Framing members to enhance thermal characteristics of walls

Abstract

Various metal framing members enhance thermally insulative characteristics of a wall. Framing members include a metal stud with a web portion having through-holes that include at least one piece of retained material. Each of the through-holes lengthens or disrupts thermally conductive paths across the framing member, forming convoluted or serpentine thermal paths. The through-holes are arranged in a pattern that defines a truss structure that includes a number of straight-line web sections that extend uninterruptedly diagonally across a width of the web portion. Framing members include tracks, to hold metal studs, each with a web portion with through-holes that lengthen or disrupt thermally conductive paths. The framing members may be the result of a continuous manufacturing processing, formed of a unitary singular piece of material (e.g., galvanized metal). Thermally insulative gaskets or membranes may insulate the tracks from adjacent structure or surfaces. Structures may be provided as a kit.

1 . A metal framing member, comprising:
 an elongated channel member, the elongated channel member made of a metal and having a web portion, a first end, a second end, a major length between the first and the second ends, a first edge along the major length, a second edge along the major length, a first flange that extends along the first edge at a non-zero angle to the web portion of the elongated channel member, and a second flange that extends along the second edge at a non-zero angle to the web portion of the elongated channel member, the web portion having a pattern of elongated through-holes which are elongated along the major length of the elongated channel member, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along at least a portion of a width of the web portion of the elongated channel member, each row extending along at least one intermediate portion of the major length of the elongated channel member, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, the elongated through-holes which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the elongated channel member the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.   
     
     
         2 . The metal framing member of  claim 1  wherein the number of straight-line web sections comprise at least a first plurality of straight-line web sections and a second plurality of straight-line web sections that respectively extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes, and wherein the first plurality of straight-line web sections respectively intersect the second plurality of straight-line web sections. 
     
     
         3 . The metal framing member of  claim 1  wherein the truss structure comprises the number of straight-line web sections that respectively extend uninterrupted diagonally across the width of the web portion from the first edge to the second edge through at least a portion of the pattern of elongated through-holes in at least two different diagonal directions. 
     
     
         4 . The metal framing member of  claim 3  wherein the at least two different diagonal directions comprise a first diagonal direction offset from the major length of the elongated channel member by an offset angle in a first rotational direction and a second diagonal direction offset from the major length of the elongated channel member by the offset angle in a second rotational direction, the second rotational direction opposite the first rotational direction, the offset angle greater than zero degrees and less than ninety degrees. 
     
     
         5 . The metal framing member of  claim 4  wherein the offset angle comprises a forty-five degree angle. 
     
     
         6 . The metal framing member of  claim 1  wherein a width of each of the number of straight-line web sections is at least three fourths of an inch. 
     
     
         7 . The metal framing member of  claim 1  wherein a width of each of the number of straight-line web sections is at least three thirty-seconds of an inch. 
     
     
         8 . The metal framing member of  claim 1 , further comprising:
 for at least a majority of the elongated through-holes, a respective piece of retained material that extends from the respective elongated through-hole out of a plane of the web portion, the piece of retained material which overlies the respective elongated through-hole, attached to the web portion at each of a pair of opposed ends across a major axis of the respective elongated through-hole and attached to the web portion along a first lateral edge of the respective elongated through-hole and spaced from a second lateral edge of the respective elongated through-hole to form a slot therewith that provides fluid communications between the first major face of the web portion and the second major face of the web portion via the respective elongated through-hole.   
     
     
         9 . The metal framing member of  claim 1  wherein the elongated through-holes are arranged in three or four rows. 
     
     
         10 . The metal framing member of  claim 1  wherein a largest lateral dimension of the elongated channel member is no greater than four inches. 
     
     
         11 . The metal framing member of  claim 1  wherein the width of the web portion of the elongated channel member is three and five eighths inches. 
     
     
         12 . The metal framing member of  claim 1  wherein the elongated through-holes are arranged in at least three rows, the elongated through-holes of each row are shifted longitudinally along the major length with respect to the elongated through-holes of a nearest neighboring row, and two of the number of straight-line web sections pass between each elongated through-hole and at least one nearest neighboring elongated through-hole within the same row. 
     
     
         13 . The metal framing member of  claim 1  wherein at least a majority of the number of straight-line web sections pass between two neighboring elongated through-holes of each of the plurality of rows. 
     
     
         14 . The metal framing member of  claim 1  wherein the pattern of elongated through-holes extend continuously between a first location and a second location, the first and the second locations spaced inwardly from respective ones of the first and the second ends by not more than 6 inches from the first and the second ends, respectively. 
     
     
         15 . The metal framing member of  claim 1  wherein the major length of the elongated channel member has at least two intermediate portions, the web portion has the pattern of elongated through-holes that defines the truss structure at each of the at least two intermediate portions, and a knock out portion is positioned between each of one or more pairs of the at least two intermediate portions. 
     
     
         16 . The metal framing member of  claim 1  wherein every direct shortest line path laterally across the width of the web portion over at least a majority of the major length of the elongated channel member encounters at least one of the elongated through-holes. 
     
     
         17 . The metal framing member of  claim 1  wherein each of the plurality of rows comprises at least three elongated through-holes. 
     
     
         18 . The metal framing member of  claim 1  wherein each of the plurality of rows comprises at least five elongated through-holes. 
     
     
         19 . The metal framing member of  claim 1  wherein the truss structure comprises a pattern of straight-line web sections, the pattern of straight-line web sections complementary at least in part to the pattern of elongated through-holes. 
     
     
         20 . The metal framing member of  claim 8  wherein each of the respective pieces of retained material comprise a first portion and a second portion, the first portion of the retained material forms a first angle measured with respect to a plane formed by the web portion, and the second portion of the retained material forms a second angle measured with respect to the plane formed by the web portion. 
     
     
         21 . The metal framing member of  claim 1  wherein the elongated through-holes are respectively elongated in a direction substantially parallel to the major length of the elongated channel member. 
     
     
         22 . A wall kit, comprising:
 a plurality of metal studs, the metal studs each including a respective elongated stud channel member having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the metal stud, the web portions of each of the metal studs having a respective major length and a minor width, the minor width perpendicular to the major length; and   at least a first track, the first track including a first elongated track channel member, the first elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the first track having a respective major length and a minor width, the minor width perpendicular to the major length,   wherein the web portion of at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member has a pattern of elongated through-holes which are elongated along a direction parallel to the major length, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, the elongated through-holes which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.   
     
     
         23 . The wall kit of  claim 22  wherein the elongated through-holes are arranged in at least three rows, every direct shortest line path laterally across the width over the at least one intermediate portion of the web portion of the first elongated stud channel member encounters a plurality of the elongated through-holes, and two of the number of straight-line web sections pass between each elongated through-hole and at least one nearest neighboring elongated through-hole within the same row. 
     
     
         24 . The wall kit of  claim 22  wherein the truss structure comprises the number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes in at least two different diagonal directions, the at least two different diagonal directions comprising a first diagonal direction offset from a longitudinal axis of the at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member by an offset angle in a first rotational direction and a second diagonal direction offset from the longitudinal axis by the offset angle in a second rotational direction, the second rotational direction opposite the first rotational direction, the offset angle greater than zero degrees and less than ninety degrees. 
     
     
         25 . The wall kit of  claim 22  wherein the web portions of both: i) the elongated stud channel members and ii) the first track channel member each respectively have the pattern of elongated through-holes and the truss structure. 
     
     
         26 . The wall kit of  claim 22  wherein each of the plurality of rows comprises at least three elongated through-holes. 
     
     
         27 . The wall kit of  claim 22  wherein the web portion of the at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member further has, for at least a majority of the elongated through-holes, at least one piece of retained material that extends from the respective elongated through-hole out of a plane of the web portion, the piece of retained material which overlies the respective elongated through-hole, attached to the web portion at each of a pair of opposed ends across a major axis of the respective elongated through-hole and attached to the web portion along a first lateral edge of the respective elongated through-hole and spaced from a second lateral edge of the respective elongated through-hole to form a slot therewith that provides fluid communications between the first major face of the web portion and the second major face of the web portion via the respective elongated through-hole. 
     
     
         28 . The wall kit of  claim 22 , further comprising:
 at least a second track that includes a second elongated track channel member, the second elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the second track having a major length and a minor width, the minor width perpendicular to the major length;   wherein the web portion of the second elongated track channel member has a pattern of elongated through-holes which are elongated along a direction parallel to the major length of the second elongated channel member, the elongated through-holes arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated through-holes of each row shifted longitudinally along the major length with respect to the elongated through-holes of at least one other row, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated through-holes define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated through-holes, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated through-holes.   
     
     
         29 . A wall, comprising:
 at least a first track; and   a plurality of metal studs extending perpendicularly from the first track and spaced apart from each other by a defined distance, wherein:   the metal studs each include a respective elongated stud channel member having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the metal stud, the web portions of each of the metal studs having a respective major length a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length;   the first track includes a first elongated track channel member, the first elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portion of the first track having a respective major length, a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length, and   the web portion of at least one of: i) at least one of the elongated stud channel members, or ii) the first elongated track channel member has at least one set of a pattern of elongated discontinuities which are elongated along a direction parallel to the major length, the elongated discontinuities arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated discontinuities of each row shifted longitudinally along the major length with respect to the elongated discontinuities of at least one other row, the elongated discontinuities which respectively provide fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated discontinuities define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated discontinuities, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated discontinuities.   
     
     
         30 . The wall of  claim 29  wherein the web portions of both: i) the elongated stud channel members and ii) the first track channel member each respectively have the pattern of elongated discontinuities and the truss structure. 
     
     
         31 . The wall of  claim 29  wherein the discontinuities are arranged in at least three rows, every direct shortest line path laterally across the width at least over the one or more intermediate portions of the web portion of the first elongated stud channel member encounters at least one of the discontinuities, and two of the number of straight-line web sections pass between each discontinuity and at least one nearest neighboring discontinuity within the same row. 
     
     
         32 . The wall of  claim 29  wherein each of the plurality of rows comprises at least three discontinuities. 
     
     
         33 . The wall of  claim 29 , further comprising:
 at least a second track that includes a second elongated track channel member, the second elongated track channel member made of a metal and having a web portion and a pair of flanges that extend from the web portion in spaced apart relation opposed across a width of the first track from one another to closely receive the width of the metal studs therebetween, the web portions of the second track having a respective major length, a minor width, a first edge along the major length, and a second edge along the major length, the minor width perpendicular to the major length; and   wherein the web portion of the second elongated track channel member has a pattern of elongated discontinuities which are elongated along a direction parallel to the major length, the elongated discontinuities arranged in a plurality of rows, the rows arranged laterally along the minor width of the web portion, each row extending along at least one intermediate portion of the major length of the web portion, the elongated discontinuities of each row shifted longitudinally along the major length with respect to the elongated discontinuities of at least one other row, and along the at least one intermediate portion of the major length of the web portion the pattern of elongated discontinuities define a truss structure in the web portion, the truss structure comprising a number of straight-line web sections that extend uninterrupted diagonally across the width of the web portion through at least a portion of the pattern of elongated discontinuities, and where every direct shortest line path laterally across the width of the web portion at the at least one intermediate portion encounters at least one of the elongated discontinuities.   
     
     
         34 . A metal framing member, comprising:
 an elongated channel member, the elongated channel member made of a metal and having a web portion, a first end, a second end, a major length between the first and the second ends, one or more intermediate portions located at least between a first location and a second location, the first and the second locations which are spaced inwardly from respective ones of the first and the second ends, respectively, a first edge along the major length and a second edge along the major length, a first flange that extends from the first edge, and a second flange that extends from the second edge, the web portion having a pattern of through-holes, the through-holes arranged in a plurality of rows, the rows arranged laterally along at least a portion of a width of the web portion of the elongated channel member, each row extending along at least the one or more intermediate portions of the major length of the elongated channel member, the through-holes of each row shifted longitudinally along the major length with respect to the through-holes of at least one other row to provide serpentine thermally conductive paths laterally across the width of at least the one or more intermediate portions of the web portion of the elongated channel member, each through-hole which provides fluid communications between a first major face of the web portion and a second major face of the web portion, the second major face of the web portion opposed across a thickness of the web portion from the first major face of the web portion, at least one of the one or more intermediate portions which has a truss structure comprising a plurality of truss elements that respectively extend directly and uninterruptedly through at least a portion of the pattern of through-holes in at least two different diagonal directions, each of the plurality of truss elements passing between two neighboring through-holes in at least one of the plurality of rows.   
     
     
         35 . The metal framing member of  claim 34  wherein each of the plurality of rows comprises at least three through-holes. 
     
     
         36 . The metal framing member of  claim 34  wherein at least a majority of the plurality of truss elements pass between two neighboring through-holes of each of the plurality of rows. 
     
     
         37 . The metal framing member of  claim 34  wherein the first and second locations are spaced inwardly from respective ones of the first and the second ends by more than 4 inches but not more than 6 inches from the first and the second ends, respectively. 
     
     
         38 . The metal framing member of  claim 34  wherein the through-holes are arranged in three or four rows. 
     
     
         39 . The metal framing member of  claim 34  wherein a width of each of the plurality of truss elements is at least three thirty-seconds of an inch. 
     
     
         40 . The metal framing member of  claim 34  wherein a largest lateral dimension of the elongated channel member is no greater than four inches.