U.S. patent application number 12/005413 was filed with the patent office on 2009-01-15 for metal framing members.
Invention is credited to Gordon Aubuchon.
Application Number | 20090013633 12/005413 |
Document ID | / |
Family ID | 40251974 |
Filed Date | 2009-01-15 |
United States Patent
Application |
20090013633 |
Kind Code |
A1 |
Aubuchon; Gordon |
January 15, 2009 |
Metal framing members
Abstract
Methods of producing a metal framing member having a plurality
of screw tunnels, metal framing members prepared using such
methods, and metal framing systems using such metal framing
members. The metal framing sheet in one aspect has an undulating
surface where projections and associated depressions are formed on
opposite sides of the metal sheet in a coordinated pattern. The
metal sheets may be produced through the use of rolls having a
variety of patterns and/or projections and recesses that the sheet
metal is pressed between. In one aspect the rolls have a honeycomb
pattern that is advantageous in many ways including enhanced screw
retention, surface penetration, acoustical and thermal performance,
sheet rigidity and load bearing capability.
Inventors: |
Aubuchon; Gordon; (Houston,
TX) |
Correspondence
Address: |
MORGAN LEWIS & BOCKIUS LLP
1111 PENNSYLVANIA AVENUE NW
WASHINGTON
DC
20004
US
|
Family ID: |
40251974 |
Appl. No.: |
12/005413 |
Filed: |
December 27, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60877700 |
Dec 29, 2006 |
|
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Current U.S.
Class: |
52/634 ;
29/897.312 |
Current CPC
Class: |
E04C 3/07 20130101; Y10T
29/49627 20150115; E04C 2003/0473 20130101; B21D 13/02
20130101 |
Class at
Publication: |
52/634 ;
29/897.312 |
International
Class: |
E04C 3/09 20060101
E04C003/09; B21D 47/04 20060101 B21D047/04 |
Claims
1. A metal member for use in framing buildings and adapted to
preferentially receive screws to attach peripheral materials to the
metal member, comprising: a sheet of metal having one or more
generally planar surfaces with at least a portion of one generally
planar surface being embossed such that a plurality of screw
tunnels having mating surfaces for substantial screw engagement are
formed, wherein a cross-sectional dimension of the screw tunnel at
a plane at which a screw enters the screw tunnel is between about
40% and about 80% of a minor diameter of the thread of a screw to
be received by the metal member.
2. The metal framing member of claim 1, further comprising a web
and at least one flange.
3. The metal framing member of claim 2, wherein one or more of the
screw tunnels are in the web.
4. The metal framing member of claim 2, herein one or more of the
screws tunnels are in the flange.
5. The metal framing member of claim 2, wherein both the structural
portion and at least one flange have screw tunnels.
6. The metal framing member of claim 1, wherein the metal framing
member comprises at least one of the galvanized, aluminized,
galv-annealed, electro-galvanized and pre-painted steel.
7. The metal framing member of claim 1, wherein the metal framing
member is made of steel.
8. The metal framing member of claim 1, wherein the metal framing
member has a thickness of between about 0.01'' and about
0.140''.
9. The metal framing member of claim 1, further comprising a
coating comprising at least one of paint, resin, and lacquer.
10. The metal framing member of claim 1, wherein the plurality of
screw tunnels has a circular, hexagonal, or octagonal cross
section.
11. The metal framing member of claim 1, wherein the plurality of
screw tunnels has conical, cylindrical, or flat-bottomed
projections.
12. The metal framing member of claim 1, wherein the plurality of
screw tunnels has a honeycombed cross-section with conical,
cylindrical, or flat-bottomed projections.
13. The metal framing member of claim 1, wherein the metal framing
member has a top surface and a bottom surface, and the screw
tunnels protrude from at least one of the top surface and the
bottom surface.
14. A method of producing a metal framing member comprising:
providing a metal sheet having a top surface and a bottom surface,
forming a plurality of screw tunnels having mating surfaces for
substantial screw engagement, wherein a cross-sectional dimension
of the screw tunnel at a plane at which a screw enters the screw
tunnel is between about 40% and about 80% of a minor diameter of
the thread of a screw to be received by the metal member.
15. The method of claim 14, wherein the metal framing member
comprises a structural portion and at least one flange.
16. The method of claim 15, wherein one or more of the screw
tunnels are in the structural portion.
17. The method of claim 15, wherein one or more of the screw
tunnels are in the flange.
18. The method of claim 15, wherein both the structural portion and
at lest one flange have screw tunnels.
19. The method of claim 14, wherein the metal sheet is made of at
least one of galvanized, galv-alume, galv-annealed,
electro-galvanized, and pre-painted steel.
20. The method of claim 14, wherein the metal sheet is made of
steel.
21. The method of claim 14, wherein the metal sheet has a thickness
of between about 0.01'' and about 0.140''.
22. The method of claim 14, further comprising applying a coating
material to the metal framing member.
23. The method of claim 22, wherein the coating material is a
paint, a resin, or a lacquer.
24. The method of claim 22, wherein the coating material is applied
by spraying, dipping, or rolling.
25. The method of claim 14, wherein the screw tunnels are formed by
embossing or pressing.
26. The method of claim 14, wherein the screw tunnels are formed by
embossing, wherein the embossing is performed using embossing
rolls.
27. The method of claim 14, wherein the plurality of screw tunnels
has a circular, hexagonal, octagonal or other geometric
cross-section.
28. The method of claim 14, wherein the plurality of screw tunnels
has conical, cylindrical, or flat-bottomed projections.
29. The method of claim 14, wherein the plurality of screw tunnels
has a honeycomb cross-section with conical, cylindrical, or flat
bottomed projections.
30. The method of claim 14, wherein the plurality of screw tunnels
have lengths of between 0.018'' and 0.250''.
31. The method of claim 14, wherein the metal sheet has a top
surface and a bottom surface, and the screw tunnels protrude from
at least one of the top surface and the bottom surface.
Description
BACKGROUND OF THE INVENTION
[0001] The invention of the present application is directed to the
manufacture of metal sheet material and the material itself;
including metal framing, as may be used in building construction,
among other applications. The invention is more particularly
directed to metal framing members (i.e., metal studs) having screw
tunnels, also referred to as "screw sleeves" or "screw sockets",
for securely fastening materials (i.e., sheet rock or plywood,
among others) to the studs during construction as well as the
processes and structures for forming the sheets of material and the
metal frame segments.
SUMMARY OF THE INVENTION
[0002] Gypsum board, cement board, insulation panels, plywood, OSB
board, nail board, fire/water/impact resistant wall panels (i.e.
DragonBoard), stucco and synthetic stucco systems, interior and
exterior fascia materials, metal stiffeners, and metal framing may
be fastened to commercially available metal framing sections using
screws. When attaching materials to the metal framing member,
screws (such as penetrating metal screws) are utilized. The contact
between the screw and the metal framing anchors the screw,
permitting a material to be sandwiched between the framing and the
head of the screw. In conventional systems, only a limited surface
area of the sections contacts the screws. By increasing the contact
area between a screw and the metal framing, the "surface screw
penetration" is improved to more firmly anchor the screw, and
consequently more securely fasten a material to the metal framing.
Additionally, the secure fastening of building materials is a
consequence of the improved screw retention disclosed by the
invention. Screw retention is a significant performance indicator
and demonstrates the resistance of the screw from stripping when
applied at high speeds with a screw gun. In one aspect, screw
retention is measured by an amount of force required for "pull-out"
of the attached screws. ASTM 645 is a standard associated with this
method of testing and measurement.
[0003] Conventional sheet metal material is enhanced by processes
of the invention that form undulating surfaces throughout the
entire sheet or a portion thereof. Advantages of weight reduction
and cost savings by using less material (thinner sheet), improved
acoustical and thermal performance, and rigidity and load bearing
ability both transversely and longitudinally are just a few of the
benefits of the disclosed invention. Certain aspects of the present
invention are directed to the metal framing members comprising a
plurality of screw tunnels. In some embodiments, the metal framing
members include a structural portion (web) and at least one flange
portion, whereby at least one or more screw tunnels may be formed
in at least one of the structural portion and the flange. According
to the invention, in other embodiments screw tunnels are formed in
both flanges. In some embodiments, the metal framing member may
have a top surface and a bottom surface, and the screw tunnels may
protrude from at least one of the top surface and the bottom
surface.
[0004] Some aspects of the present invention are directed to
methods of producing a metal framing member including, forming a
plurality of screw tunnels in at least a portion of a top surface
or a bottom surface of a metal sheet. The tunneled metal sheet may
then be formed into a metal framing member. In certain embodiments,
the screw tunnels may be formed by embossing or pressing. In some
embodiments of the present invention, the metal sheet may be
embossed using embossing rolls to form screw tunnels. Embossing
rolls known in the art may be used.
[0005] Certain embodiments of the present invention are directed to
the methods of attaching a peripheral material to the metal framing
member. A screw (i.e., a penetrating metal screw) may be screwed
through a peripheral material and into a screw tunnel in the metal
framing section. According to certain aspects of the invention, the
screw tunnel comprises an interior surface and the screw may be
brought into contact with the interior surface of the screw tunnel,
wherein the surface screw penetration is significantly improved
compared to prior art systems and screw retention is superior.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1(a) depicts a plan view of one embodiment according to
the invention showing projections on one side of a material
sheet;
[0007] FIG. 1(b) is a cross-section view of the embodiment shown in
FIG. 1(a);
[0008] FIG. 2(a) depicts a plan view of another embodiment
according to the invention showing projections formed on both sides
of a material sheet;
[0009] FIG. 2(b) is a cross-section view of the embodiment shown in
FIG. 2(a);
[0010] FIG. 2(c) is a perspective view of the embodiment shown in
FIG. 2(a)
[0011] FIG. 3 depicts a structural member with screw tunnels in a
portion of a web according to one aspect of the invention;
[0012] FIG. 4 depicts a structural member with screw tunnels in a
portion of a flange according to another aspect the invention;
[0013] FIG. 5 depicts a structural member with screw tunnels
covering both the web and flanges; and
[0014] FIG. 6 depicts one embodiment of a screw tunnel according to
the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Certain embodiments of the present invention are directed to
metal framing members comprising a plurality of screw tunnels
(screw sleeves or sockets). The metal framing member (i.e., metal
stud) may have a variety of different cross sections and may be
structural (e.g., weight carrying/load bearing) or
nonstructural.
[0016] In some embodiments the metal framing section may include at
least one of galvanized, aluminized, galv-alume, galv-annealed,
electro-galvanized, and pre-painted steel. When painted the paint
can be applied over bare steel (cold rolled and hot rolled) but is
typically applied over one of the previously listed finishes. The
sheet material is preferably mild steel, which may be galvanized or
otherwise coated for protection against corrosion. High Strength
Steels are also employed according to the invention. Pre-painted
galvanized is a popular combination. Many of the known materials
and coatings may be used for metal stud applications due to their
common availability and suitability for the manufacture of metal
stud and metal framing members. In some aspects, metal framing is
able to employ these materials in conditions of prime, secondary,
reject or surplus provided the materials are within the intended
specifications of thickness, formability and corrosion resistance.
Certain materials, such as aluminum and stainless steel, may be
used but are generally too costly for this application. The metal
framing member may have a thickness of between 0.01'' and 0.140''
in some embodiments. In certain aspects, the metal framing member
may have a coating comprising at least one of paint, resin, and
lacquer.
[0017] The metal framing member may be produced by shaping a metal
sheet. The metal framing member may be formed to comprise a
structural portion and at least one flange. The structural portion
may contribute to the ability of the metal framing member to
withstand a specific load. At least some of the screw tunnels may
be formed in the web of the metal framing member and/or in a
flange. In some embodiments, screw tunnels are formed in only one
flange. In certain aspects, screw tunnels are located in both
flanges.
[0018] According to the invention, the amount and location of the
embossing may be a design and/or performance consideration. For
example, the sheet material may be embossed only in the web or
flanges or only in a portion of the web or flanges. Such a design
may reduce tooling costs and maintenance and this is typically
where the screws are used to engage the sheet material. In these
embodiments, the web sections may be stiffened through the use of
partial or complete embossing, stamping or corrugations to provide
additional strength and/or to compensate for a reduction of the
sheet material thickness.
[0019] The present invention relates to sheet material having on
one side or both of its faces a plurality of rows of projections
whereby each projection is formed by deforming the sheet material
locally to leave a corresponding depression at the opposite face,
such that the mass or thickness of the material required for a
particular application may be reduced. In one aspect the metal
framing sheet has an undulating surface where projections and
associated depressions are formed on opposite sides of the metal
sheet in a coordinated pattern such that projections from one side
are integrated with projections formed from the other side. Of
course, the patterns need not be coordinated or may be random. In
one embodiment, rows of alternating projections and depressions
extend in one direction wherein straight lines can be drawn on a
surface of the material between adjacent ones of these rows.
Perpendicular rows of alternating projections and depressions may
also extend wherein a second group of straight lines can be drawn
on the surface of the material. In some of the embodiments, the
array of projections on one face of the material is substantially
identical with the array of projections on the other face of the
material. The undulating surface is formed in the sheet metal by
pressing the material past its yield point. Such an embodiment
results in "stretching," rigidizing," and increasing the strength
of the original material both by its design and by work hardening
of the metal. The stiffening effect associated with deep metal
embossing is one of the advantages of the current invention.
[0020] The screw tunnels may be formed by embossing or pressing a
metal sheet according to certain aspects of the invention. The
metal sheets may be produced through the use of rolls having a
variety of patterns or projections and recesses that the sheet
metal is pressed between. In certain aspects, a metal sheet may be
embossed using power-drive, mated embossing rolls. The sheet metal
may have a top surface and a bottom surface, and the screw tunnels
may be formed to protrude from at least one of the top or bottom
surface. Each screw tunnel may have a circular, hexagonal,
octagonal or other geometric cross-section. In one aspect the rolls
have a honeycomb pattern. The projections/recesses of the rolls and
the corresponding screw tunnels may be rounded, cone shaped, edged,
flat, fluted, etc. as long as the tunnels meet the screw retention
and surface penetration requirements, and the other precepts set
forth by the invention. In one preferred embodiment a honeycomb
cross-section is combined with a conical projection/recess. In
certain embodiments, a hole or opening may be constructed or formed
at the peak of the projection or projections or elsewhere in the
surface area through the use of rollers or via other means. Such a
design has many advantages including enhancing screw starts,
acoustical dissipations, and holding less moisture.
[0021] In one aspect of the invention, the objective of the screw
tunnel's initial and tapering dimensions is to correspond with the
dimensions of the body and threads of the metal screws typically
used in the application of affixing building materials to metal
studs. The screw body dimensions are measured in terms of the Major
Diameter, the measurement of the outside diameter of the screw
threads; and the Minor Diameter, the measurement of the screw body
inside of the threads.
[0022] The screw tunnel dimensions have a purpose and similarity to
the "pilot hole" dimensions used in preparing wood studs, as the
interior surface of the screw tunnel provides for the metal to form
around the screw body and control the breakage and splitting of the
sheet metal as the screw pierces the metal thickness of the framing
member and the metal forms around the body of the screw.
[0023] The Major and Minor dimensions of screws associated with
Metal Framing usage are typically expressed in the industry
standardized numerical sizing of #0, #1, #2, #3, #4, #5, #6, #7,
#8, #9, #10, etc. and larger. Numbered sizes of #6, #7 and larger
are typical for usage with metal framing. In addition to the
numbered size, a thread type is also specified, such as "coarse" or
"fine" or "high-low", which primarily affects only the Major
Diameter and number of threads per inch, leaving the Minor Diameter
consistent within the numbered type. The scope of the present
invention provides for the correspondences on all screw types and
sizes used for application with metal studs. The relationship of
dimensions required is that the screw tunnel entrance diameter
exists in a range of ratios from about 4/10ths to about 8/10ths to
the Minor Diameter of the screw being applied.
[0024] For example, the #6 drywall screw in both "coarse" and
"fine" thread design is among the most common used with
non-structural steel studs, which are typically 0.040'' and lighter
in parent metal thickness for the framing member. The #6 screw is
designed with a Major Diameter of about 0.145'' and a Minor
Diameter of about 0.102''. Therefore the screw tunnel may be
present with an initial opening dimension of about 0.040'' (
4/10ths) to 0.080'' ( 8/10ths) relative to the Minor Diameter of
the screw body.
[0025] In another example, the #7 screw in both "coarse" and "fine"
thread is designed with a Major Diameter of about 0.156'' and a
Minor Diameter of about 0.113. Therefore the screw tunnel may be
present with an initial opening of about 0.045'' ( 4/10ths) to
0.090'' ( 8/10ths).
[0026] By way of further example, the #8 screw in both "coarse" and
"fine" thread is designed with a Major Diameter of about 0.170''
and a Minor Diameter of about 0.123''. Therefore the screw tunnel
may be present with an initial opening of approximately 0.048'' (
4/10ths) to 0.098'' ( 8/10ths).
[0027] This relationship of Minor Diameters to the Screw Tunnel
opening dimensions exists throughout the full industry standardized
range of screw sizes as described in the #6, #7 and #8 examples
presented above.
[0028] The relationship between the screw size and the screw tunnel
has an effect upon the screw retention and pull out values as the
amount of contact area between the screw and the metal which it is
penetrating increases. Pull out values will be further improved
when the screw is pulled out, rather than screwed out, as the screw
tunnel will collapse in the direction that the screw is being
pulled, increasing the metal thickness embracing the screw body in
the direction of the pull out.
[0029] Screw retention is improved with screw tunnel depth. In one
preferred embodiment, the screw tunnel depth may be about
1.5.times. or greater than the original parent metal thickness and
not less than about 0.030'' regardless of the parent metal
thickness. A starting thickness of 0.0438'' (18 gauge) therefore
requires a tunnel depth of about 0.065''; 0.0329'' about 0.049'';
0.025'' about 0.037''; 0.0179'' about 0.026''; 0.015'' about
0.022''; and 0.012'' about 0.018''. In this preferred embodiment,
an increase in screw retention of about 20% is achieved by the use
of the screw tunnel when compared to flat material of the same
average thickness not employing the inventive screw tunnel
design.
[0030] Certain aspects of the invention are directed to methods of
producing a metal framing member (i.e., metal stud) including,
forming a plurality of screw tunnels in at least a portion of a top
surface or a bottom surface of a metal sheet, and shaping the
tunneled metal into a metal framing member by means roll forming,
press brake forming or other conventional methods of cold forming
metals. A coating material, such as paint, resin, or lacquer, may
be applied to the metal framing member, in some aspects of the
present invention. A coating material may be applied by spraying,
dipping, or rolling in some embodiments.
[0031] In certain embodiments the studs, including the screw
tunnels, may be coated. A lacquer or other corrosion inhibitor may
be applied alone or in combination with the coating as deep
embossing may result in some cracking and stretching of the
galvanized finish or other original coating applied to the parent
metal. Additionally, embossed areas may hold water and therefore
are preferably manufactured in a way to prevent against rust and
other environmental problems. The coatings, when applied, dependent
upon type and thickness, may improve screw retention.
[0032] As discussed above, the screw tunnels may be produced in the
sheet material by using power-driven embossing rolls. Alternative
methods of embossing include conventional stamping or rotary
stamping.
[0033] Embossing rolls may be manufactured in a variety of ways
including machining, direct casting, acid etching, laser cutting
and other methods. The projections and recesses needed to produce
the undulating sheet material, creating the plurality of screw
tunnels may be arranged in a variety of forms according to the
invention. A honeycomb or hexagonal shape is shown in FIGS.
1(a)-(b) in sheet 10. Screw 12 is shown inserted into one of screw
tunnels 11 in sheet 10. A symmetrical projection design in which
projections alternate between projecting to one side and the other
side is shown in FIGS. 2(a)-(c). According to the principles of the
invention, suitable sheets may be embossed with various patterns of
different geometric shapes, allowing for variations in sheet
rigidity.
[0034] Screws 22 are shown inserted into two of screw tunnels 21 of
sheet 20. In one embodiment, the rolls are mounted for relative
rotation about respective parallel axes spaced apart by a distance
such that the projections on a first roll extend into the recesses
between projections on the second roll. In this aspect, the rolls
are driven at the same speed as the parent sheet metal is passed
between the rolls.
[0035] According to the invention, in any of these methods of
creating a honeycomb or alternate pattern through rolling, the
resulting screw tunnel projections can be conical, cylindrical, or
flat bottomed.
[0036] Certain embodiments of the invention are directed to methods
of attaching a peripheral material to a metal framing member (i.e.,
metal stud) including, screwing a screw (i.e., a penetrating metal
screw) through the peripheral material and into a screw tunnel.
Each screw tunnel has an interior surface and during attachment of
the peripheral material the screw may be brought into contact with
the interior surface of the screw tunnel. The peripheral material
may be gypsum board, cement board, insulation panels, plywood, OSB
board, nail board, fire/water/impact resistant wall panels (i.e.,
DragonBoard), stucco and synthetic stucco systems, interior and
exterior fascia materials, metal stiffeners, or metal framing,
among others.
[0037] In an embodiment shown in FIG. 6, the interior dimensions of
a screw tunnel of the present invention may be sized in accordance
with a metal screw's minor and major diameters thereby increasing
the surface area of the screw body engaging the interior of the
screw tunnel and increasing the screw retention and surface screw
penetration. In one aspect the conical depression of a screw tunnel
forms a type of metal wrapping about the exterior body of the metal
screw. Retention may be further improved by concavity of a screw
tunnel, because the concavity must be pulled towards the neutral
axis of the metal sheet material before failure will occur (i.e.,
screw stripping). The design and structure of the screw tunnels are
such to avoid or minimize this type of failure.
[0038] In FIG. 6, metal sheet 70 may include screw tunnel 71.
Dimension a at the top of the plate at the entrance to screw tunnel
71 may be roughly equal to about 40-80% of the minor diameter of
the metal screw to be inserted into screw tunnel 71. For example,
dimension a may be between about 40% and about 80% of the minor
diameter, or between about 50% and about 70% of the minor diameter,
or between about 55% and about 65% of the minor diameter of the
screw to be inserted into the screw tunnel 71. The interior wall 72
of screw tunnel 71 may be beveled toward longitudinal axis 73 of
screw tunnel 71 as shown. Dimension b is depicted as being the
width of screw tunnel 71 at a distance from the top of the plate
roughly equal to the thickness of metal sheet 70 prior to
embossing.
[0039] In another embodiment, the screw tunnel 71 is defined as
having a cross-sectional dimension b that is in a plane that is a
distance equal to the thickness of the metal sheet prior to
embossing as measured from the plane at which a screw enters the
screw tunnel 71, and is about 0% to about 100% of dimension a
depending on the depth of the screw tunnel. The screw tunnel 71 may
have an interior surface that is tapered with respect to an axis of
the screw tunnel from at least the plane at which the screw enters
the metal sheet to a depth equal to a thickness of the sheet of
metal prior to embossing.
[0040] The sheet material which results from the process is
suitable for use on its own as a structural member, for example a
post, beam or panel. The sheet material may be formed into a
channel, angle, or other profile wherein the formed shape possesses
one or more flanges and web. The surfaces or a portion of the
surface of both the flanges and the web may have rows of
projections and depressions. In one aspect, only a portion of the
surface of the sheet material such as the flanges has projections
and depressions. The invention is useful for the manufacture of
studs used in stud and panel partitions and for channels (track) in
which lower end portions and upper end portions are received.
[0041] As can be seen in the figures, the depressions/projections
may be one-sided as in FIGS. 1(a)-(b) or present on both sides of
the embossed surface as in FIGS. 2(a)-(c). In a preferred
embodiment, the screw tunnel design is matched to the intended
screw shape and size so as to effectively grasp the screw and
engage it with a higher percentage of metal surface area of the
material as compared to conventional arrangements. This provides
improved surface screw penetration and increases the retention of
the screw in the metal stud.
[0042] FIGS. 1(a)-(b) and 2(a)-(c) demonstrate the undulating
surface of sheet metal material having honeycomb
recessions/projections according to one aspect of the invention.
The wrapping of the sheet material about the penetrating screw is
also demonstrated. The sizes shown are for the depicted embodiments
and, of course, a variety of sizes and shapes are contemplated
according to the principles of the invention.
[0043] As shown, the embossed screw tunnel may be present on the
entire surface area of the metal stud (both web and flanges) or
limited to the web or limited to the flanges (those areas where
metal screws are most commonly fastened) of the metal studs or
limited to a portion of the flanges or web. FIG. 3 shows screw
tunnels 51 in the web 52 of a channel 50, while FIG. 4 shows screw
tunnels 61 in the flange 62 of a channel 60. FIG. 5 shows screw
tunnels on both the flanges and web of a channel. Although a
channel is shown, other structural members may be used, including
but not limited to angles, square tubing, and I-beams. Corrugations
and embossed patterns other than the screw tunnel may be used both
transversely and longitudinally to further strengthen the metal
stud in both transverse and longitudinal directions.
[0044] It should be noted that the elements depicted in the figures
are not necessarily to scale and are exaggerated for illustrative
purposes in certain instances.
[0045] In addition to the invention's enhanced screw retention,
according to the principles of the invention a weight reduction of
the material is achievable by allowing for a reduction in metal
thickness due to the equal or greater properties achievable through
the "screw tunnel" function when using lighter gauge material than
employed in conventional systems. Acoustical performance is also
improved compared to smooth metal studs as sound is dissipated
through the embossed metal pattern. The thermal performance is also
enhanced as the invention effects a slower transfer of both
elevated and reduced temperatures by way of dissipation through the
embossed metal surface. The invention also provides improved load
carrying ability as a result of the embossed "rigidity". The
track/stud "fit-up" features are also superior to prior systems as
the design of both the single sided and doubled sided "screw
tunnels" provide for a mating of the embossed surfaces (embossed
projections fitting into the corresponding embossed depressions).
The result is a more secure fit and easier handling in the
workplace.
[0046] Known prior art including U.S. Pat. Nos. 5,011,743,
5,689,990 and 6,183,879 and Swiss Reference CH-486,281 are
incorporated by reference herein in their entireties. It will be
apparent to one skilled in the art that various modifications can
be made to the invention without departing from the spirit or scope
of appended claims.
* * * * *