Process to Improve the Manufacture and Installation of Metal Assemblies, Used in Building Construction

Abstract

An improved method and component design that makes for a more precise fit between steel studs and steel track, used in cold formed light gauge steel construction.

Description

This patent application is the continuing work from the provisional patent applications No. 61911587, filed Dec. 4, 2013 and provisional application, No. 61941065, Feb. 18, 2014.

Title,

Process to Improve the Manufacture and Installation of Metal Assemblies, Used in Building Construction

Field of patent search, 52/633; 52/634; 52/645; 52/656.1; 52/690; 52/693; 52/694; 52/696; 52/731; 52/733; 52/745;

BACKGROUND

Cold formed light gauge steel is commonly used in commercial and residential construction. This is usually accomplished with “U” shaped track and “C” shaped studs. The standard manufactured material has variations, such as different inner radiuses in the “U” shaped track material. This varies from manufacture to manufacture and batch to batch. Because of this inner radius in the “U” shaped track, the stud doesn' t make a precise fit with the web or flat section of the track as shown in FIG. 1. The resulting gap can cause the structure/building to settle and weaken under load.

One approach to this problem has been to widen the web or flat section of the track and bend the flanges or legs inward past 90° to compensate for the extra width. This commercially available, as “Sigma Track” from, The Steel Network, Inc., Durham N.C. By doing this, the flange of the track makes only point contact with the stud, at the end of the flange. With this approach the track can walk or slip during assembly as shown in FIG. 1,a, 1,b, 1,c. and FIG. 13.

DESCRIPTION OF INVENTION/PROCESS

This process/method improves the fit between the stud and track components used in light gauge metal assemblies. The primary use is in building/construction industry. Engineering the metal to metal connections to be a precise fit, improves the physical properties of the assemblies and the structure. This is accomplished by the use of an adjustable forming tool to adjust the fit of the connection components. Or, by modifying the profile of the track as its roll formed, to allow for a precise fit with stud.

The process starts by making the track so the inner surface of the flanges or legs is inside the inner radius of the track and is a precise fit with the outer surface of the stud. This allows the end of the stud 5 to miss the inner radius 4 of the track 7 and contact only the flat surface of the web 6 and the inner surface of the flange 2 .

This can be accomplished in several ways. One would be to extend the length of the tracks web or use “Sigma Track”, so the inner radius is outboard or wider than the width of the stud as shown in FIG. 2,b. Then using an adjustable forming tools to adjust the width between the flanges to precisely fit the stud as shown in FIG. 2,c if only the area to be formed is where the stud 3 makes contact with the track 7 as shown in FIG. 5. Or the track profile shown in FIG. 2,c and FIG. 4 could be longitudinally rolled along its length on a roll former.

Another approach would be to use standard off the shelf material such as shown in FIG. 1. The first step shown in FIG. 2 would be to determine the distance 1 the flange or leg would need to be adjusted so the inner surface of the flange 2 would be inside the inner radius 4 of the track 7. Then using an adjustable forming tool, punch/crimp the track to the needed width as shown in FIG. 9. Then using an adjustable end forming tool, swage the end of the stud 3 to the proper width to form a precise fit with the track 7 as shown in FIG. 10.

This process can also be done on a CNC roll former as shown in FIG. 13. In this connection a dimple punch was used in the track 7 as shown in FIG. 6 and an elongated dimple was used as shown in FIG. 7. The elongated dimple punch 27 and 28 allows the stud 3 to seat into the track 7 without any interference with the dimple punch 26 in the track 7.

DESCRIPTION OF DRAWINGS

FIG. 1 is a photo of a typical metal track and stud connection, using off the shelf material, made on a compression table. It shows the stud resting on the inner radius of the track, resulting in a gap between the end of the stud and the web/flat surface of the track. This also shows the gap in between the track and stud.

FIG. 1, a. shows how track 7 can shift or walk when downward pressure is applied to the stud 3 during assembly.

FIG. 1, b. shows how a track 7 with an extended web can shift or walk when a fastener is attached to one side.

FIG. 1, c is a photo showing what track & shift or walk looks like.

FIG. 2 shows a cross section of standard off the shelf material. 1 the distance the inner flange surface 2 of the track needs to move to allow the outer surface the of the stud 3 to miss the inner radius 4 of the track and allow the end of the stud 5 seat on the inner web/flat surface 6 of the track 7.

FIG. 2, a. shows the distance 1 the outer surface of the stud 3 would need to be swaged or crimped to make a precise fit with the stamped or longitudinally rolled track 7 profiles from FIG. 2.

FIG. 2, b. is the cross section of a track 7, where the inner web/flat surface 6 has been extended so the inner radius 4 of the track is outside of the outer surface of the stud 3.

FIG. 2, c. is a cross section of stud 3 and track 7 where the track has either been stamped or longitudinally rolled so the inner flange surface 2 is a precise fit with the stud 3. The inner flange surface 2 and the inner web/flat surface 6 of the track 7 are at 90° to each other.

FIG. 2, d. is another example of a precise fit between the stud 3 and track 7 where part of the inner flange surface 2 and the track 7 are at 90° to each other.

FIG. 3 is a cross section of a typical as rolled track 7 and the dimension 8 the inner flange surface 2 of the track 7 needs to be to, allowing the end of the stud 5 fit flush with the web/flat surface 6 of the track.

FIG. 4 shows the cross section of a track 7 that has been formed so the inner flange surface 2 has been adjusted so it is inboard of the inner radius 4. This can be accomplished on a roll former, where the profile is continuous along the entire length of the track. However, an alternative method would be use a standalone adjustable forming tool no only the areas where the stud 7 will intersect with the track 3. A small hole 17 can be punch or drilled for the fasteners if desired.

FIG. 5 shows two track 7 elements back to back with pre-punched/drilled holes 17 for fasteners and indentations 19 to match the top and bottom track 7. Both of them can be made on a CNC roll former or by a standalone work station. The track 7 elements take the most amount of time to process on a CNC roll former, because of the number of stop-punch-start operations needed. If two track 7 elements were placed back to back as shown, then a double multi-axis forming work station could process two track 7 elements at the same time. A bar code 18 or other identification could be printed on the track 7 elements at the time of rolling or punching then this bar information could be integrate into other manufacturing operations such as material tracking, assembly, QC, shipping and installation operations.

FIG. 6 shows a cross section of a track 7 the same as in FIG. 4 and a swaged stud 3 with the addition of an extra depression sometimes referred to as a dimple 26 with a pre-punched/drilled hole 17 for a fastener. If the dimple 26 is used it is preferable to have elongate dimple 27 indentations, as shown on the left side of the stud 3 or an elongated slot 28 as shown on the right side of the stud 3

FIG. 7 shows the outer flange surface of the stud 3 using an elongated oval dimple 27 no hole.

FIG. 8 is the same as FIG. 14 but is an open ended dimple slot 28 making assembly much easier, alien with no hole. When using corresponding indentations to keep the head of a fastener below the outer surface of the track 7 it is desirable not to have a hole in the stud so there will be no miss match of holes when the assembly is put under load before the fasteners are used. Any miss match in the hole alignment will reduce the fasteners effectiveness, because less of the thread will be engaged. With no hole in the stud all of the thread is engaged.

FIG. 9 is a photo of a standard track 7 and stud 3 connection that has been sized with a standalone multi-axis adjustable forming tool.

FIG. 10 is a photo of the opposite view of FIG. 9

FIG. 11 is a photo of a stud 3 and track 7 connection that has been sized with a standalone multi-axis adjustable forming tool, and then soldered instead of using a mechanical fastener.

FIG. 12 is the inside view of FIG. 11.

FIG. 13 shows a stud 3 and track 7 that was made on a CNC roll former. This connection is using a dimple punch in the track 7 as described in FIG. 6 and an elongated dimple punch in the stud 3 as described in FIG. 7 and FIG. 8

Claims

1. A “U” shaped track, where the web section has been extended so the inner radius of the track is wider than the stud to be used; and the flange sections have been bent back towards the center of the track, up to 180°, then the flanges bent away from the center, up to 90° forming a double radius bend at the web and flange intersection that results in a “U” shape, where the inner surface of the flanges are at a 90° angle to the web and inboard of the web radius, allowing the stud to fit precisely in between the flanges and make full contact with the web section of the track and not contact the inner radius of the track.

2. A “U” shaped track of claim 1, where the second bend is 85° to 95° so the flanges have a plus or minus 5° camber to the stud.

3. A “U” shaped track of claim 1, where the forming is done on a roll former.

4. A “U” shaped track of claim 1, where the forming is don't with an adjustable swage, crimping or punching tool and only where contact with a stud is needed.

5. A “U” shaped track of claim 3, where the second bend is 85° to 95° so the flanges have a plus or minus 5° camber to the stud.

6. A “U” shaped track, of standard sized commercially available material, has been crimped, swaged or punched with an adjustable forming tool, so the inner area of the flanges that will contact a stud has been moved inwards so the inner side of the flanges are inboard of the inner radius of the web/flange intersection and the flanges are at 85° to 95° to the web, so a stud that has been swaged or crimped with an adjustable forming tool will fit precisely in between the flanges and make full contact with the web section of the track and not contact the inner radius of the track.

7. A precise stud and track connection where a recess/depression has been formed in the flanges of the track so the head of a fastener is below or flush with the outer surface of the flanges and an elongated recess/depression in the form of an oval or slot, has been formed at each side of end of the stud, where the length of the oval or slot is up to the same length as the flange of the track and the width and depth of the negative side of the elongated oval or slot fits into the positive side of the flanges recess/depressions allowing the stud to fit down to the web without an interference between the recess/depressions of either the stud or track.