This invention generally relates to apparatus for manufacturing metal studs for the building industry.
Studs, joists, beams, rafters, etc. are terms used to describe various framing and support components in the building industry. For purposes of simplification and better understanding, the term “stud” or “studs” will be used generically in this disclosure to represent any framing or support component. Specifically, a metal stud of the type being manufactured is disclosed in a copending United States patent application entitled “Metal Stud”, filed 21 Nov. 2008, bearing Ser. No. 12/275,914, and incorporated herein by reference.
The metal stud of the type disclosed in the copending application can be relatively difficult to manufacture. The various components must be fabricated and assembled, preferably with a minimum amount of labor and effort on the part of workmen. The present fabricator or manufacturing system produces a complete metal stud from raw materials with substantially no intervention by workmen. Further, the manufacturing system is a continuous process so that complete metal studs are manufactured continuously until the raw materials are depleted.
Accordingly, it is an object of the present invention to provide new and improved manufacturing apparatus for producing metal studs.
It is another object of the present invention to provide new and improved manufacturing apparatus for producing metal studs that are complete and consistent.
It is another object of the present invention to provide a new and improved manufacturing apparatus for producing metal studs that is easy to use and requires relatively little intervention by workmen.
Briefly, to achieve the desired objects of the instant invention in accordance with a preferred embodiment thereof, metal stud manufacturing apparatus is disclosed that includes a plurality of metal shaping rollers positioned to shape a continuous metal strip into continuous first and second spaced apart metal panels each having first and second longitudinal edges turned to provide support along the longitudinal axis. A pair of opposed wire shaping elements are positioned to form a continuous wire into a continuous zig-zag pattern of wire. An assembly component is positioned to receive the continuous first and second spaced apart metal panels and the continuous zig-zag pattern of wire and to position the zig-zag pattern of wire between the spaced apart metal panels and in contact with one of the first and second longitudinal edges of each of the spaced apart metal panels to form a continuous beam assembly. A welding component receives the continuous beam assembly and spot welds the zig-zag pattern of wire to the one of the first and second longitudinal edges of each of the spaced apart metal panels to form a continuous fixed beam. A cutting component is reciprocally mounted to receive the continuous fixed beam and to hold the continuous fixed beam at selected areas and to shear the continuous fixed beam at the selected areas to form a plurality of separate metal beams of a desired length.
The desired objects of the instant invention are further achieved in accordance with a specific embodiment thereof in which a metal stud manufacturing apparatus includes a source of a continuous metal strip and a source of a continuous wire. A plurality of metal shaping rollers are positioned to receive the continuous metal strip from the source and to shape the continuous metal strip into continuous first and second spaced apart metal panels each having first and second longitudinal edges turned to provide support along the longitudinal axis. The plurality of metal shaping rollers shape the first and second spaced apart metal panels to each include an outwardly directed flat surface, and shape each first and second longitudinal edge turned to provide support of each first and second spaced apart metal panel to include at least one bend away from the outwardly directed flat surface, and the plurality of metal shaping rollers also provide a knurled surface on each of the outwardly directed flat surfaces of the first and second spaced apart metal panels. A wire straightening element is positioned to receive the continuous wire from the source and includes a first plurality of rollers oriented in the horizontal plane to straighten out any bends in the wire parallel with the horizontal plane and a second plurality of rollers oriented in the vertical plane to straighten out any bends in the wire parallel with the vertical plane. A pair of opposing wire shaping elements are positioned to receive the straightened continuous wire from the wire straightening element and to form the straightened continuous wire into a continuous zig-zag pattern of wire. The zig-zag pattern of wire forms an angular metal coupling element positionable between the first and second spaced apart metal panels and bent to periodically and alternately contact the first and second spaced apart metal panels at contact points. An assembly component positioned to receive the continuous first and second spaced apart metal panels and the continuous zig-zag pattern of wire and to position the zig-zag pattern of wire between the spaced apart metal panels and in contact with one of the first and second longitudinal edges of each of the spaced apart metal panels to form a continuous beam assembly. A welding component receives the continuous beam assembly and spot welds the zig-zag pattern of wire to the one of the first and second longitudinal edges of each of the spaced apart metal panels to form a continuous fixed beam. A cutting component is reciprocally mounted to receive the continuous fixed beam and to hold the continuous fixed beam at selected areas and to shear the continuous fixed beam at the selected areas to form a plurality of separate metal beams of a desired length. The apparatus is designed to continuously move the continuous metal strip and the continuous wire through the apparatus at a continuous and fixed speed, and the cutting component is designed to reciprocally move with the continuous fixed beam at the fixed speed to perform the shear cutting at a selected cutting area and after the shear cutting reciprocate to the next cutting area.
The foregoing and further and more specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof taken in conjunction with the drawings, in which:
a and 7b are enlarged perspective views of a wire straightening element of the wire shaping component of
a through 10f are enlarged perspective views of some of the elements of the metal shaping and cutting component of
Turning first to
Metal stud 40 also includes an upper panel 50 forming an upper flat stud surface 52 with one edge 54 turned downwardly at 54a and inwardly at 54b, for the length of panel 50. Also, upper panel 50 of metal stud 40 includes an opposing edge 56 turned downwardly at 56a a distance greater than the width of portion 46a (and in this specific embodiment a distance approximately equal to the combined widths of portions 54a and 54b), for the length of upper panel 50. For convenience portion 56a of upper panel 50 is referred to as a side wall herein.
Lower panel 42 and upper panel 50 are positioned in parallel spaced apart relationship with lower stud surface 44 directed downwardly and upper stud surface 52 directed upwardly. An angular coupling element 60 extends between lower panel 42 and upper panel 50 and is bent periodically at some predetermined angle, generally between 30° and 90°, so as to alternately contact the inner surface of lower panel 42 and the inner surface of upper panel 50 at regular intervals (e.g. six inches). In this embodiment coupling element 60 is positioned adjacent turned-up edge 48a of lower panel 42 and turned-down edge 56a of upper panel 50.
Generally, coupling element 60 is a single continuous length of some relatively heavy gauge wire (e.g. 0.100″ to 0.200″ thick) that is bent or formed to provide desired contact points 62 with the inner surfaces of lower panel 42 and upper panel 50. Also, in this embodiment each span of coupling element 60 is affixed to the inner surface of adjacent turned-up edge 48a of lower panel 42 or turned-down edge 56a of upper panel 50. In this preferred embodiment coupling element 60 is affixed to the adjacent surfaces of edges 48a and 56a by some convenient method such as spot welding or the like. Fixing coupling element 60 to adjacent turned-up edge 48a and turned-down edge 56a adds strength and extra support to coupling element 60 for horizontal building components requiring more transverse (vertical) pressure along the span.
Turning now to
Referring additionally to
Elongated continuous metal strip 112 has a width approximately equal to the entire width of lower panel 42, including flat stud surface 44, edge 46 turned upwardly at 46a and inwardly at 46b, and opposing edge 48, plus the entire width of upper panel 50, including flat stud surface 52, edge 54 turned downwardly at 54a and inwardly at 54b, and opposing edge 56. To place this measurement in context and assuming (for example only) metal stud 40 is a 2×4, stud surfaces 44 and 52 are each approximately 2 inches wide, edges 48 and 56 are each approximately 1 inch wide, and the combined width of portions 46a/46b and 54a/54b are each approximately 1 inch. Thus, to produce this metal stud the total width of metal strip 112 would be approximately 8 inches. As can be seen in
Turning next to
Referring to
Wire 122 exiting wire straightening element 131 enters a wire shaping element 132. Wire shaping element 132 includes a plurality of sprockets with driven chains extending around opposing pairs. Referring additionally to
Referring now to
As flat continuous sheet metal strip 112 continues through series of rollers 142 the opposed outer edges are gradually rolled to produce the first edges 46a and 54a and ultimately the second rolled edges 46b and 54b. During the same time a central area of continuous sheet metal strip 112 is gradually bent to form edges 48 and 56. As flat continuous sheet metal strip 112 reaches a last series of rollers, designated 144-146, the opposed portions of strip 112, which will ultimately become lower panel 42 and upper panel 50 (see
Referring additionally to
Turning now to
Since edges 48 and 56 (i.e. metal 122) are tangential to wheels 162, 163, 165, and 166, a point or short line electrical contact is formed with wire 122 on the upper surfaces of edges 48 and 56 and the lower surfaces of edges 48 and 56. To perform the spot welding process, a pulse of electrical current is applied between wheels 162 and 163 and between wheels 165 and 166 at substantially the exact moment that the upper wheels (162 and 165) are in contact with wire 122. Since metal 112 and wire 122 are traveling through apparatus 100 at a continuous and steady speed and since wire 122 is formed in a zig-zag pattern with the tips of the bends separated horizontally at a known and fixed distance, the timing of the electrical pulses supplied to the welding members can be very accurate. Further, it should be clear that the speed with which metal 112 and wire 122 travel through apparatus 100 and the distance between the tips of the bends in wire 122 can be varied to produce different configurations of metal beam 40 if desired.
Referring now to
The movement and cutting process of cutting element 172 is preferably controlled to cut assembled and welded metal 112 and wire 122 at one of the tips of the zig-zag pattern of wire 122. It is generally preferable to supply metal beams 40 in a standard length (e.g. 8 foot, 10 foot, 16 foot, etc.). This also dictates that the angle of the bends or the distance between tips of the bends formed in the zig-zag pattern are selected to result in a tip being positioned at each metal beam length selected. This requirement is easily achieved since any number with a multiple that results in twelve can be selected, e.g. 3, 4, 6, etc.
It is apparent from the above discussion that control of the process can be achieved through some central control system. Referring additionally to
Referring to
Thus, it will be understood that the new and improved metal stud manufacturing apparatus is relatively easy to use. Further in this apparatus the spaced apart panels are formed by simple bending and separating a continuous role of metal. The coupling element of the beams is also simple to form from a continuous roll of wire. Connecting the coupling element to the spaced apart panels is accomplished by the machine designed to provide the spot welds at regular intervals. Also, the cutting component is designed to operate with the continuously moving assembly of metal and wires so that no stopping or hesitations are inherent in the system. Therefore, new and improved metal stud manufacturing apparatus is disclosed that is constructed to form consistent and reliable metal studs of any desired length.
Various changes and modifications to the embodiment herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims.
Having fully described the invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is: