Patent Application
20190186120
Vertical metal framing components are commonly used in construction. Examples of vertical metal framing components include but are not limited header systems, doorjamb systems, area separation wall systems, shaft wall systems and studs. The stud is the most well-known vertical metal framing component.
According to U.S. Pat. No. 6,708,460 (the “460 patent”), “[m]etal studs are used to form walls in building structures today, including load bearing walls such as exterior walls, [interior walls] and curtain walls. In a typical installation, the metal studs are secured by screws at their lower ends to a bottom track secured to a floor, and extend at their upper ends into a top track secured to overhead joists which may form the framework for an upper floor. The upper ends of the studs generally also are secured to the top track. Exterior wall materials and/or wall boards or other panels are applied to the sides of the studs to form a closed wall structure.”
“The load bearing walls are subject to axial loads (compressive loads on the studs) applied to the studs through the overhead joists, and also may be subject to transverse loads (for example, exterior walls may be subject to transverse loads from wind effects) and lateral loads acting in the plane of the wall. These loads may cause flexing (including bowing, twisting or other deformation of the stud) or turning of the metal studs which may cause the [Gypsum in the] walls to crack or otherwise be flawed or damaged. In load bearing walls, this problem is structural as well as aesthetic.”
“Bridging systems heretofore have been used to reinforce the metal stud walls by adding structural support between adjacent studs. Three known bridging systems include braced channel, welded channel, and block-and-strap bridging systems.”
“In the braced channel bridging system, a U-shape channel spans two or more metal studs, extending through a conduit hole in the web of each stud. An angled brace is fastened to both the channel and the web of the stud, generally with screws or rivets.”
“The welded channel bridging system also uses a U-shape channel which spans two or more metal studs and extends through conduit holes in the webs of the studs. The channel is then welded to the studs on one or both sides of the channel.”
“In the block-and-strap bridging system, sheet metal “blocks” are fastened between adjacent studs through bent tabs at their distal ends. Then a strap is fastened to one or both sides of two or more metal studs as well as to the respective side or sides of the blocks. Thus the studs are interconnected by the blocks between the studs as well as the straps along the sides of the studs, and the blocks and straps also are connected to each other.”
“The installation of metal stud wall systems, including the reinforcing bridging systems, heretofore has been a time consuming process. In a typical installation where the metal studs are fastened at their upper ends to a top track or channel, the attachment positions of the studs are marked off along the top track. Then each stud is fastened to each flange of the top track by screws. A ladder or a scaffold may be required if the top track is too high for the installer to reach. If a ladder is used, the installer climbs the ladder and fastens as many studs as he can reach to the near flange of the top track. Then he must climb down the ladder, move the ladder along the wall so that when he again climbs the ladder he can reach the next one or more studs for fastening to the top track. If a scaffold is used, much more time is expended setting up the scaffold. After doing this along one side of the wall, the process is repeated on the other side of the wall to fasten the studs to the other flange of the top track.”
“The metal studs must then be fastened at their lower ends to a bottom track or channel. Each stud must be carefully aligned and squared before being fastened to the bottom track. In addition, the bridging members described above also must be installed to interconnect the metal studs at one or more points between the top and bottom tracks. Because of the time consuming nature of the installation process, fasteners can be missed or forgotten. In the welded channel bridging systems, welders and their equipment are relatively expensive, and welds also can be missed, or can be improperly formed. Defects in welds can be particularly difficult to detect.”
“In addition, once the studs are installed, other trades people, such as plumbers and electricians, may remove the bridging members between two studs to give them more room to work, running plumbing lines or electrical lines, for example. If the bridging member is not replaced, the strength of the wall may be reduced.”
The invention described in the '460 patent attempts to solve the problems by providing “a stud bridging/spacing member includes an elongate member having at least three longitudinally spaced apart notches for receiving and engaging therein a web of a metal stud. The notches extend at an incline to the longitudinal axis of the elongate member to accommodate different gauges of metal studs while maintaining on-center spacing of studs when assembled in a stud wall.”
According to one embodiment of the invention in the '460 patent, “the notches extend inwardly at an angle of about two to about fifteen degrees relative to a perpendicular to the longitudinal axis, and more preferably about five and a half degrees to about eight degrees, and most preferably about seven degrees. The notches have a width of about 0.050 inch (about 0.13 cm) to about 0.1 inch (about 0.2 cm), more preferably about 0.065 inch (about 0.16 cm) to about 0.080 inch (about 0.20 cm), and most preferably about 0.080 inch (about 0.20 cm). The elongate member is formed of fourteen, sixteen or eighteen gauge metal (more preferably steel and most preferably galvanized steel).”
The '460 patent continues with “[t]he at least three notches generally extend laterally inwardly from laterally outer edges of the elongate member. The elongate member may include a fourth notch equally spaced between at least two of the at least three notches. Each of the at least three notches in one portion of the elongate member may be laterally aligned with a corresponding notch in another portion of the elongate member, and/or the laterally aligned notches may incline in the same direction. The sides of the notches generally are parallel, and straight.”
“Further in accordance with an embodiment of the invention [disclosed in the '460 patent], the elongate member has a V-shape lateral cross-section formed by longitudinally extending planar first and second portions joined at respective longitudinal edges to form the sides and vertex of the V-shape. The elongate member further may include a pair of wing portions extending laterally outwardly from respective distal ends of the V-shape elongate member. The wing portions may extend in opposite directions from the V-shape elongate member, and each wing portion may extend a distance which is approximately one-third the width of the widest part of the V-shape elongate member. The angle of the V is at least about 90°, more preferably at least about 120° and most preferably about 130°. A shallow angle increases the transverse stiffness of the elongate member, although other means may be used for this purpose.”
“In assembling a metal stud wall including a row of metal studs each having at least two flanges interconnected by a web, each stud is fastened at a lower end to a base track. A stud bridging/spacing member is inserted through aligned openings in at least three metal studs, and longitudinally spaced apart notches in the stud bridging/spacing member are engaged with respective webs of the metal studs, thereby establishing and maintaining a fixed spacing between the metal studs and reinforcing the studs against deflection and turning under loading. When the notches engage the webs of the studs, a portion of the webs of the studs generally is caused to bend (at least under load conditions) in the direction of the inclines of the notches to retain the web in the engaged notch. The assembly method may also include securing a top end of each of the studs to a ceiling track.”
Review of the '460 patent, particularly
Disclosed herein is a stud bridge member which will have a stud bridge member width and may comprise a web, a first flange, and a second flange. The web may have a web outer side, a web inner side, a web first edge, and a web second edge defining a web plane having a longitudinal axis. The first flange and the second flange may extend into a space on the web inner side. The stud bridge member may also comprise at least one notch set comprising a first notch and a second notch and at least one gusset having a gusset outer apex.
The first flange may comprises a first flange first edge and a first flange second edge defining a first flange plane with the first flange first edge joined with the web first edge at a first juncture having a first juncture outside angle (ΘM1) from the web outer side to the first flange, with a corresponding explementary inner angle (αM1), with the first juncture forming a first juncture line which is substantially parallel to the longitudinal axis.
The second flange comprises a second flange first edge and a second flange second edge defining a second flange plane with the second flange first edge joined with the web second edge at a second juncture having a second juncture outside angle (ΘM2) from the web outer side to the second flange, with a corresponding explementary inner angle (αM2), with the second juncture forming a second juncture line which is substantially parallel to the longitudinal axis.
The first juncture line, the first flange first edge, the first flange second edge, the second juncture line, the second flange first edge, and the second flange second edge can be substantially parallel to the longitudinal axis.
The first notch may comprise a first notch length, a first notch width measured perpendicular to the first notch length, and a first notch cut plane. The first notch length begins in the first flange at a first flange notch point and extends at least through the first juncture and to a web first notch point.
The second notch may comprise a second notch length, a second notch width measured perpendicular to the second notch length, and a second notch cut plane. The second notch length begins in the first flange at a first flange notch point and extends at least through the first juncture and to a web second notch point wherein a line passing from the web first notch point to the web second notch point is perpendicular to the longitudinal axis.
The at least one gusset extends from the first flange second edge to at least the first flange notch point or from the second flange second edge to at least the second flange notch point.
It is further disclosed that the gusset is also on the web or on the first flange and the second flange or on the web and on the first flange and on the second flange.
It is further discloses that at least one of αM1 or αM2 has a value of greater than 90° and less than about 110°, that both αM1 and αM2 may have a value of greater than 90° and less than about 110° and that both αM1 and αM2 may have substantially the same value.
It is further disclosed that the distance from the outer gusset apex to the outer edge of the opposing flange when measured perpendicular to the longitudinal axis and parallel with the web plane is less than or equal to the stud bridge member width.
It is also disclosed that the first notch or second notch are an hourglass notch.
An embodiment is further disclosed where the stud bridge member is engaged with a vertical metal framing member having a vertical metal framing member hole with vertical metal framing member hole edges and a vertical metal framing member hole depth; with the bridge member passing through the vertical metal framing member hole so that the first notch and the second notch are engaged with the vertical metal framing member hole edges; and the distance from the outer gusset apex to the outer edge of the opposing flange when measured perpendicular to the longitudinal axis is less than the vertical metal framing member hole depth.
This invention is to an improved stud bridge member. The specification is best understood referring to
As described in the background section, the traditional method of installing stud bridge members is to lay the stud bridge member at a hole through the stud, and then use clips on either side to secure the stud bridge member to the stud.
Advances were made to also provide stud bridge members with slots. As indicated in the background section these slots pass through the flanges of the stud bridge member. The stud bridge member is used with the channel, trough, or inner side facing down, making the stud bridge unsuitable for laying cable or wiring.
The novel stud bridge member in this specification can be installed without using a clip at each stud, thus reducing the cost and time to install. As the clips are only used at the end of each stud bridge member, a stud bridge member spanning 3 studs and clipped to 2 other studs would eliminate the time and expense of using 3 clips.
This novel stud bridge member is also installed so that the channel faces up, allowing the channel to be used for cabling or electrical lines.
Additionally, as the stud bridge member places a single horizontal metal channel across the stud and in between the studs, the stud bridge member is much stronger and not susceptible to bending as seen in the commonly used V-bridging member described in U.S. Pat. No. 6,708,460.
As the novel stud bridge member uses notches, water gathered during construction is naturally drained out of the upward facing channel through the notches.
This specification uses the term web to describe a middle planar component (200) and the term flange to describe the outer planar components (300 and 400). These terms are interchangeable.
The invented stud bridge member is best described by starting with
In
Either or both of the first juncture (510) and the second juncture (530) could be a weld, a bend, glue, or any another means known where two components can be joined. The first juncture and the second juncture are not required to use the same means of joining two components together. For instance, the first juncture may be a weld while the second juncture is a bend. Preferably the stud bridge member (100) is made of a unitary piece of construction and the junctures are bends of the same piece, preferably made of metal. Examples of such metals include steel, stainless steel, iron, aluminum, copper, brass, titanium, and the like. However, the stud bridge member could alternatively be extruded through a die where it is formed into shape and could be made of a metal or plastic material.
As shown in
The longitudinal axis (500), the first juncture line (520) and the second juncture line (540) are all preferably parallel with or substantially parallel with each other.
The stud bridge member (100) will have at least one notch set, comprised of a first notch and a second notch. As noted in
The detail of one notch embodiment is shown beginning with
In one embodiment, each notch is an opening passing through the outer side to the inner, or channel side, of one of the flanges, the corresponding juncture and the web. The invention is best understood using the preceding notch description.
There are other embodiments. One alternative embodiment comprises a notch which is an opening passing through the outer side to the inner, or channel side, of one of the flanges, through the corresponding juncture and only slightly into the web. Another alternative embodiment is a notch passing through one of the flanges, and the corresponding juncture, but not into the web.
Starting with the first notch (600), the first notch has a first notch length (620). The first notch length is the line running from a reference point called the first flange notch point (680) to the web first notch point (660). In this case, the first notch is an opening starting at the first flange notch point. The first notch runs from the first flange notch point to the web first notch point.
Although not required to be symmetrical with the first notch (600), the second notch (700) can have the same analogous features. The second notch (700) has a second notch length (720). The second notch length is the line running from a reference point called the second flange notch point (780) to the web second notch point (760). In this case, the second notch is an opening starting at the second flange notch point. The second notch runs from the second flange notch point to the web second notch point.
In the case where a notch—either the first notch of the second notch—passes through the juncture, but does not pass into the web, the web notch point is at the web edge where the juncture begins.
Preferably, the notch does not extend across the entire flange. However, in some embodiments, it is possible for a notch to run across the entire flange. In some embodiments, one notch of the notch set may extend across the entire flange, while the other notch does not. In some embodiments, both notches extend across the entirety of their respective flanges. Preferably, both notches do not extend across the entirety of their respective flanges.
As can be seen, the first flange plane (350), the web plane (250), and the second flange plane (450) are substantially parallel with the longitudinal axis (500).
From the outer view,
A preferable embodiment is depicted in
The first notch cut plane (630) is defined by a cut made into the web and the first flange if the web and the first flange had been flat, or not bent, when the cut for the first notch was made. After bending, the cut in the web and the first flange form two legs of a triangle, which define the first notch cut plane.
In the current embodiment, there is a first inflection line (690) which is the line perpendicular to the first notch length at which the first notch width (640) is at its greatest value. Because of the rectangular nature of this particular embodiment, the first inflection line coincides with, or is parallel with, the first juncture line (520).
Analogously,
The second notch cut plane (730) is defined by a cut made into the web and the second flange as if the web and the second flange had been flat, or not bent, when the cut for the second notch was made. After bending, the cut in the web member and the second flange form two legs of a triangle, which define the second notch cut plane.
In the current embodiment, there is a second inflection line (790) which is the line perpendicular to the second notch length at which the second notch width (740) is at its maximum. Because of the rectangular nature of this embodiment, the second inflection line coincides with, or is parallel with, the second juncture line (540).
To facilitate straight positioning of the stud bridge member between the studs, it is preferable that the first notch length (620) and the second notch length (720) not be parallel, but in the same plane.
In a further embodiment the first notch length (620) and the second notch length (720) in a given notch set are perpendicular to the longitudinal axis.
The notches may widen and then shrink to facilitate twisting the member into place and locking it onto the stud. This can be described as the first notch width (640) increasing along the first notch length (620) beginning from the first flange notch point (680) to the first notch inflection line (690) and then decreasing from the first notch inflection line (690) to the web first notch point (660). The notches widen to help account for build variation that occurs during stud to track to building assembly.
Similarly, the second notch width (740) increases along the second notch length (720) beginning from the second flange notch point (780) to the second notch inflection line (790) and then decreases from the second notch inflection line (790) to the web second notch point (760).
The first notch cut plane (630) and the second notch cut plane (730) form what is called the notch plane. The notch plane is also defined by the line connecting the first flange notch point (680) to the web first notch point (660) to the web second notch point (760) to the second flange notch point (780). It is preferable that the line passing from the web first notch point (660) to the web second notch point (760) be perpendicular to the longitudinal axis (500) in order to keep the notches properly aligned with the longitudinal axis.
The notch plane may be perpendicular to, substantially perpendicular to, or not substantially perpendicular to, the longitudinal axis (500).
The only force needed to engage the notches with a stud when the notch plane is substantially perpendicular to the longitudinal axis (500) is a force in the inner direction to engage the notches with a stud.
In contrast, the installer slides the bridge in the longitudinal directional and pushes the bridge member in the inner channel direction to engage the notches with the stud when the notch plane is not substantially perpendicular to the longitudinal axis (500).
The notch sets are parallel when a plurality of notch sets is present on the bridge member.
It is also preferable that the notch points in the flange edges, i.e. the first flange notch point and the second flange notch point, are equidistant from the longitudinal axis.
However, in an alternative embodiment, the notch points in the flange edges, i.e. the first flange notch point and the second flange notch point, may not be equidistant from the longitudinal axis.
In one embodiment both notches in the notch set are symmetrical, i.e. the same geometric shape. In an alternative embodiment, the notches in the notch set are not symmetrical.
The value of ΘM1 is preferably greater than 270° and less than 360°. If ΘM1 is less than 270° the stud bridge member is difficult to rotate onto the walls of the stud hole.
As a corollary, there will be an explementary angle αM1, which is the value of the angle opposing angle ΘM1. ΘM1 plus αM1 will equal 360°.
The first juncture (510) of the stud bridge member forms a first juncture line (520) which is substantially parallel to the longitudinal axis (500).
The similar structure is true of the second flange. As with the first flange, one of the second flange edges (420) is joined with the web second edge (220) at a second juncture (530) having a second juncture outside angle (ΘM2).
Like ΘM1, ΘM2 is measured from the web outer side (240), i.e. the non-channel side, to the outer side of the second flange (400) as shown in
As a corollary there will be an explementary angle αM2 which is the measurement of the angle opposing angle ΘM2. ΘM2 plus αM2 will equal 360°.
It is preferred that ΘM1=ΘM2, although not required. Put another way, ΘM1 and ΘM2 have about the same value, or preferably are the same value.
The second juncture forms a second juncture line (540) which is substantially parallel to the longitudinal axis (500).
To define the C shape, or channel, as opposed to a Z, the first flange (300) and the second flange (400) must simultaneously be in a space on the web inner side (260).
One way to make the bridge member is to cut the notches into a flat piece of metal and then fold the flat piece of metal into the web with a flange on each side. This is depicted in
One preferred shape is an elongated rectangle, preferably an elongated square. This is depicted in
In
In
Referring to
There may be only one gusset on one flange. The gusset preferably runs from the flange end to the respective flange notch point. There may be a gusset on each flange and no gusset on the web. There may be a gusset on each flange and the web.
Accordingly, it can be described that the bridge member has at least one gusset that extends from the first flange second edge to at least the first flange notch point or from the second flange second edge to at least the second flange notch point.
The gusset may extend from a flange second edge through the notch to the web and then across at least portion of the web.
Accordingly, it can be described that the bridge member has a gusset extending from the first flange second edge to the first flange notch point and the second flange second edge to the second flange notch point.
Accordingly, it can be described that the bridge member has a gusset extending from the first flange second edge to the first flange notch point and the second flange second edge to the second flange notch point and extending across at least a portion of the web on a line between the web first notch point and the web second notch point.
As shown in the embodiment of
The width of the gusset to the width of the notch(es) is not so important. The gusset can be wider than the notch or the notch can be wider than the gusset.
However, both the notch width and gusset width are governed by the material thickness of the stud. Accordingly, both the notch width and the gusset width have to be wider than the stud material thickness.
Notch width 667 is needed for a lead-in for assembling the bridging member with the stud as the bridging member is twisted in the stud hole. Accordingly notch width 667 can be much wider than flange width 687. Notch width 640 needs to be narrower than 667 and the radius of the arc at 680 is smaller than the radius of the arc at 660 to taper and lock the CRC bridging member into the stud slot at 640 and 680. Thus, 640 is preferably a much smaller width than 667. In a preferred embodiment of the installation, the stud does not engage the notch in the web at 667, but the stud engages and locks with the notch at 640 and at 680
While
The notch embodiment in
For the embodiment in
For the embodiment in
For the embodiment in
While
(630) depicts the notch cut length of the first notch, when the bridge member is bent as in
(921) depicts the inner apex of the gusset or the point of the gusset line which is the furthest from the inside of the flange sticking into the channel formed by the two flanges and the web. Corresponding to (921) is (941) which is the outer apex of the gusset on the opposite side of the flange. (922) is the gusset inner depth which is at the inner apex (921) and (942) is the outer depth of the gusset from the outer side of the flange (350) at the gusset outer apex (941). (941) is the point in the gusset on the outside of the bridge member furthest away from the outer side of the flange (i.e. the apex).
(910) depicts the gusset major inner width of the gusset which occurs on the web side of the flange in this case. (920) depicts the gusset minor inner width of this embodiment. (930) depicts the gusset major outer width of this embodiment. 940 depicts the gusset minor outer width of this embodiment. The phrase inner and outer refer to the side of the flange or web relative to the channel formed by the two flanges and the web with the inner referring to channel side and outer referring to the non-channel side.
While this gusset embodiment is a half a hexagon, the gusset can be curved, or v-shaped, or square shaped, or rectangular shaped or other geometric configurations forming a small indentation into the flange at the notch. This gusset embodiment can be formed on a roll form mill or a press brake and shear machine.
As explained previously, the embodiment without the gusset cannot be inserted into the stud hole and then set into place unless the flange is bent into the channel, i.e. the inner angle (αM1 and/or αM2) between the web and the un-gusseted flange is less than or equal to 90° as shown in
However, as explained below, because the gusset allows for more room at the actual vertical framing component hole, which is a stud hole when the vertical metal framing component is a stud, the flanges can be bent outwards on the embodiment with the gusset.
Having the flanges bend outwards allows one bridge member to nest in another bridge member, thus eliminating the use of bridge clips except for the ends of the first and last bridge member.
Additionally, having the flanges of the gusseted bridge members bend outwards towards the edges of the stud hole provides for even further support of the stud by the bridge member. This is shown in
As shown in
While the maximum angle for each flange of the bridge member can be calculated, an easier way to understand this is to realize that the length of a line perpendicular to the longitudinal axis (500) running from the outside of the gusset at the flange edge (gusset outer apex (941)) to the outside of the opposing flange second edge is preferably less than or equal to the stud hole depth (820), or more preferably, less than or equal to the stud bridge member width (150).
If the opposing flange has a gusset, then the length of the line is the length of a line perpendicular to the longitudinal axis (500) running from the outside of the gusset at the flange second edge (the second flange's outer apex) to the outside of the gusset on the opposing flange second edge.
For example, the standard stud has a hole depth of 1.5″+/−0.01″. Thus, the hole depth could be as small as 1.49″. The distance between the gusset apex on flange (300) and the gusset apex on flange (400), measured perpendicular to the longitudinal axis must be less than or equal to 1.49″. In the case where only one flange has a gusset, the maximum distance between the flange second edges is again measured along the line perpendicular to the longitudinal axis from the outer apex of the single gusset to the outer side of the opposing flange second edge.
This is typically accomplished with an inner angle of from greater than 90° to less than about 110°, with 100° being preferred. In this case both αM1 and αM2 would have a value of greater than 90° and less than about 110°. However, experience has shown that an inner angle of about 100°+/−1° of standard manufacturing variance is preferred in order for the gussets to nest within each other and eliminate the use of bridge clips except for the un-nested ends of the first and last bridge member.
This application is a continuation in part of U.S. patent application Ser. No. 15/987,120 filed on 23 May 2018 and claims the benefit of priority of U.S. Provisional Application No. 62/643,925 filed on 16 Mar. 2018, 62/644,050 filed on 16 Mar. 2018, 62/645,223 filed on 20 Mar. 2018; 62/663,481 filed on 27 Apr. 2018; 62/663,431 filed on 27 Apr. 2018 and 62/662,839 filed on 26 Apr. 2018, and U.S. patent application Ser. No. 15/987,120 filed on 23 May 2018; the teachings of each of which are incorporated by reference herein in their entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62645223 | Mar 2018 | US | |
| 62644050 | Mar 2018 | US | |
| 62643925 | Mar 2018 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 62663481 | Apr 2018 | US |
| Child | 15987120 | US | |
| Parent | 62663431 | Apr 2018 | US |
| Child | 62663481 | US | |
| Parent | 62662839 | Apr 2018 | US |
| Child | 62663431 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15987120 | May 2018 | US |
| Child | 16281371 | US |
