This invention disclosure generally relates to a metal stud and track framing system for use in building construction and, more specifically, to a metal tab bending tool and a method for securing a metal stud relative to an elongated metal track of a wall system.
A wall assembly typically used in the construction industry primarily includes an elongated header track that is secured to a ceiling or overhead framework, an elongated lower track that is secured to the floor, and a plurality of vertical studs extending therebetween. Gypsum wall board members or other suitable sheathing materials, amongst other components, are usually fastened to the tracks and studs to form a closed wall assembly. To reduce the spread of fire while increasing the strength and enhancing termite resistance of such walls, building construction framing is increasingly moving toward use of steel rather than wood for the header track, lower track and studs.
The elongated metal header track and the elongated metal lower track typically have a generally U-shaped cross-sectional configuration defining an elongated channel sized to receive, accommodate and cover the ends of the studs. The header track and lower track each generally have an elongated generally flat web with first and second free-ended flanges extending in the same direction from first and second side edges, respectively, of the web. After the studs are placed in a vertical orientation into the channel of each track to extend between the elongated header track and elongated lower track, suitable fasteners are used on both sides of the wall to connect the stud to each track. In some designs, the header track and lower track are suitably configured to permit the wall studs to move generally orthogonally relative to the tracks. If the wall studs are rigidly secured to the to the track and not allowed to move freely in at least one direction, the stability of the wall and possibly the building may be compromised.
In one form, and as disclosed in more complete detail in U.S. Pat. No. 9,551,148 to D. A. Pilz, there is provided an elongated track having a plurality of bendable tabs arranged in side-by-side relation relative to each other along the length of each flange on the header track and lower track. Each bendable tab extends toward the generally flat web from a free-end of each flange. In one form, each flange is defined between a pair of slits or openings provided on opposite sides of each tab. In one embodiment, each tab extends about ½ inch to about one inch from the free-end of each flange.
After the studs are freely nested within and between the elongated upper header track and the lower header track in a vertical orientation, two tabs on each flange of both the header track and lower track of the elongated track are bent on adjacent but opposed sides of each stud whereby straddling and capturing the stud therebetween. Having the tabs extend along the length of each flange readily and easily permits locating the studs along the length of the wall in substantially any desired location. Moreover, capturing the stud between the bent tabs inhibits movement of the stud along the length of the header and lower tracks while permitting vertical movements of the studs relative to the header and lower tracks. As such, precise placement of the studs can be readily accommodated without undue hardship or effort.
The elongated tracks are typically formed from sheet steel and can be manufactured with standard roll steel with suitable tooling or on a brake press, for example. As such, the four tabs on the flanges take a directed effort to be bent or angled into position on opposed sides of each stud. Additionally, the height of various wall assemblies continue to increase to advantageously affect a desired spacious appearance. As such, and with increased wall heights, workers need to sometimes climb ladders to reach and bend the tabs on the header tracks. Typically, a worker will be required to individually strike or hit each of the tabs with a hammer or other suitable tool with some force to move or bend them into and angled position relative to the stud captured therebetween. As will be appreciated, this can be a time consuming and tedious process. Depending upon a number of factors including the time of day, the workers state of mind, and because all four tabs at the upper and lower end of each stud will usually be required to bent to secure each stud in place, the workers will inevitably sometimes miss the tab and strike the track or stud with the hammer by mistake. Of course, and albeit in error, missing the tab and inadvertently striking or hitting either track or the stud with the hammer can either damage the track, the stud or adversely affect the securement of the track to the other building structure. As will be appreciated, inadvertently striking the track or stud can cause the metal to bend and create a bump. As a result, when the drywall is installed over such a bump, the drywall can likewise bump up and undesirably flare outward from the framing.
In view of the above, there is a continuing need and desire for a tool which can readily and easily bend the tabs on a manufactured metal framing system simultaneously relative to each other so as to significantly reduce the time and effort required to complete construction of the wall assembly as well as a method of quickly and inexpensively securing an upright stud in place and relative to an elongated track.
In view of the above, there is provided a metal tab bending tool for securing an upright stud in place and relative to an elongated upper or lower track in the context of a wall assembly. The track includes an elongated generally flat web with first and second free-ended flanges extending in the same direction from opposed first and second side edges, respectively, of the web. Each flange of the web defines a plurality of spaced tabs extending toward the flat web from a free-end of each flange.
In accordance with one aspect of this invention disclosure the tool for connecting the stud in place and relative to the track includes a base. The tool also includes at least two pairs of bending arms each pivotally mounted to the base. Each pair of bending arms includes a first bending arm, adapted to be disposed to one side of the upright stud, and a second bending arm spaced apart from the first bending arm and adapted to be disposed to an opposite side of the stud. A mechanism is provided for moving at least one bending arm of each pair of bending arms from a first position and into engagement with a tab on each of the first and second free-ended flanges so as to bend opposed tabs on said first and second free-ended flanges engaged by the bending arms toward a center of the elongated track whereby inhibiting movement of said stud therepast.
Preferably, the base of the tool includes a guide portion for positioning the tool relative to the upright stud and the flat web. In one form, the tool further includes an apparatus for spacing the stud a selected and predetermined distance from an adjacent stud. In a preferred embodiment, the mechanism of the tool simultaneously moves both bending arms of each pair of bending arms toward the center of the elongated track. In a preferred embodiment, the mechanism for the tool further includes structure for returning both bending arms of each pair of bending arms to the first position following the bending arms being moved into engagement with the opposed tabs on the first and second flanges of said elongated track.
In a preferred embodiment, the mechanism for the tool also includes a handle movable relative to the base of the tool. In one form, the mechanism further includes a transmission operably disposed between the movable handle and the bending arms for transferring movement of the handle to the bending arms.
In accordance with another aspect of this invention disclosure, the bending tool includes a base configured to locate the tool relative to the upright stud and the flat web. In accordance with this aspect of the invention disclosure the bending tool also includes first and second pairs of bending arms each pivotally mounted to the base. Each pair of bending arms includes a first bending arm adapted to be disposed to one side of the upright stud and a second bending arm spaced apart from the first bending arm and adapted to be disposed to an opposite side of the stud. The first and second bending arms of the first pair of bending arms are laterally aligned with the first and second being arms of the second pair of bending arms. A mechanism is provided for simultaneously moving the first and second bending arms of each pair of bending arms from a first position and into engagement with spaced tabs on each of the first and second free-ended flanges so as to bend the spaced tabs engaged by the bending arms toward a center of the elongated web whereby straddling and entrapping the stud therebetween.
The base of the tool is preferably configured to include a guide portion for positioning said tool relative to said upright stud and said flat web. In one form, the tool furthermore includes an apparatus for spacing the stud a selected and predetermined distance from an adjacent stud. The mechanism of the tool includes structure for automatically returning both bending arms of each pair of bending arms to the first position following the bending arms being moved into engagement with the opposed tabs on the first and second flanges of the elongated track. In a preferred embodiment, the mechanism includes a handle movable relative to the base.
In a preferred form, the mechanism further includes a transmission operably disposed between the movable handle and the bending arms for transferring movement of the handle to the bending arms. The transmission for the mechanism preferably includes a pair of intermeshing gear segments arranged in operable combination with at least one of the bending arms on each pair of bending arms. In another form, the transmission for the mechanism preferably includes an apparatus for interconnecting the first bending arm on the first pair of bending arms with the first bending arm on the second pair of bending arms.
According to another aspect of this invention disclosure, the metal tab bending tool includes a base configured to position the tool relative to the upright stud and the flat web on the elongated track. According to this aspect, the tool also includes first and second pairs of bending arms each pivotally mounted to the base. Each pair of bending arms includes a first bending arm adapted to be disposed to one side of said upright stud and a second bending arm spaced from the first bending arm and adapted to be disposed to an opposite side of the stud. The first and second bending arms of the first pair of bending arms are laterally aligned with the first and second being arms of the second pair of bending arms. A force transfer mechanism is disposed between and for simultaneously moving the bending arms of each pair of bending arms from a first position and into engagement with tabs on each of said first and second free-ended flanges so as to bend the spaced tabs engaged by the bending arms toward a center of the elongated track whereby straddling and entrapping the stud therebetween.
In a preferred embodiment, the base of the tool includes a guide portion for locating the tool relative to the upright stud and the elongated flat web of the track. In one form, the tool further includes an apparatus for spacing the stud a selected and predetermined distance from an adjacent stud. The mechanism of the bending tool further includes structure for automatically returning both bending arms of each pair of bending arms to the first position following the bending arms being moved into engagement with the opposed tabs on the first and second flanges of the elongated track.
Preferably, the force transfer mechanism for the tool includes a handle operably connected to one of the bending arms and movable relative to the base. The force transfer mechanism furthermore preferably includes a transmission operably disposed between the movable handle and the bending arms for transferring movement of the handle to the bending arms. In one form, the force transfer mechanism transmission includes a pair of intermeshing gear segments arranged in operable combination with at least one of the bending arms on each pair of bending arms. Alternatively, the force transfer mechanism includes an apparatus for interconnecting one bending arm on the first pair of bending arms with the opposed bending arm on the second pair of bending arms.
Another aspect of this invention disclosure relates to a method or way for securing an upright stud in place and relative to an elongated track. The elongated track includes an elongated generally flat web with first and second free-ended flanges extending in the same direction from first and second opposed side edges, respectively, of the web. Each flange of said track defines a plurality of spaced tabs extending toward the web from a free-end of each flange. The tabs on the first flange of the elongated track are generally and laterally aligned with the tabs on the second flange of the elongated track. The method includes the step of: bending one of the tabs on each flange of the elongated track inwardly and simultaneously toward a center of the elongated track, with the tabs being bent being disposed immediately adjacent to one side of the stud whereby inhibiting movement of the stud therepast.
The method for securing an upright stud in place and relative to the elongated track can further include the step of: positioning a tool relative to the upright stud and the elongated track. In one form, the tool includes at least two pairs of bending arms. Each pair of bending arms includes a first bending arm adapted to be disposed to one side of the upright stud and a second bending arm spaced apart from the first bending arm and adapted to be disposed to an opposite side of the stud.
Preferably, the method for securing an upright stud in place and relative to the elongated track also includes the step of: bending a second tab on each flange of the elongated track inwardly and simultaneously toward a center of the elongated track. The second tabs being bent are disposed immediately adjacent an opposed side of the stud whereby the first and second tabs on each flange of the elongated track straddle and entrap the stud therebetween.
Still another aspect of this invention disclosure relates to a method or way for securing an upright stud in place and relative to both upper and lower elongated tracks. The elongated tracks each include an elongated generally flat web with first and second free-ended flanges extending in the same direction from first and second opposed side edges, respectively, of the web. Each flange of each track defines a plurality of spaced tabs extending toward the web from a free-end of each flange. The tabs on the first flange of each elongated track are generally and laterally aligned with the tabs on the second flange of that track. The method includes the step of: bending laterally aligned tabs on each flange of each elongated track inwardly and simultaneously toward a center of the respective track, with the tabs being bent being disposed immediately adjacent to one side of the stud whereby inhibiting movement of the stud therepast.
The method for securing an upright stud in place and relative to the elongated tracks can further include the step of: positioning tools relative to the upright stud and the elongated track web of each track. In one form, each tool includes at least two pairs of bending arms. Each pair of bending arms of each tool includes a first bending arm adapted to be disposed to one side of the upright stud and a second bending arm spaced apart from the first bending arm and adapted to be disposed to an opposite side of the stud.
Preferably, this method for securing an upright stud in place and relative to the elongated tracks also includes the step of: bending a second tab on each flange of each elongated track inwardly and simultaneously toward a center of the respective elongated track. The second tabs being bent are disposed immediately adjacent an opposed side of the stud whereby the first and second tabs on each flange of each elongated track straddle and entrap the stud therebetween.
While this invention disclosure is susceptible of embodiment in multiple forms, there is shown in the drawings and will hereinafter be described preferred embodiments, with the understanding the present disclosure is to be considered as setting forth exemplifications of the disclosure which are not intended to limit the disclosure to the specific embodiments illustrated and described.
Referring now to the drawings, wherein like reference numerals indicate like parts throughout the several views, the metal tab bending tool of the present invention disclosure can advantageously be used in the construction of a manufactured wall assembly 10. As illustrated in
In the manufactured wall assembly 10 shown in
In the manufactured wall assembly 10 illustrated in the drawings, the upper track 12 and the lower track 16 are identical relative to each other and are preferably made from a rigid but deformable galvanized steel material. It should be appreciated, however, other materials could be used without detracting or departing from the spirit and scope of this invention disclosure. As mentioned above, the upper track 12 and the lower track 16 are of the type shown and described in U.S. Pat. No. 9,551,148 to D. A. Pilz; the entirety of which is incorporated herein by reference.
Suffice it to say, and as shown in
As shown in
In a preferred form, the tabs 42 on each flange 32, 34 of the tracks 12 and 16 are of substantially equal length or height. Preferably, each tab 42 extends from the free end of the respective flange 32, 34 for a distance of about ½ inch. Accordingly, and with each flange 32, 34 extending for a predetermined distance PD of about 2 inches from the web 30, a distance of about 1.5 inches will separate a top of each tab 42 and the web 30.
In a preferred embodiment shown in
The slits 44 preferably extend from the free-end of each flange 32, 34 toward the web 30 for approximately one-third the predetermined distance PD′ each flange 32, 34 projects from the web 30 of the elongated track 12,16. That is, in a preferred embodiment, the slits 44 extend only partially along the predetermined distance PD′ each flange 32, 34 of each track 12, 16 projects from the track web 30. As such, the bulk of each track 12, 16 (preferably that portion closet to the web 30) maintains a solid and uninterrupted C or U-shaped profile to inhibit sound, smoke or light from passing through the head-of-wall or bottom-of-wall interface with the ceiling or floor, respectively. Additionally, this design advantageously permits the drywall or other suitable sheathing material to be tight and flush against the wall framing members because no headed mechanical fasteners are required to attach the stud 20 to the tracks.
The tabs 42 on the flanges 32, 34 take a directed effort to be bent or angled into position on opposed sides of each stud 20. To ensure the tabs 42 are correctly bent into position to assure capturing the stud 20 straddled thereby, and to enhance the ability to correctly position and or bend the tabs 42 on opposed sides of the stud, especially on those header tracks of heightened wall assemblies, the present invention disclosure provides a metal tab bending tool 100 for accomplishing these desired ends. In operation, the metal tab bending tool 100 is used to secure each upright stud 20 of wall assembly 10 in place and relative to an elongated track 12, 16 (
In a preferred embodiment shown in
In a preferred form, the guide portion 120 of tool 100 further includes a guide 125 carried by arm 116 of tool 100. In one form, guide 125 extends or projects into the open-sided channel 118 from wall 116 and defines an open-sided slot or channel 126. In the embodiment shown in
Returning to the embodiment illustrated by way of example in
Turning to
As illustrated by way of example in
As illustrated in
In the embodiment illustrated by way of example, mechanism 150 further includes an elongated operating handle 160 extending from and for transferring movement to the bending arms 132, 136 of the first pair of bending arms 130. Preferably, the transmission 151 of mechanism 150 is operably disposed between the operating handle 160 and the bending arms 132, 136 for transferring movement of the handle 160 to the bending arms 132, 136 of the first pair of bending arms 130. Moreover, the elongated configuration of the handle 160 arranged in depending relation from either bending arms 132, 136 facilitates placement and operation of the tab bending tool 100 in operable combination with the elongated header track 12 notwithstanding the height of the ceiling 14 from the floor 18.
As will be appreciated from a proper understanding of the metal tab bending tool 100 operation, movement of the handle 160 from the first position illustrated in
In a preferred embodiment of the invention disclosure, the metal tab bending tool 100 further includes structure 166 for returning both bending arms 132, 136 of the first pair of bending arms 130 to the first position shown in
Preferably, and to further reduce the time and effort required to bend opposed tabs 42 on the opposed flanges 32, 34 disposed to an opposed side of the stud 20 whereby capturing the stud 20 between bent tabs on each side thereof, the metal tab bending tool 100 can be easily and readily configured such that the third and fourth bending arms 142, 144 of the second pair of bending arms 140 are moved conjointly relative to each other and simultaneously with the first and second bending arms 132 and 134, respectively, of the first pair of bending arms 130. To accomplish these desired ends, and in a preferred embodiment of the invention disclosure, the second pair of bending arms 140 are designed as substantial mirror images of the first pair of bending arms 130.
That is, in a preferred embodiment, the third and fourth bending arms 142 and 146, respectively, of the bending tool 100 are interconnected to each other by a mechanism, similar to mechanism 150, for effecting simultaneous movement of both bending arms 142, 146 of the second pair of bending arms from a first position and into engagement with the tabs on each of the first and second free-ended flanges 32, 34 of the elongated track so as to bend laterally opposed tabs on the first and second free-ended flanges 32, 34 of the track engaged by the bending arms 142, 146 toward a center of the elongated track whereby inhibiting movement of the stud therepast. As mentioned, the mechanism for simultaneously moving both bending arms 142 and 146 includes intermeshing gear segments like those mentioned above regarding the first pair of bending arms 132 and 136. As such, movement of either bending arm 142, 146 results in simultaneous movement of the other bending arm.
To still further reduce the time and effort required to bend and position opposed tabs 42 on the flanges 32, 34 of either track 12, 16 (
In the form shown by way of example in
When the operating handle 160 is actuated to move bending arm 132 of the first pair of bending arms 130, movement of the bending arm 132 is conjointly transferred to bending arm 142 of the second pair of bending arms 140 by the force transfer assembly 170. As will be appreciated from an understanding of the operation of tool 100, movement of the bending arm 132 will likewise be simultaneously transferred to bending arm 136. Similarly, movement of the bending arm 142 will likewise be simultaneously transferred to bending arm 146. As a result of all four bending arms 132, 136 and 142, 146 being conjointly operated, two laterally opposed tabs 42 on each of the flanges 32, 34 of the elongated track are simultaneously bent into the position shown in dash lines in
In the embodiment illustrated in
To facilitate proper spacing between adjacent studs 20, the tool 100 of the present invention disclosure furthermore preferably includes an apparatus 189 including a spacer bar 190. In the embodiment illustrated by way of example in
Another embodiment of mechanism 189 is illustrated by way of example in
Another embodiment of a metal tab bending tool having an alternative force transfer mechanism for effecting simultaneous movement of at least one bending arm of each pair of bending arms from a first position and into engagement with laterally opposed tabs on each of the first and second free-ended flanges 32, 34 (
The alternative tool 200 illustrated in
As shown in
In the embodiment illustrated in
Returning to the embodiment illustrated by way of example in
As will be appreciated from a proper understanding of the metal tab bending tool 200 operation, movement of handle 260 from the first position illustrated in
In a preferred embodiment of the invention disclosure, metal tab bending tool 200 further includes structure 266 for returning both bending arms 232, 236 of the first pair of bending arms 230 to the first position, shown in
Returning
As with tool 100, and to further reduce the time and effort required to bend and position laterally opposed tabs on the opposed flanges of the elongated track disposed to both sides of a stud whereby effectively and efficiently capturing a stud between bent tabs on each side thereof, the metal tab bending tool 200 is preferably configured such that the third and fourth bending arms 242, 246 of the second pair of bending arms 240 are moved conjointly relative to each other and simultaneously with the first and second bending arms 232 and 236, respectively of the first pair of bending arms 230. To accomplish these desired ends, and like tool 100, tool 200 includes a force transfer assembly 270 preferably disposed between the first and second pairs of bending arms 230 and 240, respectively. In this embodiment, the force transfer assembly 270 is substantially similar to the force transfer assembly 170 described in detail above. It should be appreciated, however, the force transfer assembly 170 can take different forms from that shown and described without detracting or departing from the spirit and scope of this invention disclosure.
When the operating handle 260 (
To further reduce the efforts required to easily and quickly manufacture the structure of wall assembly 10, another aspect of this invention disclosure involves bending the tabs on both the upper track 12 and lower track 16 of the wall assembly 10 (
As schematically illustrated by way of example in
In a preferred arrangement illustrated by way of example in
The present invention disclosure also includes a method or way for securing an upright stud in place and relative to an elongated track. The elongated track including an elongated generally flat web with first and second free-ended flanges extending in the same direction from first and second opposed side edges, respectively, of the web. Each flange of the elongated track defines a plurality of side-by-side tabs extending toward the web from a free-end of each flange. The tabs on the first flange of the elongated track are generally laterally aligned with the tabs on the second flange of the track. The method includes the step of: bending laterally aligned tabs on each flange of the elongated track inwardly and simultaneously toward a center of the elongated track. The tabs being bent are disposed immediately adjacent to one side of the stud whereby inhibiting movement of the stud therepast.
The method for securing an upright stud in place and relative to the elongated track can further include the step of: positioning a tool relative to the upright stud and the elongated track. In one form, the tool includes at least two pairs of bending arms. Each pair of bending arms includes a first bending arm adapted to be disposed to one side of the upright stud and a second bending arm spaced apart from the first bending arm and adapted to be disposed to an opposite side of the stud.
Preferably, the method for securing an upright stud in place and relative to the elongated track also includes the step of: bending other laterally aligned tabs on the flanges of the elongated track inwardly and simultaneously toward a center of the elongated track. Wherein, the other laterally aligned tabs being bent are disposed immediately adjacent an opposed side of the stud whereby the bent tabs on each flange of the elongated track straddling and entrapping the stud therebetween.
To further reduce the efforts required to easily and quickly manufacture the structure of wall assembly 10, another aspect of this invention disclosure involves a method or way for securing an upright stud in place and relative to upper and lower tracks. Each elongated track includes an elongated generally flat web with first and second free-ended flanges extending in the same direction from first and second opposed side edges, respectively, of the web. Each flange of each elongated track defines a plurality of side-by-side tabs extending toward the web from a free-end of each flange. The tabs on the first flange of the each track are generally laterally aligned with the tabs on the second flange of the same track. The method includes the step of: bending laterally aligned tabs on each flange of each elongated track inwardly and simultaneously toward a center of the respective elongated track. The tabs being bent are disposed immediately adjacent to one side of the stud whereby inhibiting movement of the stud therepast.
The method for securing an upright stud in place and relative to the elongated tracks can further include the step of: positioning tools relative to the upright stud and the elongated tracks. In one form, each tool includes at least two pairs of bending arms. Each pair of bending arms of each tool includes a first bending arm adapted to be disposed to one side of the upright stud and a second bending arm spaced apart from the first bending arm and adapted to be disposed to an opposite side of the stud.
Preferably, the method for securing an upright stud in place and relative to the elongated tracks also includes the step of: bending other laterally aligned tabs on the flanges of the elongated tracks inwardly and simultaneously toward a center of the respective elongated track. Wherein, the other laterally aligned tabs being bent are disposed immediately adjacent an opposed side of the stud whereby the bent tabs on each flange of the elongated track straddle and entrap the stud therebetween.
From the foregoing, it will be observed that numerous modifications and variations can be made and effected without departing or detracting from the true spirit and novel concept of this invention disclosure. Moreover, it will be appreciated, the present disclosure is intended to set forth exemplifications which are not intended to limit the disclosure to the specific embodiments illustrated. Rather, this disclosure is intended to cover by the appended claims all such modifications and variations as fall within the spirit and scope of the claims.
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