U.S. patent application number 11/983371 was filed with the patent office on 2009-05-07 for metal construction member.
This patent application is currently assigned to Scafco Corporation. Invention is credited to Neal L. Peterson, Lawrence B Stone.
Application Number | 20090113827 11/983371 |
Document ID | / |
Family ID | 40586709 |
Filed Date | 2009-05-07 |
United States Patent
Application |
20090113827 |
Kind Code |
A1 |
Stone; Lawrence B ; et
al. |
May 7, 2009 |
Metal construction member
Abstract
A metal construction member is disclosed in which the main body
is fabricated from a high yield steel sheet which has a thickness
dimension of about 0.015 inches to about 0.045 inches, and a yield
strength of about 57 ksi to about 65 ksi, and has a cross sectional
shape which imparts increased strength to the metal construction
member.
Inventors: |
Stone; Lawrence B; (Spokane
Valley, WA) ; Peterson; Neal L.; (Philomath,
OR) |
Correspondence
Address: |
WELLS ST. JOHN P.S.
601 W. FIRST AVENUE, SUITE 1300
SPOKANE
WA
99201
US
|
Assignee: |
Scafco Corporation
|
Family ID: |
40586709 |
Appl. No.: |
11/983371 |
Filed: |
November 7, 2007 |
Current U.S.
Class: |
52/846 ;
52/223.12; 52/635 |
Current CPC
Class: |
E04C 3/07 20130101; E04C
2003/0473 20130101 |
Class at
Publication: |
52/223.12 ;
52/635 |
International
Class: |
E04C 3/09 20060101
E04C003/09; E04C 3/10 20060101 E04C003/10; E04B 1/24 20060101
E04B001/24 |
Claims
1. A metal construction member, comprising: a main body fabricated
from a high yield strength steel sheet which has a reduced
thickness dimension, and a cross sectional shape which imparts
increased strength to the metal construction member.
2. A metal construction member as claimed in claim 1, and wherein
the high yield strength steel sheet has a yield strength of greater
than about 57 ksi.
3. A metal construction member as claimed in claim 2, and wherein
the high yield strength steel sheet has a yield strength of less
than about 65 ksi.
4. A metal construction member as claimed in claim 1, and wherein
the reduced thickness dimension of the high yield strength steel
sheet lies in a range of about 0.015 to about 0.045 inches.
5. A metal construction member as claimed in claim 1, and wherein
the high yield strength steel sheet comprises a steel having a
yield strength of greater than about 57 ksi, and a thickness
dimension of less than about 0.045 inches.
6. A metal construction member, as claimed in claim 1, and wherein
the main body of the metal construction member has a substantially
C-shaped cross section which is defined, at least in part, by a web
portion.
7. A metal construction member as claimed in claim 6, and wherein
the web portion of the main body is corrugated, at least in
part.
8. A metal construction member as claimed in claim 7, and wherein
the main body of the metal construction member further comprises a
pair of flange members which are made integral with the web portion
and which extend normal upwardly relative thereto, and which are
disposed in predetermined spaced relation, one relative to the
other, and wherein the main body of the metal construction member
further comprises a pair of return members which are individually
made integral with respective flange members and which are oriented
in substantially perpendicular relation relative to the individual
flange members, and are further disposed in substantially parallel
spaced relation relative to the web portion.
9. A metal construction member as claimed in claim 8, and wherein
the web portion of the main body has a width dimension of about 1
and 5/8 inches to about 12 inches; the flange members of the main
body have a width dimension of about 1 and 7/16 inches; and the
return members of the main body have a width dimension of less than
about 7/16 inches.
10. A metal construction member as claimed in claim 9, and wherein
the main body is fabricated from a high yield strength steel sheet
having a yield strength of greater than about 57 ksi, and a
thickness dimension of less than about 0.045 inches.
11. A metal construction member as claimed in claim 10, and wherein
the corrugated web portion is defined, at least in part by a pair
of longitudinally oriented channels which are formed therein, and
which have a width dimension which lies in a range of about 0.05
inches to about 4 inches.
12. A metal construction member as claimed in claim 11, and wherein
the corrugated web portion has opposite longitudinally oriented
peripheral edges, and wherein the respective longitudinally
oriented channels are located adjacent to the respective
longitudinally oriented peripheral edges, and wherein the
corrugated web portion has an intermediate region located between
the longitudinally oriented channels, and which has a width
dimension of about 0.5 inches to about 11 inches.
13. A metal construction member as claimed in claim 12, and wherein
the respective longitudinally oriented channels each have a depth
dimension of about 0.05 inches to about 0.5 inches.
14. A metal construction member, comprising: a main body having a
substantially C-shaped cross section and which is defined, at least
in part, by a longitudinally elongated and corrugated web portion,
and wherein the main body is fabricated from a high yield strength
steel sheet which as a thickness dimension of less than about 0.045
inches, and wherein the corrugated web portion of the main body
further defines a pair of longitudinally disposed channels and
which impart strength to the main body.
15. A metal construction member as claimed in claim 14, and wherein
the thickness dimension of the high yield strength steel sheet is
greater than about 0.015 inches.
16. A metal construction member as claimed in claim 14, and wherein
the high yield strength steel sheet has a yield strength of about
57 ksi to about 65 ksi.
17. A metal construction member as claimed in claim 14, and wherein
the thickness dimension of the high yield strength lies in a range
of about 0.015 inches to about 0.045 inches; and the yield strength
of the high yield strength steel sheet lies in a range of about 57
ksi to about 65 ksi, and wherein as the yield strength of the high
yield strength steel sheet decreases the thickness dimension of the
high yield strength steel sheet increases.
18. A metal construction member as claimed in claim 14, and wherein
the respective longitudinally disposed channels have a width
dimension of about 0.05 to about 4 inches, and a depth dimension of
about 0.05 to about 0.5 inches.
19. A metal construction member as claimed in claim 14, and wherein
the yield strength of the high yield steel sheet is about 65 ksi
when the thickness dimension of the high yield strength steel sheet
is about 0.015 to about 0.030 inches, and wherein the yield
strength of the high yield strength steel sheet is 57 ksi when the
thickness dimension of the high yield strength steel sheet is about
0.030 to about 0.045 inches.
20. A metal construction member for non load bearing construction
applications, comprising: a C-shaped main body which is defined by
a web portion which has opposite, longitudinally extending
peripheral edges, a pair of flange members which are made integral
with the web portion and which individually extend substantially
normally upwardly relative to the opposite, longitudinally
extending peripheral edges of the web portion, and a pair of return
members which are individually made integral with the respective
flange portions and which are oriented in substantially parallel
spaced relation relative to the web portion, and wherein the main
body is fabricated from a high yield steel sheet which has a
thickness dimension of about 0.015 inches to about 0.045 inches,
and a yield strength of about 57 ksi to about 65 ksi, and wherein
as the yield strength of the high yield strength steel sheet
increases the thickness dimension of the high yield steel sheet
decreases.
21. A metal construction member as claimed in claim 20, and wherein
web portion has a length dimension of about 1 and 5/8 inches to
about 12 inches.
22. A metal construction member as claimed in claim 21, and wherein
the respective flanges have a width dimension of at least about 1
and 7/16 inches.
23. A metal construction member as claimed in claim 22, and wherein
the respective return members have a width dimension of about 3/8
inches to about 7/16 inches.
24. A metal construction member as claimed in claim 23, and wherein
the web portion of the main body is corrugated.
25. A metal construction member as claimed in claim 24, and wherein
the corrugated web portion has at least one longitudinally disposed
channel formed therein which has a width dimension of about 0.05
inches to about 4 inches; and a depth dimension of about 0.05
inches to about 0.5 inches.
Description
TECHNICAL FIELD
[0001] The present invention relates to a metal construction
member, and more specifically, to a metal construction member
fabricated from a high yield strength steel with a reduced
thickness dimension.
BACKGROUND OF THE INVENTION
[0002] The use of metal construction members, such as studs,
trusses, braces, and the like, has become increasingly popular and
necessary in commercial, industrial, and even residential
structures. Metal studs are dimensionally stable, lightweight and
quite strong, and building codes will often require the use of
metal framing members for both interior and exterior walls. These
metal studs are joined together by screws or other fasteners to
provide walls upon which wallboard is then attached by screws. They
may further have apertures formed therein and which allow
electrical and plumbing conduits to pass therethrough.
[0003] The specific material used to fabricate construction
members, and the shape, thickness and yield strengths of these
materials, has never been optimized with respect to price and
performance. The art is replete with examples of steel construction
members which have been designed for specific applications. For
example, U.S. Pat. No. 5,687,538 to Frobosilo et al. teaches a
metal C-shaped floor joist member with formed, structure-enhancing
areas along the web of the member in order to add strength and
rigidity not offered in a traditional construction member design.
This prior art construction member, however, is overly complex, and
expensive to manufacture, and would be difficult to utilize in
place of a standard-sized wall stud. In U.S. Pat. No. 6,688,066 to
Cottier et al., the thicknesses of the disclosed metal studs is
reduced in a wall construction system, but the invention requires
these studs to be used with a certain solid material between or
adjacent to the studs for adequate strength, and the invention
requires specific fasteners such as power driven nails, to join the
studs to the solid material. Furthermore, the use of high strength
steel for the fabricating of metal studs has not been favored by
manufacturers because of the higher costs associated with the
material, and the associated difficulties of fastening wall board
and the like to this material by employing self tapping screws
which are applied by powered screw fastening tools. There is no
prior art that teaches the design of a metal construction member in
which the specific material, its shape, and its dimensions are
optimized to provide substantial cost and weight savings in common,
everyday applications where standard metal construction members are
currently employed.
[0004] A metal construction member fabricated from a high yield
strength steel which avoids the shortcomings attendant with the
prior art devices and practices utilized heretofore is the subject
matter of the present application.
SUMMARY OF THE INVENTION
[0005] A first aspect of the present invention relates to a metal
construction member which has a main body fabricated from a high
yield strength steel sheet which has a reduced thickness dimension,
and a cross sectional shape which imparts increased strength to the
metal construction member.
[0006] Another aspect of the present invention relates to a metal
construction member which has a main body having a substantially
C-shaped cross section and which is defined, at least in part, by a
longitudinally elongated and corrugated web portion, and wherein
the main body is fabricated from a high yield strength steel sheet
which as a thickness dimension of less than about 0.045 inches, and
wherein the corrugated web portion of the main body further defines
a pair of longitudinally disposed channels and which impart
strength to the main body.
[0007] Yet another aspect of the present invention relates to a
metal construction member for non load bearing construction
applications which has a C-shaped main body which is defined by a
web portion which has opposite, longitudinally extending peripheral
edges; a pair of flange members which are made integral with the
web portion and which individually extend substantially normally
upwardly relative to the opposite, longitudinally extending
peripheral edges of the web portion; and a pair of return members
which are individually made integral with the respective flange
portions and which are oriented in substantially parallel spaced
relation relative to the web portion. The main body is fabricated
from a high yield steel sheet which has a thickness dimension of
about 0.015 inches to about 0.045 inches, and a yield strength of
about 57 ksi to about 65 ksi, and wherein as the yield strength of
the high yield strength steel sheet increases the thickness
dimension of the high yield steel sheet decreases.
[0008] These and other aspects of the present invention will be
described in greater detail hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Preferred embodiments of the invention are described below
with reference to the following accompanying drawings.
[0010] FIG. 1 is a perspective view of one form of the construction
member which is the subject of the present invention.
[0011] FIG. 2 is a cross-sectional, transverse view of the
construction member which is seen in FIG. 1.
[0012] FIG. 3 is a cross-sectional, transverse view of another form
of the construction member which is the subject of the present
invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] This disclosure of the invention is submitted in furtherance
of the constitutional purposes of the U.S. Patent Laws "to promote
the progress of science and useful arts" (Article 1, Section
8).
[0014] Referring now to FIGS. 1-3, a construction member which is
the subject of the present invention is generally indicated by the
numeral 10. The construction member as shown depicts two possible
forms of a "C-profile" or "C-shaped" wall stud, although one
skilled in the art will recognize that the teachings of the present
invention may also be applied to the fabrication of other metal
construction members such as trusses, braces, and the like. The
construction member 10 may be a wall stud, a floor or ceiling truss
or brace, or any other construction member used in a commercial,
industrial, or residential construction. Further, the construction
member 10 may be used as either a load bearing or a non-load
bearing member. In FIGS. 1-3, the construction member 10 is
generally shown with a conventional C-shaped cross-section,
although it will be recognized that the teachings of the present
invention may also be applied to the fabrication of other
construction members, which may have, for example, a U-shape or an
H-shape. The purpose of these assorted cross-sectional shapes is
to, on the one hand, impart increased strength to the metal
construction member 10, or to provide surfaces upon which another
construction member, or wall board, for example, may be
attached.
[0015] Referring still to FIGS. 1-3, the construction member 10
comprises a main body 11 which has a first end 12 and a second end
13. The length of the construction member is defined as the
distance between the first and second ends 12 and 13, and is
generally indicated by the numeral 16. It should be recognized that
the length dimension 16 of the construction member 10 can vary
greatly depending upon the structural application of same. The main
body 11 of the construction member 10 is also defined by a first
side 14 and a second side 15. A web portion 40 extends between the
first side 14 and the second side 15, and is discussed in greater
detail below. In the substantially C-shaped cross-sectional shape
shown in FIGS. 1-3, the first side 14 comprises a first flange
member 20 which extends perpendicularly, upwardly, relative to the
web 40. Similarly, the second side 15 comprises a second flange
member 21 which also extends perpendicularly, upwardly, relative to
the web 40. The first and second flange members 20 and 21 are
disposed in predetermined substantially parallel, spaced relation,
one relative to the other. The first and second flange members 20
and 21 also have a width dimension 22 and 23, respectively, which
also defines the width dimension of the construction member 10.
Typically, the width dimension 22 and 23 of flange members 20 and
21, respectively, is 1 and 7/8 inches for a standard wall stud. Of
course, one skilled in the art will recognize that the respective
width dimensions of the respective flange members 20 and 21 may
vary depending upon the particular cross-sectional shape of the
construction member and the structural application in which it is
used.
[0016] Referring still to FIGS. 1-3, the main body 11 of the
construction member 10 also comprises a first return member 30,
which is made integral with the first flange member 20, and a
second return member 31, which is made integral with the second
flange member 21. Each return member 30 and 31 are oriented in
substantially perpendicular relation relative to the respective
flange members 20 and 21, and are further disposed in substantially
parallel, spaced relation relative to the web portion 40. The
intersecting corners 34 and 35 between the first and second return
members 30 and 31, and the first and second flange members 20 and
21, respectively, are typically rounded or knurled so as to provide
increased structural strength. The return members 30 and 31 each
have a width dimension 32 and 33, respectively, which is typically
less than about 7/16 inches and may range from about 3/8 inches to
about 7/16 inches. Of course, one skilled in the art will recognize
that this width dimension may vary considerably depending upon the
particular cross-sectional shape of the construction member chosen,
and the structural application in which it is used.
[0017] The main body 11 of the construction member 10 also
comprises a web portion 40. As shown in FIGS. 1-3, the web portion
40 extends from the first flange member 20 to the second flange
member 21, and is further made integral with each of the first and
second flange members 20 and 21. The intersecting corners 42 and 43
between the web portion 40, and the first and second flange members
20 and 21, respectively, are typically rounded or knurled so as to
provide increased structural strength. The web portion 40 has a
width dimension 41, which may range from about 1 and 5/8 inches to
about 12 inches, depending upon the structural application in which
the construction member 10 is used.
[0018] As seen in FIG. 3, the web portion 40 in one possible form
of the invention may be characterized as substantially planar or
otherwise featureless. In another possible form of the invention,
such as seen in FIGS. 1 and 2, the web portion 40 may be
corrugated, at least in part, or may include other features such as
indentations, deformations or the like, and which are made in the
web portion 40, and which provide increased strength, and rigidity
for the main body 11 of the construction member 10. In the form of
the invention as shown in FIGS. 1 and 2, the corrugated web portion
40 is defined, at least in part, by one or more longitudinally
oriented channels 44, which are formed therein during the
fabrication of the construction member 10. The longitudinally
oriented channels 44 have a width dimension 45 which may lie in a
range of between about 0.05 inches to about 4 inches, although the
width dimension 45 of each channel 44 may differ depending upon the
application. Further, the longitudinally oriented channels 44 also
have a depth dimension 49, which may lie in a range of between
about 0.05 inches to about 0.5 inches. Similarly, the depth
dimension could conceivably vary depending upon the application. In
the form of the invention as shown in FIGS. 1 and 2, the web
portion 40 of the main body 11 has opposite longitudinally oriented
and substantially parallel peripheral edges 48 which are located
adjacent to the respective longitudinally oriented channels 44. The
peripheral edges 48 adjacent to the channels 44 define an
intermediate region 46 of the web portion 40, and which is located
between the peripheral edges 48. This intermediate region has a
width dimension 47 of about 0.5 inches to about 11 inches,
depending upon the width dimension 41 of the web portion 40. It
will be recognized that a corrugated web portion 40 may have more
than two corrugations, and thus a construction member 10 may have
multiple longitudinal channels 44; peripheral edges 48; and several
intermediate regions 46. The number, cross-sectional shape, and
width dimensions of the corrugations may vary substantially in
various forms of the invention in order to provide adequate
structural strength and rigidity of the construction member 10.
These features will vary based upon the width dimension 41 of the
member 10; the gauge of material used to fabricate the construction
member; and yield strength of the material employed in the
fabrication of the construction member 10.
[0019] Referring still to FIGS. 1-3, a salient feature of the
present invention is to provide a construction member 10 having a
main body 11 which is fabricated from a high yield strength steel
sheet, and which has a reduced thickness dimension in relative
comparison to the steel sheets which are presently used in the
fabrication of prior art construction members. Currently, the
thickness dimension of the steel sheets used to fabricate the prior
art construction members have a thickness dimension of about 0.0179
inches and greater, and a yield strength of about 33 ksi. "Yield
strength" for purpose of this application, is defined in
engineering and the material sciences as the stress at which a
material begins to plastically (i.e., inelastically, or
non-reversibly) deform. It is commonly measured in kilopounds per
square inch (ksi) or megapascals (MPa). In the present invention,
as the yield strength of the high strength steel sheet increases,
the thickness dimension of the high strength steel sheet decreases.
In one form of the invention, the high strength steel sheet has a
yield strength of greater than about 57 ksi, and in another form of
the invention, the yield strength lies in a range of greater than
about 57 ksi to less than about 65 ksi. This allows the use of a
steel sheet with a thickness dimension that lies in a range of
about 0.015 inches to about 0.045 inches. Thus, if a high strength
steel sheet with a yield strength of about 65 ksi is employed, the
steel sheet may have a thickness of about 0.015 to about 0.030
inches. Further, where a high strength steel sheet with a yield
strength of about 57 ksi is used, the steel sheet may have a
thickness of about 0.030 to about 0.045 inches. The use of high
strength steel sheets with these reduced thickness dimensions for
the main body 11 of the construction member 10 has not been
utilized heretofore with conventional stud wall applications,
especially for non-load bearing walls. Moreover, the teachings of
the prior art suggest that such reduced thickness sheet steel
construction or framing members should only be used with a layer of
solid sheet material in order to provide the requisite strength and
rigidity. Thus, the prior art teaches away from the application of
high strength steel sheet with reduced thicknesses in conventional
stud wall applications, including those in non-load bearing walls,
as is possible with the present invention.
[0020] The American Society for Testing and Materials (ASTM)
published a Standard Specification for Nonstructural Steel Framing
Members as Designation: C 645-00 (where "00" indicates the year of
the Standard's adoption). The C 645-00 Standard specifies a minimum
thickness of 0.0179 inches before application of protective
coating. Effective properties for various studs under the Standard,
as calculated in accordance with the American Iron and Steel
Institute (AISI) specifications, are based on a yield strength,
Fy=33 ksi. The ASTM Standard does not make an express allowance for
the use of high strength steel sheet, such as described above.
Instead, a clear inference exists that high strength steel sheet
would not meet the ASTM Standard. Based on the accepted ASTM
Standard, it is thus surprising to construct a framing member using
high strength steel sheet.
[0021] Further, and more surprisingly, the reduced thickness
dimension of the high strength steel sheets as described above has
not impaired, in any significant fashion, the use of traditional
self tapping screws for attachment of wall boards or other
construction members to construction member 10. Additionally, from
an economic standpoint, the high strength reduced thickness steel
sheets have not significantly increased the cost of the resulting
product even though the raw material is much greater in cost pound
for pound when compared with the steel used heretofore to fabricate
the prior art construction member. The observations indicated,
above, support a conclusion that the specific material used to
fabricate construction members, and the shape, thickness and yield
strengths of these materials, has never been optimized with respect
to price and performance.
Operation
[0022] The operation of the described embodiments of the present
invention are believed to be readily apparent and are briefly
summarized at this point.
[0023] In one of its broadest aspects, the invention relates to a
metal construction member 10 that comprises a main body 11
fabricated from a high strength steel sheet which has a reduced
thickness dimension, (in relative comparison to current industry
standards which is now 0.0179 inches or greater) and a
cross-sectional shape which imparts increased strength to the metal
construction member. The high strength steel sheet has a yield
strength of about 57 ksi to about 65 ksi, and a thickness dimension
of about 0.015 to about 0.045 inches.
[0024] In another aspect of the present invention, a metal
construction member 10 has a main body 11 having a substantially
C-shaped cross section. The main body 11 is defined, at least in
part, by a longitudinally elongated and corrugated web portion 40,
and which further defines a pair of longitudinally disposed
channels 44, and which impart strength to the main body.
[0025] In yet another aspect of the invention, a metal construction
member 10, for use in non-load bearing construction applications,
has a C-shaped main body 11 which is defined by a web portion 40
which has opposite, longitudinally extending peripheral edges 48, a
pair of flange members 20 and 21 which are made integral with the
web portion 40, and which individually extend substantially
normally upwardly relative to the opposite, longitudinally
extending peripheral edges 48 of the web portion 40. Further, the
main body 11 defines a pair of return members 30 and 31 which are
individually made integral with the respective flange portions 20
and 21, and which are oriented in substantially parallel spaced
relation relative to the web portion 40. The main body 11 is
fabricated from a high strength steel sheet which has a thickness
dimension of about 0.015 inches to about 0.045 inches, and a yield
strength of about 57 ksi to about 65 ksi. As the yield strength of
the high strength steel sheet increases, the thickness dimension of
the high strength steel sheet decreases.
[0026] In compliance with the statute, the invention has been
described in language more or less specific as to structural and
methodical features. It is to be understood, however, that the
invention is not limited to the specific features shown and
described, since the means herein disclosed comprise preferred
forms of putting the invention into effect. The invention is,
therefore, claimed in any of its forms or modifications within the
proper scope of the appended claims appropriately interpreted in
accordance with the doctrine of equivalents.
* * * * *