APPARATUS FOR CURVING METAL STUD TRACK

Abstract

An apparatus and method for creating a curved shape of a stud track are provided. According to an example embodiment, an apparatus may include a first and a second support rail. The first and second support rails may be spaced from one another and may be generally parallel. Each support rail may include a flange slot configured to receive a first flange of a stud track. A web crimping feature may be movable between a first position at least partially disposed between the first and second support rails and a second position at least partially spaced from the first and second support rails. The apparatus may also include a flange crimping feature movable between a first position at least partially disposed between the first and second support rails and a second position at least partially spaced from the first and second support rails.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This subject application claims the benefit of U.S. Provisional Application Ser. No. 62/049,453, filed on 12 Sep. 2014, the contents of which are herein incorporated by reference in its entirety.

TECHNICAL FIELD

The present disclosure generally relates to metal building framing systems, and more particularly relates to shaping metal stud track.

BACKGROUND

Metal studs are commonly used in commercial construction. Typically, the metal studs may be attached to a track at the top and bottom of the metal stud. The track may generally maintain a desired alignment and spacing of the metal studs relative to one another. The track may also secure, or aid in securing, the studs to the floor and ceiling structures and/or framing. Conventional metal studs are generally formed having a channel cross-section including a web having two opposed flanges extending generally perpendicularly from either edge of the web. Often, each flange may include an inwardly directed lip or return along an opposite edge from the web. The lip or return may, for example, stiffen the stud. Similarly, conventional metal tracks may also include a web having two flanges, or legs, extending generally perpendicularly from either edge of the web. The interior spacing between the flanges, or legs, of the channel may be generally sized to receive a corresponding stud. Metal studs may often be joined to the track using screws that may connect the flanges, or legs, of the track to the flanges of the studs. For example, with a stud positioned within a track such that each opposed flange of the stud is positioned adjacent a respective opposed flange of the track, a screw may be driven through each track flange of the corresponding adjacent stud flange. Studs may be provided having various different sizes (e.g., web widths) that may generally provide walls having different thicknesses. Similarly, tracks may also be provided having different sizes (e.g., web widths) that may generally accommodate different correspondingly sized studs.

SUMMARY

According to an implementation, an apparatus for providing a curved shape of a stud track may include a first and a second support rail. The first and second support rails may be spaced from one another and may be generally parallel. Each support rail may include a flange slot configured to receive a first flange of a stud track. The apparatus may also include a web crimping feature movable between a first position at least partially disposed between the first and second support rails and a second position at least partially spaced from the first and second support rails. The apparatus may further include a flange crimping feature movable between a first position at least partially disposed between the first and second support rails and a second position at least partially spaced from the first and second support rails.

One or more of the following features may be included. The apparatus may further include a baseplate. The first and second support rails may be affixed to, and upstanding relative to, the baseplate. The first and second support rails may further include at least a second flange slot configured to receive a second flange of the stud track. The first and second flange slots may be spaced along the first and second support rails a distance to receive the respective first and second flanges of the stud track and to support a stud track web on the support rails between the first and second flange slots. The first and second support rails may include a plurality of flange slots configured to receive flanges of stud tracks having different widths.

The web crimping feature may be pivotally movable between the first position and the second position. The flange crimping feature may be pivotally movable between the first position and the second position. The flange crimping feature and the web crimping feature may be coupled for common movement between the respective first and second positions. The flange crimping feature and the web crimping feature may include a unitary structure.

The apparatus may include a handle coupled to each of the flange crimping feature and the web crimping feature. The handle may be configured for common movement of the flange crimping feature and the web crimping feature between the respective first and second positions. The apparatus may include a depth stop for controlling a depth of the flange crimping feature and the web crimping feature between the support rails in the respective first positions. The depth stop may be adjustable for adjustably controlling the depth of the flange crimping feature and the web crimping feature between the support rails in the respective first positions. The depth stop may be threadably adjustable. The depth stop may be coupled to a handle configured for commonly moving the flange crimping feature and the web crimping feature.

According to another implementation, a method for providing a curved shape to a stud track may include positioning the stud track on a pair of support rails. The pair of support rails may include respective flange slots receiving a flange of the stud track. The method may include moving a flange crimping feature to engage the flange of the stud track deforming the flange of the stud track between the pair of support rails. The method may further include moving a web crimping feature to engage a web of the stud track deforming the web of the stud track between the pair of support rails.

One or more of the following features may be included. Moving the flange crimping feature and moving the web crimping feature may include commonly moving the flange crimping feature and the web crimping feature. Moving the flange crimping feature and moving the web crimping feature may include pivotally moving the flange crimping feature and the web crimping feature relative to the pair of support rails. Pivotally moving the flange crimping feature and the web crimping feature may include pivotally moving a handle relative to the pair of support rails. The handle may be coupled to the flange crimping feature and the web crimping feature.

The method may also include providing a depth stop coupled with one or more of the flange crimping feature and the web crimping feature to control a degree of deformation of one or more of the flange of the stud track and the web of the stud track. The method may include adjusting the depth stop to achieve a desired degree of deformation of one or more of the flange of the stud track and the web of the stud track.

The method may further include adjusting the stud track relative to the pair of support rails. The method may also include moving the flange crimping feature to engage the flange of the stud track deforming the flange of the stud track between the pair of support rails at a location on the stud track spaced from the previously deformed portion of the stud track. The method may further include moving the web crimping feature to engage the web of the stud track deforming the web of the stuck track between the pair of support rails at a location on the stud track spaced from the previously deformed portion of the stud track.

The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will become apparent from the description, the drawings, and the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 diagrammatically depicts an example metal stud framing arrangement including a curved stud track, according to an example embodiment;

FIG. 2 diagrammatically depicts an example stud track crimped to provide a curved shape, according to an example embodiment;

FIG. 3 diagrammatically depicts a side view of a track curving apparatus, according to an example embodiment;

FIG. 4 is a top plan view of baseplate and support rail portion of the track curving apparatus of FIG. 3;

FIG. 5 is a side view of the baseplate and support rail portion of the track curving apparatus of FIG. 3;

FIG. 6 is an enlarged view of the crimping features of the track curving apparatus of FIG. 3; and

FIG. 7 diagrammatically depicts another embodiment of a track curving apparatus, according to an example embodiment.

DESCRIPTION OF EXAMINER EMBODIMENTS

Consistent with an embodiment, a track bending apparatus is provided for shaping track members to have a desired curvature, or radius. For example, generally track members may be provided having a substantially linear, or straight, configuration. Referring to FIGS. 1 and 2, a plurality of studs (e.g., stud 10) may generally extend between a top track (e.g., top track 12) and a bottom track (e.g., bottom track 14). Herein, the tracks (e.g., tracks 12, 14) may be generally referred to as “tracks” or “stud tracks.” The track (e.g., top track 10 shown in FIG. 2) may generally include web 16 having two opposed flanges (e.g., flanges 18 and 20) extending generally perpendicularly from either edge of web 16. The track bending apparatus consistent with the present disclosure may form one or more crimps, or indentations, in the web (e.g., web crimp 22) and at least one of the flanges or legs (e.g., flange crimp 24) of track 12, thereby causing a localized arching, or bending, of track 12. As shown, in an embodiment, crimp 24 formed in flange 18 of track 12 may be substantially the same depth along the height of flange 18. Crimp 22 formed in web 16 of track 12 may generally increase (e.g., in depth) as crimp 22 extends across web 16 toward the crimped flange 18. For example, in one embodiment, web crimp 22 may increase from little to no crimp adjacent uncrimped flange 20 to a full crimp adjacent crimped flange 18. In an embodiment, the depth of flange crimp 24 and web crimp 22 may be adjusted to provide a desired degree of curvature. Additionally, the spacing between the crimps in the track (e.g., the spacing between adjacent sets of web crimps/flange crimps) may also be varied to achieve the desired degree of curvature of the track. In an embodiment, the track bending apparatus may shape track members into a desired curvature while maintaining the structural integrity of the track member.

In an embodiment, the track bending apparatus may allow tracks to be bent having controllable and/or repeatable curvatures. For example, two or more track members (e.g., top track 12 and bottom track 14) may be formed having a generally similar, if not the same, curvature, by providing each track member with similarly spaced crimps. Additionally, the two or more tack members may be formed having crimps that are generally similar in depth and/or geometry. For example, the two or more track members may be provided having the same number of crimps in each track member. Further, the crimps in each track member may have generally the same spacing between the crimps. In this manner it may be possible to generally, if not exactly, create the same curvature in each track member. Forming more than one track member having the same curvature may, for example, allow a top track and a bottom track to be formed having generally the same curvature. Similarly, forming more than one track member having the same curvature may allow multiple wall sections to be produced having the same, or generally similar, curvature.

Referring also to FIGS. 3-7, example embodiments of a track bending apparatus are shown. It will be appreciated that the general dimensions and/or proportions depicted in the illustrated example embodiment are intended for illustrative purposes, and may be varied, e.g., to suit additional track sizes and/or desired crimp dimensions. FIG. 3 generally depicts a complete track bending apparatus. FIG. 4 generally depicts a top view of the track bending apparatus, not including the handle. FIG. 5 generally depicts a side view of the track bending apparatus, not including the handle. FIG. 6 generally depicts an example combined crimping feature. FIG. 7 generally depicts an exploded view of another embodiment of a track bending apparatus. As shown, the example track bending apparatus 26 may include a first and a second support rail (e.g., support rails 28, 30). First and second support rails 28, 30 may be spaced from one another and may be generally parallel. Each support rail 28, 30 may include a flange slot (e.g., flange slot 32) configured to receive a first flange (e.g., flange 18) of a stud track 12. Track bending apparatus 26 may also include a web crimping feature (e.g., web crimping feature 34) movable between a first position at least partially disposed between the first and second support rails 28, 30 (e.g., as shown in FIG. 3) and a second position at least partially spaced from the first and second support rails. The apparatus may further include a flange crimping feature (e.g., flange crimping feature 36) movable between a first position at least partially disposed between the first and second support rails 28, 30 (e.g., as also shown in FIG. 3) and a second position at least partially spaced from the first and second support rails.

Track bending apparatus 26 may also include a baseplate (e.g., baseplate 38). Support rails 28, 30 may be generally arranged in an upstanding orientation extending from baseplate 38. For example, support rails 28, 30 may be affixed to, and upstanding relative to, baseplate 38. According to various embodiments, support rails 28, 30 may be integral with baseplate 38, and/or support rails 28, 30 may include separate features from baseplate 38, and may be affixed thereto (e.g., by being welded or coupled using suitable fasteners).

As generally described above, track bending apparatus may include flange slot 32. In some embodiments, first and second support rails 28, 30 may further include at least a second flange slot (e.g., flange slot 40) configured to receive a second flange (e.g., flange 20) of the stud track. The first and second flange slots (e.g., flange slots 32, 40) may be spaced along first and second support rails 28, 30 a distance to receive the respective first and second flanges (e.g., flanges 18, 20) of stud track 12 and to support a stud track web (e.g., track web 16) on support rails 28, 30 between first and second flange slots 32, 40. That is, the pair of flange slots may be spaced apart to accommodate the flanges of a track member. For example, when track 12 is placed on support rails 28, 30 with flanges 18, 20 of the track facing downwardly (e.g., toward baseplate 38), the flanges of the track member may be at least partially received in the respective flange slots. In an embodiment, the flange slots may have a sufficient depth such that when the flanges of a track member are received within the flange slots the web of the track member may be at least partially supported by the support rails of the track bending apparatus. In some embodiments, the length of support rails 28, 30 may be such that one, or both, flanges of the track may generally abut the ends of the support rails. That is, the support rails may have a length (and/or a distance between the flange slot and the end of the support rails) such that the support rails (and/or a portion of the support rails between the flange slot and the end of the support rails) may generally be the same as the inside width (between the flanges) of the track. Other implementations may be equally utilized.

In an embodiment, first and second support rails 28, 30 may include a plurality of flange slots configured to receive flanges of stud tracks having different widths. For example, in the illustrated embodiment shown in FIGS. 3 through 5, at one end each support rail 28, 30 may include a pair of flange slots (e.g., flange slots 32, 40). The other end of each support rail 28, 30 may include another set of flange slots (e.g., flange slots 42, 44). In an embodiment, the sets of flange slots (e.g., flange slots 32, 40, and flange slots 42, 44) at each end of support rails 28, 30 may be spaced apart to accommodate tracks having different web widths. In such an embodiment, the track bending apparatus may be suitably used in connection with different size tracks. In a further embodiment, for example as shown in FIG. 7, one, or both, ends of support rails (e.g., support rail 28a shown in FIG. 7) may include multiple sets of flange slots (e.g., flange slots 32, 40, 46). In such an embodiment, more than one size of track may be accommodated at one, or both, ends of the support rails via the respective sets of flange slots. For example, a first width track may be accommodated in slots 32, 40 (e.g., with a respective flange of the track received in each flange slot). Further, a second, wider, track may be accommodated in slots 32, 46.

Web crimping feature 34 may be pivotally movable between the first position and the second position. Similarly, flange crimping feature 36 may be pivotally movable between the first position and the second position. As shown in the example embodiment, and referring also to FIG. 6, web crimping feature 34 and flange crimping feature 36 may be coupled for common movement between the respective first and second positions. According to one such example, and as shown in the depicted example embodiment, web crimping feature 34 and flange crimping feature 36 may include a unitary structure. As such, web crimping feature 34 and flange crimping feature 36 may be pivotally movable relative to at least one of the flange slots (e.g., relative to flange slot 32). For example, as shown, the crimping features (e.g., which may include both web crimping feature 34 and flange crimping feature 36) may be coupled to pivot 48. As such, the crimping features may be pivotally movable between a first position and a second position. In the first position, web crimping feature 34 is at least partially between support rails 28, 30 and flange crimping feature is at least partially between support rails 28, 30 and within flange slot 32. In the second position web crimping feature 34 may be at least partially separated from (e.g., above) support rails 28, 30, and flange crimping feature 36 may be at least partially removed from flange slot 32. As such, when the crimping features are in the second position a track member may be positioned on the support rails with the flanges of the track disposed within the flange slots. When the crimping features are in the first position, the web crimping feature may contact and deform (e.g., crimp) the web of the track by moving down between the support rails. Similarly, when the crimping features are in the first position, the flange crimping feature may contact and deform (e.g., crimp) the flange of the track by moving between the support rails and the first flange slot.

As shown in the illustrated example embodiment, track bending apparatus 26 may include a handle (e.g., handle 50) coupled to each of web crimping feature 34 and flange crimping feature 36. As such, handle 50 may be configured for common movement of web crimping feature 34 and flange crimping feature 36 between the respective first and second positions. For example, pivotal movement of handle 50 may move the crimping features relative to flange slot 32 and support rails 28, 30. In another embodiment, the handle may rotate via the pivot, and the crimping features may be coupled to the handle. Various alternative arrangements may be utilized. As shown, in an embodiment the crimping features may include a component including both a web crimping feature and a flange crimping feature. In some embodiments, the web crimping feature and the flange crimping feature may include separate components, e.g., which may be coupled for pivotal movement relative to the flange slot. Further, operation mechanisms other than a handle may be utilized. For example, hydraulic, pneumatic, and/or electric actuators may be utilized for moving the crimping features between the first position and the second position.

As generally described above, in operation, the crimping features may be placed (e.g., pivoted) in the second position, in which the crimping features are not engage relative to the flange slot. For example, the handle may be pivoted upwardly from the baseplate, thereby pivoting the crimping features to the second position. A track member may be positioned such that the flanges of the track member are received in the respective flange slots. The crimping features may then be moved to the first position in which the crimping features are at least partially engaged relative to the flange slot and support rails. When the crimping features are at least partially engaged with the flange slot and the support rails, the flange crimping feature may be at least partially disposed within the flange slot and the web crimping feature may be at least partially disposed between the support rails. Movement of the crimping features to the second position may crimp at least a portion of flange and the web of the track member, e.g., by deforming the flange and web inwardly between the two support rails. As generally discussed above, in an embodiment, web crimping feature 34 may be arranged such that the crimp formed in the track web may increase in depth across the web of the track toward the flange that is also to be crimped. Further, in an embodiment, the flange crimping feature 36 may be arranged such that the crimp formed in the track flange may have a generally constant depth along the height of the track flange.

In the illustrated embodiment, handle 50 may be pivotally coupled to the support rails, e.g., via pivot 48, such as a pivot pin, bolt, etc. In other embodiments, the handle may be pivotally coupled to the baseplate via a pivot support or other structure that may be separate from the support rails. The handle may include a bar or tube. In some embodiments, as shown, the handle may be bent to provide an off-set arrangement, e.g., which may provided improved clearance between the handle and the support rails. However, in other embodiments, the handle may include a generally straight member.

Track bending apparatus 26 may include a depth stop for controlling a depth of the flange crimping feature and the web crimping feature between the support rails in the respective first positions. The depth stop may be adjustable for adjustably controlling the depth of the flange crimping feature and the web crimping feature between the support rails in the respective first positions. For example, as shown in the illustrated embodiment, handle 50 may include adjustable depth stop 52, e.g., which may include a post, such as a bolt or and at least partially threaded rod, that may be threadably engaged with a cooperating feature to allow the length of protrusion beyond the handle to be adjusted. In an embodiment, adjustable depth stop 52 may engage a stop plate (e.g., one or more of stop plates 54, 56) when handle 50 is pivoted downwardly toward the support rails. The engagement between the adjustable depth stop and the stop plate may control the extent of pivotal movement of the handle toward the support rails. Controlling the extent of pivotal movement of the handle toward the support rails may also control the extent of engagement between the crimping features and the web and flange of a track member being crimped. As such, the depth of a crimp in the web and flange of the track member may also be controlled. In such an embodiment, the depth of crimp of the web and flange of the track member may be adjusted, at least in part, by adjusting the depth of the adjustable depth stop. Additionally, in some embodiments, the depth, and shape, of the crimp may be influenced by the shape of the crimping features and the position of the crimping features relative to the pivot. Further, in some embodiments, the depth stop may be coupled to one or more of the crimping features and may engage one or more cooperating features of the support rails or the baseplate.

In an embodiment, a track member may be shaped to have a curved profile by crimping the track member in a plurality of locations along the length of the track member. That is, the stud track may be positioned in the track bending apparatus and a first set of crimps may be formed in the track web and one of the track flanges. The track may then be repositioned in the track bending apparatus so that another portion of the stud track may be crimped. For example, the track member may be crimped at regular intervals along the track member. It will be appreciated that, depending upon the curvature to be formed in the stud track, the track member may be crimped at irregular intervals, as well as at regular intervals. Generally, when the crimps are spaced more closely, a relatively smaller radius curvature may be achieved. Conversely, when the crimps are positioned further apart, a relatively larger curvature may be achieved.

According to various embodiments, the baseplate and support rails may be formed from a suitable materials, such as steel plate, angle and/or channel stock, etc. However, it will be appreciated that various different materials and/or fabrication techniques may be utilized.

A variety of features of example implementations of a track bending apparatus and system have been described. However, it will be appreciated that various additional features and structures may be implemented in connection with a track bending apparatus according to the present disclosure. As such, the features and attributes described herein should be construed as a limitation on the present disclosure.

Claims

1. An apparatus comprising:

a first and a second support rail, the first and second support rails being spaced from one another and being generally parallel, each support rail including a flange slot configured to receive a first flange of a stud track;

a web crimping feature movable between a first position at least partially disposed between the first and second support rails and a second position at least partially spaced from the first and second support rails; and

a flange crimping feature movable between a first position at least partially disposed between the first and second support rails and a second position at least partially spaced from the first and second support rails.

2. The apparatus of claim 1, further comprising a baseplate, the first and second support rails being affixed to, and upstanding relative to, the baseplate.

3. The apparatus of claim 1, wherein the first and second support rails further include at least a second flange slot configured to receive a second flange of the stud track, the first and second flange slots being spaced along the first and second support rails a distance to receive the respective first and second flanges of the stud track and to support a stud track web on the support rails between the first and second flange slots.

4. The apparatus of claim 1, wherein the first and second support rails include a plurality of flange slots configured to receive flanges of stud tracks having different widths.

5. The apparatus of claim 1, wherein the web crimping feature is pivotally movable between the first position and the second position.

6. The apparatus of claim 1, wherein the flange crimping feature is pivotally movable between the first position and the second position.

7. The apparatus of claim 1, wherein the flange crimping feature and the web crimping feature are coupled for common movement between the respective first and second positions.

8. The apparatus of claim 7, wherein the flange crimping feature and the web crimping feature comprise a unitary structure.

9. The apparatus of claim 1, further comprising a handle coupled to each of the flange crimping feature and the web crimping feature, the handle being configured for common movement of the flange crimping feature and the web crimping feature between the respective first and second positions.

10. The apparatus of claim 1, further comprising a depth stop for controlling a depth of the flange crimping feature and the web crimping feature between the support rails in the respective first positions.

11. The apparatus of claim 10, wherein the depth stop is adjustable for adjustably controlling the depth of the flange crimping feature and the web crimping feature between the support rails in the respective first positions.

12. The apparatus of claim 11, wherein the depth stop is threadably adjustable.

13. The apparatus of claim 10, wherein the depth stop is coupled to a handle configured for commonly moving the flange crimping feature and the web crimping feature.

14. A method comprising:

positioning a stud track on a pair of support rails, the pair of support rails including respective flange slots receiving a flange of the stud track;

moving a flange crimping feature to engage the flange of the stud track deforming the flange of the stud track between the pair of support rails; and

moving a web crimping feature to engage a web of the stud track deforming the web of the stud track between the pair of support rails.

15. The method of claim 14, wherein moving the flange crimping feature and moving the web crimping feature includes commonly moving the flange crimping feature and the web crimping feature.

16. The method of claim 14, wherein moving the flange crimping feature and moving the web crimping feature includes pivotally moving the flange crimping feature and the web crimping feature relative to the pair of support rails.

17. The method of claim 16, wherein pivotally moving the flange crimping feature and the web crimping feature includes pivotally moving a handle relative to the pair of support rails, the handle being coupled to the flange crimping feature and the web crimping feature.

18. The method of claim 14, further including providing a depth stop coupled with one or more of the flange crimping feature and the web crimping feature to control a degree of deformation of one or more of the flange of the stud track and the web of the stud track.

19. The method of claim 18, further including adjusting the depth stop to achieve a desired degree of deformation of one or more of the flange of the stud track and the web of the stud track.

20. The method of claim 14, further comprising:

adjusting the stud track relative to the pair of support rails;

moving the flange crimping feature to engage the flange of the stud track deforming the flange of the stud track between the pair of support rails at a location on the stud track spaced from the previously deformed portion of the stud track; and

moving the web crimping feature to engage the web of the stud track deforming the web of the stuck track between the pair of support rails at a location on the stud track spaced from the previously deformed portion of the stud track.