U.S. patent application number 10/119231 was filed with the patent office on 2002-08-15 for metal structural member.
Invention is credited to Frobosilo, Raymond C., Walker, Steven H..
Application Number | 20020108345 10/119231 |
Document ID | / |
Family ID | 23739984 |
Filed Date | 2002-08-15 |
United States Patent
Application |
20020108345 |
Kind Code |
A1 |
Walker, Steven H. ; et
al. |
August 15, 2002 |
Metal structural member
Abstract
A metal structural member having an elongate web member having a
first side and a second side, a pair of flanges extending laterally
from the first side of the web member, each of the flanges having
an outer wall member and an end wall member, the end wall member
being substantially parallel to the web member wherein one of the
flanges further includes an inner wall member in spaced-apart
relationship with the outer wall member and extending from the end
wall member toward the web and terminating with a lip member formed
parallel to and juxtaposed with the web.
Inventors: |
Walker, Steven H.;
(Maitland, FL) ; Frobosilo, Raymond C.; (Lido
Beach, NY) |
Correspondence
Address: |
CLIFFORD G. FRAYNE
Suite 7A
136 Drum Point Road
Brick
NJ
08723
US
|
Family ID: |
23739984 |
Appl. No.: |
10/119231 |
Filed: |
April 9, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10119231 |
Apr 9, 2002 |
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09438274 |
Nov 12, 1999 |
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6397550 |
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Current U.S.
Class: |
52/842 ;
52/481.1 |
Current CPC
Class: |
E04C 2003/043 20130101;
E04C 2003/0421 20130101; E04C 2003/0486 20130101; E04B 2/7412
20130101; E04C 3/07 20130101; E04C 2003/0456 20130101; E04C
2003/0439 20130101; E04C 2003/0473 20130101 |
Class at
Publication: |
52/731.9 ;
52/731.5; 52/729.5; 52/733.3; 52/481.1 |
International
Class: |
E04C 003/30 |
Claims
We claim:
1. A metal structural member comprising: an elongate web member
having a first side and a second side; a pair of flanges extending
laterally from said first side of said web member, each of said
flanges having an outer wall member and an end wall member said end
wall member substantially parallel to said web member, wherein one
of said flanges further having an inner wall member in spaced apart
relationship with said outer wall member and extending from said
end wall member toward said web and terminating with a lip member,
said lip member formed parallel to said web member and juxtaposed
thereto forming a structural member of generally C-shaped cross
section.
2. The metal structural member in accordance with claim 1 wherein
both of said flange members include said inner wall member in
spaced apart relationship with said outer wall member and having
said lip member formed parallel to said web member and juxtaposed
thereto.
3. The metal structural member in accordance with claims 1 or 2
wherein said inner wall member and said outer wall member are in
parallel spaced apart relationship.
4. The metal structural member in accordance with claims 1 or 2
wherein said inner wall member and said outer wall member are in
spaced apart non-parallel relationship wherein a portion of said
web member, said outer wall member, said end wall member, and said
inner wall member define a space of trapezoidal cross section.
5. The metal structural member in accordance with claim 2 wherein
said end wall member of said flanges and a portion of said web
member between said outer wall member and said inner wall member
are formed with a plurality of perforations.
6. The metal structural member in accordance with claim 5 wherein
said plurality of perforations are staggered longitudinal
slots.
7. The metal structural member in accordance with claim 1 wherein
said outer wall member of said flanges has positioned thereon a
non-heat conducting layer of insulation.
8. The metal structural member in accordance with claim 7 wherein
said non-heat conducting layer is continuous with said outer wall
of said flanges.
9. A method forming a metal structural member for providing
multiple frictional contact points for a fastener comprising: a.
forming an elongate web member having a first side and a second
side and two parallel longitudinal edges; b. bending one
longitudinal edge of said web member substantially perpendicular to
said web member to form an outer wall of a flange member; c.
bending said outer wall of said flange member to form an end wall
of said flange member said end wall of said flange member being
substantially perpendicular to said web member; d. bending said end
member to form an inner wall member in spaced apart relationship to
said outer wall of said flange member; e. bending said inner wall
of said flange member to form a lip member in parallel relationship
to said web member and juxtaposed thereto; f. performing steps b
and c with respect to said second longitudinal edge of said web
member.
10. The method in accordance with claim 5 wherein step f is
performed simultaneously with steps b and c.
11. The method in accordance with claim 5 wherein steps f, d and e
are performed simultaneously with respect to said second
longitudinal edge of said web member.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The present invention relates to a metal structural member
and in particular, to an improved C-section structural member
having improved fastening and thermal conductivity
characteristics.
2. Description of the Prior Art
[0002] The rising cost of lumber has caused increased interest in
fabricating and constructing homes with frames of metal
construction members. These construction members include roof
joists, trusses, exterior walls and interior walls.
[0003] One of the main structural elements utilized in such metal
frame construction is commonly referred to as the C-stud or
C-shaped stud or member. Its name is derived from its cross section
which resembles the letter C and comprises a longitudinal web
having flanges depending from the longitudinal edges of the web to
the same side of the web and flanges being substantially parallel
to each other and perpendicular to the web. Such C-shaped members
are used as the vertical support members for exterior and interior
walls and are positioned at their tops and bottoms in a rail or
track which is essentially a C-shaped member positioned in a
horizontal configuration with the vertical C-shaped stud positioned
within the rails and tracks such that the respective flanges of the
vertical C-shaped stud and the horizontal C-shaped track are
secured together to form the framework for a wall.
[0004] A particular short coming with the C-shaped studs as
currently utilized in the construction industry is that the flanges
depending from the central elongate web portion are normally of one
ply and therefore a nail fastener securing an outer sheathing or
inner sheathing to the C-shaped web member may become dislodged
over time. This is particularly common with respect to a C-shaped
stud member forming the exterior wall of the house. Typically the
exterior sheathing will consist of ply wood which is normally
secured by a nail fastener while the interior wall may consist of
gypsum board or dry wall which may be secured by a threaded
fastener or a nail. The fact that the nail penetrates the
sheathing, be it the ply wood or the gypsum board, and then through
one ply of the C-shaped stud member results in a nail fastener
which essentially has a pivot point at its intersection with the
flange of the C-shaped stud member. The vibration, loading or the
like may cause this nail fastener to become dislodged from the
flange member of the C-shaped stud member or to angularly rotate
about the pivot point, thereby affecting the integrity of the
exterior sheathing or the interior sheathing.
[0005] Applicant's C-shaped metal construction member provides for
a double walled, spaced apart flange on the C-shaped stud member in
order to provide the fastener with two contact points. The same
double walled, spaced apart flange also provides improved
connection when a threaded fastener is utilized.
[0006] In addition to the above identified improved C-section metal
construction member, the construction member can also be formed to
reduce thermal conduction from the exterior flange which is in
communication with the exterior sheathing to the flange which is in
communication with the interior sheathing thereby lessening
concerns with respect to heat loss or heat gain within the
building.
OBJECTS OF THE INVENTION
[0007] An object of the present invention is to provide for a novel
metal construction member of C-shaped configuration having a double
walled spaced apart flange.
[0008] A further object of the present invention is to provide for
a novel C-shaped metal construction member in which both flanges
are double walled and spaced apart.
[0009] A still further object of the present invention is to
provide for a novel C-shaped metal construction member which
decreases thermal conductivity between the outer sheathing and the
inner sheathing of an exterior wall of a building.
SUMMARY OF THE INVENTION
[0010] A C-shaped metal construction member having an elongate
longitudinal web having a first flange and a second flange
depending from the longitudinal edge of the web, one or both of the
longitudinal flanges being formed of a double wall, spaced apart
configuration for improved frictional engagement with a fastening
means utilized to secure sheathing to one or both of the flanges.
The C-shaped metal stud construction member further comprising a
means for reducing the thermal conductivity from flange to flange
without affecting the integrity of the C-shaped construction
member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] These and other objects of the present invention will become
evident particularly when taken in light of the following
illustrations wherein:
[0012] FIG. 1 is a cross sectional view of a first embodiment of
the C-shaped construction member;
[0013] FIG. 2 is a cross section of a second embodiment of the
C-shaped construction member;
[0014] FIG. 3 is a top cross-section view of the C-shaped member of
FIG. 2 with interior and exterior sheathing.
[0015] FIG. 4 is a third embodiment of the C-shaped construction
member;
[0016] FIG. 5 is a cross section of a fourth embodiment of the
C-shaped cross section member;
[0017] FIG. 6 is a perspective end view of FIG. 2 illustrating a
means by which the thermal conductivity across the C-shaped member
may be reduced; and
[0018] FIG. 7 is a prospective end view of FIG. 1 illustrating a
means by which thermal conductivity across the C-shaped member may
be reduced.
DETAILED DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a cross-sectional view of a first embodiment of
the C-section member 10. It comprises a longitudinal, elongate web
member 12 having a hollow flange member 14 formed along one
longitudinal edge thereof extending laterally from one side of the
web 12 and a second flange member 16 formed along the opposing
longitudinal edge extending laterally from the same side of the web
as hollow flange member 14, flange member 16 having an end wall
member 18 formed substantially parallel to web member 12.
[0020] Hollow flange member 14 is formed from web member 12 with an
outer wall 20, an end wall 22 and an inner wall 24, inner wall 24
in spaced apart relationship to outer wall 20. End wall 22 of
hollow flange member 14 is in substantially the same plane as end
wall member 18 of second flange member 16 and substantially
parallel to web 12. In this embodiment, outer wall 20 and inner
wall 24 are substantially parallel to each other. Inner wall 24
terminates with a lip member 26 which is juxtaposed with web member
12. The lip member 26 may or may not be secured to web member 12,
however, if it is secured, it could be secured by any suitable
fastening means including a clinch punch.
[0021] FIG. 2 is a cross-sectional view of a second embodiment of a
C-section member 30. It comprises a longitudinal elongate web
member 32 having a first hollow flange member 34 formed along one
longitudinal edge thereof extending laterally from one side of web
32 and a second hollow flange member 36 formed along the opposing
longitudinal edge of web member 32 and extending laterally to the
same side of the web as first hollow flange member 34.
[0022] First and second hollow flange members 34 and 36 are
comprised of structural members identical to that of hollow flange
member 14 of the first embodiment of the C-section member. Namely,
each has an outer wall 40 and 40a, an end wall 42 and 42a, and an
inner wall 44 and 44a, inner wall 44 and 44a in spaced apart
relationship to outer wall 40 and 40a. End walls 42 and 42a of
first hollow flange member 34 and second hollow flange member 36
would be in substantially the same plane and substantially parallel
to web 32. Inner walls 44 and 44a of first hollow flange member 34
and second hollow flange member 36 would terminate with a lip
member 46 and 46a which would be juxtaposed with web member 32.
[0023] The advantages of the C-section member 10 or the alternative
embodiment C-section member 30 are illustrated in FIG. 3 which is a
top cross-sectional view of C-section member 30 having sheathing
members secured thereto. With respect to the exterior of a
building, sheathing of any type, but typically plywood or
composition plywood 50 is typically utilized and this sheathing
material 50 is normally secured by means of a nail member 52. The
interior sheathing 54 of a building is typically dry wall of gypsum
board which is oftentimes secured by a threaded fastener 56 or by a
nail member 52. The C-section member of the present invention
provides a hollow flange member proximate to at least the exterior
sheathing of the building such that the nail member 52 will
penetrate the sheathing and the outer wall and inner wall of the
C-section member, thus giving the nail member 52 two contact points
in the stud member which provides further stability to the nail
member.
[0024] The threaded fastener 56 utilized on the interior sheathing
54 is sufficiently secured by penetration through a single wall of
a flange member. Therefore in the instance when threaded fasteners
are used on the interior sheathing 54, a C-section member of the
type illustrated in FIG. 1 may be used. If nails and/or a
combination of nails and threaded fasteners are going to be used on
the interior sheathing, then an embodiment of the C-section member
as illustrated in FIG. 2 would be used in order to provide the nail
with two points of contact with the C-section member.
[0025] FIGS. 4 and 5 illustrate further embodiments of the present
invention, FIG. 4 being a C-section member in accordance with the
teachings of the C-section member of FIG. 1 and FIG. 5 being a
C-section member in accordance with the teachings of FIG. 2.
[0026] FIG. 4 illustrates a C-sectioned member 60 comprised of a
longitudinal, elongate web member 62 having a hollow flange member
64 formed along one longitudinal edge thereof extending laterally
from one side of the web 62 and a second flange member 66 formed
along the opposing longitudinal edge extending laterally from the
same side of the web as hollow flange member 64, flange member 66
having an end wall member 68 formed substantially parallel to web
member 62.
[0027] The hollow flange member 64 is formed from web member 62
with an outer wall 70, an end wall 72 and an inner wall 74, inner
wall 74 being in spaced apart non-parallel relationship to outer
wall 70. End wall 72 of hollow flange member 64 is in substantially
the same plane as end wall member 68 of second flange member 66 and
substantially parallel to web 62. Inner wall 74 terminates with a
lip member 76 which is juxtaposed with web member 62. In this
configuration, hollow flange member 64 is generally trapezoidal in
cross-sectional area.
[0028] FIG. 5 is a cross-sectional view of a further embodiment of
the C-section member. C-section member 80 comprises a
longitudinally elongate web member 82 having a first hollow flange
member 84 formed along one longitudinal edge thereof extending
laterally from one side of the web 82 and a second hollow flange
member 86 formed along the opposing longitudinal edge of web member
82 and extending laterally to the same side of the web as first
hollow flange member 84. First and second hollow flange members 84
and 86 are comprised of structural members identical to that of
hollow flange member 64 of the embodiment illustrated in FIG. 4.
Namely, each has an outer wall 90 and 90a, an end wall 92 and 92a
and an inner wall 94 and 94a, inner wall 94 and 94a in spaced apart
non-parallel relationship to outer wall 90 and 90a. End walls 92
and 92a of first hollow flange member 84 and second hollow flange
member 86 would be in substantially the same plane and
substantially parallel to web 82. Inner walls 94 and 94a of first
hollow flange member 84 and second hollow flange member 86 would
terminate with a lip member 96 and 96a which would be juxtaposed
with web member 82.
[0029] Similar advantages with respect to threaded fasteners and
nail members are achieved with respect to the embodiments disclosed
in FIGS. 4 and 5 as with the embodiments disclosed in FIGS. 1 and
2.
[0030] The C-shaped member, which is the subject of the present
invention, may also incorporate a structure which reduces the
thermal conductivity of the C-shaped member by incorporating a
thermal break. FIG. 6 is a perspective partial end view of C-shaped
member 30 of FIG. 2 which incorporates two types of thermal breaks.
The first type of thermal break is formed on the end walls 42 and
42a of the hollow flanges 34 and 36 and on that portion of the web
32 positioned between the outer wall 40 and 40a and the inner wall
44 and 44a of the hollow flanges 34 and 36. The thermal break
comprises a plurality of apertures 100 formed in the end walls 42
and 42a and in the web portion which apertures serve to reduce the
surface area over which heat can be conducted. Assuming that hollow
flange 34 were adjacent the exterior sheathing of the building and
hollow flange 36 or adjacent the inner sheathing of a building and
a temperature differential existed between the outside ambient
temperature and the inside ambient temperature, the C-shaped stud
30 would tend to transmit heat from outer wall 40 across web 32 to
outer wall 40a of hollow flange 36. Heat would also be conducted
from outer wall 40 across end wall 42, down inner wall 44 to web 32
and thence to outer wall 40a of hollow flange 36. The apertures 100
serve as a thermal break to disrupt this conductive route and
thereby lessen the amount of heat conducted. In the embodiment
illustrated in FIG. 6, the apertures comprise a plurality of
staggered slots formed on end walls 42 and 42a and that portion of
web 32 bounded by the outer wall and inner wall of the hollow
flange.
[0031] In addition to or separately from the slotted apertures 100
utilized to disrupt the thermal conductivity across the C-shaped
member, a non-conductive material 102 may also be utilized on the
outer walls of hollow flanges 34 and 36 of C-shaped member 30 or on
the outer wall of hollow flange 14 and flange 16 of C-shaped member
10. This non-conductive thermal break 102 consists of a layer of
non-conductive material affixed to the outer walls such that when
the outer sheathing and inner sheathing are affixed to the C-shaped
stud, the metal outer walls of the hollow flanges are not in direct
contact with the sheathing. FIG. 6 illustrates a non-conductive
material 102 having a ribbed configuration and FIG. 7 illustrates a
non-conductive material 102 having a planar configuration. Both
configurations serve to deter the thermal conductivity from one
outer wall of C-shaped member 30 to the opposing outer wall of
C-shaped member. The thermal break in the form of apertures 100 and
the thermal break in the form of non-conductive material 102 may be
used separately or in conjunction with each other and it will be
recognized that they may also be used with respect to the
embodiment of the C-shaped member illustrated in FIGS. 4 and 5.
[0032] While the present invention has been described with respect
to the exemplary embodiments thereof, it will be evident to one of
ordinary skill in the art that many modifications may be made
without departing from the spirit and scope of the invention.
Therefore it is manifestly intended that the invention be limited
only by the claims and the equivalence thereof.
* * * * *