U.S. patent application number 12/457339 was filed with the patent office on 2009-10-08 for stud with lengthwise indented grooves, and with intervening planar surfaces, and method.
Invention is credited to Ernest R. Bodnar.
Application Number | 20090249743 12/457339 |
Document ID | / |
Family ID | 41131978 |
Filed Date | 2009-10-08 |
United States Patent
Application |
20090249743 |
Kind Code |
A1 |
Bodnar; Ernest R. |
October 8, 2009 |
Stud with lengthwise indented grooves, and with intervening planar
surfaces, and method
Abstract
A steel stud member for use in supporting structures and having
reduced thickness as compared with conventional studs, and having a
web having side edges, flanges on the side edges, formed at angles
to the web, the web and the flanges enclosing inside surfaces, and
having outside surfaces for mounting structure, and plurality of
narrow indented longitudinal grooves formed in the flanges, and in
the web, indented inwardly from the outside to the inside of the
flanges, providing greater load bearing capacity for a given gauge
of steel. Also disclosed is a method of making such a steel member.
In another embodiment the flanges are indented with a plurality of
separate dimples
Inventors: |
Bodnar; Ernest R.;
(Burlington, CA) |
Correspondence
Address: |
GEORGE A. ROLSTON
45 SHEPPARD AVE EAST, SUITE 900
TORONTO
ON
M2N5W9
CA
|
Family ID: |
41131978 |
Appl. No.: |
12/457339 |
Filed: |
June 8, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11652073 |
Jan 11, 2007 |
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12457339 |
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60759068 |
Jan 17, 2006 |
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Current U.S.
Class: |
52/846 ;
29/897.33 |
Current CPC
Class: |
Y10T 29/49631 20150115;
E04C 3/09 20130101; E04C 2003/0473 20130101 |
Class at
Publication: |
52/846 ;
29/897.33 |
International
Class: |
E04C 3/04 20060101
E04C003/04; B21D 47/01 20060101 B21D047/01 |
Claims
1. A reinforced indented sheet metal stud for use in construction
and having a web defining side edges and an axis, a first flange
along one side edge, and a second flange along the other side edge,
said web and said flanges defining inside surfaces and outside
mounting surfaces on opposite surfaces of said sheet metal, and
comprising; longitudinal indented grooves formed along at least one
of said first and second flanges, parallel to said web axis wherein
said indented grooves in said flanges are formed as depressions
from said outside mounting surface extending into said inside
surface; and, planar surface spaces on the outside mounting surface
of said at least one flange between said indented grooves.
2. A reinforced indented sheet metal stud as claimed in claim 1,
including two said flanges bent at right angles to said web and
longitudinal indented grooves in both said flanges, and planar
surfaces spaces between said grooves on each said flange.
3. A reinforced indented sheet metal stud as claimed in claim 1
including depressions formed in said web at spaced intervals, and
openings formed in said depressions.
4. A reinforced indented sheet metal stud as claimed in claim 1
having an embedment edge formed along one said flange, for
embedment in concrete.
5. A reinforced indented sheet metal stud as claimed in claim 1
including openings through said web at spaced intervals therealong,
of predetermined size and profile, at least a side portion of said
web displaced from said opening remaining attached integrally to
said web, a first bend formed in said side portion, a second bend
formed in said side portion spaced from said first bend, said first
and second bends being formed along axes parallel to said web axis
to define reinforcing channels.
6. A reinforced indented sheet metal stud as claimed in claim 5
including a cross brace member having fastenings with a snap-in
engagement for insertion into said web openings.
7. A reinforced indented sheet metal stud as claimed in claim 5
including depressions formed in said web at spaced intervals and,
openings formed in said depressions to reduce heat transfer.
8. A reinforced indented sheet metal stud as claimed in claim 5 and
having openings shaped with opposed linear side edges, side
portions of said web integral with said linear side edges being
formed into said channel shapes.
9. A reinforced indented sheet metal stud as claimed in claim 1 and
having an embedment edge on a said flange being angled at an angle
to said web and a locking strip formed along said embedment edge
for embedment in a concrete panel.
10. A reinforced indented sheet metal stud as claimed in claim 9
and having openings through said web at spaced intervals
therealong, of predetermined size and profile, at least a side
portion of said web displaced from said opening remaining attached
integrally to said web, a first bend formed in said side portion, a
second bend formed in said side portion spaced from said first
bend, said first and second bends being formed along axes parallel
to said web axis to define reinforcing channels.
11. A reinforced indented sheet metal stud as claimed in claim 1
and being formed of sheet metal having a gauge between 0.149 inch
and 0.1196 inch, and a web width of between 3.625 and 14.00 inch,
and flange width of between 1.25 and 3.0 inch, and wherein the
indented grooves have a depth of between 0.125 and 50 inch and a
groove width of between 0.0625 and 0.50 inch, and having a planar
spacing between said indented grooves in said web of between 0.50
and 1.25 inch.
12. A reinforced indented sheet metal stud as claimed in claim 9
being further characterized by being formed of sheet metal having a
gauge between 0.149 inch and 1.196 inch, and a web width of between
3.625 and 14.00 inch, and flange width of between 1.25 and 3.0
inch, and wherein the indented grooves have a depth of between
0.125 and 0.50 inch and a groove width of between 0.0625 and 0.50
inch and a spacing between said indented grooves in said web of
between 0.50 and 1.25 inch.
13. A reinforced indented sheet metal stud for use in construction
and having a web defining side edges and an axis, a first flange
along one side edge, and a second flange along the other side edge,
said web and said flanges defining inside surfaces and outside
mounting surfaces on opposite surfaces of said sheet metal, and
comprising; multiple separate dimples indented in each of said
first and second flanges, forming depressions from said outside
mounting surface extending into said inside surface; and,
longitudinal and transverses ridges on the outside mounting surface
of each said flange between said dimples.
14. A reinforced indented sheet metal stud for use in construction
as claimed in claim 13 and including transverse indented L-shaped
corner grooves, formed in said web and in each said flange, located
at spaced apart intervals therealong.
15. A reinforced indented sheet metal stud for use in construction
as claimed in claim 14 wherein said dimples are generally of
pyramid shape.
16. A reinforced indented sheet metal stud for use in construction
as claimed in claim 15, and including web openings formed in said
web at spaced intervals therealong.
17. A reinforced indented sheet metal stud for use in construction
as claimed in claim 13, and including grooves indented across said
web, generally from one flange to the other.
18. A method of making a reinforced indented sheet metal stud and
comprising the steps of; forming a sheet metal strip having a web
with side edges; forming longitudinal indented grooves in said
flanges, said grooves being spaced apart and defining planar web
portions between said grooves; forming flanges along each said side
edge, said flanges having lips on said flanges; bending said
flanges relative to said web whereby to define an outer mounting
surface and an inside surface of said stud, said grooves being
formed as depressions indented from said outer mounting surface
into said inside surface; and, forming longitudinal indented
grooves in said web.
19. A method of making a reinforced indented sheet metal stud as
claimed in claim 18 and further comprising the steps of; forming
main web openings in said sheet metal strip at spaced intervals,
subsequently forming edge flanges around said openings and, prior
to forming said indented grooves.
20. A method of making a reinforced indented sheet metal stud as
claimed in claim 19 and further comprising the steps of; bending
said edge flanges to form a reinforcement channel on at least one
side of each said opening.
Description
[0001] This application is a Continuation in Part of application
Ser. No. 11/652,073 filed, Jan. 11 2007, Title, STUD WITH
LENGTHWISE INDENTED RIBS AND METHOD, Inventor Ernest R Bodnar,
which turn claimed priority of U.S. Provisional Application Ser.
No. 60/759,068 Filed Jan. 11 2006 Title STUD WITH LENGTHWISE
INDENTED RIBS AND METHOD, inventor Ernest R Bodnar.
FIELD OF THE INVENTION
[0002] The invention relates to steel studs or structural members
formed with edge formations, with planar edge flanges and indents
located between planar portions of the edge flanges. The stud
indents may be grooves or dimpled surfaces. In a particular
preferred form the studs are formed with web main openings and edge
formations along at least one side of the openings formed with at
least two indented parallel spaced apart grooves in each said edge
flange.
BACKGROUND OF THE INVENTION
[0003] Steel studs of a wide variety have been proposed for
erecting structures. Usually such studs are used to replace wooden
studs. Wood is a relatively poor heat transfer medium. Heat loss
through wooden studs has not been a significant problem in the
past. Metal studs having solid webs however, do create a heat loss
transfer path through the exterior wall or other structure. This
results in cold patches along the lines of the studs. Condensation,
known as "ghosting" appears along these lines.
[0004] Such studs usually were formed as a C-section, i.e. there
was a central web, and the opposite side edges of the web were
formed into edge flanges. Several such bends were sometime
incorporated in an effort to get greater strength, while using
thinner gauge metal. However this did not overcome the heat
transfer problem. Accordingly metal studs have been proposed with
reduced heat transfer properties. These studs were formed with
generally triangular or trapezoidal openings, in the web, while the
two edges were bent over as flanges or legs at 90 degrees, as
before. Heat losses were thus reduced since there was less metal
through which the heat could pass.
[0005] The shape of these openings tended to restrict the size of
the conduits which could be passed through the studs.
[0006] Rounded openings in the studs avoid the problems caused by
the corners of the triangular or trapezoidal openings and splitting
of metal, and greatly facilitate high speed manufacture of such
studs because there is less stud length lost in the cut to length
process.
[0007] Proposals have been suggested to form studs with
corrugations in the flanges or even in the webs themselves.
Corrugations involve essentially folding the sheet metal first in
one direction and then in the other. The end result looks, in
section, like a kind of sine wave shape. The folds are continuous,
ie they fold back and forth without any spacing between them. An
example is shown in U.S. Pat. No. 6,092,349 Trenerry, issued Jul.
25, 2000. The folds are similar to what is known as "corrugated
iron", which has been used for simple roofing purpouses form very
many years.
[0008] This proposal has many disadvantages. Corrugations do not
provide a surface suitable for attachment of structure such as wall
panels. There are no "flats" between the folds. If a panel is set
against such folds the panel will make point contact with the peak
of every alternate fold. If screws are secured through the panel
into the metal the screws may penetrate the metal in a random
fashion, and cause unequal pressure points in the panel, and may
damage the panel. A more serious problem with corrugations in a
stud, is that the manufacturing process by which corrugations are
folded into the sheet metal, causes the metal to be drawn from the
edges in towards the centre of the strip. Essentially the strip
"shrinks" across its width.
[0009] This means that it is difficult to produce a stud as an end
product, which has a definite preset width. Also the stud so
produced will use a greater quantity of steel, making it more
costly.
[0010] It is now found that the load bearing capacity of a given
stud of a given gauge can be increased substantially, by forming
indented grooves, which are formed from the outside surface in to
the inside surface, of the eventual stud. The process of indenting
the grooves is carried out while at the same time clamping the
metal strip along its edges, so as to prevent any reduction in the
width of the metal strip. In effect the indenting of the grooves
causes a slight stretching of the medial portion of the strip,
between the grooves, where the strip is not subject to any clamping
action. Between the grooves the strip remains flat and planar. This
facilitates the attachment of material such as dry wall.
[0011] This can be achieved by forming the stud with planar
surfaces, in the edge flanges along each edge of the web, and
forming narrow, longitudinal indented grooves, spaced apart by
planar surfaces formed in the edge flanges, and also by forming
narrow longitudinal indented grooves spaced apart by planar
surfaces in the web, while holding the two edges of the strip
clamped so that the edges cannot be drawn inwardly.
[0012] The actual stretching action is scarcely noticeable, in the
overall width of the stud, but it is significant in that it holds
the width of the finished stud stable, and maintains specifications
for the product.
[0013] Another use of such studs is in concrete panels. Concrete
panels of reduced thickness are now reinforced by a framework of
metal studs partially embedded in the concrete. The studs provide
great strength to the panels, and also facilitate erection and
attachment of the panels to the structure.
[0014] These novel studs with longitudinal indented grooves can be
made with edge formations for embedment in concrete.
BRIEF SUMMARY OF THE INVENTION
[0015] With a view to achieving the foregoing and other objectives
the invention comprises a steel member for use in supporting
structures and having a web defining edges and an axis, and the web
defining an inner planar surface on one side, and an outer planar
surface on the other side an edge flange formed on at least one web
edge, the flange and the web defining inside surfaces and outside
surfaces, and being characterized by indented grooves formed along
said at least one flange, parallel to said web axis, the
indentations being formed. from said mounting surfaces into said
inside surfaces, and leaving planar surfaces along the flange on
either side of each said groove.
[0016] The stud may also have longitudinal indented grooves formed
along its web. The invention further seeks to provide a steel
member as described including openings formed in said web at spaced
intervals, and flanges formed around said openings, being indented
from said outside to said inside surfaces.
[0017] The invention further provides a steel member as described,
which is particularly suited for embedment in concrete, and has a
further edge flange which is formed as embedment edge.
[0018] The invention further seeks to provide a steel member as
described, which is particularly suited for use in the supporting
of dry wall partitions, and may incorporate a cross brace with a
snap-in engagement. This type of stud does not have the problem of
heat transfer since the partition walls are usually erected inside
the building, dividing up the space into separate rooms. They will
not necessarily use the complex web openings and ribs of the other
embodiments. Such studs may be made of ultra light weight, thin
gauge steel. For this purpouse the studs have flanges which are
formed with numerous point-like depressions or dimple-like
indentations. These add stiffness and also provide pints for easy
secure insertion of screw fastenings.
[0019] The invention further provides a steel member for use in
supporting structures and having reduced heat transfer
characteristics as compared with solid web studs, and having a web
defining side edges and an axis, a flange on at least one side
edge, openings through said web at spaced intervals therealong, of
predetermined size and profile, at least a side portion of said web
displaced from said opening from said outside to said inside
surfaces and remaining attached integrally to said web, a first
bend formed in said side portion, a second bend formed in said side
portion spaced from said first bend, said first and second bends
being formed along axes parallel to said web axis, and thus
defining three-sided channel shaped reinforcements.
[0020] The invention further seeks to provide a steel member as
described with diagonal ribs between the web openings, and with
depressions formed in the web at each end of each rib, indented
from said outside to said inside surfaces and, rib openings formed
in the depressions to reduce heat transfer.
[0021] The invention further seeks to provide a steel member as
described wherein said openings are shaped with opposed linear side
edges, side portions of said web integral with said linear side
edges being formed into said channel shapes along said inside
surfaces.
[0022] The invention further seeks to provide a steel member as
described wherein a further flange is formed on a second edge of
said web, said further flange being angled at an angle to said web
and an embedment lip formed along said further flange for embedment
in a concrete panel.
[0023] The invention also provides a method of making a steel
member having a web and side edges, and an edge flange along at
least one said side edge, and longitudinal indented grooves in said
web and said edge flange, being characterized by the steps of,
clamping the strip along both side edges of the strip, and forming
a strip of sheet metal with longitudinal indented grooves in a web
portion and in at least one edge flange portion, and by bending the
edge flange portion relative to said web portion, so as to form
inside and outside surfaces, and bending a lip on said edge flange
portion.
[0024] Since the foregoing steps are carried out while continuing
the clamping of the strip along both side edges, to maintain a
predetermined width, the forming of the grooves causes a small
degree of stretching of the strip. The actual amount of stretching
is small, and is spread over almost the entire width of the strip,
and therefor has little or no effect on the end product.
[0025] 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
[0026] FIG. 1 is a perspective illustration of a stud illustrating
one embodiment of the invention, with narrow longitudinal indented
grooves;
[0027] FIG. 2 is a side elevation of the stud of FIG. 1;
[0028] FIG. 3 is a section along line 3-3 of FIG. 2;
[0029] FIG. 4 is a perspective of a further embodiment of stud
illustrating another embodiment of the invention for embedment in
concrete in which are numerous, narrow, longitudinal indented
grooves; and an embedment edge for embedment in concrete;
[0030] FIG. 5 is a side elevation of the stud of FIG. 4;
[0031] FIG. 6 is a section along line 6-6 of FIG. 5;
[0032] FIG. 7 is a perspective of a further embodiment of stud for
use in reinforcing concrete panels;
[0033] FIG. 8 is a side elevation of the stud of FIG. 7;
[0034] FIG. 9 is a section along 9-9 of FIG. 8;
[0035] FIG. 10 is a section of a modification similar to FIG.
1;
[0036] FIG. 11 is a perspective of a further embodiment, and
incorporating x-shaped transverse indented grooves, as well as
longitudinal indented grooves;
[0037] FIG. 12 is a side elevation of FIG. 11;
[0038] FIG. 13 is a section along the line 13-13 of FIG. 12;
[0039] FIG. 14 is a section of a modification similar to FIG.
3;
[0040] FIG. 15 is a perspective of a further embodiment of a stud
particularly suitable for the erection of dry wall partitions;
[0041] FIG. 16 is an enlarged perspective of portion of FIG.
15;
[0042] FIG. 17 is a perspective illustration illustrating a cross
bracing member adapted to extend transversely between two
studs;
[0043] FIG. 18 is a perspective illustration of a further
embodiment of a dry wall stud;
[0044] FIG. 19 is a illustration of a further embodiment of a dry
wall stud;
[0045] FIG. 20 is a schematic section illustrating the ranges of
dimensions of the various indented grooves and flanges and webs of
the studs;
[0046] FIG. 21 is an enlarged detail of the detail 21 of FIG.
20;
[0047] FIG. 22 is a table of the ranges of dimensions, which may be
used for various modified forms of studs;
[0048] FIG. 23 is an illustration of an indenting roll forming
tool, suitable for indenting grooves according to the invention
into the metal webs used manufacture of these studs;
[0049] FIG. 24 is a schematic section of a roll forming line
showing the forming of the grooves by indenting parallel grooves
from one side only of the web;
[0050] FIG. 25 is a schematic section of a roll forming line
showing the forming of grooves by indenting parallel grooves from
one side only of the web, while clamping the side edges of the
strip to resist shrinking across its width;
[0051] FIG. 26 is schematic section corresponding to FIG. 25
showing further grooves being indented, and the edge flanges bent
inwards;
[0052] FIG. 27 is a perspective of a further embodiment of stud
showing grooves spaced lengthwise at intervals; and,
[0053] FIG. 28 is a top plan of the stud of FIG. 27.
DESCRIPTION OF A SPECIFIC EMBODIMENT
[0054] As already described the invention provides sheet metal
structural members referred to herein generically as studs,
suitable for use in erecting various structures, walls, floors,
roofs, and the like and also internal partition walls. The
invention also provides sheet metal studs suitable for use in
reinforcement of thin-shell concrete panels which are widely used
in completing walls, in particular. Such thin-shell structures can
also form floors, roofs and the like, and can also serve as
shuttering or form work for pouring concrete, such as columns and
beams, and even flooring and concrete partitions. Such thin-shell
panels, when used as shuttering, may be left in place, thus
avoiding the need for removing and repositioning shuttering or form
work, many times over. The invention also provides a method of
making such studs.
[0055] Referring to FIG. 1 it will be seen that the invention is
there illustrated in the form of a stud (10), formed of sheet
metal, in this case steel. The stud (10) has a web (12) which is
essentially planar, and edge flanges, or "legs", (14) and (16)
along each side edge of the web (12). Each of the flanges (14) (16)
is formed by bending side edges of the web (12) at right angles.
Lips (18) are formed on each edge flange (14-16) again at right
angles.
[0056] The flanges, and the web define a generally C-shape in
section, having "inside" surfaces, around the inside of the
C-shape, and outer "mounting" surfaces, around the outside of the
C-shape, to which other structure can be attached. These outer
surfaces are planar surfaces, such that for example, dry wall
panels or the like can be placed against them and secured in
position.
[0057] Longitudinal indented flange grooves (20) are formed by
indenting two spaced apart grooves along each edge flange (14-16)
for greater load bearing capacity. Between grooves (20) there are
planar flange portions (21), (FIG. 3), for supporting other
structure such as wall panels or the like. Longitudinal indented
web grooves (22) are also formed by indenting grooves inwardly
along web (12). Alongside each of the web grooves (22) there are
further planar surfaces (23). The longitudinal indented flange
grooves (20), and web grooves (22) are indented from the outward
surfaces inwardly into the inside surfaces. In this way the outward
mounting surfaces (21) and (23) are left clear for the attachment
of other structure, which may be any form of wall material, such as
outer sheathing, or for example, drywall panels, not shown.
[0058] It also assists in the insertion of fastenings for such
structure, as will be explained below.
[0059] The grooves are formed during the roll forming of the stud,
in a manner to be described below.
[0060] This stud may be intended for external or internal use,
typically in the erecting of walls or partitions between spaces in
a commercial or office building, for example. Studs of larger
dimensions can be used for floor, ceilings, roofs and any structure
requiring greater load capacity.
[0061] This stud may also be made for embedment in a thin-shell
concrete panel, and would then have an embedment flange (16A) (FIG.
4) in place of flange (16). These two features of longitudinal
flange grooves (20) (and in larger studs web grooves (22)) enable
the studs to be made of a reduced thickness or gauge of sheet
metal, without sacrificing anything in the load bearing capacity of
rigidity or firmness.
[0062] Web openings (24) are formed through the web at regular
spaced intervals. Between the web openings (24), portions of the
web define transverse struts (26). This form of construction
substantially reduces the heat transfer from one side edge of the
web to the other.
[0063] Depressions (28), which in this case are generally circular,
are formed at each end of struts (26), and strut openings, such as
slots (30) are formed in depressions (28). This further restricts
heat transfer across the stud.
[0064] The rigidity of such studs can be further increased by
transverse grooves (32) formed across the web at each end of the
member. These transverse grooves (32) may simply be straight
grooves running at right angles to the web axis. Diagonal grooves
can also be provided, as described below.
[0065] The spacing between, and alongside, the grooves (20),
defines the planar surfaces (21) and enables the secure attachment
of structure, by for example screws (S) FIG. 23, secured in grooves
(20). When tightened down the screws will pull a structure such as
a panel firmly up against the planar surfaces (21), without
distorting the flanges or studs, and without damaging the panel
itself. A further form of stud is shown in FIGS. 4, 5 and 6. In
these Figures, similar components as in FIGS. 1, 2 & 3 have the
same numbers. The web openings (24) are trapezoidal, defining
opposite linear sides, parallel to the longitudinal axis of the
stud. The struts (26) are diagonal. Reinforcing side portions (25)
integral with the web (12), are bent over at right angles and thus
form three sided channel-shaped reinforcements on opposite linear
sides of the web openings. Depressions (28) have circular holes in
place of slots. However, the flange (16) of the FIG. 1 embodiment
is replaced by the flange (16A). The flange (16A) is formed with an
embedment edge (34), and a locking strip (36). Typically, the
embedment edge (34) will be formed with a series of through
openings punched out. The purpose of the embedment edge and the
locking strip is that they can be embedded in poured concrete, when
forming a composite concrete wall panel, so as to provide a secure
anchoring of the concrete to the frame work of studs, all of which
is known in the art. This stud may also have the flange (16) of
FIG. 1 where the embedment edge is not required.
[0066] FIGS. 7, 8 and 9 illustrate a stud similar to the FIG. 4
embodiment, that is to say, this particular stud is designed for
concrete embedment and reinforcement, in the same way as at the
FIG. 4 embodiment.
[0067] It has essentially the same features as the FIG. 1 and the
FIG. 4 embodiments, and has the same modified flange (16A) with
embedment edge (34) and locking strip (36) in the same way as the
FIG. 4 embodiment. In this case, however, additional longitudinal
indented web grooves (22) are shown, extending along the web
longitudinally. These web grooves add significantly to the load
bearing capacity of the stud.
[0068] In this embodiment, the web openings (24) are of somewhat
different shape than the web openings (24) in the FIGS. 1 and 4
embodiments, and by virtue of their different shape, the transverse
struts (26) between the openings are somewhat wider and are
arranged in alternating diagonal fashion.
[0069] The other modification in this embodiment is that the end
transverse grooves (38) are somewhat diagonal, rather than being
simply transverse to the axis of the stud, at right angles.
[0070] FIG. 10 illustrates the stud of FIGS. 7, 8 and 9, with the
right angle edge flange (16) in place of the embedment flange
(16A).
[0071] The embodiment of FIGS. 11, 12, 13 and 14 is a further
modification of the FIG. 7 embodiment, of still greater load
bearing capacity. In this case, the stud has all of the same
essential features as shown in FIGS. 1, 4 and 7. However, in this
case, there are lip grooves (40) indented in the lips (18). In
addition, the transverse grooves (42) are now arranged the form a
letter X. Grooves (42) are placed in pairs along the ribs between
each web opening (24).
[0072] Depressions (28) are formed with holes (44) rather than the
slots (30) of the FIGS. 1 though 7 embodiments.
[0073] The embodiment also uses the feature of the internal
reinforcement channel (46) (also shown in FIG. 4). These are formed
by turning a portion of the web (12), which has been struck out
from the web openings (24), inwardly around two right angle bends
(FIG. 13) so as to form three sided reinforcement channels along
opposite linear sides of the web openings (24).
[0074] FIG. 14 shows a modification of this embodiment of FIG. 11,
having an embedment flange (16A), with an embedment edge (34) and a
locking strip (36) in the same manner as the embodiment of FIG.
7.
[0075] FIG. 15 is a front perspectives of a dry wall stud indicated
generally as (50). This dry wall stud is usually formed of thinner
gauge material than the heavier duty studs of FIGS. 1 through 14.
In this case, the stud (50) has a web (52), and flanges (54) (56)
with lips (58). In place of the flange grooves of FIGS. 1 to 14,
this embodiment has numerous separate point depressions (60)
indented into the outer surfaces of flanges (54-56)
[0076] Similar separate point shaped depressions (62) are indented
in the web (52). Openings (64) are formed through the web, and are
preferably surrounded by depressions (66).
[0077] L-shaped corner grooves (68) extend transversely of the web
and the flanges (54) and (56) respectively. These are indented at
spaced intervals along the stud so as to add further rigidity to
the flanges (54) and (56). This will materially assist in the
insertion of dry wall screws when dry wall panels are secured.
[0078] FIG. 16 shows the surface of part of one flange (54), and
part of the web, greatly enlarged. It will be seen that the
depressions (60), and formed in an essentially four-sided pyramid
shape, indented down from the outer surface into the interior
surface of the stud. Between each depression (60) there are
lengthwise and transverses ridges (61).
[0079] The ridges (61) define what is the planar outside surface of
the stud. Thus the ridges (61) will provide contact and support for
any other structure such as dry wall, which may be secured to the
stud.
[0080] The depressions (60) give the stud significantly greater
strength and rigidity. This greatly assists in the attachment of
material such as dry wall, using self tapping screws. The tip or
drill point of a screw will seat down in one of the depressions
(60). When the installer applies pressure to the screw, to make it
bite into the strip material, the strip will not deflect as
readily. In addition the screw will penetrate more surely into the
metal.
[0081] Also it is significant that each depression (60) already has
side surfaces which converge downwardly below the planar outer
surface of the metal. When the screw does penetrate and create
screw threads, the metal will extrude along the length of the screw
and the threads will form along the length of the screw threads and
form or extrude a tube of sheet metal around the screw. This will
ensure that the screw holds securely, when tightened down, and does
not gradually becomes loose.
[0082] When erecting dry wall framing in particular, it is
desirable to incorporate some form of transverse cross braces
between adjacent upright studs. Such a transverse bracing is
illustrated in FIG. 17. In this case, the stud of FIG. 15 is shown,
connected with a transverse bracing member (70). This bracing
member is a simple right-angular L shaped section, formed with a
series of generally L shaped slots (72). The L shaped slots (72)
define flexible tongues (74), which are deflected slightly out of
the plane of the material.
[0083] The bracing members (70) can simply be flexed slightly, and
inserted through the openings (64) in the stud (50). The tongues
(74) will flex slightly and allow the bracing members to spring
outwardly into the original position. The slots (72) and tongues
(74) will lock and capture the edges of the web (52) around the
opening (64), in the manner shown in FIG. 17.
[0084] FIGS. 18 and 19 illustrate further minor modifications for a
dry wall stud. In this case, the dry wall stud is indicated as (80)
having a web (82) and flanges (84) and (86). Multiple separate
indents or dimples (88) similar to FIG. 16, are formed in the
flanges. Web grooves (90) arranged in a generally diagonal fashion
extending across the web (82). The web grooves may simply either be
alternating diagonal defining V shapes, or may define Y shapes.
Preferably, corner bracing grooves (92) are formed to assist in
bracing the flanges against flexing, during insertion of the dry
wall screws.
[0085] FIG. 20 illustrates a schematic section of a typical stud
with indented grooves such as the stud of FIG. 7 or FIG. 11, for
example. The dimensions of the studs may vary in terms of web width
illustrated as A and in terms of flange width illustrated as B, and
in terms of lip height illustrated as C. The groove width is shown
as D (FIG. 21). The groove spacing in the flanges is shown as X-X,
between which is the planar section of the flange. These variations
may be within the range of the variations indicated in the table of
FIG. 22. The dimensions will assist materially in the erection of
dry wall. By locating the two flange grooves spaced apart, with a
planar section between them, it is possible for dry wall panels to
be installed, with the edges of two dry wall panels (not shown)
abutting each other and overlying the one stud. The installer will
then insert screws along each panel edge, and the screws will seat
into their respective grooves, which are in the correct locations
to receive them.
[0086] The thickness or gauge of the sheet material, shown as T,
may vary according to the table of FIG. 22.
[0087] The depth and width of the longitudinal indented grooves is
indicated as D and E in FIG. 21 and their variations are
illustrated in Table of FIG. 22.
[0088] The spacing between the longitudinal indented grooves in the
flanges and when used, in the web, may vary within the range
indicated in FIG. 22, by the letters X, XX, Y, Z and ZZ.
[0089] Within these ranges it is found that the longitudinal
indented grooves provide significant increases in load bearing
capacity.
[0090] FIG. 20 illustrates a schematic section of a typical stud
with indented grooves such as the stud of FIG. 7 or FIG. 11, for
example. The dimensions of the studs may vary in terms of web width
illustrated as A and in terms of flange width illustrated as B, and
in terms of lip height illustrated as C. The groove width is shown
as D (FIG. 21). The groove spacing in the flanges is shown as X-X,
between which is the planar section of the flange. These variations
may be within the range of the variations indicated in the table of
FIG. 22. The dimensions will assist materially in the erection of
dry wall. By locating the two flange grooves spaced apart, with a
planar section between them, it is possible for dry wall panels to
be installed, with the edges of two dry wall panels (not shown)
abutting each other and overlying the one stud. The installer will
then insert screws along each panel edge, and the screws will seat
into their respective grooves, which are in the correct locations
to receive them.
[0091] The thickness or gauge of the sheet material, shown as T,
may vary according to the table of FIG. 22.
[0092] The depth and width of the longitudinal indented grooves is
indicated as D and E in FIG. 21 and their variations are
illustrated in Table of FIG. 22.
[0093] The spacing between the longitudinal indented grooves in the
flanges and when used, in the web, may vary within the range
indicated in FIG. 22, by the letters X, XX, Y, Z and ZZ.
[0094] Within these ranges it is found that the longitudinal
indented grooves provide significant increases in load bearing
capacity.
[0095] The grooves may be indented into the material by using pairs
of rolls indicated schematically in FIG. 23, and in more detail in
FIGS. 24, 25, and 26.
[0096] In this case an upper clamp roll (100) and lower clamp roll
(104) holds the sheet metal.
[0097] A groove recess roll (106), and groove indent roll (108)
indent the groove (102). Within the rolls, sheet metal material of
a wide variety of thicknesses or gauge may be advantageously formed
with indented grooves, the effect of the rolls varying somewhat
depending on the thickness of the gauge of the material. These
studs enable the use of a reduction in thickness or gauge of sheet
metal. It is anticipated that a reduction of at least one gauge and
probably two gauges can be achieved while still providing adequate
support to a wall or a concrete panel. This will reduce the cost of
the walls or panels. It will also reduce the heat transfer through
the panel and stud, since the reduction in gauge reduces the actual
mass of metal available to provide a heat transfer path.
[0098] The erecting of interior partitions is commonly completed by
erecting a frame work of metal studs. Studs are erected usually on
16 inch centres. Top and bottom channels provide a means of
anchoring the tops and bottoms of the vertical studs. In order to
reduce the metal required in such studs, the thickness or gauge of
the steel is reduced to a minimum, compatible with providing a
reasonably firm wall or partition. Reduction of metal also reduces
the weight loading per floor on a building, which can also result
in substantial saving in the construction of the building fabric.
Such walls usually involve the completion of each side of the wall
by panels of gypsum wall board, so-called dry wall. Usually, these
panels are secured to the studs by screws having chisel points,
which will drill through the metal of the stud and are
self-tapping. It is well known, however, that the insertion of such
screws can be hindered, if the metal forming the stud is made too
thin. In this case, the stud flanges will simply bend when the
pressure of the screw point is applied to it, and the screw will
slip off. The present invention utilizes narrow longitudinal
indented grooves in the edge flanges of the stud and also in the
web of larger studs. These narrow longitudinal indented grooves
substantially increase the rigidity of the edge flanges which
facilitate the insertion of self-tapping screws. In addition, the
longitudinal indented grooves provide narrow grooves for anchoring
the tip of the screw so that it will not slip when pressure is
applied to it to provide the drilling and self-tapping action. The
use of the multiple separate indented dimples (60) also has the
same result, locating and holding the screw point while it bites
into the sheet metal.
[0099] Manufacture of the studs of the invention, would typically
proceed by passing a continuous strip of flat sheet metal through a
series of narrowly spaced apart web clamping roller dies (100-104).
The studs may be the FIGS. 1 and 7 embodiments, in which case they
will have been formed with web openings and channels, prior to the
forming of the indentations.
[0100] The grooves are formed by recess dies (106) and male
indenting dies (108). These dies are mounted on a series of
separate shafts spaced apart along the roll forming production
line, as shown in more detail in FIGS. 24, 25, and 26.
[0101] In FIGS. 24, 25, and 26 the indenting dies are shown in
pairs, so that they indent two spaced apart grooves (102)
simultaneously. FIG. 24 shows the indenting of two grooves
(102a-102b), side by side. FIG. 25 show the next stage in which a
further groove (102c) is indented. A bend (110) is being formed
between groove (102a) and groove (102b) to form the lip on the edge
flange.
[0102] FIG. 26 shows the indenting of two further grooves
(102d-102e), in the actual web portion of the stud.
[0103] A bend (112) is being formed between groove (102c) and
groove (102d), which will thus form the edge flange of the
stud.
[0104] The clamping dies (100-104) function to grip the sheet metal
on either side.
[0105] The indenting dies (106-108) form the grooves in the sheet
metal.
[0106] The clamping dies hold the sheet metal on either side of the
indenting dies so as to prevent the sheet metal from being drawn
inwardly from either edge.
[0107] The studs so formed will maintain their uniform preset
width, which is required for the job for which they are
intended.
[0108] The effect of passing the flat strip through these groove
roller dies will be to form narrow longitudinal indented grooves,
in the portions of the strip which will eventually form the edge
flanges and the lips of the stud, and in some cases, will form the
web as well. The studs will, of course, be cut to suitable length
in a mechanism of which several types are well known in the
art.
[0109] The multiple separate indents or dimples (60) of FIG. 16,
may be formed by using toothed indent rolls (not shown) similar to
indent rolls (108), but having a plurality of separate point shaped
tooth formations (similar to gear teeth for example). As the metal
passes between such rolls the teeth will form separate individual
indents, as shown in FIG. 16, in the sheet metal.
[0110] In the event that it is required to form any additional
formations in the web, or transverse grooves openings or the like,
then typically these will be formed in a rotary die machine, which
will be located downstream of the longitudinal groove dies, but
before the bending dies. Such rotary die machines are known in the
art. Alternatively, however, in some cases it is possible that
flying die systems may be used, although these would require a
slower production speed.
[0111] Cutting to length will normally be performed upstream of the
roller dies, where the strip sheet is still flat and unformed. In
this way each piece of sheet metal passing through the various
punching and forming and roll forming sequences is already precut
to the exact length required for the finished stud.
[0112] It also possible to cut to length downstream of the roller
dies, in some cases. It must be remembered that in cutting to
length, provision must be left at each end of each stud to leave
end portions of the stud free of openings, so that it can be placed
in an eventual structure, with all of the openings in each stud
aligned with one another across the structure. This will greatly
facilitate the installation of services through the openings.
[0113] Suitable controls which form no part of the invention are
incorporated in the rotary press so that the rotary press is timed
to operate exactly where required on each stud. Where openings are
not required, at each end of each stud, the controls disable the
rotary press so that leading and trailing ends of the sheet metal
pass through unpunched and unformed.
[0114] The term "indented" as used herein is intended to define the
effect of forming the lengthwise grooves, or multiple indented
dimples. The grooves or dimples are deflected inwardly towards the
space enclosed with the shape of the C section of the stud. This
leaves the exterior surface of the two edge flanges planar (flat)
and thus available to receive wall finishing panels such as dry
wall or similar panels.
[0115] In these illustrations, studs which are shown for
explanation only, are relatively short. Clearly in most cases the
studs would be longer, as required by the particular structure for
which they are required.
[0116] A further embodiment of stud (120) is shown in FIGS. 27 and
28.
[0117] In this case the edge flanges (122) are formed with a series
of separate indented grooves (124), which are spaced apart
lengthwise along the edge flanges. Two rows of such grooves (124)
are shown, with the grooves in one row being offset with relation
to the grooves in the other row. The ends of grooves in one row
overlap the ends of grooves in the other, adjacent row thus
providing for continuity of reinforcement along the stud. In this
stud depressions (126) of irregular triangle shape are formed in
the web at each end of each diagonal rib, and openings (128) are
formed in the depressions.
[0118] 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.
* * * * *