Steel Thermal Stud

Abstract

Disclosed herein is a steel thermal stud being capable to provide structural and non-load bearing characteristics. The steel thermal stud with more than one dual flange stud provides additional and separated penetration locations for mounting screws allowing multiple connection points on the screw. The Steel Thermal Stud with multiple stud walls for a fastener to penetrate to prevent the movement of the fastener in any direction, prevent deformation of the stud wall material, prevent fasteners from backing out by having additional contact with less potential movement, provide more pull-out strength, and more strip resistance of the fasteners during installation.

Description

BACKGROUND OF THE INVENTION

Field of Invention

The present invention relates primarily to a field of steel framing, and more particularly it relates to novel and useful steel thermal stud for buildings of all types, which is capable to provide structural and non-load bearing characteristics.

Description of Rated Art

In the past, there has been a little change in the structural and non-structural steel framing industry since its inception. The steel studs used today are essentially the same design and serve the same functions as when they were first introduced as a “C” shape showing little advancement. When compared to wood studs, the steel studs have had significant advantages in many areas, but not in thermal transfer which is much worse with steel studs.

Hence, there is a significant need and void in the market to invent a novel and improved steel studs that provide for less acoustic and thermal transfer, and can be used in structural and non-load bearing applications.

The present invention is hereinafter disclosed, which provide more thermally efficient wall assemblies. The steel studs of the present invention are configured to provide the structural and non-load bearing characteristics. The unique characteristics and features of the present invention are, therefore, unrepresented within the conventional steel studs. Hence, the present invention has been disclosed to provide solutions to the aforementioned needs, and to resolve the aforementioned deficiencies in the conventional steel framing systems.

SUMMARY OF THE INVENTION

In accordance with the present application, a novel and useful Steel Thermal Stud is herein provided that includes independent flanges with webs on each side and having various web designs and materials, some with an insulation within the studs, and where the various web designs hold the flanges on each side together, and where the flanges are symmetrical in shape to provide a more balanced stud which should perform better in structural testing.

The steel stud flanges, and webs of the present invention may be made using steel in sheet or coil form, fabricated/manufactured on roll forming machines with various in-line punches, dies, top and bottom rollers, wheels, shears, etc. They may also be made with multiple machines such as a turret press and brake press. Fiber reinforced plastics may be used with a pultrusion process, and may have holes and other apertures added for conduits, pipes, and conductors by way of a CNC milling or other suitable means. Other flanges and webs may be made of metal made in extrusion processes, roll-formed or other suitable means. Further, foam webs are made of extruded or expanded polystyrene, spray foam, or other suitable insulation products including rigid rock mineral wool. Metal or other wire and rod materials may be used on a CNC wire-forming machine or bent manually by hand using wire bending tools.

Furthermore, joining of the flanges to the webs may be accomplished by using the webs of various types having formed steel clips, wires, plastics, foam or other suitable material. The steel studs of the present invention may have additional holes, slots, ribs, or other shapes traditionally used for “EQ” structural purposes, for reduction in thermal and acoustic transfer, for running conduits, pipes, tubes, insulation and other mechanisms through, and to assist with fastener drifting as well as allowing easier penetration for pointed or self-drilling fasteners.

The studs of the present invention may be covered with a plastic shrink wrap or protective covering to help with thermal and acoustic properties by providing a thermal bridge between sheathing and the studs, as well as assisting to trap air within the stud itself, even if localized where holes are not made in the shrink wrap or protective covering.

The steel studs of the present invention may also have an additional nailing flange installed which provides additional and separated penetration locations for mounting screws allowing multiple connection points on the screw so that they become cantilevered and able to support the loads unlike a single walled stud.

Formed webs made from sheet or coil steel may have a protective plastic coating to help prevent acoustic and thermal transfer between the flanges with webs and the formed webs. Wire webs may be made on a 3D wire forming machine and may also be plastic-dipped to help prevent acoustic and thermal transfer between the webs.

Alternatively, snap-in fiber reinforced plastic pultrusion, injection molded and extruded plastics, and other materials may also be used.

The studs may be filled with an insulation material, and the insulation used within the studs may be selected from, but not limited to, foam blocks, rock mineral wool, spray in foam insulation or other types of insulation.

It may be apparent that novel and useful Steel Thermal Stud have been herein above described which work and are used in a manner not consistent with conventional products and methods. It is therefore an object of the present application to provide a Steel Thermal Stud with multiple stud walls for a fastener to penetrate to prevent the movement of the fastener in any direction, prevent deformation of the stud wall material, prevent fasteners from backing out by having additional contact with less potential movement, and provide more pull-out strength and more strip resistance of the fasteners during installation.

Another object of the present application is to provide a Steel Thermal Stud which allows the stud to be made as a single unit, or where the flanges with webs are used separately.

Another object of the present application is to provide a Steel Thermal Stud which provides for a shrink wrap plastic to cover the studs while a spray foam is injected through it to insulate the stud, and wherein the injection holes can be sealed after injection by welding or adhering plastic patches over the injection points.

Another object of the present application is to provide a Steel Thermal Stud which uses the compressive strength of insulation to help prevent stud components from moving when pressure is applied to them.

Another object of the present application is to provide a Steel Thermal Stud with a fastener that takes onto itself tensile, compressive bending, shear and other forces to strengthen the stud, such as drywall screws when penetrating our dual flanges.

Another object of the present application is to provide a Steel Thermal Stud which eliminates the need for resilient channels and/or resilient dips for sound attenuation.

Another object of the present application is to provide a Steel Thermal Stud having formed plates which help isolate and absorb vibration and thermal transfer.

Another object of the present application is to provide a Steel Thermal Stud with formed steel webs and wires which are installed perpendicular to the flanges and webs, diagonally, and/or offset on opposing sides to assist with structural strengths and/or acoustic and thermal transfer reduction in applications such as studs, joists, etc.

Another object of the present application is to provide a Steel Thermal Stud which may be used horizontally as a joist or beam, and made with aluminum or other material in an extrusion or pultrusion process in place of steel as flanges or webs.

Another object of the present application is to provide a Steel Thermal Stud having formed steel or wire webs that structurally act to connect both flanges with webs together, assist with axial and twist strengths, provide compressive and tensile strengths for increased bend strength of the complete stud assembly, and essentially prevent one flange with webs from moving without the other flange with webs moving.

Another object of the present application is to provide a Steel Thermal Stud having webs that limit or eliminate thermal and acoustic bridging between flanges with webs.

Another object of the present application is to provide a Steel Thermal Stud with the webs of the flanges being the same length, or symmetrical, which help to minimize or eliminate twist of the stud when loads are applied to the stud from any direction.

Another object of the present application is to provide a Steel Thermal Stud with bends in the stud that normally could not be made by use of aligned slots. The slots allow bends to be made by rolling the flanges over so that no other tooling is needed to make the bends at the aligned slots, allowing for more complex shapes to made especially when other materials such as insulation may be in the way. For structural strength, and in lieu of aligned slots, aligned indentations will allow for the same type of bend, with the indentations protruding to the outside of the bend once formed.

Another object of the present application is to provide a Steel Thermal Stud with insulation to be mounted within any stud part, or wherein rigid insulation is pre-cut or grooved to consume all air gaps within the completely formed stud.

Another object of the present application is to provide a Steel Thermal Stud that can be utilized as purlins or other shapes.

Another object of the present application is to provide a Steel Thermal Stud with a least expensive sound-proofing wall systems and highest thermal transfer resistance.

Another object of the present application is to provide a Steel Thermal Stud that minimizes or eliminates cross bracing, and/or increases the span distances.

Another object of the present application is to provide a Steel Thermal Stud which allows all known adhesives and fabrication methods to be used in any and all locations required within these framing and other components to attach them together better, help prevent vibration (sound) travel, help prevent thermal transfer, and/or to help increase strength.

Another object of the present application is to provide a Steel Thermal Stud where all components, parts, structural shapes, and any other aspect of these studs are considered to be one or more in quantity and/or location, and aspects of one stud may be used in any other stud.

Another object of the present application is to provide a Steel Thermal Stud where the process of forming and assembly is done in a continuous manufacturing line having punches, roll forming, insulation insertion, and robotic placement of various webs for installation.

Another object of the present application is to provide a Steel Thermal Stud which allows for the same flanges with webs to be used for multiple thicknesses and widths, such as 2×4 to 2×6 and only the web portion is changed, or the web portions are used with different flanges with webs such as 2×4 and 4×4, etc.

Another object of the present application is to provide a Steel Thermal Stud which provides an additional level of safety for cut protection by not fully exposing metal edges by covering them fully or partially with insulation or covering them with a shrink wrap.

Another object of the present application is to provide a Steel Thermal Stud forming process, which includes compression of the flanges with webs to force them over the web segments, and the use of electro-magnetic to control the positioning of the flanges with webs during web segment installation to ensure proper alignment with minimal tolerances, and with electronic alignment control of the flanges with webs and web segments.

Another object of the present application is to provide a Steel Thermal Stud which is a direct replacement for wood studs, yet lighter and with better thermal acoustic performances, and used with traditional steel stud tracks.

Another object of the present application is to provide a Steel Thermal Stud process which allows the final bends at the aligned perforations to be over-bent, pushing into the insulation, and recovering or springing-back to the correct angle and tensioned final position to hold the web segments in place, and where the insulation assists in maintaining the shape of the stud both during this forming process and once the stud is ready for use.

Another object of the present application is to provide a Steel Thermal Stud which utilizes any added strengths of the insulation towards the overall structural performance of the stud.

Another object of the present application is to provide a Steel Thermal Stud which utilizes foam as the web for applications such as in non-load bearing conditions, and where the webs of the flanges have small interior facing barbs, formed with a punch press or other suitable means, that penetrates the insulation to help prevent separation of the flanges with webs, and to keep the insulation positioned within between the flanges with webs. The barbs may be straight or at an angle like the radius of a flange web as it rotates down onto and into the foam board (if not filled with liquid foam) via the aligned perforations,

Another object of the present application is to provide a Steel Thermal Stud with secondary flanges, wherein the air gap between the flanges acts as an opening for vibration to be trapped, or wherein the secondary flange is a wood or similar nail-able product in place of formed metal.

The invention possesses other objects or advantages especially with concerns to particular characteristics and features thereof which will become apparent as the specification continues, including using aspects of these different concepts together.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description of the invention, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, exemplary constructions of the invention are shown in the drawings. However, the invention is not limited to the specific structures disclosed herein. The description of a structure referenced by a numeral in a drawing is applicable to the description of that structure shown by that same numeral in any subsequent drawing herein.

FIG. 1 illustrates an isometric plan view of Stud A, according to an embodiment of the present invention.

FIG. 2 illustrates an isometric plan view of Stud B, according to an embodiment of the present invention.

FIG. 3 illustrates an isometric plan view of segmented Stud C, according to an embodiment of the present invention.

FIG. 4 illustrates an isometric plan view of segmented Stud D with a formed wire web and having foam filled alternatives, according to an embodiment of the present invention.

FIG. 5 illustrates an isometric plan view of Stud E which is a simplified version of Stud D of FIG. 4, which is designed to use as little steel as possible, according to an embodiment of the present invention.

FIG. 6 illustrates an isometric elevation view of Stud F having a foam board sandwiched between two stud flanges, and held in place by protruding fingers inserted into the foam from the webs of the flanges or by adhesives, according to an embodiment of the present invention.

FIG. 6A illustrates an isometric elevation view of Stud F having an inserted piece of steel providing secondary flanges within the primary flanges, and held in place by mechanical means, according to an embodiment of the present invention.

FIG. 6B illustrates an isometric elevation view of Stud F of FIG. 6A having a foam insulation filling, or spray foam installed within the cavity, or all cavities, according to an embodiment of the present invention.

FIG. 6C illustrates an isometric elevation view of Stud F having square tubing added therebetween the flanges to act as a web, allowing for less thermal transfer through the stud's cross-section, according to an embodiment of the present invention.

FIG. 6D illustrates an isometric elevation view of a web tube having openings on two sides that would avoid contact for fasteners being installed into the flanges, while still allowing for clinching or other mechanical attachment, according to an embodiment of the present invention.

FIG. 6E illustrates an isometric elevation view of a web channel with slots in the ends so that the flanges of the channel fit over the top of the webs of the flanges with webs and are then welded into place by any suitable welding practice, according to an embodiment of the present invention.

FIG. 7 illustrates an isometric elevation view of Stud G that provides multiple flanges on each side of the stud, according to an embodiment of the present invention.

For a better understanding of the invention of this application, reference is made to the following detailed description of the preferred embodiments thereof which should be referenced to the prior described drawings.

DETAILED DESCRIPTION OF THE INVENTION

Various aspects of the present application will evolve from the following detailed description of the preferred embodiments thereof which should be taken in conjunction with the prior described drawings.

Before explaining the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the construction and arrangement of parts illustrated in the accompanying drawings. The invention is capable of other embodiments, as depicted in different figures as described above and of being practiced or conducted in a variety of ways. It is to be understood that the phraseology and terminology employed herein is for the purpose of description and not of limitation.

It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness.

Use of the phrases and/or terms such as but not limited to “exemplary embodiment,” “an embodiment,” “an alternate embodiment,” “one embodiment,” “another embodiment,” or variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments.

Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” or in the form “at least one of A and B” means (A), (B), or (A and B), where A and B are variables indicating a particular object or attribute. When used, this phrase is intended to and is hereby defined as a choice of A or B or both A and B, which is similar to the phrase “and/or”. Where more than two variables are present in such a phrase, this phrase is hereby defined as including only one of the variables, any one of the variables, any combination of any of the variables, and all of the variables, for example, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C).

It is to be understood that the term “comprises” and grammatical equivalents thereof are used herein to mean that other components, ingredients, steps, etc. are optionally present. For example, an article “comprising” (or “which comprises”) components A, B, and C can consist of (i.e., contain only) components A, B, and C, or can contain not only components A, B, and C but also contain one or more other components.

It is to be understood that the terms “steel stud” and “stud” are interchangeable throughout the disclosure, unless otherwise specified.

Reference will now be made in detail to preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings.

According to a first preferred embodiment of the present invention, an isometric plan view of a stud A is shown in FIG. 1. With reference to FIG. 1, the Stud A is mainly comprising, a pair of left and right flanges aa, and a web ab. The left and right flanges aa are comprised of: a web 10 which is bent into perpendicularly positioned an outer flange 12, which is further bent to form a lip 14 which is positioned parallel to the web 10 and terminates into an inner flange 18 at a plurality of aligned slots 16 once formed. The web ab, on both ends, comprising: a bend 20 which is bent at a leg 22 at a sharper angle, which is then bent perpendicularly into an arm 24, which is further bent into a ramp 26 at a sharp angle and terminates into a base 30 at a slight angle, so that the base 30 and the leg 22 are in line with each other and perpendicular to the arm 24. The opposite end of the web ab is mirror imaged so that the web ab may allow both the left and right flanges aa, one on each end to be installed therein. The inner flange 18 is forced up via the ramp 26 and ultimately is pushed between the arm 24 and the bend 20 so that the inner flange 18 is permanently and positionally fixed in place.

According to an embodiment of the present invention, the base 30 may be clinched or welded to the respective web 10 of the left and right flanges a to add structural strengths and avoid movement of the web ab.

According to an embodiment of the present invention, the left and right flanges aa are made on a roll-forming machine that punches the aligned slots 16 and forms at least two of the three flanges. Further, the respective web 10 may also be made in a roll forming process, or may be made using a shear and brake press. Furthermore, the left and right flanges may be made up of a material such as a galvanized steel.

According to an embodiment of the present invention, the web ab may be provided in a full length or segmented stainless steel as shown in FIG. 1. Further, the web ab may be installed by an automated roll-forming process using robotics with locating and positioning automation to set the web ab, or assembled manually using a powered roller system to make the final bends. Furthermore, the web ab may be made up of a material such as stainless steel.

According to a second preferred embodiment of the present invention, an isometric plan view of a stud B is shown in FIG. 2. Referring now to FIG. 2, the stud B is comprised of: a pair of first webs 32, which is configured to terminate into respective perpendicular flanges 34, which further terminate into respective perpendicular lips 36 that are parallel to the first webs 32; and a second web 38 which is linear and configured to attach with the pair of first webs 32. The first webs 32 may be clinched, welded, or otherwise permanently mechanically fastened to the second web 38 at a plurality of locations 40 along the length of the stud B on both sides as shown in FIG. 2.

According to an embodiment of the present invention, the first webs 32 may be roll-formed galvanized steel web and the second web 38 may be sheared-to-size stainless steel web.

According to a third preferred embodiment of the present invention, an isometric plan view of a segmented stud C is shown in FIG. 3. As depicted in FIG. 3, the stud C, on both sides, comprising: a roll-formed galvanized flange end ca, that further comprises a first leg 44 bent perpendicularly into a first return 46, which bent perpendicularly into a second leg 48, which bent into a second return 50, which then bent perpendicularly into a flange 52, which bent perpendicular into a third return 54, which terminates perpendicularly into a third leg 56, which bent perpendicularly into a fourth return 58, which then bent into a fourth leg 60. The first leg 44 and the fourth leg 60 comprise a one-way hole 62 for every location of at least one stainless-steel rod cb.

According to an embodiment of the present invention, the stainless-steel rod cb can be made on a CNC wire-forming machine (not shown) and comprised of a middle portion 42 which extends to a step 43 on each side, which then extend to a respective end 45 on each side. When the respective end 45 is inserted into the respective hole 62 of both the galvanized flange ends ca, the stainless-steel rod cb cannot be easily pulled out. The galvanized flange ends ca are not positionally separated by the steps 43 of the stainless-steel rods cb. Further, the ends 45 of the stainless-steel rods may be blunted or otherwise deformed to ensure they are permanently affixed in the Stud C assembly.

In one embodiment, a straight threaded stainless-steel rod (not shown) may also be used to connect the galvanized flange ends ca together in the stud C assembly.

In one embodiment, a foam 64 may be sprayed into the stud C to fill all gaps with insulation and help hold all pieces together as shown in FIG. 3. A shrink wrap (not shown) may be used to seal the stud C prior to injecting the foam 64 into the Stud C, with holes (not shown) in specific locations of the shrink wrap to allow air to escape while the foam 64 is being injected.

According to a fourth preferred embodiment of the present invention, an isometric plan view of a segmented stud D is shown in FIG. 4. As depicted in FIG. 4, the Stud D, on both sides, comprising: a galvanized flange with webs da which is made on a roll-forming machine, wherein the galvanized flange with webs da comprising a first lip 66 bent at an angle to a first web 68 which bent perpendicularly to a flange 70 which then terminates perpendicularly into a second web 72, which then terminates into a second lip 74 which terminate at an end 65; and a plurality of stainless steel rod webs db which are made on a CNC wire forming machine, wherein each stainless steel rod web db comprised of a base 76 extending towards both sides and terminating into a first u-shape 78 on both of the sides that is perpendicular to the base 76, wherein each first u-shape 78 then extends straight to a respective arm 80, which further terminates straight into a second u-shape 82 on both sides, which then terminate into a bend end 84.

Further, the first and second webs 68, 72 have a plurality of slots 67, and the first and second U-shapes 78, 82 push apart the first and second lips 66, 74 as well as the first and second webs 68, 72 until they insert into the slots 67, wherein the first and second lips 66, 74 as well as the first and second webs 68, 72 spring back into their original position locking all components of the Stud D together. Furthermore, the stainless-steel rod webs db are positionally fixed in the locations of the slots 67 of the galvanized flange with webs da as a press pushes the galvanized flange with webs da together until the first and second U-shapes 78, 82 are locked into their final resting positions.

According to an embodiment of the present invention, a foam 86 may be injected into a shrink wrap (not shown) so that the injected foam 86 does not get on the outside of the galvanized flange with webs da for aesthetic purposes if the shrink wrap is taken off, and the foam 86 as well as the shrink wrap help to cover ends to prevent them from cutting hands during handling.

In an alternate embodiment of the present invention, an isometric plan view of a stud E is shown in FIG. 5. Referring to FIG. 5, the Stud E is shown in the form of a simplified version of the Stud D and is similar to the stud D in all respects except that the stud E does not include the first and second lips 66, 74 to act as a ramp for a plurality of rods ea during insertion.

Continue referring to FIG. 5, each rod ea of the stud E further comprises a base 94 which extends both directions and terminates into a first u-shape 96, which then extends straight as a leg 97 which terminates into a second u-shape 95 which then terminates into a bent end 100. The first and second u-shapes 96, 95 have respective round corners that are used to push apart a first web 88 and a second web 92, wherein the first web 88 and the second web 92 are parallel to each other and separated by a flange 90. Further, the first and second u-shapes 96, 95 are inserted into slots 98, and while into the slots 98, the first and second webs 88, 92 spring back into their normal positions to lock the assembled stud together. The rods ea are positionally held in place (not shown) while pressure pushes flanges eb over the rods ea until they are locked together as explained in foregoing description.

According to a fifth preferred embodiment of the present invention, an isometric plan view of a stud F is shown in FIG. 6. As depicted in FIG. 6, the stud F, on both sides, comprising: a galvanized flange fa which is made in a roll-forming process and comprised of a pair of webs 107 terminating perpendicularly and separated by a flange 104. The webs 107 have a plurality of protrusions 102, 106 which prevent a foam 108 from backing out once installed, or which may penetrate the foam 108 after insertion by way of holding mechanism such as a pair of arms of FIG. 6A. In an embodiment, adhesives (not shown) or other mechanical means may replace the protrusions 102 and 106 as a holding mechanism.

In an alternate embodiment, FIG. 6A shows the Stud F with the galvanized flanges fa as primary flanges having a respective inner flange fb as secondary flange, wherein each inner flange fb comprises a first web 118 terminating into a first flange 120 which then terminates into a second web 122. The first and second webs 118, 122 having a plurality of knock-outs 116 extended inwards as shown in FIG. 6A. Once the inner flange fb is inserted by pressure beyond the knock-outs 116 of the galvanized flange fa, the inner flange fb is positionally fixed in the position shown. This configuration provides for increased structural strengths and allows for increased fastener strengths such as pull-out, strip resistance, and fastener cantilevering.

In an alternate embodiment, FIG. 6B shows the stud F with a foam 124 inserted therebetween the assembled flanges fa and fb on both sides and are permanently fixed together. Further, a spray foam may be installed within a cavity or all cavities.

In an alternate embodiment, FIG. 6C shows the stud F having at least one stainless-steel tube webs fc inserted between the assembled flanges fa and fb and permanently fixed by a weld 113 in one or more locations at each location on both sides of the stud F. The stainless-steel tube webs fc are square-shaped (or other shaped) tubing that added between the assembled flanges fa and fb to act as a web, allowing for less thermal transfer through the stud's cross-section. The tubing provides structural strength in all directions for the stud F, and can be used without the inner, or the secondary flanges fb, and can be insulated between, around, and inside of the webs. The ends of the tubing may be beveled for easy insertion into the galvanized flanges fa with webs, and the webs of the galvanized flanges fa may have a small bend outward to provide “ramps”, or guides to easily allow the tubing inside. More than one clinch, rivet, spot weld, adhesive or other mechanical attachment of the tube to the flanges fa with webs allows for greater structural strengths compared to just one at each location, i.e., currently shown with 4 mechanical connections per web tube. The ends of the flanges fa with webs may also be turned in, such as during the shearing process leaving an in-ward facing edge of metal which is commonly found in the shearing process, which helps prevent the secondary (or inner) flange fb from escaping out the ends of the stud assembly.

In an embodiment, the secondary flange fb may also be a little shorter to allow for other mechanical “stoppers”, such as indentations in the webs of the flanges fa which accomplishes the same objective, the secondary webs fb may be used as a means to extend the stud height in order to be attached to a track system if the stopping mechanism is removed. An insert, such as a small channel, may be placed between the primary and secondary flanges to act as a means to extend the stud when needed to connect to tracks, wherein fastening can be done from the inside of the stud F to avoid fasteners on the outside of the stud flanges where they may interfere with drywall planarity. When a spray foam is used to fill the inside of the stud cavity and/or between the primary and secondary flanges, a peel-off protective tape may be installed over the stud F on all sides prior to adding the foam so that the foam can be inserted from the open ends, and/or injected through the protective tape as needed along the length of the stud F. When the tape is installed over the open sides of the web, such as the 6″ side of a 2×6 assembled stud, the tape extends beyond 6″ so that some tape extends beyond the 6″ on both sides, such as 1″ over on each side, and the 1″ is then roiled down and over the flanges of the stud F.

In an embodiment, the protective tape may be left on the stud F indefinitely acting as a vibration reducer to minimize sound transmission, acting as a thermal break between the sheathing and stud F, acting to trap air to assist with thermal efficiency, acting as a surface for brand identification and to provide specific stud, joist, or other structural member information, and acting to maintain the integrity of the stud F and insulation by minimizing or eliminating exposure to the elements before, during or after installation. The protective coating may be used to identify the tube web locations and add other information via inkjet printer or other known means.

In an alternate embodiment, FIG. 6D shows a tube web fc′ having an opening 132 that is laser cut into each end leaving upper and lower connection arms 128 on each end as well as perpendicular walls 130 which remain inset from the ends of the tube web fc′ so that fasteners (not shown) inserted into the galvanized flange fa or the assembled flanges fa and fb may not contact the perpendicular walls 130. The upper and lower connection arms 128 may be positioned inside or outside of the galvanized flange fa whether the secondary flange fb is used or not.

According to an embodiment of the present invention, the tube web fc′ may be used to support pipes, conductors, conduits, and other material is as needed in a wall, floor, roof or other assembly. This stud assembly would be made by having the flanges with webs manufactured side-by-side in a roil forming process, oppositely facing each other as shown in FIG. 6C. (Secondary flanges fb would not be used in this illustration, but if they were they would be installed in a separate step). Further, the tube web fc′ may be robotically positioned between the opposing flanges with webs, and the webs are then pushed together and over the tube web fc′ where they are then clinched between the open area of the tube web fc′ as shown in FIG. 6D and the outer web of the flange, or spot welded or otherwise mechanically attached in all locations in an automated manufacturing process. In one embodiment, the tube web fc′ may also have slots in it at the ends, aligned with the webs of the flanges, so that the tube is able to be fit over the top of all webs of the flanges with webs.

In an alternate embodiment, FIG. 6E shows the Stud F having a galvanized or stainless-steel roll-formed web channel fd having a pair of legs 111 parallel to each other and separated by a base 115. The legs 111 are shown outside of the galvanized flange fa with a plurality of slots 117 allowing the webs 110 of the galvanized flange fa to position inside them, and with the base 115 located inside of the webs 110. Clinching locations are shown (which can also be any form of suitable welding or other mechanical attachment). Further, the tube web fc′ is shown in the background as it may be installed inside of the assembled flanges fa and fb. The shrink wrap or protective tape (not shown) may be installed over the stud F to seal the stud prior to injecting a foam (not shown), with holes (not shown) in specific locations of the shrink wrap (not shown) to allow air to escape while the foam is being injected.

According to abovementioned embodiment, the webs of the flanges fa are more structurally supported against deflection in any direction which may come from loads placed onto the studs. If the web channel fd is smaller than the flanges with webs fa, the web channel fd may fit inside the flanges with webs fa and be welded into position as well. The welding may be replaced by any mechanical fastening means such as clinching. FIG. 6E also shows the tube web fc′ of FIG. 6D installed as a visual reference of how it would avoid fasteners being installed into the flanges.

According to a sixth preferred embodiment of the present invention, an isometric plan view of a stud G is shown in FIG. 7. Now referring to FIG. 7, the stud G which is identical to the Stud A, but comprising a structural fiber reinforced plastic pultrusion web ga used in place of the stainless-steel web ab. The web ga may also be made of structural extruded plastic, and is comprised of a base 150 extending to both sides to steps 152 which extends straight to first flats 154, which extend straight to ramps 156, which extend straight to slots 158, which extend straight to stops 160 and which extend to second flats 162 which bent at ends 164.

Continue referring to FIG. 7, the stud G further comprising flanges gb which include webs 134, which extend to first bends 136 which extend to outer flanges 138, which extends to second bend 142, which extends to third bends 146 having a plurality of aligned slots 148 and terminating in inner flanges 149. The web ga may be full length or provided in shorter segments, and may have holes for conduits, pipes, and conductors to pass through. The web ga is placed inside and between the left and right flanges gb when the inner flanges 149 are roll-formed over the ramps 156 and into the slots 158. The inner flanges 149 are then trapped in the slots 158 between the ramps 156 and the stops 160 and is unable to move since its own spring-back tension holds it in place.

Moreover, the ends 164 do not allow the flanges gb to be positioned closer together, however, if desired for recycling or other purposes, the outer flanges 138 could be pulled away from each other on each side to separate the web ga from the flanges gb. This will not work if the inner flanges 149 are tried to be pulled apart, so dis-assembly (not shown) is not possible with normal handling.

According to abovementioned embodiment, the Stud G of the present invention provides multiple flanges on each side of the stud for improved structural performance as well as improved fastener and external cantilevered load capabilities, and has a structural plastic or fiber reinforced plastic web which, is installed between the two outer flange assemblies so that when the inner flanges are bent down, they are forced up the ramp and into the slot to permanently lock the stud flanges to the stud web, using spring-back of the steel to open enough to allow this process to happen, then dose back using its own spring back tension.

Claims

1. A steel thermal stud to provide structural and non-load bearing characteristics, said stud comprising: a pair of left and right flanges aa, wherein each flange comprising a web which is bent into perpendicularly positioned an outer flange, which is further bent to form a lip which is positioned parallel to said web and terminates into an inner flange at a plurality of aligned slots 16 once formed; anda web ab, wherein said web ab, on both ends, comprising a bend which is bent at a leg at a sharper angle, which is then bent perpendicularly into an arm, which is further bent into a ramp at a sharp angle and terminates into a base at a slight angle, so that said base and said leg are in line with each other and perpendicular to said arm, wherein said inner flange is forced up via said ramp and is pushed between said arm and said bend hence to fix said inner flange permanently and positionally.

2. The stud of claim 1, wherein said base may be clinched or welded to respective web of said left and right flanges aa to add structural strengths and avoid movement of said web ab.

3. The stud of claim 1, wherein said left and right flanges aa may be made on a roll-forming machine that punches said aligned slots.

4. The stud of claim 1, wherein said left and right flanges may be made up of a material such as a galvanized steel.

5. The stud of claim 1, said web ab may be provided in a full length or segmented stainless steel.

6. The stud of claim 1, wherein said web ab may be installed by an automated roll-forming process using robotics with locating and positioning automation to set said web ab, or assembled manually using a powered roller system to make final bends.

7. The stud of claim 1, wherein said web ab may be made up of a material such as stainless steel.

8. A steel thermal stud to provide structural and non-load bearing characteristics, said stud comprising: a pair of first webs, wherein each first web is configured to terminate into respective perpendicular flanges, which further terminate into respective perpendicular lips that are parallel to said each first web; anda second web, wherein said second web is linear and configured to attach with said pair of first webs.

9. The stud of claim 8, wherein said each first web may be clinched, welded, or otherwise permanently mechanically fastened to said second web at a plurality of locations along the length of said stud on both sides.

10. The stud of claim 8, wherein said each first web may be a roll-formed galvanized steel web and said second web may be a sheared-to-size stainless steel web.

11. A steel thermal stud to provide structural and non-load bearing characteristics, said stud comprising: a roll-formed galvanized flange end ca at both sides, wherein each roll-formed galvanized flange end ca comprises a first leg bent perpendicularly into a first return, which bent perpendicularly into a second leg, which bent into a second return, which then bent perpendicularly into a flange, which bent perpendicular into a third return, which terminates perpendicularly into a third leg, which bent perpendicularly into a fourth return, which further bent into a fourth leg; andat least one stainless-steel rod cb, wherein said stainless-steel rod cb is configured to connect with said each roll-formed galvanized flange end ca via a one-way hole provided on said first leg and said fourth leg for each location of said stainless-steel rod cb.

12. The stud of claim 11, wherein said stainless-steel rod cb further comprises a middle portion which extends to a step on each side, which then extend to a respective end on each side.

13. The stud of claim 11, wherein a foam may be sprayed into said stud to fill all gaps and may help to hold all pieces together.

14. A steel thermal stud to provide structural and non-load bearing characteristics, said stud comprising: a galvanized flange with webs da at both sides, wherein each galvanized flange with webs da comprises a first lip bent at an angle to a first web which bent perpendicularly to a flange which then terminates perpendicularly into a second web, which then terminates into a second lip which terminate at an end; anda plurality of stainless-steel rod webs db, wherein each stainless-steel rod web db comprised of a base extending towards both sides and terminating into a first u-shape on said both sides that is perpendicular to said base, wherein each first u-shape extends straight to a respective arm, which further terminates straight into a second u-shape on said both sides, which then terminate into a bend end,wherein said first and second webs comprise a plurality of slots, and said first and second U-shapes push apart said first and second lips as well as said first and second webs until they insert into said slots,wherein said first and second lips as well as said first and second webs spring back into their original position locking all components of said stud together.

15. The stud of claim 14, wherein a foam may be injected into a shrink wrap, and said foam as well as said shrink wrap may help to cover said ends to prevent them from cutting hands during handling.

16. The stud of claim 14, may also be formed without said first and second lips.

17. A steel thermal stud to provide structural and non-load bearing characteristics, said stud comprising: a galvanized flange fa at both sides, wherein each galvanized flange fa comprises a pair of webs terminating perpendicularly and separated by a flange, wherein said webs include a plurality of protrusions which prevent a foam from backing out once installed, or which may penetrate said foam after insertion by way of holding mechanism, wherein said galvanized flanges fa may be formed as primary flanges, wherein each primary flange comprises a respective inner flange fb as a secondary flange, wherein each inner flange fb comprises a first web terminating into a first flange which then terminates into a second web.

18. The stud of claim 17, wherein said first and second webs having a plurality of knock-outs extended inwards in order to provide for increased structural strengths and allows for increased fastener strengths such as pull-out, strip resistance, and fastener cantilevering.

19. The stud of claim 17, wherein a foam may be inserted therebetween an assembled flanges fa and fb on both sides and are permanently fixed together.

20. The stud of claim 17, may comprise at least one stainless-steel tube webs fc which can be inserted between said assembled flanges fa and fb and may be permanently fixed by a weld in one or more locations on both sides of said stud.

21. The stud of claim 17, wherein a spray foam may be used to fill the inside of a stud cavity and/or between said primary and secondary flanges, and a peel-off protective tape may be installed over said stud on all sides prior to adding said foam so that said foam can be inserted from open ends, and/or injected through said protective tape as needed along the length of said stud.

22. The stud of claim 17, may further comprise a tube web fc′ having an opening that is laser cut into each end leaving upper and lower connection arms on said each end as well as perpendicular walls which remain inset from said ends of said tube web fc′ so that fasteners inserted into said galvanized flange fa or said assembled flanges fa and fb may not contact said perpendicular walls.

23. The stud of claim 22, wherein said tube web fc′ may be used to support pipes, conductors, conduits, and other material is as needed in a wall, floor, roof or other assembly.

24. The stud of claim 17, may further comprise a web channel fd having a pair of legs parallel to each other and separated by a base, wherein said legs may be located outside of said galvanized flange fa with a plurality of slots allowing webs of said galvanized flange fa to position inside them, and with said base located inside of said webs.

25. A steel thermal stud to provide structural and non-load bearing characteristics, said stud comprising: a structural fiber reinforced plastic pultrusion web ga, wherein said web ga comprises a base extending to both sides to steps which extends straight to first flats, which extend straight to ramps, which extend straight to slots, which extend straight to stops and which extend to second flats which bent at ends; anda pair of flanges gb, wherein each flange includes a web, which extend to a first bend which extend to an outer flange, which extends to a second bend, which extends to a third bend having a plurality of aligned slots and terminating into an inner flange, wherein said web ga may be placed inside and between said pair of flanges gb when said inner flanges may be roll-formed over said ramps and into said slots,wherein said inner flanges may be trapped in said slots between said ramps and said stops and is unable to move since its own spring-back tension holds it in place.

26. The stud of claim 25, wherein said web ga may be full length or provided in shorter segments, and may have holes for conduits, pipes, and conductors to pass through.