Metal framing member with off site manufactured locking tabs

Abstract

A metal framing member for use as a stud, joist, rafter, truss, etc. is disclosed. The framing member includes at least one knock out opening and a corresponding tab that is positioned onto the metal framing member during the manufacturing process via computer so that structures built using the studs such as window frames, door jams, etc. are accurately and quickly fabricated. The knock out opening can also be used as a chase to allow wiring or a stiffening rod to pass through the member. Each tab is also preferably provided with a pair of pre-punched holes so that the tab can be fastened to other building components using standard screws.

Description

This application is a continuation-in-part of U.S. application Ser. No. 11/066,678 filed on Feb. 25, 2005, which is a continuation-in-part of U.S. application Ser. No. 10/459,868 filed on Jun. 12, 2003, now abandoned, which is a continuation-in-part of U.S. application Ser. No. 09/885,843 filed Jun. 20, 2001, now abandoned.

FIELD OF THE INVENTION

This invention relates to dwelling framing members, and in particular, to an attachment locking tab and opening which is used to attach one stud to another in such members by having the tab and its corresponding knock out positioned onto the metal stud via computer in accordance with the layout plans of the structure that is to be formed.

BACKGROUND OF THE INVENTION

Structural members are frequently made of metal, as it has advantages over wooden structural members. Compared to wood, metal is insect proof, fire proof, and has high uniformity and strength. However, its use is limited due to high cost, erection problems, and handling difficulties. U.S. Pat. No. 5,315,804, issued to Attalla, addresses some of these concerns. The patent discloses an improved metal framing member (STRONG STUD) that utilizes stiffening sections to enable a lighter gauge of metal to be used. The framing member also features embossed surfaces that facilitate fastening using standard self-tapping fasteners. Safety edges are provided to eliminate the sharp edge problem of handling metal framing members.

In addition to the above concerns, a framing member often must be provided with a chase to allow wiring or other objects to pass through the member. Introducing this chase after the framing member has been fabricated, as well as clipping or attaching the wiring to the member, can be tedious and time consuming. The patent mentioned above does not address this concern.

U.S. Pat. No. 5,943,838, issued to Madsen et al. on Aug. 31, 1999, discloses the use of a bendable tab which must be bent on the job by the metal stud installer. The use of the STRONG STUD taught in the '804 patent which utilizes heavy gauge, high strength material would make accurate and effective bending by the installer costly and difficult. Further, manual bending for even heavier gauge material that might be necessary in certain construction environments would be impossible.

Further, Madsen et al. teaches the use of a tab that is substantially less than that of the opening or knock-out. However, the Madsen et al. knock-out opening is substantially greater than the size of the tab which weakens the stud and potentially can cause buckling or torsion problems. Nor does Madsen et al. disclose or suggest the use of pre-punched pilot holes but instead relies solely on the use of self-tapping screws to connect the tab to another structure.

Therefore, what is needed is an improved metal framing member that includes a manufactured locating tab that is suitable for all metal studs, irrespective of the gauge of the metal, that can be placed at predetermined positions within the stud to serve to locate the attachment of other studs, has a knock-out opening that is substantially the same size as the size of the tab, that has pre-formed pilot holes for simplifying the installation of standard screw fasteners, and can serve as a preformed chase and a means of clipping objects passing through the chase to the member. Further, the use of a locking tab that enables one stud to be attached to a track member which can serve as a plate, header, footer, etc. without the need for additional fastening is also needed. A metal framing member including such a chase, locking tabs, that is low cost and can be handled safely is not found in the prior art.

SUMMARY OF THE INVENTION

The present invention is a metal framing member including at least one manufactured locking tab. The framing member has a substantially rectangular cross-section. Preferentially, at least two stiffeners run longitudinally along the metal framing member. Two locking tabs are punched out of the bottom portion between the two stiffeners. The locking tabs resulting from the punched out section of the framing member have an angled locking guide which serves to assist the locking tabs to be mated to corresponding punched out tab openings in a slotted tab punched out of a track meant to be attached to said framing member. Once the framing member locking tab is slid over its mating slotted tab so that tab openings are aligned with the locking tabs, the framing member is locked into place along the track. Additional locking tabs are optionally provided on each leg of the framing member to enable the framing member to be more securely attached to the track member. The tab openings that engage by locking tabs on the framing member can be either round or rectangular. Also, rather than provide another tab arrangement on the legs of the framing member, an opening that matches a mating opening in the track member can be pinned together using press pins well known in the art. Each locking tab assembly on the framing member and its corresponding track member is made at the factory using computer software to accurately match each position in accordance with the building design. Thus, the two parts can be put together securely and quickly without the use of screws, bolts or other fasteners.

Therefore, it is an aspect of this invention to provide an improved metal stud framing member.

It is another aspect of the invention to provide a framing member with a locking tab assembly that will mate with a locking tab assembly on a track or channel member.

It is a further aspect of the invention to provide a metal framing member with a receiving opening for a locking tab that is preferably rectangular shaped.

It is a further aspect of the invention to provide a metal track channel member with a receiving opening for a locking tab that is circular shaped.

It is still another aspect of the invention to provide a metal stud and corresponding track member that can be attached together without the use of screws, bolts or other fasteners well known in the art.

Another aspect of the invention is to provide a metal framing member and track member that has computer generated tabs to enable the two parts to mate together accurately and easily.

Another aspect of the invention is to provide a metal framing member and track member that can also be locked with a press pin through openings in the respective members.

Still another aspect of the invention is to provide a metal framing and corresponding track member that has accurate and dependable fixed locations to eliminate installation errors and increase the productivity of the framing process.

Still another aspect of the invention is to provide a metal stud framing member that has a punched locking tab having an angled material guide so that the metal framing member will easily snap over the mating locking tab openings on the track member.

These aspects of the invention are not meant to be exclusive and other features, aspects, and advantages of the present invention will be readily apparent to those of ordinary skill in the art when read in conjunction with the appended claims and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view with a partial cut away view of the stud framing member showing one manufactured layout locating tab.

FIG. 2 is a detail showing the knock out opening that can be used as a chase in the framing member.

FIG. 3 is a top view of the tab.

FIG. 4 is a cross sectional view of the framing member illustrating the stiffeners used in the preferred embodiment.

FIG. 5 is a cross sectional view of another embodiment of the framing member without the stiffeners.

FIG. 6 is still another alternative embodiment of the framing member showing a plurality of manufactured layout locating tabs.

FIG. 7 is a detailed view of one tab positioned within the framing member shown in FIG. 6.

FIG. 8 is cross sectional view of the tab within the framing member shown in FIG. 6.

FIG. 9 is another embodiment of manufactured layout locating tab shown in the framing member depicted in FIG. 6.

FIG. 10 is a detailed view of the tab embodiment shown in FIG. 9.

FIG. 11 is a cross sectional view of the alternative embodiment of the tab.

FIG. 12 is front view of a typical wall that is constructed with framing members in accordance with the invention.

FIG. 13 illustrates a stiffening member that is inserted through the knock out opening of the framing member and attached to the tab provided via the knock out.

FIG. 14 shows a typical stress that may be constructed using the framing members in accordance with the invention.

FIG. 15 illustrates that the manufactured layout locating tab may be positioned anywhere on the framing member including the end.

FIG. 16 is an isometric view of locking tabs being used to connect a stud with a track channel in accordance with the invention.

FIG. 17 is a detailed isometric view of the preferred embodiment of the locking tab that is used on a stud.

FIG. 18 is a front detailed view of the locking tab shown in FIG. 17.

FIG. 19 is a detailed cross sectional view across section 4-4 shown in FIG. 18.

FIG. 20 is a detailed cross sectional view of the stud locking tab and its corresponding mating track channel locking tab in position prior to having the stud inserted on the track channel.

FIG. 21 is an isometric view of an alternative embodiment of the locking tabs.

FIG. 22 is an isometric view of still another alternative embodiment of the locking tabs that use a press fit pin to improve the stability of the attachment.

FIG. 23 illustrates a detailed view of the press pin.

FIG. 24 illustrates still another embodiment of FIG. 22.

FIG. 25 illustrates a detailed alternative embodiment of a method of attachment.

FIG. 26 illustrates the attached stud using the alternative embodiment shown in FIG. 25.

FIG. 27 illustrates the alternative embodiment for the stud used in the track.

FIG. 28 illustrates use of a punching locking tab for the stud in combination with an angled dimple at the track.

FIG. 29 illustrates an angled dimple at the track.

FIG. 30 illustrates the use of a round dimple at the track.

FIG. 31 illustrates a detailed view of the round dimple.

FIG. 32 illustrates how a stud with a longitudinal rib at the flange may be attached.

FIG. 33 illustrates a detailed view of the oblong dimple that is used to attach the ribbed stud to the track.

FIG. 34 illustrates a large oblong dimple on the track.

FIG. 35 illustrates a top view of an alternative stud.

FIG. 36 illustrates a bottom view of the alternative stud shown in FIG. 35.

FIG. 37 is a side view of an alternative locking clip that is a punched ‘louvered’ type which is attached to the web member of the stud.

FIG. 38 is a punched louvered member that provides an attachment position for the stud member attachment.

FIG. 39 is a bottom view of the ‘louvered’ tab embossed member.

FIG. 40 is a top view of the ‘louvered’ tab embossed member showing the triangular shape.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates metal framing member 10 with knock out opening 12 and tab 14. While tab 14 is usually made so that tab 14 is approximately 90 degrees with surface 16, since tab 14 is made at the factory using computer assisted machinery, any precise angle may be selected. (See, e.g. FIG. 13) Tab 14 and its corresponding knock out opening 12 are preferably located centrally in surface 16, which runs the length of framing member 10. However, since the stud is manufactured to the design specifications necessary to ensure precision and ease of fastening, other positions can be easily selected. In fact, different locations on surface 16 as well as different tab angles could be provided in each framing member if desired.

Surface section 16 is generally 6″ to 8″ wide. In the preferred embodiment, surface section 16 includes stiffeners 18, which run longitudinally along surface section 16. Typically, as noted above, knock out opening 12 is centrally located between stiffeners 18. Note that the geometry and size of knock out opening 12 and tab 14 are substantially the same, differing primarily due to the width of the cut. By having opening 12 and tab 14 substantially the same, less material is wasted and the framing member is stronger thus exhibiting a greater resistance to torsion forces and axis buckling.

Knock out opening 12 is shown in detail in FIG. 2. Opening 12 is cut out of surface portion 16 in an area preferably no greater than two inches by two inches. Because this opening and tab 14 are made during the time of manufacturing the framing member 10, the gauge of framing member 10 can be far thicker than would be otherwise possible if the installer had to bend tab 14 at the construction site.

In the preferred embodiment, opening 12 is 1 11/16″ by 1 11/16″, with upper end 20 of the chase having a radius of ⅞″ instead of being cut square. Tab 14 is not completely severed from opening 12, but is connected along lower edge 22. Preferably, tab 14 is folded up at lower edge 22 so that tab 14 is substantially perpendicular to raised surface section 16. However, as noted above, other angles are easily selectable depending on the needs of the construction project.

FIG. 3 details tab 14. In addition to the primary purpose of tab 14 to provide an accurate positioning and fastening location for adjacent framing members, tab 14 can serve as a point of attachment for any objects passing through opening 12 such as wiring. Wiring or other objects may be passed from one side of the framing member to the other through opening 12 thus serving as a chase. These objects may then be fastened to tab 14 without adding additional clips.

In the preferred embodiment, two holes 24 are provided in tab 14 to serve as fastener holes. One hole 24 is positioned ½″ from lower edge 22, while the other is positioned ½″ from rounded edge 26. Holes 24 are otherwise centered on tab 14. Holes 24 preferably have a radius of 3/32″ and are capable of receiving standard screw fasteners (not shown) to attach wiring, stiffening rods, or other framing members to tab 14.

Returning to FIG. 1, stud framing member 10 includes left and right rectangular sections 28. Rectangular side sections 28 are preferably at least 1 ⅝″ in length, but may vary depending on the particular need for the framing member. Rectangular side sections 28 share an edge with surface section 16 and are substantially perpendicular to surface section 16 while being parallel to each other. At the distal ends of rectangular side sections 28 are left and right rectangular returns 30. Left and right rectangular returns 30 are preferably perpendicular to rectangular side sections 28 and parallel to bottom section 16.

FIG. 4 is a cross section of stud framing member 10, including stiffeners 18 that run the length of the member. Stiffeners 18 are ideally located on surface section 16 about 1 ½″ to 2″ from rectangular side sections 28, depending on the width of bottom section 16. As can be seen from FIG. 4, rectangular returns 30 do not generally extend out over stiffeners 18. It can also be seen that corners 32, formed where rectangular side 10 sections 28 meet bottom section 16, and corners 34, formed where rectangular returns 30 meet rectangular side sections 28, may be radiused edges rather than sharp comers.

FIG. 5 is a cross section of an alternate embodiment of framing member 10. In this embodiment, bottom section 16 does not include stiffeners 18. Rather, surface section 16 is flat across its entire width other than opening 12 and tab 14.

As shown in FIG. 6-8, there is another alternative embodiment of the framing member 15 showing a plurality of manufactured layout locating tabs 14. Note that the position of tabs 14 and the corresponding knock out openings 12 can be located anywhere along the framing member. That is, it is unnecessary to use only 16 inches on center as would be required if tabs 14 and openings 12 were not made specifically to meet the requirements of each and every construction project.

FIG. 9 is another embodiment of manufactured layout locating tabs 14′ shown in the framing member depicted in FIG. 6. In this embodiment, tabs 14′ and their corresponding knock out openings 12′ are rectangular in shape. Clearly, other shapes are likewise possible such as triangular, octagonal, hexagonal, etc. depending on the job requirements. Since the tabs and openings are made during the construction process of the framing member, with the tab aligned at the predetermined angle relative to the web surface of framing member, a virtual infinite number of tab permutations and combinations are possible.

FIG. 12 shows a typical framed wall that uses the tabs 14 to attach one framing member to the next in precise alignment. Note that the distance between the respective framing members is not always a standard (16 inches O.C.) so that the tabs (not shown) on header framing member 42 are adjusted accordingly. Also, openings and tabs can be provided so that cross bracing members 44 and 46 are accurately position therethrough thus providing a tab for attachment as well as making certain the framed wall is square. This can be seen more clearly in FIG. 13 which shows that tab 14 is positioned at an angle other than 90 degrees with respect to surface portion 16.

As shown in FIG. 14, the framing member invention can even be used to construct trusses which require joining one framing member to another at varying angles and positions. The flexibility of this system is clearly illustrated in FIG. 15 which illustrates that tab 14 can be positioned at the top of framing member 10 such that one framing member 10 can be attached to another at substantially right angles.

FIG. 16 is an isometric view of locking tabs being used to connect a stud member 50 with a track channel member 58 in accordance with the invention. While the stud member 50 is shown as the applicant's patented STRONG STUD described above, a track channel, other metal structural members can also be used with the invention.

A tab attachment assembly having at least two raised portions 52 is provided in the web of stud member 50. A punched locking tab 54 is provided in each of raised portion 52. An angled material guide 56 is also provided in each of raised portion 52. At least two punched knock-out tabs openings 62 are provided in the upper portion of slotted tab 60 in track or channel member 58. Track or channel member locking assembly is aligned so that tab opening 62 is aligned with the tab attachment assembly of stud member 50. Once stud member 50 is inserted over upper portion of slotted tab 60, the two parts are attached together. The stability of the attachment is augmented by the use of knock-out locking surface 64 of stud member 50 which engages locking surface of locking tab 66 of track channel member 58. This is shown only on one leg of the respective parts but could also be used as a match set on both legs.

Referring now to FIGS. 17-19, detailed views of the preferred embodiment of the locking tab assembly that is provided on stud member 50 are shown. Note that guide member 56 is angled slightly to enable the locking tab assembly to be slid over the upper portion of slotted tab 60 of the track channel member 58. Punched locking tab 54 engages punched knock-out tab opening 62 of tab 60 so that the two parts are held firmly together as shown in FIG. 20.

FIG. 20 is a detailed cross sectional view of the stud locking tab and its corresponding mating track channel locking tab in position prior to having the stud member 50 attached to track channel member 58. Note that once fully engaged, locking tab 66 is inserted into punched knock-out tab opening 62 thus holding the two parts firmly together.

FIG. 21 is an isometric view of an alternative embodiment of the locking tabs. In this embodiment, the knock-outs are a radius locking tab 74 and a corresponding circular opening 76. As can be seen, the tab and its receiving knock-out opening can be any mating shaped pair such as a rectangle, square, circular, oval, etc. as long as the opening and its tab are dimensioned so that the tab fully engages the opening once one member engages the other.

The remaining drawings show the various permutations and combinations that can be used to attach stud member 50 to track channel member 58.

FIG. 22 is an isometric view of still another alternative embodiment of the locking tabs that use a press fit pin 72 to improve the stability of the attachment. Matched openings 68 and 70 are provided wherein press pin 72 is pressed through the two fully engaged parts to more firmly hold the two together. Press pin 72 may be plastic or metal or another material that has sufficient structural strength to withstand the forces expected when the two parts are attached. Press pin 72 is preferably shaped so that once press pin 72 is inserted, removal is extremely difficult thus ensuring that the two parts are locked together as is accomplished with locking tab assembly.

FIG. 23 illustrates a detailed view of the press pin 72.

FIG. 24 illustrates still another embodiment of FIG. 22. In this embodiment, press pin 72 is eliminated. Instead, a square receiving hole 78 is provided on track channel member 58. The stud is attached to the track by a square angled dimple 77.

FIG. 25 illustrates a detailed alternative embodiment of a method of attachment. It shows a detailed view of the square angled dimple 77.

FIG. 26 illustrates the attached stud member 50 using the alternative embodiment shown in FIG. 25. In this embodiment, the stud member 50 is attached to track channel member 58 using a square receiving hole 79 as a dimple which engages a square angled dimple 80 on track 58.

FIG. 27 illustrates a detailed view of the square angled dimple 80 that is positioned on the track channel member 58.

In this view, FIG. 28 illustrates a squared dimple 82 on track channel member 58 and a square receiving hole 79 on the stud member 58.

FIG. 29 is a detailed view of the squared dimple 82 on track channel member 58.

FIG. 30 illustrates the use of a round receiving hole 83 on stud member 50 as a dimple. Correspondingly on track channel member 58, round dimple 84 is used to attach to receiving hole 83.

FIG. 31 is a detailed view of the round dimple 84 on track channel member 58 that is shown being used in FIG. 30.

As shown in FIG. 32, a stud member 50 that has a longitudinal rib 85 may also be attached to track channel member 58 using this method. In this embodiment, a large oblong dimple is provided on track channel member 58. The stud member 50 is attached by moving the stud member 50 as shown by the arrows so that the rib 85 lines up with dimple 86.

FIG. 33 is a side view of the dimple that is found on track channel member 58.

FIG. 34 is a top view of the oblong dimple 86 on track channel member 58.

FIG. 35 illustrates a top view of an alternative stud member 50.

FIG. 36 illustrates a bottom view of the alternative stud member 50 shown in FIG. 35.

FIG. 37 is a side view of an alternative locking clip that is a punched ‘louvered’ type which is attached to the web member of the stud.

FIG. 38 is a punched louvered member that provides an attachment position for the stud member attachment. The use of the punched ‘louvered’ type of catch is positioned within the flat portion of the tab/clip. Thus, it provides a greater holding power.

FIG. 39 is a bottom view of the ‘louvered’ tab embossed member.

FIG. 40 is a top view of the ‘louvered’ tab embossed member showing the triangular shape. When attached to the clip shown in FIG. 37, a more secure lock is provided than can be achieved by merely the use of the punched version of the tab and dimpled locking mechanism.

Although the present invention has been described with reference to certain preferred embodiments thereof, other versions are readily apparent to those of ordinary skill in the art. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein.

Claims

1. An off site manufactured attachment apparatus for attaching a metal stud framing member to a metal track structural channel member, said apparatus comprising;

at least one first pair of opposing projection portions on said stud member;

a corresponding at least one first pair of opposing receiving portions on said track member;

at least one second pair of projections portions aligned on a plane of said stud member;

a corresponding at least one second pair of receiving portions on said track member aligned on said plane parallel to that of said stud member;

wherein inserting said at least first pair of projection portions of said stud member into the corresponding said at least one first pair of receiving portions of said track member; and

wherein sliding said stud member over said track member such that said at least one second pair of projection portions are aligned with said at least one second pair of said receiving portions of said track member;

such that said at least one first pair of receiving portions are engaging said at least one projection portions and said at least one second pair of receiving portions are engaging said at least one second pair of receiving portions; whereby said stud member and said track member are locked together.

2. The framing attachment apparatus of claim 1 wherein said at least one second pair of projection portions and receiving portions are rectangular in shape.

3. The framing attachment apparatus of claim 1 wherein said at least one second pair of projection portions and receiving portions are circular in shape.

4. The framing attachment apparatus of claim 1 further comprising at least one press pin and whereby said at least one press pin is inserted into said at least one first pair of opposing openings to lock said stud member to said track member.

5. The framing attachment apparatus of claim 1 wherein said track member and said stud member each have a u-shaped configuration having two legs separated by a web and wherein said at least one first pair of projection portions and receiving portions are positioned on at least one immediately adjacent leg of said track member and said stud member.

6. The framing attachment apparatus of claim 5 wherein said at least one pair of second projection portions is on the web of said stud member and the corresponding said at least one second pair of receiving portions is on the web section of said track member.