U.S. patent application number 09/907873 was filed with the patent office on 2003-01-23 for sheet metal stud and composite construction panel and method.
Invention is credited to Bodnar, Ernest R..
Application Number | 20030014935 09/907873 |
Document ID | / |
Family ID | 25424782 |
Filed Date | 2003-01-23 |
United States Patent
Application |
20030014935 |
Kind Code |
A1 |
Bodnar, Ernest R. |
January 23, 2003 |
Sheet metal stud and composite construction panel and method
Abstract
A composite construction panel having a thin panel of concrete
material and a reinforcing grid of sheet metal studs with embedment
portions which are actually embedded into the concrete panel, each
of the studs having a web, right angular flange formed on a free
edge of the web, an angled edge strip formed along the free edge of
the right angular flange, an embedment angled flange portion formed
along the opposite edge of the web, an edge strip formed on the
angled flange at an angle thereto; and, spaced apart angled flange
openings formed in the angled flange for flow of concrete
therethrough. An alternate form of stud has a triangular tube
structure along one edge of the web. Another form of stud has a
discontinuous webs defining spaces between them. In one embodiment
two concrete panels may be secured to the studs in spaced relation
to create a hollow structure.
Inventors: |
Bodnar, Ernest R.; (Toronto,
CA) |
Correspondence
Address: |
ERNEST R. BODNAR
2 Danrose Crescent
Toronto
ON
M3B 3N5
CA
|
Family ID: |
25424782 |
Appl. No.: |
09/907873 |
Filed: |
July 18, 2001 |
Current U.S.
Class: |
52/481.1 ;
428/595; 428/597; 428/603; 52/600; 52/634; 52/636 |
Current CPC
Class: |
E04C 2003/046 20130101;
E04C 2003/0452 20130101; Y10T 428/12354 20150115; E04C 2/384
20130101; Y10T 428/12368 20150115; Y10T 428/1241 20150115; E04C
2003/0434 20130101; E04C 2003/0439 20130101; E04C 2003/0473
20130101; E04C 2003/0421 20130101; E04C 3/083 20130101 |
Class at
Publication: |
52/481.1 ;
52/600; 52/634; 52/636; 52/733.2; 428/595; 428/597; 428/603 |
International
Class: |
E04C 002/34 |
Claims
What is claimed is
1. A composite construction panel and having a thin panel of cast
material, and a reinforcing grid of sheet metal studs comprising
parallel studs and top and bottom studs, wherein said reinforcing
studs have embedment portions which are embedded into the cast
panel, and wherein each of said reinforcing studs comprises; a web
defining a free edge, which is not embedded in the panel; right
angular flange formed on said free edge; an angular edge strip
formed along the free edge of said right angular flange an
embedment flange portion formed along the opposite edge of said
web, opposite to said free edge; an edge strip formed on said
embedment flange portion; and, a plurality of spaced apart
embedment flange openings formed in said embedment flange
portion:
2. A composite construction panel as claimed in claim 1 wherein
said embedment flange openings are formed by a series of
semi-arcuate openings located spaced apart lengthwise along said
embedment flange portion.
3. A composite construction panel as claimed in claim 2 and
including web openings of generally circular shape formed through
said web between said embedment flange portions and said free edge
right angular flanges, and edges of said circular openings being
formed out of the plane of said web, to define an annular
continuous ring.
4. A composite construction panel as claimed in claim 3 and
including generally circular depressions formed in said web between
said web openings and said right angular flanges, and between said
web openings and said embedment flange portions, and semi-circular
openings formed within said depressions.
5. A composite construction panel as claimed in claim 4 wherein
said web between said web openings defines generally hour-glass
shaped web portions, which are narrower at about the mid point of
said web, and wherein said semicircular openings are directed
towards said narrower portions of said hour-glass shaped web
portions.
6. A composite construction panel having a thin panel of cast
material, a reinforcing grid of sheet metal studs formed by
parallel reinforcing studs and top and bottom studs, wherein said
reinforcing studs have embedment portions which are embedded in the
cast panel, and wherein each of said reinforcing studs comprises; a
web defining a free edge which is not embedded in said panel; a
triangular tube formation formed on said free edge, having a first
angled tube wall, a second transverse tube wall, and a return tube
wall; a free edge of said return tube wall being fastened to said
web; an embedment flange portion formed along the opposite edge of
said web; an embedment edge strip formed on said embedment flange
portion; and, a plurality of spaced apart flange openings formed in
said embedment flange portion.
7. A composite construction panel as claimed in claim 6 wherein
said embedment flange openings are formed by a series of
semi-arcuate openings located spaced apart lengthwise along said
embedment flange portion.
8. A composite construction panel as claimed in claim 7 and
including web openings of generally circular shape formed through
said web between said embedment flange portions and said free edge
tubular formations, and edges of said circular openings being
formed out of the plane of said web, into a continuous annular
ring.
9. A composite construction panel as claimed in claim 8 and
including generally circular depressions formed in said web between
said web openings and said triangular formation, and between said
web openings and said embedment flange portions, and semi-circular
openings formed within said depressions.
10. A composite construction panel as claimed in claim 9 wherein
said web between said web openings defines generally hour-glass
shaped web portions, which are narrower at about the mid point of
said web, and wherein said semi-circular openings are directed
towards said narrower portions of said hourglass shaped web
portions.
11. A reinforcement stud for use in forming a composite
construction panel wherein the panel is formed with a thin panel of
cast material, and a reinforcing grid of sheet metal studs wherein
said reinforcement studs have embedment portions which are embedded
in the cast panel, and wherein each of said reinforcement studs
comprises; a web defining a free edge, which is not embedded in the
panel; right angular flange formed on said free edge; an angular
edge strip formed along the free edge of said right angular flange
an embedment flange portion formed along the opposite edge of said
web, opposite to said free edge; a retention edge strip on said
embedment flange portion formed out of the plane of said embedment
flange portion; and, a plurality of spaced apart embedment flange
openings formed in said embedment flange portion.
12. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 11 and wherein said embedment flange
portion is formed at an angle to said web and wherein said
embedment flange openings are formed by a series of semi-arcuate
openings located spaced apart lengthwise along said embedment
flange portion.
13. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 12 and including web openings of
generally circular shape formed through said web between said
embedment flange portions and said free edge right angular flanges,
and edges of said circular openings being formed out of the plane
of said web into a continuous annular ring.
14. A reinforcing stud for use in forming a composite construction
panel as claimed in as claimed in claim 13 and including generally
circular depressions formed in said web between said web openings
and said right angular flanges, and between said web openings and
said embedment flange portions, and semicircular openings formed
within said depressions.
15. A reinforcing stud for use in forming a composite construction
panel as claimed in as claimed in claim 14 wherein said web between
said web openings defines generally hour-glass shaped web portions,
which are narrower at about the mid point of said web, and wherein
said semi-circular openings are directed towards said narrower
portions of said hour-glass shaped web portions.
16. A reinforcing stud for use in forming a composite construction
panel wherein the panel is formed with a thin panel of cast
material, and a reinforcing grid of sheet metal studs wherein said
reinforcing studs have embedment portions which are embedded in the
cast panel, and wherein each of said reinforcement studs comprises;
a web defining a free edge which is not embedded in said panel; a
triangular tube formation formed on said free edge, having a first
angled tube wall, a second transverse tube wall, and a return tube
wall; a free edge of said return tube wall being fastened to said
web; an embedment flange portion formed along the opposite edge of
said web; a retention edge strip formed on said embedment flange
portion and formed out of the plane of said embedment flange
portions; and, a plurality of spaced apart flange openings formed
in said embedment flange portion.
17. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 16 wherein said embedment flange portion
is formed at an angle to said web and wherein said embedment flange
openings are formed by a series of semi-arcuate openings located
spaced apart lengthwise along said embedment flange portion.
18. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 17 and including web openings of
generally circular shape formed through said web between said
embedment flange portions and said free edge tubular formations,
and edges of said circular openings being formed out of the plane
of said web, into a continuous annular ring.
19. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 18 and including generally circular
depressions formed in said web between said web openings and said
triangular formation, and between said web openings and said
embedment flange portions, and semi-circular openings formed within
said depressions.
20. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 19 wherein said web between said web
openings defines generally hour-glass shaped web portions, which
are narrower at about the mid point of said web, and wherein said
semi-circular openings are directed towards said narrower portions
of said hour-glass shaped web portions.
21. A reinforcing stud for use in forming a composite construction
panel wherein the panel is formed with a thin panel of cast
material, and a reinforcing grid of sheet metal studs wherein said
reinforcing studs have embedment portions which are embedded in the
cast panel, and wherein each of said reinforcing studs comprises; a
web defining a free edge which is not embedded in said panel; a
triangular tube formation formed on said free edge, having a first
angled tube wall, a second transverse tube wall, and a return tube
wall; a free edge of said return tube wall being fastened to said
web; a series of generally V-shaped web portions extending from
said free edge; an apex on each of said V-shaped web portions; an
embedment portion formed on each said apex; and, each said apex
having an embedment opening formed therein.
22. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 21 wherein said embedment openings are
formed by a series of semi-arcuate openings.
23. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 22 and including web openings of
generally circular shape formed through said web in said V-shaped
web portions and edges of said circular openings being formed out
of the plane of said web, into a continuous annular ring.
24. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 23 and including generally circular
depressions formed in said V-shaped web portions between said web
openings and said triangular formation. and semi-circular openings
formed within said depressions.
25. A reinforcing stud for use in forming a composite construction
panel as claimed in claim 24 wherein said web between said web
openings defines generally web portions, which are narrower at
about the mid point of said web, and wherein said semi-circular
openings are directed towards said narrower portions.
26. The method or making a composite construction panel comprising
the steps of; assembling a plurality of reinforcing studs, each
having webs with circular openings therethrough, in parallel spaced
apart relation with said circular openings aligned with one
another, and with cross members arranged transversely at the ends
of said parallel reinforcing studs thereby forming a grid of studs,
said parallel reinforcing studs having embedment flange portions
thereon; pouring panel material into a form shaped to provide a
planar cast panel; placing reinforcing mesh in said panel material;
placing said grid of studs over said panel material in said form
and lowering the same until said embedment flange portions of said
reinforcing studs are at least partially immersed in said panel
material; allowing said panel material to cure, and removing said
formed composite panel consisting of cured material with said grid
of studs secured in and extending from said panel.
27. The method or making a composite construction panel as claimed
in claim 26 and wherein said reinforcing studs have web openings of
generally circular shape formed through said web and edges of said
circular openings being formed out of the plane of said web into a
continuous annular ring.
28. The method or making a composite construction panel as claimed
in claim 27 and wherein said reinforcing studs are formed with
generally circular depressions formed alongside said web openings
and semi-circular openings formed within said depressions.
29. A steel stud suitable for use in construction of thermally
efficient buildings and comprising; a web defining two edges; a
first right angular flange formed on one said edge; a first angular
edge strip formed along the free edge of said first right angular
flange; a second right angular flange formed on the other said
edge; a second angular edge strip formed along the free edge of
said second right angular flange; web openings of generally
circular shape formed through said web between said first and
second right angular flanges; edges of said circular openings being
formed out of the plane of said web into generally annular rings;
generally circular depressions formed in said web between said web
openings and said right angular flanges; and, semi-circular
openings formed within said depressions.
30. A steel stud as claimed in claim 29 and wherein said web
between said web openings defines generally hour-glass shaped web
portions, which are narrower at about the mid point of said web,
and wherein said semi-circular openings are directed towards said
narrower portions of said hour-glass shaped web portions.
31. A steel stud suitable for use in construction of thermally
efficient buildings and comprising; a web defining two edges; a
first triangular tube formation formed on one said edge; a second
triangular tube formation formed on the other said edge; web
openings of generally circular shape formed through said web
between said first and second triangular tube formations; edges of
said circular openings being formed out of the plane of said web
into generally annular ring; generally circular depressions formed
in said web between said web openings and said triangular tube
formations; and, semi-circular openings formed within said
depressions.
32. A steel stud as claimed in claim 31 and wherein said web
between said web openings defines generally hour-glass shaped web
portions, which are narrower at about the mid point of said web,
and wherein said semi-circular openings are directed towards said
narrower portions of said hour-glass shaped web portions.
33. A composite construction member having a first thin panel of
cast material, and a second thin panel of cast material spaced from
said first panel, and a reinforcing grid of sheet metal studs
comprising parallel studs wherein said reinforcing studs have
embedment portions which are embedded into one said cast panel, and
said reinforcing studs are secured to the other said panel and
wherein each of said reinforcing studs comprises; a web defining a
free edge, which is not embedded in the panel; right angular flange
formed on said free edge; an angular edge strip formed along the
free edge of said right angular flange an embedment flange portion
formed along the opposite edge of said web, opposite to said free
edge; a retention edge strip formed on said embedment flange
portion; and, a plurality of spaced apart embedment flange openings
formed in said embedment flange portion.
34. A composite construction member as claimed in claim 33 and
including generally circular depressions formed in said web between
said web openings and said right angular flanges; and,
semi-circular openings formed within said depressions.
35. A composite construction member having a first thin panel of
cast material, and a second thin panel of cast material spaced from
said first panel, and a reinforcing grid of sheet metal studs
comprising parallel studs wherein said reinforcing studs have
embedment portions which are embedded into one said cast panel, and
said reinforcing studs are secured to the other said panel and
wherein each of said reinforcing studs comprises; a web defining a
free edge which is not embedded in a said panel; a triangular tube
formation formed on said free edge, having a first angled tube
wall, a second transverse tube wall, and a return tube wall; a free
edge of said return tube wall being fastened to said web; an
embedment flange portion formed along the opposite edge of said
web; a retention edge strip formed on said embedment flange
portion; and, a plurality of spaced apart flange openings formed in
said embedment flange portion; said embedment edge strip and edge
flange being embedded in said one panel, and said triangular tube
portion being secured to said other panel.
36. A composite construction member having a first thin panel of
cast material, and a second thin panel of cast material spaced from
said first panel, and a reinforcing grid of sheet metal studs
comprising parallel studs wherein said reinforcing studs have
embedment portions which are embedded into one said cast panel, and
said reinforcing studs are secured to the other said panel and
wherein each of said reinforcing studs comprises; a web defining a
free edge which is not embedded in said panel; a triangular tube
formation formed on said free edge, having a first angled tube
wall, a second transverse tube wall, and a return tube wall; a free
edge of said return tube wall being fastened to said web; a series
of generally V-shaped web portions extending from said free edge;
an apex on each of said V-shaped web portions; an embedment portion
formed on each said apex; and, each said apex having an embedment
opening formed therein; wherein said apex on each said V-shaped
portion is embedded in said one panel, and wherein said tubular
portion is secured to the other said panel.
37. A composite construction member as claimed in claim 36 and
including web openings of generally circular shape formed through
said web in said V-shaped web portions and edges of said circular
openings being formed out of the plane of said web, into a
continuous annular ring.
38. A composite construction member as claimed in claim 37 and
including generally circular depressions formed in said V-shaped
web portions between said web openings and said triangular
formation, and semi-circular openings formed within said
depressions.
39. A reinforcement stud for use in forming a composite
construction panel wherein the panel is formed with a thin panel of
cast material, and a reinforcing grid of sheet metal studs wherein
said reinforcement studs have embedment portions which are embedded
in the cast panel, and wherein each of said reinforcement studs
comprises; a web defining a free edge, which is not embedded in the
panel; right angular flange formed on said free edge; an angular
edge strip formed along the free edge of said right angular flange
an embedment flange portion formed along the opposite edge of said
web, opposite to said free edge, and having a retention edge strip
shaped in section as a semi-arcuate profile, formed along said
embedment flange portion; and, a plurality of spaced apart
embedment flange openings formed in said embedment flange portion.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a sheet metal stud, and in
particular to a sheet metal stud adapted to be partially embedded
in a panel of cast concrete for reinforcement of such a panel, and
to a composite panel of cast concrete having reinforcing studs
partially embedded in said concrete, and to a method of forming a
composite panel.
PRIOR ART
[0002] Steel studs of a wide variety have been proposed for
erecting structures. Usually such studs are used to replace wooden
studs. Concrete panels are also in wide use for attachment to the
exterior of structure to provide for a wide variety of functional
and aesthetic effects. Concrete panels are usually of relatively
heavy thick material of great weight. Great costs are involved in
both materials, labor transportation, and erection of such heavy
panels. Proposals have been made for using panels of reduced
thickness. Such panels are reinforced by a framework of metal
studs. Usually the metal studs are partially embedded in the
concrete. They provide great strength to the panels, and also
facilitate erection and attachment of the panels to the structure.
Usually the inside surfaces of the resulting walls are covered in
with wall sheeting, typically plaster wallboard. The sheeting is
often attached directly to the metal studs. The space between the
concrete panels and the inner sheeting is usually insulated with
suitable batts or the like. However it is known that the metal
studs conduct heat from the building interior to the concrete
panels and there are thus substantial heat losses through the
panels due to such metal studs.
[0003] Accordingly studs have been proposed with reduced heat
transfer properties. These studs were formed with generally
triangular or trapezoidal openings. These openings were positioned
so as to define diagonal struts extending across the studs. Heat
losses were thus reduced since there was less metal through which
the heat could pass. However when these panels are erected, it is
usual for the builder to run services through the studs, within the
wall. Where the openings are of these specialized shapes the
services must be such that they can fit the openings. It is not
possible to the builder to cut away any of the diagonal struts to
provide larger openings for services, since this would drastically
reduce the strength of the studs.
[0004] Another problem arose in that the triangular openings were
formed with edge flanges around their perimeter. Where these edge
flanges extended around an angular corner of the opening there was
a tendency for the sheet metal to crack. Consequently the corners
had to be radiussed or rounded out. This meant that there was more
metal at each of the corners, than was desirable for heat transfer,
and thermal losses could occur.
[0005] Another problem arose in cutting these studs to length. The
openings were arranged in pairs with one triangle facing one way
and the next facing the opposite way. Cutting such studs to length
requires that all of the openings of a particular orientation, in
all of the adjacent studs in a wall frame, shall line up. This
required to facilitate passing of services through the studs.
However due to the alternating orientation of the openings, this
requirement resulted in cutting off end portions of studs equal in
length to the space occupied by two openings, in many cases. This
was waste metal and increased the cost of the building. It has now
been surprisingly found that the use of the specialized shapes of
these stud openings, defining diagonal struts, is unnecessary, and
that heat transfer reduction is possible using circular openings in
the studs. This was not thought to be possible since circular
openings would leave excessive metal in the stud which would still
cause heat transfer losses. It has been found that by the use of
relatively small additional openings the actual heat transfer path
can be so reduced, at critical points in the stud, so as to be
substantially improve on the heat transfer reduction achieved by
the use of the specialized trapezoidal openings and diagonal struts
of earlier studs, which were generally equivalent to the heat
transfer curves of wooden studs.
[0006] Circular openings avoid the problems caused by the corners
of the triangular or trapezoidal openings and splitting of metal,
and results in a much stronger stud. The use of circular openings
greatly facilitates high speed manufacture of such studs by
punching out circular blanks of sheet metal. This leads to
economies from higher production speeds.
[0007] The circular blanks of sheet metal removed in this process
provide secondary products of a more convenient shape. This leads
to economies in the process since the blanks can be remanufactured
into secondary products and can thus be sold instead of being
discarded as waste. The cutting to length of such studs becomes
easier since every opening is the same shape and the same spacing
along the stud. This leads to economies in manufacture since the
studs can now be cut to length with less wastage of material than
was possible in the past. Most importantly, the circular openings
remove the problems for the builder who wishes to pass services
through the studs within the wall. Much larger diameter pipes can
now be fed through the studs, than was possible before. This leads
to less sales resistance due to a greater acceptance of the product
in the market place. Finally, cutting to length of a stud with
identical circular openings results in much less wastage of
material and this is another cost saving.
[0008] It will be appreciated that a stud which improves on all
these problems associated with prior studs, will have application
in general use, apart from the reinforcement of a concrete panel.
Such a general purpose stud will have minor modifications from the
panel reinforcement stud, but will be otherwise similar.
BRIEF SUMMARY OF THE INVENTION
[0009] The invention seeks to overcome the various disadvantages of
earlier systems by providing a composite construction panel and
comprising, a thin panel of concrete material, a reinforcing grid
of sheet metal studs comprising parallel studs and top and bottom
studs, wherein said studs have embedment portions which are
actually embedded into the concrete panel, and wherein each of said
studs comprises, a web defining a free edge, right angular flange
formed on said free edge, an angular edge strip formed along the
free edge of said right angular flange, an embedment flange portion
formed along the opposite edge of said web, a retention edge strip
formed on said embedment flange portion at an angle thereto, and, a
plurality of spaced apart embedment flange openings formed in said
angled flange.
[0010] The invention further provides such a composite construction
panel wherein said flange openings are formed by a series of
semi-arcuate openings located spaced apart lengthwise along said
embedment flange.
[0011] The invention further provides such a composite construction
panel and including web openings of generally circular shape formed
through said web between said embedment flanges and said free edge
flanges, and edges of said circular openings being formed out of
the plane of said web to define an annular ring.
[0012] The invention further provides a reinforcing stud for use in
forming a composite construction panel wherein the panel is formed
in a thin panel of cast material such as concrete type material,
and a reinforcing grid of sheet metal studs wherein said studs have
embedment portions which are embedded into the panel, and wherein
each of said studs comprises, a web defining a free edge, right
angular flange formed on said free edge, an angular edge strip
formed along the free edge of said right angular flange, an
embedment flange portion formed along the opposite edge of said
web, a retention edge strip formed on said flange portion at an
angle thereto and, a plurality of embedment openings formed
longitudinally spaced apart along said embedment flange
portion.
[0013] The invention further provides such a reinforcing stud
wherein said embedment openings are formed by a series of
semi-arcuate openings located spaced apart lengthwise along said
embedment flange portion.
[0014] The invention further provides such a reinforcing stud
including web openings of generally circular shape formed through
said web between said embedment flange portions and said free edge
flanges, and edges of said circular openings be formed out of the
plane of said web to define generally annular rings.
[0015] The invention provides a further form of such a stud which
is formed with a tubular formation along the free edge.
[0016] The invention provides a further form of such a stud which
is formed without a continuous embedment flange portion. In this
embodiment the web is formed as a series of generally V-shaped web
portions with spaces therebetween, and with embedment formations at
the apex of each V-shaped web portion.
[0017] The invention further seeks to provide a method or making a
composite construction panel comprising the steps of, assembling a
plurality of reinforcing studs, each having webs with circular
openings therethrough, in parallel spaced apart relation with said
circular openings aligned with one another, and with cross members
arranged transversely at the ends of said parallel studs thereby
forming a grid of studs, said parallel studs having embedment
flange portions thereon,
[0018] pouring cast material such as concrete into a form shaped to
provide a planar panel, placing reinforcing mesh in said cast
material, placing said grid of studs over said cast material in
said form and lowering the same until said embedment flange
portions are immersed in said cast material, allowing said cast
material to cure, and removing said formed composite panel
consisting of cured cast material with said grid of studs secured
in and extending from said panel.
[0019] The invention further provides a plurality of general
purpose studs for use as a replacement for conventional studs in
walls, floors, roofs and the like. Such a general purpose studs
will be similar to the several embodiments of reinforcement stud
described above, but without the embedment flange portion.
[0020] The various features of novelty which characterize the
invention are pointed out with more particularity in the claims
annexed to and forming a part of this disclosure For a better
understanding of the invention, its operating advantages and
specific objects attained by its use, reference should be made to
the accompanying drawings and descriptive matter in which there are
illustrated and described preferred embodiments of the
invention.
IN THE DRAWINGS
[0021] FIG. 1 is a perspective general illustration of a typical
thin wall panel of cast material such as concrete, of the type to
which the invention relates illustrating the reinforcing frame of
sheet metal studs partially embedded therein;
[0022] FIG. 2 is a partial perspective of an embodiment of sheet
metal reinforcing stud for use with a panel such as the panel of
FIG. 1;
[0023] FIG. 3 is a side elevation of the stud of FIG. 2;
[0024] FIG. 4 is a section along line 4-4 of FIG. 3;
[0025] FIG. 5 is a side elevation of a further embodiment of sheet
metal reinforcing stud for use where greater loading bearing is
required;
[0026] FIG. 6 is a section along line 6-6 of FIG. 5;
[0027] FIG. 7 is a schematic perspective of a further embodiment of
cast panel, in this case there being two such panels poured on
opposite sides of the reinforcing frame, to provide a two panel
wall construction;
[0028] FIG. 8 is a section of a further alternate embodiment of
stud shown used in the assembly of a two-panel structure, similar
to FIG. 7;
[0029] FIG. 9 is a side elevation of another embodiment of stud
showing a modified edge flange;
[0030] FIG. 10 is a section of the embodiment of FIG. 9;
[0031] FIG. 11 is a side elevation of one embodiment of a general
purpose stud;
[0032] FIG. 12 is a section of the embodiment of FIG. 11;
[0033] FIG. 13 is a side elevation of another embodiment of general
purpose stud, suitable for heavier duty applications; and,
[0034] FIG. 14 is a section of the embodiment of FIG. 13.
DESCRIPTION OF A SPECIFIC EMBODIMENT
[0035] Referring first of all to FIG. 1 it will be understood that
the invention relates generally to a composite wall panel 10
typically looking somewhat like the illustration of FIG. 1. Such a
composite panel 10 has a thin panel 12 of cast material , and a
reinforcing frame or grid indicated generally as 14, formed of
sheet metal studs indicated generally as 16. Typically the cast
material is concrete, but various special forms of concrete are
available, which would be suitable for the purpose. However the
invention is not limited to concrete materials as such, but
includes other panel materials which are capable of being cast into
a thin panel and allowed to cure. As will be explained below such
studs have embedment portions which are embedded into the concrete
12.
[0036] Typically the studs 16 may be arranged on twenty-four inch
centers , and may have top and bottom transverse studs 18 joining
the top and bottom ends of the studs 16. The top and bottom studs
will usually be plain C-section studs, for the sake of simplicity
in assembly.
[0037] Stud reinforced panels of earlier designs have been known,
in general, for some years. However they have suffered from various
defects, and have not achieved wide acceptance in the market place
in spite of their great advantages in theory. Some such panels were
made with studs which had undesirable and excessive heat transfer
characteristics. This resulted in heat transfer through the studs
to the exterior of the building and in cool weather produced cold
spots on the interior wall, along the line of each stud.
[0038] Condensation or so-called "ghosting" lines would then occur
along the lines of the studs.
[0039] Other panels were made with studs which were of a highly
technical design. Such studs had reduced heat transfer, but
required great care in design and manufacture to provide adequate
strength for reinforcing such a panel. In addition the design of
such studs made it difficult to pass services through the studs
within the wall. Such studs were complex in design and manufacture
of the studs was time consuming and wasteful of material.
[0040] In accordance with one embodiment of the invention , as
shown in FIGS. 2,3 and 4, one preferred form of stud 20 is shown by
way of illustrating the invention .
[0041] The stud 20 has a web 22, of whatever width is desired for
the particular application. Along one edge of the web, the "free"
edge, ie the edge that will be remote from the concrete panel,
there is formed a right angular flange 24.
[0042] Typically a further angular edge strip 26 is formed along
the edge of flange 24, for added stiffness.
[0043] Along the opposite edge, the "embedment" edge, of web 22
there is formed, in this case, an embedment flange portion 28
formed at obtuse angle, in this particular embodiment, and having a
retention edge strip 30 at an angle to flange portion 28.
Preferably strip 30 makes an acute angle relative to flange portion
28, so as to form a type of partial "hook" formation, for secure
retention in the panel.
[0044] The apex of the embedment flange portion 28 and retention
strip 30 will usually be about 3/4 of an inch from the edge of the
web for reasons to be described below. However these measurements
are merely an indication of what might be typical and are without
limitation.
[0045] Along the length of embedment flange portion 28 there are
formed a plurality of spaced apart openings 32. Openings 32 are
formed as struck out portions of sheet metal. In this case the
struck out portions will leave openings 32 which will have one
straight edge and one generally arcuate edge. Thus they will form
openings 32 of a semi-oval shape.
[0046] They are relatively long and wide so as to permit material,
such as concrete and aggregate to flow readily through such
openings during assembly as described below. The straight edge
portion of the openings 32 may in fact extend partially into the
web 22 itself.
[0047] Between the flanges 24 and flange portions 28, there is
defined the central portion of the stud known as the web 22. The
sheet metal of which the whole stud is formed has a relatively high
rate of heat conduction, much greater than that of a conventional
wooden stud, for example.
[0048] As already explained earlier forms of stud were formed with
openings through the web of a complex geometrical shape, leaving
diagonal strut portions extending across the web between the
flanges. It was thought that by forming these struts along diagonal
lines, that the heat conduction path would thus become elongated,
and therefore lead to a slower rate of heat conduction across the
web. These shapes were to some extent disadvantageous since they
required careful engineering of the diagonal struts, particularly
at their opposite ends in order to withstand shear forces across
the stud. Because the openings were generally triangular in shape
they formed relatively sharp corners. The edge lips on the cross
members had to be substantially reduced at these corners, to
eliminate splitting of the metal during forming.
[0049] It has now been surprisingly found that the rate of heat
conduction can be slowed down to the same, or to a greater degree,
without forming diagonal struts and complex shaped openings in the
web.
[0050] In accordance with the invention the web is now provided
with a series of identical circular openings 34 spaced apart along
the web 22 at regular equal intervals. These openings are formed
simply by punching out circular shaped blanks of metal from the
web. The circular blanks clearly provide an opportunity for
secondary manufacture of unrelated products, thus avoiding wastage
of sheet metal.
[0051] Around each of the circular openings the edges of the sheet
metal are formed over into generally annular flanges 36, which
define rings more or less at right angles to the plane of web 22.
These have the effect of enlarging the diameter of each opening,
and also adding stiffness to the stud. Because there are no sharp
angles, and the openings are circular, the bent over edge flanges
or rings 36 define a smooth continuous curve.
[0052] It is thus possible to provide deeper edge flanges than was
possible with the diagonal strut stud, with triangular openings.
This provides greater stiffness. Between each opening 34 there is
defined a transverse web portion 38 which is of generally hourglass
shape. The narrowest part of the web portion 38 is clearly at its
mid point 38A. This narrow area will define one area of heat
transfer reduction, since clearly the actual mass of sheet metal is
least at this point, and heat flow at any given temperature
gradient is a function of the mass of the conductor.
[0053] In order to increase still further the stiffness of the
stud, generally annular depressions 40 are formed in the web, at
each end of each of the transverse web portions 38. In order to
further slow down the rate of heat transfer, semi-circular openings
42 are formed in depressions 40. The base or straight edge of each
of these semi-circular openings forms a diameter of the depression.
Each semicircular opening 42 is formed so that its curved edge
extends towards the midpoint 38A of each web portion 38.
[0054] In this way by removing these small semi-circular portions
in the depressions 40 to leave openings 42 located at each of the
ends of the web portions 38, the heat transfer path is narrowed
once again towards each end of the web portions 38, on either side
of the openings 42. This also results in creating generally
sinusoidal heat transfer paths, which are thus longer than a direct
line from end to end of the web portion 38. These factors still
further slow down the rate of heat transfer.
[0055] The end result is a metal stud which has heat transfer
characteristics close to that of a wooden stud.
[0056] Studs made in this way have numerous advantages. They can be
manufactured more readily than more complex shaped studs.
[0057] The needed engineering characteristics of the studs can be
more readily achieved.
[0058] The manufacturing process is simpler. The process produces
less waste material, and by using the circular blanks for secondary
products the waste is almost nil. Given suitable machines the
secondary products could in fact be stamped out as part of the
whole manufacturing process of the studs themselves. The studs are
easier to use since they can be more readily be cut to length than
more complex studs, and with less wastage. The circular openings in
the studs are much more suitable for construction techniques, since
is becomes possible to pass relatively large services through these
openings.
[0059] For some applications it may be desirable to provide a stud
of greater strength. In this case the stud of FIGS. 5 and 6 may be
used.
[0060] In this case a stud 50 is shown having a web 52, and , along
one side a generally triangular tubular edge formation 53 is
formed, comprising, and first angled tube wall 54, a transverse
tube wall 56, and a return tube wall 58. The three tube walls are
formed integrally with the sheet metal of the web. The free edge 59
on return tube wall 58 is secured back to web 22 by any suitable
means, indicated generally as 60. This could be by spot welding, or
by a technique known as "metal stitching". In this latter process a
punch is forced into the two sheets of sheet metal. A female die
opposite the punch receives the formed portions of sheet metal and
allows them to expand outwardly, thus forming something like a
rivet in the two pieces of sheet metal making a secure bond between
the two portions of sheet metal. Another technique is simply to
punch out tongue portions (not shown) from both the web and the
return flange, and then simply fold the two tongue portions back
over themselves, as at 61 (FIG. 6), substantially as shown in U.S.
Pat. No 5,592,848.
[0061] Along the opposite edge of the web 52 an embedment flange
portion 62 is formed, in this case at an angle to the web 52. An
acute angle retention edge strip 64 is formed on flange portion 62.
Embedment openings 66 are formed in flange portion 62 as in the
embodiment of FIGS. 2 ,3 and 4.
[0062] In the use of either the embodiment of FIGS. 2 ,3 and 4 or
of FIGS. 5 and 6, the studs are assembled into a grid similar to
that shown in FIG. 1 and the ends of the studs are secured in any
suitable manner. Usually top and bottom studs are used to hold all
the studs into a framework. The top and bottom studs can be simple
C-sections, for convenience.
[0063] A thin layer of cast material, such as for example ,
concrete, is then poured into an open topped mold or form . The
mold or form will define the size and shape of the finished panel.
In one typical case the layer of cast material may be about 11/2
inches thick, although this may vary significantly from one job to
another. Concrete, or other such materials as thin as 1/2 inch
total may be suitable in some cases. The usual reinforcing steel
mesh will be attached to the embedment edges of the grid of studs.
The grid of studs with the mesh attached is then brought over the
open topped form, with the angled flanges 28 or 62 facing
downwards. The grid, and mesh attached thereto, is then lowered
down to the material in the form. The mesh and the angled flanges
28 or 62 are then pressed down through the surface of the material.
This will also cause the mesh and the edge strips 30 or 64 to be
completely submerged in the cast material, such as concrete.
[0064] This will allow the still semi-liquid cast material to flow
through the embedment openings 32 or 66, in the angled flanges 28,
or 62.
[0065] The cast material such as concrete is then allowed to cure
and set.
[0066] The entire composite panel can then simply be lifted out of
the form by attaching lifting gear to the grid of studs.
[0067] The panel may then be transported to a work site. The panel
can then be raised into position and secured to the building
fabric, by securing the grid of studs to the existing building.
[0068] Once in place the panel covers the exterior of the building,
and the grid of studs provide the support for placing insulation
batts (not shown), and dry wall panels (not shown) for finishing
the interior walls of the building.
[0069] Clearly, if desired, similar or modified panels can be made
of lighter gauge materials. Materials other than conventional
concrete can be used with advantage By using modified light weight
concrete, or special high strength concretes, the panel weight can
be reduced. With some such materials it is possible to provide a
panel without the use of reinforcing mesh at all. This will permit
the use of such panels for finishing interior walls of the
building. Special exterior finishes can be cured in place with the
cast panel.
[0070] Simulated brick veneers can be placed in the form before the
material is poured. They will then form the exterior finish of the
building on which the panels are erected.
[0071] The system can also be used for making hollow structures, in
which two thin wall panels are formed on opposite sides of a grid
of studs.
[0072] Such structures can be used for floors and ceilings and
roofs, or for making more substantial building walls if such are
desired. If heavier gauge studs are used these structures can be
used as load bearing walls in themselves. This will eliminate the
need for pouring building columns and floors, at least in lower
buildings.
[0073] If desired concrete or other such materials can be poured
into the interior of the hollow structure, at intervals, thus
providing what are in effect cast columns (not shown), to give
still further load bearing capacity.
[0074] Such an embodiment is shown in FIG. 7.
[0075] In this case studs similar either to the FIG. 2, 3 and 4
embodiment, or for greater strength, to the FIG. 5 and 6
embodiment, are used, as before. Their embedment flange portions 28
or 62 are embedded in a thin-wall panel, such as concrete,
indicated as 70, as already described.
[0076] On the free exposed flanges 24 or transverse tube walls 56 a
layer of metal furring of expanded mesh 72 of a type well-known in
the art, and having spaced apart attachment strips 74 formed
integrally therewith, is secured by for example bolts 76, or any
other suitable fastening system.
[0077] A second thin-wall layer of material, such as concrete, 78
is then poured directly onto the mesh 72. The material will flow
into the openings in the mesh and will form an effective bond
securing the cured material in position, attached to the grid of
studs. The composite structure formed by combining a second panel
spaced from the first panel 70 defines a hollow wall structure of
great strength supported internally by the grid of studs.
[0078] For added security the flanges 24 (or transverse walls 56)
of the studs may be formed with locking loops 80. Loops 80 are
formed simply by forming two parallel incisions in the flange and
then forming the metal outwardly into loops as shown (FIG. 7).
[0079] The loops will embed securely in the panel and make a secure
bond.
[0080] It will be appreciated that the studs may be formed of
lighter gauge sheet metal for some applications, and heavier gauge
for other applications. Similarly the specifications of the studs
may vary from one application to another. For flooring, using the
composite spaced panels of FIG. 7, studs of up to say 14 inches in
depth may be desired in some case, and made of say 12 gauge metal.
This will provide great savings in material cost, and savings of
costly down time on site, which are normally experienced while
thick concrete slab floors are poured and then allowed to cure.
[0081] Such composite floors panels can be preassembled with all
wiring and ventilation ductwork, and plumbing pipes and fittings,
in place, in a factory, under controlled conditions using mass
production practices.
[0082] For walls however studs of say 21/2 to 8 inches width may be
used and formed of 12 to 24 gauge metal. For interior building
partitions much lighter specifications may be used, and still
produce building partitions superior to conventional building
partitions made of two layers of dry wall in the conventional
manner. Interior partitions made in this way will have the great
advantage that they can be made in a secure factory location, and
completely finished, and even dry walled and painted if desired,
before they are brought to the actual building site.
[0083] Thus factory labor and mass production practices can replace
costly on site labor conventionally used for covering in and
plastering and painting walls.
[0084] For adding still further strength to the studs of FIGS. 5
and 6 the angled walls 54, and the return walls 58 may be formed
with indentations 82 at spaced intervals there along. These
indentations may be in a zig zag diagonal pattern as shown or any
other pattern suitable for the purpose.
[0085] A further embodiment of stud is shown in FIG. 8. This stud
will typically be used in fabricating a two-panel spaced structure
similar to FIG. 7. In most cases this stud would be used for
somewhat lighter duty applications, although it could be made of
heavier gauge metal for greater loads.
[0086] In this embodiment the stud 90 has a series of generally
triangular shaped webs 92 all of which extend from a generally
tubular edge formation 94. Between the webs 92 are defined
generally inverted triangular spaces 96. The webs and the spaces
are not truly triangular since the apex of each web 92 is
flattened, and the apex of each space is elongated and linear. The
word"triangular" is therefor used here as suggesting the general
shape, without being in any way limiting to a specific triangular
definition.
[0087] The tubular edge formation 94 is formed in the same way as
the tubular edge section 53 of stud 50 of FIGS. 5 and 6. The
details are not illustrated since repetition is unnecessary.
[0088] Each of the webs 92 is formed with a larger circular opening
98, formed with an annular edge flange (not shown) as in the case
of the previous embodiments. At the wider base edge of each web 92
two smaller depressions 100 and 102 are formed for added stiffness.
A semi-circular opening 104 is formed in each depression 100 and
102 as in the earlier embodiments. The apex of each web 92 is
formed with a flattened linear embedment formation 106, and
semi-arcuate embedment openings 108 are formed through the webs 92
for passage of concrete and aggregate, for locking the apex
formation 106 of each web 92 securely in a panel of concrete
110.
[0089] Locking loops 112 and formed along tubular edge formation 94
as in the case of the FIGS. 5 and 6 embodiment. These loops will
extend into the second panel of concrete 114 for locking in place.
Furring mesh (not shown) would usually be attached to tubular edge
formation 94, much the same as shown in FIG. 7. It will be
appreciated that in the foregoing description the embedment flange
portions 28 or 62 and the retention edge strips 30 or 64, have been
described and shown as bent at defined angles. This is simply to
provide added stiffness.
[0090] In many cases these two features could be made as a simple
continuous radius. Such a feature is shown in FIGS. 9 and 10.
[0091] The stud 120 has the same large openings 122 and
indentations and small openings as the studs of FIGS. 2, 3, 4, 5,
and 6.
[0092] However the embedment flange portions and retention edge
strips are formed by the smoothly curved radius bend portion 124,
having openings 126 along its length.
[0093] The studs described are intended for use in reinforcement of
concrete panels in the manner described above.
[0094] However it will be understood that with minor modifications
studs of this type could be used for general purpose studs, for use
in construction, whether such concrete panels are used on the
building exterior or not.
[0095] FIGS. 11 and 12 illustrate one form of general purpose stud
130. This is similar to the stud of FIGS. 2, 3, and 4 in many
respects. The stud 130 has first and second right angular flanges
132-132, with first and second edge strips 134-134.
[0096] Between the flanges there is a web 136, formed with larger
central circular openings 138, with annular flanges or rings 140,
as before. Depressions 142 are formed adjacent the openings 138 and
have semi-circular openings 144.
[0097] The stud 130 can be used for general construction, and can
be made wider, or of heavier gauge metal, to suit many different
applications.
[0098] FIGS. 13 and 14 show a general purpose stud or beam 150
similar in many respects to FIGS. 5 and 6. The stud or beam 150 has
first and second triangular tube formations 152-152, formed as
before, with first and second fastenings 154-154.
[0099] Between the tube formations 152 there is a web 156, formed
with larger central circular openings 158, with annular flanges
160, as before. Depressions 162 are formed adjacent the openings
158 and have semi-circular openings 164.
[0100] The stud or beam 150 can be used for general construction,
and can be made wider, or of heavier gauge metal, to suit many
different applications.
[0101] The foregoing is a description of a preferred embodiment of
the invention which is given here by way of example only. The
invention is not to be taken as limited to any of the specific
features as described, but comprehends all such variations thereof
as come within the scope of the appended claims.
* * * * *