a first pair of opposing notches defined in said side edges proximate said support element first end portion; and    a second pair of opposing notches defined in said side edges proximate said support element second end portion, said first and second pairs of notches being sized and shaped for removable engagement with adjoining studs to provide lateral support thereof.    
   
   
       18 . The brace member of  claim 17 , wherein said support element second end portion includes a third pair of opposing notches defined in said side edges and spaced a distance inwardly from said second pair of notches approximately equal to the width measurement of a stud side flange.  
   
   
       19 . The brace member of  claim 18 , wherein said support element channel is sized to carry electrical and fluid conduit members.  
   
   
       20 . The brace member of  claim 17 , wherein each said adjoining stud includes at least one elliptically-shaped opening defined by an elliptical edge in the center web portion thereof, said opening including a pair of opposed slots disposed in the elliptical edge thereof, and wherein said notches of said brace member support element are sized and shaped for snug engagement with the slots of said stud elliptical opening to maintain said brace member in firm support position between said adjoining studs.