U.S. patent application number 10/459868 was filed with the patent office on 2004-04-22 for metal framing member with off site manufactured layout locating tabs.
Invention is credited to Attalla, Anthony P..
Application Number | 20040074200 10/459868 |
Document ID | / |
Family ID | 34811149 |
Filed Date | 2004-04-22 |
United States Patent
Application |
20040074200 |
Kind Code |
A1 |
Attalla, Anthony P. |
April 22, 2004 |
Metal framing member with off site manufactured layout locating
tabs
Abstract
A metal framing member for use as a stud, joist, rafter, truss,
etc. is disclosed. The framing member includes at least one knock
out opening and a corresponding tab that is positioned onto the
metal framing member during the manufacturing process via computer
so that structures built using the studs such as window frames,
door jams, etc. are accurately and quickly fabricated. The knock
out opening can also be used as a chase to allow wiring or a
stiffening rod to pass through the member. Each tab is also
preferably provided with a pair of pre-punched holes so that the
tab can be fastened to other building components using standard
screws.
Inventors: |
Attalla, Anthony P.;
(Amherst, NH) |
Correspondence
Address: |
Anthony P. Attalla
Hexport International
10 North Riverdale Road
Weare
NH
03281
US
|
Family ID: |
34811149 |
Appl. No.: |
10/459868 |
Filed: |
June 12, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10459868 |
Jun 12, 2003 |
|
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09885843 |
Jun 20, 2001 |
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Current U.S.
Class: |
52/846 ; 52/241;
52/317 |
Current CPC
Class: |
E04C 2003/0434 20130101;
E04B 2/789 20130101; E04B 2002/7488 20130101; E04C 3/07 20130101;
E04C 2003/0473 20130101; E04C 2003/0421 20130101 |
Class at
Publication: |
052/731.1 ;
052/317; 052/241 |
International
Class: |
E04H 001/00; E04H
006/00; E04B 001/94; E04C 003/30 |
Claims
What is claimed is:
1. An off site manufactured metal framing member comprising: a
rectangular section having left and right substantially parallel
edges along the length of said section, said section also having
top and bottom surfaces; at least one knock out opening having a
lower edge, left and right side edges, and an upper radiused edge
with said edges together define a opening profile, said opening
profile disposed in said rectangular section and allowing passage
to and from said top surface and said bottom surface of said bottom
section; and at least one tab corresponding to said at least one
knock out opening and disposed at said lower edge of said opening
profile, said tab also having left and right side edges and having
an upper radiused edge with said edges taken together define a tab
profile such that said tab profile and said opening profile are
substantially the same; said at least one tab positioned at
predetermined angle with respect to rectangular section; said tab
also having at least one pair of pre-punched pilot holes such that
standard screw fasteners made be utilized to fastening a structure
to said at least one tab; and wherein said structure may be passed
through said at least one opening profile such that are passed
through said framing member by way of said opening profile.
2. The off site manufactured metal framing member of claim 1
wherein said at least one knock out opening and said corresponding
at least one tab are positioned during the manufacturing process by
a computer in accordance with a predetermined layout plan such that
the configuration and position of said at least one knock out
opening and said corresponding at least one tab serve to precisely
locate any other structural member that is to be attached to said
framing member.
3. The metal framing member of claim 1 further comprising a
plurality of knock out openings with each knock out opening have a
corresponding tab with each opening tab pair wherein at least one
opening tab pair is located at different distance along said metal
framing member than another opening tab pair.
4. The metal framing member of claim 1 wherein the predetermined
angle of at least one tab is substantially different than 90
degrees.
5. The metal framing member of claim 1 wherein the predetermined
angle of at least one tab is approximately 90 degrees.
6. An off site manufactured metal framing member comprising: a pair
of opposed flanges; and a central web portion disposed between said
pair of opposed flanges; said central web portion having at least
one knock out opening; and said central web portion having at least
one tab that corresponds to said knock out opening wherein said at
least one knock out opening and its corresponding said at least one
tab are cut into said central web portion such that said at least
one knock out opening and its corresponding said at least one tab
are hinged together at a common edge and are positioned onto said
central web portion during the manufacturing process of
constructing said metal framing member; and wherein said tab is
angled at a predetermined angle relative to said central web
portion and wherein said at least one tab and its corresponding
said at least one knock out opening and its corresponding said at
least one tab are approximately the same size and approximately the
same peripheral shape.
7. The off site manufactured metal framing member of claim 6 where
each of said tabs further comprises at least one pair of
pre-punched pilot holes such that standard screw fasteners made be
utilized to fastening a structure to said tab
8. The off site manufactured metal framing member of claim 6
wherein the position of said at least one knock out opening and its
corresponding said at least one tab is accomplished by a computer
that places said position in accordance with structural layout for
which said metal framing member is to be used.
9. The off site manufactured metal framing member of claim 6 where
the peripheral shape of at least one said tab and its corresponding
at least one knock out opening is rectangular.
10. The off site manufactured metal framing member of claim 7 where
the peripheral shape of at least one said tab and its corresponding
at least one knock out opening is rectangular and has an curved
edge opposite to said hinged edge wherein said curved edge has an
predetermined radiused arc.
Description
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 09/885,843, filed Jun. 20, 2001, now
abandoned.
FIELD OF THE INVENTION
[0002] This invention relates to dwelling framing members, and in
particular, to an attachment tab and opening which may be used a
chase or to attach one stud to another in such members by having
the tab and its corresponding knock out positioned onto the metal
stud via computer in accordance with the layout plans of the
structure that is to be formed.
BACKGROUND OF THE INVENTION
[0003] Structural members are frequently made of metal, as it is
advantages over wooden structural members. Compared to wood, metal
is insect proof, fire proof, and has high uniformity and strength.
However, its use is limited due to high cost, erection problems,
and handling difficulties. U.S. Pat. No. 5,315,804, issued to
Attalla, addresses some of these concerns. The patent discloses an
improved metal framing member that utilizes stiffening sections to
enable lighter gauge of metal to be used. The framing member also
features embossed surfaces that facilitate fastening using standard
self-tapping fasteners. Safety edges are provided to eliminate the
sharp edge problem of handling metal framing members.
[0004] In addition to the above concerns, a framing member often
must be provided with a chase to allow wiring or other objects to
pass through the member. Introducing this chase after the framing
member has been fabricated, as well as clipping or attaching the
wiring to the member, can be tedious and time consuming. The patent
mentioned above does not address this concern.
[0005] U.S. Pat. No. 5,943,838, issued to Madsen et al. on Aug. 31,
1999, discloses the use of a bendable tab which must be bent on the
job by the metal stud installer. The use of the STRONG STUD taught
in the '804 patent which utilizes heavy gauge, high strength
material would make accurate and effective bending by the installer
costly and difficult. Further, manual bending for even heavier
gauge material that might be necessary in certain construction
environments would be impossible.
[0006] Further, Madsen et al. teaches the use of a tab that is
substantially less than that of the opening or knock-out. However,
the Madsen et al. knock-out opening is substantially greater than
the size of the tab which weakens the stud and potentially can
cause buckling or torsion problems. Nor does Madsen et al. disclose
or suggest the use of pre-punched pilot holes but instead relies
solely on the use of self-tapping screws to connect the tab to
another structure.
[0007] Therefore, what is needed is an improved metal framing
member that includes a manufactured locating tab that is suitable
for all metal studs, irrespective of the gauge of the metal, that
can be placed at predetermined positions within the stud to serve
to locate the attachment of other studs, has a knock-out opening
that substantially the same size as the size of the tab, has
pre-formed pilot holes for simplifying the installation of standard
screw fasteners, and can serve as a preformed chase and a means of
clipping objects passing through the chase to the member. A metal
framing member including such a chase and that is low cost and can
be handled safely is not found in the prior art.
SUMMARY OF THE INVENTION
[0008] The present invention is a metal framing member including at
least one manufactured locating tab. The framing member has a
substantially rectangular cross-section. Preferentially, at least
two stiffeners run longitudinally along the metal framing member. A
tab is cut out of the bottom portion between the two stiffeners.
The tab resulting from the knock out is bent substantially
perpendicular to the surface which the tab is positioned thereon.
The bent punch tab operates with a fastener as a clip to attach
objects passing through the chase to the framing member. The tab
also serves to define how the framing members are laid out to
provide window locations, door locations, headers, etc. Each tab is
made at the factory using computer software to accurately match
each position in accordance with the building design.
[0009] Left and right rectangular side sections are substantially
perpendicular to the bottom portion containing the stiffeners. The
side sections have radiused edges along their top and bottom
lengths. The bottom lengths join the left and right edges of the
bottom section respectively. Rectangular returns are attached to
each side section so that the returns are substantially
perpendicular to the side sections. The returns are substantially
parallel to the bottom portion.
[0010] Therefore, it is an aspect of this invention to provide an
improved metal framing member.
[0011] It is another aspect of the invention to provide a framing
member with a prefabricated chase.
[0012] It is a further aspect of the invention to provide a metal
framing member with a means to secure objects passing through a
chase to the framing member.
[0013] It is still another aspect of the invention to provide a
metal framing member that has computer generated tabs to
intricately mark the metal framing member to provide precise
attachment points to ensure that the structure is being fabricated
in accordance with design plans.
[0014] Another aspect of the invention is to provide a metal
framing with at least one tab wherein the tab has a knock out area
or opening that is substantially the same size and geometry of the
tab.
[0015] Still another aspect of the invention is to provide a metal
framing with at least one tab that provide accurate and dependable
fixed locations for key elements of the design to eliminate
installation errors and increase the productivity of the framing
process.
[0016] These aspects of the invention are not meant to be exclusive
and other features, aspects, and advantages of the present
invention will be readily apparent to those of ordinary skill in
the art when read in conjunction with the appended claims and
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is an isometric view with a partial cut away view of
the framing member showing one manufactured layout locating
tab.
[0018] FIG. 2 is a detail showing the knock out opening that can be
used as a chase in the framing member.
[0019] FIG. 3 is a top view of the tab.
[0020] FIG. 4 is a cross sectional view of the framing member
illustrating the stiffeners used in the preferred embodiment.
[0021] FIG. 5 is a cross sectional view of another embodiment of
the framing member without the stiffeners.
[0022] FIG. 6 is still another alternative embodiment of the
framing member showing a plurality of manufactured layout locating
tabs.
[0023] FIG. 7 is a detailed view of one tab positioned within
framing member shown in FIG. 6.
[0024] FIG. 8 is cross sectional view of the tab within the framing
member shown in FIG. 6.
[0025] FIG. 9 is another embodiment of manufactured layout locating
tab shown in the framing member depicted in FIG. 6.
[0026] FIG. 10 is a detailed view of the tab embodiment shown in
FIG. 9.
[0027] FIG. 11 is a cross sectional view of the alternative
embodiment of the tab.
[0028] FIG. 12 is front view of a typical wall that is constructed
with framing members in accordance with the invention.
[0029] FIG. 13 illustrates a stiffening member that is inserted
through the knock out opening of the framing member and attached to
the tab provided via the knock out.
[0030] FIG. 14 shows a typical stress that may be constructed using
the framing members in accordance with the invention.
[0031] FIG. 15 illustrates that manufactured layout locating tab
may be positioned anywhere on the framing member including the
end.
DETAILED DESCRIPTION OF THE INVENTION
[0032] FIG. 1 illustrates metal framing member 10 with knock out
opening 12 and tab 14. While tab 14 is usually made so that tab 14
is approximately 90 degrees with surface 16, since tab 14 is made
at the factory using computer assisted machinery, any precise angle
may be selected. (See, e.g. FIG. 13) Tab 14 and its corresponding
knock out opening 12 are preferably located centrally in surface
16, which runs the length of framing member 10. However, since the
stud is manufactured to the design specifications necessary to
ensure precision and ease of fastening, other positions can be
easily be selected. In fact, different locations on surface 16 as
well as different tab angles could be provided in each framing
member if desired.
[0033] Surface section 16 is generally 6" to 8" wide. In the
preferred embodiment, surface section 16 includes stiffeners 18,
which run longitudinally along surface section 16. Typically, as
noted above, knock out opening 12 is centrally located between
stiffeners 18. Note that the geometry and size of knock out opening
12 and tab 14 are substantially the same, differing primarily due
to the width of the cut. By having opening 12 and tab 14
substantially the same, less material is wasted and the framing
member is stronger thus exhibiting a greater resistance to torsion
forces and axis buckling.
[0034] Knock out opening 12 is shown in detail in FIG. 2. Opening
12 is cut out of surface portion 16 in an area preferably no
greater than two inches by two inches. Because this opening and tab
14 are made during the time of manufacturing the framing member 10,
the gauge of framing member 10 can be far thicker than would be
otherwise possible if the installer had to bend tab 14 at the
construction site.
[0035] In the preferred embodiment, opening 12 is 1 {fraction
(11/16)}" by 1{fraction (11/16)}", with upper end 20 of the chase
having a radius of 7/8" instead of being cut square. Tab 14 is not
completely severed from opening 12, but is connected along lower
edge 22. Preferably, tab 14 is folded up at lower edge 22 so that
tab 14 is substantially perpendicular to raised surface section 16.
However, as noted above, other angles are easily selectable
depending on the needs of the construction project.
[0036] FIG. 3 details tab 14. In addition to the primary purpose of
tab 14 to provide an accurate positioning and fastening location
for adjacent framing members, tab 14 can serve as a point of
attachment for any objects passing through opening 12 such as
wiring. Wiring or other objects may be passed from one side of the
framing member to the other through opening 12 thus serving as a
chase. These objects may then be fastened to tab 14 without adding
additional clips.
[0037] In the preferred embodiment, two holes 24 are provided in
tab 14 to serve as fastener holes. One hole 24 is positioned 1/2"
from lower edge 22, while the other is positioned 1/2" from rounded
edge 26. Holes 24 are otherwise centered on tab 14. Holes 24
preferably have a radius of {fraction (3/32)}" and are capable of
receiving standard screw fasteners (not shown) to attach wiring,
stiffening rods, or other framing members to tab 14.
[0038] Returning to FIG. 1, metal framing member 10 includes left
and right rectangular sections 28. Rectangular side sections 28 are
preferably at least 15/8" in length, but may vary depending on the
particular need for the framing member. Rectangular side sections
28 share an edge with surface section 16 and are substantially
perpendicular to surface section 16 while being parallel to each
other. At the distal ends of rectangular side sections 28 are left
and right rectangular returns 30. Left and right rectangular
returns 30 are preferably perpendicular to rectangular side
sections 28 and parallel to bottom section 16.
[0039] FIG. 4 is a cross section of metal framing member 10,
including stiffeners 18 that run the length of the member.
Stiffeners 18 are ideally located on surface section 16 about
11/2"to 2" in from rectangular side sections 28, depending on the
width of bottom section 16. As can be seen from FIG. 4, rectangular
returns 30 do not generally extend out over stiffeners 18. It can
also be seen that corners 32, formed where rectangular side
sections 28 meet bottom section 16, and corners 34, formed where
rectangular returns 30 meet rectangular side sections 28, may be
radiused edges rather than sharp corners.
[0040] FIG. 5 is a cross section of an alternate embodiment of
framing member 10. In this embodiment, bottom section 16 does not
include stiffeners 18. Rather, surface section 16 is flat across
its entire width other than opening 12 and tab 14.
[0041] As shown in FIG. 6-8, another alternative embodiment of the
framing member 15 showing a plurality of manufactured layout
locating tabs 14. Note that position of tabs 14 and the
corresponding knock out openings 12 can be located anywhere along
framing member. That is, it is unnecessary to use only 16 inches on
center as would be required if tabs 14 and openings 12 were not
made specifically to meet the requirements of each and every
construction project.
[0042] FIG. 9 is another embodiment of manufactured layout locating
tabs 14' shown in the framing member depicted in FIG. 6. In this
embodiment, tabs 14' and their corresponding knock out openings 12'
are rectangular in shape. Clearly, other shapes are likewise
possible such triangular, octagonal, hexagonal, etc. depending on
the job requirements. Since the tabs and openings are made during
the construction process of framing member, with the tab aligned at
the predetermined angle relative to the web surface of framing
member, a virtual infinite number of tab permutations and
combinations are possible.
[0043] FIG. 12 shows a typical framed wall that using the tabs 14
to attached on framing member to the next in precise alignment.
Noted that distance between the respective framing members is not
always a standard (16 inches O.C.) so that the tabs (not shown) on
header framing member 42 are adjusted accordingly. Also, openings
and tabs can be provided so that cross bracing members 44 and 46
are accurately position therethrough thus providing a tab for
attachment as well as making certain the framed wall is square.
This can be seen more clearly in FIG. 13 which shows that tab 14 is
positioned at an angle other 90 degrees with respect to surface
portion 16.
[0044] As shown in FIG. 14, the framing member invention can even
be used to construct trusses which require joining one framing
member to another at varying angles and positions. The flexibility
of this system is clearly illustrated in FIG. 15 which illustrates
that tab 14 can be positioned at the top of framing member 10 such
that one framing member 10 can be attached to another at
substantially right angles.
[0045] Although the present invention has been described with
reference to certain preferred embodiments thereof, other versions
are readily apparent to those of ordinary skill in the art.
Therefore, the spirit and scope of the appended claims should not
be limited to the description of the preferred embodiments
contained herein.
* * * * *