Polymer Construction Studs and Sheathing

Abstract

A building construction stud and sheathing panel are affixed together by at least one fastener. A stud end cap terminates the stud. The stud has an outer wall that defines a pair of plastic sheathing faces and first and second side walls, and at least one longitudinally extensive void space. At least one fastener anchoring and structurally reinforcing member is contained substantially within the interior of the stud outer wall. In some embodiments, the fastener anchoring and structurally reinforcing member comprises a plurality of longitudinally extensive stud wall ribs protruding internally from the first sheathing face. In other embodiments, cell dividers are provided that are parallel with and spaced slightly from the first and second sheathing faces. In yet other embodiments, internal reinforcing members define an “X”-geometry within the cells. These fastener anchoring and structurally reinforcing members are configured to increase stiffness and strength, and also enhance fastener engagement.

I claim: 
     
         1 . A building construction stud, comprising:
 a plastic generally contiguous outer wall defining a length, width, depth, cross-section transverse to said length, and an interior, said interior contained substantially within said plastic generally contiguous outer wall;   at least one void space longitudinally extensive parallel with said plastic generally contiguous outer wall and contained substantially within said interior; and   at least one fastener anchoring and structurally reinforcing member contained substantially within said interior.   
     
     
         2 . The building construction stud of  claim 1 , wherein said plastic generally contiguous outer wall and said at least one fastener anchoring and structurally reinforcing member comprise an homogenous composition. 
     
     
         3 . The building construction stud of  claim 1 , wherein said plastic outer wall further comprises:
 a generally planar first sheathing face parallel with said outer wall longitudinal and width axes;   a generally planar second sheathing face distal to and generally parallel with said generally planar first sheathing face;   a generally planar first side wall parallel with said outer wall longitudinal and depth axes; and   a generally planar second side wall distal to and generally parallel with said generally planar first side wall.   
     
     
         4 . The building construction stud of  claim 3 , wherein said plastic outer wall length is greater than said plastic outer wall depth, said plastic generally contiguous outer wall cross-section defines a rectangle, and said plastic generally contiguous outer wall depth is greater than said plastic generally contiguous outer wall width. 
     
     
         5 . The building construction stud of  claim 1 , wherein said at least one fastener anchoring and structurally reinforcing member is unitary with said plastic generally contiguous outer wall. 
     
     
         6 . The building construction stud of  claim 4 , wherein said at least one fastener anchoring and structurally reinforcing member is contained substantially within and divides said interior into a plurality of void spaces. 
     
     
         7 . The building construction stud of  claim 6 , further comprising:
 a first cell divider and internal reinforcing member intermediate between said generally planar first sheathing face and said generally planar sheathing second face and relatively more adjacent to said generally planar first sheathing face than to said generally planar sheathing second face; and   a second cell divider and internal reinforcing member intermediate between said first cell divider and said generally planar sheathing second face.   
     
     
         8 . The building construction stud of  claim 6 , wherein said at least one fastener anchoring and structurally reinforcing member further comprises at least one pair of fastener anchoring and structurally reinforcing members arranged to define an X-shaped cross-section. 
     
     
         9 . The building construction stud of  claim 7 , wherein said at least one fastener anchoring and structurally reinforcing member further comprises:
 a first pair of fastener anchoring and structurally reinforcing members arranged to define an X-shaped cross-section within a first interior cell space defined by said generally planar first sheathing face, said first cell divider, said generally planar first side wall, and said generally planar second side wall; and   a second pair of fastener anchoring and structurally reinforcing members arranged to define an X-shaped cross-section within a second interior cell space defined by said generally planar second sheathing face, said second cell divider, said generally planar first side wall, and said generally planar second side wall.   
     
     
         10 . The building construction stud of  claim 1 , further comprising a plurality of longitudinally extensive wall ribs protruding internally from said outer wall, said wall ribs configured to increase stiffness and strength, and also configured to enhance fastener engagement. 
     
     
         11 . The building construction stud of  claim 4 , further comprising a plurality of longitudinally extensive wall ribs protruding internally from said generally planar first sheathing face, said wall ribs configured to increase stiffness and strength, and also configured to enhance fastener engagement. 
     
     
         12 . The building construction stud of  claim 1 , further comprising at least one tab protruding exterior of said outer wall and configured to engage sheathing. 
     
     
         13 . The building construction stud of  claim 7 , further comprising a generally planar third cell divider and internal reinforcing member extending between said first cell divider and internal reinforcing member and said second cell divider and internal reinforcing member, said generally planar third cell divider and internal reinforcing member parallel to said generally planar first side wall. 
     
     
         14 . The building construction stud of  claim 13 , further comprising:
 a generally planar fourth cell divider and internal reinforcing member extending between said first cell divider and internal reinforcing member and said second cell divider and internal reinforcing member, said generally planar fourth cell divider and internal reinforcing member parallel to said generally planar second side wall;   wherein said generally planar third cell divider is adjacent to said generally planar first side wall and distal to said generally planar fourth cell divider, and   wherein said generally planar fourth cell divider is adjacent to said generally planar second side wall and distal to said generally planar third cell divider.   
     
     
         15 . In combination, a building construction stud, a building construction sheathing panel, and at least one fastener affixing said building construction sheathing panel to said building construction stud,
 said building construction stud comprising:
 a plastic generally contiguous stud outer wall defining a stud length, stud width, stud depth, stud cross-section transverse to said stud length, and a stud interior, said stud interior contained substantially within said plastic generally contiguous stud outer wall, said plastic stud outer wall having
 a generally planar first sheathing face parallel with said stud outer wall longitudinal and width axes, 
 a generally planar sheathing second face distal to and generally parallel with said generally planar first sheathing face, 
 a generally planar stud first side wall parallel with said stud outer wall longitudinal and depth axes, 
 a generally planar second side wall distal to and generally parallel with said generally planar first side wall, and 
 at least one void space longitudinally extensive parallel with said plastic generally contiguous stud outer wall and contained substantially within said stud interior, 
 
 wherein said plastic stud outer wall length is greater than said plastic stud outer wall depth, said plastic generally contiguous stud outer wall cross-section defines a rectangle, and said plastic generally contiguous stud outer wall depth is greater than said plastic generally contiguous stud outer wall width; and 
 a plurality of longitudinally extensive stud wall ribs protruding internally from said generally planar first sheathing face, said stud wall ribs configured to increase stiffness and strength, and also configured to enhance fastener engagement; 
   said at least one fastener penetrating each of said building construction sheathing panel, said generally planar first sheathing face, and said plurality of longitudinally extensive stud wall ribs, and thereby affixing said building construction sheathing panel to said building construction stud.   
     
     
         16 . The combination building construction stud building construction sheathing panel, and at least one fastener of  claim 15 , wherein said building construction sheathing panel comprises:
 a plastic generally contiguous sheathing outer wall defining a sheathing length, sheathing width, sheathing depth, sheathing cross-section transverse to said sheathing length, and a sheathing interior, said sheathing interior contained substantially within said plastic generally contiguous sheathing outer wall, said sheathing outer wall having
 a generally planar first room face parallel with said outer wall longitudinal and width axes, 
 a generally planar wall cavity face distal to and generally parallel with said generally planar room sheathing face, 
 a generally planar first sheathing side wall parallel with said sheathing outer wall longitudinal and depth axes, and 
 a generally planar second sheathing side wall distal to and generally parallel with said generally planar first sheathing side wall; 
   a generally planar first sheathing cell divider and internal reinforcing member intermediate between said generally planar first sheathing side wall and said generally planar second sheathing side wall and relatively more adjacent to said generally planar first sheathing side wall than to said generally planar second sheathing side wall;   a generally planar second sheathing cell divider and internal reinforcing member intermediate between said first sheathing cell divider and internal reinforcing member and said generally planar second sheathing side wall;   a first pair of generally planar sheathing fastener anchoring and structurally reinforcing members arranged to define an X-shaped cross-section within a sheathing first interior cell space defined by said generally planar room face, said first sheathing cell divider, said generally planar first sheathing side wall, and said generally planar second sheathing side wall;   a second pair of fastener anchoring and structurally reinforcing members arranged to define an X-shaped cross-section within a sheathing second interior cell space defined by said generally planar room face, said second sheathing cell divider, said generally planar first sheathing side wall, and said generally planar wall cavity face; and   a plurality of sheathing void spaces longitudinally extensive parallel with said sheathing length and contained substantially within said sheathing interior,   wherein said plastic sheathing outer wall length is greater than said plastic sheathing outer wall depth, said plastic generally contiguous sheathing outer wall cross-section defines a rectangle, and said plastic generally contiguous sheathing outer wall depth is less than said plastic generally contiguous sheathing outer wall width.   
     
     
         17 . The combination building construction stud and building construction sheathing panel of  claim 15 , wherein said generally planar first room face has a depth parallel to said sheathing depth greater than a depth of said generally planar wall cavity face parallel to said sheathing depth. 
     
     
         18 . In combination, a building construction stud and a building construction stud end cap, said building construction stud comprising:
 a plastic generally contiguous stud outer wall defining a stud length, stud width, stud depth, stud cross-section transverse to said stud length, and a stud interior, said stud interior contained substantially within said plastic generally contiguous stud outer wall;   at least one void space longitudinally extensive parallel with said plastic generally contiguous stud outer wall and contained substantially within said stud interior;   a generally planar first sheathing face parallel with said stud outer wall longitudinal and width axes;   a generally planar second sheathing face distal to and generally parallel with said generally planar first sheathing face;   a generally planar first stud side wall parallel with said stud outer wall longitudinal and depth axes; and   a generally planar second stud side wall distal to and generally parallel with said generally planar first stud side wall;   
       said building construction stud end cap comprising:
 a terminating cap orthogonal to and abutted with each of said generally planar first sheathing face, said generally planar second sheathing face, said generally planar first stud side wall, and said generally planar second stud side wall; 
 at least one end cap side wall rising from said terminating cap and inserted within said stud interior; and 
 an end cap top face bordered by said at least one end cap side wall and distal to said terminating cap. 
 
     
     
         19 . The combination building construction stud and building construction stud end cap of  claim 18 , wherein said at least one end cap side wall further comprises four side walls, each orthogonal to each other and to said terminating cap. 
     
     
         20 . The combination building construction stud and building construction stud end cap of  claim 18 , wherein said at least one end cap side wall further comprises:
 four side walls, each of said four side walls rising from said terminating cap and defining a volume enclosed by said four side walls, said terminating cap, and said end cap top face;   wherein said volume has a volume cross-section transverse to said stud outer wall longitudinal axis; and   wherein said volume cross-section has a greater area adjacent to said terminating cap than adjacent to said end cap top face.